Pentair 920 Series Assembly instructions

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INDUSTRIAL HEAT TRACING SOLUTIONS
920 Series Heat Trace Controller
InstallatIon, operatIng and MaIntenance InstructIons
A/B
ALARM
LOCK
MONITOR CONFIG STATUS
ALARM
OUTPUT
SHIFT
ENTER
BACK
Raychem
920 SERIES
PROGRAMMABLE DUAL POINT
HEAT TRACING CONTROLLER
Tx
Rx
A
B
A/B
ALARM MONITOR CONFIG STATUS
ALARM
OUTPUT
SHIFT
BACK ENTER
Raychem
920 SERIES
LOCK
Firmware versions # up to V3.2X

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CONTENTS
Introduction .....................................................................................................................................................4
Certification..........................................................................................................................................4
Limited Warranty..................................................................................................................................4
Warranty Exclusion/Disclaimer ...........................................................................................................4
Exclusive Remedies .............................................................................................................................4
Conducted and Radiated Emissions—FCC/DOC Statement of Compliance .......................................4
What’s New ......................................................................................................................................................5
New Controller Features...................................................................................................................... 5
New Operator Console Features.......................................................................................................... 5
Section I – Overview.........................................................................................................................................6
1.1 Controllers Covered by this Manual..............................................................................................6
1.2 Product Overview...........................................................................................................................6
1.3 Modular Components....................................................................................................................8
1.4 Controller Assemblies...................................................................................................................9
1.5 Ordering and Configuration Guide ................................................................................................9
Section 2 – Installation and Wiring................................................................................................................11
2.1 Introduction ................................................................................................................................. 11
2.2 Initial Inspection .......................................................................................................................... 11
2.3 Operator Safety Considerations .................................................................................................. 11
2.4 Operating Environment ............................................................................................................... 11
2.5 Installation Location.................................................................................................................... 11
2.6 Mounting Procedures .................................................................................................................. 11
2.7 Wiring........................................................................................................................................... 13
2.8 Initial Power-up........................................................................................................................... 16
2.9 Setup for the 920 ......................................................................................................................... 17
Section 3 – Programming and Configuration.................................................................................................18
3.1 Introduction ................................................................................................................................. 18
3.2 Front Panel Features................................................................................................................... 18
3.3 920 Operator Console Display..................................................................................................... 19
3.4 920 Functions .............................................................................................................................. 19
3.5 Control Point Setup ..................................................................................................................... 19
3.6 Common Controller Setup .......................................................................................................... 28
3.7 Temperature Alarms ................................................................................................................... 30
3.8 Other Alarms ............................................................................................................................... 33
3.9 Communications Setup ............................................................................................................... 40
3.10 Operator Console Functions...................................................................................................... 43
3.11 Copy Configuration Functions (V3.11 and up) ........................................................................... 44
Section 4 – Monitored Parameters ................................................................................................................46
4.1 Introduction ................................................................................................................................. 46
4.2 Analog Readings.......................................................................................................................... 46
4.3 Maintenance Data........................................................................................................................ 47
Section 5 – Control Modes .............................................................................................................................49
5.1 Introduction ................................................................................................................................. 49
5.2 Switch Control Modes.................................................................................................................. 49
5.3 Load Shedding Control Mode ...................................................................................................... 51
5.4 TEMPBUS™ Control Mode .......................................................................................................... 52

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Section 6 – Troubleshooting ..........................................................................................................................53
