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nvent RAYCHEM Elexant 4010i, User Manual

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nVent RAYCHEM Elexant 4010i/4020i User Manual

RAYCHEM-AR-H60624-40X0iOpsManual-EN-1905

nVent.com 

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  10

CHAPTER – 2

2.  INSTALLATION AND WIRING

2.1 

Initial Inspection

Inspect the shipping container for damage. If the shipping container or cushioning material is damaged, it should be kept 
until the contents of the shipment have been verified for completeness and the equipment has been checked mechanically 

and electrically. 

If the shipment is incomplete or shows visible damage, notify the nearest nVent representative

.

2.2 

Operator Safety Considerations

The Elexant 4010i/4020i controllers using Solid State Relays are suitable for Class 1, Division 2, Groups A, B, C, and D 
hazardous areas and is IEC Ex/ATEX Zone 2 approved. Variants using EMR are suitable for 

 

non-hazardous areas only.

Refer to the Elexant 4010i Installation Manual (H59271) and the Elexant 4020i Installation Manual (H59270) for more 

details. 

2.3 

Elexant 4010i/4020i Assembly

The figure below displays the different physical assemblies for 1-Phase (Elexant 4010i) and 3-Phase (Elexant 4020i) 

variants of the unit.

1 Phase Version

Front 

Front 

Top

Top

Bottom

Bottom

Side

Side

3 Phase

Figure 1 - The Elexant 4010i/4020i Assembly

Summary of Contents for RAYCHEM Elexant 4010i

Page 1: ...RAYCHEM AR H60624 40X0iOpsManual EN 1905 nVent com 1 nVent RAYCHEM Elexant 4010i 4020i User Manual ...

Page 2: ... procedure 10 2 5 2 Elexant 4020i mounting removal procedure 10 2 6 Wiring and Interfaces 11 2 6 1 Input Power 11 2 6 2 Load Connections 11 2 6 3 AC Voltage Sense 12 2 6 4 RS 485 IN 12 2 6 5 RS 485 OUT 13 2 6 6 Ethernet 14 2 6 7 Profibus 14 2 6 8 USB Connector 14 2 6 9 Reset Button 15 2 6 10 3 Wire RTD Connections 15 2 6 11 2 Wire RTD Connections 15 2 6 12 4 20 mA Connections 16 2 6 13 Connections...

Page 3: ... 37 4 1 Safety Limiter 37 4 1 1 Safety Function of the Limiter in the Elexant 4020i 37 4 1 2 Area of Use 37 4 1 3 Block Diagram 37 4 1 4 Resetting the Safety Limiter 38 4 1 5 Setting the Temperature Set Point 38 4 1 6 Main Output Interlock 39 4 1 7 Internal Diagnostic 39 4 1 8 Functional Test 39 4 1 9 Functional Test Procedure 39 4 1 10 Test in the Event of a Fault 40 4 1 11 Determining Safety Int...

Page 4: ...m Settings 54 5 5 3 Output Type 55 5 5 4 Heater Configuration 56 5 6 Output Limiting Page 57 5 6 1 Output Limiting Mode 57 5 6 2 SSR Limiting Switch Protection 58 5 6 3 Circuit Breaker Limiting 59 5 6 4 Turns Ratio Dependent Settings 60 5 6 5 Load Shedding Page 61 5 6 6 Load Shedding Failsafe Mode 62 5 6 7 Miscellaneous Page 62 5 7 Temperature Settings Page 65 5 7 1 Temp Sensor x Reading 65 5 7 2 ...

Page 5: ...l 86 5 13 Safety Limiter Settings Page 86 5 13 1 Safety Limiter Setup 87 5 13 2 Safety Limiter Maintenance 88 5 14 User Interface Settings 90 5 14 1 Language 90 5 14 2 Temperature Units 90 5 14 3 Passcode 91 5 14 4 Calibrate 91 6 FIRMWARE UPGRADE 93 6 1 Firmware Upgrade Procedure 93 7 TROUBLESHOOTING 94 7 1 Troubleshooting 94 8 APPENDIX A 95 ...

Page 6: ...des 41 Table 15 Trace Status Values 46 Table 16 Fail Modes 50 Table 17 Control Temperature Alarms 52 Table 18 Control Modes 53 Table 19 Control Algorithms 55 Table 20 Output Type 55 Table 21 3 Phase Heater Configuration Settings 57 Table 22 Temperature Alarm Settings 68 Table 23 High Low Limit Cut out Settings 69 Table 24 High Low Trace Current Alarm Settings 71 Table 25 High Trip Ground Fault Ala...

Page 7: ...azardous areas 1 1 1 2 Elexant 4010i 4020i Series Variants P N Type Description 10380 001 4010i EMR FW Elexant 4010i EMR Controller in Fiberglass Enclosure with Window 10380 002 4010i SSR FW Elexant 4010i 4010i SSR Controller in Fiberglass Enclosure with Window 10380 003 4010i EMR SW Elexant 4010i EMR Controller in Stainless Steel Enclosure with Window 10380 004 4010i SSR SW Elexant 4010i SSR Cont...

