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INSTALLATION MANUAL - Pentair Thermal Management

1. TB 1 NGC 30 Panel 2 without UIT installed 2 l l l l l 3 NGC 30 CRM CRMS 1 Fig 2 10 RS 485 field wiring between two Raychem NGC 30 panels 2 7 CONNECTIONS FOR REMOTE ANNUNCIATION Relay 1 on the NGC UIT has been factory configured and wired for Any Alarms unless otherwise specified It is powered by 120 Vac and will energize a light on the front of the panel if any alarm occurs Relay 1 was also wired to a common alarm relay terminal block for remote annunciation of any alarms Please see below the NGC UIT Relay 1 in non energized energized and in alarm condition NGC UIT Relay 1 Non energized AR NO ARZ 1 AR COM ARX 5 AR NC Fig 2 11 Relay 1 wiring TB 2 Common alarm output Energized without an alarm condition ARS 1 AR NO AR COM AR NC TB 2 Common alarm output AR AR Reference panel drawing for terminal block number 2 1 ott Energized with an alarm condition AR NO AR COM AR NC TB 2 Common alarm output INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 12 31 The NGC UIT has two other Form C alarm relays configurable through the NGC UIT program for external alarms
2. 23 Appendix B Panel Specifications eene nennen nennen rennen nenne 24 Appendix C NGC 30 CRM CRMS Specifications 27 Appendix D NGC UIT2 Specitications coire Eia 28 Appendix E Deviee AddEess uae eredi ipe tede on eed ant Dea sere tea bonds 30 INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 2 31 SECTION 1 OVERVIEW 1 1 INTRODUCTION The Raychem NGC 30 is a fully wired and tested control and monitoring system used with electric heat tracing This manual provides information pertaining to the installation operations testing adjustment and maintenance of all components of the Raychem NGC 30 For information about how to program the Raychem NGC 30 see the Raychem NGC 30 Programming Guide H58186 A typical Raychem NGC 30 is made up of at least a User Interface Terminal NGC UIT one Card Rack NGC 30 CR one Card Rack Module with connectors NGC 30 CRM or NGC 30 CRMS and one Current Transformer Module NGC 30 CTM Optional Remote Monitoring Module RMM2 Power Line Carrier Interface PLI and Voltage Monitoring Module NGC 30 CVM may be used The information in this document coincides with the specific releases of firmware listed in Table 1 1 for the User Interface Terminal NGC UIT and Card Rack Module NGC 30 CRM CRMS components As Pentair Industrial Heat Tracing Solutions releases new firmware to significantly modify or
3. pm NGC CRM CRMS v fa 00000 eo J 000000 Hh a S S NGC CRM CRMS oS WW NGC CRM CRMS O a 0 00000 41778 obg mb aes SOOT Lana s s T7 fon OOO Fe 5 MODE ud Fig 2 5 RS 485 network configuration for the NGC UIT system In order for the RS 485 network to work properly you must enable the termination resistor for the first and last device The devices shown in gray in Fig 2 5 represent the devices for which you must enable the termination resistors The devices that are not grayed out represent the devices for which you should not enable the termination resistors INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 8 31 Optional RMM2 Installed in the Field Refer to the RMM2 Installation Instructions H56848 for field installation instructions You must connect a RS 485 connection from the 2 to an open RS 485 connector on the NGC 30 CRM CRMS board in the Raychem NGC 30 panel To make this connection a pre wired terminal block has been provided in the Raychem NGC 30 panel Connect the RS 485 wire from the RMM2 to TB per the panel drawing while maintaining the correct polarity If the
4. 5 2 0040 00 000 14 2 8 ETHERNET CONNECTIONS wise retire em aerem e i ne EU e bere 14 2 9 Testing the NGC 30 SySter i o actio ro e Red edt rd n eed 15 Section 3 Raychem NGC 30 Components and eene enne nnne 16 3 1 User Interface Terminal NGGC UIT retainer epe dette teet teen e beet eere ct Pe ERE Heins 16 3 11 MULTIPEENGCSULIT MODELS nire terrere tee eene 16 3 1 2 NGC UIT LOCAL AND REMOTE NETWORK 5 16 3 4 3 NGCSUIT BED STATUS octets tt irt nett ttr ter D ORE rtu nsec ee Deoa vn 18 3 1 4 CONFIGURATION SWITCHES sese 18 3 1 5 NGC UIT RESET SWITCLED denen en P ee tse rete kin lettre E yen es 18 3 2 Card Rack Module NGC 30 CRM CRMS and Current Transformer Module NGC 30 CTM 19 3 3 Card Rack NGC 30 CR ssssssssssseeeeeeenennent eene nennen neret treten tentent 20 3 4 Voltage Monitoring Module NGC 30 CVM Optional 2 20 3 5 Remote Monitoring Module 2 Optional 21 3 6 Power Line Carrier Interface Module Optional sss 22 Section Appendices corii ttr s tei ae rr ge en aree reves ba sexed a PARE EX eee R 23 Appendix A Replacement Component Ordering
5. LED function LED description LED color o gt 26 8 Alarm Energized upon Alarm Red w fs fe Power Energizes upon power to unit Green Relays 1 2 3 4 5 Energizes upon relay closed Red RX amp TX Energizes upon received and Amber E z B 5 transmit of RS 485 data 9 foc ge LED functions 3 3 CARD RACK NGC 30 CR The Card Rack NGC 30 CR has the capability to house one to four Card Rack Modules CRMs Fig 3 5 NGC 30 card rack 3 4 VOLTAGE MONITORING MODULE NGC 30 CVM OPTIONAL The optional voltage sensor can monitor 80 290 Vac This voltage sensor connects to one of the five line current ground fault inputs of the NGC 30 CRM CRMS Note By using the optional Fig 3 6 NGC 30 voltage monitoring module INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 20 31 3 5 REMOTE MONITORING MODULE RMM2 OPTIONAL The Raychem Remote Monitoring Module RMM2 provides additional temperature monitoring capabilities Each RMM2 accepts up to eight RTDs that measure pipe vessel or ambient temperatures The RMM2 can be installed in the Raychem NGC 30 enclosure or can be located in the field to reduce RTD field wiring The Raychem NGC 30 system supports 260 temperature inputs via the CRM CRMs boards Sixteen 16 RMM2s can be connected via a single twisted pair RS 485 cable to provide up to 128 additional RTD inputs into the Raychem NGC 30 system Fig 3 7 RMM2 mod
