Pentair Digitrace NGC-20-C-E Manual

100 -
254 VAC
Baseefa08ATEX0184X
IECEx
BAS 08.0047X
II 2 GD
GB Ex e mb ib IIC T* See Sch edule
Db Ex tD A21 IP66T95°C
Lot/Los/Lot N°:
Serial number inside
Seriennummer innen
N° de série à l’in terieur
Operating voltage:
Betriebsspannung:
Tension nominale:
PN-1244-007036
1180
ModBus:
Connections / Anschlüsse / Raccordements
Switch currentde-rating table / Tabelletemparaturabhängiger Schaltstrom /
Tableaude dégrèvement courant de coupure
Texte Français dans le manuel technique
Deutsche Texte siehe Betriebsanleitung
TemperatureClass T5
Ambient temp. range Maximum switch current
–40°C – +50°C 25 A
TemperatureClass T4
Ambient temp. range Maximum switch current
–40°C – +54°C 20 A
–40°C – +56°C 16 A
–40°C – +56°C 25A
Leuven, Belgium
Ex i
Connections / Anschlüsse / Raccordements
Ex e
Safety Temperature Limiter according to:
Sicherheitstemperaturbegrenzer nach:
Limiteur de Sécurité selon:
Baseefa08SR0134 SIL2
IEC 61508-1:1998 &
IEC 61508-2:2000
Heat-Tracing Temperature Control Unit with safety limiter
Temperaturregler mit Sicherheitstemperaturbegrenzer
Contrôleur/Limiteur de Température pourTraçage Electrique
NGC-20-C(L)-EDIGITRACE
ML-DigiTraceNGC20CLE-IM-INSTALL130
THERMAL MANAGEMENT SOLUTIONS
InstallatIon, operatIng and MaIntenance InstructIons
InstallatIons-, BetrIeBs- und WartungsanleItung
guIde d’InstallatIon, d’utIlIsatIon et de MaIntenance
Instruções de Instalação, operação e Manutenção
pokyny k InstalacI, provozu a údržBe
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For English text, go to page 3
Für Deutsch, siehe Seite 21
Pour la version française, voir page 39
Para a versão em português, vá para a págian 57
Češtinu najdete na straně 75
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NGC-20 INSTALLATION MANUAL 3
TABLE OF CONTENTS
1. Introduction 4
1.1 Certification 4
1.2 Warranty 4
1.3 Limitation of warranty 4
1.4 Exclusive remedies 4
1.5 Statement of compliance 4
1.6 Declaration of conformity 5
1.7 Area of use 6
1.8 Safety instructions 6
1.9 Conformity with standards 6
1.10 Technical data 6
2. Installation 11
2.1 Tools required 11
2.2 Mechanical installation 11
2.3 Temperature sensors 11
2.3.1 Lead compensation of RTD connections. 11
2.3.2 Installation of temperature sensors 12
2.3.3 Remote temperatures via DigiTrace RMM 14
2.4 Electrical installation 14
2.5 Communication and networking 15
2.6 Configuration 15
3. Maintenance 15
4. Safety instructions for DigiTrace NGC-20-CL-E 15
4.1 Safety function of temperature limiter in DigiTrace NGC-20-CL-E 15
4.2 Area of use 15
4.3 Requirements to be met by the temperature limiter 16
4.3.1 Temperature limiter (schematic) 16
4.3.2 Reset by hand only 16
4.3.3 Reset by hand via tool or keyed lock 16
4.3.4 Temperature setting secured and locked to prevent manipulation 17
4.4 Changing limiter set point 17
4.4.1 Procedure to write new temperature set point to limiter 17
4.5 Functional test 18
4.5.1 Functional test description 18
4.5.2 Functional test procedure 18
4.5.3 Test in the event of a fault 18
4.6 Safety Integrity level 18
4.6.1 Safety integrity of the DigiTrace NGC-20 hardware 19
4.6.2 PFDavg safety function 19
4.6.3 SIL related to SFF and HFT 19
4.6.4 Safety related system characteristics 20
4.6.5 Response in operation and fault conditions 20
NGC-20-C(L)-E
InstallatIon, operatIng and MaIntenance InstructIons
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NGC-20 INSTALLATION MANUAL
4
1. INTRODUCTION Please read all instructional literature carefully and thoroughly before starting. Refer to
the inside front cover for the listing of Liabilities and Warranties.
NOTICE: The information contained in this document is subject to change without notice.
Please read these Operating Instructions before Commissioning the instrument. Keep the
operating instructions in a place which is accessible to all users at all times. Please assist
us to improve these operating instructions, where necessary. We are always grateful for
your suggestions.
Should any difficulties arise during start-up, you are asked not to carry out any
unauthorized manipulations on the instrument as this could affect your warranty rights!
Please contact the nearest Pentair Thermal Management subsidiary or the head office.
If any servicing is required, the instrument must be returned to the head office.
1.1 Certification
Pentair Thermal Management certifies that this product met its published specifications
at the time of shipment from the Factory.
1.2 Warranty
This Pentair Thermal Management product is warranted against defects in material
and workmanship for a period of 12 months from the date of installation or 30 months
maximum from the date of shipment, whichever occurs first. During the warranty period,
Pentair Thermal Management 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 Management. The Buyer shall prepay shipping charges
to Pentair Thermal Management and Pentair Thermal Management 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 Management from
another country.
Pentair Thermal Management warrants that the software and firmware designated
by Pentair Thermal Management for use with a product will execute its programming
instructions properly when installed on that product. Pentair Thermal Management
does not warrant that the operation of the hardware, or software, or firmware will be
uninterrupted or error-free.
