nvent Raychem NGC-30 User manual

Installation Manual
NGC-30
Firmware version # - V1.18

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CONTENTS
Section 1 – Overview ................................................................................................................................ 3
1.1 Introduction.................................................................................................................................. 3
Section 2 – Installation and Wiring ........................................................................................................... 4
2.1 Introduction.................................................................................................................................. 4
2.2 Initial Inspection .......................................................................................................................... 4
2.3 Operating Environment................................................................................................................ 4
2.4 Installation Location.................................................................................................................... 5
2.5 Mounting Procedures.................................................................................................................. 5
2.6 Wiring Procedures ....................................................................................................................... 5
2.6.1 INCOMING POWER WITH DISTRIBUTION SYSTEM.......................................................... 5
2.6.2 OUTGOING POWER WITH DISTRIBUTION SYSTEM.......................................................... 6
2.6.3 INCOMING/OUTGOING POWER WITHOUT DISTRIBUTION PANEL BOARD.................... 6
2.6.4 INCOMING RTD WIRING ..................................................................................................... 7
2.6.5 CONNECTING THE RS-485 DEVICE NETWORK................................................................. 7
2.7 Connections for Remote Annunciation.................................................................................... 12
2.8 RS-232, RS-485, or Ethernet Remote Port Connections to a Host Computer........................ 14
2.8.1 RS-232 SERIAL CONNECTIONS ....................................................................................... 14
2.8.2 RS-485 SERIAL CONNECTIONS ....................................................................................... 14
2.8.3 ETHERNET CONNECTIONS.............................................................................................. 14
2.9 Testing the nVent RAYCHEM NGC-30 System......................................................................... 15
Section 3 – nVent RAYCHEM NGC-30 Components and Operation ........................................................ 16
3.1 User Interface Terminal (NGC-UIT)........................................................................................... 16
3.1.1 MULTIPLE NGC-UIT MODELS ........................................................................................... 16
3.1.2 NGC-UIT LOCAL AND REMOTE NETWORK CONNECTIONS........................................... 16
3.1.3 NGC-UIT LED STATUS ....................................................................................................... 18
3.1.4 CONFIGURATION SWITCHES ........................................................................................... 18
3.1.5 NGC-UIT RESET SWITCH .................................................................................................. 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).............................................................................................................20
3.4 Voltage Monitoring Module (NGC-30-CVM) – Optional.......................................................... 20
3.5 Remote Monitoring Module (RMM2) – Optional..................................................................... 21
3.6 Power Line Carrier Interface Module (PLI) – Optional............................................................ 22
Section 4 – Appendices .......................................................................................................................... 23
Appendix A – Replacement Component Ordering Guide.............................................................. 23
Appendix B – Panel Specications................................................................................................. 24
Appendix C – NGC-30-CRM/-CRMS Specications....................................................................... 27
Appendix D – NGC-UIT2 Specications ......................................................................................... 28
Appendix E – Device Address......................................................................................................... 30

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SECTION 1 – OVERVIEW
1.1 INTRODUCTION
The nVent 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 nVent RAYCHEM 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 nVent RAYCHEM 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 nVent releases new firmware to significantly modify
or 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
nVent.com
Table 1.1 Component versions
Component Version number
NGC-CRM/CRMS V1.0X
NGC-UIT V1.1X
RMM2 V1.0X

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SECTION 2 – INSTALLATION AND WIRING
2.1 INTRODUCTION
WARNING:
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 components of the RAYCHEM NGC-30.
2.2 INITIAL INSPECTION
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 nVent representative. If the shipping container is damaged, or the cushioning
material shows signs of stress, notify the carrier as well as your nVent representative. Keep the
shipping materials for the carrier’s inspection.
2.3 OPERATING ENVIRONMENT
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
• The NGC-UIT-ORD-12 must be installed in an • (Indoors)
nonhazardous, indoor location.
• The NGC-UIT-ORD-12 connects to NGC-30
panels using RS-485 communication wiring.
NGC-UIT-OUT Hazardous Locations* NEMA 4 or 4X
• Designed for mounting on the RAYCHEM • (Outdoors, solid-state
NGC-30 external panel door. re-lays)
• Class I, Division 2, Groups A, B, C, D NEMA 4X-P
• Class I, Zone 2, Group IIC • (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.
WARNING:
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.

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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.
CAUTION:
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 I, Section 18 of
the Canadian Electrical Code.
2.5 MOUNTING 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 nVent
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.
Power wiring diagram
Panelboard
ground bus
Panelboard
neutral bus
ØA ØB
Incomming service
Three phase, 4 wire, 60 Hz
Main circuit
breaker
3-pole
ØC
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.

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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 panel’s Load Power Terminal Blocks to the heat-trace power junction box.
Heat tr
ace cable
TB- (Y)
CRM
TB*
EMR or
SSR
contacts
Branch
circuit
breaker
Load Power
Terminal
Block
Heat trace
junction
box
17
16
15
14
13
Cable-CT**
* Reference panel drawing for terminal block number
** Represents HTC circuit number 1-40
LCGF
CTM
connector
X
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 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.
L1
LP *–L1 *–T1
C*
CB*
CB*
CTM–*
CT GF CT
TB*
T1
TB*
Heat trace cable
Single pole C.B.
Tw
o pole C.B.
N
N*–N *–N N
L1
LP *–L1 *–T1
C*
CTM–*
CT GF CT
TB*
T1
TB*
Heat trace cable
Line Power
Terminal Blocks
Load Power
Terminal Blocks
Line Power
Terminal Blocks
Load Power
Terminal Blocks
L2
LP *–L2 *–T2 T2
* Reference panel drawing for terminal block number
Fig. 2.3 Single pole and two pole circuit breaker wiring diagrams

