NGC-40 Control System - NVent
NGC-40 Control SystemInstallation Manual
CONTENTSSection 1 – Overview 31.1 Introduction 3Section 2 – Installation and Wiring 42.1 Introduction 42.2 Initial Inspection 42.3 Operating Environment 42.4 Installation Location 42.5 Mounting Procedures 52.6 Wiring Procedures 52.6.1 INCOMING POWER WITH DISTRIBUTION SYSTEM 52.6.2 OUTGOING POWER WITH DISTRIBUTION SYSTEM 62.6.3 INCOMING/OUTGOING POWER WITHOUT DISTRIBUTION PANEL BOARD 72.6.4 INCOMING RTD WIRING 82.6.5 NGC-40-BRIDGE SWITCH SETTINGS 92.6.6 OPTIONAL RMM2 CONNECTION 102.6.7 OPTIONAL TOUCH 1500R CONNECTIONS 112.6.8 OPTIONAL DIGITAL INPUTS 132.6.9 OPTIONAL ALARM RELAY 142.6.10 C ONNECTING TO REM PC W/ RAYCHEM SUPERVISOR ORCUSTOMER DCS SYSTEM 152.6.11 CONNECTING MULTIPLE NGC-40 PANELS (BRIDGES) USING RS-485 (COM 1) 18Section 3 – RAYCHEM NGC-40 Components and Operation 203.1 NGC-40-HTC and HTC3 203.2 NGC-40-BRIDGE 253.3 NGC-40-IO 293.4 NGC-40-PTM 323.5 Touch 1500 and Touch 1500R Touch Screens 353.6 Touch 1500-HAZ 40Section 4 – Appendix A 434.1 Software License Agreement 434.1.1 SOFTWARE LICENSES 432 nVent.com
SECTION 1 – OVERVIEW1.1 INTRODUCTIONThe nVent RAYCHEM NGC-40 is a fully functional, self-contained control and monitoringsystem used with electric heat-tracing systems. It is designed for installation requiringminimal wiring on site. This manual provides information pertaining to the installation,operation, testing, adjustment, and maintenance of all components of the RAYCHEM NGC40 Control System. For information about how to program the RAYCHEM NGC-40 ControlSystem, see the RAYCHEM NGC-40 Control System with DTS User Guide (H58269).A typical RAYCHEM NGC-40 Control System consists of at least a one Power and Terminationmodule (NGC 40 PTM), one Bridge module (NGC-40-BRIDGE), one or more Heat-TraceControllers (NGC-40-HTC or HTC3) and one IO module (NGC-40-IO). Additional IO modules(NGC-40-IO) are optional and may be used. The system is intended to provide configurationand component flexibility so that it may be optimized for a customer’s specific needs.The information in this document coincides with the specific releases of firmware (listed inthe table below) for the Heat-Trace Controllers (NGC-40-HTC or HTC3) and Bridge module(NGC-40-BRIDGE) components. As nVent releases new firmware to significantly modify orenhance any of these components, new documentation will accompany these releases.To ensure that the correct documentation is being used for your particular version of theNGC-40-HTC/HTC3 and NGC-40-BRIDGE, compare the firmware version number of eachcomponent against the number listed in the table below. As subsequent changes are made,supplements to this document will be included in manuals shipped after the firmware isreleased. Supplements will make specific reference to the operation or functional change.Copies of this manual and updates may be downloaded from the Literature section ofnVent.com.ComponentVersion 0-BRIDGE5.xIMPORTANT WARNINGS AND NOTESThe following icons are used extensively throughout this manual to alert you to importantwarningsthat affect safety and to important notesthe unit. Be sure to read and follow them carefully.that affect the proper operation ofnVent.com 3
SECTION 2 – INSTALLATION AND WIRING2.1 INTRODUCTIONWARNING:Electrical Hazard! Ensure all personnel involved in installation, servicing, and programmingare qualified and familiar with electrical equipment, its ratings, safe electrical practices andnational and local electrical codes. Multiple voltages and signal levels may be present duringthe installation, operation, and servicing of this product. Do not power the NGC-40 untilthe safety provisions specified in this manual have been observed.This section includes information regarding the initial inspection, preparation for use,and wiring instructions for the components of the RAYCHEM NGC-40 