1.3 Limitation of warranty
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 MANAGEMENT
DISCLAIMS THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE.
1.4 Exclusive remedies
THE REMEDIES PROVIDED HEREIN ARE THE BUYER’S SOLE AND EXCLUSIVE REMEDIES.
PENTAIR THERMAL MANAGEMENT SHALL NOT BE LIABLE FOR ANY DIRECT, INDIRECT,
SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, WHETHER BASED ON
CONTRACT, TORT, OR ANY OTHER LEGAL THEORY.
1.5 Statement of compliance
This equipment has been tested and found to comply with the low voltage directive
2006/95/EC and the electromagnetic compatibility directive 2004/108/EC. These limits
are defined to provide reasonable protection against harmful interference in a residential
installation (technical data mentions industrial application). This equipment generates
uses and can radiate radio frequency energy and, if not installed and used in accordance
with the instructions, may cause harmful interference to radio communications. However,
there is no guarantee that interference will not occur in a particular installation. If this
equipment does cause harmful interference to radio or television reception, which can be
determined by turning the equipment off and on, the user is encouraged to try to correct
the interference by one or more of the following measures:
• Reorientate or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the
receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
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NGC-20 INSTALLATION MANUAL 5
1.6 Declaration of conformity Our products satisfy
the requirements of the
relevant European Directives.
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NGC-20 INSTALLATION MANUAL6
1.7 Area of use
DigiTrace NGC-20-C(L)-E controllers are used for temperature control and temperature
limiting of electrical heaters in industrial and potentially explosive atmospheres. The
DigiTrace NGC-20-CL-E consists of a temperature controller and an additional safety
temperature limiter. DigiTrace NGC-20-C(L)-E units are approved for use in hazardous
area Zone 1 and Zone 2 (Gas) and Zone 21 and Zone 22 (Dust). Where needed the
temperature sensor of the unit can be placed in Zone 0 (Zone 20) However, the control
unit itself is not approved for being installed in Zone 0 (Zone 20).
1.8 Safety instructions
During operation, do not leave this Instruction Manual or other objects inside the
enclosure. Use the temperature controller and limiter only for its intended purpose and
operate it only in clean, undamaged condition. In the event of incorrect assembly, the
requirements of IP66 as specified by IEC 60529:2001 are no longer met. Do not make any
modifications to the temperature controller and limiter that are not expressly mentioned
in this Instruction Manual.
Whenever work is done on the temperature controller and limiter, be sure to
observe the national safety and accident prevention regulations and the safety
instructions given in this Instruction Manual.
1.9 Conformity with standards
DigiTrace NGC-20-C(L)-E units meet the requirements of the following Hazardous
area- and functional safety standards and are developed, manufactured and tested in
accordance with state-of-the-art engineering practice.
Table 1: Standards overview.
1.10 Technical data
Application type DigiTrace NGC-20-Cx-E units are approved for use in Hazardous area Zone 1 or Zone 2
(Gas) or Zone 21 or Zone 22 (Dust) and non hazardous areas
Hazardous area Approval Baseefa08ATEX0184X
II 2 GD Gb Ex e mb ib IIC T* Db Ex tD A21 IP66 T95°C
IECEx BAS 08.0047X
Gb Ex e mb ib IIC T*
Db Ex tD A21 IP66 T95°C
T*: The switching capacity depends on the hazardous area temperature classification
(T-Class) and the maximum expected use temperature. Ratings as shown in table below
Functional Safety Approval Baseefa08SR0134 SIL2
IEC 61508-1:1998 & IEC 61508-2:2000
IEC 60079-0, EN60079-0 General requirements
IEC 60079-7, EN60079-7 Increased safety Ex e
IEC 60079-18, EN60079-18 Encapsulation Ex m
IEC 60079-11 EN60079-11 Intrinsic safety Ex i
IEC 61241, EN 61241 Parts 1 to 3 Electrical apparatus for use in the
presence of combustible dust
IEC 61508-1:2000 and IEC 61508-2:2000 For NGC-20-CL-E only: Functional Safety
of Electrical /Electronic / Programmable
Electronic Safety-related Systems
Temperature Class T5 Temperature Class T4
Maximum Ambient
Temperature Maximum Switching Current Maximum Ambient Temperature Maximum Switching Current
+ 50 °C 25 A
Up to 56 °C 25 A+ 54 °C 20 A
+ 56 °C 16 A
All values as per hazardous area certification.
Current ratings are given for a supply voltage of 254V +/-10%, 50/60 Hz and
resistive loads only.
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NGC-20 INSTALLATION MANUAL 7
Special Conditions for Safe Use Cable entry devices shall be suitably certified and maintain the IP66 minimum of the
enclosure. Unused cable entries must be filled with suitable certified stopping plugs.
Not more than one single or multiple strand wiring lead shall be connected into either
side of the terminals.
Leads connected to the terminals shall be insulated for the appropriate voltage and this
insulation shall extend to within 1 mm of the metal of the terminal throat.
When used in dust atmospheres any dust layers occurring shall have a maximum depth
of no greater than 50 mm.
The max permitted current of the Non IS alarm contacts is 3A.
The earth pillar adjacent to the RTD connectors must be used only for RTD cable screens.
The external RTDs must be capable of withstanding a 500V test to earth.