Page 8: ...Alarms The Elexant 4010i 4020i controller generates different types of alarms to draw the user s attention to any event that does not fall within the defined limits of normal operation See Sections 3 5 and 5 9 for a detailed description of different types of alarms generated by the Elexant 4010i 4020i controller 1 1 2 3 Control The Elexant 4010i 4020i supports several control mode algorithms as li...

Page 9: ...ontrollers IMPORTANT All information including illustrations is believed to be reliable Users however should independently evaluate the suitability of each product for their particular application nVent Thermal LLC makes no warranties as to the accuracy or completeness of the information and disclaims any liability regarding its use nVent Thermal LLC s only obligations are those in the nVent Therm...

Page 10: ...rest nVent representative 2 2 Operator Safety Considerations The Elexant 4010i 4020i controllers using Solid State Relays are suitable for Class 1 Division 2 Groups A B C and D hazardous areas and is IEC Ex ATEX Zone 2 approved Variants using EMR are suitable for non hazardous areas only Refer to the Elexant 4010i Installation Manual H59271 and the Elexant 4020i Installation Manual H59270 for more...

Page 11: ...ICATORS A TB1 Wiring Terminals Function 1 TS1 White TS1 Red TS1 Red TS2 White TS2 Red TS2 Red TS3 White TS3 Red TS3 Red TS Lim White TS Lim Red TS Lim Red 2 3 4 5 6 7 8 9 1 3 10 11 12 B TB2 Wiring Terminals Function 1 TC3 TC2 TC1 TC3 TC2 TC1 No Connect SSR SSR DIGITAL INPUT COM DIGITAL INPUT 1 DIGITAL INPUT 2 2 3 4 5 6 7 8 9 10 11 12 RS485 IN RS485 IN RS485 COM RS485 OUT RS485 OUT 13 14 15 16 17 R...

Page 12: ...uld be terminated on the field terminal block located on the mounting plate in the enclosure Connect earthing or grounding wire to terminal 1 of TB 4 Line 1 to terminal 2 of TB 4 Line 2 or neutral to terminal 3 of TB 4 as shown in the figure below For Elexant 4010i assemblies the module earthing grounding wire will be pre wired at the Factory Figure 5 Input Power 2 6 2 Load Connections This sectio...

Page 13: ...respectively as shown in the figure below Figure 7 Elexant 4020i AC Voltage Sense 2 6 4 RS 485 IN RS 485 IN along with RS 485 OUT are used for setting up series RS 485 communications connections when using multiple controller modules Wiring for the RS 485 data connections may be terminated directly on the module TB 2 terminal blocks as shown or on panel mounted terminal blocks Shielded cables shou...

Page 14: ...be terminated directly on the module TB 2 terminal blocks as shown or on panel mounted terminal blocks Shielded cables should not be terminated on terminals of TB2 Terminate RS 485 cable shields on panel mounted field terminals as shown in the figure below Note Install a 120 Ohm termination resistor as shown if this is the last device in the communication bus Figure 9 RS 485 Out ...

Page 15: ...thernet port 2 6 7 Profibus Profibus connectivity is available only on specific Elexant 4020i variants The connection is made via the DB9 connector at the bottom of the unit using a certified Profibus connector and cable Figure 11 Profibus Interface on Elexant 4020i Variant 2 6 8 USB Connector The USB connector on the front of the unit can be used to import export User Settings to simplify the com...

Page 16: ...hree 3 wire RTD inputs and a limiter version of the controller can accept up to four 3 wire RTD inputs Connections are the same for all of the three 3 wire RTD inputs and optional fourth input for the Limiter Terminate all cable shields on external panel mounted field terminal blocks Note If a unit has a Limiter the Limiter s RTD must be connected and operational for the control output to work See...

Page 17: ...Wire RTD connections 2 6 12 4 20 mA Connections Wiring for 4 20 mA connections may be terminated on terminal block TB 2 terminals 1 to 6 Connections are the same for all of the three 4 20 mA channels Terminate all cable shields on external panel mounted field terminal blocks Figure 16 Elexant 4 20 mA Connections ...

Page 18: ...ections to SSRs The control output connections to SSRs are made using TB2 terminals 8 and 9 Note the polarity of the output connections CAUTION Shock hazard disconnect from live voltage before accessing terminals Figure 17 Terminals 8 and 9 on TB2 Figure 18 Elexant 4020i Single Phase One Pole Connections to SSR ...

Page 19: ... RAYCHEM AR H60624 40X0iOpsManual EN 1905 nVent com 19 Figure 19 Elexant 4020i Single Phase Two Pole Connections to SSRs L3 L2 L1 N 3PH TB2 Circuit Breaker SSR SSR SSR L2 L1 L3 N 8 9 To Load Figure 20 Elexant 4020i Three Phase Connections to SSRs ...