6. 123 23 End of Line EOL Jumper If this device NGC 30 CRM CRMS is the first or last device in the RS 485 network move the J1 jumper from terminals 2 amp 3 to terminals 1 amp 2 Fig 2 9 Termination of RS 485 network for NGC 30 CRM CRMS NGC 30 Panel with NGC UIT Connected to an NGC 30 Panel without NGC UIT This wiring is used when a single UIT in one panel is the central point for multiple NGC 30 panels Because the NGC UIT can handle up to 260 heat tracing circuits it can be cost effective to use one NGC UIT for multiple panels An RS 485 connection must be made from the panel that has the NGC UIT panel 1 installed to the NGC 30 CRM CRMS board in NGC 30 panel 2 that does not have the NGC UIT installed see Fig 2 10 To make this connection a pre wired terminal block has been provided in the panel 1 and in panel 2 Connect the RS 485 wire from TB in panel 1 and the other end to TB in panel 2 maintaining the correct polarity INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 11 31 If the NGC 30 CRM CRMS is the first or last device in the RS 485 network see Fig 2 9 and Table 3 2 for details on how to terminate the RS 485 network Reference panel drawing for terminal block numbers RS 485 NGC 30 CRM CRMS 1 Reference panel drawing for terminal block number
7. A B BC Main circuit breaker 3 pole Panelboard gt ii neutral bus EUN Panelboard AG aa ms ground bus Y Em Power wiring diagram Fig 2 1 Main circuit breaker wiring Branch Circuit Breakers The branch circuit breakers are pre wired to the contactors or solid state relays in the panel so no further incoming power wiring is required INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 5 31 2 6 2 OUTGOING POWER WITH DISTRIBUTION SYSTEM Load Power Terminal Blocks Locate the outgoing heater terminal blocks using the supplied elevation layout drawing and connect per the associated schematic drawings Depending upon the size of the branch circuit breaker and voltage loss calculations use the appropriate size and number of wires to connect from the panels Load Power Terminal Blocks to the heat trace power junction box Branch EMR or Load Power Heat trace circuit SSR Terminal junction breaker T contacts Block box F 7 abe Heat trace cable 6 9 4 TWEEN X s Ie RES CTM cable cTs I connector Reference panel drawing for terminal block number Represents HTC circuit number 1 40 Fig 2 2 Heat trace power wiring diagram 2 6 3 INCOMING OUTGOING POWER WITHOUT DISTRIBUTION PANEL BOARD Line Power Terminal Blocks Locate the incoming power terminal blocks in the panel using the supplied elevation layout drawings
8. CRMS board in the Raychem NGC 30 panel IF the PLI is the first or last device in the RS 485 network remove the shorting block jumper location J2 from 1 and 2 and place it across pins 2 and 3 NGC 30 Panel O Reference panel drawing for terminal block number RS 485 connections l S 8 4 Obese leees m Q se eed g LH N H A B CN RS 485 NGC 30 CRM CRMS 1 Default position for all PLI Termination mode units in network except first or last one first or last PLlin network J2 KO J2 o EE T 23 T 2 3 Last PLI in network Fig 2 7 PLI RS 485 panel wiring and termination jumper setting NGC UIT Installation The NGC IUT ORD and NGC UIT OUT will come pre wired into any NGC 30 panel Exceptions exist when a remote mount NGC UIT NGC UIT ORD 12 is used or the NGC 30 panel is wired to the NGC UIT in another panel Fig 2 8 shows the wiring for the NGC 30 ORD 12 and Fig 2 10 shows the wiring between a separate panel and the NGC UIT NGC UIT ORD 12 Installation You must make an RS 485 connection from the NGC UIT ORD 12 to the NGC 30 CRM CRMS board in the NGC 3
9. Each relay can be connected to an annunciator light or distributed control system Each relay s contacts have been wired from the NGC UIT to a terminal block in the panel NGC UIT Relay 2 Non energized Energized without an Energized with an alarm condition alarm condition UIT R2 NO a UIT R2 NO UIT R2 NO 1 216 48 16 e urRecoM i UmRecoM j UT R2 COM T UIT R2 NC 5 T UIT R2 NC i 7 UIT R2 NC NGC UIT Relay 3 Non energized Energized without an Energized with an alarm condition alarm condition UIT R3 NO ps UIT R3 NO E UIT R3 NO UA 10 AD 210 UIT R3 COM td UIT R3 NC T urr Rs NC 5 T Reference panel drawing for terminal block number Fig 2 12 Relays 2 and 3 wiring Note An energized relay with no alarm condition will change state with loss of power or an alarm condition INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 13 31 2 8 RS 232 RS 485 OR ETHERNET REMOTE PORT CONNECTIONS TO A HOST COMPUTER The NGC UIT can communicate with a distributed control system DCS or other host computer through the NGC UIT external communication ports The NGC UIT provides ports for RS 232 RS 485 and Ethernet communication All of these communication ports provide data read access Howeve
10. 32 16 213 511 Fax 32 16 213 603 thermal info pentair com ASIA PACIFIC Tel 86 21 2412 1688 Fax 86 21 5426 2937 cn thermal info pentair com WWW PENTAIRTHERMAL COM LATIN AMERICA Tel 1 713 868 4800 Fax 1 713 868 2333 thermal info pentair com Pentair is owned by Pentair or its global affiliates All other trademarks are the property of their respective owners Pentair reserves the right to change specifications without prior notice 2002 2015 Pentair INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 31 31
