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Thermon TraceNet TCM2 Installation, Start-Up, Operating And Maintenance Manual

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Installation, Start-Up,
Operating and Maintenance Guide

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Summary of Contents for Thermon TraceNet TCM2

  • Page 1 TraceNet Control and Monitoring System TCM2 Installation, Start-Up, Operating and Maintenance Guide...
  • Page 2  ...
  • Page 3 This document may not, in whole or in part, be copied, photocopied, reproduced, translated, or reduced to any electronic medium or machine-readable form without prior consent in writing from Thermon Manufacturing Company. This document is subject to change without notice.

  • Page 4: Table Of Contents

    Contents 1  Introduction  ........................ 1  1.1  The Panel Location .................. 1  1.2  Initial Inspection and Handling ............... 1  1.3  The TCM2  .................... 3  1.4  Features  ..................... 3  2  Specifications  ....................... 5  Table 2.1: TCM2 Panel Specifications  ............. 5  Table 2.2: TCM2 Module Specifications  ............ 6  3 ...
  • Page 5 7.3  The TCM2 in Process Sensing Applications  ........  2 8  7.4  The TCM2 in Ambient Sensing Applications  ........  2 9  7.5  Single-Circuit 3-Phase  ................  3 0  8  The TCM2 Data Highway Communications ............  3 1  9  System Start-Up ......................  3 3  9.1 ...

  • Page 6: 1  Introduction

    1.2 Initial Inspection and Handling Upon receiving the TraceNet TCM2 control panel, it is important to confirm that the contents of the shipping containers agree with the shipping documents and with the purchase order. Also, it is important to check the shipped container exterior and packing materials for any possible freight damage.
  • Page 7 clearance be allowed between heat 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) clearance between heat sinks for sufficient natural air movement. Warning: Heat Sink Temperatures May Exceed 60°C Adequate door clearance for service work entry and conduit panel entries should be anticipated when establishing the exact panel location.

  • Page 8: The Tcm2

    The TCM2 is a microprocessor-based temperature control and monitoring module developed specifically for heat tracing. Designed for use exclusively in Thermon manufactured control systems, the TCM2 module provides a complete control solution for up to two heat tracing circuits. Each TCM2 module is supplied with all necessary connection hardware.
  • Page 9 HeatChek TC Series Systems formerly utilizing a TC202a, TC201a or TC101a control and monitoring module. The TCM2 module is intended for installation exclusively in Thermon designed TCM2 panels. The Mains feed to the TCM2 module shall be current limited, either by a breaker or a fuse, with a current rating no higher than 30 A.

  • Page 10: 2  Specifications

    Specifications TCM2 control panels are available in a variety of configurations. The table below serves as general specification information for these control panels. Table 2.1: TCM2 Panel Specifications Parameter Description 100 to 600 V~, 50/60 Hz (See Table 2.2 for Control Heat Trace Mains Supply Module supply information) Control Points...
  • Page 11 The table below serves as general specification information for the TCM2 control module. Table 2.2: TCM2 Module Specifications Parameter Description Mains Supply 100 to 240 V~, 50/60 Hz, Overvoltage Category II Max. Input Current 740 mA Power Consumption 95 VA max Control Points Up to 2 Heat Tracing Circuits Up to Two per Control Point;...
  • Page 12 Table 2.3: Maximum Heater Current Through Each Solid State Relay SSR30A SSR15A SSR30B SSR15B SSR50C SSR30B/2R (single pole (double pole (single pole (double pole Up to 3 single (single pole Enclosure Module relay) relay) relay) relay) pole relays (1,2,3) relay) Option Type 40°F...
  • Page 13 Table 2.4: TCM2 System Enclosure Options Enclosure Dimensions Dimensions Material Type Option (inches) (mm) Fiberglass 4X (IP54) 12 x 14 x 6 305 x 356 x 152 Stainless Steel 4X (IP54) 12 x 14 x 6 305 x 356 x 152 Fiberglass 4X (IP54) 16 x 14 x 6...

  • Page 14: 3  Module Connections & Wiring

    Module Connections & Wiring The TCM2 is intended for use exclusively in TraceNet TCM2 Control and Monitoring System panels. Refer to Figures 3.1 for TCM2 Module connections. Design considerations within panel:  Control wiring is rated to 105°C  GFI test loop wires should be passed through their corresponding GFI CT’s...

