Thermon TraceNet TCM18 Installation, Start-Up, And Maintenance Manual Download Page 1

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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

Summary of Contents for 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: ...n 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 If any part of the equipment proves to be defective in workmanship or material...

Page 3: ...Module Connections 5 Chapter 4 Field and Panel Wiring 9 Chapter 5 The User Interface 13 Chapter 6 Heat Trace Control 21 Chapter 7 System Start Up 23 Chapter 8 Maintenance 24 Chapter 9 Notes 29 Chapter 10 More Information 30 Appendix A 31 Appendix B 43 Appendix C 44 PN 50312_0414 ...

Page 4: ...els can be located in site locations having electrical clas sifications ranging from ordinary to hazardous The actual panel markings provided with the panel will detail the design intended specific location requirements INITIAL INSPECTION AND HANDLING Upon receiving the TraceNet TC Series panel it is important to confirm that the contents of the shipping containers agree with the shipping document...

Page 5: ...ld be constructed Once the panel has been properly located refer to the project specific installation details for the recommended floor mounting as well as wall mounting details Once bolted in place the panel is ready for final configuration wiring and site required assembly Note that the TCM18 control and monitoring module is normally shipped in a separate container to minimize any undue impact s...

Page 6: ...trol voltage 100 to 240 Vac 50 60 Hz Temperature sensor types 100 Ohm 3 Wire Platinum RTD Control temperature range 200 F to 1112 F 129 C to 600 C Maximum power consumption of TCM18 module 70 Watts Current ratings in hazardous classified locations based on TraceNet TC Series panels for up to 72 circuits are as follows1 Maximum Panel Exterior Ambient C For 1 36 Circuits For 37 72 Circuits Maximum A...

Page 7: ...turer for the maximum allowable amps per relay for custom enclosure sizes Note 2 Based on factory panel wiring rated for 105 C TCM18 LCD heated display 1 3 4 44 mm x 4 875 124 mm TCM18 touchpad tactile feel stainless steel dome keys TCM18 communication 2 RS485 ports TCM18 operating temperature range 40 F 40 C to 140 F 60 C TCM18 alarm relay outputs U Option Three sealed dry contacts rated 0 4 Amp ...

Page 8: ... of the inner workings of this panel the following general connection diagrams are provided The TCM18 Connections The TCM18 is the TraceNet interface to the outside world It monitors the condition of the heat tracing circuits as well as the heat traced piping temperatures and allows inter rogation of heat trace status alerts the operator to alarm and trip events and allows the changing of the oper...

Page 9: ...l 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 The connections within a TraceNet panel for the RTB6 are shown in the illustration which follows Figure 2 RTB6 Wiring and Connections 6 PN 50312_0414 ...

Page 10: ...rmers solid state heat trace control relays and the heat dissipating heat sink This module in cludes a ground leakage functional test circuit In addition alarm and trip output capabil ity to indicating lights on the panel front door are also provided The module connections for the PM6 are as detailed in the following illustration Figure 3 PM6 Wiring and Connections 7 PN 50312_0414 ...

Page 11: ...dual pilot and mechanical relays are to be used The module connections for the RM6 are as de tailed in the following illustration Figure 4 RM6 Wiring and Connections When receiving a new TraceNet TC Series control panel shipment it is recommended that all module connections within the panel be re torqued to the recommended tightness levels as provided in the project panel drawing and in Table 1 Ch...

Page 12: ...onflicts arise contact the project engineer for resolution Heat Trace and Insulation Installation 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 RTD Installation and Wiring RTD c...

Page 13: ... up to and exceeding 221 F 105 C unless otherwise higher values are noted in project specifications Power supply wiring from the power transformers to the power distribution panel and distribution wiring to the heat trace circuits shall be rated for the heat trace use voltage or higher and sized sufficiently large in wire size to minimize voltage drop Circuit breakers if not already supplied in th...

Page 14: ...ing the field wiring within the panel Field wiring is conventionally shown by dashed lines All field power wiring materials used shall be suitable for the intended service and shall be rated for insulation service temperatures up to and exceeding 221 F 105 C unless otherwise higher values are noted in project specifications All TraceNet components terminal block connections should be tightened usi...

Page 15: ...equal 120 Ohm 30 to 80 C 24AWG PE insula tion PVC outer jacket Belden 9842 or equal 120 Ohm 70 to 200 C 24AWG Teflon FFEP insulation Teflon FEP outer jacket Belden 89842 or equal Note all these products are designated as 120 ohm impedance for balanced line com munication uses Table 2 Recommended RS485 Cable Type 12 PN 50312_0414 ...