6.1 Operator Checks ......................................................................................................................... 53
6.2 Common Problem Areas ............................................................................................................. 53
6.3 Common Alarms—What to look for ............................................................................................ 56
6.3 Common Alarms—What to look for(Continued) ......................................................................... 57
6.3 Common Alarms—What to look for(Continued) ......................................................................... 58
Section 7 – Maintenance................................................................................................................................59
7.1 Operator Maintenance................................................................................................................. 59
7.2 Replaceable Parts ....................................................................................................................... 59
Appendix A Specifications..............................................................................................................................60
Appendix B Typical Enclosure Dimensions...................................................................................................62
B.1 Single-Point Assemblies #10160-003 and #10160-009............................................................. 62
B.2 Dual-Point Assemblies #10160-120 and #10160-121 ................................................................ 63
B.3 Four-Point Assembly #10160-125............................................................................................... 64
B.4 Eight-Point Assembly #10160-035 .............................................................................................. 65
B.5 Twenty-Point Assembly #10160-045 ........................................................................................... 66
Appendix C Wiring Diagrams.........................................................................................................................67
C.1 TS Wiring..................................................................................................................................... 67
C.1.2 100Ω NICKEL IRON RTD WIRING.............................................................................................. 68
C.2 Power Wiring................................................................................................................................ 69
C.3 Communication Wiring C.3 Communication Wiring.................................................................... 70
C.4 Alarm Output Wiring .................................................................................................................... 70
C.5 External Input/Output Port Wiring............................................................................................... 72
Appendix D HTC Load Shedding Sequence ....................................................................................................73
Appendix E 100 Ω Platinum RTD Table ..........................................................................................................74
Appendix F 100 Ω Nickel-Iron RTD Table.......................................................................................................75
Appendix G Factory Default/Configuration Sheets ........................................................................................76
G.1 Configuration Sheet V3.00 ........................................................................................................... 76
G.2 920 Series HTC Configuration Sheet V3.1X and V3.2X................................................................. 79

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INTRODUCTION
Installation and Maintenance Instructions for Firmware Versions up to and Including V3.2X
This manual provides information pertaining to the installation, operation, testing, adjustment,
and maintenance of the Raychem Model 920 Series Heat Trace Control and Monitoring products.
Additional copies of the operating manual may be ordered separately through your Pentair
Thermal Managament representative or online at www.thermal.pentair.com using the document
number H56874.
Notice: The information contained in this document is subject to change without notice.
CERTIFICATION
Pentair Thermal Managament certifies that this product met its published specifications at the
time of shipment from the Factory.
LIMITED WARRANTY
This Pentair Thermal Managament product is warranted against defects in material and
workmanship for a period of 18 months from the date of installation or 24 months from the date of
purchase, whichever occurs first. During the warranty period, Pentair Thermal Managament will,
at its option, either repair or replace products that prove to be defective.
For warranty service or repair, this product must be returned to a service facility designated by
Pentair Thermal Managament. The Buyer shall prepay shipping charges to Pentair Thermal
Managament and Pentair Thermal Managament shall pay shipping charges to return the product
to the Buyer. However, the Buyer shall pay all shipping charges, duties, and taxes for products
returned to Pentair Thermal Managament from another country.
Pentair Thermal Managament warrants that the software and firmware designated by Pentair
Thermal Managament for use with the Raychem 920 Controller will execute its programming
instructions properly. Pentair Thermal Managament does not warrant that the operation of the
hardware, or software, or firmware will be uninterrupted or error-free
WARRANTY EXCLUSION/DISCLAIMER
The foregoing warranty shall not apply to defects resulting from improper or inadequate
maintenance by the Buyer, Buyer-supplied software or interfacing, unauthorized modification or
misuse, operation outside of the specifications for the product, or improper installation.
No other warranty is expressed or implied. Pentair Thermal Managament disclaims the implied
warranties of merchantability and fitness for a particular purpose.
EXCLUSIVE REMEDIES
The remedies provided herein are the buyer’s sole and exclusive remedies. Pentair Industrial Heat
Tracing Solutions shall not be liable for any direct, indirect, special, incidental, or consequential
damages, whether based on contract, tort, or any other legal theory.
CONDUCTED AND RADIATED EMISSIONSFCC/DOC STATEMENT OF COMPLIANCE
This equipment has been tested and found to comply with the limits for a Class A digital device,
pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection
against harmful interference when the equipment is operated in a commercial envi-ronment.
This equipment generates, uses, and can radiate radio frequency energy and, if not installed
and used in accordance with the instruction manual, may cause harmful interference to radio
communications. Operation of this equipment in a residential area is likely to cause harmful
interference, in which case the user will be required to correct the interference at his own
expense.
This equipment does not exceed Class A limits for radio emissions as set out in Schedule V to VIII
of the Radio Interference Regulations of Communication Canada.
