ITC 2000 HEATING CONTROL CABINET Installation & Operation Manual VTI, Incorporated 24 McMillan Way Newark, DE 19713 Phone (302) 738 0500 FAX (302) 738 6594 Revision Level 0.03 Manual No. 90003314 June, 1997 TO INSURE PROPER INSTALLATION, THIS MANUAL MUST BE READ PRIOR TO STARTING THE INSTALLATION PROCESS.
1. INTRODUCTION This manual covers installation instructions and operation for the ITC 2000 Series Heating Control Cabinets consisting of Model ITC 2024 with provisions for 24 TCM 100 Temperature Control Modules or Model ITC 2036 with provisions for 36 TCM 100 Temperature Control Modules. 1.1 REFERENCE DRAWINGS 1.1.1 90003251E IT2024 MAIN CABINET ASSEMBLY 1.1.2 90003239E ITC2024 SINGLE LINE WIRING DIAGRAM 1.1.3 90003250E ITC2036 MAIN CABINET ASSEMBLY 1.1.4 90002611E ITC2036 SINGLE LINE WIRING DIAGRAM 1.1.5 90002586E TCM100 MAIN ASSEMBLY 1.1.6 90002406B TCM100 SCHEMATIC 2. GENERAL DESCRIPTION The ITC2000 Series Heating Control Cabinets consist of an enclosure, similar to a motor control center, containing a power transformer compartment, a distribution compartment and a temperature control module compartment. The cabinet also contains vertical and horizontal wireways for routing heater and control cables as well as a compartment for the alarm monitor PC board. The power transformer compartment accommodates either a 45 KVA (ITC 2036) or a 30 KVA (ITC 2024) three phase power transformer with a 480 VAC delta primary and 208/120 VAC wye secondary. A transformer with a 600 VAC delta primary may be provided as an option. If required for higher voltage heater, VTI can also provide a three phase power transformer with a 240/138 VAC wye secondary as an option. The primary feed to the transformer is routed through a 1 1/2 conduit located in the rear of the cabinet and extending vertically from the top of the cabinet to the transformer compartment in the bottom of the cabinet. A chimney is provided in the rear of the cabinet to vent the heat from the transformer out the top of the cabinet. The distribution compartment is located above the transformer in the center of the cabinet. This compartment contains either three (ITC 2036) or two (ITC 2024) 24 position panel boards each capable of accepting 12 two pole 25 Amp circuit breakers plus a three pole 250 VAC 150 Amp (ITC 2036) or 100 Amp (ITC 2024) secondary circuit breaker to coordinate with the power transformer. Each two pole branch circuit breaker is designed to protect one of the 36 (ITC 2036) or 24 (ITC 2024) tcm100 control circuits. The 120 VAC or 208 VAC voltage to the tem100 controller is determined by connecting one of the power feed wires from the circuit breaker to the tcm100 to either the second pole of the circuit breaker for 208 VAC operation or an adjacent neutral bus for 120 VAC operation. This compartment is
thermally isolated from the transformer compartment via fiberglass insulation and also contains a vent into the chimney to allow heat from the circuit breakers to escape out the top of the cabinet. The module compartment contains three (ITC 2036) or two (ITC 2024) 12 position racks each capable of accepting up to 12 tcm100 Temperature Control Modules. Each tcm100 module may be configured to operate from either a common ambient temperature sensor, such as a VTI TS10A, or a separate pipe temperature sensor, such as a VTI PTS100, to control heater power. Each tcm100 Temperature Control Module contains a power switching contactor, heater current indicator, high and low current alarms, GFI alarm, as well as power line low voltage and heater continuity alarm circuits. The output from each tcm100 Temperature Control Module is connected to a terminal block located in the terminal compartment to facilitate customer heater load connections. The alarms from all tcm100 Temperature Controllers are connected together via a back plane which in turn is connected to a master alarm relay located in the top compartment. A power fail relay is also provided in this compartment of the cabinet. The output from these two relays are wired to terminals in the terminal compartment for customer connection. 3. CABINET INSTALLATION Move the ITC2000 Series Heating Control Cabinet to the desired location and remove the shipping crate. Remove the field wiring entry plate on top of the cabinet to obtain access to wireways. Make sure that the main 120/208 VAC circuit breaker is in the OFF position. Remove the transformer compartment cover, load terminal compartment cover, alarm compartment cover, and horizontal wireway cover to obtain access for field wiring. The ITC2000 Heating Control Cabinet as shipped from the factory contains the tcm1000 Series Controllers configured as requested at time of order. If no configuration instructions were included with order, all modules are shipped with default configuration values. Before energizing the equipment, verify that the controllers are configured properly to prevent damage to the module.