  • Page 15: Top Side Connections

    The positive legs of each output are electrically connected. The outputs may be used to drive indicators or audible alarms, etc., or may be used to drive relays to connect to field wiring. TRIP and ALARM are configurable to be normally on or normally off. The TRIP output activates if either circuit trips for any reason.
  • Page 16 current (about 50 mA~) through the GFI CT to verify functionality on command or at a user configurable interval.  CTRL OUT 1 & 2: These output signals control the power SSRs or mechanical relays which energize the heat trace. Signal voltage defaults to 12 VDC but can be changed to 24 VDC in the Factory Menu.

  • Page 17: 4  Field And Panel Wiring

    All heat trace circuits and insulation shall be installed in accordance with project installation details provided. In addition, refer to the Electric Heat Tracing Maintenance and Troubleshooting Guide (Thermon Form No. 20745) for general procedures and installation tips. 4.2 RTD Installation and Wiring...

  • Page 18: Power Distribution Wiring And Breakers

    Figure 4.1: RTD Sensor Location Where RTD sensors are installed on the process piping, follow the guidelines above. In special cases where the limiting temperature sensor is to be installed on the heater itself, it is important to recognize that an offset should be anticipated in the trip set-point to allow for sensor reading error and overshoot.

  • Page 19: Tracenet Panel Wiring

    * Required torque values may vary depending on individual system designs and size of terminals. Refer to project documentation for additional information. Protective earth/ground connection is required. Ground/earth with minimum 12 AWG conductors to a known and proven plant ground or by grounding rods. 4.4 TraceNet Panel Wiring TraceNet TCM Series panels are configured and prewired into an integrated heat trace control and monitoring panel.
  • Page 20 Table 4.2: Recommended RS-485 Cable Type Cable Type Recommended 120 ohm, -20°C to +60°C (-4°F to +140°F) Belden 3107A or equal 22AWG FHDPE insulation PVC outer jacket 120 ohm, -30°C to +80°C (-22°F to +176°F) Belden 9842 or equal 24AWG PE insulation PVC outer jacket 120 ohm, -70°C to +200°C (-94°F to +392°F) Belden 89842 or equal 24AWG Teflon FEP insulation Teflon FEP outer...

  • Page 21: 5  Monitoring Heat Tracing Circuit Status

    Monitoring Heat Tracing Circuit Status 5.1 The Interface Local interaction with the TCM2 panel takes place through the TCM2 module’s simplified four-button membrane switch, four-line display and its three tri-color LEDs. See Table 5.1 which follows for a complete explanation of the physical interface.
  • Page 22 Table 5.1: TCM2 Keypad and Indicators Key/Indicator Description Function Green: Power On Power LED Red: System Fault Off: Heater OFF Green: No Alarms & Heater ON Flashing Yellow: One or more Unacknowledged ALARM Present Circuit 1 and Circuit 2 LED Solid Yellow: One or more Acknowledged ALARM Present Flashing Red:...

  • Page 23: Basic Navigation

    5.2 Basic Navigation At the Circuit Screen, alternate between circuits 1 and 2 using & Acknowledge Alarms and reset Trips using . Press to access the Main Menu of the TCM2. Figure 5.3: Main Menu The Main Menu gives the user access to all set-points and configuration options. &...

  • Page 24: Trips

    5.4 Trips In the event that the measured conditions of the heat trace circuit go beyond the TRIP settings of the circuit, the circuit will trip, i.e. turn off. When a circuit trips, the circuit will be deactivated, the corresponding tri-color LED will flash red, the common TRIP digital output will annunciate and a corresponding message will be displayed on the Alarm Line of the display.
  • Page 25 Table 5.2: Alarm Messages Message Explanation An RTD reading is out of range when the resistance exceeds 313 Ω or is less than 48 Ω. In either case, the RTD FAULT ALARM RTD has been damaged or has been disconnected in service.
  • Page 26 Table 5.2: Alarm Messages (Continued) Message Explanation The measured heater current has fallen lower than LOW AMPS ALARM the LOW CURRENT ALARM set-point. The measured heater current rise is higher than the HIGH AMPS ALARM HIGH CURRENT ALARM set-point but not above the HIGH CURRENT TRIP/HIGH.