Cet apparel respecte les limites de bruits radioelectriques applicables aux appareils numeriques
de Classe A prescrites dans la norme sur le materiel brouilleur: “Appareils Numeriques,” NMB-
003 edictee par le Ministre des Communications.

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WHAT’S NEW
This section provides a summary of the new features that have been added since the last version
of this manual was printed. It is assumed that the reader is already familiar with the earlier
versions of the 920 Controller.
NEW CONTROLLER FEATURES
• Alarmfilteringisnowavailablefor:
– LOW and HIGH TS ALARMS (see sections 3.7.7 on page 33 and 3.7.8 on page 34)
– LOW and HIGH CURRENT ALARMS (see sections 3.8.2 on page 35 and 3.8.4 on page 36)
– HIGH GFI ALARMS (see section 3.8.6 on page 36)
– LOW and HIGH VOLTAGE ALARMS (see sections 3.8.9 on page 37 and 3.8.11 on page 38)
– LOW and HIGH RESISTANCE ALARMS (see sections 3.8.13 on page 38 and 3.8.15 on page 39).
Alarm filtering will prevent an alarm from being indicated until the alarm condition has existed for
the duration of the alarm filter time.
• TwonewSWITCHCONTROLMODEShavebeenaddedforusewithAmbientTemperaturecontrol:
– Proportional Ambient SSR
– Proportional Ambient Contactor (see sections 3.5.3 on page 21 and 5.2 on page 50).
• ASCIIandRTUModBus™communicationsprotocolsupport(seesection3.9.1onpage42).
• Supportforanisolated,2-wireRS-485communicationsinterface(seesection1.4.5).
• A3-phasepowercalculationfeaturehasbeenincludedforusewithbalanced,Y-connected
heating loads (see section 3.5.10 on page 23).
• ATemperatureSensor(TS)FailModefeatureisnowavailabletoallowtheoutputtobeforced
ON or OFF when a control temperature failure occurs (see section 3.5.11 on page 23).
• ATEMPBUS™featuretoallowone“master”920controllertoshareitstemperaturesensor
information with up to 25 “slave” controllers (up to 50 control points). This includes the addition
of three TS CONTROL MODES (see sections 3.5.12 on page 24 and 5.4 on page 53).
• Supportfor100ohmnickel-ironRTDsalongwiththestandard100ohmplatinumtypes(see
sections 3.5.13 on page 24 and 3.5.16 on page 25).
• Manualvoltagesourceselection(seesection3.5.19onpage26).
• SupportforFORCEONandFORCEOFFmodesusingtheEXTERNALinput(seesections3.5.27
on page 28 and 3.6.3 on page 29).
• Featurestoreloadfactorydefaultparametersaswellascopyconfigurationparametersfrom
one point to another are now included (see section 3.11 on page 46).
• Newmaintenancealarmingtotrackcontactorwear(seesection3.8.23onpage42).
• MonitorPEAKLOADCURRENT,PEAKGFI,andtheEXTERNALINPUTSTATUSthrough
communications (see sections 4.3.6 on page 50, 4.3.7 on page 50, and 4.3.8 on page 50).
NEW OPERATOR CONSOLE FEATURES
• Theabilitytoadjustthedisplayscrollrateisnowavailable(seesection3.6.10onpage31).
• Maintenancedataresettingisnowsupported(seesection4.3onpage49).
• DisplayandresettheCONTACTORCYCLECOUNTER(seesection4.3.3onpage49).
• LimittherangeoftheCONTROLSETPOINTsettingfor920OperatorConsoleusers
(see sections 3.5.29 on page 29 and 3.5.30 on page 29).
• AnUNLOCKDATABASEfeaturewasaddedtothe920OperatorConsole’s“ConfigurationMode
Main Menu” (see section 3.10.3 on page 46).
• Thedisplaytestnolongeroccursatstartup;instead,theusermayactivateitfromamenu
option (see section 3.10.5 on page 46).
IMPORTANT WARNINGS AND NOTES
The following icons are used extensively throughout this manual to alert you to important
warnings that affect safety and to important notes that affect the proper operation of the
unit.