Environmental
Temperature range controller From –80 to +700°C in steps of 1K
Temperature range limiter From –60 to +599°C in steps of 1K (NGC-20-CL-E only)
Ambient operating temperature From –40°C to +50°C in T5 and from –40°C to +56°C in T4
Storage temperature From –55°C to +80°C
Enclosure DigiTrace NGC-20-C(L)-E units can be installed directly on the pipe via an appropriate
support bracket as long as the maximum permitted ambient temperature is not
exceeded. Alternatively, units can be mounted on any stable structure via the
molded holes in the enclosure.
Protection IP66 to IEC-60529
Material Glass fiber reinforced polyester with internal earth plate on the bottom
Installation position Any position allowed, typical use with glands facing down.
Electrical data
Power supply & own power consumption 100 V to 254 V +/-10 % 50/60 Hz.
20 VA max.
Connection terminals All cage clamp style connection terminals:
L, N and PE terminals 9 pc (0.2 to 6 mm²)
Alarm output terminals 3 pc (0.2 to 2.5 mm²)
Pt100 (RTD) terminals 12 pc (0.2 to 1.5mm²)
RS-485 communication 7 pc (0.2 to 1.5mm²)
Internal Earth stud 1 pc (Max 6 mm²)
Contact lifetime 500 K operations at 25 A / 254 VAC (resistive load)
Alarm output relay Contact rated 254 VAC / 3A
Relay output is software programmable to open, close or to toggle in case of alarm.
Electromagnetic compatibility EN 61000-6-2:2005 (Gen. Immunity standard for industrial environments)
EN 61000-6-3:2007 (Gen. Emission standard for residential, commercial and light industrial)
EN 61000-3-2-2006 (Limits for harmonic current emissions)
EN 61000-3-3:1995+A1:2001+A2:2005 (limitation of voltage fluctuations and flicker)
Electrical safety EN 61010-1, Category III, Pollution degree 2.
Vibration & Shock Shock to EN 60068-2-27: 1/2 sine wave of 11 ms duration, 15 g
Vibration to EN 60068-2-6 / sine wave 10 to 150 Hz (p-p), 2 g
Temperature sensors
Type 100 Ωplatinum, 3-wire, α= 0.00385 Ω/°C. Can be extended with a three core shielded or
braided cable of maximum 20 Ωlead resistance per conductor.
Quantity Two RTD inputs for the controller plus one independent temperature input for the limiter.
In case it is required, more RTDs can be monitored with optional RMM2 units.
All temperature sensors are permanently monitored for “sensor open” and “sensor
break”
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NGC-20 INSTALLATION MANUAL
8
Communications
Physical network RS-485 and Class 1 Bluetooth
Protocol / topology ModBus RTU or ASCII. Multi drop / Daisy chain
Cable and maximum length Shielded twisted pair cable, 0.5 mm² (AWG 24) or larger.
Maximum cable length between should be no more than 1200 m.
Maximum quantity of controllers in Max. of 247 units per NGC-UIT or per communication port
one network
(ModBus) Network address Software programmable via DigiTrace NGC-CMA-NH or DigiTrace NGC-CMA-EX
Programming and setting
Method Through handheld programming device DigiTrace NGC-CMA and a wireless Bluetooth
connection or via RS485 interface and DigiTrace Supervisor software or DigiTrace User
Interface Terminal (DigiTrace NGC-UIT-ORD, DigiTrace NGC-UIT-OUT) and customized
DigiTrace software.
Units of measure °C or °F, software selectable.
Memory Nonvolatile. There is no loss of parameters after the event of power outage or long term
shut down. Data holding time ~10 years.
LED indicators Status LEDS are available for:
NGC-20-C-E Heater, Alarm, RS485 communication, Bluetooth communication
NGC-20-CL-E Heater, Alarm, Limiter (tripped), RS485 communication and Bluetooth.
Measuring ranges
Temperature range controller From –80°C to +700°C in steps of 1K
Temperature range limiter From –60°C to +599°C in steps of 1K (NGC-20-CL-E only)
Voltage From 50 VAC to 305 VAC
Load Current From 0.3 A to 30 A
Ground fault current From 10 mA to 250 mA
Heater Time Alarm From 1 to 1x 106hours
Relay Cycle Alarm From 0 to 2x 106operations
Ordering information
DigiTrace NGC-20 control units
Product name DigiTrace NGC-20-C-E (Standard temperature control unit)
Part number & (weight) 1244-007035 (3.3 kg.)
Product name DigiTrace NGC-20-CL-E (Temperature control unit with integrated temperature limiter)
Part number & (weight) 1244-007036 (3.4 kg.)
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NGC-20 INSTALLATION MANUAL 9
DigiTrace NGC-20 Accessories
Temperature Sensors
Product name MONI-PT100-260/2 (Flexible temp. sensor with measuring range from –50 to 260°C)
Part number & (weight) 1244-006615 (0.09 kg.)
Support Bracket for installation on pipe
Product name SB-125
Part number & (weight) 1244-06603 (0.5 kg.)
Bluetooth enabled handheld programming device with customized DigiTrace software
Product name DigiTrace NGC-CMA-EX (Hazardous area approved device for use in Zone 1 / Zone 21)
Part number & (weight) 1244-006605 (1.2 Kg.)
Product name DigiTrace NGC-CMA-NH (Industrial grade, not approved for use in hazardous area)
Part number & (weight) 1244-006606 (0.8 Kg.)
