CONTROL AND MONITORING - NVent

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CONTROL AND MONITORINGThis section provides complete information for the design and selection ofheat-tracing control and monitoring systems. Part 1 identifies control andmonitoring options for use with heat-tracing applications. Part 2 details eachnVent control and monitoring product. For additional information contact yournVent representative or visit our web site at nVent.com.CONTENTSINTRODUCTION. 1PRODUCT OVERVIEW. 1Thermostats.2Controllers.2Control and Monitoring Systems.3CONTROL SOLUTIONS. 5Control Considerations.5Application Temperature Range.6Control Options.7Control Selection.8MONITORING SOLUTIONS. 12Types of Monitoring.12Monitoring Selection.17Additional Considerations. 20NVENT CONTROL AND MONITORING SYSTEMS. 21MICROPROCESSOR-BASED CONTROLLERS. 22Multipoint Control and Monitoring Systems. 22Single- and Dual-Point Control and Monitoring Systems. 26THERMOSTATS. 28Ambient-Sensing Thermostats. 28Line-Sensing Thermostats. 28TEMPER ATURE SENSORS. 30RAYCHEM RMM2 (Remote Monitoring Module). 30RAYCHEM PLI (Power-Line Carrier Interface). 30RAYCHEM SES Transmitter (Smart End Seal). 31RAYCHEM RTDs. .com 1

Control and MonitoringPart 1: Control and Monitoring OptionsI NTRODUCTIONnVent provides a wide variety of control and monitoring products, from simplemechanical thermostats and signal lights to sophisticated digital controllersand control and monitoring systems designed specifically for use with our heattracing products. This section will help you select and specify the right control andmonitoring products for your application. For details on nVent RAYCHEM panelproducts such as the nVent HTPG and HTPI, refer to Heat-Trace Panels (H56890).PRODUCT OVERVIEWnVent RAYCHEM control and monitoring products include thermostats, controllers,and control and monitoring systems. Following are descriptions of some of ourmost common control and monitoring products.THERMOSTATSMechanical Ther mostatsntnVeRAMC-1AMechanical thermostats, such as the ambient-sensing AMC-1A and line-sensingE507S-LS, provide cost-effective control for self-regulating and constant-wattageheat-tracing applications in both nonhazardous and hazardous locations.E507S-LSElectronic ThermostatsRAYSTAT-EX-03-AElectronic thermostats, such as the nVent RAYCHEM RAYSTAT-EX-03-A, offeradditional features, including precise set points and long-lasting switches.CONTROLLERSElectronic ControllersElectronic controllers include the nVent RAYCHEM JBS-100-ECP-A,JBS-100-ECW-A, and the RAYCHEM 910 and 920 controllers.JBS-100-ECP-A and JBS-100-ECW-AJBS-100-ECP-AJBS-100-ECW-AThe nVent RAYCHEM JBS-100-ECP-A and JBS-100-ECW-A are electronictemperature controllers that provide accurate control of a heating circuit usinga RTD sensor. The JBS‑100‑ECP-A is pipe mounted and serves as a powerconnection kit for both RAYCHEM self-regulating, power-limiting, and RAYCHEMmineral insulated heating cables. The JBS-100-ECW-A is wall mounted and maybe used to control all types of heating cables. The JBS-100-ECW-A can only beused as a power connection with RAYCHEM mineral insulated cables. Combiningthe power connection and controller into one single unit will significantly reduceinstallation cost. Both the JBS-100-ECP-A and JBS-100-ECW-A have adjustable setpoints between 32 F to 425 F (0 C to 218 C), power input of 120 Vac to 277 Vac,and switches current up to 30 A. A local display allows for monitoring of set point,actual temperature, and also indicates alarm conditions (high/low temperatureand sensor failure). A form C contact allows for remote annunciation of alarms.These units are c-CSA-us (certified to U.S. and Canadian Standards) for use innonhazardous locations.RAYCHEM 910 and 920RAYCHEM 9102 nVent.comRAYCHEM 920The nVent RAYCHEM 910 and 920 controllers are microprocessor-based, singlepoint and dual-point controllers for heat-tracing circuits located in nonhazardousor Class I Division 2 (and Zone 2) hazardous locations. These controllers combinethe temperature control of a thermostat with integral ground-fault protection, whileproviding alarms for low and high temperatures, line current, and ground-faultcurrent. Operation, programming, circuit status, currents, and temperatures areprovided at the control panel and remotely by means of a network connection tothe plant DCS or a PC with nVent RAYCHEM Supervisor 5