Be sure to read and follow them carefully.

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SECTION I  OVERVIEW
1.1 CONTROLLERS COVERED BY THIS MANUAL
This document covers the 920 Series of heat trace controllers and available options. The
information coincides with the specific releases of firmware for the 920 product which are listed
on the cover. As Pentair Thermal Managament releases new firmware to modify or enhance
the product significantly, new documentation will accompany these releases. To ensure that
you are using the correct documentation for your particular version of controller, please check
the firmware version number of the 920 against the version number listed on the front of this
manual. This can be displayed using the optional 920 Operator Console or a communicating
device. 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
operational or functional changes.
1.2 PRODUCT OVERVIEW
1.2.1 DESCRIPTION
The 920 Series Heat-Tracing Controller controls, monitors, and communicates alarms and data
for one or two heating circuits. As a dual-point device, it offers a complete range of control and
monitoring features, as well as superior reliability compared to multipoint systems. Its modular,
scalable architecture yields cost-effective multipoint assemblies without the expense of additional
control points that are not required. Available for use with external solid-state relays (SSRs) or
contactors in either one-, two-, or three-pole configurations and the ability to switch loads up to
600 Vac makes the 920 the most versatile product on the market.
1.2.2 FEATURES
A detailed description of available features can be found in Section III of this manual. Highlights of
specific features are included in the following text.
Front Display
The control module includes LED status indicators to show output and alarm conditions. Using
the optional 920 Operator Console, the setpoint temperature, actual control temperature, and load
current are immediately accessible to plant operators and maintenance staff. The display units are
field selectable for °F or °C.
–40°F to 140°F (–40°C to 60°C) Operation
Extended temperature operation permits installation in all but the harshest environments. SSR
output modules are limited to operating ambient temperatures of 104°F (40°C) without derating.
Single or Dual Temperature Sensor Inputs
The ability to use one or two temperature sensor (TS) inputs for each control point allows the
selection of one of eleven control modes and programming of all temperature parameters.
High and Low Temperature Alarms
High and low temperature alarms are offered for both inputs of each control point.
High and Low Current Alarms
Low current alarm is more than just a continuity level alarm. The 920 offers full adjustment over
the entire current measurement range for both high and low current alarm limits.
Solid State or Contactor Output
The 920 is available with externally-mounted solid-state relay (SSR) output switches or contactors.
With the SSR option, the user may select a time-proportional control algorithm, a simple
deadband mode, or one of two ambient control algorithms. The contactor versions always use
either the deadband mode or the proportional ambient contactor mode. Switching device failure
alarms are supported for both types of output devices.

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Ground-Fault Alarm and Trip
Ground-fault (GF) current levels are monitored and displayed in milliamps. The availability of the
actual ground-fault level gives the user the choice of both alarm and trip levels suitable for the
particular installation. Using multiple SSRs or a multipole contactor allows all powered legs of
non-neutral circuits to be switched off under GF conditions.
Overcurrent Protection
A unique overcurrent protection algorithm greatly reduces the possibility of damage to the circuit
or the controller in the event of a temporary overload while allowing for initially high in-rush
currents (SSR options only).
Soft Starting
Given the circuit breaker size, the 920 will limit the energy let-through to help prevent nuisance
breaker trips due to cable in-rush. This feature makes the controller particularly attractive for use
with self-regulating cables (SSR options only).
Minimum/Maximum Temperature Tracking
The controller maintains the minimum and maximum temperature values seen by the controller
since the last reset of these values. This is helpful in determining causes of temperature alarms.
Latching/Non-Latching Temperature Alarms
User-selectable, non-latching temperature alarms allow the controller to automatically clear the
alarm when the condition no longer exists.
High and Low Voltage Alarms
Operating at voltages less than design can cause serious loss of heater output. The alarming of
preset voltage deviations ensures availability of sufficient wattage output.
Power Limiting
The 920 will control the maximum output wattage if the full load power exceeds the specified
maximum power setpoint. This feature eliminates the need for low voltage transformers in many
applications and can assist in standardization of heating cable types (SSR options only).