Page 20: ...relay connections provide a Form C dry contact rated at 277 V maximum 3 A Figure 21 Alarm Relay 2 6 15 Digital Inputs The Elexant 4010i 4020i provides multi purpose inputs terminals 10 11 12 of TB2 for connection to external dry voltage free contacts or DC voltages for extending the functionality of the controller Digital Inputs support a maximum of 100 Ohm loop resistance or may be used with 5 to...

Page 21: ...nal Limiter variants the Limiter Relay output Terminal 2 of TB3 drives an external limiter contactor coil Note that this is a wet contact and provides an output voltage derived from the incoming module power The Limiter contactor is placed in line with the load connections to ensure that when the Limiter has tripped the Limiter contactor will interrupt the power to the load heating circuit See Cha...

Page 22: ...contact and provides an output voltage derived from the incoming module power The load contactor is placed in line with the load connections Note When using Limiter modules the Limiter output see Section 2 6 17 also needs to be energized in order for the Electric Heat Tracing EHT to be powered Figure 25 Elexant 4020i Single Phase Contactor Output Connections Figure 26 Elexant 4020i Three Phase Con...

Page 23: ...n electric heat tracing cables including series parallel self regulating and constant wattage types and applications requiring equipment protection algorithms When using the SSR Output control type the Contactor Output is held in a user defined state continually unless the SSR fails In that case the Contactor output is switched to the opposite state This allows the Contactor output to be used to c...

Page 24: ...nd maintain a particular temperature the main variable in controlling the pipe temperature becomes the ambient air temperature This approach greatly reduces the amount of energy used in ambient temperature control applications versus traditional ambient temperature control 3 1 2 3 Proportional The Proportional algorithm monitors the temperature of the heating circuit and compares it to the setpoin...

Page 25: ...ows simple external devices to extend the functionality of the controller The 24V tolerant digital input which can also accept 5V logic levels or dry contacts asserts an alarm or overrides the control algorithm to force the output on or off It also supports HOA Hand Off Auto func tionality Use of a digital input overrides normal control Other overrides have a higher priority If the switch does not...

Page 26: ...en using an SSR output switch 3 1 3 2 6 Solid State Relay Switch Protection Default Disabled The SSR Switch Protection algorithm may be used to protect an SSR from damage due to temporary in rush current caused by the heating cable 3 1 3 2 7 Safety Limiter The Safety Limiter provides an independent high temperature cut out capability suitable for use in safety critical applications It disconnects ...

Page 27: ... during start up Failed no valid reading Open circuit some or all of the sensor leads are open or Short Circuit some or all of the sensor leads have been shorted to each other IMPORTANT If the TS X input is not being used by the controller the TS X TEMPERATURE is not displayed 3 2 1 3 Control Monitor Toggle Purpose This parameter selects the use of the sensor for control or monitoring purposes Whe...

Page 28: ...Enabled TS2 Disabled TS3 Disabled b Latch Purpose This parameter is used to configure the behavior of the High Low Alarm conditions Disabling the Latch function will allow the alarm to self clear once the alarm condition has resolved Enabling latching will keep the alarm active until it is reset by the user or the controller is reset by a cycling the power on off for example High Temperature Alarm...

Page 29: ...oment of the failure This state continues until at least one valid control temperature reading is restored Table 6 Control Temperature Fail Modes 3 2 2 Electrical This section describes the electrical setting options for the Elexant 4010i 4020i modules 3 2 2 1 Trace Current Trace current represents the load current in the EHT circuit Trace current can be inferred from Line Current and Heater Confi...

Page 30: ...Sustained electrical arcing or fire can result To minimize the risk of fire if a GF condition has been detected shut off the power to the heating cable and repair the system immediately IMPORTANT In order to safely implement a ground fault trip function all non grounded power conductors must be opened upon detection of a ground fault condition Multi pole switch configurations should be used on non...

Page 31: ...ions This value is written to the controller s non volatile memory once every 24 hours or whenever any maintenance data is reset by the user IMPORTANT The CONTACTOR CYCLE COUNTER is only indicated if the SWITCH CONTROL MODE is set to either DEADBAND or PROPORTIONAL AMBIENT CONTACTOR Note Once the CONTACTOR CYCLE COUNTER reaches 999 999 999 it will stop counting until it is reset 3 2 3 2 Hours in U...

Page 32: ...vices to extend the functionality of the controller It offers the option to alarm or override the electrical heat tracing mode from an external device and can be configured in the following ways None Default No action taken or no device connected Force On when input is open or closed Open closed is also configurable Force Off when input is open or closed Open closed is also configurable Alarm when...

Page 33: ...e unit Configuration parameters and defaults are shown below Variable Description Default Range Options Enable DHCP Allows the unit to use Dynamic Host Configuration Protocol Enabled Enabled Disabled Network Address Defines the Ethernet Port IP Ad dress 192 168 1 100 0 to 255 for each address field Network Mask A 32 bit number that masks the network address and divides it into network address and ...