Product OverviewCONTROL AND MONITORING SYSTEMSMultipoint Control And Monitoring SystemsMultipoint control and monitoring systems include the nVent RAYCHEM NGC-30, and NGC‑40 systems.NVENT RAYCHEM NGC-30The RAYCHEM NGC-30 is a distributed architecture control and monitoring system that can manage up to 260 heat-tracingcircuits. Approved for use in both hazardous and nonhazardous areas, it allows user selection of several control modes,temperature setpoints and all alarm thresholds of individual heat-tracing circuits. During operation it monitors temperatures,ground-fault currents, operating currents and voltages and provides alarms via local indicators and remotely using dry contactrelay outputs or through the RAYCHEM Supervisor software. The RAYCHEM NGC-30 system utilizes a touch screen-baseduser interface terminal for programming and monitoring at the panel. This user interface terminal provides an intuitiveinteraction with the control and monitoring system which allows users to quickly and easily access heat-tracing systeminformation. Alarm information is communicated in plain language rather than codes.Temperature inputs are provided through directly connected RTDs, through a Remote Monitoring Module (RMM2) or through aPower Line Carrier Interface (PLI) Module with special transmitters. Operation, programming, circuit and RTD status and alarmreporting are provided at the control panel or remotely via a network connection to the plant DCS or the RAYCHEM Supervisorsoftware.Remote configuration andmonitoring with RAYCHEMSupervisor softwareHeat-tracing systemDNGC-30 systemACRAYCHEM RMM2RAYCHEM PLIBA: NGC-30-CRM or CRMSB: NGC-30-CTMC: NGC-30-CR (card rack)D: ng-EN1805nVent.com 3

Control and MonitoringRAYCHEM NGC-40The NGC-40 control and monitoring system differs from the NGC-30 in that it dedicates a single control module to eachindividual heat-trace circuit. It provides the highest reliability for heat tracing applications based on single controllerarchitecture. The RAYCHEM NGC-40 control system offers a truly modular heat-tracing control, monitoring and powerdistribution system. NGC-40 modules are packaged in DIN Rail housing and are installed in an NGC-40 panel that can manageup to 80 heat tracing circuits. Operation, programming and easy intuitive access to the heat tracing data can be achievedlocally at the control panel from a 15" touch screen (TOUCH 1500) or remotely from a central location using RAYCHEMSupervisor software. The system is fully flexible from a configuration point of view and offers individual single-phase andthree-phase electricalheat-tracing control and TMLocal configuration and monitoringwith RAYCHEM Touch 1500 touchscreen displayRemote configurationand monitoring withRAYCHEM SupervisorsoftwareHeat-tracing system4 nVent.comNGC-40 systemRaychem-DG-H56889-ControlMonitoring-EN1805