Page 16: ...age lines on the TCM18 display All interfacing to the TCM18 and the heat tracing circuit information is via the dedicated tactile feel membrane touch pad and the companion four line 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 Sc...

Page 17: ...A typical SCAN MODE screen when the heat tracing circuit is operating normally is as shown below in Figure 8 CKT 7 TEMP 61 C MAINTAIN TEMP 60 C HEATER ON 80 12 0A Figure 8 Typical TCM18 information when in SCAN MODE Note that the fourth message line on the display screen will be empty as long as there are no alarm or trip conditions present on a given circuit During SCAN MODE the TCM18 will sequen...

Page 18: ... key and subsequently followed by the PROG key Next successively select a numerical code using the UP and DOWN arrow keys along with the ENTER key An entry of 0000 will deactivate the security code feature Note that once a security code has been entered the user has unlimited access as long as activity is present A period of inactivity of 30 minutes or more will result in program ming access being...

Page 19: ... circuit control settings or control parameters multiple keys in sequence will need to be pressed For example to change the settings associated with the MAINTAIN TEMP key first press the green PROG key Figure 11 TCM18 PROG Key The Display now reads as shown below PROGRAM MODE ENABLED SELECT FUNCTION KEY Figure 12 Program Mode Enabled Press the MAINTAIN TEMP key 16 PN 50312_0414 ...

Page 20: ...presenting the active data entry field PROGRAM CIRCUIT 7z 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 17 PN 50312_0414 ...

Page 21: ...ging 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 Holding these keys down will increase the indexing speed for cases where a significantly large increase or decrease in set point is required Once the new set point is reached press the green ENTER key to save the new set point 18 PN 503...

Page 22: ...e 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 Alternatively press the green PROG key to exit and return to SCAN MODE However if for some reason this is not done the screen will automatically return to SCAN mode operation 19 PN 50312_0414 ...

Page 23: ...he values programmed into the first circuit will initially appear as a starting point for any value changes This TCM18 user interface should be found to be very intuitive and require minimal train ing to perform day to day operations The TraceNet system is a fully featured heat trace control and monitoring system and thus has many advanced options in setup and con figuration A companion document T...

Page 24: ...ce will be set to operate at 100 power at the maintenance temperature which is the minimum ambient condition and then ramp down to a 20 power level at the maintenance temperature plus the control band If the ambient rises above this value the heat trace will then turn off For example to freeze protect a process unit in a minimum ambient of 40 F 40 C one would set the circuit to operate on APC The ...

Page 25: ...turally be some tempera ture overshoot expected in the process as the ambient approaches the turn off point In this case mechanical relay switching of the heat tracing circuits may be used Ambient Sensing ON OFF control should not be used where steam outs and high exposure tem perature process conditions are expected and where the heat trace due to its inherent characteristics cannot be operated d...

Page 26: ...d be insu lated and weather sealed to achieve the expected heat up and temperature maintenance performance of the system Troubleshooting Tips When starting up a newly installed heat trace and control system it is not uncommon to encounter numerous alarm and trip events Data entry errors unanticipated tempera ture overshoots due to system inertia or too tight control band settings and incomplete in...

Page 27: ...esting within the control panel to ensure that the specific heat tracing and control circuit of interest is fully de energized and the equipment is grounded If it becomes necessary to service or test live equipment the following instructions must be followed Use one hand when servicing the equipment Accidental death or severe injury may occur especially if a current path is created through the bod...

Page 28: ...records dictate The recommended typical list of tools and test equipment follows Tools Comment Multimeter Calibrated and in Safe Working Order Flashlight Vacuum Cleaner Nonmetallic Nozzle Screw Drivers Standard as Well as Torque Type Wrenches Standard as Well as Torque Type Fuse Extractor Stiff Bristle Wire Brush Infrared Camera Helpful in Checking Out Connections The recommended spare parts inven...

Page 29: ...n as indicated by mineral deposits and rust Where feasible replace any gaskets which appear to be faulty Survey panel exterior and interior for dust lint moisture or foreign residue Remove any such residue with the lint free cloth material Heavy residues may be addressed with wood scrapers and a cleaning agent Do not soak parts with cleaning agent but only use dampened cloths in removing heavy res...

Page 30: ...ock connections should be tightened using a torque indicating screw driver to the levels indicated in Table 1 and project installation drawings Check for corrosion at electrical connections and terminations Where corrosion of electrical terminals is observed this may be additional evidence of loose connections and excessive heat A part replacement may be necessary Inspect wiring for abrasion wear ...