Page 34: ...he alarm relay offers three modes of operation to support a range of attached equipment Normal In the event of an alarm the relay de energizes It stays in the de energized state until all alarms are cleared When no alarms are present the alarm relay is energized Flash An alarm causes the relay to energize and de energize each second When there are no alarms present the alarm relay is held in the e...

Page 35: ...eded the heater ON time setpoint External Input The Digital Input is configured to Alarm and an alarm condition has been triggered Temperature Temp Sensor x Temperature Sensor x High Sensor x s measured temperature exceeds the sensor high temperature setpoint Temperature Sensor x Low Sensor x s measured temperature is below the sensor low temperature setpoint Temperature Sensor x Failure Sensor x ...

Page 36: ...ent of the process temperature line sensing See Appendix A for more details 3 Ambient This profile loads settings that are appropriate for control based on ambient temperature ambient sensing This profile uses the PASC algorithm default settings See Appendix A for more details 4 User 1 Allows the user to name the profile and both load and save the settings on demand 5 User 2 Allows the user to nam...

Page 37: ...ored using the GUI See Section 5 1 for more details 3 9 LED Status Indicators The front panel of the Elexant 4010i 4020i Heat Trace Controller has 4 LED indicators to indicate conditions LED STATUS DESCRIPTION STATUS OFF No power Faulty LED Flashing Red Green Calibrated Unlocked Flashing Yellow Green Uncalibrated Locked Flashing Yellow Red Uncalibrated Unlocked Solid Red Device Reset Alarm Active ...

Page 38: ... equipment without delay Power may be restored to the attached equipment by manually resetting the safety function after the temperature returns below the permissible limit and no fault is present The safety function may be reset using the TRIP RESET button on the front of the unit or by using the product GUI or through supervisory software connected via the communication ports In specific circums...

Page 39: ...f the safety limiter must be set in such a way that the maximum allowable temperature of the equipment is not exceeded For example the surface temperature of a heat tracing cable in a hazardous area cannot exceed the local maximum temperature allowed based on the classification rating T rating of the area The set point should be the maximum allowed temperature less 5 K for temperatures below or 20...

Page 40: ...nterval for the safety limiter can be set to 1 10 or 20 years depending on the application The functional test procedure is described in Section 4 1 9 Functional Test Procedure Conformance to the SIL certification is limited to the 20 year lifetime of the unit Type Safety Integrity Level Systematic Capability Proof Check Interval Unit Lifetime 4020i Mod IS LIM SIL 2 SC 2 1 10 or 20 years 20 years ...

Page 41: ...replaced See Section 1 3 for nVent Customer Care contact information 4 1 11 Determining Safety Integrity of the Elexant 4020i Mod IS LIM The Elexant 4020i Mod IS LI is a Type B system as defined in IEC61508 2 2010 A sub system is a Type B system when all of the following apply 1 The failure mode of at least one component that is used is not adequately defined 2 The response of the sub system in fa...

Page 42: ...rt A trip is reset silently or without user intervention A forced Trip clears on its own or can t be forced Detected Dangerous 3 60E 04 3 59E 03 8 96E 03 Undetected Dangerous 4 00E 05 4 00E 04 1 00E 03 Output short The limiter output relay but not the main output override is stuck in the ON position regardless of the temperature Detected Dangerous 8 15E 03 7 85E 02 1 85E 01 Undetected Dangerous 7 ...

Page 43: ...e 30 Control Setup Touch this icon to navigate to the Control Setup Screen This screen allows the user to set configuration parameters for the Temperature setpoint Control mode Output type Load Shedding and other Miscellaneous settings The details are covered in Section 5 4 5 1 2 Temperature Figure 31 Temperature Icon Touch this icon to navigate to the GUI screen for Temperature Sensors In this sc...

Page 44: ... in the device The Alarm page also allows resetting of any alarms The details are covered in Section 5 9 5 1 5 Maintenance Figure 34 Maintenance Icon Touch this icon to navigate to the GUI screen for Maintenance information In this screen the user can see the current temperatures of each controller sensor measured voltage power and current along with several other min max parameters tracked by the...

Page 45: ...ngs of the SIL Safety Integrity Level 2 certified Safety Limiter This is only available in the Elexant 4020i IS LIM variants The details are covered in Section 5 13 5 1 9 User Interface Figure 38 User Interface Touching this icon navigates to the screen that allows configuring the controller passcode language and the temperature units C or F The details are covered in Section 5 14 5 1 10 Info Figu...

Page 46: ...3 main areas as listed below A The top left area displays the alarm status Touching this area will cause the display to jump directly to the Alarm Screen B The top right area displays information related to the temperature C The lower half of the area displays the electrical information and trace status 3 A C 8 4 1 2 B 5 7 6 Figure 40 Main Screen for Single Phase Controller The details of the Main...

