nVent RAYCHEM 460 Controller Firmware Version 5.1.1 Or Higher User Manual

nVent RAYCHEM 460 Controller Firmware Version 5.1.1 Or Higher

Product Information

The nVent RAYCHEM 460 pipe heat trace controller is an electronic control unit used for pipe trace heating systems. It is c-UL-us listed for heat tracing applications. The controller has a touchscreen display that provides easy-to- read messages and prompts. It can utilize one or two temperature sensor inputs for ambient or line sensing control modes and programming of all temperature parameters. It has high and low-temperature alarms for both temperature sensor inputs, a high-temperature cutout, and a low current condition indicator. Additionally, it has an electromechanical relay (EMR) output switch with device failure alarm status change and Proportional Ambient Sensing Control (PASC) mode to maximize energy efficiency. The controller also can detect both open and shorted sensors.

Product Usage Instructions

1. Installation: Follow the installation instructions provided in the manual carefully. Ensure that the controller is installed in a suitable location that is easily accessible for maintenance but not exposed to extreme temperatures, humidity, or vibration. The controller should also be connected to a grounded electrical outlet.
2. Operation: Once installed, the controller can be programmed using the touchscreen display. Select the appropriate temperature sensor input and control mode based on the application requirements. Set the desired temperature parameters and ground fault level if necessary. The controller will monitor the temperature and control the heat tracing system accordingly.
3. Maintenance: Regular maintenance is crucial for the optimal performance of the controller and heat tracing system. Inspect and clean the controller periodically to ensure it is free from dust, dirt, or moisture. Check the temperature sensors and heating cables regularly for any damage or wear and tear, and replace if necessary.
4. Troubleshooting: If any issues arise with the controller, refer to the Troubleshooting section of the manual. It includes a list of possible error codes and solutions to resolve them.

OVERVIEW

Introduction
This manual provides information about the installation, operation, testing, and maintenance of the nVent RAYCHEM 460 pipe heat trace controller. The controller is c-UL-us listed heat tracing applications. Additional copies of this user manual may be ordered separately through your nVent Thermal Management representative or online at nVent.com.

Product Overview Description

The 460 controller monitors, controls, and communicates alarms and data for one heat tracing circuit.

Each unit is a single-point controller with a 5″ inch color touchscreen display for intuitive setup and programming right out of the box. The 460 controllers may be used with line-sensing or ambient-sensing and proportional ambient-sensing control (PASC) modes. It measures temperatures with two 2 KOhm / 77°F (25°C), 2-wire thermistors connected directly to the unit. The controller can also measure ground fault current to ensure system integrity. If the equipment is used in a manner not specified by nVent Thermal Management the protection provided by the equipment may be impaired.

Features

A detailed description of available features may be found in Section 4 of this manual. Highlights of specific features are as follows:

Touchscreen Display
The touchscreen display provides the operator with large easy-to-read messages and prompts, eliminating complex and cryptic programming.

Single or Dual Temperature Sensor Inputs
The ability to utilize one or two temperature sensor inputs allows the selection of ambient or line sensing control modes and the programming of all temperature parameters.

High and Low Temperature
High and low-temperature alarms are offered for both temperature sensor inputs.

High-Temperature Cutout
The high-temperature cutout is provided for both temperature sensor inputs.

Low Current Condition
The 460 controller offers a low current condition to identify situations where the heating cable is not pulling adequate current.

Electromechanical Relay (EMR) Output
The 460 controllers is equipped with a 24 A-rated electromechanical relay (EMR) output switch with a device failure alarm status change.

Ground Fault Condition and Trip
Ground fault (GF) current levels are monitored and are displayed in milliamperes (mA). The adjustable ground fault level gives the user the choice of ground fault current levels suitable for the particular installation.

Proportional Ambient Sensing Control (PASC)
The 460 controller includes the Proportional Ambient Sensing Control (PASC) mode to maximize the energy efficiency of the heat tracing system.

Temperature Sensor Failure
Both open and shorted sensors are detected by the controller.

Certification
nVent Thermal Management certifies that this product met its published specifications at the time of shipment from the factory.

Limited Warranty

This nVent Thermal Management product is warranted against defects in material and workmanship for 18 months from the date of installation or 24 months from the date of purchase, whichever occurs first. During the warranty period, nVent 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 nVent Thermal Management. The Buyer shall prepay shipping charges to nVent Thermal Management and nVent 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 nVent Thermal Management from another country. nVent Thermal Management warrants that the software and firmware designated by nVent Thermal Management for use with the 460 controllers will execute its programming instructions properly. nVent Thermal Management does not warrant that the operation of the hardware, 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. nVent Thermal Management 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. nVent 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.