11. RMM2 is the first or last device in the RS 485 network connect the J17 termination jumper to pins 1 and 2 If the 2 is not the first or last device in the RS 485 network connect the J17 termination jumper to pins 2 and 3 Reference panel drawing for terminal block number ee RS 485 Se 66006 rey Wu 50 60Hz 2 L1 L2 230V 115V wc Voltage Selector Max ambient temperature 60 C Last RMM2 in network RTD2 RTD3 RTD4 RTD6 RTD7 RTD8 EJ RTDS Termination mode first or last RMM2 in network J17 o J17 rmn o 1238 172 3 Default position for all RMM2 units in network except first or last one Fig 2 6 RMM2 RS 485 field wiring and termination jumper setting INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 9 31 Optional PLI Installed in the Panel Refer to the PLI Installation Instructions H56850 You must connect a RS 485 connection from the PLI to an open RS 485 connector on the NGC 30 CRM
12. RaychemNGC30 IM H57878 04 15 24 31 Monitoring Temperature Low alarm range High alarm range 99 F to 900 F 739 to 482 C or OFF 99 F to 900 F 739 to 482 C or OFF Ground fault Alarm range Trip range 10 mA to 200 mA 10 mA to 200 mA or OFF Current Low alarm range High alarm range 0 A to 100 A where 0 equals OFF 0 A to 100 A where 0 equals OFF Voltage 100 277 Vac supply voltage to heat tracing Note Requires the loss of one circuit Autocycle Each loop can be programmed from 1 to 1000 hours or OFF Temperature Sensor Inputs Temperature inputs per control point Up to 4 inputs per circuit One input standard per control point Up to 3 additional RTDs can be assigned to each circuit Monitoring Raychem NGC 30 system can monitor up to 1040 260 x 4 temperatures Temperature sources Hard wired RMM2 PLI module Quantities Hard wired Up to 260 hard wired temperature inputs one per circuit RMM2 optional Up to 128 RTD inputs via RMM2 Modules Up to 8 RTDs per RMM2 Module and up to 16 RMM2 Modules per NGC 30 controller PLI module optional Up to 127 RTDs via SES Transmitter per PLI Module Up to 127 RTDs via SPC Transmitter per PLI Module Up to 255 RTDs via 700 TT Transmitter per PLI Module Four PLI Modules per circuit maximums 1040 RTDs Types 100 Q platinum RTD 3 wire a 0 00385 ohms ohm C Can be extended with a 3 conductor shielded c
13. and connect per the associated schematic drawing Depending upon size and type of the remotely located branch circuit breakers use the appropriate size and number of wires to connect directly to the Line Power Terminal Blocks Load Power Terminal Blocks Locate the outgoing power terminal blocks in the panel using the supplied elevation layout drawings and connect per the associated schematic drawing Depending upon size and type of the remotely located branch circuit breakers use the appropriate size and number of wires to connect from the Load Power Terminal Blocks to the heater s power connection box Single pole C B tine Dawes Load Power Terminal Blocks crTM Terminal Blocks TB TB LP Cx E CT GFCT p M cS ac Ei PEE ci UND 4 Heat trace cable Ls Il REN aee 28 00 Two pole C B Line Power Load Power Terminal Blocks Terminal Blocks CBx TB TB LP e Cx E CT GFCT 1 s d Heat trace cable L2 2 H Pa nis Reference panel drawing for terminal block number Fig 2 3 Single pole and two pole circuit breaker wiring diagrams INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 6 31 2 6 4 INCOMING RTD WIRING Nonhazardous and Hazardous Location Installations Wired to Terminal Block in Panel The RTD wiring from the NGC 30 CRM CRMS have been pre wired to RTD terminals The field RTD wiring 3 wir
14. gt PENTAIR Raychem NGC 30 INSTALLATION MANUAL Firmware version V1 18 INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 1 31 CONTENTS Section 1 Overview 1 1 Introduction Section 2 Installation and Wiring ccsesseceesesseeeeessseeeeenenseeeeneeseneeeeesseeeesecneesesaeseeeesseseeeeeseneeseesesseeeenees 4 VAR M Tor wore ei rates Me 4 2 2 Initial InSpeCctioi tegeret dua beds 4 2 3 Operating EnvIFOFIIIeDE 4 2 4 InstallatiohilbOCAtlOFri oe 5 2 5 Mounting a a sea 5 2 6 Wiring dace 5 2 6 1 INCOMING POWER WITH DISTRIBUTION SYSTEM senes 5 2 6 2 OUTGOING POWER WITH DISTRIBUTION SYSTEM sese 6 2 6 3 INCOMING OUTGOING POWER WITHOUT DISTRIBUTION PANEL BOARD 6 2 6 4 INGOMING RTD WIRIING 16 err rre tpe ne e eas 7 2 6 5 CONNECTING THE RS 485 DEVICE NETWORK sess 7 2 7 Connections for Remote 12 2 8 RS 232 RS 485 or Ethernet Remote Port Connections to a Host 14 2581 RS 232 SERIAL CONNECTIONS rrt gic area n e rn gi ent E HR gere 14 2 8 2 RS 485 SERIAL
15. 0 panel To make this connection a pre wired terminal block has been provided in the NGC UIT ORD 12 and in the NGC 30 panel Connect the RS 485 wire from TB3 in the NGC UIT ORD 12 and the other end to TB in the NGC 30 panel maintaining the correct polarity If the NGC UIT ORD 12 and or the NGC 30 CRM CRMS is the first or last device in the RS 485 network see Fig 2 9 and Table 3 2 for details on how to terminate the RS 485 network Reference panel drawing for terminal block numbers INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 10 31 NGC UIT ORD 12 Line voltage Alarm relay RS 485 TB1 TB3 Field Host Grounding bar NGC 30 Panel 1 Reference panel drawing for terminal S Mlb NGC 30 CRM CRMS 1 RS 485 NGC 30 CRM CRMS 8 Fig 2 8 NGC UIT RS 485 field wiring The following figure shows the RS 485 termination options for the NGC 30 CRM CRMS NGC 30 CRM CRMS nnnnnnnn TOUT Normal End of Line position position
