tcm100, tcm101 Series Temperature Control Modules and PTS100, PTS100/3 Pipe Temperature Sensors Operations Manual This manual covers operation of the tcm100 and tcm101 Series Temperature Control Modules. The term "tcm100" is used throughout this manual as the generic name for this family of temperature controllers. Likewise, the term "itc2000" is the generic name for a family of heating system cabinets that includes the itc20l2, itc2024 and itc2036 Series Temperature Control Systems. VTI, Inc. 24 McMillan Way Newark, DE 19713 Phone (302) 738 0500 FAX (302) 738 6594 90003105 Manual No. Revision Level 0.03 June 1998 Operations Manual
1. INTRODUCTION To insure proper operation, this manual must be read prior to starting the equipment. 2. GENERAL DESCRIPTION The tcm100 Temperature Control Module is designed as a plug in temperature controller for the VTI itc2000 Series Temperature Control System. The tcm100 module contains the following: two miniature contactors which switch power to the heater, an ammeter to indicate heater current, heater current high and low current alarms, heater continuity monitor and alarm circuitry, ground fault monitoring and alarm circuits. The power switching devices in the tcm100 Temperature Control Module consists of UL Listed contactors rated at 30 Amps for 240 VAC operation. The power contactors are arranged to interrupt both sides of the line simultaneously and therefore assures that the heater is completely disconnected from the line when heat is not required. For 208 VAC and 240 VAC applications, this is especially important to assure that no ground leakage current flows once the circuit is interrupted. An analog meter (0 to 25 Amp range) is provided on the front panel to indicate heater current. Electronic monitoring circuitry is provided to detect when the current increases or decreases outside of the user programmed limits. If the current exceeds the high limit for more than a pre selected time, then a high current alarm will be initiated. If the current drops below the low limit for more than 5 seconds, then a low current alarm will be initiated. The tcm100 contains circuitry to monitor heater circuit continuity when used with the PTS100 or the PTS100/3 Pipe Temperature Sensor and monitor wire heater cable. This circuit operates at all times (even when the heater is not powered) to detect an open monitor circuit (and therefore an open heater circuit) and initiates an alarm. This alarm is combined with a voltage monitoring circuit to detect if the input line voltage drops below 85% of nominal while power is applied to the heater. A ground fault current monitor circuit is included in the tcm100 to monitor any leakage current in the heater circuit. This GFI current monitor utilizes a detector which can detect current imbalance in the range of 30 to 100 Milliamps. An alarm is initiated if the GFI current exceeds a user preset limit. 2
The tcm100 Temperature Control Module provides a six contact connector (rated at 30 Amps per contact) for the power circuits plus a 16 pin DIN connector for the alarm and control signals. These connectors mate with companion connectors located on the back of the racks in the VTI itc2000 Series Temperature Control System cabinets. 3. MODULE CONFIGURATION The model number imprinted on the handle of the tcml00 or tcm101 Temperature Control Module determines the operating voltage for that module: tcm100 module is designed to operate on 120 VAC or 208 VAC. The voltage selection jumpers on the tcm100 are installed from P4 to P5, P6 to P7, and from P9 to P10. tcm101 module is designed to operate on 240 VAC. The voltage selection jumpers on the tcm101 are installed from P5 to P6 and from P8 to P9. The operating mode and alarm setpoint parameters must be programmed by placing the appropriate jump jax to the desired selection, as described in the table below: DESIG PARAMETER SELECTIONS JP1 HEATER TYPE TWO WIRE or THREE WIRE JP2 JP3 or CONTROL SOURCE PIPE SENSING or AMBIENT SENSING JP4 SENSOR TYPE CONTACT (thermostat) or PTS100 JP5 HIGH CURRENT TIME DELAY 1.1, 2.3, or 4.5 MINUTES JP6 CONTINUITY LATCH or NONLATCH JP7 HIGH CURRENT LATCH or NONLATCH JP8 LOW CURRENT LATCH or NONLATCH DP1 HIGH CURRENT ALARM Disable, 3, 4, 5, 8, 10, 15, 20, 25 Amps DP2 LOW CURRENT ALARM Disable, 0.1, 1, 2, 3, 5, 7, 10, 15 Amps DP3 GROUND FAULT ALARM 30, 50, 70, 100 Milliamps 3.1 CONTROL SOURCE The tcm100 is designed to operate in two modes: Pipe Temperature Sensing or Ambient Temperature Sensing. This choice is made by placing the Control Source jump jax selector to the desired position: for PIPE SENSING place on header JP2 or for AMBIENT SENSING place on header JP3. 3 In the Pipe Temperature Sensing mode, the temperature sensor is located at the point where the desired temperature is to be maintained. An individual temperature sensor