4. CABINET WIRING 4.1 LOAD WIRING Select a wire type and gauge that will meet NEC safety and design requirements to minimize voltage drop from the controller output to the heater loads (recommended size is #10 AWG). Ensure that each cable from the heater junction box or PTS100 Temperature Sensor is electrically disconnected from all power sources prior to handling. Pull the cable from each heater junction box or PTS100 Temperature Sensor to the ITC2000 Cabinet and route through the field wiring entry in the top of the cabinet across the horizontal wireway and into the load terminal compartment. Cut and strip the cable for termination on the appropriate load terminal block. Prior to connecting the wires to the load terminal block, use a MEGGER to verify the integrity of the insulation in the cold lead wire and heater cable. The insulation resistance of each wire measured between conductor and ground with 2500 VDC applied must be greater than 20 Megohms. If the wires test normal, proceed to connect the heating load circuits as shown in details F1, F2, F3, or F4 on VTI Single Line Diagram 90002611E (ITC 2036) or 90003239E (ITC 2024) for the type of circuit configuration selected for the particular application. If the MEGGER test indicates abnormally low resistance, inspect the heater cable for chafed insulation or wrong connections. Correct the high leakage condition before connecting the cable to the load terminal blocks. 4.2 MODULE VOLTAGE SELECTION The operating voltage of each tcm100 Temperature Control Module must be configured to match the operating voltage of the heating cable. Each tcm100 Heating Control Module is capable of operating on 120 VAC or 208 VAC. This voltage is selected by connecting the wire from pin 4 of each tcm100 Temperature Control Module to either the second (lower) pole of the corresponding two pole 25 Amp circuit breaker for 208 VAC operation or to the neutral bus for operation on 120 VAC. If the appropriate configuration information has not been provided at time of shipment, VTI will ship the ITC2000 cabinet with default configuration which is 120 VAC. 4.3 AMBIENT TEMPERATURE SENSOR WIRING If the tcm100 modules installed in the ITC2000 Series Cabinet are to be used in an ambient temperature sensing mode, an ambient temperature sensor must be connected to the terminal block TB2 located on the alarm PC board (90002557) mounted in the alarm compartment. If a capillary type mechanical thermostat is used for this purpose, the thermostat cable connects to terminals TB2 4 and TB2 5. If a Model TS10A Electronic Ambient Temperature Sensor is utilized, the control and power connections are detailed in the table below:
FUNCTION 120VAC hot 120VAC neutral Control Control Ground TS10A TERMINAL TB1 2 TB1 3 TB1 4 TB1 5 TB1 G ITC2000 TERMINAL TB2 3 TB2 2 TB2 5 TB2 4 TB2 1 WARNING: THE TS10A TEMPERATURE SENSOR MAY BE SHIPPED FROM THE FACTORY WITH A JUMPER BETWEEN TERMINAL BLOCK TB1 2 AND TB1 5 OR TB1 3 AND TB1 5. THIS JUMPER SHOULD BE REMOVED WHEN OPERATING WITH AN ITC2000 CABINET TO PREVENT APPLYING LINE POTENTIAL TO THE LOW VOLTAGE DC SIGNAL INPUT!! Ensure that the cable from the field thermostat or temperature sensor is electrically disconnected from all power sources prior to handling. Pull the cable from the thermostat or TS10A Ambient Temperature Sensor to the ITC2000 Series Cabinet and route through the field wiring entry in the top of the cabinet to the alarm compartment. Cut and strip the cable for termination on terminal block TB2. Prior to connecting the wires to the load terminal block, Hypot the conductors to ground to verify the integrity of the insulation with 1200 VAC. If the leakage current is less than 1 milliamps, proceed to connect the ambient temperature sensor conductors to TB2. If a shield or ground is provided in the cable, connect it to terminal point TB2 1. It is recommended to use at least a number 14 AWG wire for the ambient temperature sensor conductors. 4.4 ALARM OUTPUT WIRING The ITC2000 Series Heating Control enclosure is supplied with an alarm PC board assembly (90002557) which functions in conjunction with each tcm100 module to provide a master alarm output. The contacts of the master alarm relay are combined with the contacts of a incoming power fail relay to provide several modes of operation. Terminals TB1 A NO s are connected to a circuit which will provide a contact closure if either the power fails to the cabinet or if any of the tcm100 modules detect an alarm condition. Terminals TB1 A NC are connected to a circuit which will provide a contact opening if either the power fails to the cabinet or if any of the tcm100 modules detect an alarm condition. Terminals TB1 A PF are contacts of the power fail relay and may be configured on the printed circuit board for either close on alarm or open on alarm operation. Prior to connecting the field cables to the alarm terminals, Hypot each of the conductors at 1200 VAC to verify the integrity of the circuit insulation. If the leakage current is less than 1 milliamp, proceed to connect the field cable to the terminals to provide the desired response. If the cable has appreciable leakage to ground, stop testing and repair the cable prior to proceeding.