Conducted and Radiated Emissions:

FCC Statement of Compliance

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a commercial/ residential installation. 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:

• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and the receiver.
• Connect the equipment to 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.

CAUTION!
Do not modify the device. Any changes or modifications made to the device that are not expressly approved by nVent could void EMC compliance.

Innovation, Science and Economic Development (ISED) Canada ICES-003 Compliance Label: CAN ICES-3 (B)/NMB-3(B)

General|
---|---
Area of use| Nonhazardous locations
Approvals| Type 12 QUYX / QUYX7 PROCESS CONTROL EQUIPMENT
Supply voltage| 120 V to 277 V, +/–10%, 50/60 Hz

Common supply for controller and heat-tracing circuit

Enclosure|
Protection| TYPE 12
Materials| Polycarbonate
Ambient operating temperature range| 32°F to 105°F (0°C to 40°C)
Ambient storage temperature range| –4°F to 122°F (–20°C to 50°C)
Relative humidity| 0% to 95%, noncondensing
Control|
Relay type| Double pole single throw
Voltage, maximum| 277 V nominal, 50/60 Hz
Switching current, maximum| 24 A @ 105°F (40°C)
Control algorithms| EMR: Ambient On/Off, proportional ambient sensing control (PASC), Line sensing
Control range| 32°F to 105°F (0°C to 40°C)
Monitoring|
Temperature| Low range –40°F to 190°F (–40°C to 88°C) or OFF High range 32°F to 190°F (0°C to 88°C) or OFF
Ground fault| Alarm range               20 mA to 200 mA

Trip range                  20 mA to 200 mA

Current| Low condition             0.25 A
Autocycle| Daily, Weekly, Monthly, Never
Temperature Sensor Inputs|
Quantity| Two inputs standard
Types| Thermistor 2 KΩ/77°F (25°C), 2 Wire 10 ft (3 m) long, can be extended to 328 ft (100 m) / 2 x 16 AWG
Sensor temperature range| –40°F (–40°C) to 194°F (90°C)
Sensor data| Temperature (°F)| Resistance (KΩ)
---|---|---
| –40| 32.34
| –31| 24.96
| –22| 19.48
| –13| 15.29
| –4| 12.11
| 5| 9.655
| 14| 7.763
| 23| 6.277
| 32| 5.114
| 41| 4.188
| 50| 6.454
| 59| 2.862
| 68| 2.387
| 86| 1.684
| 104| 1.211
| 122| 0.8854
| 140| 0.6587
| 158| 0.4975
| 176| 0.3807
Alarm Output| |
Alarm relay| Single pole double throw relay, volt-free, rating 1 A/24 VDC, 1 A/24 VAC
Programming and Setting| |
Method| Programmable touchscreen
Units| Imperial (°F, in.) or Metric (°C, mm)
Touchscreen

display

| Setpoint, status, sensor temperatures, alarm condition, settings
Memory| Nonvolatile, restored after power loss
Stored parameters

(measured)

| Last event, maintain temperature, last event sensor temperatures, control mode

Alarm conditions

| Low/high temperature, low current Ground fault condition, trip

Sensor failure, or EMR failure Loss of continutiy

Loss of incoming supply voltage

Other| Password protection|
Connection Terminals| |
Power supply input| Push-in Cage Clamp 18–10 AWG
Heating cable

output

| Push-in Cage Clamp 18–10 AWG
Ground| Push-in Cage Clamp 18–10 AWG
Sensors/alarm

relay

| Push-in Cage Clamp 22–16 AWG
Mounting| |
Enclosure| Mounting DIN Rail 35 mm (Indoor only)

Note:
The 460 controllers can’t monitor the load current and ground fault current in each cable segment when an external contactor is used. These alarm conditions are disabled when an external contactor is used.

INSTALLATION AND WIRING

Introduction
This section includes information regarding the initial inspection, preparation for use, and storage instructions for the 460 controllers.

Note:
If the 460 controllers is used in a manner not specified by nVent Thermal Management, the protection provided by the controller may be impaired.