  • Page 27: 6  Accessing Control Settings

    Accessing Control Settings 6.1 Password Protection The TCM2 module features password protection for settings. The user has the option to set a four-digit numerical password which must be entered in order to authorize changes to any set-point or setting. Without the password, all setting and set-points may be viewed, alarms/trips may be acknowledged and circuits may be reset but no settings or set-points may be modified.
  • Page 28 submenu using & . Pressing , selects the circuit and advances the cursor to the first set-point or setting available for editing. Use & change the value and to accept the new value and advance the cursor to the next set-point or setting available for editing. When finished editing within a submenu, use to return to the Main Menu.
  • Page 29 Table 6.1: Main Menu Options Menu Option Applies To Set-Point/Settings Available Range/Options Precision -129°C to 600°C; -200°F to 1112°F (LOW MAINTAIN TEMPERATURE TEMP ALARM to HIGH TEMP ALARM) 1° MAINTAIN Individual *see Section 7.4 for Ambient setting TEMPERATURE Circuit BANDWIDTH (Control Band) 1°C to 300°C;...
  • Page 30 Table 6.1: Main Menu Options (Continued) Menu Option Applies To Set-Point/Settings Available Range/Options Precision Individual LOW CURRENT ALARM ALARM 0.0 A to HIGH CURRENT ALARM -1.0A 0.1 A Circuit HEATER ENABLED, FORCED ON or DISABLED Individual ON/OFF MEC, ON/OFF SSR, HEATER ENABLE Circuit CONTROL (Control Method)
  • Page 31 Table 6.1: Main Menu Options (Continued)  Menu Option Applies To Set-Point/Settings Available Range/Options Precision NETWORK ID 1-247 DATA HIGHWAY Controller MODBUS Protocol ASCII 7, 2, NP or RTU 8, 1, NP BAUD RATE 9600, 19200, 38400, 57600 Controller ENTER PASSWORD in View PASSWORD 0000 – 9999 Mode ON or OFF (enable or disable PASSWORD...

  • Page 32: 7  Heat Trace Control And Monitoring

    Heat Trace Control and Monitoring 7.1 Control Method To provide the most flexible and application specific heat trace solution, the TCM2 is capable of controlling using several different algorithms or control methods. These include ON/OFF MEC, ON/OFF SSR, Proportional and Ambient Proportional Control (APC and APCM).

  • Page 33: Setting The Control Method

    7.2 Setting the Control Method Before attempting to change settings and set-points, be sure the TCM2 is in Program Mode. To determine whether the control module is in View Mode or Program Mode, check the first line of the Main Menu. If in View Mode, first enter the password to enter Program Mode (see Section 6.1 Password Protection more information).

  • Page 34: The Tcm2 In Ambient Sensing Applications

    7.4 The TCM2 in Ambient Sensing Applications The TCM2 may also be configured for Ambient Proportional Control (APC). One or two RTD’s may be used to sense ambient temperatures in the process area. Under the APC method, the HEATER 100% and HEATER OFF are shown in place of MAINTAIN TEMP and BANDWIDTH.

  • Page 35: Single-Circuit 3-Phase

    APC control is not recommended where steam outs and high exposure temperature process conditions are expected and where the heat-trace due to its inherent characteristics cannot be operated during such events. 7.5 Single-Circuit 3-Phase A new feature unique to the TCM2 among the TraceNet family of control and monitoring systems is the ability to directly monitor all three phases of a 3-phase system.

  • Page 36: 8  The Tcm2 Data Highway Communications

    Highway uses Modbus over RS-485, a world-wide standard in reliable industrial communications. Available with two user selectable protocol configurations and four common Baud rates, the TCM2 is ready to be integrated into the vast majority of current user systems including Thermon legacy HeatChek® control systems. Appendix A shows the memory map which should be used by DCS programmers to integrate the TCM2 into the plant’s DCS.
  • Page 37 RTU 8, 1, NP or ASCII 7, 2, NP and the baud rate to either 9600 (if used on the same network as legacy Thermon HeatChek systems), 19200, 38400 or 57600. For best results, a 120 Ω shielded twisted-pair cable is recommended. The Data Highway port on the TCM2 is isolated to 5 kVrms with protection against ESD to 15 kV.

  • Page 38: 9  System Start

    System Start-Up All heat trace circuits should be properly terminated and meggered prior to energizing the heat trace power distribution and control panels. In addition, all pipes should be insulated and weather sealed to achieve the expected heat up and temperature maintenance performance of the system. 9.1 Initial Start-Up Procedure Heat trace circuits are on independent circuit breakers from the TCM2 controller.

