Chromalox IntelliTrace ITAS-EXT Bedienungsanleitung

Installation Manual & Set-Up Guide

Ordinary Area

ITAS Ambient Sensing Control Panel

ITAS-EXT Ambient Sensing Extender Control Panel

ITLS Line Sensing Control Panel

ITLS-EXT Line Sensing Extender Control Panel

Hazardous Area

ITASC1D2 Ambient Sensing Control Panel

ITASC1D2-EXT Ambient Sensing Extender Control Panel

ITLS C1D2 Line Sensing Control Panel

ITLS C1D2-EXT Line Sensing Extender Control Panel

PK497-5

0037-75514

June 2018

Throughout the IntelliTrace®Setup Guide, these sym-

bols will alert you to potential hazards. Safety precau-

tions should always be followed to reduce the risk of

ﬁre, electrical shock, injury and even death to persons.

Please read all instructions before operating your

IntelliTrace®ITLS, ITAS, ITLS-EXT or ITAS-EXT Control

Panel.

To avoid electrical shock or injury, always remove pow-

er before servicing a circuit. Personnel working with

or near high voltages should be familiar with modern

methods of resuscitation. Contact an area supervisor

or safety personnel for more information.

IMPORTANT SAFEGUARDS

Safety Precautions

WARNING

HIGH VOLTAGE is used in the opera-

tion of this equipment; DEATH ON

CONTACT may result if personnel fail

to observe safety precautions.

Learn the areas containing high-volt-

age connections when installing or

operating this equipment.

Be careful not to contact high-volt-

age connections when installing or

operating this equipment.

Before working inside the equipment,

turn power off and ground all points

of high potential before touching

them.

WARNING

ELECTRIC SHOCK HAZARD

Any installation involving control

equipment must be performed by a

qualiﬁed person and must be effec-

tively grounded in accordance with

the National Electrical Code to elimi-

nate shock hazard.

iii

Table of Contents

Contents Page Number

Safety Precautions .................................................................................................................................................ii

Table of Contents .................................................................................................................................................iii

Introduction............................................................................................................................................................ 1

Model Overview ..................................................................................................................................................... 2

Theory of Operation .............................................................................................................................................. 3

Types of Sensing Control..................................................................................................................................... 4

Pre-Service Storage .............................................................................................................................................. 5

Before Powering Up ............................................................................................................................................. 5

General Panel Notes ............................................................................................................................................ 6

Installation............................................................................................................................................................. 7

Main Menu Screen ............................................................................................................................................... 8

Temp Setup Menu.. .............................................................................................................................................. 9

Security Levels & Password Screen ................................................................................................................. 10

Temp Setup Menu (Cont.) ................................................................................................................................. 11

Apply Settings Globally .................................................................................................................................... 13

Soft Start Feature .............................................................................................................................................. 13

Load Setup Menu .............................................................................................................................................. 14

Tuning Menu......................................................................................................................................................... 16

Control Modes: ON/OFF, Autotune & PID ......................................................................................................... 17

Sensor Mapping ................................................................................................................................................ 18

System Properties ............................................................................................................................................. 19

Auto Cycle Feature ............................................................................................................................................ 20

Communications ............................................................................................................................................... 21

Remote Monitoring & System Management ................................................................................................... 21

Alarm Log ........................................................................................................................................................... 22

Active Alarms ..................................................................................................................................................... 23

Clearing Alarms ................................................................................................................................................ 23

Alarm Troubleshooting ..................................................................................................................................... 24

Extension Panels – Connection & Considerations ......................................................................................... 25

Connecting the Extension panel to the Main Panel ......................................................................................... 25

Extension Panel Considerations ....................................................................................................................... 25

Wireless Temperature Sensing ......................................................................................................................... 26

Appendix A ......................................................................................................................................................... 37

Panel Speciﬁcations ......................................................................................................................................... 37

Default Settings ................................................................................................................................................ 38

Appendix B ......................................................................................................................................................... 44

ModBus Speciﬁcation ...................................................................................................................................... 44

Service Contact Information .......................................................................................................................... 106

Introduction

For nearly 100 years, customers have relied upon Chromalox for premiere quality and innovative solutions for

industrial heating applications. Chromalox manufactures the world’s largest and broadest line of electric heat and

control products.

The IntelliTrace®ITLS & ITAS Series Multiple Circuit Panels and Extender Panels are a complete temperature

control and system management solution for electrical heat trace applications. They are designed for industrial

applications in Hazardous (Class I, Division 2) or Non-Hazardous environments.

IntelliTrace®provides the user with an easy to navigate touch-screen interface, system parameter monitoring, off

duty preventative maintenance, application ﬂexibility and system customization.