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 and the equipment has been checked mechanically and electrically. If the shipment is incomplete, there is mechanical damage, a defect, or the controller does not pass the electrical performance tests, notify the nearest nVent Thermal Management representative. If the shipping container is damaged, or the cushioning material shows signs of stress, notify the carrier as well as your nVent Thermal Management representative. Keep the shipping materials for the carrier’s inspection.

Product Contents:

Tools Required:

Installation Location
The 460 controllers standalone version is approved for the TYPE 12 protection class for Indoor-use. Install the controller in an indoor, dry, clean, accessible location. Make sure you install the controller within 328 ft (100 m) of where you want to monitor the pipe or ambient temperature. The ambient temperature sensor shall be installed in the location representative of the ambient temperature of the system, including elevation. Considerations should include accessibility for maintenance and testing and the location of existing conduits.

Mounting Procedures
The mounting steps are shown in Figure 2.1 A, B, C, and D. Drill conduit entry holes before mounting. Conduit entries should be made in the bottom of the enclosure if possible to reduce the possibility of water entry from condensation or leakage. Conduit entries must be drilled or punched using standard industry practices. Use bushings suitable for the environment and install them such that the completed installation remains waterproof. Grounding hubs and conductors must be installed in accordance with Article 250 of the National Electrical Code and Part I of the Canadian Electrical Code. The hubs shall be connected to the conduit before they are connected to the enclosure.

Figure 2.1 Mounting procedures for the 460 controller

Wiring
The following drawings provide sample wiring diagrams for the 460 controller and optional accessories. Grounding hubs and conductors must be installed in accordance with Article 250 of the National Electrical Code and Part I of the Canadian Electrical Code.

Power and Load Connections
The 460 controllers may be powered directly from a 120 V to 277 V supply. All of the power terminals are labeled for easy identification. Do not attempt to use wire sizes that exceed the marked terminal ratings and avoid terminating two wires on the same terminal whenever possible.

Note:
Follow the industry standard grounding practices. Do not rely on conduit connections to provide a suitable ground. Grounding terminals/screws are provided for the connection of system ground leads.

Power wires are connected to terminals labeled L (line), N (neutral), and PE (Ground). The conduit is screwed to the gland provided with the controller .

Figure 2.2 Power connection

The heating cable conductors are connected to terminals labeled L/, N/ and the braid is connected to PE.

Figure 2.3 Heating cable connection

Temperature Sensor and Extension Cables
The 460 controller has two (2) temperature sensor inputs. Use only 2-wire Thermistor 2 KOhm / 77°F (25°C) sensors provided. Sensor 1 should be connected to terminals S1 and while Sensor 2 should be connected to terminals S2 and. The controller also operates with just one sensor.

Note:
The ambient temperature sensor shall be installed in the location representative of the ambient temperature of the system including elevation .

Figure 2.4 Temperature sensor wiring

Alarm Relay Connections
The 460 controller includes terminals for one alarm relay as shown in figure 2.5. It can support both AC and DC power sources (please refer to the max voltage and current specifications for the relay above). It may be wired for normally open (N.O.) or normally closed (N.C.) operations. The contractor shall connect the alarm indicator to NO, COM to have the relay signal an alarm condition when it’s open. In normal operation, the NO contact is closed. In case of power loss or an alarm condition, the NO contact is open.

The contractor shall connect the alarm indicator to NC, and COM to have the relay signal an alarm condition when it’s closed. In normal operation the NC contact is open. In case of power loss or an alarm condition, the NC contact is closed.

The alarm relay is used to provide an alarm signal to the system for any of the following conditions:

1. Ground fault current
2. Low system temperature
3. High system temperature
4. Temperature sensor failure
5. Internal error
6. Loss of continuity
7. Loss of incoming supply voltage

Note: The alarm relay is intended to be used for switching low-voltage, low-current signals. Do not use this relay to directly switch line voltages.

Figure 2.5 Alarm wiring

After all connections are made, connect the network cable from the touchscreen to the port on the controller as shown below:

Figure 2.6 Connect the touchscreen cable to the controller.

Close the lid with a screwdriver and turn on the circuit breaker for the circuit. The circuit breaker used for branch circuit protection should be a maximum of 30 A circuit breaker. The power wires used should be of appropriate size for the current rating as per NEC/CEC.

Initializing the Controller

Initial Heating Cable Test
To minimize the risk of damage to the controller due to a heating cable fault, the integrity of the heating cable should be verified by performing the commissioning tests detailed in the appropriate product installation and operating manual. These manuals can be found on nVent.com. These tests must be performed with the controller output disconnected. Once the cable has been checked, it may be reconnected to the controller and power applied.

