Related Manuals for Thermon TraceNet TCM18
Summary of Contents for Thermon TraceNet TCM18
- Page 1 TraceNet™ TC Series Control System TCM18 Panel Installation, Start-Up, and Maintenance Guide Thermon Manufacturing Company TraceNet™is a registered trademark of Thermon Manufacturing Company. PN 50312...
- Page 2 This information is subject to change without notice. It is recommended that a quick check of the current revision status be done at www.Thermon.com prior to proceeding. This guide is written and designed at Thermon Manufacturing Company, 100 Thermon Drive, San Marcos, TX 78667-0609, USA. Copyright ©2013 Thermon Manufacturing Company. All Rights Reserved. PRODUCT WARRANTY INFORMATION The seller warrants all equipment manufactured by it to be free from defects in workmanship or material under normal use and service.
- Page 3 Contents Chapter 1: Introduction ....................Chapter 2: Panel Specifications .
- Page 4 In the unlikely event that a conflict or uncertainty arises, contact the Thermon engineering support personnel assigned to this project to clarify. All installation personnel should be properly trained and qualified to safely install, service, and program this TraceNet heat tracing control panel as well as to operate the associated heat tracing system.
- Page 5 relay switching, it is recommended that a minimum of 6” (150 mm) of space be allowed between sinks and walls or other panels to minimize heat buildup at the heat sinks. Where heat sinks are present on adjacent panels, allow 12” (300 mm) spacing between heat sinks for sufficient natural air movement.
- Page 6 Specifications The general TraceNet TC Series panel specifications are as given below. Interior panel operating ambient range -40 F to 140 F (-40 C to 60 C) Exterior panel operating ambient range -40 F to 131 F (-40 C to 55 C) Ambient storage range -40 F to 158 F (-40 C to 70 C) Relative humidity range...
- Page 7 Current ratings in nonhazardous (ordinary) location based on TraceNet TC Series panels for up to 72 circuits are as follows For: 1 - 36 Circuits For: 37 - 72 Circuits Maximum Panel Exterior Maximum Allowable Average Amps per Relay Ambient ( C) (Calculated for each side of enclosure) 27 0 22 7...
- Page 8 Module Connections Due to its flexible architecture, a variety of TraceNet TC Series panel configurations are available. The specific project drawings should be followed when installing the power supply and field distribution wiring into the TraceNet panel as well as when installing the data highway interface wiring.
- Page 9 The RTB6 Module Connections The RTB6 module allows the connection of six 3-wire 100 Ohm platinum RTD inputs to the TraceNet control system. The RTB6 circuit board is a passive device which commu- nicates the discrete temperature inputs into a 26 pin bundled ribbon cable which then interconnects to a TCM18 module.
- Page 10 The PM6 Connections The PM6 serves as the heat trace power solid state switching module for a TraceNet TCM18 controller. It includes the heater and ground current measurement transformers, solid state heat trace control relays, and the heat dissipating heat sink. This module in- cludes a ground leakage functional test circuit.
- Page 11 The RM6 Connections The RM6 is a DIN rail mounted six circuit relay interface module for linking to individual solid state or mechanical relays via ribbon cable from the TCM18 controller. The RM6 includes individual terminal strips which allow the interconnection of individually mounted heater and ground current sensing transformers.
- Page 12 All heat trace circuits and insulation shall be installed in accordance with project instal- lation details provided. In addition, refer to the Electric Heat Tracing Maintenance and Troubleshooting Guide (Thermon Form No. 20745) for general procedures and installa- tion tips.
- Page 13 Figure 5: RTD Sensor Location Where limiter RTD sensors are installed on the process piping it should follow the guide- lines above. In cases where the limiter is to be installed on the heater itself, it is important to recognize that an offset should be anticipated in the limiter trip value to allow for sen- sor reading error and overshoot.
- Page 14 Location of Terminals Torque Values (Typical)* RTB6 5.3 to 7.0 in. lbs. (0.60 to 0.79 N-m) 12.5 to 13.5 in. lbs. (1.41 to 1.53 N-m) Distribution Equipment 13.2 to 15.9 in. lbs. (1.49 to 1.80 N-m) *Required torque values may vary depending on individual panel designs and size of terminals.
- Page 15 Cables for RS485 Communication CableType Recommended 120 Ohm, -20 to +60 C 22AWG FHDPE Belden 3107A or equal insulation PVC outer jacket 120 Ohm, -30 to +80 C 24AWG PE insula- Belden 9842 or equal tion PVC outer jacket 120 Ohm, -70 to +200 C 24AWG Teflon Belden 89842 or equal FFEP insulation Teflon FEP outer jacket Note all these products are designated as 120 ohm impedance for balanced line com-...
- Page 16 LCD display as shown in Figure 6 Figure 6: TCM18 Control and Monitoring Module Front Panel On power up, the TCM18 will display the following start-up screen message: THERMON TCM18 COPYRIGHT 2013 Figure 7: TCM18 Start-Up Screen...