The ITAS and ITASC1D2 provide Ambient Sensing control while the ITLS and ITLSC1D2 provide either Line Sens-

ing control or a hybrid of both Line and Ambient Sensing control.

IntelliTrace®Features:

• 40 Amps/Circuit @ 100 – 600 VAC

• SSR Output Power Control

• 2 to 72 Circuit

• Large Touch Screen HMI

• Integral Control Panel and Circuit Breaker Distribution (non-hazardous areas)

• 1-pole or 2-pole Designs

• Soft Start, On/Off, PID and Manual (Hand) Control

• Modbus RTU/RS485 or TCP/Ethernet Communications

• Full Monitoring & Alarms (Lo/Hi Current & Temperature, Sensor, Transmitter Battery, Communications & GFEP)

• Hazardous (Class I, Division 2) and Non Hazardous Environments

• NEMA 4 Enclosure (Optional NEMA 4X 304 SS)

• UL, cUL Listing (CE available)

Touch Screen Computer:

• 10” on 6 – 72 Circuit Systems and 7” On 2 – 8 Circuit Systems

• 2 or 6 Circuit Circuit Detail Displayed at a Time

• Quick Launch to any 2 or 6 Circuit Group Display

• Remote Desktop Monitoring

• Extremely Intuitive Navigation, User Setting and Operation

• Fully Customizable Circuit Naming and Parameter Programming

Options:

• Powerful and Flexible Sensor Mapping (ITLS, ITLSC1D2 only)

• Enclosure Heater

• Fully Integrated Wireless Temperature Sensing

• IntelliTrace®Supervisory Control (ISC) for Central Command of Multiple Systems

The Chromalox line of IntelliTrace®Heat Trace Control

Panels provides a signiﬁcant amount of application

and feature ﬂexibility.

The ITAS and ITASC1D2 are designed for Ambient

Sensing applications while the ITLS and ITLSC1D2 are

designed for Line Sensing applications. Additionally,

the ITLS and ITLSC1D2 have the capability to function

as both a Line Sensing control panel and an Ambient

Sensing control panel should the Customizable Sensor

Mapping feature be selected.

The IntelliTrace®matching ITAS-EXT, ITASC1D2-EXT

and ITLS-EXT, ITLSC1D2-EXT Extension Panels pro-

vide the ﬂexibility for the owner to meet their process

expansion needs. Simply connect the Extension Panel

to its matching ITLS, ITLSC1D2 or ITAS, ITASC1D2

Base Panel and circuit capacity is seamlessly in-

creased. The Extension Panels do not have a HMI, but

otherwise are identical.

These panels are UL and cUL Listed for Ordinary (Non

Hazardous ITLS/ITAS) and Hazardous (Class I, Division

2 ITLS/ITAS C1D2) Environments. CE is available.

Please see Table 1 below for applicable features and

capabilities by model type.

Model Overview

Table 1

Standard Features/Capabilities

ITLS

C1D2 ITAS

ITAS

C1D2 ITLS-EXT

ITLS

C1D2-EXT ITAS-EXT

ITAS

C1D2-EXT

Ordinary, Non-Hazardous Area X n/a X n/a X n/a X n/a

Hazardous Area (Class I, Division 2) n/a X n/a X n/a X n/a X

7" Touch Screen HMI (2-4 Loop Versions) X X X X n/a n/a n/a n/a

10" Touch Screen HMI (6-48 Loop Versions)

X X X X n/a n/a n/a n/a

40 Amps/Loop @ 100-600 VAC X X X X X X X X

Circuits 2, 4, 6, 8, 12, 18, 24, 30, 36, 42, 48 (Expandable to 72 with -EXT Panel)

SCR Control X X X X X X X X

NEMA 4 Enclosure X X X X X X X X

Integral Circuit Panel with Circuit Breakers X n/a X n/a X n/a X n/a

Soft Start Feature X X X X 1 1 1 1

Full Communications X X X X 1 1 1 1

Full Alarm Capabilities X X X X 1 1 1 1

Complete GFEP Monitoring & Alarms X X X X 1 1 1 1

Load Monitoring & Alarms X X X X 1 1 1 1

Sensor Mapping X X X X 1 1 1 1

UL, cUL Listing X X X X X X X X

Options

Enclosure Heater X X X X X X X X

Wireless Temperature Sensing X X X X 1 1 1 1

Main Breaker/Disconnect X n/a X n/a X n/a X n/a

Nema 4X 304 SS Enclosure X X X X X X X X

HMI Sunshield X X X X n/a n/a n/a n/a

Panel Weathersheild X X X X X X X X

Heater Power and RTD Terminal Blocks X X X X X X X X

Z-purge system X n/a X n/a X n/a X n/a

Panel Light (on separate breaker) X X X X X X X X

Powered Receptacle (on separate breaker) X X X X X X X X

Copper Ground Bar X X X X X X X X

CE available X X X X X X X X

X - Available as a standard or option for this model

1 - This feature is enabled when paired with matching base panel

n/a - This feature is not available for this model

Theory of Operation

The set-up of the individual and global circuit parameters is explained in the Temp/Load Set-up sections of this

manual. This Theory of Operation overview is intended to give a quick summary of how it all works together.

