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intech 21 HCCM-2100 Operation Manual

Heating cable control and monitoring system
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H C C M - 2 1 0 0
Heating Cable Control
and Monitoring System
Operational
Manual

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Summary of Contents for intech 21 HCCM-2100

  • Page 1 H C C M - 2 1 0 0 Heating Cable Control and Monitoring System Operational Manual...

  • Page 2: Table Of Contents

    HCCM-2100 OVERVIEW ............................... 22 COMMUNICATION TECHNOLOGY ......................4 SYSTEM ARCHITECTURE ..........................6 OPERATION ................................ 7 SYSTEM INTEGRATION ..........................11 SYSTEM SELECTOR ............................12 SYSTEM COMPONENTS ..........................13 ENGINEERING SPECIFICATIONS ......................17 Page 2 21 Harbor Park Drive North, Port Washington, NY 11050 Phone: 516.626.7221|Fax: 516.626.7021|...

  • Page 3: Overview

    Power Wiring To Heat Trace Cable Figure 2. System Overview Figure 1. Power Line Communication of the HCCM-2100 (208V, 3 wire system shown) Page 3 Figure 1 Power Line Communication of the HCCM-2100 (208V, 3 wire system shown) 21 Harbor Park Drive North, Port Washington, NY 11050 Phone: 516.626.7221|Fax: 516.626.7021|...
  • Page 4 HCCM-2100 Circuit Distribution Control Breaker Transformer Panel Panel Controller and IO Remote Terminal (shown with a temperature sensor) Heater Cable Figure 2. System Overview Page 4 21 Harbor Park Drive North, Port Washington, NY 11050 Phone: 516.626.7221|Fax: 516.626.7021| www.intech21.com...

  • Page 5: Communication Technology

    The HCCM-2100 System is designed to operate at voltages from 120V to 230V, single and three-phase power. The HCCM-2100 System is immune to voltage spikes and can withstand megger insulation tests of up to 5,000 Volts.

  • Page 6: System Architecture

    HCCM-2100 System Architecture The HCCM-2100 System can be configured as a star or bus network using heating cable and/or power wiring as the communication media as shown in Figure 4. The system is comprised of NC-2104 Network Controllers and RT-2104 Remote Terminals.

  • Page 7: Operation

    HCCM-2100 Operation Figure 4. Typical Schematic HCCM-2100 monitors individual process (i.e. pipe) temperatures at the end of each heating circuit where the available voltage to power the heater cable is lowest (due to voltage drop). For long or critical Page 7 21 Harbor Park Drive North, Port Washington, NY 11050 Phone: 516.626.7221|Fax: 516.626.7021|...
  • Page 8 HCCM-2100 monitors individual process (i.e. pipe) temperatures at the Figure 5. Typical Schematic (continued from previous page) end of each heating circuit where the available voltage to power the heater cable is lowest (due to voltage drop).
  • Page 9 The same LED provides indication of sensor failure or damage by blinking and energizing an alarm relay. The HCCM-2100 system monitors the integrity for the entire system, cables, wiring and monitoring components, and includes comprehensive self-diagnostic routines to insure that all of the system components are operational.
  • Page 10 HCCM-2100 Timing Procedure Upon initiation the HCCM-2100 System stays energized for a maximum of five minutes to run self-diagnostics of the entire heat tracing system, including the heating cable, power wiring, field connections and splices, remote terminals, temperature sensors, and associated components of the control and monitoring system.

  • Page 11: System Integration

    HCCM-2100 System Integration Intech 21 provides industrial grade, UL approved HCCM-2100 components and systems for use on critical heat tracing applications. Any alarm condition results in the zone being energized for continuous communication between associated RT-2104 and NC-2104 units until the condition is remedied.

  • Page 12: System Selector

    HCCM-2100 System Selector Standard Monitor and Control Panel (MCP) enclosures are rated NEMA 12 and include viewing window for LED’s, and remote alarm contacts. NEMA 4X stainless steel enclosures, alarm strobe light, and/or alarm siren, and auto-dialer are available as standard MCP options.

  • Page 13: System Components

    LAMP TEST FAULT RESET FAULT RESET MCP Monitoring and Control System Description The complete HCCM-2100 system control panel consists of enclosure, system circuit breaker, necessary NC-2104 and IO-2104 units, contactors, relays, and terminal blocks. Specifications Standard Enclosure: NEMA 12 (with viewing window), Optional...
  • Page 14 HCCM-2100 RT-2104 Remote Terminal Remote Terminal Heat Trace Cable Temperature Sensor (36” Length) Description The RT-2104 Remote communicates pipe temperature, and system integrity status to the NC-2104. The RT-2104 is connected to the heat trace cable with the cable manufacturer’s UL/FM Approved splice kit.
  • Page 15 HCCM-2100 NC-2104 Network Controller L G U HCCM-2100 NC 2104 Heater Control Monitoring System Network Controller POWER ON COMMON FAULT ALARM SIGNAL FAILURE HEATER ON HIGH TEMPERATURE LOW TEMPERATURE SENSOR LOSS LAMP TEST FAULT RESET CON1 CON2 CON3 CON4 ALARM...
  • Page 16 HCCM-2100 IO-2104 Expansion Unit L G U HCCM-2100 IO 2104 Heater Control Monitoring System Network Controller POWER ON SIGNAL FAILURE HEATER ON HIGH TEMPERATURE LOW TEMPERATURE SENSOR LOSS CON1 CON2 CON3 CON4 ALARM NC NO C NC NO C NC NO C...