- Page 17 MODE. The TCM18 will operate in a heat tracing circuit SCAN MODE during normal operation. That is, the LCD display will automatically scroll through each enabled heat tracing cir- cuit number, indicating the actual measured temperature and the control set point for maintain temperature on the first two display screen lines.
- Page 18 Figure 9: TCM18 Touch Pad This will result in the display screen response as illustrated below in Figure 10. CIRCUIT = 7 MAINTAIN TEMPERATURE MAINT= 49 C Figure 10: TCM18 LCD Response The TCM18 has an electronic password security provision. To access the programming mode, enter the 4 digit numerical security code.
- Page 19 minutes after power is applied to the TCM18) as the security code, then a new code may be entered by pressing the ALARM ACK key and subsequently followed by the PROG key. To program circuit control settings or control parameters, multiple keys in sequence will need to be pressed.
- Page 20 Figure 13: MAINTAIN TEMP Key The Display now reads as shown below with the flashing cursor representing the active data entry field: PROGRAM CIRCUIT = 7 MAINTAIN TEMPERATURE MAINT= 49 C Figure 14: Programming Maintain Temperature Pressing the green UP or DOWN Arrow programming keys followed by the green EN- TER key allows the selection of the heat tracing circuit to program.
- Page 21 Figure 15: Programming Keys The display screen will now shift the cursor to the next value to program as shown in the following display. PROGRAM CIRCUIT = 7 MAINTAIN TEMPERATURE MAINT= 49 C← 49 C Figure 16: Changing Maintain Temperature A single press of the green UP or DOWN arrow programming key will increase or lower the Maintain Temperature set point by a single degree.
- Page 22 Figure 17: The ENTER Key The DISPLAY screen now appears as shown in Figure 18. PROGRAM CIRCUIT = 7 MAINTAIN TEMPERATURE MAINT= 52 C Figure 18: Selecting a New Circuit Number At this point, pressing the green UP or DOWN arrow key will select the next heat tracing circuit to program.
- Page 23 TIP: In many cases, the programmed value can be the same for a majority of heat tracing circuits. Note that when sequencing through the circuit numbers, there is an ALL option. This allows the programming of the same set point for all circuits on this particular TCM18 module and permits only entering the set point once.
- Page 24 Heat Trace Control The TraceNet system allows a variety of control options for heat trace operation. The most energy efficient control mode is to use one or more process sensing RTD’s for each heat trace circuit. When configured with two RTD sensors, TraceNet will control off of the lowest reading and alarm off of the highest reading encountered.
- Page 25 below the maintenance temperature which is typically set at 50 F (10 C). If the ambient rises above this value, the heat trace will turn off. Obviously, this type of control mode will also reduce RTD requirements. In this case, there will naturally be some tempera- ture overshoot expected in the process as the ambient approaches the turn off point.
- Page 26 System Start-Up For information on entering and/or changing individual control and monitoring parame- ters through the TCM18, refer to the System Start-Up Operating Guide PN 50308. Starting Up the Heat Trace System All heat trace circuits should be properly terminated and meggered prior to energizing the heat trace power distribution and control panels.
- Page 27 Maintenance Preventative maintenance consists of inspection, testing, checking connections, and general cleaning of equipment at scheduled intervals. The maintenance recommen- dations that follow are intended to support and in some cases “add to” those procedures detailed in the facility’s Planned Maintenance System (PMS). In case of conflicts, con- tact the project engineer for resolution.
- Page 28 Maintenance Schedule Recommendation The service schedule is somewhat dependent on the “in service” hours. As a general rule, however, it is recommended that the heat tracing control and monitoring panel be serviced on a twelve month basis to start. The schedule may be adjusted depending on the operating history of the panel and as the historical maintenance records dictate.
- Page 29 Touch up paint Machine oil Grease Electrical tape Refer to specific panel materials list for tapes being used. Use only Thermon ap- proved or equivalent materials. Damp cloth To avoid electrostatic discharge, clean win- dow with damp cloth only. Recommended Visual Inspection Procedures...
- Page 30 • Check for mechanical damage to any windows as well as check the window seals. Repair or replace damaged materials. In all cases where equipment damage is observed, a root cause analysis should be ini- tiated to determine any future corrective action needed to prevent a recurrence. Wiring and Connections Survey The wiring and connections survey recommended is as follows: •...
- Page 31 Tests Description Perform Self Test The Self Test function (under the CONFIG key) checks circuit breaker and output re- lay functionality. This function also checks for high ground/earth leakage alarms in the heat tracing circuits. Perform SCAN Mode Review Operator should do a visual check for out of range temperatures and low or high heater and ground/earth leakage current in the heat tracing circuit(s).
- Page 32 Notes PN 50312_0414...