Autocycling
The controller will energize the circuit for 10 seconds at a programmable interval. Circuit alarms
will be generated at the time of autocycle instead of when the heat is required. This feature
eliminates the need for a preventive maintenance program as these tests are performed at regular
intervals by the controller.
Temperature Sensor Failure Alarm
Both open and shorted sensors are detected and alarmed by the controller.
Random Start
A startup delay between 0 and 9 seconds ensures that all units do not come on line at the same
time.
Full Digital Communications
An optional internal communications interface allows the communication of alarms and analog
data to a monitoring system. Industry-standard RS-232 or RS-485 serial communications are
available for applications requiring direct interfacing to other devices. The modem version
maintains compatibility with legacy products including the GCC-9000/780 Series (Group
Communications Controller). With the availability of the heat trace data at the user’s fingertips,
historical trending of temperatures, power consumption, or other parameters are available for
analysis and system optimization.

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CSA C/US and c-ETL-us Approved
The 920 series of controllers is approved for Class I, Division 2, Groups A,B,C,D and Zone 2
hazardous locations, making it ideal for direct installation in the field. This can save the significant
expense of wiring back to a central-ly-located electrical distribution center.
1.3 MODULAR COMPONENTS
The 920 series controller is made up of a number of building blocks, allowing the ultimate in
design flexibility. Each component’s primary function is described below.
1.3.1 CONTROL MODULE
The 920 control module forms the heart of a single- or dual-point heat trace control solution. Each
plug-in module provides all of the intel-ligence required to control and monitor two independent
heat trace circuits. It includes indicators for alarm and output status and a connector for use with
a 920 Operator Console. An internal connector is provided to plug into an optional communications
interface.
The control module packaging provides a rugged, vibration-proof design. Once it is plugged into a
terminal board, the module is fastened using the two captive screws included as part of the rear
cover. It is important that these two screws be securely fastened whenever the module is powered.
1.3.2 TERMINAL BOARD
The terminal board eases maintenance and troubleshooting by providing a termination point for all
of the low-voltage signals. The 920 control module may be installed or removed without disturbing
the field wiring. Temperature sensor, communications, and alarm control wiring are connected to
the lever-operated spring terminals, providing gas-tight, vibration-resistant connections.
1.3.3 OPERATOR CONSOLE
A large, easy-to-read alphanumeric display and menu-driven interface ease controller
configuration and eliminate the need for an external programmer. The console may be left
installed permanently or may be installed temporarily for display/setup during maintenance and
trou-bleshooting. Access is available for all monitored parameters, programmed values, and
alarm information. Enhanced security is provided by password protection.
The unique design of the operator console allows it to be installed or removed under power, even
in hazardous areas.
1.3.4 SWITCH INTERFACE
Universal single-phase current monitoring, single- or 3-phase ground-fault detection, and voltage
monitoring are provided by the Switch Interface (SIS/SIC) module. One device is required for each
control point, and two versions are available: SIS for use with SSRs, and SIC for use with the
contactor. Both units also incorporate a universal power supply, allowing operation directly from
100 Vac to 277 Vac. Use with higher trace voltages is also possible, using a separate power source
or a small step-down transformer.
Redundant operation is supported, allowing a control module to automatically power itself from
either of two switch interface modules or both. This permits one heat-trace circuit to be turned off
for maintenance without affecting the operation of the other circuit.
1.3.5 COMMUNICATIONS INTERFACE
In applications where the user wishes remote configuration capability or wants to communicate
trace information and/or alarms to another device such as the GCC (Group Communications
Controller), an optional communications interface may be installed in the control module.
A modem version that maintains compatibility with legacy products is available, or other industry-
standard interfaces such as RS-232 and RS-485 may be specified.

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1.3.6 SOLID-STATE RELAY OUTPUT MODULE
In applications where the benefits of solid-state control are desired, a modular solid-state relay
(SSR) is available. This component is easily installed on the outside of an enclosure using a single
3/4 NPT knockout and locknut providing a weatherproof seal. This allows the heat generated by
the SSR to be dissipated directly to the ambient air, without increasing the internal temperature of
the enclosure. When appli-cations require two-pole or 3-phase switching, multiple SSR modules
may be ganged together, allowing the same component to be used.