Table 2: Technical data
Figure 1: Dimensions NGC-20-C(L)-E
220 120
120
Baseefa08SR0134 SIL2
IEC 61508-1:1998 &
IEC 61508-2:2000
100 - 254 VAC
Baseefa08ATEX0184X IECEx BAS 08.0047X
II 2 GD
GB Ex e mb ib IIC T* See Schedule
Db Ex tD A21 IP66 T95°C
Lot/Los/Lot N°/N° do lote:
Serial number inside
Seriennummer innen
N° de série à l’interieur
Número de série no interior
Operating voltage:
Betriebsspannung:
Tension nominale:
Tensão de operação:
PN-1244-007036
1180
ModBus:
Connections / Anschlüsse / Raccordements / Conexões Connections / Anschlüsse / Raccordements / Conexões
Texte Français dans le manuel technique
Deutsche Texte siehe Betriebsanleitung
Texto em português (Brasil) no manual técnico
Leuven, Belgium
Ex i Ex e
Safety Temperature Limiter according to:
Sicherheitstemperaturbegrenzer nach:
Limiteur de Sécurité selon:
Limitador de temperatura de segurança de acordo com:
Switch current de-rating table / Tabelle temparaturabhängiger Schaltstrom / Tableau de
dégrèvement courant de coupure / Tabela de redução de potência de corrente de comutação
Temperature Class T5
Ambient temp. range Maximum switch current
–40°C – +50°C 25 A
Temperature Class T4
Ambient temp. range Maximum switch current
–40°C – +54°C 20 A
–40°C – +56°C 16 A
–40°C – +56°C 25A
Heat-Tracing Temperature Control Unit with safety limiter
Temperaturregler mit Sicherheitstemperaturbegrenzer
Contrôleur/Limiteur de Température pour Traçage Electrique
Unidade de Controle de Temperatura por Traço Térmico com
limitador de segurança
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NGC-20 INSTALLATION MANUAL
10
Figure 2: connection diagram NGC-20-C(L)-E
W/B
W/B
R
R
RRPE
L1
N
PE
RS485 cable from
previous device RS485 cable to
next device
To next NGC-20
Heating cable
PT100
temperature sensor
Only to be used for the LIMITER
PT100
temperature
sensor(s)
RTD 1
RTD 2 RS485
RS485 S
S
+Li Lo Ni No PE PE PE Lo No
Internal RS485
end of line
termination
resistor
When the device is the last on the communication
line install a wire bridge between the - and
T terminal as shown by the dotted line
Alarm
3A Max
Heater
+
–
–T
PE
RTD LIMITER
RPE
RPE
W/B
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NGC-20 INSTALLATION MANUAL 11
2. INSTALLATION For installation/operation, always observe the Equipment Safety Law, the rules of
generally accepted engineering practice (IEC60079-14/EN 60079-14), and the instructions
stated in this Manual. Carry out work on the thermostats in the de-energized state only.
2.1 Tools required
Figure 3: tools required for installation
2.2 Mechanical installation
DigiTrace NGC-20-CL-E units comprise a temperature controller and a safety
temperature limiter installed in one enclosure. The controllers can be installed in any
position either on a stable structure by means of the 4 mounting holes. Alternatively the
DigiTrace NGC-20-C(L)-E units can be mounted directly on a pipe by means of a support
bracket type SB-125. In order to provide enough stability the support bracket needs to be
attached on to the pipe by means of 2 pipe straps.
Figure 4: Mounting positions NGC-20
2.3 Temperature sensors
The DigiTrace NGC-20C(L)-E temperature inputs are designed as intrinsically safe circuits
(IEC 60079-11/EN60079-11 Ex [ib]) therefore any type of three wire DIN IEC 751 Class B
PT100 resistance temperature devices can be used. The DigiTrace NGC-20-CL-E supports
3 local temperature inputs, where 2 are allocated to the temperature controller (RTD 1
and RTD 2). The third temperature input is reserved for the temperature limiter (RTD
limiter). DigiTrace NGC-20-C-L units on the other hand do not support the third input
(RTD limiter)
2.3.1 Lead compensation of RTD connections.
DigiTrace NGC-20-C-E and DigiTrace NGC-20-CL-E units are capable of providing up to
20 Ohm lead resistance compensation. This implies that sensor connections may be
extended using a three core shielded or braided cable with a maximum length of up to
150 meter. (3 x 1.5 mm² minimum required) The screen or braid of the extension cable is
to be grounded at the controllers end only.
100 -
254 VAC
Heat-TracingTemperatureControl Unit
Temperaturreglerfür Begleitheizungen
Unitéde Contrôle de Température pourTraçage Electrique
Baseefa08ATEX0184X
I ECEx BAS 08.00 47X
II2G D
GBE x e mb ib IIC T* See Sc hedule
DbE x tD A21 IP66 T95°C
Lot/Los/LotN°:
Serialnu mber inside
Seriennummer innen
N°de série à l ’interieur
Operatingvoltage:
Betriebsspannung:
Tensionnominale:
PN-1244-007035
1180
ModBus:
Connections/ Anschlüsse / Raccordements
Switchcurrentde-rating table / Tabelletemparaturabhängiger Schaltstrom/
Tableaudedégrèvement courant de coupure
TexteFrançaisdans le manuel technique
DeutscheTextesiehe Betriebsanleitung
TemperatureClassT5
Ambienttemp.range Maximum switch current
–40°C–+50°C 25 A
TemperatureClassT4
Ambienttemp.range Maximum switch current
–40°C–+54°C 20 A
–40°C–+56°C 16 A
–40°C–+56°C 25A
Leuven,Belgium
Exi
Connections/ An schlüsse / Raccordements
Exe
100 -
254 VAC
Heat-TracingTemperatureControl Unit
Temperaturreglerfür Begleitheizungen
Unitéde Contrôle de Température pourTraçage Electrique
Baseefa08ATEX0184X
I ECEx BAS 08.00 47X
II2 GD
GBE x e mb ib IIC T* Se e Schedule
DbE x tD A21 IP66 T95°C
Lot/Los/LotN°:
Serialn umber inside
Seriennummer innen
N°de sérieàl’interieur
Operatingvoltage:
Betriebsspannung:
Tensionnominale:
PN-1244-007035
1180
ModBus:
Connections/Anschlüsse / Racc ordements
Switchcurrentde-rating table / Tabelle temparaturabhängigerSchaltstrom /
Tableaudedégrèvement courant de coupure
TexteFrançaisdans le manuel technique
DeutscheTextesiehe Betriebsanleitung
TemperatureClassT5
Ambienttemp.range Maximum switch current
–40°C–+50°C 25A
TemperatureClassT4
Ambienttemp.range Maximumswitch current
–40°C–+54°C 20 A
–40°C–+56°C 16 A
–40°C–+56°C 25A
Leuven,Belgium
Exi
Connections/Anschlü sse/R accordements
Exe
3 mm terminal screwdriver
7 mm screwdriver
Trimming knife
25 mm spanner (for 20 mm glands)
36 mm spanner (for 20/25 adapter)
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NGC-20 INSTALLATION MANUAL
12
2.3.2 Installation of temperature sensors
The temperature sensors must be installed in such a way that the sensor(s) measure(s)
the surface temperature as reliable as possible. Therefore the guidelines as described in
section 2.3.2.1 need to be followed.