16. 04 15 28 31 USB host Three colors showing status Red Green Yellow USB key fault USB key inserted USB in use UIT status Three colors showing system status Green Red Yellow Normal condition Fault condition Loading software configuration LCD Display Display LCD is a 6 5 inch QVGA color TFT transflective device with integral CCFL backlight For use indoors or when protected from direct sunlight Touch screen 4 wire resistive touch screen interface for user entry Usable with gloved fingers INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 29 31 APPENDIX E DEVICE ADDRESS Table E 1 Device Address Device Device Type Switch Setting Device Address NGC 30 CRM CRMS Relay Output RTD 1 99 1 99 If RMM2s are equipped or will be added in the future skip addresses 32 47 RMM2 RTD 0 32 RMM2 RTD 1 33 RMM2 RTD 2 34 RMM2 RTD 3 35 RMM2 RTD 4 36 RMM2 RTD 5 37 RMM2 RTD 6 38 RMM2 RTD 7 39 RMM2 RTD 8 40 RMM2 RTD 9 41 RMM2 RTD A 42 RMM2 RTD B 43 RMM2 RTD C 44 RMM2 RTD D 45 RMM2 RTD E 46 RMM2 RTD F 47 PLI module RTD 1 99 1 99 INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 30 31 gt PENTAIR NORTH AMERICA Tel 1 800 545 6258 Fax 1 800 527 5703 Tel 1 650 216 1526 Fax 1 650 474 7711 thermal info pentair com EUROPE MIDDLE EAST AFRICA Tel
17. 20 Ohm Termination For the REMOTE RS 485 Remote Port Termination Enabled Disabled network connected to a PC Termination Select Factory Default If this NGC UIT is the first Terminates remote or last RS 485 device in the RS 485 network remote network it must be connected to PC and set to ENABLED ON If the Raychem Supervisor NGC UIT is NOT the first or software last device it must be set to DISABLED OFF WOT WDT Enabled WDT Disabled WDT should normally Watch Dog Timer Factory Default be enabled 3 1 5 NGC UIT RESET SWITCH The reset switch is located on the side of the NGC UIT panel A pointed object is required to press the restart switch and restart the UIT software Fig 3 2 Reset switch INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 18 31 3 2 CARD RACK MODULE NGC 30 CRM CRMS AND CURRENT TRANSFORMER MODULE NGC 30 CTM Each Card Rack Module NGC 30 CRM and NGC 30 CRMS and Current Transformer Module NGC 30 CTM provide ground fault and line current sensing alarming switching and RTD input for five Loops The NGC 30 CRM is used with electromechanical relays The NGC 30 CRMS is used with solid state relays The NGC 30 CRM CRMS may be connected to one User Interface Terminal NGC UIT Each NGC 30 CRM CRMS must have a unique communication address The valid address switch range for the NGC UIT is 1 99 SW1 is the ones digit 0 9 and SW2 is the tens digit 0 9 See F
18. CONNECTIONS The Ethernet port can be used to connect multiple NGC UIT units to a host computer by connecting to the user s LAN system INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 14 31 Network node Ethernet cable Fig 2 15 Ethernet connection 2 9 TESTING THE NGC 30 SYSTEM Once the wiring to the panel has been finished confirm that it was done properly by completing the following steps 1 Turn the power on to all network devices NGC 30 CRMs CRMSs and optional RMM2s amp PLI modules and the NGC UIT 2 Once the NGC UIT has booted up to the Main screen Go to the Network Device Screen and press Update Network 0 17 5 Relays RTD 1 2 3 4 Fig 2 16 Network Devices screen 3 Confirm all NGC 30 CRM CRMS RTDs and or RMM2s and PLI modules have been scanned into the Network database 4 If a device or an RTD is installed but does not show up in the Network Devices Screen turn the power off to the system and For Devices a Confirm the device has a unique address refer to section 3 2 on page 21 b Confirm the device is being powered c Confirm the RS 485 connection is in place with the correct polarity refer to section 2 6 5 For RTDs a Confirm the RTD connection is in place with the correct polarity b Perform a resistance check of the RTD The resistance should be in a range of 70 250 ohms Turn the power on to all devices NGC 30 CRMs CRMSs and optional RMM2s a
19. Remote Mounting User Interface Terminal NGC UIT OUT 10332 003 Hazardous Locations Outdoors Panel Mounting UIT Adaptor Cable NGC UIT 232 10332 005 Card Rack Module CRM for EMRs NGC 30 CRM 10720 001 Card Rack Module CRMS for SSRs NGC 30 CRMS 10720 004 Current Transformer Module CTM NGC 30 CTM 10720 002 Card Rack CT NGC 30 CR 10720 003 Voltage Monitoring Module NGC 30 CVM 10720 005 Remote Monitoring Module RMM2 051778 Remote Monitoring Module RMM2 A4X with NEMA 4X 2 4 523420 Enclosure Power Line Carrier Interface Module PLI 488323 INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 23 31 APPENDIX B PANEL SPECIFICATIONS Panel Specifications Table B 1 Panel Specifications General Area of use NGC 30 EMR for nonhazardous locations NGC 30 EMR with Z purge for hazardous locations NGC 30 SSR for hazardous locations Approvals reas no peligrosas reas peligrosas versi n depurada de EMR reas peligrosas versi n SSR ene ETL EN LISTA EN ETL EN LISTA TI ETL EN LISTA m se p ED C KI es 9700701 UL nl ad 9700701 UL STD 508A Bc 9700701 ANSVSA STD 12 12 01 Intertek Intertek ITEM M c PE uir ETL EN LISTA IV CUMPLE CON c 4 NFPA STD 496 Supply voltage 100 240 Vac 5 1096 50 60 Hz common supply for controller and heat tracing circuit Up to 600 Vac for heat tracing circuit when controller is powered from a separate circui
