Bartec PBTC-200, Operation And Installation Manual

Page 1: ...Translation of the origin Operating Instructions keep for future reference Operation and Installation Manual Junction Box with Electronic Thermostat Module PBTC 200 27 54C2 4412 E210 ...

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Page 3: ...12 6 2 Operating Data 13 6 3 Accessories 15 6 4 Spare parts 16 7 Functional Description 17 8 Transport 18 9 Installation and Assembly 19 Required Tools Equipment 19 Safety Instructions 19 Installing the Heating Cable 19 Pre assembling the Mounting Stand 20 Preparing the Heating Cable 21 Installing the Mounting Stand 25 Connecting the Heating Cable and Power Supply 27 Mounting the Resistance Temper...

Page 4: ...onic thermostat module junction box so that it is always available to all personnel involved Read these instructions carefully and completely before working with the product The contents of the manual must be read and understood thoroughly before installing commissioning using or maintaining the product This manual must be passed on to future owners or operators if necessary The safety notes and i...

Page 5: ...rred to in these operating instructions as junction box with thermostat module In this case it refers to the connection housing with PBTC electronic thermostat module A Pt100 Resistance Temperature Device is connected to the connection housing with the thermostat module In this document it may only be referred to as a Resistance Temperature Device In this case the Pt100 Resistance Temperature Devi...

Page 6: ...with electrical systems the relevant installation and operating conditions e g according to ATEX Directive 2014 34 EU EN 60079 0 EN 60079 14 EN 60079 17 EN 60079 30 2 and any other relevant national standards must be observed Information on the type plate the EU type examination certificate must be observed Technical data on the thermostat module and in the operating instructions must be observed ...

Page 7: ...th thermostat module Non compliance with the approval and marking of the heating system The operation of the Electronic Thermostat Module is also considered as misuse Without properly designed overcurrent protection device With not approved heating cable or more than one heating cable Outside defined maintenance and ambient temperature With unsealed or unsuitable CAK seal no replacement of the CAK...

Page 8: ...ems in hazardous areas The operation together with a Resistance Temperature Device Pt100 and BARTEC heating cables of the type PSB MSB HSB or HTSB is certified The thermostat module is a temperature controller type ETM 25Ex C and meets the requirements of IEE E IEC EN 60079 30 1 The LED status display shows the current operating status of the device by means of color and flash codes The connection...

Page 9: ...ing from alternations errors or misprints shall be allowed Page 7 45 4 Scope of Delivery Product PBTC 200 E 1 x Silicone pants 1 x End seal 1 x Green yellow tube for grounding braid 2 x Trace heater grommet 1 x Silicone adhesive 1 x Cover for junction box incl 4 fixing screws 1 x Junction box with thermostat module and Resistance Temperature Device Pt100 M ...

Page 10: ...e mounting stand incl sealing ring and lock nut 1 x Base unit of the mounting stand 5 Device Description 5 1 Thermostat module in junction box Illustration with cover for junction box Nr Description 1 Junction box with thermostat module 2 LED status indication 3 Top unit of the mounting stand 4 Base unit of the mounting stand 5 Resistance thermometer Pt100 6 Cable gland Resistance thermometer Pt10...

Page 11: ... notice No claims for damage arising from alternations errors or misprints shall be allowed Page 9 45 Illustration without cover for junction box Nr Description 1 Electronic thermostat module ETM 25Ex C 2 Connection cable Resistance Temperature Device Pt100 3 Lock nut 4 Resistance thermometer Pt100 5 DIN rail TS35 3 2 5 4 1 ...

Page 12: ...g switch 10 s Adjustment of the temperature setpoint Digit for 10s value 3 Rotary coding switch 1 s Adjustment of the temperature setpoint Digit for for 1 value 4 LED Status indication Display of the operating status as color and blink code 5 Selector switch F C Switch Temperature unit 6 Pt100 Connection terminal resistance de vice Pt100 7 LH Connection load el Trace heating 8 L Power connection P...