  • Page 39: Safety Precautions

    Maintenance Preventive maintenance consists of inspection, testing, checking connections and general cleaning of equipment at scheduled intervals. The maintenance recommendations 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, contact the project engineer for resolution.
  • Page 40 Notes                                        ...
  • Page 41 Appendix A: Memory Map Table 12.1: Circuit Measurement and Status (Read Only) Function Code(s) Address Description Values Alarm Acknowledge Circuit 1 Table 12.2 Alarm Acknowledge Circuit 2 Temp RTD1 Circuit 1 Temp = value x 10 Temp RTD1 Circuit 2 Temp = value x 10 Temp RTD2 Circuit 1 Temp = value x 10...
  • Page 42 Function Code(s) Address Description Values Alarm status Circuit 2 Temp RTD1 Circuit 2 Temp = Value x 10 Temp RTD2 Circuit 2 Temp = Value x 10 Control Temp Circuit 2 Temp = Value x 10 Control RTD Circuit 2 RTD 1 or RTD 2 Ground/Earth Current Circuit 2 Percent ON Circuit 2...
  • Page 43 Table 12.4: Circuit Measurements/Status Function Code(s) Address Description Values Alarm Acknowledge Circuit 1 Table Alarm Acknowledge Circuit 2 12.2 Maintain Temp Circuit 1 Maintain Temp Circuit 2 Control Band Circuit 1 Control Band Circuit 2 High Temp Trip RTD 1 Circuit 1 High Temp Trip RTD 1 Circuit 2 High Temp Trip RTD 2 Circuit 1 High Temp Trip RTD 2 Circuit 2...
  • Page 44   Figure 12.4: Circuit Measurements/Status (Continued) Address Function Code(s) Decimal Description Values 0x0024 RTD Fault Clamp Circuit 1 0x0025 RTD Fault Clamp Circuit 2 0x0026 Trips Enable/Disable Circuit 1 Table 0x0027 Trips Enable/Disable Circuit 2 12.3 0x0028 High Temp Seen RTD 1 Circuit 1 0x0029 High Temp Seen RTD 1 Circuit 2 0x002A...
  • Page 45 Table 12.6: Read Only Controller Data Function Code(s) Address Description Values 2008 Language 0 = English; 1 = Spanish; 2 = Russian; 2009 Password 0000 – 9999 2010 Password Enable 0 = Disabled; 1 = Enabled 2011 TCM2 Type 0 = 2-circuit (Default) 1 = 1-circuit, 1 CT;...
  • Page 46 Appendix B: Additional Information     Figure 13.1: Program Mode Menu Figure 13.3: View Mode Menu Figure 13.2: External Keypad Wiring Diagram...
  • Page 47 Appendix C: Troubleshooting Tips 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.
  • Page 48 Wrong insulation size, type, or thickness Measure circumference of insulation, on all of the line being traced. divide by π, and compare to insulation diameter charts for proper over sizing. Check insulation type and thickness against design specification. Replace insulation or review system design for alternate operating possibilities.
  • Page 49 Low Temperature Reading/Alarm The following summarizes some of the possible causes and solutions for heat tracing low temperature readings/alarms. Cause Possible Solutions Temperature of product in process line is Let process operations return to below the alarm set point or expected reading normal conditions and then recheck due to events other than heat tracing- low for alarms.
  • Page 50 Improperly located RTD temperature sensor. Is RTD sensor next to pipe support, equipment, or other heat sink? Move RTD sensor to location more representative of the majority of the piping. Improperly installed RTD temperature sensor Permanent RTD temperature or RTD temperature probe. sensors are most accurate when installed along the pipe or equipment with at least a foot of...
  • Page 51 Heat tracing does not heat. Breaker has As soon as maintenance activities been switched off due to maintenance cease and after conferring with activities or has possibly malfunctioned. operations manager, switch breaker back ON. Note that some period of time will elapse before the temperature alarm goes away (pipes and equipment take time to heat up).
  • Page 52 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 wiring of the relay or low current in heater. of the heater.
  • Page 53 Self-regulating or power limiting heater When reading current on one of these may be operating in its cold start regime. type 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.
  • Page 54 Short circuit in a series resistance Disconnect heater from power, circuit meg between each of the conductors and ground for proper dielectric rating. If okay, measure resistance of circuit for agreement with design values. Low Current Readings/Alarms The following summarizes the possible causes and solutions for heat tracing low current readings/alarms.
  • Page 55 Heater circuit may be shorter than Verify installed length (if possible) anticipated in the design stage. and if different review design. If length is different but performance- wise the “as built” design is acceptable, initiate “as built” drawing change and change controller low current setting.
  • Page 56 (if approved by project engineer). 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.
  • Page 58 Thermon, Inc. 100 Thermon Drive ∙ San Marcos, TX 78666 ∙ U.S.A. www.Thermon.com The information in this guide is subject to change without notice. Thermon Form: PN80514-0421...

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