Control SolutionsCONTROL SOLUTIONSControl products vary the output of the heating source to keep pipes from freezing or to maintain process piping atelevated temperatures. The choice of control product depends on whether the system is controlled on the basis of ambienttemperature or pipe temperature.Most heat-tracing systems use a control element.Applications that may benefit from a control element are those: Requiring a narrow operating temperature range. With temperature-sensitive fluids or equipment. For which energy consumption is a key concern.CONTROL CONSIDERATIONSThe most important step in providinga reliable control system is to designthe heat-tracing system properly forthe specific application.Heat-tracing systems maintain the temperature of stagnant fluids in pipesand tanks by replacing the heat lost through the thermal insulation. Overallperformance of the heat-tracing system is highly dependent on the integrity ofthe thermal insulation, the heat-tracing design, and the installation. Therefore, themost important step in providing a reliable control system is to properly designthe heat-tracing system for the specific application, as detailed in other nVentdesign guides.When designing your heat-tracing system, consider these factors: A dding control elements increases the installation and maintenance costs ofthe system, but should result in tighter temperature control, energy savings andmore efficient use of plant maintenance personnel’s time. E lectronic controllers increase initial system costs, but offer reliabilityand feedback superior to that provided by mechanical thermostats. Themonitoring and alarm information available from electronic controllers can helpmaintenance personnel react to heat-tracing problems more quickly, before pipefreeze-up or process temperature issues cause a plant or process shutdown. T he thermal environment of a heat-tracing system varies greatly — especially atvalves, pipe supports, and other heat sinks — so it is seldom possible to achievevery tight temperature control. T he temperature of a heat tracing system is based on ambient temperature andcan vary by as much as 20 C when the system is uncontrolled. However, pipetemperature sensing will provide tighter temperature control than is possiblewith ambient sensing. T raceCalc Pro, nVent design software, estimates the temperature range of yourheat-tracing system, both with and without control. If an uncontrolled RAYCHEMself-regulating heating cable provides an acceptable range, consider choosingthis approach for its high reliability and low installed nt.com 5

Control and MonitoringFig. 1TraceCalc Pro heat-tracing design softwareAPPLICATION TEMPERATURE RANGEThe options for control depend on the expected temperature range for the application. Ranges are grouped into threecategories, as follows:Freeze ProtectionFreeze protection applies to fluids that must be kept above a minimum temperature, typically 32 F (0 C) for water lines.Moderate overheating of the fluid (30 F to 40 F; 17 C to 22 C) is not a major concern. (IEEE 515-2011, Process Type I)Broad temperature maintenanceBroad temperature maintenance is appropriate when the process temperature must be controlled within a moderate range;e.g., set point plus approximately T 35 F (19 C). This is generally used for viscosity control to keep process fluidsflowing, such as in fuel oil and cooking oil lines. (IEEE 515-2011, Process Type II)Narrow Temperature MaintenanceNarrow temperature maintenance applies to fluids that must be kept within a narrow temperature range to maintainviscosity and prevent fluid or pipe degradation. Examples include sulfur and acrylic acid lines, as well as food syrup and sugarsolutions. (IEEE 515-2011 Process Type III)6 5

Control SolutionsCONTROL OPTIONSThe control method you select will be driven by your application. Table 1 summarizes the recommended control optionsfor each application type. Following the table is an overview of the three basic control types: ambient-sensing, proportionalambient-sensing (PASC), and line-sensing control.TABLE 1 RECOMMENDED CONTROL METHODSApplicationControl methods recommendedFreeze protectionAmbient-sensing control to reduce energy consumptionProportional ambient-sensing control (PASC) for lowest energy consumptionBroad temperaturemaintenanceProportional ambient-sensing control (PASC) for tighter temperature controlNarrow temperaturemaintenanceLine-sensing controlAmbient RTDControllerAmbient RTDAmbient-Sensing ControlAmbient-sensing control uses an on-off thermostat that senses ambienttemperature. It is more energy efficient than self-regulating control because theheating circuit is energized only when the temperature drops below the setpoint.This type of control is most suitable for freeze-protection applications. Thecontrol device can be either a mechanical thermostat or an electronic controller.Mechanical thermostats are more commonly used since they are less expensiveand are sufficiently accurate and reliable. However, they do not provide themonitoring and alarm functions that are available from an electronic controller.Proportional Ambient-Sensing Control (PASC)Proportional ambient-sensing control (PASC) uses an electronic controller thatsenses ambient temperature and continuously matches the heat-tracing powerapplied to the pipe to the predicted heat loss that occurs due to changing ambientconditions. A preprogrammed algorithm calculates the cycle time that the heatingcircuits will be energized in order to maintain the desired temperature. This controlmethod results in tighter temperature range control and lower energy usage thanthe ambient-sensing method. PASC control is suitable for all broad temperaturecontrol and some narrow temperature-control applications, as well as freezeprotection applications.PASCcontrollerLine-sensing ControlControllerLine-sensing sensing control is based on pipe temperature. With this option, each flow pathmust have a separate circuit controlled by a mechanical line-sensing thermostat orelectronic controller. When the pipe temperature falls below the desired maintaintemperature, the control unit turns on the heating circuit. The same cost-benefittrade-offs between electronic and mechanical controllers should be made for linesensing applications. An electronic controller with monitoring and alarm features isrecommended for critical pipes.nVent.com 7