Page 47: ...ays On The Always On control mode is in use 3 Trace Test Trace test is currently active See Section 5 10 4 6 4 Always Off The Always Off control mode is in use 5 Load Shed Active The load shedding feature is active See Section 5 6 5 6 Load Shed Failsafe Load shedding failsafe is active 7 Force Off The digital input is forcing the control output off See Section 5 6 7 4 8 Force On The digital input ...

Page 48: ... phase Controller except that it includes a phase indicator This indicator cycles through each one of the three monitored phases with updated current and power values 5 3 Information Screen The Information Screen displays information about the specific unit such as Model Firmware version Manufacture Date Serial Number and the Limiter Version if applicable Figure 43 Information Screen This screen c...

Page 49: ...red 5 4 1 Control Temp Setpoint Figure 45 Control Temp Setpoint Setting Purpose This is the temperature value at which the controller will maintain the circuit temperature This value is compared to the temperature measured by the control temperature sensor s and the power to the EHT is turned on or off in accordance to the user selected algorithm Range 200 to 700 C Procedure Touching the text box ...

Page 50: ... tem perature reading Options Average Selecting this option will cause the output of the unit to be controlled using the average of all valid temperature readings from any temperature sensors configured to be used for control Lowest Selecting this option will cause the output of the unit to be controlled using the lowest of all valid temperature readings from any temperature sensors configured to ...

Page 51: ...red to working condition Fixed The heat trace output is held at a fixed duty cycle until a control sensor is restored to working condition When this mode is selected an additional field will appear to allow the user to enter the desired duty cycle as shown in Section 5 4 3 Last The heat trace output is held at the same duty cycle that existed at the moment of the failure This state continues until...

Page 52: ...hen the latch ing is selected the alarm will need to be manually reset each time the corresponding alarm occurs Figure 54 Control Temperature Alarms Settings Touching the text box next to Setpoint or Filter will display the numeric entry keypad Enter the desired value using the numeric keypad and touch the button to set the new value Figure 55 Control Temperature Alarm Filter Settings Filter When ...

Page 53: ...the control tempera ture is below the value of Low Temperature Setpoint This condition is monitored by the temperature sensor s selected for control 5 C 200 C to 700 C 0 to 59940 seconds Failure This alarm is active when no valid control temperature reading is available E L E D N A Table 17 Control Temperature Alarms 5 5 Control Mode Page This page provides access to the settings that govern the c...

Page 54: ...mperature desired maintain tem perature minimum ambient temperature and size of the smallest pipe diameter to deter mine the optimum duty cycle and cycle period to maintain the temperature minimize energy consumption and prolong the switch life Minimum Ambient Minimum Pipe Diameter Power Adjust Proportional This algorithm constantly monitors the control sensor temperature and adjusts the output du...

Page 55: ...HEM Elexant 4010i 4020i User Manual RAYCHEM AR H60624 40X0iOpsManual EN 1905 nVent com 55 5 5 2 Algorithm Settings Figure 60 Deadband Setting Figure 61 PASC Parameters Settings Figure 62 Proportional Band Setting ...

Page 56: ...and This value represents the proportional band within the Proportional algorithm 2 C 1 C to 50 C Table 19 Control Algorithms Procedure Select an algorithm and configure accordingly 5 5 3 Output Type Figure 63 Output Type Setting Purpose To select the type of Output that matches the output switch type connected to the controller Options Output Type Description Contactor This output type should be ...

Page 57: ... fails 5 5 4 Heater Configuration This section applies to Elexant 4020i 3 phase variants Figure 66 Heater Configuration Selection Purpose Selects the topology of the 3 phase heater to enable the controller to properly calculate trace power and trace resistance Table 21 lists various 3 phase heater configuration settings and wiring configurations that are used for the calculations of trace voltage ...

Page 58: ...ta Measured voltage 3 Measured current 3 L N L N L N Wye Measured voltage Measured current Table 21 3 Phase Heater Configuration Settings 1 L L Line to Line 2 L N Line to Neutral 5 6 Output Limiting Page This page is available only when the Output Type is selected as SSR Figure 68 Output Limiting Page 5 6 1 Output Limiting Mode Figure 69 Output Limiting Mode Setting Purpose The output of the contr...

Page 59: ...g Switch Protection Figure 71 SSR Rating Setting Range 20 0 A to 100 0 A for Current Turns Ratio 1 1 Default 30 0 A Purpose The SSR Limiting Switch Protection feature is available when an SSR output switch is used It is intended to minimize the chance of damaging an SSR during unusual inrush current situations The SSR Rating alarm if enabled will only inform the user that switch limiting is active...

Page 60: ...m will need to be manually reset each time the corresponding alarm occurs Figure 72 SSR Limiting Alarm Settings 5 6 3 Circuit Breaker Limiting 5 6 3 1 C B Type Circuit Breaker Type Figure 73 C B Type Purpose Selects the circuit breaker curve to be used when performing circuit breaker current limiting Each type of breaker has a different allowance for brief over currents and this parameter must be ...