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2.6.4 INCOMING RTD WIRING
Nonhazardous and Hazardous Location Installations Wired to Terminal Block in Panel
The nVent RAYCHEM RTD wiring from the NGC-30-CRM/-CRMS have been pre-wired to
RTDterminals. The field RTD wiring (3-wire with shield) will be terminated by the installer at the
RTD terminal blocks. Refer to the 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.
OPENOPEN
REDRED
REDRED
WHWH
SHLDSHLD
REDRED
REDRED
WHWH
RTD-RTD-
CRMCRM
Card Rack ModuleCard Rack Module
TB*TB*
SHLDSHLD
REDRED
REDRED REDRED
REDREDWHWH
(+)(+) (–)(–)
(+)(+)
(–)(–)
WHWH
44
33
22
11
CHASSIS GRDCHASSIS GRD
NGC-30-CRM/-CRMSNGC-30-CRM/-CRMS Panel Rear
Terminal Block
Panel Rear
Terminal Block
Field
Wiring
Field
Wiring
RTD-RTD-
* Reference panel drawing for terminal block number
Fig. 2.4 Typical RTD installation
2.6.5 CONNECTING THE RS-485 DEVICE NETWORK
The nVent RAYCHEM NGC-UIT display is typically linked to a network of RAYCHEM NGC-30-CRMs/-
CRMSs and optional RMM2s 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.

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TB12
MSBLSB
TB7TB6
TB13 TB 14 TB 15 TB 16 TB 17
TB1TB 2TB 3TB4TB 5
TB19
12 3
NGC-CRM/-CRMS
PLI
TB12
MSBLSB
TB7TB6
TB13 TB 14 TB 15 TB 16 TB 17
TB1TB 2TB 3TB4TB 5
TB19
12 3
0
Jumper
0
NGC-CRM/-CRMS
TB12
MSBLSB
TB7TB6
TB13 TB 14 TB 15 TB 16 TB 17
TB1TB 2TB 3TB4TB 5
TB19
12 3
NGC-CRM/-CRMS
TB12
MSBLSB
TB7TB6
TB13 TB 14 TB 15 TB 16 TB 17
TB1TB 2TB 3TB4TB 5
TB19
12 3
NGC-CRM/-CRMS
TB12
MSBLSB
TB7TB6
TB13 TB 14 TB 15 TB 16 TB 17
TB1TB 2TB 3TB4TB 5
TB19
12 3
NGC-CRM/-CRMS
RMM2
NGC-UIT
RMM2
PLI
nVent
NGC-UIT
NGC-UIT
NGC-
Device must be mounted in series.
(Terminated devices are shown in gray)
Branching of the network is not allowed.
Connect no more than two RS-485 cables to any device.
.
110
S2 S1
6
S
Norm
HN/H GABCNMixed
+
S
36
S+
0-9
.
220
6
0
.
110
S2 S1
6
S
Norm
HN/H GABCNMixed
+
S
36
S+
0-9
.
220
6
0
Fig. 2.5 RS-485 network configuration for the NGC-UIT system
In order for the nVent RAYCHEM 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.

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Optional RMM2 Installed in the Field
Refer to the nVent RAYCHEM RMM2 Installation Instructions (H56848) for field installation
instructions. You must connect a RS-485 connection from the RMM2 to an open nVent
RAYCHEM 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 RMM2 is the first or last device in the RS-485 network,
connect the J17 termination jumper to pins 1 and 2.
If the RMM2 is not the first or last device in the RS-485 network, connect the J17 termination
jumper to pins 2 and 3.
0
Jumper
RMM2
NGC-30-CRM/-CRMS #1NGC-UIT RS-485 NGC-30-CRM/-CRMS #8
NGC-30 Panel
RS-485 RS-485
RS-485
BK
WH
(–)
S
(+)
S
BK
TB*
WH
BK
TB*
3
WH
+
–
1
2
3
1
2
S
BK
TB*
WH
S
BK
TB*
3
WH
+
–
+
–
1
2
3
1
2
SS
BK
WH
S
+
–
BK
WH
S
6
4
5
TB*
1
3
2
4
6
5
J17
123
Default position (for all RMM2
units in network except first or last one)
J17
123
Termination mode
(first or last RMM2 in network)
Last RMM2 in network
J17
123
* Reference panel drawing for terminal block number
Fig. 2.6 RMM2 RS-485 field wiring and termination jumper setting

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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/-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-CRM/-CRMS #1NGC-UIT RS-485 NGC-30-CRM/-CRMS #8
NGC-30 Panel
RS-485 RS-485
BK
WH
(–)
S
(+)
S
BK
TB*
WH
BK
TB*
3
WH
+
–
1
2
3
1
2
S
BK
TB*
WH
S
BK
TB*
3
WH
+
–
1
2
3
1
2
SS
1
3
2
4
6
5
J2
123
Default position (for all PLI
units in network except first or last one)
J2
123
Termination mode
(first or last PLIin network)
* Reference panel drawing for terminal block number
.
110
S2 S1
6
S
Norm
HN/H GABCNMixed
+––
S
36
S+
5
.
220
9
5
Last PLI in network
J2
123
RS-485 connections
Fig. 2.7 PLI RS-485 panel wiring and termination jumper setting
NGC-UIT Installation
The nVent RAYCHEM NGC-UIT-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-30 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.