Control System.2.2 INITIAL INSPECTIONInspect the shipping container for damage. If the shipping container or cushioning materialis damaged, it should be kept until the contents of the shipment have been verifiedfor completeness and the equipment has been checked mechanically and electrically.Procedures for installing the RAYCHEM NGC-40 Control System are given in this section. Ifthe shipment is incomplete, mechanically damaged, defective in any way, or does not passthe electrical performance tests, notify the nearest nVent representative. If the shippingcontainer is damaged, or the cushioning material shows signs of stress, notify the carrier aswell as your nVent representative. Keep the shipping materials for the carrier’s inspection.2.3 OPERATING ENVIRONMENTThere are three types of enclosures available with the RAYCHEM NGC-40 panel, as shownbelow.Enclosure TypeArea ClassificationUsageTYPE-12Nonhazardous (Unclassified) LocationsIndoorsTYPE-4/3RNonhazardous (Unclassified) LocationsOutdoors, painted steelTYPE-4/3R withZ purge optionHazardous Locations Class I, Division 2, Groups A, B, C, D Class I, Zone 2, Group IICHazardous Locations Class I, Division 2, Groups A, B, C, D Class I, Zone 2, Group IICOutdoors, painted steelwith mechanical relaysTYPE-4XOutdoors, stainless steelwith solid-state relaysWARNING:Shock Hazard. Some wiring configurations will use more than one power source. All powersources must be de-energized prior to performing any maintenance on a module or itsheating circuit. The operating environment should be within the limitations specified forthe RAYCHEM NGC-40 components as outlined in Appendix A.2.4 INSTALLATION LOCATIONThe wide ambient operating temperature range of the RAYCHEM NGC-40 Control Systempermits installation in almost any convenient location. Considerations should include:expected atmospheric conditions (weather), accessibility for maintenance and testing,the location of existing conduits, and hazardous location rating. Ambient temperatureconditions may affect load current ratings.WARNING:Fire Hazard. Always be sure that the intended location is classified as an area that theproduct is approved for use in as defined by Article 500 of the National Electrical Code and/orPart I, Section 18 of the Canadian Electrical Code.4 nVent.com
2.5 MOUNTING PROCEDURESEach RAYCHEM NGC-40 panel includes a set of “As Built” drawings that have beenengineered, designed, and drafted based upon the model number and any specialrequirements that were requested when ordering. The “As Built” drawings include anelevation/layout (with bill of materials) and schematics. If these drawings are not included,contact your nVent Representative and request the “As Built” drawings for your panel. Uponrequest, an electronic copy of these drawings can be provided.For mounting the panel, locate the elevation and layout drawing which includes a bill ofmaterials. The enclosure mounting information will be provided on the “As Built” drawings.2.6 WIRING PROCEDURESRefer to the “As Built” drawings for wiring of incoming/outgoing power and incoming RTDconnections. The RAYCHEM NGC-40 panel can be purchased with, or without, a distributionpanel board.2.6.1 INCOMING POWER WITH DISTRIBUTION SYSTEMMain Circuit BreakerLocate the main circuit breaker in the panel by using the supplied elevation/layout drawing,and connect per the associated schematic drawings. Depending upon the size and type ofmain circuit breaker and voltage loss calculations, use the appropriate size and number ofwires to connect directly to the main circuit breaker, and panel board neutral and ground busin the panel.Incomming serviceThree-phase, 4-wire, 60 HzØA ØB ØCMain circuitbreaker3-polePanelboardneutral busPanelboardground busPower wiring diagramFig. 2.1 Main circuit breaker wiringBranch Circuit BreakersThe branch circuit breakers are pre-wired to the contactors or solid- state relays in the panel,so no further incoming power wiring is required.nVent.com 5