• Each circuit of the system may be enabled (active) or disabled (inactive). A disabled loop will have no

output and will not map into the common alarm. It will display “Circuit #” and “Disabled” text above

the process temperature. Alarms for disabled circuit will not be monitored or displayed on the screen.

• Each circuit of the system may use unique individual control parameters or the control parameters may

be alike. The Global Settings function facilitates this action.

• The GFEP and Load current are automatically and continuously being calculated. The horizontal orange

bar indicates the average output current for that circuit. The GFEP current value is not displayed on

the screen but its value is compared to the GFEP setpoint. A GFEP alarm condition will occur when

the GFEP current value exceeds the GFEP setpoint value.

• If a ground fault that exceeds the GFEP setpoint value is detected during normal operation and “Trip”

button on the Load Setpoints screen is checked, the output of the defective circuit is set to 0% and

that circuit goes into an alarm condition. If “Trip” button is not selected, the operation of that circuit

continues and that circuit goes into alarm condition. The GFEP alarm may be either Latching or Non-

Latching.

• During extended periods of time where the output of all circuits are off, such as during warmer sea-

sons, the Auto Cycle feature may be engaged. This feature initiates power to each circuit and checks

for alarms. Each output is tested for one minute within the desired Auto Cycle Interval. The Auto Cycle

feature may be disabled by setting the Auto Cycle Interval time to “0 Hours”.

• To limit inrush current on the overall system, a proprietary Soft Start algorithm is applied during sys-

tem start-up. This will ONLY occur while the operation mode is set to AUTO. The Soft Start program

will increment output % by 1% every 1 second until the desired temperature is reached or the output

% achieves 100%. After the Soft Start program completes its cycle, the Control Mode of the system

will either be PID or ON/OFF Control Mode, depending what was selected by the user. The Soft Start

Program will not function if the control mode is set to Manual.

• Centralized control of multiple ITAS or ITLS panels is accomplished via the ISC-IntelliTrace Supervisory

Controller.

Types of Sensing Control

Ambient Sensing Control

Strict ambient-sensing control utilizes a thermostat or a simple electronic controller which senses the ambient tem-

perature via an RTD, Thermocouple or Bulb & Capillary sensor. This is the simplest type of control as the heating

circuit is energized only when the ambient temperature drops below the setpoint of the controlling device. This is

also known as On/Off control. A relatively large temperature variation around the setpoint is anticipated. Mechani-

cal thermostats are often employed due to their low cost and acceptable accuracy. Multiple heater circuits are

controlled by a singular ambient sensed temperature. This is the least efﬁcient type of control and it is typically

limited to freeze-protection applications.

PASC - Proportional Ambient Sensing Control

Proportional ambient sensing control (PASC) utilizes an electronic controller which continuously compares ambient

temperature and the rate of the change of the ambient temperature to the desired temperature setpoint and regulates

the heater output power accordingly. The result is a smaller temperature variation around the desired setpoint and

a much smoother response to changing weather conditions. Like ambient sensing control, multiple heater circuits

are controlled by a singular ambient sensed temperature. PASC control is therefore signiﬁcantly more energy ef-

ﬁcient than ambient sensing control. PASC control can be employed in a variety of heat trace temperature control

applications but is typically used for freeze protection.

Line Sensing Control

Line sensing control is where each heated section of pipe (or heated surface area) is controlled independently of

other sections of pipe and therefore must have its own controller. Multiple sections of pipe may also be independently

controlled by an electronic multiple circuit control system. The control method may be either proportional or On/

Off control. Each section may have different setpoints and different allowances around the setpoint temperature.

Line sensing control is typically found in process temperature maintenance applications. These applications are

typically more critical and thus demand tighter temperature control. Electronic control is highly recommended over

thermostat control. Like PASC, the pipe surface temperature and the rate at which it is changing is continuously

compared to the setpoint temperature. The controller responds to these variations and regulates the heater output

power accordingly. Mission critical applications should only be managed by controllers which monitor all parameters

and present alarms both locally and remotely via communications or supervisory control means.