2.3.2.1 Temperature sensor of the temperature controller
Important guidelines on sensor positioning and installation:
• The correct position is on top of the pipe. (Figure 2)
• The sensor needs to be attached with sufficient glass tape (GT-66 or GS-54).
• Use two bands of glass tape to ensure its position. (Figure 1)
• The lead wire need to leave the insulation so that no moisture can enter the cladding-
insulation system. (Figure 2)
• Fix the sensor lead wire to prevent accidental strain on the sensor tip, which could
alter its position.
WARNING:
• Do not install sensor at ambient temperatures below –20°C. Do not bend sensor
(last 50 mm), keep it straight under all circumstances. Minimum bending radius for
extension cable: 5 mm.
• No metal straps may be used for fastening, because they could damage the
sensor when tightened. For this reason the use of fibre-glass self-sticking tapes is
recommended.
Figure 5: Mounting temperature sensing on pipe
Figure 6: Sensor and lead entrance
Sensor
Pipe
Lead entrace
No No
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NGC-20 INSTALLATION MANUAL 13
2.3.2.2 Installation of the temperature sensor of the safety temperature Limiter
The DigiTrace NGC-20-CL-E knows two methods of limiting the surface temperature of
the heating cable.
2.3.2.2.1 On the pipe surface
The first method consists of using the surface temperature of the pipe as reference and
preventing powering the heating cable when the pipe temperature is above a calculated
value. This value is depended on the make of the cable and the design of the heating
circuit. Use TraceCalc Pro®to determine this value and document the calculation in your
filing.
The sensor is installed identical to the normal temperature sensor, at the top of the pipe,
firmly attached to the surface by means of glass tape. Special attention needs to be taken
that the sensor lead does not cool the pipe/sensor; nor that moisture could enter the
insulation, cooling the sensor tip or reducing the insulation capacity in this area.
2.3.2.2.2 On an artificial HOT-SPOT
The second way of surface temperature limiting is to create an artificial hot-spot.
In order to guarantee the limiter sensor measures the highest possible temperature of
the installation, the temperature sensor of the limiter shall be installed on an artificial
hotspot.
For this method you should use the DigiTrace NGC-20-LIM which comes with all the
needed parts.
Only use the 10 mm insulation pad supplied with the DigiTrace NGC-20-LIM for this
purpose. The offset value has been verified and proven with this insulating pad and the
sensor as supplied with the thermostat.
Figure 7: Artificial hot-spot
Important guidelines on sensor positioning and installation:
• The correct position is on top of the pipe. See Figure 7.
• Fix the insulation pad with sufficient glass tape. (GT-66 or GS-54)
• Guide the heater from the bottom of the pipe to the insulation pad and fix it well so that
it keeps its position.
• The sensor needs to be attached with sufficient glass tape to the heater. Use two bands
of glass tape to ensure its position.
• The lead wire needs to leave the insulation so that no moisture can enter the cladding-
insulation system. Fix the lead wire to the pipe with glass tape if needed to ensure the
stability of the hot spot system.
• Make sure that the nominal insulation thickness is respected over the hot spot, it might
be necessary to use oversized insulation shells.
Limiter temperature setting:
• The limiter value (Tlim) needs to be set at the maximum allowed surface temperature
(Tmax) minus 10 K.
• Tlim = Tmax – 10. Temperatures in Kelvin or Celsius.
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14
W/B
W/B
R
R
RRPE
L1
N
PE
RS485 cable from
previous device RS485 cable to
next device
To next NGC-20
Heating cable
PT100
temperature sensor
Only to be used for the LIMITER
PT100
temperature
sensor(s)
RTD 1
RTD 2 RS485
RS485 S
S
+Li Lo Ni No PE PE PE Lo No
Internal RS485
end of line
termination
resistor
When the device is the last on the communication
line install a wire bridge between the - and
T terminal as shown by the dotted line
Alarm
3A Max
Heater
+
–
–T
PE
RTD LIMITER
RPE
RPE
W/B
2.3.3 Remote temperatures via DigiTrace RMM
When used in combination with the optionally available DigiTrace NGC-UIT and
DigiTrace RMM2 units, the DigiTrace NGC-20-C(L)-E controllers are able to read
temperatures from up to 6 remote temperature sources (RTD type) via the RS485
network.