Page 61: ...ee Section 5 8 1 2 Procedure Touch the C B Rating text box to display the numeric pad and set the numeric value Touch the Enable check box to turn on off the Alarm indication or touch the Latch check box to configure a latching or a non latching type of alarm When the latching is selected the alarm will need to be manually reset each time the corresponding alarm occurs Figure 76 C B Limiting Alarm...

Page 62: ... a load shedding mode only after receiving a load shedding command issued from a Modbus Master This mode overrides the temperature control and forces the output of the control module off until reset by the Modbus Master The Modbus Master issues a load shedding broadcast command to the control modules at least once every Timeout period If the controller has this feature Enabled and does not receive...

Page 63: ...6 6 Load Shedding Failsafe Mode Purpose Load Shedding Failsafe mode is used to protect the EHT circuit from freezing if the control output is off due to a load shedding command issued by the Modbus Master Once the temperature of the TS used in the TS CONTROL MODE drops to that sensor s LOW TEMP ALARM setting the control output will go ON and use the Low Temp Alarm setting as the temporary control ...

Page 64: ...etect any alarm conditions Circuit alarms are be generated at the time of autocycle instead of when heat is required This feature eliminates the need for a preventive maintenance program as these tests are performed at regular intervals by the controller Default 8 Hours 5 6 7 3 Alarm Mode Purpose The Alarm Mode defines the behavior of the alarm output 1 Normal Figure 84 Alarm Mode Normal Setting T...

Page 65: ...gital Input Setting Purpose The digital input offers the option to generate an alarm or override the electrical heat tracing mode using an external dry contact or DC voltage source The digital input can be configured in the following ways Not Used no action taken Force On when input is open Force On when input is closed Force Off when input is open Force Off when input is closed Alarm when input i...

Page 66: ...e Settings Page This page provides access to the selection and settings of Temperature Sensor x and to Temperature Limiting features Figure 90 Temperature Settings Page 5 7 1 Temp Sensor x Reading Purpose This temperature is the value that the controller is reading from the temperature sensor connected to the corresponding temperature sensor input Depending on the TS Control Mode it may be used to...

Page 67: ...oring purposes Selecting Control enables the High Temperature and Low Temperature settings and displays the Control Temperature Alarm settings As a Control Sensor it will be used as part of the output control algorithm and contributes to the measurement for control sensor alarms Selecting Monitor disables the High Temperature and Low Temperature Settings Default TS1 Control TS2 TS3 Monitor Figure ...

Page 68: ...to a temperature sensor for easy identification of location area etc Default The default value of the Tag is in the format Elexant 4010i 4020i TSx where x is 1 2 or 3 for the corresponding sensor 5 7 1 4 Lead Resistance Figure 95 Lead Resistance Setting Purpose When using 2 wire temperature sensors a sensor lead resistance value may be entered correcting the resistance measurement for better tempe...

Page 69: ...ature Setpoint or drops below the Low Temperature Setpoint the unit only triggers an alarm if the corresponding High Low alarm condition is present for the Filter period If immediate alarm output is required for an alarm condition then the corresponding filter value should be set to 0 Alarm Setpoint Description Default Value Range Filte seconds High Temperature This alarm is active when the sen so...

Page 70: ...mit Cut out and alarm Value Description Default Value Range High Limit This value defines the High Limit Cut out Setpoint for each of the 3 temperature sensors where the corresponding temperature sensor has High Limit Cut out enabled This overrides the Control Tem perature Setpoint value and forces the controller output off if any one of the corresponding tem perature sensors exceeds the High Limi...

Page 71: ...the corresponding Alarm Touch the corresponding Latch check box to select a latching or a non latching alarm type When Latch is selected the alarm will to be manually reset each time the corresponding alarm occurs Figure 103 High Low Trace Current Setpoint Filter Settings Filter When the current exceeds the High Current Setpoint or drops below the Low Current Setpoint the controller will only trig...

Page 72: ...the setpoint value is highlighted in red its setting is invalid Check the Current Turns Ratio and adjust its setting within the correct range 5 8 1 2 Current Turns Ratio Purpose The Current Turns Ratio adjusts current readings for applications where a control module is monitoring a load through an external step up or step down current transformer The highest Trace Current supported by the controll...

Page 73: ...Ground Fault Alarm Settings Procedure Touch the corresponding Enable check box to turn on off the corresponding Alarm indication and touch the corresponding Latch check box to select a latching or a non latching alarm type When latching is selected the alarm will need to be manually reset each time the corresponding alarm occurs Figure 108 High Trip Ground Fault Setpoint Filter Settings Filter Whe...

Page 74: ...io and adjust its setting within the correct range 5 8 2 2 Ground Fault Turns Ratio Purpose The Ground Fault Turns Ratio may be used to adjust the Ground Fault Current readings in applications where a control module is monitoring the load through an external step up or step down current trans former The highest Ground Fault current tolerated by the controller is a function of the external Ground F...