20. TING PROCEDURES Each Raychem NGC 30 panel includes a set of As Built drawings that have been engineered designed and drafted based upon the model number and any special requirements that were requested when ordering The As Built drawings include an elevation layout with bill of materials and schematics If these drawings are not included contact your Pentair Industrial Heat Tracing Solutions Representative and request the As Built drawings for your panel Upon request an electronic copy of these drawings can be provided For mounting the panel locate the elevation and layout drawing which includes a bill of materials The enclosure mounting information will be provided on the As Built drawings 2 6 WIRING PROCEDURES Refer to the As Built drawings for wiring of incoming outgoing power and incoming RTD connections The Raychem NGC 30 panel can be purchased with or without a distribution panel board 2 6 1 INCOMING POWER WITH DISTRIBUTION SYSTEM Main Circuit Breaker Locate 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 of main circuit breaker and voltage loss calculations use the appropriate size and number of wires to connect directly to the main circuit breaker and panel board neutral and ground bus in the panel Incomming service Three phase 4 wire 60 Hz 2
21. able of 20 W maximum per conductor Note power wire and RTD wire should not be housed in the same conduit Alarm Outputs Relay outputs 3 SPDT Form C Rating 3 A 100 277 Vac Each relay may be assigned to alarm outputs Programming and Setting Method Via NGC UIT2 User Interface Terminal Units F or C Digital display 5 inch x 3 inch LCD color touch screen 14 61 cm X 8 26 Memory Nonvolatile restored after power loss Stored parameters measured Minimum and maximum temperatures contactor cycle count heater time in use Alarm conditions Low high temperature low high current ground fault alarm and trip RTD failure communications failure relay failure relay count total time heater energized contactor failure INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 25 31 Connection Terminals Heating cable output Screw terminals 20 6 AWG 30 A versions 14 2 AWG 60 A versions Ground 14 4 AWG ground bar RTD alarm communications 28 12 AWG spring clamp terminals Distribution for Raychem NGC 30 EMR only Load power 120 208 240 277 347 480 600 Vac Standard circuit breakers US United States country code in ordering details Square D type QOB 120 208 240 Square D type NF 277 480 CA Canada country code in ordering details Cutler Hammer Canada type BAB 120 208 240 Cutler Hammer Canada t
22. ccuracy 4 of range at 30 A line current Voltage Sensor Range 80 290 Vac 50 60 Hz Accuracy 1 of span Outputs CRM output relays Form A 3 Amp 277 Vac max 50 60 Hz CRMS SSR outputs 12 Vdc 30 mA max per output Alarm relay Form C 3 Amp 277 Vac max 50 60 Hz Communication to NGC UIT2 or 200N Type 2 wire RS 485 Cable One shielded twisted pair Length 4000 ft 1200 maximum Note May require an RS 485 repeater if communication length is greater than 4000 ft Quality Up to 52 NGC 30 CRM CRMS may be connected to one NGC UIT2 Up to 16 NGC 30 CRM CRMS may be connected to one 200N Connection Terminals Power supply pilot relay RTD comm port RS485 18 12 AWG 0 8 3 3mm2 INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 27 31 APPENDIX D NGC UIT2 SPECIFICATIONS General Approvals NGC UIT2 ORD reas no peligrosas amp LR67275 NGC UIT2 ORD R reas no peligrosas S Supply voltage 100 240 Vac 10 25 A max 25 VA 50 60 Hz Operating temperature 40 F to 149 F 40 C to 65 C EMC Immunity industrial Emission commercial light industrial Vibration Unit tested to IEC 60068 2 6 Shock Unit tested to IEC 60068 2 27 Dimensions 10 1 4 wide X 6 5 8 high X 3 deep 260 mm wide X 168 mm high X 76 mm deep Control Outputs Relay outputs Three relay outputs Form C contacts switching load
23. dous Locations NEMA 4 or 4X Designed for mounting on the Raychem Outdoors solid state NGC 30 external panel door re lays e Class l Division 2 Groups A B C D NEMA 4X P e Class 1 Zone 2 Group Outdoors mechanical Temperature Class T4 relays with Z purge Outdoor Locations option Hazardous locations are defined by Article 500 of the National Electrical Code and or Part 1 Section 18 of the Canadian Electrical Code Some wiring configurations will use more than one power source All power sources must be de energized prior to performing any maintenance on a card rack module or its heating circuit The operating environment should be within the limitations specified for the Raychem NGC 30 components as outlined in Appendices B C and D INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 4 31 2 4 INSTALLATION LOCATION The wide Operating Temperature of the Raychem NGC 30 permits 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 temperature conditions may affect load current ratings Always be sure that the intended location is classified as an area that the product is approved for use in as defined by Article 500 of the National Electrical Code and or Part Section 18 of the Canadian Electrical Code 2 5 MOUN
24. e with shield will be terminated by the installer at the RTD terminal blocks Refer to the Installation Drawings for the RTD Termination Schedule See Fig 2 4 on page 8 for a typical RTD installation Note To meet the requirements for hazardous location installations a separate RTD terminal block must be installed and wired to the NGC 30 CRM CRMS RTD terminal connector NGC 30 CRM CRMS Panel Rear Field Terminal Block Wiring Card Rack Module WH 4 1 nA RED J RED 2 e 3 RED RED 4 OPEN SHLD 777 CHASSIS GRD Reference panel drawing for terminal block number Fig 2 4 Typical RTD installation 2 6 5 CONNECTING THE RS 485 DEVICE NETWORK The NGC UIT display is typically linked to a network of Raychem NGC 30 CRMs CRMSs and optional 25 and PLIs These are connected to the Raychem NGC UIT using an RS 485 communication cable shielded two conductor twisted pair The following illustration shows how the RS 485 network for the NGC UIT system may be configured INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 7 31 Device must be mounted in series Branching of the network is not allowed Terminated devices are shown in gray Connect no more than two RS 485 cables to any device NGC UIT NGC UIT
