Chromalox Installation Instructions DTS-HAZ For Use With Self-Regulating & Constant Wattage Heating Cables

Chromalox Installation Instructions DTS-HAZ For Use With Self-Regulating & Constant Wattage Heating Cables
Heat Tracing Sales Mt. Airy, Maryland www.heattracingsales.com
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®
Chromalox
SERVICE REFERENCE
DIVISION
Installation Instructions
4
SALES
REFERENCE
SECTION
(Supersedes PJ944-5)
DTS
PJ944-6
161-562581-049
MARCH, 2012
DATE
DTS-HAZ For Use With Self-Regulating &
Constant Wattage Heating Cables
Junction Box
Compression Fitting
RTD
O-Ring
Protective
Sleeve
Locknut
Silicone Termination Boot
Pipe Sandoff
Self-Regulating and Constant
Wattage Cable Grommets
RTV
9VDC Battery Connector
Description
Quantity
Junction box
Line/Ambient Sensing RTD
Compression Fitting
Locknut
Silicone Termination Boot
Pipe Standoff
RTV
O-Ring
Self-regulating Cable Grommet
Constant Wattage Cable Grommet
9 VDC Battery Connector
Protective Sleeve
1
1
1
1
1
1
1
1
1
1
1
1
GENERAL
The DTS-HAZ is used for electrical termination of self-regulating and
constant wattage cables. Each kit contains the terminations needed to
make all electrical connections.
process temperature maintenance of pipes or tanks protected by heat
tracing products. This thermostat can be used with Constant Wattage,
Mineral Insulated or Self regulating heating cables in ordinary area or
Div 2 hazardous area locations.
The DTS-HAZ digital thermostat kit is a microprocessor based temperature control and power connection kit used for freeze protection or
© 2012 Chromalox®, Inc.
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INSTALLATION
Explanation of Symbols Used:
Means WARNING.
(Chromalox type PS not included) as shown. Leave braid of the
cable outside of pipe standoff and connect to ground (grounding
clamp not included). Tape cable to pipe as shown. Small slice will
need to be cut in grommet to allow the RTD wire to exit the pipe
standoff out the bottom. For pipes smaller than 1-1/2" dia. a small
pipe adapter (Chromalox model SPA not included) is required.
Means Earth (ground) terminal.
HAZARD OF ELECTRIC SHOCK. Disconnect all power
before starting. All installations must be effectively
grounded in accordance with the National Electrical
Code to eliminate shock hazard.
Turn off power before removing junction box cover at
all times.
Users should install adequate controls and safety
devices with their electric heating equipment. Where
the consequences of failure may be severe, back-up
controls are essential. Although the safety of the installation is responsibility of the user, Chromalox will be
glad to assist in making equipment recommendations.
Figure 3
4. Score the inner insulation 7 inches from the end. Lightly cut the
inner jacket up the center to end of heating cable and remove the
inner jacket from the cable.
A disconnect device and circuit breaker should be
provided in the end installation. The installation and
proximity for the disconnect device must satisfy the
electrical Authority having jurisdiction for the installation. Branch circuit protection should be set for 40
amps or lower.
Figure 4
In all cases where the
symbol is used on the product, consult the documentation to find out the nature
of the potential hazard and any actions to be taken.
5. Shave the core material from the outside of each bus wire. *Skip
this step if using CWM-C constant wattage cable.
Braid only cable instructions for SRL-C, SRF-C, SRM/E-C.
CWM-C cable special instructions denoted by *
1. For each cable, push braiding back from the end of the cable. 11
inches from cable end create a bulge. At the bulge, separate the
braid to make an opening.
Figure 5
6. Starting at the end of the heating cable, using needle nose pliers or
a knife pull each bus wire away from the core material. *Separate
CWM-C leads and strip 1/4" from each leadwire.
Figure 1
2. While bending the heating cable, work the cable through the braid
opening. Pull the braid tight.
Figure 6
7. Remove the exposed core material and cut 1/4" off the end of each
bus wire. *Skip this step if using CWM-C constant wattage cable.