Before Powering Up

Chromalox takes great pride in knowing that we have provided to you a product of premium quality and workman-

ship. We have taken every precaution to ensure that your equipment arrives safe and secure.

However, vibration and temperature changes during shipping can cause some components to become loose.

Additionally, throughout the life span of this product, other environmental and application conditions may have

affected the mechanical and electrical continuity of several internal components. Therefore, for your safety and

overall product performance, please take the time to familiarize yourself with the MAINTENANCE, OPERATION,

AND INSTALLATION INSTRUCTIONS technical manual that was shipped with your panel.

Since it is not uncommon for electrical wiring and mechanical connections to become slightly loosened during

shipment, we ask that you pay particular attention to section 4-5.3 Wiring and Connections:

4-5.3 WIRING AND CONNECTIONS. Check wiring and connections as follows:

a. Inspect wiring for wear, fraying, chipping, nicks, and evidence of over-

heating. Repair minor defects with a good grade of electrical tape, or

replace if needed.

b. Inspect for loose electrical and mechanical connections. Tighten or

replace defective crimp-style lugs. Re-solder loose solder connections.

Tighten or replace all loose or missing hardware.

Pre-Service Storage

If this equipment cannot be placed into service upon receipt, prevent damage caused by impact, harsh environmental

conditions, condensation or liquid ingress. Preferably store in a clean, dry, air conditioned, or ventilated building.

During storage, assemblies should be placed on a ﬁrm, level surface to prevent distortion.

Outdoor storage of indoor equipment is not recommended. The covering provided during shipment of indoor as-

semblies is NOT adequate for outdoor storage.

Cover the equipment to keep it free from dust, dirt, and corrosive elements. The covering must protect the assembly,

but permit adequate ventilation. Blocking placed between the roof of the equipment and the cover will help keep

covering material from restricting the air ﬂow.

If the storage area is subject to humidity and signiﬁcant temperature changes, energize the anti-condensation heat-

ers provided in the equipment, or add heat from a separate source to prevent condensation inside the equipment.

The internal temperature must be at least 5˚C (9˚F) above the ambient.

If storage temperatures fall below 0°C (32°F), energize the internal equipment heaters provided, or add sufﬁcient

heat from a separate source to keep the internal temperature of the panel to at least 0°C (32°F).

In areas with high humidity, inspect the equipment regularly, and add additional heat if necessary to keep the

equipment dry.

Remove all loose packing, documents, and ﬂammable materials before energizing heating elements.

Heat from a separate source must be removed before the equipment is put into service.

WARNING: Care must be taken that integral control power transformers are not accidentally

back-fed from the heater circuits. Disconnect primary and secondary fuses.

Summer Standby Operation

If equipment is switched off during warm periods, and they are subject to humidity and signiﬁcant temperature

changes, energize the anti-condensation heaters provided in the equipment, or add heat from a separate source to

prevent condensation inside the equipment. The internal temperature must be at least 5˚C (9˚F) above the ambient.

General Panel Notes

1. This panel is designed to UL508A to facilitate NEC and CEC compliance, However it is the responsibility of

installer(s) and end user(s) to make sure that the installation wiring and all equipment, including this panel,

fulﬁll appropriate national and local electrical code requirements.

2. Incoming and outgoing branch circuit conductors may not be protected by fuses or breakers in this panel.

Consult appropriate national and local electrical codes and device speciﬁcations for selective coordination.

3. Protection relays must be set on site according to the requirements of the site engineer’s protection study.

Low-level ground fault protection, if required, should be provided.

4. Consult all applicable instruction manuals.

5. Customer interlocks are provided for use of external shutdown device(s). Interlocks require contacts that open

to trip or shutdown.

6. Contacts are shown in the de-energized state. Controller contacts shown on electrical schematics are internal

to the controller. Most of these contacts are programmable to suit the mode of operation. Consult the appro-

priate user manual(s).

7. Dashed lines indicate user ﬁeld wiring connections.

8. The panel installer must ground the panel according to appropriate national and local electrical code require-

ments.

9. Conduit openings in enclosure are to be user installed, sized and located as required. Hubs or ﬁttings must be

of the same environmental rating as the enclosure to maintain integrity.

10. Unless ﬁtted with an HMI sun sheild, do not place this equipment in direct sunlight.

11. Unless panel is properlly equipped with an enclosure heater for ambient temps below 0°C (32°F), the ambient

temperature outside this panel must be between 0°C (32°F) and 40°C (104°F).

12. If the panel cannot be placed into service upon receipt, an anticondensation heater must be used to prevent

condensation from forming inside the panel. This heater can be user supplied or factory supplied but must be

used to prevent damage to the panel.

13. Dimensions are for reference only, and are nominal unless otherwise speciﬁed.

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