is required for each controller operating in this mode. In the Ambient Temperature Sensing mode, the temperature sensor simply measures the outside ambient temperature. A single Ambient Temperature Sensor is used to control a large number of tcm100 Series Temperature Control Modules. 3.2 SENSOR TYPE When operating in the Pipe Temperature Sensing mode, the tcm100 is designed to accept an external temperature signal from either a contact making device such as a capillary thermostat or a VTI PTS100 Pipe Temperature Sensor. This choice is made by placing the jump jax selector to the desired position: CONTACT or PTS100 on header JP4. 3.3 HEATER TYPE The tcm100 is designed to operate with either a two conductor heating wire or a three conductor heating wire which contains a monitor wire. The monitor wire is used to assure that the heating cable is intact. This choice is made by placing the jump jax selector to the desired position: 2 WIRE HEATER or 3 WIRE HEATER on header JP1. 3.4 HIGH CURRENT TIME DELAY The tcm100 contains a heater current monitor circuit which may be programmed to alarm if the current exceeds the high limit after a programmable time delay period. This time period may be selected for 1.1, 2.3, or 4.5 minutes by moving a jump jax to one of these three locations on header JP5. These numbers represent the time delay after the heater is turned on until the high current alarm circuit is enabled. With self limiting heating cable, the heater current will be higher than normal during the first few minutes of operation. This current will gradually decrease and stabilize after several minutes. This programmable time delay will enable the operator to select a time period sufficient to allow the cable to stabilize before enabling the high current alarm. The time delay will be repeated each time that heat is required. 3.5 CONTINUITY and VOLTAGE The tcm100 contains a continuity and line voltage monitoring circuit which lights a green LED whenever both the heater continuity circuit is complete and the line voltage is greater than 85%. The LED indicator is programmable as LATCH or NONLATCH by placing the JP6 jump jax selector to L for latch or N for nonlatch. In the latch position, if the line voltage drops below 85% or if the heater circuit continuity is interrupted for any reason, the ALARM LED indicator will light and the CONTINUITY & VOLTAGE LED indicator will go off and remain off until the problem has been corrected and the RESET push button is momentarily depressed. 4
In the nonlatch position, if the line voltage drops below 85% or if the heater circuit continuity is interrupted momentarily, the ALARM LED indicator will light and remain lighted, however, the CONTINUITY & VOLTAGE LED indicator will remain off only as long as the low voltage condition exists or as long as the heater continuity is interrupted. 3.6 HIGH CURRENT ALARM The tcm100 contains a current monitoring circuit which monitors the heater current and provides an alarm output whenever the heater current exceeds the pre selected limit after the time delay selected in Section 3.4 above. This limit may be set by placing the jump jax selector for DP1 to one of the following positions: DISABLE 3 AMPS 4 AMPS 5 AMPS 8 AMPS 10 AMPS 15 AMPS 20 AMPS 25 AMPS A red HIGH CURRENT LED alarm indicator is provided on the front panel to indicate when a high current alarm has occurred. A programming selector JP7 has been provided to enable the operator to select the mode of operation of the high current alarm. When the JP7 jump jax selector is placed in the L or LATCH mode, the red HIGH CURRENT LED, as well as the red master ALARM LED, will light when a high current condition exists for a time in excess of the preset time delay and will remain lit even if the heater current eventually decreases below the preset limit. The HIGH CURRENT LED and ALARM LED indicator can only be reset by momentarily depressing the RESET push button after the heater current drops below the high current setpoint. When the JP7 jump jax selector is placed in the N or NONLATCH position, the red HIGH CURRENT LED, as well as the red master ALARM LED, will light when a high current condition exists for a time in excess of the preset time delay, but the red HIGH CURRENT LED indicator will go off if the heater current eventually decreases below the high current setpoint. However, the red master ALARM LED indicator can only be reset by depressing the RESET push button after the condition causing the alarm has been corrected. 5
3.7 LOW CURRENT ALARM The tcm100 contains a current monitoring circuit which monitors the heater current and provides an alarm output whenever the heater current decreases below the pre selected limit for 5 seconds. This limit may be set by placing the jump jax selector for DP2 to one of the following positions: DISABLE 1 AMPS 2 AMPS 3 AMPS 5 AMPS 7 AMPS 10 AMPS 15 AMPS A red LOW CURRENT LED alarm indicator is provided on the front panel of the tcm100 module to indicate when a low current alarm has occurred. A programming selector JP8 has been provided to enable the operator to select the mode of operation of the low current alarm. When the JP8 jump jax selector is placed in the L or LATCH mode, the red LOW CURRENT LED, as well as the red master ALARM LED, will light after a short time delay when the heater current decreases below the selected current. The LOW CURRENT LED and ALARM LED indicator can only be reset by momentarily depressing the RESET push button once the heater current returns to a level above the selected current. When the JP8 jump jax selector is placed in the N or NONLATCH position, the red LOW CURRENT LED, as well as the red master ALARM LED, will light after a short time delay when a low current condition exists but the red LOW CURRENT LED indicator will go off if the heater current eventually increases above the low current setpoint. However, the red master ALARM LED indicator can only be reset by depressing the RESET push button after the condition causing the alarm has been corrected. 