4.5 FEEDER WIRING WARNING: MAKE SURE THAT THE THREE PHASE 480/600 VOLT, 60 HZ CIRCUIT BREAKER OR DISCONNECT SWITCH WHICH WILL FEED POWER TO THE CABINET IS DE ENERGIZED AND LOCKED OUT BEFORE ATTEMPTING TO PULL THE FEEDER CABLE TO THE SERIES ITC2000 CABINET! Based on the transformer rating of the ITC2000 cabinet, pull appropriately sized four conductor cable from the main disconnect switch or circuit breaker through the input power conduit at the top of the cabinet. DO NOT CONNECT EITHER END AT THIS TIME! The minimum size wire is listed in the table below: MODEL# ITC 2036 ITC 2024 CABLE SIZE FOR 480 VAC PRIMARY KVA RATING 45 KVA 30 KVA WIRE SIZE 6 AWG 8 AWG CABLE SIZE FOR 600 VAC PRIMARY MODEL# KVA RATING WIRE SIZE ITC 2036 45 KVA 6 AWG ITC 2024 30 KVA 10 AWG Now terminate the feeder wiring at the transformer located in the compartment at the bottom of the ITC2000 Series Cabinet. Connect the three phase conductors in the cable (black, blue, and red) to the transformer primary terminals identified at H1, H2, and H3 respectively. Connect the ground conductor (green) to the ground lug provided in the transformer compartment of the cabinet. Make sure that these terminations are secure. DO NOT CONNECT THE FEEDER WIRING TO THE POWER SOURCE AT THIS TIME! Measure the phase to phase voltage of the power source that will feed the ITC2000 Cabinet. Referring to the tap chart on the transformer, connect the numbered taps on each coil which correspond most closely with the measured source voltage as shown in the table below: 480 VOLT TRANSFORMER TAP CHART Line Voltage 504 492 Tap Number 1 2
480 468 456 444 432 7 3 4 5 6 600 VOLT TRANSFORMER TAP CHART Line Voltage Tap Number 600 1 585 2 570 3 555 4 540 5 Replace the cover on the transformer compartment after completing the voltage tap adjustment. Ensure that the secondary circuit breaker and the 36 (ITC 2036) or 24 (ITC 2024) circuit breakers on the ITC2000 Cabinet are all in the OFF position. Hypot each of the three phase line feeders at 2000 VAC to insure the integrity of the circuit. If the leakage current is less than 1 milliamp, proceed to connect the ground wire in the feeder cable to the ground lug at the feeder supply point. Now proceed to connect each of the three phase conductors in the feeder cable to the circuit breaker or disconnect switch at the feeder supply point. This completes the installation of the series ITC2000 cabinet.