25. enhance any of these components new documentation will accompany these releases To ensure that the correct documentation is being used for your particular version of the Raychem User Interface Terminal NGC UIT compare the firmware version number of each component 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 is released Supplements will make specific reference to the operation or functional change Copies of this manual and updates may be downloaded from the Literature section of www pentairthermal com Table 1 1 Component versions Component Version number NGC CRM CRMS V1 0X NGC UIT WK RMM2 V1 0X INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 3 31 SECTION 2 INSTALLATION AND WIRING 2 1 INTRODUCTION 2 2 INITIAL INSPECTION 2 3 OPERATING ENVIRONMENT Electrical Hazard Ensure all personnel involved in installation servicing and programming are qualified and familiar with electrical equipment their ratings and proper practices and codes Multiple voltages and signal levels may be present during the installation operation and servicing of this product Do not power the product until the safety provisions outlined in this section have been observed This section includes information regarding the initial inspection preparation for use and wiring instructions for the compon
26. ents of the Raychem NGC 30 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 Procedures for installing the Raychem NGC 30 are given in this section If the shipment is incomplete mechanically damaged defective in any way or does not pass the electrical performance tests notify the nearest Pentair Industrial Heat Tracing Solutions representative If the shipping container is damaged or the cushioning material shows signs of stress notify the carrier as well as your Pentair Industrial Heat Tracing Solutions representative Keep the shipping materials for the carrier s inspection There are three types of User Interface Terminals UITs available with the Raychem NGC 30 panel as shown in Table 2 1 The term NGC UIT in this document refers to any of the available NGC UITs regardless of which model is actually installed Table 2 1 NGC 30 User Interface Terminals UITs UIT type Area classification Usage NGC UIT ORD Nonhazardous Unclassified Locations NEMA 12 Indoors NGC UIT ORD 12 Nonhazardous Unclassified Locations NEMA 12 e The NGC UIT ORD 12 must be installed inan Indoors nonhazardous indoor location The NGC UIT ORD 12 connects to NGC 30 panels using RS 485 communication wiring NGC UIT OUT Hazar
27. es about topology and termination of network end devices Remote Monitoring and Control Network Connection The remote monitoring and control network communicates via a selectable network connection port using either RS 485 RS 232 or 10 100Base T Ethernet This network is used to connect to multiple NGC UIT systems and communicate with a central PC running Raychem Supervisor software The Raychem Supervisor software provides centralized status and alarm monitoring data logging and remote configuration control over all attached NGC UIT systems in the network The remote monitoring and control network must also follow configuration rules about topology and termination of the network end devices Side View TX OO RX Field TX OO RX _ Local Remote 1002 30 relays USB O Status Q Reset Front view ON OFF TERM R Field ON OFF TERM R Remote Not to scale ON OFF WOT Side view Bottom view Fig 3 1 NGC UIT touch screen display controls and connections INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 17 31 3 1 3 NGC UIT LED STATUS The LED Status lights are located on the side of the NGC UIT Refer to Table 3 1for LED functions Table 3 1 LED Status Light Functions Field Local Remote 7 766 525 Status 80 NN Relays TX RX Local Remole OFF No power USB key No activity No activity No act
28. ig 3 3 K4 Note RMM2s use ModBus addresses 32 through 47 and PLIs use Modbus addresses 1 99 When using RMM2s and PLI modules in an NGC 30 system care must be taken to not assign the same addresses to an RMM2 PLI module or an NGC 30 CRM CRMS board LSB MSB Fig 3 3 Communication address switch Note When adding an NGC 30 CRM CRMS to the system power must be cycled to the board and a network update on the NGC UIT must be performed NGC 30 CRM CRMS Ed Ne OO TM 7 QU Moos Em n DN wen Alarm output End of Line EOL jumper Relay outputs 5x RS 485 Communications LEDs 9x Line amp ground fault sensor inputs bx O Fuse RTD Inputs 12 Vdc Inputs 2x Address Switches Fig 3 4 NGC 30 CRM CRMS Board l Layout Each NGC 30 CRM CRMS has a cluster of nine LED lights to advise the status of the board Number 3 in Fig 3 4 shows the location of the LED lights INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 19 31 Table 3 3 LED Display
