Raychem Zone 2 Control, Monitoring, and Switching Systems
Brand: Raychem
Product Overview
The Raychem Zone 2 control, monitoring, and switching systems are configurable electric heat tracing (EHT) control cabinets certified for ATEX and IECEx. The enclosures and all components are approved for Zone 2, including fuses, Raychem controllers, and solid-state relays used for switching heat tracing circuits. These systems comply with IEC/EN 61439 and 60079 standards, are designed, manufactured, tested, and certified for Zone 2 applications.
The control, monitoring, and power distribution solution can consist of a combination of different cabinets mounted on a frame. The enclosures on the frame can be configured differently for:
- Control and Monitoring
- Power Distribution
- Combined Control, Monitoring, and Power Distribution in a single enclosure
Each cabinet on the frame has its own approval and is configured separately via a configuration string, as described in the datasheet. The following table shows the maximum configuration possible in an enclosure. The detailed content shall be defined via the configuration string, depending on circuit loads and ambient temperatures.
| Enclosure Type (cm) | Controller/Max. Heating Circuits (NGC-40) | Controller/Max. Heating Circuits (NGC-30) | Controller/Max. Heating Circuits (Elexant 4020i) |
|---|---|---|---|
| Regelung (60 x 60 x 30) | 6 Heating Circuits | 5 Heating Circuits | - |
| Regelung (107 x 93 x 32) | 18 Heating Circuits | 20 Heating Circuits | - |
| Regelung & Leistungsschrank (75 x 50 x 21) | 6 Heating Circuits, 6 RCBO 32A, 30mA | - | 2 Heating Circuits |
| Regelung & Leistungsschrank (107 x 93 x 32) | 18 RCBO's 32A, 30mA | - | - |
| Stromverteilung (107 x 93 x 32) | - | - | - |
Product Specifications
Zone 2 Systems
- Protection Rating: IP66
- Min. Ambient Temperature (Control Cabinet) - Operation: -55°C
- Ambient Temperature (Storage Control Cabinet): -55°C to +70°C
- Min. Ambient Temperature (Power Cabinet) - Operation: -20°C
- Ambient Temperature (Storage Power Cabinet): -20°C to +70°C
- Max. Altitude: 2000 m
- Humidity: 5-90% non-condensing
- Controller Types: NGC-40 (various modules), NGC-30 (various modules), Elexant 4020i (all versions). Other electronics available upon request and verification.
- Flange Entry: Systems can be supplied with pre-drilled holes and flanges upon order. Special safety instructions must be followed if holes need to be drilled on-site.
Configuration String
The configuration for the Zone 2 control cabinet is represented by a configuration string, where parameters define the cabinet's content. Comments can be added to the string or discussed with the field service representative. The following table lists all parameters and provides examples:
Configuration String Parameters and Values
| Parameter | Values |
|---|---|
| Enclosure Type | NGC30: NGC-30, NGC40: NGC-40, E4020i: Elexant 4020i |
| Electrical Norm | E: IEC |
| Area Class | SICHERHEIT: Safety Area, ZONE2: Zone 2 |
| Enclosure Size (No. of Circuits) | 0-40 |
| Housing | SS: Stainless Steel (IP66), SW: Stainless Steel with Window (IP66), AL: Aluminum |
| Control Voltage (L-N) | 230: 230 V AC, 400: 400 V AC |
| Power Distribution | PDY: Power distribution included, PDN: Power distribution not included |
| MCB/Isolator | LS180: 180A Isolator, MCB160: 160A MCCB, 10kA |
| Heated | HTN: Not heated, HTY: Patented cabinet heating |
| Control | CNTRL: Control, PD: Power Cabinet, PD/CNTRL: Power Cabinet and Control |
| Number of Circuits | 0-40 |
| Circuit Breaker Type | RCBO/2P20C: 2-pole, 20A Type C RCD, RCBO/2P25C: 2-pole, 25A Type C RCD, RCBO/2P32C: 2-pole, 32A Type C RCD |