Page 13: ...RNING Temperature at the Re sistance Temperature De vice Pt100 outside the set temperature warning thresholds Device tempera ture of the ther mostat module exceeds the de fined warning limits 80 lifetime of the thermostat module reached plan and prepare replacement of the thermostat module Contact problem at the Re sistance Tem perature Device Pt100 or temper ature rise at the Resistance Tem perat...

Page 14: ...anual PBTC 200 21 54C3 7D0001 04 2021 EHT 441168 Notice Technical data subject to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 12 45 6 Technical Data 6 1 Dimensions ...

Page 15: ... Measuring Range Resistance Tempera ture Device Pt100 50 C to 200 C max operating temperature 200 C Length of connecting lead Re sistance Temperature Device Pt100 1 5 m Measurement accuracy 0 5 of the entire measuring range Control method On off control Switching capacity of the load contact See table Maximum heating circuit length max heating cable length Temperature adjustment by rotary coding s...

Page 16: ...F 07 584B 715F 07 584B 730F 07 584B 745F 07 584B 760F 07 584C 715F 07 584C 730F 07 584C 745F 07 584C 760F 07 584C 775F 07 584C 790F Order no 3PSB2 5PSB2 8PSB2 10PSB2 3MSB2 5MSB2 10MSB2 15MSB2 20MSB2 5HSB 2 10HSB 2 15HSB 2 20HSB 2 5HTSB2 CT 10HTSB2 CT 15HTSB2 CT 20HTSB2 CT 25HTSB2 CT 30HTSB2 CT Heat output W m 10 15 25 33 10 15 30 45 60 15 30 45 60 15 30 45 60 75 90 Start up temperature C max ambie...

Page 17: ...ature 100 C Catalog No PT 164 Order No 100706 Part No 02 5500 0005 Tipp Anhand der folgenden Tabelle können Sie die für Ihre Installation benötigte Anzahl an Klebeband Rollen abschätzen Pipe diameter DN inch DN8 1 4 DN15 1 2 DN20 3 4 DN25 1 DN32 1 1 4 DN40 1 1 2 DN50 2 DN65 2 1 2 DN80 3 DN100 4 DN150 6 DN200 8 DN250 10 DN300 12 DN350 14 DN400 16 DN450 18 DN500 20 DN600 24 Required no of tape rolls...

Page 18: ...lete list of kit contents and approvals see data sheet Catalog No ELS 200 Order No 430293 Part No 27 54E2 4012 A000 Resistance Temperature Device Pt100 Enables measurement of the process temper ature in the measuring range 50 C to 200 C protection class IP65 See data sheet for further technical data Length 1 5 m Catalog No Order No 122776 Part No 03 9040 0006 Length 5 0 m Catalog No Order No 12862...

Page 19: ...ce Pt100 falls below the adjusted temperature set point Toggle switch C F is used to switch the temperature unit 3 rotary coding switches are used to set the temperature setpoint The connected Resistance Temperature Device Pt100 measures the actual temperature and ensures the temperature control func tion In case of a malfunction of the thermostat module or the Resistance Temperature Device Pt100 ...

Page 20: ...ful transport of the junction box with thermostat module must be ensured NOTICE Plant damage possible due to improper transport Transport connection housing with thermostat module properly Transport connection housing with thermostat module only in original packaging Protect the connection housing with thermostat module from damage e g due to impacts moisture contamination WARNING Risk of fire and...

Page 21: ...nt protection device Only one heating cable per junction box Only connect heating cable types approved for this purpose Observe maximum permissible heating circuit length Observe Design Guide for trace heating systems Observe the project planning documentation of the trace heating system Installing the Heating Cable Install the heating cable in a straight line along the pipe if possible If possibl...

Page 22: ...the heating cable through the lower part of the mount ing stand Do not fix the mounting stand on the pipe yet Slide a trace heater grommet onto the trace heater and into the seal seat Slide the other trace heater grommet into the free seal seat Make sure that the trace heater stands out approximately 25 cm This makes cable preparation easier Ensure that all heating cable feed throughs of the lower...