Control and MonitoringCONTROL SELECTIONSelecting a control system suitable for your application involves four steps:1.Select the nVent heat-tracing solution.2.Identify the control application.3.Choose the control method.4.Review the specifications for your control selection.The selection process outlined on the following pages results in a reliable, cost-effective control system optimized forsimplicity. If you are installing multiple heat-tracing circuits, a more detailed analysis of the application may yield a differentresult with lower installed and operating costs. Contact your nVent representative for assistance.Step 1 Select the nVent heating solutionControl Selection1. Select nVent heatingsolution2. Identify controlapplicationThis is the most important step in designing a heat-tracing system. Use the heattracing product selection sections in this publication to select the heating systemand components for your application. Assistance is available on-line (nVent.com),in nVent TraceCalc Pro design software, or from your nVent representative.3. Choose control method4. Review specificationsfor control selectionStep 2 Identify the control applicationControl Selection1. Select nVent heatingsolution2. Identify controlapplication3. Choose control method4. Review specificationsfor control selectionFor the pipes and tanks to be heated, identify the specific control application inTable 2TABLE 2 CATEGORIES OF CONTROLControl applicationTemperature range/goalFreeze protectionTo keep water lines above 32 F (0 C)Broad temperature controlFor viscosity control to keep process fluidsflowingNarrow temperature controlTo keep process fluids within a narrowtemperature band to maintain viscosity andprevent fluiddegradationIf your project includes multiple heat-tracing circuits and a combination ofapplications, or monitoring and alarm reporting capability is desired, use theRAYCHEM NGC-30 or NGC-40 control and monitoring system and contact yournVent representative for design assistance. Otherwise, continue to Step 3 to selectyour control method.8 5

Control SolutionsStep 3 Choose the control methodControl SelectionFor freeze-protection applications3. Choose control methodUse Table 3 to select the appropriate control solution for your application. Baseyour selection on the number and type of heat-tracing circuits to be installed,the type of control you need, and the area classification. Other nVent productsthat include monitoring and ground-fault protection are discussed later under“Monitoring Solutions.”4. Review specificationsfor control selectionTABLE 3 CONTROL SELECTION FOR FREEZE PROTECTION1. Select nVent heatingsolution2. Identify controlapplicationnVent heating solution:individual circuits1Control optionsRAYCHEMcontrol productQuantityrequiredSelf-regulating heating Ambient-sensingcircuits on pipescontrolAMC-1A, AMC-1H,JBS-100-ECP-A, orJBS-100-ECW-AOne percircuitConstant-wattage/Line-sensing controlpower-limiting heatingcircuit(s) on pipes(includes MI and VPLcables)AMC-1B, E507S-LS, One per910, 920,circuitJBS-100-ECP-A, orJBS-100-ECW-AAny heating circuit(s)on tanksAMC-1B, E507S-LS, One per910, 920,circuitJBS-100-ECP-A, orJBS-100-ECW-ALine-sensing controlMultiple circuits1 grouped in panelsSelf-regulating heating Ambient-sensingcircuits on pipescontrol for maincontactor in panelHTPG, HTPIEnergy-savingNGC-30, NGC-40,electronic proportional 920control for maincontactor in panelOne persystemOne persystemConstant-wattage/Proportional controlpower-limiting heating for each contactor incircuits on pipespanelNGC-30, NGC-40,920One persystemAny heating circuitson tanksNGC-30, NGC-40,920One persystemMulticircuit linesensing control1. A heat-tracing circuit is defined as one circuit breaker with its associated branch wiring,heat-trac

Control and Monitoring Part 1: Control and Monitoring Options I NTRODUCTION nVent provides a wide variety of control and monitoring products, from simple mechanical thermostats and signal lights to sophisticated digital controllers and control and monitoring systems designed specifically for use with our heat-tracing products.

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