3.8 GROUND FAULT CURRENT ALARM 6 The tcm100 contains a current monitoring circuit which monitors imbalance in the heater current and provides an alarm output whenever the imbalance in heater current exceeds the pre selected limit for 1 second. This limit may be set by placing the jump jax selector for DP3 to one of the following positions: 30 Milliamps 50 Milliamps
70 Milliamps 100 Milliamps A GROUND FAULT ALARM state is indicated when both the red GFI LED and master red ALARM LED on the front panel are lighted. This alarm is always a latched alarm and will remove power from the heater when it occurs. The condition causing the alarm must be corrected before normal operation can be restored. 4. OPERATION 7 The tcm100 Series Temperature Control Module should be installed in either an itc2012, itc2024 or itc2036 Series Temperature Control System cabinet which has been installed and connected according to the itc2000 INSTALLATION AND OPERATION MANUAL. If the tcm100 module has been configured and installed in the rack properly and the circuit breaker for that zone has been placed in the ON position, then the green CONTINUITY & VOLTAGE LED should illuminate. If heat is required as sensed by either the pipe sensor or the ambient sensor, then the yellow TEMP. LOW LED will illuminate and power will be applied to the heater. No red ALARM LED indications should appear. If the heater current exceeds the high current setpoint (DPl) for a time greater than the selected time delay, then the red HIGH CURRENT LED alarm indicator, as well as the red master ALARM LED indicator, will illuminate and the master alarm relay will be de energized. If JP7 is programmed to operate in the latch mode of operation, the HIGH CURRENT and master ALARM indication, as well as the alarm relay, may be cleared/energized by momentarily depressing the RESET push button on the front panel. If JP7 is programmed to operate in the nonlatch mode of operation, the HIGH CURRENT LED indicator will remain illuminated only as long as the heater current exceeds the high current set point. If the heater current decreases below the low current setpoint (DP2) for more than 5 seconds, the red LOW CURRENT LED alarm indicator, as well as the red master ALARM LED indicator, will illuminate and the master alarm relay will be de energized. If JP8 is programmed to operate in the latch mode of operation, the LOW CURRENT and master ALARM indication may be cleared/energized by momentarily depressing the RESET push button on the front panel. If JP8 is programmed to operate in the nonlatch mode of operation, the LOW CURRENT LED indicator will remain illuminated only as long as the heater current remains below the low current set point. If the leakage current in the heater load circuit exceeds the ground fault current setpoint, the red GFI LED indicator as well as the master red ALARM LED indicator will illuminate and the master alarm relay will be de energized. Simultaneously, the load contacts on the tcm100 module will open to remove power from both sides of the heating circuit. Power must be removed from the heating
circuit and the cause of the ground fault must be identified and corrected prior to restoring power to the heater circuit. The tcm100 Series Temperature Control Module may be tested when not powering the load by momentarily depressing the TEST push button on the front panel. As long as the TEST push button is depressed, power will be applied to the heater and the master alarm relay and ALARM LED will be illuminated. 5. OPERATION with PTS100 or PTS100/3 PIPE TEMPERATURE SENSOR The tcm100 is designed to operate with either a VTI model PTS100 Pipe Temperature Sensor (single temperature sensor channel) or a PTS100/3 Pipe Temperature Sensor (three temperature sensing channels). If the temperature sensed by the one type "K" thermocouple probe (PTS100) or by any one of the three type "K" thermocouple probes (PTS100/3) decreases below the setpoint, then the HEAT ON LED in the PTS100 will light and power will be applied to the heater. As the temperature of the single thermocouple (PTS100) or all three thermocouples (PTS100/3) increases approximately 3 F above the setpoint, then the HEAT ON LED will go off. The tcm100 provides the DC power required for operating the PTS100 Temperature Sensor, as well as the current mode temperature monitoring circuitry, which enables the tcm100 to sense when heat is required. This is accomplished by using a third wire in the connection cable from the tcm100 located in the itc2000 Temperature Control System cabinet to the PTS100 located at the heater. Two wires power