2.6.2 OUTGOING POWER WITH DISTRIBUTION SYSTEMLoad Power Terminal BlocksLocate the outgoing heater terminal blocks using the supplied elevation/layout drawing, andconnect per the associated schematic drawings. Depending upon the size of the branchcircuit breaker and voltage loss calculations, use the appropriate size and number of wires toconnect from the panel’s Load Power Terminal Blocks to the heat-trace power junction box.Single pole C.B.CB*LPN*–L1NGC-40-HTCCT GFCTC*–N–N**Two pole C.B.CB*NGC-40-HTCLP*–L1LP*–L2CT GFCTC**NGC-40-HTC3CT –L1NGC-40-HTC3CT GFCTLP*–L2CTLP*–L3CTN*–NFig. 2.2 Heat-trace power wiring diagram6 nVent.comC*Heat-trace cableNLoad PowerTerminal BlocksTB*–T1LPThree pole C.B. (Three-phase, 4-wire)Heat-trace cableNLoad PowerTerminal BlocksTB**–T1 T1*–T2Three pole C.B. (Three-phase, 3-wire)CBLoad PowerTerminal BlocksTB**–T1 T1*Heat-trace cableLoad PowerTerminal BlocksTB*–T1**–T2*–T3*–NHeat-trace cable
2.6.3 INCOMING/OUTGOING POWER WITHOUT DISTRIBUTION PANEL BOARDLine Power Terminal BlocksLocate the incoming power terminal blocks in the panel using the supplied elevation/layoutdrawings and connect per the associated schematic drawing. Depending upon size and typeof the remotely located branch circuit breakers, use the appropriate size and number of wiresto connect directly to the Line Power Terminal Blocks.Load Power Terminal BlocksLocate the outgoing power terminal blocks in the panel using the supplied elevation/layoutdrawings and connect per the associated schematic drawing. Depending upon size and typeof the remotely located branch circuit breakers, use the appropriate size and number of wiresto connect from the Load Power Terminal Blocks to the heater’s power connection box.Single pole C.B.CB*LPNLine PowerTerminal BlocksTB*NGC-40-HTC–L1 CT GFCTL1*N*–NC**–NTwo pole C.B. Line PowerCB*LPLPTerminal BlocksTB*–L1L1 *L2Load PowerTerminal BlocksTB**–T1 T1NGC-40-HTCCT GFCTC**–L2NLoad PowerTerminal BlocksTB**–T1 T1*–T2Heat-trace cableHeat-trace cableNThree pole C.B. (Three-phase, 3-wire)CB*LPLPLPLine PowerTerminal BlocksTB*–L1L1 *NGC-40-HTC3CT GFCTC*Load PowerTerminal t-trace cableThree pole C.B. (Three-phase, 4-wire)CB*LPLPLPNLine PowerTerminal BlocksTB*–L1L1 *NGC-40-HTC3CT GFCTL2*–L2CTL3*–L3CTN*–NC*Load PowerTerminal BlocksTB*–T1**–T2*–T3Heat-trace cable*–NFig. 2.3 Load power terminal block configurationsnVent.com 7
2.6.4 INCOMING RTD WIRINGNonhazardous and Hazardous Location Installations Wired to Terminal Block in PanelEach RAYCHEM NGC-40-HTC/HTC3 module has one RTD input. The RTD wiring from the NGC40-HTC/HTC3 have been pre-wired to RTD terminals. The field RTD wiring (3-wire with shield)will be terminated by the installer at the RTD terminal blocks. Refer to the “As Built” Drawingsfor the RTD Termination Schedule. Refer to Section 3.1 for additional NGC-40-HTC/HTC3wiring information.RTD Connections - North American Installation TechniqueControl PanelFieldRTD-QAHTC – QWHRBKTS COMM 13TS SENSE 14TS SOURCE 15Not used 16TB2WHRBK ––WHRRSHLDRWHR( ) (–)RTD-QAFig. 2.4 Typical RTD installation from the NGC-40-HTC/HTC3 module in a North Americanstyle panelRTD Connections - European Installation TechniqueControl PanelFieldRTD-QAHTC – QWHRBKTS COMM 13TS SENSE 14TS SOURCE 15Not used 16WHRBKTB2 ––Earth ground locatedat the moduleWHRRSHLDRWHR( ) (–)RTD-QAFig. 