1.4 CONTROLLER ASSEMBLIES
Due to its modular packaging, the 920 easily supports single-, dual-, or multi-point configurations.
Factory standard assemblies are available in a variety of enclosure types, and panels made up
of multiple points are also available. Refer to the Ordering Guide in section 1.5 on page 10 for
a sample listing of available configurations. If your application requires a customized solution,
please contact your Pentair Thermal Managament representative for help in specifying an
assembly suited to your particular requirements.
1.5 ORDERING AND CONFIGURATION GUIDE
920 series control assemblies are ordered as three separate items:
Tx
Rx
A
B
A/B
ALARM
LOCK
MONITOR CONFIG STATUS
ALARM
OUTPUT
SHIFT
BACK ENTER
Raychem
920 SERIES
PROGRAMMABLE DUAL POINT
HEAT TRACING CONTROLLER
Enclosure assembly Control module(s)
(One for every two circuits)
Optional operator
console(s)
PROGRAMMABLEDUAL POINT
HEATTRACING CONTROLLER
A/B
ALARM
LOCK
MONITOR CONFIG STATUS
ALARM
OUTPUT
SHIFT
BACK ENTER
Raychem
920 SERIES
Fig. 1.6 920 series control assemblies
Pentair Thermal Managament maintains a shelf stock of enclosure assemblies, control modules,
and consoles. All other enclosure assemblies are built to order. Not all options may be listed.
Contact your local representative for any special applications you may have.

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1.5.1 ENCLOSURE ASSEMBLY
Enclosure Assemblies
Description Catalog number Part number Weight/lbs
Raychem 920 controller–2 Pt in a 14" x 12" x 8" FRP
enclosure with window and quick-release latches,
control module, and operator console. 1P 30 A 277 V
SSR/pt. Controls two circuits, each with a 1-pole
solid-state relay. (Approved for Class 1, Div. 2 areas)
920*E4FWL*SIS302*SS3102*HTC*CON 10160-010 27
Raychem 920 controller–2 Pt in a 14" x 12" x 8" FRP
enclosure with window and quick-release latches,
control module, and operator console. Includes an
isolated 2-wire RS-485 communication option. 1P
30 A 277 V SSR/pt. Controls two circuits, each with
a 1-pole solid-state relay. (Approved for Class 1, Div.
2 areas)
920*E4FWL*SIS302*SS3102*HTC485*CON 10160-011 27
Raychem 920 controller–2 Pt in a 14" x 12" x 8" FRP
enclosure with window and quick-release latches,
control module, and operator console. 2P 30 A 277 V
SSR/pt. Controls two circuits, each with a 2-pole
solid-state relay. (Approved for Class 1, Div. 2 areas)
920*E4FWL*SIS302*SS3202*HTC*CON
10160-012 32
Raychem 920 controller–2 Pt in a 14" x 12" x 8" FRP
enclosure with window and quick-release latches,
control module, and operator console. Includes an
isolated 2-wire RS-485 communication option. 2P
30 A 277 V SSR/pt. Controls two circuits, each with
a 2-pole solid-state relay. (Approved for Class 1, Div.
2, areas)
920*E4FWL*SIS302*SS3202*HTC485*CON 10160-013 32
Raychem–Raychem Supervisory Software Raychem Supervisor 10391-002 1
IMPORTANT: The NEC (and CEC) rules specify that all ungrounded—i.e., hot—legs of a circuit, must be switched in the event of a
ground fault. This means for 207 V single-phase applications, you must specify a 2-pole (2P) version if you are not using external GFI
breakers.
Control Modules
Raychem 920 controller–Control module only
(No communications options installed)
920HTC 10260-001 1
Raychem 920 controller–Control module
with an isolated
2-wire RS-485 communication option installed
920HTC*485 10260-004 1
Raychem 920 controller–Control module
with modem
communications option installed
920HTC*MDM 10260-002 1
Operator Console
Raychem 920 controller–Operator console 920CON 10260-005 1
Contact your local representative for other available configurations that are not
listed above.