Figure 2
3. Insert cables and capillary tube though pipe standoff and grommet
as shown. There should be 8 inches of cable past the grommets
edge. Attach the pipe standoff to the pipe with a pipe strap
Figure 7
2
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INSTALLATION (cont’d.)
8. Liberally apply RTV over the exposed matrix and leads. Push the
rubber boot over the heating cable. Trim lead ends as needed.
*Boot is not needed when using CWM-C constant wattage cable.
Up to 277 VAC may be
present at these terminals.
Use 14 AWG copper wire
or better.
Figure 8
9. Slide compression fitting over cable. Grommet should be placed
inside pipe standoff. Termination boot should be spaced 1/2" from
sealing grommet. Tighten compression fitting until it bottoms out
against pipe standoff.
Alarm
Contacts
L or L1
N or L2
G
To
Grounding
Hub
Compression Fitting
Grounding braid shall
be secured to UL listed
grounding hub.
Up to 277 VAC may be
present at these terminals.
Use 10 AWG copper wire
or better.
Grommet
Figure 12 – DTS-HAZ External Ground
+
Red
White
COM
Red
Figure 9
10. Assemble junction box to compression fitting as shown. Tighten
locknut until the junction box bottoms out against the lip of the
compression fitting.
Figure 12a
3 Wire RTD
Be sure to install this device vertically as pictured in
Fig. 10. This controller utilizes a heat sink which is
designed to cool the unit during operation. Under no
circumstance should air flow around the controller
be compromised in any way. Failure to do so may
result in the overheating of the controller, product
failure, product temperatures which exceed the
Hazardous Area maximum temperature limit and
even fire.
Figure 10
Enclosure lid must be properly sealed prior to operating. Each of the four (4) screws are to be evenly
tightened by hand with appropriate screw driver
ONLY until snug. It is recommended that the lid be
secured with a torque of 12-15 inch-lbs per screw.
Overtightening or uneven tightening may cause the
lid to break which would void all environmental and
hazardous location approvals. Due to an electrical
shock hazard, do not operate thermostat if lid is
cracked, broken or uneven with enclosure.
11. Attach 3/4” conduit hub. Please see the electric diagrams below for
proper wiring for your application. Attach junction box cover to
seal enclosure. Note: The conduit hub shall be listed for Class 1,
Div. 2; Class II Div. 1 & 2, Class III, Div. 1 & 2, and 4X rated by
a nationally recognized testing laboratory.
Figure 11
3
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INSTALLATION (cont’d.)
Overjacketed cable instructions for SRL-CR, SRL-CT,
SRF-CR, SRM/E-CT. CWM-CT cable instructions denoted by *
1. Insert heating cable and capillary tube through pipe standoff and
grommet as shown. 8 inches of cable should extend past the grommet. Attach the pipe standoff to the pipe with a pipe strap
(Chromalox type PS not included) as shown. Attach extra cable to
pipe as appropriate. Small slice will need to be cut in grommet to
allow the RTD wire to exit the pipe standoff out the bottom. For
pipes smaller than 1 1/2" diameter optional small pipe adapter
(Chromalox model SPA not included) is required.
5. Score the inner insulation 6 inches from the end. Lightly cut the
inner jacket up the center to end of heating cable and remove the
inner jacket from the cable.
Figure 17
6. Shave the core material from the outside of each bus wire. *Skip
this step if using CWM-C constant wattage cable.
Figure 18
Figure 13
2. Score the outer insulation 7 inches from the end of the cable.
Lightly cut the outer jacket up the center to the end of heating cable
and remove the outer jacket from the cable. WARNING: DO NOT
CUT METAL BRAID.
7. Starting at the end of the heating cable, using needle nose pliers or
a knife pull each bus wire away from the core material. *Separate
CWM-C leads and strip 1/4" from each leadwire.
Figure 19
8. Remove the exposed core material and cut 1/4" of the end of each
bus wire. *Skip this step if using CWM-C constant wattage cable.
Figure 14
3. Move braid back toward the overjacket, creating a bulge. At the
bulge, separate the braid to make an opening.
Figure 20
9. Liberally apply RTV over the exposed matrix and leads. Push the
rubber boot over the heating cable. Trim lead ends as needed.