Figure 8: DigiTrace NGC-20 in a network with NGC-UIT and RMM modules
The DigiTrace RMM2 units are used to read remote temperature inputs. One RMM2 device
supports up to 8 RTD inputs. A maximum of 16 RMM2 units can be connected on one
network. The DigiTrace NGC-UIT will collect up the temperatures from the RMM2 units
and distribute it to the required DigiTrace NGC-20 controller. Please refer to the
MONI-RMM2 datasheet and installation instructions for more details.
2.4 Electrical installation
Figure 9 shows the electrical connection diagram of the DigiTrace NGC-20 controller.
The limiter temperature sensor connection is only applicable with the DigiTrace
NGC-20-CL-E. The optional second Pt100 temperature sensor for the control unit is
omitted for clarity.
Figure 9: electrical connection diagram DigiTrace NGC-20
HEATER
ALARM
LIMITER
RS485
BLUETOOTH
RESET
LIMITER
SET
T
HEATER
ALARM
LIMITER
RS485
BLUETOOTH
NGC-20-C-E
HEATER
ALARM
LIMITER
RS485
BLUETOOTH
RESET
LIMITER
SET
T
HEATER
ALARM
LIMITER
RS485
BLUETOOTH
NGC-20-C-E
HEATER
ALARM
LIMITER
RS485
BLUETOOTH
RESET
LIMITER
SET
T
HEATER
ALARM
LIMITER
RS485
BLUETOOTH
NGC-20-C-E
0
RMM2
0
RMM2
NGC-UIT-ORD
Optional remote
connection to DTS
Optional
To next drive
Heat-TracingTe mperatureControl System
Temperaturregelungsystem für Begleitheizungen
Système de Contrôle de Température pour Traçage Electrique
Heat-TracingTe mperatureControl System
Temperaturregelungsystem für Begleitheizungen
Système de Contrôle de Température pour Traçage Electrique
Heat-TracingTe mperatureControl System
Temperaturregelungsystem für Begleitheizungen
Système de Contrôle de Température pour Traçage Electrique
Sistema de Controle de Temperatura por Traço Térmico Sistema de Controle de Temperatura por Traço Térmico Sistemade Controle de Temperatura por Traço Térmico
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NGC-20 INSTALLATION MANUAL 15
2.5 Communication and networking
The DigiTrace NGC-20 controller is equipped with a RS485 interface. Through this
interface up to 247 DigiTrace NGC-20 units can be networked to a DigiTrace NGC-UIT or
to one serial port of standard PC running Pentair Thermal Management´ Windows based
DigiTrace Supervisor software.
The DigiTrace NGC-UIT can be placed indoors (DigiTrace NGC-UIT-ORD-E) or outdoors
(DigiTrace NGC-UIT-OUT-E) in non hazardous areas. DigiTrace supervisory software
allows DigiTrace NGC-20 units to be monitored or programmed from any location due
to the client-server architecture. Please refer to the datasheet and operating manual of
the individual products for more information (DigiTrace NGC-UIT-ORD: INSTALL-112;
DigiTrace Supervisor: INSTALL-117).
2.6 Configuration
The DigiTrace NGC-20 controllers can be configured locally by means of a handheld
programming device (DigiTrace NGC-CMA) or from a central location using the DigiTrace
NGC-UIT or DigiTrace Supervisor Software. After programming, all settings are
permanently stored in the nonvolatile memory of the DigiTrace NGC-20 control unit,
avoiding loss of data
in the event of power failure or after a long term power shutdown.
3. MAINTENANCE Equipment placed into hazardous areas needs to comply with EN 60079-17 regarding
inspection and maintenance requirements. The EN 60079-17 describes in more detail the
requirements regarding documentation, qualifications of personnel, inspections, regular
periodic inspections, continuous supervision by skilled persons, maintenance, isolation of
apparatus, earthing and inspection schedules.
4. SAFETY INSTRUCTIONS FOR DIGITRACE NGC-20-CL-E
4.1 Safety function of temperature limiter in DigiTrace NGC-20-CL-E
The application areas for (safety) temperature limiters can be found anywhere where
there are thermal processes to be monitored, and where the system must be set to
a safe operating condition in the event of a fault. If the permitted temperature limit
(Temperature classification) is reached, or a fault occurs within the normal operating
temperature (probe break/short-circuit, component defect, power failure), then the
instrument switches to the safe state without delay. If the fault is no longer present,
then the safety temperature limiter must be manually reset. This can be done either by
means of the internal reset button inside the unit, The DigiTrace Supervisory Software or
the handheld programming device. The unit will only accept to be reset after the normal
operating conditions have returned.
4.2 Area of use
Safety temperature limiters are required in all areas where thermal processes need to
be prevented from overheating. In case of a temperature upset they will put the system
into a safe operating condition. The safety function will invoke in the event of a fault,
when the permissible temperature limit is reached or in case a fault occurs (such as
probe break, probe short-circuit, component failure, or supply failure) even when the
process conditions are within the permissible temperature range. In all these cases
the equipment is immediately switched off. If the fault is no longer present, than the
safety temperature function must be manually reset before the unit goes back to normal
operation. DigiTrace NGC-20-CL-E units can be reset by means of an internal push button
or via dedicated software. The output of the unit will only be enabled when all conditions
are safe; meaning that the temperature measured by the limiter RTD has dropped below
the limiter set point and when there are no other faults being detected. In other words,
the unit will only reset after the normal operating conditions have returned.