Page 23: ...htly tighten the 4 fixing screws using a crosshead screwdriver Do not tighten them fully yet to allow the trace heaters to be moved Preparing the Heating Cable Remove 145 mm of the outer jacket on the end of the trace heater Push the grounding braid back Use the screwdriver to form an eyelet Be careful not to damage the internal insulation jacket Bend the trace heater and pull the heating element ...

Page 24: ...for damage arising from alternations errors or misprints shall be allowed Page 22 45 Slide the green yellow tube onto the twisted grounding braid Remove 115 mm of the internal insulation jacket Take care not to damage the bus wires Carefully make an incision into the edges of the heating element Take care not to damage the bus wires 11 12 13 ...

Page 25: ...s wires while holding the heating element CAUTION Risk of malfunction of the heating system Before you continue make sure that the bus wires are intact and not nicked or damaged Remove any remaining heating element that sticks to the bus wires Twist the bus wires Remove the remaining heating element Take care not to damage the bus wires Carefully cut in a triangle 5 mm between the bus wires Take c...

Page 26: ...TION The silicone adhesive may cause irritation to skin and eyes Avoid eye contact Avoid repeated or prolonged skin contact In case of contact with eyes rinse with water and seek medical advice Put silicone adhesive onto the exposed heating ele ment and insulation jacket Thread the silicone pants onto the bus wires Thread the bus wires into the silicone pants You might add further silicone adhesiv...

Page 27: ...ms for damage arising from alternations errors or misprints shall be allowed Page 25 45 Installing the Mounting Stand Pull back the trace heaters For easy cable connection it is enough when the silicone pants stands out of the mounting stand Now tighten the 4 fixing screws of the top unit of the mounting stand using a 4 mm hex wrench 21 22 ...

Page 28: ...C3 7D0001 04 2021 EHT 441168 Notice Technical data subject to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 26 45 Install the pipe straps and tighten them firmly using a screwdriver 23 ...

Page 29: ...rom alternations errors or misprints shall be allowed Page 27 45 Connecting the Heating Cable and Power Supply Screw the lock nut off the upper part of the mounting foot Insert heating cable into junction box Position junction box on the upper part of the mounting foot Screw the lock nut onto the thread of the mounting foot tighten the lock nut with a wrench 24 ...

Page 30: ...hnical data subject to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 28 45 Unscrew and remove the screw cap from the cable gland body of the cable bushing Use adjustable spanner Slide the screw cap onto the power cable 25 26 ...

Page 31: ...l data subject to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 29 45 Feed the mains cable through the cable gland body and junction box Tighten gland cap with 2 Nm tightening torque Using a torque wrench combination wrench 27 28 ...

Page 32: ... to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 30 45 Connect the wires to the thermostat module according to the wiring diagram Open the catch of the connection terminals with a slotted screwdriver 3 5 mm and connect the cable 29 PE N L H L ...

Page 33: ...rs or misprints shall be allowed Page 31 45 Set temperature unit C or F on the changeover switch Set the temperature setpoint at the rotary coding switch enter the 100 10 1 digit values see the minimum maximum value from the temperature control range in section 6 2 Operating Data Use a 2 5 mm slotted screwdriver Mount junction box cover tighten screws with slotted screwdriver 30 31 ...

Page 34: ...shock from heating cable Risk of injury due to electric voltage Mount the end seal on the open end of the heating ca ble commissioning of the junction box is only permit ted with the end seal mounted Cut the trace heater off straight Remove the outer jacket on 20 mm Remove the exposed grounding braid Make sure that the insulation jacket is not damaged Cut in a triangle 5 mm between the bus wires C...

Page 35: ...45 NOTICE Manufacturer recommendation Measure insulation resistance before proceeding further Make sure that it is free of any faults eliminate faults if necessary Procedure for insulation resistance measurement in Chapter 10 Commissioning Applying the Pipe Insulation Apply the pipe insulation according to the manufacturer s installation instructions Apply an electrical warning label every 3 m on ...