2.5 Typical RTD installation from the NGC-40-HTC/HTC3 module in an European style panelOptional RTD inputs via the NGC-40-IO moduleOne NGC 40 IO module is mandatory. The digital output of this module is used for activatingthe Common Alarm Light on the RAYCHEM NGC 40 panel door. Additional NGC 40 IOmodules are optional components that may or may not be included in a panel depending onits design. If used, each RAYCHEM NGC-40-IO module provides up to four additional RTDinputs. The RTD wiring from the NGC-40-IO have been pre-wired to RTD terminals. The fieldRTD wiring (3-wire with shield) will be terminated by the installer at the RTD terminal blocks.Refer to the “As Built” Drawings for the RTD Termination Schedule. Refer to Section 3.3 foradditional NGC-40-IO wiring information.RTD Connections - North American Installation TechniqueControl PanelFieldRTD-QBI/O – Q – 1TS COMM 9TS SENSE 10TS SOURCE 11Not Used 12WHRBKWHRBKTB2 ––WHRRSHLDRWHR( ) (–)RTD-QBFig. 2.6 Typical RTD installation from the NGC-40-IO module in a North American style panelRTD Connections - European Installation Technique8 nVent.com
Control PanelFieldRTD-QBI/O – Q – 1TS COMM 9TS SENSE 10TS SOURCE 11Not Used 12WHRBKTB2WHRBK ––Earth ground locatedat the moduleWHRRSHLDRWHR( ) (–)RTD-QBFig. 2.7 Typical RTD installation from the NGC-40-IO module in a North American style panel2.6.5 NGC-40-BRIDGE SWITCH SETTINGSUser Interface – Configuration SwitchA slide switch is provided on the front of the module to allow the user to set the RS-232 (COM 3)into a known state, as shown in the following table:Switch PositionBridgeModule SettingsSETConfiguration modeModbus address1RUNNormal operating modeLocal RS-232ProtocolRTUData rate9600 baudData bits8Stop bits2ParityNo parity ettings based on the userSconfiguration parametersIf the present user parameters of the communications port of an NGC-40-BRIDGE are notknown, the NGC-40-BRIDGE can be placed in the SET mode by its Configuration Switch andthe RAYCHEM Supervisor or any other device that needs to communicate with the NGC-40BRIDGE, can then be used to establish communications. The user parameters (includingthose of the communications port) can then be read.While in the SET mode, modifications to the NGC-40-BRIDGE user parameters of thecommunications port will be saved but will not take effect until the Configurations Switch ismoved to the RUN mode.The parameters of the two RS-485 ports (COM 1 and COM 2) and the ethernet port are notaffected by the position of the Configuration Switch.For firmware upgrades only: When in SET mode, the NGC-40-BRIDGE 10/100 LAN (Ethernet)port settings are those defined by the Boot loader.In the RUN mode, these port settings are defined by the user parameters of the Bridge(the default user parameters are the same as those in the table above).nVent.com 9
RESETNGC-40 BRIDGE MODULECommunicationsslide switch (Red)(shown in Run Mode)Fig. 2.8 Communication Slide Switch2.6.6 OPTIONAL RMM2 CONNECTIONWhen using the field mounted RMM2 for RTD input, it must be connected to the COM2 In asshown below.RESETNGC-40 BRIDGE MODULEEarth groundingCOM 2 In bar located at thebridge module3 7 11Panel –Panel Terminal Block – – RS-485 ShieldedTwisted PairTo nextRMM2 FieldFig. 2.9 RMM2 Connection10 nVent.com– – –
2.6.7 OPTIONAL TOUCH 1500R CONNECTIONSWhen using the Touch 1500R (Remote User Interface Terminal) with the NGC-40 system,the user must connect main power to the Touch 1500R and communication cable fromthe NGC-40-BRIDGE to the Touch 1500R.Fig. 2.10 Touch 1500RConnecting Main Power to the Touch 1500RUse only copper conductors for field wiring. A close-up of the power connection terminals isshown below. This connection energizes the RAYCHEM TOUCH 1500 electronics only; it doesnot provide power to the heat tracing or contactor coils.IMPORTANT: If the RAYCHEM TOUCH 1500R controller has a different source of power thanthe heat tracing, it may be worthwhile to install an uninterruptible power supply (UPS)so the unit can continue to control and/or monitor the heat tracing in the event of a localizedpower failure.Ø or N 100 – 240 Vac 10%ØGFig. 2.11 Touch 1500R Main Power Terminal BlocknVent.com 11