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4.3 Requirements to be met by the temperature limiter
The DigiTrace NGC-20-CL-E safety temperature limiter meets the requirements of
IEC 60079-30-1 For applications installed in a hazardous area Zone 1 (Zone 21) this
means that the protective device shall de-energize the system to prevent exceeding
the maximum permissible surface temperature. In case of an error by, or damage to
the sensor, the heating system shall be de-energized before replacing the defective
equipment. The protective device operates independently from the temperature
controller.
4.3.1 Temperature limiter (schematic)
Figure 10: Limiter block diagram.
4.3.2 Reset by hand only
The safety temperature limiter is designed such that after the temperature limiter has
tripped the device needs to be reset by hand. Resetting is possible only after the normal,
safe operating conditions have returned.
4.3.3 Reset by hand via tool or keyed lock
In order to RESET the limiter after it has tripped, the user needs to press the internal
Limiter Reset pushbutton as is shown in Figure 11. The figure shows where the limiter
RESET button is located inside the enclosure (lid removed). Alternatively the safety
temperature limiter can be reset via DigiTrace Supervisor, DigiTrace NGC-UIT or the
handheld configuration and monitoring device DigiTrace NGC-CMA and keying a specific
number on the keyboard. Refer to the operating manual of the specific units for more
detailed instructions on how to use these devices.
Reset Set
Principle limiter analog circuit
Sensor 2
Sensor 1
Limiter
sensor
Temperatue control
Alarm
R485
Alarm relay
..........
..........
..........
..........
..........
..........
LN PE L-load N-load
limiter
relay
ground
fault relay
..........
– 12V
SPI
AND
ground fault
current sensor
load current
current sensor
Temperature -
controller
RTD check
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NGC-20 INSTALLATION MANUAL 17
4.3.4 Temperature setting secured and locked to prevent manipulation
The lock out temperature (set point) of the safety temperature limiter must be set in such
a way that maximum T-class temperature cannot be exceeded. The surface temperature
of the heat-tracing cables is limited to the temperature applicable in this T class -5 K
for temperatures below or equal to 200°C or -10 K for temperatures greater than 200°C.
Refer to section 4.4 below for the procedure to change the safety limiter set point.
Independence from control system
The safety temperature limiter operates totally independent from the temperature control
system and has an own temperature input (RTD Limiter) In case of a defect to any part of
the DigiTrace NGC-20 unit the device shall be de-energized before replacing the defective
equipment.
4.4 Changing limiter set point
Changing the set point of the limiter requires the combination of the internal limiter set
button and an external user interface.
4.4.1 Procedure to write new temperature set point to limiter
In order to write a new set point to the temperature limiter a safety procedure needs to
be followed. Changing the set point of the temperature limiter requires the combination
of the internal limiter set button as is shown in Figure 11 and a programming device. As
programming device one can use; DigiTrace Supervisor software, DigiTrace NGC-UIT
terminal or the handheld configuration and monitoring assistant DigiTrace NGC-CMA-EX
or DigiTrace NGC-CMA-NH.
The procedure to change the limiter set point is the same for all user interfaces. The
configuration tool will write the new set point to the input buffer of the DigiTrace NGC-
20-CL-E controller. Only when the internal temperature set button is pressed will the
new set point be forwarded to the internal memory of the temperature limiter. The limiter
set point button needs to be activated within a certain time after the buffer has been
loaded with the new set point. If the button has not been pressed before the programming
window is elapsed, the buffer will be emptied and the old value remains active. Once the
new set point has been written the new or in case the write procedure was not successful
the old set point will be read back by the programming device as confirmation to the user.
After changing the limiter set point the user shall verify whether the set point has been
updated correctly. The limiter set point can be shown on the DigiTrace NGC-20 hardware
by pressing and holding the black Limiter SET button. While the limiter set point is shown
the red LED indicator marked with LIMITER will blink. After the button is released the
display will show the controllers measured temperature again and the LIMITER LED
will go off. Each time after the limiter set point has been altered a functional test as per
paragraph 4.5.1 is to be performed.
Figure 11: Internal Limiter control buttons: Limiter (temperature) SET and Limiter RESET
pushbuttons.
HEATER
ALARM
LIMITER
RS485
BLUETOOTH
RESET
LIMITER
SET
Pentair Thermal Management DigiTrace NGC-20
Limiter reset button (rearm the limiter after it has tripped)
Limiter temperature set button to be pressed after
the polling process has been initiated
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4.5 Functional test
The DigiTrace NGC-20-CL-E units are meeting the requirements of SIL2 (see paragraph
4.6 for more details) accordingly to IEC 61508-1:2000 and IEC 61580-2:2000 In this
standard is stipulated that in order to guarantee safe and reliable operation the units
need to be subjected to a functional test at regular intervals. In the case of the DigiTrace
NGC-20 limiter this is set at 12 months (1 year) intervals. These tests must be performed
according to the guidelines provided. When the operational lifetime has expired, the
systems no longer conform to the requirements of their SIL certification.
Table 3: Functional test
4.5.1 Functional test description
In general the functional test always starts from the “normal” state, meaning that there
should not be any alarms present on the unit and that the limiter tripped LED (Lim
Tripped) on the display of the unit should not be lit. In case the Lim Tripped LED is ON
than the unit should be reset before the functional test is being performed. Apart from
the scheduled test intervals a functional test is to be performed after every malfunction of
the system and each time the limiter set point has been changed.