460 CONTROLLER OPERATION

Quickstart
When the unit is powered up for the first time, a Quickstart must be executed before the unit is ready to start. The Quickstart helps to set all important settings, the unit will go into main screen mode automatically when done. Quickstart is sufficient for normal operations. More settings are available from the settings menu.

Quickstart menu

will check the heating cable connection, ambient sensor and pipe sensor connection.

A connection of the unit to an external contactor needs to be confirmed by the user.

Warning: The 460 controller can’t monitor the load current and ground fault current in each cable segment when an external contactor is used. External ground fault protection must be provided using appropriate GFEPD.

Country| Select a country in this menu.
Date| Use the up/down arrow keys to select the year, month and day.
Time| Use the up/down arrow keys to set the hour and minute.
Voltage| Select voltage.
Cable Type| Select the heating cable used in the application.
Sensors Set-up| Setting up Sensors 1 and 2 is fully flexible. Assign each sensor to be a line or ambient sensor. Select if you want the circuit to remain on if the given sensor fails by clicking “Power On TS Fail”. Select which sensor you would want to use for the high-limit cutout. Make sure Sensor 1 is connected to terminals S1 and.

Fine-tune the individual sensor settings in the parameters setting menu.

If only one sensor is used, leave the other sensor settings blank.

Control Mode| This allows the selection of the type of algorithm to be used to maintain the setpoint temperature. Select Ambient On/Off, PASC (Proportional Ambient Sensing Control) or Line Sensing Control. If no ambient or line sensor was assigned, the corresponding control mode will be disabled.
| Setpoint| This is the temperature that the controller uses to determine whether its output switch should be on or off.

Range: 32°F (0°C) to 176°F (80°C)

---|---|---
| Pipe Diameter| Select the appropriate pipe diameter from the menu.
Parameter Settings| Low Temperature| This allows the user to set the low temperature setting for temperature sensor 1 and 2.

Range: –40°F (–40°C) to 190°F (88°C)

Default: 35°F (2°C)

| High Temperature| This allows the user to set the high temperature setting for temperature sensor 1 and 2.

Range: 32°F (0°C) to 190°F (88°C)

Default: 110°F (43°C)

Start Test Program| | The test program runs for 30 minutes, during which all parameters will be ignored to check heating cable and connection on site. You can stop the test program at any time.
Key Lock| | Key lock gets activated after the quick start process. Please enter the passcode 3000 to unlock the controller.

After QUICKSTART completion, the main menu screen will appear as follows :

Figure 3.1 Main menu screen

The Green LED will blink as follows:

• Normal operation, heater on: 5 sec on/0.5 sec off
• Normal operation, heater off: 1 sec on/ 1 sec off
• Alarm condition: 2 sec on/1.8 sec off

Press the Settings button on the Main Menu Screen to get to the Settings Menu.

Settings Menu

Figure 3.2 Settings menu

The settings menu has three sections:

1. The System section allows you to read system information, run test programs, select Autocyle test interval, service the system such as upgrade the firmware, export event log/energy consumption/temperatures or calibrate the screen, read status of the heat tracing circuit, enable key lock, assign device ID and reset the system to factory settings.
2. The Heating Cable and Pipe section allows you to set circuit parameters such as control mode, set point, sensors, minimum ambient temperature, temperature conditions and filters and ground fault setting.
3. The General settings enables you to select country, language, voltage, date, time, and units.

The details of each section are provided on the next page.

System Menu

Figure 3.3 System menu

Info
Purpose General info about the unit, name, commissioning date, firmware version, nVent Thermal Management contact info per country.

Test Program
Purpose The test program runs for 30 minutes, during which all parameters will be ignored to check the heating cable and the connection on site. You can stop the test program at any time.

Autocycle Test
Purpose The autocycle function applies power to the heating cable circuit for approximately 10 seconds at the selected interval. It is used to test the integrity of the heating cable circuit.

Note:
Although the autocycle function helps monitor the functionality of the heating cable circuits, it does not eliminate the need for preventative maintenance as detailed in the heating cable operating manuals.

Service

Purpose
This is a password-protected area for users to service the unit.

The default password is 2017.