5. OPERATION 5.1 MODULE CONFIGURATION The input voltage for the tcm100 Temperature Control Modules is factory set for operation on 120 VAC or 208 VAC. The input voltage for the tcm101 Temperature Control Modules is factory set for operation on 240 VAC. Other than this distinction, the tcm101 functions identically to the tcm100 and the term tcm100 is used generically throughout this manual to represent both controllers. If the customer has provided configuration data at the time of purchase or even prior to shipment of the equipment, the tcm100 Temperature Control Modules would be configured as requested by the customer during final test. If not, the tcm100 module is configured and shipped as described in the table below: DESIG PARAMETER CONFIGURED JP2/3 Control Source Ambient JP4 Sensor type PTS100 JP1 Heater Type Two Wire JP5 High Current Time Delay 1.1 Minutes DP1 High Current Alarm Disabled DP2 Low Current Alarm Disabled DP3 Ground Fault Alarm 30 Milliamps If the tcm100 Temperature Control Modules require field configuration, proceed with the following: Remove each of the tcm100 Temperature Control Modules from the rack by first loosening the retaining screw at the top center of the module and then turning the ejection wing screw in the upper left hand corner of the front panel in the clockwise direction until the module disconnects from the rack connector. Withdraw the tcm100 Temperature Control Module from the rack and configure each controller for the desired operating voltage, operating mode, and alarm setpoints. The operating mode and alarm setpoints must be programmed by moving the appropriate jump jax to the desired position as described in the table below:
DESIG PARAMETER JP2/3 Control Source JP4 Sensor type JP1 Heater Type JP5 High Current Time Delay DP1 High Current Alarm DP2 Low Current Alarm DP3 Ground Fault Alarm SELECTIONS Ambient or Pipe Sensor Contact (thermostat) or PTS100 Two Wire or Three Wire 1.1, 2.3, or 4.5 Minutes Disable, 3, 4, 5, 8, 10, 15, 20 Amps Disable, 1, 2, 3, 5, 7, 10, 15 Amps 30, 50, 70, 100 Milliamps After the configuration has been completed for each module, plug the tcm100 module into the proper rack slot. Verify that the controller is completely seated in the rack with the back surface of front panel touching the front mounting rail. If the module does not appear to be seated completely, try removing the controller from the rack and then forcefully plugging the controller into the rack position to fully engage the connector. Each of the six contacts in the connector rated at 30 Amps and therefore requires considerable force to engage and withdraw the two parts of the connector. 5.2 POWERING THE ENCLOSURE Apply power to the ITC2000 enclosure by closing the fused disconnect switch or circuit breaker that feeds the cabinet. Now switch the main circuit breaker on the front of the ITC2000 cabinet to the ON position. This provides power to each of the individual branch circuit breakers. To energize any of the individual tcm100 Temperature Control Modules, simply switch the corresponding circuit breaker to the ON position. If the load is connected properly, the green CONTINUITY & VOLTAGE LED should illuminate. If heat is required, as sensed by either the pipe sensor or ambient sensor, the yellow TEMPLOW LED will illuminate and power will be applied to the heater. No red ALARM indications should appear. If the heater current exceeds the High Current Alarm setpoint after the selected time delay, 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 energized. The HIGH CURRENT and master ALARM indications as well as the alarm relay may be cleared/de energized by momentarily depressing the RESET push button on the front panel.
If the heater current decreases below the Low Current Alarm setpoint 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 may be cleared/de energized by momentarily depressing the RESET push button on the front panel. If the leakage current in the heater load circuit exceeds the ground fault current setpoint, the red GFI LED alarm indicator as well as the red master ALARM LED indicator will illuminate and the master alarm relay will be energized. The controller will also disconnect both legs of the heater circuit, thereby removing power from the load and interrupting the ground fault condition. The GFI and master alarm indications as well as the alarm relay may be cleared/de energized by momentarily depressing the RESET push button on the front panel. The tcm100 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, the master alarm relay will be energized, and the ALARM LED will be illuminated for test purposes. If High Current Alarm, Low Current Alarm, or Ground Fault Alarm conditions exist, these indicators will also be lit. This completes the configuration and operation of the tcm100 Temperature Control Module.
6. ADDENDUM 1 6.1 REFERENCE DRAWINGS 6.1.1 90003236E ITC2024 MAIN CABINET ASSEMBLY 6.1.2 90003237E ITC2024 SUB ASSEMBLY 6.1.3 90003240E ITC2024 CABINET WIRING 6.1.4 90003247E ITC2024 GROUNDING DRAWING 6.1.5 90003246E ITC2024 LABELING DRAWING 6.1.6 90003239E ITC2024 SINGLE LINE WIRING DIAGRAM 6.1.7 90002923E ITC2036 MAIN CABINET ASSEMBLY 6.1.8 90002546E ITC2036 SUB ASSEMBLY 6.1.9 90003024E ITC2036 GROUNDING DRAWING 6.1.10 90003023E ITC2036 LABELING DRAWING 6.1.11 90002989E ITC2036 CABINET WIRING 6.1.12 90002611E ITC2036 SINGLE LINE WIRING DIAGRAM 6.1.13 90002586E TCM100 MAIN ASSEMBLY 6.1.14 90002406B TCM100 SCHEMATIC 6.1.15 90002855C PTS100 MAIN ASSEMBLY 6.1.16 90002810C PTS100 PC ASSEMBLY 6.1.17 90002898C PTS100 SCHEMATIC