| Module Type | 4020iMOD, 4020iModIS, 4020iModISLIM, 4020iMod3P, 4020iMod3PIS, 4020iModISPROF, 4020iModISLIMPRF, 4020iMod3PISPRF, NGC40HTC, NGC40-HTC3, NGC40-IO, NGC30CRM, NGC30-CRMS, NGC20CE, NGC-20CLE, NGC-40SLIM, NGC30CTM, NGC30CVM |
| Additional Module | (Various NGC and Elexant module codes listed in the PDF) |
| Pole | 1, 2, 3 |
| Phase Selection | LN, LL, L1L2L3, L1L2L3N |
| Relay & Rating Type | SS3EX (32A 277V AC, 6mm²), SS3ZEX (32A 277V AC, 6mm², low-smoke halogen-free), SS3LEX (32A 277V AC, 10mm²), SS3LZEX (32A 277V AC, 10mm², low-smoke halogen-free), SS3REX (32A 277V AC, high inrush, 6mm²), SS3RZEX (32A 277V AC, high inrush, 6mm², low-smoke halogen-free), SS3RLEX (32A 277V AC, high inrush, 10mm²), SS3RLZEX (32A 277V AC, high inrush, 10mm², low-smoke halogen-free), SSH3EX (32A 690V AC, 6mm²), SSH3ZEX (32A 690V AC, 6mm², low-smoke halogen-free), SSH3LEX (32A 690V AC, 10mm²), SSH3LZEX (32A 690V AC, 10mm², low-smoke halogen-free), SSH6LEX (63A 690V AC, 10mm²), SSH6LZEX (63A 690V AC, 10mm², low-smoke halogen-free). Heated versions: 3SSR-SS3, 3SSR-SS3R, 3SSR-SSH3. |
| Frame | Yes/No |
| Transformer | Yes/No |
| General Options | T1500 (TOUCH 1500-EX), UIT (NGC-UIT3-EX), W800 (Wireless 868 MHz), W2400 (Wireless 2.4 GHz), Ant (Omnidirectional antenna), AL (Alarm Lights), AR (Alarm Relays), RMM3, RMM2-DI. |
Examples of configuration strings are provided in the original document, detailing specific setups for NGC-40 systems.
Controller Details
Raychem NGC-40
The Raychem NGC-40 is an electronic multi-channel system for regulating heat tracing applications, used for process temperature maintenance and freeze protection. Its innovative modular design allows for flexible system configuration to meet individual project requirements. For maximum reliability, the NGC-40 uses a single controller module for each heating circuit. The NGC-40 system can be used with solid-state relays for single-phase and three-phase heating circuits up to 63 Amperes at 690 VAC. NGC-40 controller modules include ground fault measurements and single-phase and three-phase line current measurements. The temperature safety limiter can be used in conjunction with Ex-approved contactors for applications with controller limitation in Zone 1 (with control system in Zone 2).
Temperature Inputs: Each I/O module supports up to four additional temperature sensor inputs. Up to eight temperature sensors can be connected to each field-installed RMM3 module. Up to 16 RMM3 modules can be networked via RS-485, providing up to 128 (8x16) temperature sensor inputs. This allows multiple RMM3 modules to be connected to the NGC-40 via a single cable, significantly reducing wiring costs for temperature sensors.
Digital Inputs: The NGC-40 system can be expanded with the RMM2-DI digital input module, increasing the capability to monitor field devices such as circuit breakers and switches.
Communication: The NGC-40 supports Industry 4.0 and the Internet of Things (IoT) by offering a flexible Modbus card, enabling easy integration of the TOUCH 1500 interface into external control systems. The NGC-40 system supports multiple communication ports for connecting external devices via serial connection (RS-485 and RS-232) or Ethernet network. All communication with the NGC-40 system is managed through the NGC-40-BRIDGE module, which acts as the central router for the system. It connects the control cabinet's control modules, I/O modules, the Raychem TOUCH 1500 touchscreen, and RMM3 modules, as well as downstream devices like Raychem Supervisor.