- Page 33 More Information More extensive information about TraceNet and Thermon heat trace products may be downloaded at www.Thermon.com. Contact your nearest engineering service center for more detailed information regarding this specific project panel. In addition, Thermon’s product support group may be contacted for information of a more general nature.
- Page 34 Appendix A Troubleshooting tips are provided here as a beginning point in correcting start-up issues and clearing out alarm and trip events. High Temperature Reading/Alarm The following summarizes some of the possible causes and solutions for heat tracing high temperature alarms. Cause Possible Solutions Temperature of product in process line is...
- Page 35 Improperly located RTD sensor. Is the RTD sensor installed next to a heated tank or a steam jacketed pump that might cause a higher than expected reading? Is the RTD sensor on the heater itself? Move the RTD sensor to location more represen- tative of the majority of the piping.
- Page 36 Heat tracing over designed in heat output Review design as well as installation instruc- and or/ due to cable availability or natural tions. Check heat tracing for presence of design selections available. This can result proper current. Since replacing the circuit in higher than expected temperatures due to may not be a desirable option here, the first overshoot (especially when used with on-off...
- Page 37 Cause Possible Solutions Temperature of product in process line is be- Let process operations return to normal con- low the alarm set point or expected read- ditions and then recheck for alarms. Alter- ing due to events other than heat tracing-low nately adjust alarm set point (with project pumping temperatures, etc.
- Page 38 Improperly installed RTD temperature sen- Permanent RTD temperature sensors are sor or RTD temperature probe. most accurate when installed along the pipe or equipment with at least a foot of probe and sensor wire running along the pipe be- fore exiting through the insulation. Perma- nent RTD sensors which enter the insula- tion at 90 degrees may be more sensitive to error associated with them depending on...
- Page 39 RTD Sensor Alarm The following summarizes some of the possible causes and solutions for a heat tracing RTD sensor reading alarm. Cause Possible Solutions RTD connections are wired improperly or Confirm wiring and connections are correct. have become loose. RTD has failed open or has extremely high Perhaps lightning has damaged the sensor? resistance or RTD has failed shorted or has Maybe the piping has had some welding go-...
- Page 40 Circuit Fault Alarm The following summarizes some of the possible causes and solutions for heat tracing circuit fault alarms. Cause Possible Solutions Upon initial installation start-up, improper Confirm correct wiring and presence of the wiring of the relay or low current in heater. heater.
- Page 41 Self-regulating or power limiting heater may When reading current on one of these type be operating in its cold start regime. heaters, it is necessary to read the current at steady state. One may have to wait as long as 5 minutes for heater steady state values. After five minutes the current value will con- tinue to drop as the pipe or equipment be- gins to warm.
- Page 42 Short circuit in a series resistance circuit. Disconnect heater from power, meg be- tween each of the conductors and ground for proper dielectric rating. If okay, measure resistance of circuit for agreement with de- sign values. Low Current Readings/Alarms The following summarizes the possible causes and solutions for heat tracing low current readings/alarms.
- Page 43 Controller may be in error in reading current. Use a different current clamp type meter which is known to be accurate and do a comparative reading. If the current mea- suring circuitry is in error, investigate con- trols further. Note that one should only read heater currents when the heater is 100% on.
- Page 44 Open circuit in a series resistance circuit. Disconnect heater from power, meg be- tween each of the conductors and ground for proper dielectric rating. If okay, measure resistance of circuit for agreement with de- sign values. High Ground Current Alarm The following summarizes some of the possible causes and solutions for heat tracing high ground current alarm.
- Page 45 (if approved by project engi- neer). If issues remain after exercising all these possible causes and solutions for heat tracing alarms and trips, contact your nearest Thermon engineering center for assistance and/or for arranging for field service. PN 50312_0414...
- Page 46 Appendix B This Appendix applies to TraceNet TC Series panels without purge equipment. The TC Series panels have been certified to be in compliance with IEC 60079-0: 2011, IEC 60079-15: 2010, EN 60079-0: 2012, and EN 60079-15: 2010. MARKINGS FOR TC SERIES PANELS The panels shall be marked IECEx FMG 12.0018X Ex nA IIC T4 Gc, and/or II 3 G Ex nA IIC T4 Gc FM13ATEX0073X, along with Ta = -40 C to +55 C and IP54.
- Page 47 Appendix C This Appendix applies to TraceNet TC Series panels with purge equipment. The TC Series panels have been certified to be in compliance with IEC 60079-0: 2011 and IEC 60079-2: 2007. MARKINGS FOR TC SERIES PANELS The panels shall be marked IECEx FMG 11.0028X Ex pxb IIC T4 Ta = -20 C to +50 C, for Zone 1 applications.
- Page 48 Thermon Manufacturing Company 100 Thermon Drive San Marcos Texas www.thermon.com Thermon PN 50312_0414...
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