4.5.2 Functional test procedure
The following steps should be executed as part of the functional test:
• Disconnect one of the leads of the temperature sensor of the limiter RTD. (RTD 3
limiter)
• The red alarm LED “Lim tripped” should light up momentary and the output of the unit
should switch OFF.
• Re-establishing the sensor connection has no immediate effect. Switch off the mains
supply of the unit and leave the power off for one minute. Powering up the unit again
should not reset the limiter.
• After the Limiter reset button is been pressed the Lim Tripped alarm will go away and
switch the output on. (Assuming the measured temperature is below the set point
temperature and there are no other faults)
• Install a wire bridge, short cutting the limiter sensor terminals marked with R+ and R-
(RTD 3 Limiter)
• The red alarm LED “Lim tripped” should light up momentary and the output of the unit
should switch OFF.
• Removing the wire bridge has no immediate effect.
• Switch off the mains supply of the unit and leave the power off for one minute.
Powering up the unit again should not reset the safety limiter.
• Only after the Limiter reset button has been pressed will the Lim Tripped alarm go
away and switch the output on. (Assuming the measured temperature is below the set
point temperature and there are no other faults)
4.5.3 Test in the event of a fault
In the event of a system fault, the instrument switches off the load. This condition
is indicated by the LED “Lim tripped” which will light up. The fault is signalled
simultaneously by the alarm relay which changes state. Press the reset button (at least
2 sec) until the “Lim. Tripped” LED dims. If the safety circuit remains open, the system
and the probe circuit have to be checked. Press the reset button again. If the instrument
remains inhibited after pressing the reset button the unit should be replaced.
4.6 Safety Integrity level
The safety integrity level of the DigiTrace NGC-20 is SIL2. The SIL level can be achieved by
determining the following safety related parameters:
1. PFDavg: The average probability of the hazardous failure of a safety function when it is
demanded;
2. HFT: The hardware fault tolerance;
3. SFF: The fraction of non-hazardous (i.e. safe) failures
See for details on the DigiTrace NGC-20-CL-E table Table 4.
Type SIL level Proof check interval Unit Lifetime
NGC-20-CL-E SIL 2 1 year 25 years
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4.6.1 Safety integrity of the DigiTrace NGC-20 hardware
According to IEC 61508-2:2000, a distinction must be made between Type A systems and
type B systems. A sub-system can be viewed as a Type A system if, for the components
that are necessary in order to achieve the safety function:
1. The failure mode of all components that are used is adequately defined, and
2. The response of the sub-system in fault conditions can be completely determined,
3. Reliable failure data based on field experience are available for the sub-system,
to demonstrate that the assumed failure rates for recognized and unrecognized
hazardous failures can be achieved.
A sub-system can be viewed as a Type B system if, for the components that are necessary
in order to achieve the safety function:
1. The failure mode of at least one component that is used is not adequately defined, or
2. The response of the sub-system in fault conditions cannot be completely determined, or
3. No adequately reliable failure data based on field experience are available for the
sub-system, to support the assumed failure rates for recognized and unrecognized
hazardous failures.
The DigiTrace NGC-20-CL-E temperature control system with limiter corresponds to a
Type A system.
4.6.2 PFDavg safety function
The limiter sensor, limiter electronics and the limiter relay together form the safety
related system that performs a safety function. The “average probability of the hazardous
failure of a safety function for the entire safety-related system” (PFDavg) is usually
divided among the subsystems. An external device e.g. an external power contactor
installed in a panel, is specific to the installation, and shall, in accordance with the
standards for the safety loop, be considered separately.
Table 4: Safety Integrity level
MTTR = Mean time to repair
4.6.3 SIL related to SFF and HFT
The following table presents the achievable safety integrity level (SIL), depending on the
safe failure fraction (SFF) and the hardware failure tolerance (HFT) for Type A safety-
related sub-systems.
Table 5 is valid for the DigiTrace NGC-20-CL-E:
Table 5: Relation SFF to HFT
Safe failure fraction (SFF) Hardware fault tolerance (HFT) for Type A
0 1 2
SFF < 60% SIL 1 SIL 2 SIL 3
60 < SFF < 90 % SIL 2 SIL 3 SIL 4
90% < SFF < 99% SIL 3 SIL 4 SIL 4
99% < SFF SIL 3 SIL 4 SIL 4
Type SIL level Architecture Proof check
interval MTTR (hrs) PFD avg. HTF SFF
DigiTrace NGC-20-CL-E SIL 2 1oo1D 1 year 24 3.017E-3 0 (1oo1) 95.03%
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4.6.4 Safety related system characteristics
The failure types of; sensor break, sensor short, sensor misconnected and random
hardware failure are permanently monitored.
4.6.5 Response in operation and fault conditions
The response in operation and fault conditions is described in the operating manual. The
necessary functional tests are described in paragraph 4.5.3 of this operating manual.
The test to be applied in a fault condition is described in paragraph 4.5.2 of this operating
manual.
A functional test must be carried out after commissioning, repair to the safety system,
or an alteration of safety-related parameters. If a fault is detected in the course of a
functional test, then measures must be implemented to restore the reliable functionality
of the safety system. This can, for instance, be achieved through replacement of
the control unit. It is recommended that the tests that have been carried out are all
appropriately documented.
IMPORTANT NOTICE
In case a failure of the safety system is detected either during operation or during
routine maintenance when executing a function test the unit should be switched off
and taken out of service. Defects in the safety system cannot be repaired in the field.
Defective units are to be replaced and returned to the manufacturer for investigation.
Please contact your nearest Pentair Thermal Management representative for more
instructions. A list of worldwide representations can be found on the last page of this
document or on www.pentairthermal.com.
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