Sub-menu includes:

• Log File: Provides information about the warnings, the last event, control mode, heating cable, set point, ambient temperatures measured, and time stamp.
• Calibrate Screen: Press the dot to calibrate the touch screen.
• USB: A USB drive can be used to upgrade the firmware, and export temperature, energy consumption, and event log data.
• Energy Consumption: Displays the energy consumption chart over time.
• Select Power Adjustment: For Proportional Ambient Sensing Control (PASC), Power Adjustment Factor can be selected. The Range is from 10% to 200%. The default is 100%.

Status

Purpose
Displays the status and parameters for the heat tracing circuit. Displays information such as sensor 1 and sensor 2 temperatures, duty cycle, control mode, load current, GFP current and if the external contactor is connected.

Keylock Feature

Purpose
When key lock is “On”, the setup and timer menus are protected by password. To unlock the unit, enter the predefined password (3000). The unit will automatically lock itself after 10 minutes of inactivity or when Lock “On” key is pressed.

• Factory default: Key lock is “On”

Press the down arrow key to move to the next page of the System Menu

Assign Device Number

Purpose
Assign a 4 digit number to each device as an identifier for that device.

Reset

Purpose
To provide a quick method of resetting the controller’s configuration parameters to the Factory Default parameters. Select “Yes” to activate the Quick install menu and return all settings to factory settings. Quick start process restarts automatically.

Heating Cable and Pipe Menu

Figure 3.4 Heating cable and pipe menu

In this menu, every parameter line shows the actual value/attribute for each parameter.

Sensor Setup
Sensor setup allows user full flexibility in configuring the temperature sensors as shown in Figure 3.5 below:

Figure 3.5 Sensor setup

The 460 controller allows for two temperature sensors. Assign each sensor to be a line or ambient sensor. If both the sensors are assigned as a line or ambient sensors, the controller will control based on the lower measured temperature of the two sensors. Select if you want the circuit to remain on if the given sensor fails by clicking “Power On TS Fail”. Select which sensor you would want to use for the high-limit cutout. Make sure Sensor 1 is connected to terminals S1 and.

At least one sensor needs to be connected for the controller to function. The second sensor, if not connected, will be automatically disabled.

Note:
“High Limit Cutout” feature turns the circuit off when the corresponding sensor reaches the high limit cutout temperature. This feature has a higher priority over the “Power On TS Fail” feature. In other words, the circuit in high limit cutout condition will remain powered off until that condition goes away and the TS Fail condition won’t power the circuit on.

Control Mode

Purpose
Sensor setup allows user full flexibility in configuring the temperature sensors as shown in figure 3.5 above:

Setting

• Ambient On/Off Mode: Ambient sensor measures the ambient temperature. If the ambient temperature is above the setpoint temperature plus deadband, the relay output is turned off. If the ambient temperature is below the setpoint temperature, the output is turned on.
• Line Mode: The line sensor measures the line temperature. If the line temperature is above the setpoint temperature plus the deadband, the relay output is turned off. If the line temperature is below the setpoint temperature, the output is turned on.
• PASC: Ambient sensor measures the ambient temperature. The PASC algorithm auto-controls the heat output and maintains the temperature at the setpoint.

The algorithm will be derived from the following parameters:

• Setpoint: 32°F – 176°F (default 40°F)
• Minimum Expected Ambient Temperature: –40°F – 40°F (default 20°F)
• Pipe Size: 0.5″ / 1″ / >2″ (default 0.5″)
• Power Adjustment Factor: 10% – 200% (default 100%)

For more details on PASC please refer to Appendix A.

Note:
The “Power On TS Fail” feature turns the circuit On if the controlling temperature sensor fails. E.g. in line sensing control mode, the “Power On TS Fail” won’t trigger for the ambient sensor failure and vice versa.

Setpoint

Purpose
This is the temperature that the controller uses to determine whether its output switch should be on or off.