  • Page 17: Engineering Specifications

    Scope Furnish and install ___ Heating Cable Control and Monitoring Systems (HCCM-2100™) as manufactured by Intech 21, Inc. Glen Cove, NY. Each HCCM-2100™ System shall be provided to control and monitor ___ individual heating zones (total number of branches), and ___ individual heating circuits (total number of feeders).
  • Page 18 HCCM-2100 the heater energized. The system shall de-energize the cable when the pipe temperature reaches __ Deg F. The control system shall be fail-safe. A failure of the temperature sensor shall result in energizing the heater cable, and initiating the alarm.
  • Page 19 HCCM-2100 management system. The system shall have provisions for future communication interface. Sequence of Ground Fault Detection a) Ground Fault shall be detected when more than 200mA AC current is leaking to ground for more than 300 msec. When Ground Fault is detected in the circuit the circuit contactor shall be turned OFF for 10sec and the alarm indicator light for the circuit shall be ON.
  • Page 20 The INTECH 21 only obligations are those in the Standard Terms and Conditions of Sale for this product, and in no case will INTECH 21 be liable for any incidental, indirect, or consequential damages arising from the sale, resale, use, or misuse of the product.
  • Page 21 OCAL ONTROL ANEL ..................27 OCAL ONTROL ANEL ERMINAL LOCK ....................28 EMOTE ERMINAL NSTALLATION HCCM-2100 ADDRESSING PROCEDURE .................. 29 ............................. 30 ENERAL ......................31 DDRESSING ROCEDURE ......................32 WITCH DDRESSING OPERATION ..........................33 ..................34 NERGIZING THE OCAL ONTROL ANEL TROUBLESHOOTING ........................

  • Page 22: Overview

    HCCM-2100 utilizes power line communication to provide full monitoring and control functions without dedicated communication wiring. A simplified diagram of a typical three wire HCCM-2100 system is shown below. Circuit Control...

  • Page 23: Installation

    HCCM-2100 Installation Unpacking the Components A typical HCCM-2100 consists of Remote Terminals and a Local Control Panel. Remote Terminals and Local Control Panel are shipped in individual cartons. The Local Control Panel includes Network Controller(s); Input/Output Module(s) for systems larger then four zones; and associated power switching relays and contactors.

  • Page 24: Local Control Panel Terminal Block

    HCCM-2100 Local Control Panel Terminal Block The following terminal block designations are standard on all HCCM-2100 systems. Also, refer to individual wiring diagram supplied with the panel. From Individual Heater Cable To Individual Heat er Circuit s From Individual Circuit Breakers 1.

  • Page 25: Remote Terminal Installation

    HCCM-2100 Remote Terminal Installation Remote Terminals can be provided in a variety of enclosures. Installation detail below represents a typical mounting of a Remote Terminal. Remote Terminals are supplied with a three-foot length of a make and model heater cable used in the installation. Refer to the heater cable manufacturer instructions on heater cable splicing.

  • Page 26: Hccm-2100 Addressing Procedure

    HCCM-2100 HCCM-2100 Addressing Procedure General The Local Control Panel is supplied with Network Controller(s) and Input/Output Module(s) already addressed. The identification on the panel indicates the Network Controller (NC) ID. Remote Terminals are addressed after the installation. 1. Install all the Remote Terminals as described earlier in this manual.

  • Page 27: Addressing Procedure

    HCCM-2100 Addressing Procedure 1. Disconnect and lock out all power circuits before working on the Remote Terminals. 2. Note the Network Controller (NC) ID identified on the Local Control Panel. 3. Remove the Remote Terminal cover to expose the printed circuit board and the addressing dip switches.

  • Page 28: Dip Switch Addressing

    HCCM-2100 Dip Switch Addressing Table 1. Network Controller (NC) ID. Dip Switch Position NC ID … Pos1 Pos2 Pos3 Pos4 Pos1 Pos2 Pos3 down down down down down down down down down down down down down down down down down...
  • Page 29 HCCM-2100 Table 2. Remote Terminal (RT) ID. Dip Switch Position RT ID Zone No. … Pos1 Pos2 Pos3 Pos1 Pos2 Pos3 Pos4 down down down down down down down down down down down down down down down down down down...
  • Page 30 HCCM-2100 Adding Zones 1. Disconnect and lock out all power circuits before working on the Local Control Panel components. 2. Install and properly address additional Remote Terminal(s) as per instructions, and Tables 1 and 2. NC-2104 Network Controllers and IO-2104 Input / Output Modules contain dip switches for setting up the number of zones (Remote Terminal addresses) that will be monitored.

  • Page 31: Operation

    HCCM-2100 Operation Check heater cable insulation integrity using megger as per heater cable manufacturer recommendations prior to energizing the Local Control Panel. Energizing the Local Control Panel 1. Turn the Control Logic Circuit Breaker on. The Network Controller and Input / Output Modules (if any) green Power On Light(s) will illuminate.

  • Page 32: Troubleshooting

    HCCM-2100 Troubleshooting The common alarm is initiated during any monitored alarm condition. Each monitored zone has identical alarms and indicators. Any of the above alarms will result in turning the heater cable on, providing a fail-safe operation. The alarms and indicators definition and description for each...

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