*Boot is not needed when using CWMC constant wattage cable.
Figure 15
4. While bending the heating cable, work the cable through the braid
opening. Pull the braid tight.
Figure 21
Figure 16
4
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410-795-2223
INSTALLATION (cont’d.)
10. Slide compression fitting over cable. Grommet should be placed
inside pipe standoff. Termination boot should be spaced 1/2" from
sealing grommet. Tighten compression fitting until it bottoms out
against pipe standoff.
Be sure to install this device vertically as pictured in
Figure 23. This controller utilizes a heat sink which is
designed to cool the unit during operation. Under no
circumstance should air flow around the controller be
compromised in any way. Failure to do so may result
in the overheating of the controller, product failure,
product temperatures which exceed the Hazardous
Area maximum temperature limit and even fire.
Compression Fitting
Grommet
Up to 277 VAC may be
present at these terminals.
Use 14 AWG copper wire
or better.
Figure 22
Alarm
Contacts
L or L1
N or L2
G
11. Assemble junction box to compression fitting as shown. Tighten
locknut until the junction box bottoms out against the lip of the
compression fitting.
Grounding braid shall have the included
protective sleeve slid over it once inside
the enclosure. Then, insert grounding
braid into grounding terminal.
Up to 277 VAC may be
present at these terminals.
Use 10 AWG copper wire
or better.
Figure 24 – DTS-HAZ Internal Ground
Figure 23
12. Attach 3/4” conduit hub. Please see the electric diagrams below for
proper wiring for your application. Attach junction box cover to
seal enclosure. For over-jacketed cable with internally grounded
braid: Grounding braid shall have the included protective sleeve
slid over it once inside the enclosure. Then, insert grounding braid
into grounding terminal. Note: The conduit hub shall be listed for
Class 1, Div. 2; Class II Div. 1 & 2, Class III, Div. 1 & 2, and 4X
rated by a nationally recognized testing laboratory.
+
Red
White
Figure 24a
COM
Red
3 Wire RTD
Enclosure lid must be properly sealed prior to operating. Each of the four (4) screws are to be evenly tightened by hand with appropriate screw driver ONLY until
snug. It is recommended that the lid be secured with
a torque of 12-15 inch-lbs per screw. Overtightening
or uneven tightening may cause the lid to break which
would void all environmental and hazardous location
approvals. Due to an electrical shock hazard, do not
operate thermostat if lid is cracked, broken or uneven
with enclosure.
5
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START-UP
b. Hi Temperature Threshold – max. temperature value. After
reaching this threshold controller will set Alarm condition.
c. Lo Temperature Threshold – min. temperature value. After
reaching this threshold controller will set Alarm condition.
d. Deadband – The allowable temperature differential between
the Set Point and the Sensed Temperature during normal
operation. The Deadband is centered on the Setpoint. The
Deadband has a range of 2 to 10 deg. in 2 degree increments.
The Load is removed once the temperature is 1/2 way
between the Setpoint and the upper limit of the Deadband.
e. Units – selection between degrees Fahrenheit or Celsius.
f. Soft Start Function – The soft start may be enabled or disabled. When enabled, the Soft start algorithm initiates at
power on & whenever low end of dead band is realized. When
initiated, 0% - 100% Power is achieved over 167 seconds.
g. Alarm – The Alarm is rated for 12-277 VAC and 2 amperes
RMS. NOTE: The Alarm functions only with AC voltage.
The FACTORY DEFAULT SETTING IS NORMALLY
CLOSED. You may toggle this setting to Normally Open via
the control push buttons.
Connecting RTD Wire
1. Connect RTD wire according to the schematic:
For up to 30 amp loads, use minimum 10 AWG wiring
or better for 120/277 VAC power input.
Connecting power to the unit.
1. Powering up with 120/277 VAC: To power up the unit apply
120/277 VAC to the terminal block according to the schematic
below:
Connections for Power, Cable, Alarm and Sensor
AC Power & Heating Cable
Terminal Blocks
Terminal Blocks For:
Alarm
RTD
Com
RTD -
Ground
L or L1 - IN
(AC High)
RTD +
Cable OUT
No Connection
Alarm Contact
Cable OUT
N or L2 – IN
(AC Low)
Figure 25
Alarm Contact
+
2. Programming with 9VDC battery: The DTS-HAZ may be programmed with a 9VDC battery should standard service line voltage be unavailable.