Setting/Range

• 32°F to 176°F (0°C to 80°C)
• Factory Default 40°F (4°C)

Deadband

Purpose
The deadband is a window of difference between the measured control temperature and the desired control setpoint temperature and provides the decision to turn the output off or on

Setting/Range

• 1°F to 8°F (1°C to 4°C)
• Factory Default 5°F (3°C)

Minimum Expected Ambient Temperature

Purpose
This is the minimum expected ambient temperature which will be used to calculate the duty cycle for proportional ambient sensing control mode

Setting/Range

• –40°F to 40°F (–40°C to 4°C)
• Factory Default 20°F (–7°C)

Cable Type

Purpose
Select the type of cable for the heat-tracing circuit

Pipe Diameter

Purpose
Select the pipe diameter for the heat tracing circuit

Setting/Range

• 0.5 inch, 1.0 inch, 2.5+ inch
• Factory Default 0.5 inch

Low-Temperature Alarm

Purpose
This allows the user to select the low-temperature alarm for both the sensors

Setting/Range

• –40°F to 190°F (–40°C to 88°C)
• Factory Default 35°F (2°C)

High Temperature Alarm

Purpose
This allows the user to select the low-temperature alarm for both the sensors

Setting/Range

• 32°F to 190°F (0°C to 88°C)
• Factory Default 110°F (43°C)

High Limit Cutout Temperature, Setpoint

Purpose
Set high limit cutout temperature for the selected Sensor (in the sensor set- up). This setpoint is used to turn the circuit off when the sensor reaches the high limit cutout temperature.

Setting/Range

• 32°F to 190°F (0°C to 88°C)
• Factory Default 185°F (85°C)

Temperature Alarm Filter

Purpose
Set time delay filter for temperature condition

Setting/Range

• 1 to 200 seconds
• Factory Default 10 seconds

High Ground Fault Current Alarm

Purpose
This allows the user to set the ground fault current alarm level. Exceeding this limit will trigger the alarm to indicate that a ground fault condition exists in the heating cable circuit. To protect against the risk of fire or shock, ground fault level should be set at the lowest level possible to allow normal operation of the cable.

Setting/Range

• Setting/Range
• Factory Default 20 mA
• Time delay filter is factory set as immediate

Ground Fault Trip Level (HI GF Trip)

Purpose| This allows the user to set the ground fault current trip level. Exceeding this limit will result in the output switch being latched off and the ground fault level trip alarm activated to indicate a ground fault condition.

Warning: Fire Hazard. Ground fault trip condition must no be ignored. To prevent the risk of fire, do not re-energize

---|---
Setting/ Range| heating cables until the fault is identified and corrected.

20 mA to 200 mA                  Factory Default 30 mA

General Settings Menu

Figure 3.6 General settings menu

Language
Select English or French

Country
Select USA or Canada

Date
Use the up/down arrow keys to select the year, month and day

Time
Use the up/down arrow keys to set the hour and minute

Voltage
Select appropriate voltage for the application

Select Unit of Measure
Select Imperial or Metric units

Alarm Buzzer
Select buzzer to be on or off in alarm condition; default is off

Time Format
Select 24H (24 hour) or 12H (12 hour) time format

Alarm Events

Filter Times

Error Codes
The followings are the error codes for different condition and their description.

error, provide the exact error number, cable type, cable length and the setpoint temperature.
E:6.2| INTERNAL_ERROR| Internal error – replace unit. When reporting this error, provide the exact error number, cable type, cable length and the setpoint temperature.
E:6.3| INTERNAL_ERROR| Internal error – replace unit. When reporting this error, provide the exact error number, cable type, cable length and the setpoint temperature.
E:6.4| INTERNAL_ERROR| Internal error – replace unit. When reporting this error, provide the exact error number, cable type, cable length and the setpoint temperature.
E:6.5| INTERNAL_ERROR| Internal error – replace unit. When reporting this error, provide the exact error number, cable type, cable length and the setpoint temperature.
E:6.6| INTERNAL_ERROR| Internal error – If you are using low noise, humfree contactor, replace it with the non-humfree contactor. If this does not help, then replace unit. When reporting this error, provide the exact error number, cable

type, cable length and the setpoint temperature.

E:8.1| PLAUSIBILITY_CHECK_ERROR| Plausibility of Voltage <-> Cable type selection or Control mode <-> Sensor setup

TROUBLESHOOTING

The 460 controllers may be used as an effective troubleshooting tool to pinpoint problem areas of heating cable circuits. Described below are a few of the more common problem areas, their symptoms, and parameters to check to determine the actual faulty portion of the heating cable circuit.

Symptom/Alarm Condition| Probable Cause| Corrective Action
---|---|---
Sensor failure| Sensor is not a 2-wire NTC Thermistor.| Install correct sensor.
| Damaged sensor or extension cable.| Install new sensor and/or cable.
| Incorrectly wired.| Re-install sensor connections.
Seemingly incorrect temperature| Incorrect sensor used.| Install correct sensor.
| Damaged TEMPERATURE SENSOR or connection cable.| Install new temperature sensor and/or cable.
| 460 controller not functioning correctly.| Verify correct reading input. Connect a 2 KΩ resistor across S1 or S2 terminals.