29. ilable NGC UITs regardless of which model is actually installed Fig 3 1 Typical NGC UIT model showing NGC UIT ORD 12 remote user interface terminal The physical dimensions of each NGC UIT model vary the dimensions of the NGC UIT ORD 12 shown in the figure are the largest of all NGC UITs Width 15 381 mm e Height 11 8 300 mm Depth 6 1 155 mm NGC UIT LCD Touch Screen Display Each NGC UIT has a 5 inch x 3 inch 14 61 cm X 8 26 cm LCD color display with touch screen technology that provides an user interface easy and efficient programming with no keyboards or cryptic labels 3 1 2 NGC UIT LOCAL AND REMOTE NETWORK CONNECTIONS The NGC UIT communicates to both a local field network and optionally to a remote monitoring and control network INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 16 31 Local Field Network Connection The local field network always uses an RS 485 serial connection running over shielded twisted pair cable This network is used to connect the NGC UIT to its control and monitoring modules e Raychem Mechanical Contactors Controller NGC 30 CRM e Raychem Solid State Relay Controller NGC 30 CRMS e Raychem Current Transformer Module Controller NGC 30 CTM e Raychem Voltage Monitoring Module NGC 30 CVM e Raychem Remote Monitoring Module RMM2 e Raychem Power Line Carrier Interface Module PLI The local field network must follow configuration rul
30. ivity No activity Relay in detected NO position 1002 _ Output 30 relays Green Normal USB key Flicker on Flicker on Flicker on Flickeron Relay EEUU IURI EH inserted receipt of transmission receipt of transmission energized USB Stat Ot ERG data packet of data data packet of data contacts in packet packet NC position LED functions Yellow UIT loading USB in use State controlled by software all other states controlled by hardware 3 1 4 CONFIGURATION SWITCHES The configuration switches are also located on the side of the NGC UIT The TERM R FIELD setting refers to the local RS 485 network that connects the NGC UIT to attached CRM CRMS and or RMM2 devices The TERM R REMOTE SETTING refers to connections between the NGC UIT and a central PC running Raychem Supervisor software Refer to Table 3 2 for LED functions Table 3 2 Configuration Switch Functions Position ON OFF TERM R Field X Switch On off Comments ON OFF TERM R Remote a TERM R FIELD 120 Ohm Termination For the local FIELD RS 485 ON OFF WDT Field Port Termination Enabled Disabled network Ifthis NGC UIT is the Termination Select Factory Default first or last RS 485 device in the Terminates local network it must be set to RS 485 network ENABLED ON Ifthe NGC UIT is NOT the first or last device it Configuration Switches must be set to DISABLED OFF TERM R REMOTE 1
31. mp PLI and the NGC UIT Once the NGC UIT has booted up to the Main screen Go to the Network Device Screen and press Update Network Confirm all NGC 30 CRM s CRMSs RTDs and or RMM2s and PLI modules have been scanned into the Network database INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 15 31 SECTION 3 RAYCHEM NGC 30 COMPONENTS AND OPERATION The Raychem NGC 30 heat trace system is comprised of a number of modular components allowing the ultimate in design flexibility This section describes the NGC 30 control and monitoring components excluding the optional distribution section Appendix B C and D includes the specifications for these components 3 1 USER INTERFACE TERMINAL NGC UIT The NGC UIT is a panel mounted color LCD display with touch screen overlay The NGC UIT includes software that interfaces with the Card Rack Modules NGC 30 CRM and NGC 30 CRMS and the Remote Monitoring Module RMM2 and Power Line Carrier Interface PLI module The NGC UIT is used as a control panel setup device and user display 3 1 1 MULTIPLE NGC UIT MODELS There are three versions of User Interface Terminals UITs available as specified in Table 2 1 NGC 30 User Interface Terminals 01 6 on page 5 All versions use the same wiring system interface and programming The NGC UITs differ only in the environments in which they can be installed The term NGC UIT in this document refers to any of the ava
32. r only one port can be assigned read write access This is done using the NGC UIT 2 8 1 RS 232 SERIAL CONNECTIONS The RS 232 port can be used as a direct connection to a single PC located within 50 feet of the panel Refer to Fig 2 13 on page 15 For an RS 232 connection a 3 foot long RJ11 to pin female D connector NGC UIT 232 part number 10332 005 has been provided with the NGC UIT Plug the RJ11 connector into the RS 232 connector on the NGC UIT and the other end into the 9 pin male connector on the user s computer PC Laptop 9 pin male E 9 pin female 3 foot RJ11 to 9 pin female D connector Fig 2 13 RS 232 connection 2 8 2 RS 485 SERIAL CONNECTIONS Use the RS 485 port when multiple NGC UIT units are to be connected to a host computer or the connection is longer than 50 feet An RS 485 to RS 232 or RS 485 to USB converter may be required to make the connection to the user s PC To NGC 30 CRM CRMS Reference panel drawing for terminal block number r T NGC 30 Panel PC Bts i 4 RS 485 Converter BK 1 xe AN EN 1 I bases pin will e a e L male 1 l RS 485 9 pin female Fig 2 14 RS 485 connection 2 8 3 ETHERNET
33. s from 700 TTs Up to four PLIs can be connected to one NGC 30 UIT Fig 3 9 PLI module Set the RS 485 address for the PLI module using the rotary switches provided Note the orientation of the clear plastic cover then remove the cover Use a slotted screwdriver to rotate the selector switches to the appropriate positions to select the RS 485 address Each PLI module must have a unique address if two PLI modules CRM or RMM are assigned the same address communication faults will result The PLI module switch setting can be set from 1 99 O E Note S1 switch is the one digit 0 9 sol Bs and the S2 switch is the ten digit 0 9 o9 hh os RS 485 connections 5 gt Ste 36 Olege bees sea LH NR B N Norm Mixed Eyl Fig 3 10 PLI module rotary switch INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 22 31 SECTION 4 APPENDICES APPENDIX A REPLACEMENT COMPONENT ORDERING GUIDE Replacement Components Description Catalog Number Part Number User Interface Terminal NGC UIT ORD 10332 001 Nonhazardous Unclassified Locations Indoors Panel Mounting User Interface Terminal with NEMA 12 Enclosure NGC UIT ORD 12 10332 008 Nonhazardous Unclassified Locations Indoors