Page 36: ...tallation of the trace heater on the construction site Acceptance test after installation of the heating circuit and before installation of the thermal insulation Final inspection immediately after completion of work on the thermal insulation Upon commissioning Before switching on the installation The insulation resistance measurement serves as a test method to determine whether the heating cable ...

Page 37: ...ply Check for error indications by means of LED status display eliminate error if necessary If the thermostat module is free of faults i e if no LED status display shows error messages a function test is recommendable This can be carried out by setting a higher and a lower temperature set point in comparison to the actual temperature at the Resistance Temperature Device Pt100 This checks whether t...

Page 38: ... and ambient temperatures must be specified The acceptance report is available on www bartec com Each trace heating system may only be put into operation if The acceptance tests for each heating circuit have been carried out and the acceptance reports are available The correct condition of the trace heating has been confirmed The thermal insulation has been completely installed and is in a dry sta...

Page 39: ...ed in the junction box operates automatically and switches the connected heating load on or off If error messages occur they can be indicated by the flashing codes of the LED status display Error message on the thermostat module Determine and eliminate the fault with the aid of the LED status display The thermostat module automatically identifies the fault free status and continues to operate inde...

Page 40: ...fter a heating cable has been removed from the base of the junction box a new suitable CAK kit must be used when installing a new heating cable Check the thermostat module connection cables and Resistance Temperature Device for damage and to ensure that they are installed in such a way that they cannot be mechanically damaged Wipe off any dirt with a damp cloth do not use cleaning agents or solven...

Page 41: ... in accordance with the storage conditions It can be electrically and mechanically uninstalled or left in the assembled state In the event of damage malfunction or when 100 of its service life has been reached the thermostat module must be replaced To do this it must be switched off the connecting cables disconnected and dismantled It must not be operated any further or be intended for operation a...

Page 42: ...into operation depend on the state of disassembly the steps taken when the unit is taken out of operation and the state of the junction box with thermostat module It must be ensured that it is in a safe and operational condition Before the junction box with thermostat module is put into operation again after it has been taken out of service the entire operating instructions must be observed especi...

Page 43: ...t be disposed of properly in accordance with the legal regulations It consists mainly of glass fiber reinforced plastic metal and electrical components The connection housing with thermostat module must be dismantled into its components and fed back into the recycling system according to its components Disposal The device must be disposed of properly in accordance with the local laws and regulatio...

Page 44: ... the end seal according to the installation instructions Identify the cause and remedy the fault e g ensure that trace heater bus wires are not twisted together Dry the components For junction boxes be sure that the cable gland is correctly installed and sealing properly Ground fault protec tion is disengaged Trace heater damaged Moisture in the components Ground fault protection defective Replace...

Page 45: ...HT 441168 Notice Technical data subject to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 43 45 17 Acceptance and Test Report The acceptance test report is available on the company homepage www bartec com ...

Page 46: ... will at its sole discretion repair the product replace the product or refund the purchase price paid for the product This warranty gives you specific legal rights and you may also have other rights which vary by country state or province Except as specifically pro vided otherwise in this limited product warranty the BARTEC Group General Terms and Conditions shall apply General terms and condition...

Page 47: ...anual PBTC 200 21 54C3 7D0001 04 2021 EHT 441168 Notice Technical data subject to change without notice No claims for damage arising from alternations errors or misprints shall be allowed Page 45 45 19 EU Declaration of Conformity ...

Page 48: ...006 MYTISCHI MOSCOW REGION Russia Tel Fax 7 495 249 0542 mail bartec russia ru www bartec russia ru BARTEC MIDDLE EAST BARTEC Middle East HB 01 Near Round About 8 Jebel Ali Free Zone P O Box 17830 DUBAI United Arab Emirates Tel 971 4 8876 162 Fax 971 4 8876 182 bartec bartec ae www bartec com BARTEC SAUDI ARABIA Bartec MIDDLE EAST LLC 31952 AL KHOBER P O Box 3685 Kingdom of Saudi Arabia Tel 966 13...