Connecting RS-485 Field Port CommunicationThe NGC-40-BRIDGE communicates with the TOUCH 1500R over an RS-485 network,which can have a total cable length of no more than 1200 m (4000 ft), as required.The RS-485 communicating cable shall be a shielded, two conductor (twisted pair) cable.RS-485 RS-485 –ShieldTo downstream device(NGC-40-BRIDGE).Refer to “As Built” drawingsfor connection details.For RS-485 cable type, referenceBelden #8761 or Carol #C25145 4 3 2 1T 9 8 7 6Fig. 2.12 Touch 1500R RS-485 Terminal BlockShieldRS-485 RS-485 RS-485 –RS-485 –G100-240 VacØ 10% Ø or 2COMRL4NORL3COMRL4COMShield5 4 3 2 15 4 3 2 1T 9 8 7 6T 9 8 7 6RS-485Field PortCom 3RS-485Remote PortCom 4(B) GND 10(R) Vs(G) DATA –(Y) DATA INT CID2Alarm Light andoptional Alarm RelayRS-485Fig. 2.13 Touch 1500R Wiring Diagram12 nVent.comIncomingPower TerminalBlock
2.6.8 OPTIONAL DIGITAL INPUTSBoth the RAYCHEM NGC-40-HTC/HTC3 and the RAYCHEM NGC-40-IO modules have a digitalinput which is programmable and may be used for various functions such as forcing outputson and off. The field wiring for these connections will be wired directly to the module asshown below.North American Installation TechniqueNGC-40-IONGC-40-HTCHTC1PHDigital InputDigital Input778 –TerminalblockTerminalblock 8 – ––From user inputFrom user inputEuropean Installation TechniqueNGC-40-IONGC-40-HTC1PHDigital Input7 8Earth groundingbar located atthe HTC module–Terminalblock –From user inputDigital Input7 8Earth groundingbar located atthe I/O module–Terminalblock –From user inputDigital InputMulti-purpose input for connection to external dry(voltage free) contact or DC voltag
Copies of this manual and updates may be downloaded from the Literature section of nVent.com. Component Version number NGC-40-HTC 4.x NGC-40-HTC34.x NGC-40-IO3.x NGC-40-BRIDGE5.x IMPORTANT WARNINGS AND NOTES The following icons are used extensively throughout this manual to alert you to important
Haas Next Generation and Classic Controls 111 Haas NGC: Entering Mill Offsets 201 Haas NGC: Entering Lathe Offsets 202 Haas NGC: Locating Program Zero on the Mill 211 Haas NGC: Locating Program Zero on the Lathe 212 Haas Mill Classic Control: Panel Overview 250 Haas Lathe Classic Control: Panel Overview 256
PASC for an optimised electrical heat-tracing control. The DigiTrace NGC-20 offers alarms for high and low temperature, high and low current, ground-fault current and voltage. The trip and warning level of the ground-fault current is user configurable and can be used as a warning and to isolate circuits. The DigiTrace NGC-20
A: Yes, nVent NUHEAT Cable is a viable alternative to water radiators. Invisible and maintenance-free, nVent NUHEAT Cable is a perfect heating option for renovations or additions. Q: WILL NVENT NUHEAT CABLE HEAT THE WHOLE ROOM OR JUST THE FLOOR? A: The whole room!
nVent RAYCHEM Elexant 4010i/4020i Heat Tracing Controllers. Additional copies of this user manual may be ordered separately through your nVent representative or online at nVent.com using the document number H60624. 1.1.1 Product Overview This section contains an overview of the Elexant 4010i/4020i
Factory terminated System 1850 MI cable sets are available in a range of sizes and lengths. For details on terminated cable sets, contact your nVent representative or phone nVent at (800) 545-6258. Fig. 5 Terminations for System 1850 MI cable Pyropa termination it QuickTerm termination k
This manual assumes that the proper heat-tracing design has been completed according to the Pipe Freeze Protection and Flow Maintenance Design Guide (H55838). Only the applications described in Section 1.2 are approved by nVent for XL-Trace Edge systems when used with approved nVent RAYCHEM connection kits. The instructions in this manual
Certificats et logiciel nVent ERIFLEX en ligne TESTS & CERTIFICATS Les composants nVent ERIFLEX sont conformes avec plusieurs agences et normes pour répondre à toutes les exigences. LOGICIEL NVENT ERIFLEX DÉDIÉ E
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