34. s up to 277 Vac 3A Relays may be assigned for alarm outputs 11 position Phoenix style pluggable screw terminal connector with retaining screws Network Connection Local Remote Port RS 485 RS 232 selectable Port may be used to communicate with Raychem Supervisor software RS 232 is non isolated RJ 11 connection RS 485 2 wire isolated Phoenix style pluggable screw terminal connector with retaining screws Maximum number of devices 256 Fail safe design with optional termination resistors Data Rate 9600 to 57600 baud Maximum cable length for RS 485 not to exceed 4000 feet 1200 m Cable to be shielded twisted pair Field Port RS 485 2 wire isolated Used to communicate with external devices such as NGC 30 CRM NGC 30 CRMS and RMM2 Maximum cable length not to exceed 4000 ft 1200 Cable to be shielded twisted pair Phoenix style pluggable screw terminal connector with retaining screws Maximum number of devices 256 Fail safe design with optional termination resistors Data rate to 9600 baud LAN 10 100 Base T Ethernet port with Link and Activity Status LEDs USB Ports USB 2 0 Host port Type A receptacle Status LEDs Relay Three LEDs showing the ON OFF Status for each relay LED ON indicates relay is energized Field Transmit and Receive activity Local remote Transmit and Receive activity INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878
35. t Enclosure Protection materials NEMA 12 indoors painted steel NEMA 4 3R outdoors painted steel NEMA 4X 3RxX outdoors stainless steel Operating Temperature Without distribution 13 F to 140 F 25 C to 60 C Below 13 F 25 C space heater and thermostat must be used With distribution 14 F to 140 F 10 C to 60 C Below 14 F 10 C space heater and thermostat must be used Storage Temperature 40 F to 167 F 40 C to 75 Relative humidity Control 0 to 90 noncondensing Control points The Raychem NGC 30 system can control up to 260 circuits Relay types 3 pole electromechanical EMR versions 1 2 or 3 pole solid state relays SSR versions Voltage maximum 240 Vac nominal 50 60 Hz standard 600 Vac nominal optional Current maximum per circuit Depending on panelboard amperage rating the maximum current may not be used on all circuits EMR 30 A a 104 F 40 C or 60 A a 104 F 40 SSR 30 A a 104 F 40 C or 60 A a 104 F 40 C Control algorithms EMR On Off Ambient on off PASC proportional ambient sensing control SSR On Off Ambient on off PASC proportional ambient sensing control Proportional includes soft start for all SSR control modes Control range 99 F to 900 F 739 to 482 C Dead band 1 F to 50 F 19 to 50 C On Off control only INDUSTRIAL HEAT TRACING SOLUTIONS EN
36. ule Set the RS 485 address for the RMM2 using the rotary switch provided Note the orientation of the clear plastic cover then remove the cover Use a slotted screwdriver to rotate the selector switches to the appropriate positions to select the RS 485 address The single character visible on the switch indicates the RS 485 address assigned So 6606 udo diu 230V 1 1 oo 50 60 2 2 5VA Voltage Select perature Fig 3 8 RMM2 rotary switch Table 3 4 RMM2 Switch Settings Switch Settings 0 1 2 3 4 5 6 7 8 9 A B C D E F Device Address 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 21 31 3 6 POWER LINE CARRIER INTERFACE MODULE PLI OPTIONAL The Raychem Power Line Carrier Interface Module PLI together with Raychem temperature transmitters provides remote temperature monitoring capability The PLI module receives input from temperature transmitters over the power wires for the heat tracing circuits which carry the signals from special transmitters The transmitters provide pipe temperatures from RTDs and continuity confirmation Per PLI module the NGC 30 system can accept up to 127 temperature inputs from SES s SPCs or 255 temperature input
37. ype GBH 277 480 347 600 Circuit breaker amperage rating 120 Vac 20 A 30 A 40A 50A 208 240 277 347 480 600 Vac 20 A 30 A 40 A 50 60A 70 A INDUSTRIAL HEAT TRACING SOLUTIONS EN RaychemNGC30 IM H57878 04 15 26 31 APPENDIX C NGC 30 CRM CRMS SPECIFICATIONS Table C 1 NGC 30 CRM CRMS Specifications General Approvals certifications Clase I Div 2 Grupos Ex nC 1 5 us Clase l Zona 2 AEx nC IIC 5 4 Supply voltage 12 Vdc x 1096 Internal power consumption lt 5 W per NGC 30 CRM CRMS Operating temperature 40 F to 140 F 40 C to 60 Storage temperature 40 F to 167 F 40 C to 75 Environment PD2 CAT III Max altitude 2000 m Humidity 0 90 noncondensing Electromagnetic Compatibility Immunity Heavy industrial Emission Residential commercial light industrial Temperature Sensors Type 100 W platinum RTD 3 wire a 0 00385 ohms ohm C Can be extended with a 3 conductor shielded cable of 20 ohm maximum per conductor Quantity Up to five wired directly to each NGC 30 CRM CRMS Current Sensors Mounting DIN Rail 35 mm Quantity per NGC 30 CTM Line Current Sensors Five for ground current measurement Five for line current measurement Max current 60A Accuracy 2 of reading Ground Fault Sensor Range 10 200 mA A

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