Page 75: ...High Low Trace Voltage Setpoint Filter Settings Filter When the voltage exceeds the High Voltage Setpoint or drops below the Low Voltage Setpoint the unit only triggers an alarm if the corresponding High Low alarm condition is present for the duration of the filter period 0 28 seconds If an immediate alarm output is required then the corresponding filter value should be set to 0 Value Description ...

Page 76: ...t its setting within the correct range 5 8 3 2 Voltage Turns Ratio Purpose The Voltage Turns Ratio adjusts voltage readings for applications where a control module is switching a load through a step up or step down transformer or is being powered from a source with a different voltage level than the trace voltage The Voltage Turns Ratio value can be used to multiply or divide the Trace Voltage mea...

Page 77: ...ominal Resistance Settings Figure 118 High Low Trace Resistance Settings Procedure Touch the corresponding Enable check box to turn on off the corresponding Alarm indication and touch the corresponding Latch check box to indicate a latching or a non latching alarm type When latching is selected the alarm will need to be manually reset each time the corresponding alarm occurs Figure 119 Trace Resis...

Page 78: ...ance Alarm Settings Figure 120 Nominal Trace Resistance Setting Values Description Default Range Nominal Trace Resistance Set this value to the nominal heat trace resistance 6 Ohms 1 Ohms to 3000 Ohms Table 29 Nominal Trace Resistance Settings In the case of a 3 phase controller L1 L2 and L3 buttons are displayed in the top right corner of the page Touching any of these buttons displays the corres...

Page 79: ...ure 122 Alarm Icon Touch the Alarm Icon to open the Alarms page Figure 123 Alarms Page Touch Up Down button to go to the next page To reset an Alarm select the Alarm A Reset Alarm window will pop up Figure 124 Reset Alarm Window Click on button to confirm or click button to cancel To reset all alarms touch button ...

Page 80: ...und fault etc The highest and lowest values measured since they were last reset are stored in the controller s memory NOTE Maintenance data is stored until it is manually reset After being reset the measuring process restarts and stores new Minimum and Maximum values 5 10 1 Temperature Figure 126 Temperature page This page displays the actual temperatures minimum and maximum values recorded by the...

Page 81: ...splays the Trace Power and Accumulated Power for the connected load Accumulated Power is the total power consumption of the heat tracing circuit since the last time the Power Accumulator was reset Touch the button to reset the corresponding maintenance data or touch the button to reset all maintenance data In case of a 3 phase controller data for each of the three phases will be displayed Figure 1...

Page 82: ...page displays maintenance data for variables such as Contactor Cycles Hours in Use Heater On Time Hours Since Reset etc Touch the button to reset the corresponding maintenance data or touch the button to reset all of the maintenance data on this page 5 10 4 1 Contactor Cycles This field indicates the total number of Off to On transitions a contactor has completed since the last time the Contactor ...

Page 83: ...heat trace has been in the energized state 5 10 4 4 Hours Since Reset This field is used to indicate the number of hours that have passed since the unit was last powered on 5 10 4 5 Device Reset Figure 132 Device Reset This field enables or disables the Device Reset Alarm which is used to indicate 1 Power to the device has been interrupted and subsequently restored 2 A transient condition has caus...

Page 84: ...ix A for more details 3 Ambient This profile loads settings that are appropriate for heating applications that use the ambient temperature to determine heating needs ambient sensing See Appendix A for more details 4 User 1 Allows the user to assign a name to a custom profile and load save the settings on demand 5 User 2 Allows the user to assign a name to a second custom profile and load save the ...

Page 85: ...the single check mark to save the file If the file name already exists the controller will display Are you sure you wish to overwrite existing file Touch to confirm or touch to cancel Touch the Eject USB Drive to remove the USB drive 5 12 Network Setup Page Figure 136 Network Settings Figure 137 Network Settings with Profibus Option The Elexant 4010i 4020i can be connected to a communications netw...

Page 86: ...cations ports 1 1 2 Transmit Delay Sets the time the controller will wait after it receives a message before it replies 20 0 to 5000 msec Table 30 RS 485 Settings 5 12 3 Ethernet Figure 138 Ethernet Settings The Elexant 4010i 4020i controllers can also be connected to devices such as the nVent RAYCHEM TOUCH 1500 or a PC running RAYCHEM Supervisor using an Ethernet connection Variable Description D...

Page 87: ...e status of the Profibus interface as follows 1 Not Configured 2 Baud rate not detected 3 Configuration Error 4 Parameterization Error 5 In Data Exchange Table 32 Profibus Settings 5 13 Safety Limiter Settings Page Figure 140 Safety Limiter Settings The Safety Limiter provides an independent high temperature cutout capability to ensure protection against over heating of the EHT or the workpiece It...

Page 88: ... Status Tripped 5 13 1 2 Safety Limiter Temperature Figure 144 Actual Temperature Reading Purpose This field shows the temperature measured by the Limiter RTD If this value exceeds the Safety Limiter set point the Safety Limiter will trip open In the case where the Safety Limiter has tripped a manual intervention is required to reset the trip condition This is only possible once all process condit...