Raychem NGC-30
The Raychem NGC-30 is an electronic multi-channel system for regulating heat tracing applications, used for process temperature maintenance and freeze protection. The NGC-30 controller can process temperature inputs from numerous sources: hardwired to CRM(S) modules mounted on the control panel, or from remote monitoring modules (RMM3). The NGC-30 for Zone 2 applications is equipped with a carrier module for solid-state relays (CRMS), rated for up to 63 Amp at 690 VAC. Up to four Pt100 temperature sensor inputs per heating circuit allow for numerous combinations for temperature control, monitoring, and alarming. The controller can be monitored and configured both locally and remotely via the unit's interface (NGC-UIT3-EX) or Supervisor software.
Raychem Elexant 4020i
The Raychem Elexant 4020i is a compact, full-featured, touch screen based, single-point heat-tracing controller. It provides control and monitoring of Electric Heat-Tracing (EHT) circuits for both freeze protection and process temperature maintenance. This controller can monitor and alarm on high and low temperature, high and low current, ground-fault levels, voltage, and supports a host of additional features to offer the utmost in control and monitoring of EHT. The Elexant 4020i controller provides three output types: a line powered relay for driving contactors, a DC output for driving solid-state relays (SSRs), and a 0-10 V analog output for driving variable output power modules. Multiple communication ports allow flexible connectivity for remote monitoring, configuration, and ease of integration with Supervisor software, TOUCH 1500-EX, or a Process Control System.
Related Components
Solid-State Relay (SSR) Modules
The Zone 2 approved solid-state relay modules (SSRs) are available in various versions and can be used with all the controller products mentioned above. They are mounted on the outside of the control cabinet to allow for good heat exchange, keeping heat away from the inside of the cabinet. The heated SSR module consists of three solid-state relays / SSRs mounted together on a heatsink. The exact specification of the SSR (voltage, current, wiring, and connection cross-sections) is determined during the configuration of the control cabinet. The minimum ambient temperature for the operation of the heated SSRs is -55°C.
Elexant 9200i Wireless
Each system can optionally be equipped with wireless Elexant 9200i wireless modules. The wireless modules enable wireless communication between the Zone 2 systems and the network interfaces, such as TOUCH 1500-EX, UIT3-EX, and/or Supervisor. Wireless modules using 868 MHz and 2.4 GHz are available and support point-to-point, star, line, and mesh network topologies. Security is ensured through the use of the 128-bit Advanced Encryption Standard (AES). Reliability is enhanced by the network's self-healing capability and auto-negotiation of alternative paths in case of communication loss. Antennas can be installed on the control cabinet, or antenna kits are available for remote installation to improve range. Further information is available in the specifications for Elexant 9200i.
Approvals
System: For use in normal and hazardous areas, Zone 2 (Gas).
Temperature Classification: The temperature classification depends on the panel configuration.
Product Certification: CE, IECEx. For further details on product certifications, approvals, and conditions for safe use, please refer to the installation manual available at chemelex.com.
NGC-30 / NGC-40 / Elexant 4020i: For use in normal and Ex-hazardous areas of Zone 2 (Gas).
Temperature Class: NGC-40: T4, NGC-30: T5, Elexant 4020i: T4.
Product Certification: CE, IECEx. For further details on product certifications, approvals, and conditions for safe use, please refer to the installation manual available at chemelex.com.
Ordering Information
The Zone 2 systems offer flexible configurations; the following elements are optionally available:
| Article | Compatibility |
|---|---|
| TOUCH 1500-EX | NGC-40, Elexant 4010i / 4020i, (field mounted) NGC-20 |
| NGC-UIT3-EX | NGC-30, (field mounted) NGC-20 |
| Alarm Lights | All controllers and power distribution units |
| Alarm Relays | All controllers and power distribution units |
| RMM3 | RMM3 Remote monitoring module for temperature inputs |
| RMM2-DI | Remote monitoring module with digital inputs |
Contact Information:
Germany: Tel 0800 181 82 05, SalesDE@chemelex.com
Austria: Tel 0800 29 74 10, SalesAT@chemelex.com
Switzerland / Suisse: Tel +41 (41) 766 30 80, Fax +41 (41) 766 30 81, infoCH@chemelex.com
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