Page 31: ... visual check for out of range temperatures and low or high heater and ground earth leakage current in the heat tracing circuit s No alarms shall be present on any circuits in the fourth line of the display screen Perform Simulated Ground Earth Leakage Trip Exercise The TCM18 can simulate a high ground earth leakage under the CON FIG key and manually cause a trip to occur This allows operator to v...

Page 32: ...9 Notes 29 PN 50312_0414 ...

Page 33: ...ce 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 30 PN 50312_0414 ...

Page 34: ...than heat tracing high processing temperatures steam outs etc Let process return to normal condition or ad just alarm set point if approved by project engineer to allow for this processing condi tion High alarm setting programmed or expected reading did not consider natural tempera ture overshoot associated with the control scheme Move control set point down to allow for overshoot or raise the hig...

Page 35: ...heck insula tion type and thickness against design spec ification Replace insulation or review sys tem design for alternate operating possibili ties Wrong insulation size type or thickness on part of the line being traced The insulation system should be as speci fied in the design for the entire circuit be ing traced Having a lower heat loss on one part of the circuit and higher heat loss in sulat...

Page 36: ...uld be to adjust the control method which the TraceNet control system has been configured in Heat tracing circuits are miswired such that the RTD for circuit 1 is controlling circuit 2 etc Trace and recheck field and panel wiring Use circuit turn on and turn off tech nique or disconnect RTD s one at a time to see if the proper RTD failure alarm occurs on the right circuit Let process return to nor...

Page 37: ...ation size type or thickness on all of circuit being traced Measure circumference of insulation divide by π and compare to insulation diameter charts for proper over sizing Check insula tion type and thickness against design spec ification Replace insulation or review sys tem design for alternate operating possibili ties which involve more heat output Wrong insulation size type or thickness on par...

Page 38: ...r responding value of temperature Compare to pipe or equipment temperature known by another probe or sensor If different the RTD sensor may need replacement Heat tracing undersized improperly in stalled or damaged Review design installation Check heat trac ing for presence of proper current and also meg for dielectric resistance Repair or re place heat tracing Heat tracing circuits are wired such ...

Page 39: ...unications Alarm The following summarizes some of the possible causes and solutions for heat tracing communications alarms Cause Possible Solutions Improperly set controller address dupli cate addresses or improper configuration firmware software Change controller address or re configure firmware software Loose or open connection in RS485 line Recheck for continuity in all communication lines Too ...

Page 40: ... manager High Current Readings Alarms The following summarizes some of the possible causes and solutions for heat tracing high current readings or alarms Cause Possible Solutions Self regulating heater or power limiting heater current may exceed set value during normal operation or start up operations Increase high current alarm set point if ap proved by project engineer For startup op eration cur...

Page 41: ...may be installed Check heater set tags or markings on heater cable against installation drawings As an additional check disconnect heater from power and measure DC resistance Heat tracing may be powered on wrong volt age Recheck heater supply voltage Current sensing circuitry may have encoun tered a problem Use a different current clamp type meter which is known to be accurate and do a comparative...

Page 42: ...higher than design pipe tem peratures due to processing conditions and thus heaters may be drawing lower current values Decrease low current alarm setpoint if ap proved by project engineer Loss of a branch of the heat tracing circuit Measure total current and each branch cur rent Compare to design values Check all connections Breaker off Turn breaker back on after conferring with operations manage...

Page 43: ...e Wrong heater wattage or heater resistance may be installed Measure pipe temperature and measure steady state heater current voltage and length Compare to manufacturer s rated power curve Replace heat tracing cable if necessary Heat tracing may be powered on wrong volt age Recheck heater supply voltage Current sensing circuitry may have encoun tered a problem Use a different current clamp type me...

Page 44: ...racing had high leakage cur rent Disconnect heat tracing and sequentially disconnect power wiring until the alarm ceases Check last section removed for damage Improper wiring of current sense wires through toroid The current sensing toroid must have the outgoing heater current lead and the return current heater lead run through the toroid for a proper ground leakage measurement Redo wire routing i...

Page 45: ...ller with variable leakage trip functions is doing the ground leakage detection function increase ground leakage alarm set point 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 42 PN 50312_0414 ...

Page 46: ...s 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 43 PN 50312_0414 ...

Page 47: ...e line s to a compressor should not pass through a hazardous area If the compressor intake line passes through a hazardous area it should be constructed of noncombustible material and protected against mechanical damage and corrosion c The purge duration shall be increased by the time necessary to purge the free volume of the associated lines if applicable which are not a part of the certified pan...

Page 48: ...Thermon Manufacturing Company 100 Thermon Drive San Marcos Texas www thermon com Thermon PN 50312_0414 ...

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