Note: Powering unit with 9VDC should only be used for programming purposes and not operation of the unit.
3. Programming and alarm overview
Digital Thermostat must have the following components set to correctly control the temperature:
a. Setpoint – targeted temperature value that controller will aim
to reach
White
Red
COM
Red
UP
DOWN
3 Wire RTD
Figure 26
PROGRAMMING
To Program the Digital Thermostat follow the instructions below:
Press
Parameter
Display
Action
MODE
Set Point
6W3W
Press UP Or Down To Adjust
The Set Point Temperature
High Temp
+,W3
Press UP Or Down To Adjust
The High Temperature Alarm
UP
DOWN
Low Temp
/RW3
Press UP Or Down To Adjust
The Low Temperature Alarm
UP
DOWN
Dead Band
E$QG
Press UP Or Down To Adjust
The Dead Band From 2o To 10o
UP
DOWN
Temp. Units
8Q,W
Press UP Or Down To Toggle
Between Temp Units: oF Or oC
UP
DOWN
Soft Start
66UW
Press UP Or Down To Enable Or
Disable The Soft Start Function
UP
DOWN
Alarm State
$OUP
Press UP Or Down To Toggle
Alarm State To Be Normally Open
Or Normally Closed
UP
DOWN
MODE
MODE
MODE
MODE
MODE
MODE
6
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TROUBLESHOOTING
Alarm Type:
Display
Solution:
Sensor Open
Sens err
Check if your sensor is correctly connected to the unit
Sensor Shorted
Sens err
Check if your sensor is correctly connected to the unit
Lo Temperature
Blinking between sensed temperature and “LotP”
Sensed temperature is below Lo Temp. Threshold. Alarm will be cleared
automatically when sens temp > lo threshold + 5 deg
Hi Temperature
Blinking between sensed temperature and “HitP”
Sensed temperature is above HI Temp. Threshold. Alarm will be cleared
automatically when sens temp < hi threshold - 5 deg
EPR
EEprom memory error
Press UP & DOWN keys for 2 seconds. Unit will be loaded with default settings
ERR1
Program memory error
Program memory corrupt. Solution: Reprogram the unit. Consult Factory.
Product Maintenance & Care
The following inspections should occur upon receipt of product and at
least once every year.
a. Wiring
Inspect wiring for wear, fraying and evidence of overheating.
Repair minor defects with a high quality grade of electrical tape or
replace if needed.
b. Hardware & Connectors
Inspect for loose electrical and mechanical connections. Tighten or
replace all loose or missing hardware.
c. Cleaning
This product does not require cleaning. However, the heat sink fins
on back must routinely be inspected for any debris. Remove any
debris with a stiff brush or other careful means. Take care not to
break any fins. Should any of the fins break, the unit should be
replaced.
Equipment Ratings:
Voltage Rating: 100-277 VAC, 50/60 Hz
Current Rating: 30 amps
Ambient Temperature Rating: -40˚F to +104˚F
VA rating on electronics: 4.0 Watts
The electronics are protected by a 0.5 Amp 350 VAC 2AG fuse
Maximum RTD output 1.25 volts, 7 milliamps
Alarm Function:
Alarm contact rating 12-277 VAC, and 2 amps RMS
Alarm works with AC operation ONLY
Normally Closed - Factory Default
Normally Open - Optional Setting
Agency Approvals:
UL/cUL - Ordinary area, File number E336917
UL/cUL - Hazardous area (C1D2, Groups A, B, C & D) – File
number E347725
EXPLOSION HAZARD. Substitution of any component
may impair suitability for Class 1, Div. 2.
7
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Limited Warranty:
Please refer to the Chromalox limited warranty applicable to this product at
http://www.chromalox.com/customer-service/policies/termsofsale.aspx.
1347 HEIL QUAKER BLVD., LAVERGNE, TN 37086
Phone: (615) 793-3900
www.chromalox.com
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