Page 89: ...area etc Default The default value of the Tag is in the format Elexant 4010i 4020i TSLIM serial number 5 13 1 5 Test and Reset Touch the button to test the Limiter s safety function When the test safety function is activat ed it disconnects the power to the EHT circuit The safety function may be reset using the TRIP RESET button on the front of the unit or by touching the button 5 13 2 Safety Limi...

Page 90: ...3 2 4 Intelligent Limiting Figure 151 Intelligent Limiting Setting Purpose This field enables or disables the Intelligent Limiting feature When Intelligent Limiting is disabled the Safety Limiter will trip if the measured temperature rises above the Safety Limiter s setpoint or in the event of a fault Once the measured temperature returns below the permissible limit and there are no faults present...

Page 91: ...eratures on the controller GUI Options Degrees Celsius C Degrees Fahrenheit F Default Degrees Celsius C 5 14 3 Passcode Figure 155 Passcode Setting Purpose This is a four digit numeric field to stop unauthorized users from modifying the controller s configuration parameters using the touch screen Range 0000 to 9999 Default 0000 Procedure Touch the Passcode field and enter the desired passcode usin...

Page 92: ...Note that this process is time sensitive once the number above has been generated by the controller you have 24 hours to obtain a temporary passcode from Technical Support and 48 hours to enter the temporary passcode into the controller 5 14 4 Calibrate Figure 157 Calibrate Touch Interface Purpose Touching this button allows the user to re calibrate the touch interface of the controller The user w...

Page 93: ...nd hold the third point on the GUI for 3 seconds Figure 160 Calibrate GUI s Point 3 Touch the button to complete the calibration NOTE If the calibration is not completed correctly the screen will turn red A touch anywhere on the screen will bring back the calibration screen Repeat the GUI calibration process ...

Page 94: ... following screen Figure 161 USB Drive Detected Dialog Touch the Upload New Firmware From File button The controller will display a dialog with the filenames of the various firmware versions if applicable available on the USB drive Select the desired firmware file and touch the button to start the process of updating the firmware or the button to cancel The controller will display a message Please...

Page 95: ...gs or replace converter Set correct communication port Correct software setup to match controller communication settings Place 120 Ω termination resistor across RS 485 wiring on last controller No Ethernet Communication Cannot establish Ethernet communications with the controller Incorrect IP settings Bad Ethernet cable Windows Firewall Faulty port on router switch Verify IP settings Replace Ether...

Page 96: ... E NL 40 Low Temp Filter 0 0 0 0 300 Failure E L E L E L Control Mode Control Mode On Off On Off PASC Output Type Contactor Contactor Contactor Dead band 3 C 3 C 3 C Min Ambient N A N A 40 C Min Pipe Size N A N A 0 5 12 5mm Power Adjust N A N A 100 Load Shedding Load Shedding D D D FailSafe D D D Timeout 60 Sec 60 Sec 60 Sec Misc Cycle Count E 100000 E 100000 E 100000 Heater on Time E 100000 E 100...

Page 97: ...00 TS3 Failure D L D L D L Temp Limiting TS1 Use for High Low Temp D D D TS2 Use for High Low Temp D D D TS3 Use for High Low Temp D D D High Limit Alarm E NL 700 E NL 700 E NL 200 Low Limit Alarm E NL 70 E NL 70 E NL 70 Low Limit Deadband 3 3 3 Electrical Page Trace Current Current Turns Ratio 1 1 1 High Alarm D L 30 D L 30 D L 30 High Alarm Filter 0 0 0 Low Alarm E L 1 E L 1 E L 1 Low Alarm Filt...

Page 98: ...p Bits 1 1 1 Transmit Delay 20 ms 20 ms 20 ms Network Ethernet Enable DHCP E E E Network Address 192 168 1 100 192 168 1 100 192 168 1 100 Network Mask 255 255 255 0 255 255 255 0 255 255 255 0 Default Gateway 192 168 1 1 192 168 1 1 192 168 1 1 Network Profibus Option Address _______ _______ _______ User Interface Language English English English Unit C C C Passcode 0 0 0 Safety Limiter Trip Alar...

Page 99: ...RAYCHEM AR H60624 40X0iOpsManual EN 1905 nVent com 99 ...

Page 100: ...nVent RAYCHEM Elexant 4010i 4020i User Manual RAYCHEM AR H60624 40X0iOpsManual EN 1905 nVent com 100 ...

Page 101: ...M AR H60624 40X0iOpsManual EN 1905 Our powerful portfolio of brands CADDY ERICO HOFFMAN RAYCHEM SCHROFF TRACER nVent com North America Tel 1 800 545 6258 Fax 1 800 527 5703 thermal info nvent com Europe Middle East Africa Tel 32 16 213 511 Fax 32 16 213 604 thermal info nvent com Asia Pacific Tel 86 21 2412 1688 Fax 86 21 5426 3167 cn thermal info nvent com Latin America Tel 1 713 868 4800 Fax 1 7...

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