the heater and the third wire conveys the temperature status. The tcm100 can detect three levels of current in the third wire circuit: OPEN CIRCUIT (Less than 2 Milliamps) CONTINUITY (2 to 5 Milliamps) HEAT REQUIRED (8 to 10 Milliamps) The PTS100 contains a DC/DC converter which is used to isolate the temperature monitoring circuitry from the heater power circuit as well as to convert the incoming power to the low voltage required by the temperature measuring circuitry. The normal current required to operate the DC/DC converter is approximately 4 to 5 Milliamps which is monitored by the tcm100 to assure continuity exists in the heater load and monitor circuit. When the temperature sensing circuit determines that heat is required, the total current increases to 8 to 10 Milliamps. The PTS100 and PTS100/3 have provisions to detect an open thermocouple condition. If an open thermocouple condition is detected, the current flow in the PTS100 and PTS100/3 is momentarily interrupted. As a result, the green CONTINUITY LED on the front of the tcm100 module will flash at the rate of approximately 1 HZ. 8
5.1 SETTING TEMPERATURE SETPOINT on the PTS100 With power removed from the heating circuit, remove the existing type "K" thermocouple from channel #1 on the PTS100 terminal block. Connect a Thermocouple Simulator to these terminals observing polarity as shown on the PTS100 cover plate. Also turn the temperature setpoint trim pot on the PTS100 to the maximum counterclockwise position. Reapply power to this heating control circuit by turning on the appropriate branch circuit breaker. The POWER ON LED should light to indicate that power is applied to the PTS100. The Thermocouple Simulator should be set to type "K" and the desired setpoint temperature. The temperature setpoint trim pot on the PTS100 should be adjusted in the clockwise direction until the HEAT ON LED lights. To verify the accuracy of the temperature setpoint and test the 3 F temperature hysteresis designed into the PTS100, adjust the Thermocouple Simulator above and below setpoint. The HEAT ON LED should light whenever the simulated temperature is below setpoint. The HEAT ON LED should go off when the simulated temperature is adjusted 3 F above setpoint. This completes setting and testing of the PTS100 Pipe Temperature Sensor. 5.2 SETTING TEMPERATURE SETPOINT on the PTS100/3 9 With power removed from the heating circuit, remove the existing type "K" thermocouples from channel #1, #2, and #3 on the PTS100/3 terminal block. Connect three Thermocouple Simulators to these terminals observing polarity as shown on the PTS100/3 cover plate. Also turn the temperature setpoint trim pot on the PTS100/3 to the maximum counterclockwise position. Reapply power to this heating control circuit by turning on the appropriate branch circuit breaker. The POWER ON LED should light to indicate that power is applied to the PTS100/3. The Thermocouple Simulator for channel #1 should be set to type "K" and the desired setpoint temperature. The Thermocouple Simulator for channels #2 an #3 should be set 10 degrees higher than the temperature for channel #1. The temperature setpoint trim pot on the PTS100/3 should be adjusted in the clockwise direction until the HEAT ON LED lights. To verify the accuracy of the temperature setpoint and test the 3 F temperature hysteresis designed into the PTS100/3, adjust the Thermocouple Simulator for channel #1 above and below setpoint. The HEAT ON LED should light whenever the simulated temperature is below setpoint. The HEAT ON LED should go off when the simulated temperature is adjusted 3 F above setpoint. Then adjust the Thermocouple Simulator for channel #1 to l0 F above setpoint. To verify operation of channel #2, decrease the Thermocouple Simulator for channel #2 to a temperature below setpoint. The HEAT ON LED indicator should light as the simulated temperature decreases below setpoint. Now adjust the Thermocouple
Simulator for channel #2 above setpoint. As the simulated temperature increases to approximately 3 F above setpoint, the HEAT ON LED should go off. Then adjust the Thermocouple Simulator for channel #2 to 10 F above setpoint. To verify operation of channel #3, decrease the Thermocouple Simulator for channel #3 to a temperature below setpoint. The HEAT ON LED indicator should light as the simulated temperature decreases below setpoint. Now adjust the Thermocouple Simulator for channel #3 above setpoint. As the simulated temperature increases to approximately 3 F above setpoint, the HEAT ON LED should go off. Now adjust the Thermocouple Simulator for channel #3 to 10 F above setpoint. This completes setting and testing of the PTS100/3 Pipe Temperature Sensor. 6. ADDENDUM 6.1 REFERENCE DRAWINGS 7.1 90002586E tcm100 MAIN ASSEMBLY 8.1 90002406B tcm100 SCHEMATIC 9.1 90002855C PTS100 MAIN ASSEMBLY 10.1 90002810C PTS100 PC ASSEMBLY 11.1 90002898C PTS100 SCHEMATIC 12.1 90002923E itc2036 MAIN CABINET ASSEMBLY 13.1 90002989E itc2036 CABINET WIRING 14.1 90002611E itc2036 SINGLE LINE DIAGRAM 15.1 90003236E itc2024 MAIN CABINET ASSEMBLY 16.1 90003240E itc2024 WIRING DIAGRAM 17.1 90003239E itc2024 SINGLE LINE DIAGRAM 10