Apply power to the controller.

The indicated or displayed temperature should be about 77°F (25°C).

Unstable or bouncing temperature| Bad, damaged or incorrectly installed temperature sensor extension wire.| Wire used for extension of the temperature sensor should be two-wire. Each of the two lead wires must be of the same gauge.
| Terminal connections are not tight.| Verify tightness of connections.
| Temperature sensor or extension cable damaged.| Install new temperature sensor and/or cable
High temperature| Temperature setting too close to maintain temperature.| Increase setting.
| Flow of hot water through pipe.|
| Line Temperature sensor too close to the heating cable on pipe.| Install line temperature sensor on the opposite side of the heating cable on pipe.
| Incorrect heating cable wiring.| Verify heating cable wiring.
Low temperature| Temperature setting too close to maintain temperature.| Decrease setting.
| Heating cable not sized properly for the application.| Refer to the appropriate heating cable design guide for correct product selection.
| Damaged, wet, or missing thermal insulation.| Replace or install correct thermal insulation.
Temperature sensor failure| Incorrect or damaged field wiring.| Re-install temperature sensor connections.
| Damaged temperature sensors.| Install correct temperature sensor.
Symptom/Alarm Condition| Probable Cause| Corrective Action
---|---|---
Ground fault| Incorrect installation, wet system components or damaged cables.| Perform heating cable commissioning tests outlined in the heat cable operation manuals.
| Incorrect neutral return wiring.| Check that the heating cable circuit neutrals return to the controller and are not connected directly to the distribution panel.
| Setting too close to normal leakage current.

Warning: Fire Hazard. ignored. To prevent the risk cables until the fault is iden

| Ground fault level should be set at the lowest level possible, but high enough to allow normal operation of the cable.

Ground fault trip must not be of fire, do not re-energize heating tified and corrected.

Low current| Low or no source voltage.| Verify correct power distribution.
| Damaged or inoperative heating cable.| Repair or replace heating cable.
| Open connection—wiring problem.| Verify correct power distribution wiring.
| Contactor failed open.| Replace or repair controller.
Switch failure| Output switch has failed “closed”.| Replace or repair controller.
Seeing 3 dots, one by one, on the screen| Pushing the screen for 30 seconds causes the controller to enter screen calibration mode (it can be triggered also from the service menu)| All 3 dots have to be pressed one by one for calibration before jumping back to the main screen

APPENDIX

A: PROPORTIONAL AMBIENT SENSING CONTROL (PASC)

PASC takes advantage of the fact that the heat loss from a pipe is proportional to the temperature difference between the pipe and the ambient air. This is true regardless of heating cable, insulation type, or pipe size. Once the heat tracing and insulation on a pipe have been designed to balance heat input with heat loss and maintain a particular temperature, the main variable in controlling the pipe temperature becomes the ambient air temperature.

The 460 controller has a control algorithm that uses the measured ambient temperature, desired maintained temperature, minimum ambient temperature assumption used during design, and size of the smallest pipe diameter to calculate how long the heating cable should be on or off to maintain a near- constant pipe temperature. The power to the heat tracing is proportioned based on the ambient temperature. If the ambient temperature is at or below the “minimum design ambient plus 3°F” the heating cable will be on 100%. If the measured ambient is at or above the “maintain temperature –3°F” the heating cable will be on 0%. For any measured ambient between “minimum design ambient” and “maintain temperature,” the heating cable will be on a percentage of the time equal to (maintain temperature – measured ambient)/(maintain temperature – minimum design temperature).

The following parameters are used in calculating the duty cycle in PASC:

North America
Tel +1.800.545.6258
Fax +1.800.527.5703
thermal.info@nVent.com.

nVent.com/RAYCHEM

©2022 nVent. All nVent marks and logos are owned or licensed by nVent Services GmbH or its affiliates. All other trademarks are the property of their respective owners. nVent reserves the right to change specifications without notice.

RAYCHEM-IM-H60791-460Controller-EN-2210.

References

• Electrical Heat Tracing | Heat Tracing | nVent RAYCHEM

Read User Manual Online (PDF format)

Read User Manual Online (PDF format)  >>

Download This Manual (PDF format)

Download this manual  >>