1038 Series
Controllers
PRODUCT OVERVIEW
The O’Brien 1038 is a compact, full-featured, touch
screen based, single-point heat-tracing controller. It
provides control and monitoring of TRACEPAK and
STACKPAK bundles 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 O’Brien tubing
bundles.
The 1038 controller is standard with a solid-state
relay (SSR) for use in nonhazardous and Class I Div.
2 / Zone 2 hazardous locations. The controller is
protected by a Fiber reinforced plastic or Stainless
steel enclosure, both with front window (-FW or
-SW). Multiple communication ports allow flexible
connectivity for remote monitoring, configuration,
and ease of integration with supervisor software or a
Distributed Control System (DCS).
Control
The 1038 measures temperatures of up to three
directly-connected temperature sensors. The
controller also supports 4-20mA inputs, allowing the
use of external temperature sensor converters with
thermocouples or other sensor types. It provides
line sensing, ambient sensing, Proportional Ambient
Sensing Control (PASC), and power limiting modes.
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monitoring
To ensure system integrity a full set of parameters are
measured, including ground fault, temperature, current
and voltage. The 1038 can be set to periodically check
the tubing bundle for faults, alerting maintenance
personnel of a problem which eliminates costly manual
maintenance checks.
A programmable dry contact alarm relay is included
for local or remote alarm annunciation
ground-fault protection
Where electrical codes require ground-fault equipment
protection on heat-tracing circuits the 1038 controllers
provide ground-fault sensing with alarm, and trip
functionality. Internal self-tests are automated,
eliminating the need for manual testing. TRACEPAK
and STACKPAK installations equipped with the 1038
do not require additional ground-fault equipment,
which simplifys installation and reduces cost.
installation
The 1038 comes ready to install in a NEMA 4X/IP6x-
rated FRP or stainless steel enclosure and is approved
for both indoor and outdoor locations. Wiring is as
simple as connecting the incoming and outgoing
power wiring (up to 277 Vac) and temperature sensors
as needed for the application.
The 1038 has an intuitive user interface that making
it easy to use and program. Alarm conditions and
programming settings are easy to read and interpret
on the color touch screen. All settings are stored in
non‑volatile memory in the event of a power failure
communication
The 1038 supports both Modbus RTU and Modbus/
TCP protocols and is equipped with RS485 and
Ethernet ports for connection to a distributed control
system (DCS).
The controller may be networked to a host PC running
Windows based supervisor software for central
programming, status review, and alarm annunciation.
General
Area of use Nonhazardous and Class I, Division 2/Zone 2 hazardous locations
Approvals Class I, Division 2, Group A,B,C,D T4 Type 4X
Class I, Zone 2, AEx nA nC [ia Ga] IIC T4 Gc
Ex ec nC [ia Ga] IIC T4 Gc
E4905419 IP64 (FW) IP66 (SW)
Proc. Cont. Eq.
Use in Haz. Loc.
(Associated Apparatus)
DEMKO 18 ATEX 2091 X
IECEx UL 18 .0098X
II 3 (1)G Ex ec nC [ia Ga] IIC T4 Gc 1180
IP64 (FW) IP66 (SW)
Supply voltage 100 Vac to 277 Vac, +/–10 %, 50/60 Hz
Common supply for controller and tubing bundle
Power consumption <24W
Enclosure
Protection FRP: NEMA 4X/IP64 SS: NEMA 4X/IP66
Materials FRP or 304 Stainless Steel
Ambient operating temperature range –40°F to 140°F (–40°C to 60°C)
Ambient storage temperature range –40°F to 185°F (–40°C to 85°C)
Relative humidity 0% to 90%, noncondensing
Maximum altitude 2,000 m (6,562 ft)

Control
Relay type Double-pole, solid-state, normally open
Voltage, maximum 277 Vac nominal, 50/60 Hz
Current, maximum 32A @ 40°C derated to 24 A @ 50°C further derated to 16A @ 60°C
Control algorithms Line sensing on/off, proportional, PASC, always on, always off
Control range –328°F to 1292°F (–200°C to 700°C)

Typical Enclosure Dimensions & Connections

1038 FRP 1038 SS

1038 1038

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Monitoring
Temperature Low alarm range -328ºF to 1292ºF (-200ºC to 700ºC) or OFF
High alarm range -328ºF to 1292ºF (-200ºC to 700ºC) or OFF
Ground fault Alarm range 10 mA to 500 mA or OFF
Trip range 10 mA to 500 mA or OFF
Current Low alarm range 0.1 Amps to 100 Amps or OFF
High alarm range 0.1 Amps to 100 Amps or OFF
Power limit 8 W to 30 kW
Voltage Low alarm range 80 V to 300 V or OFF
High alarm range 80 V to 300 V or OFF
Resistance Low resistance range 1% to 100% of deviation from nominal
High resistance range 1% to 250% of deviation from nominal
Autocycle Diagnostic test interval adjustable from 1 to 750 hours

Temperature Sensor Inputs

Quantity 3 - each input can be individualy set to one of the types listed belowt
Types 100 W platinum RTD, 3-wire, a = 0.00385 ohms/ohm/ºC
-328ºF to 1292ºF (-200ºC to 700ºC) +/-1ºC
Can be extended with a 3-conductor shielded cable of 20 W maximum per conductor
Thermocouple, requires optional 1038SC-002 signal converter in FRP enclosure.

Alarm Outputs
AC relay Form-C dry contact: 100 VAC to 277 VAC, 3A , 50/60Hz

Programming and Configuration

Method Touch screen display
Units ºF or ºC
Normal display Sensor temperature, control temperature, heater current, voltage, power, alarm status
LEDs Status, heater on, alarm conditions, receive / transmit data
Memory Nonvolatile, restored after power loss, checksum data checking
Stored parameters (measured) Minimum and maximum process temperature, maximum ground-fault current, minimum
and maximum voltage, maximum heater current, power accumulator, contactor cycle count,
total time in use, heater on time
Alarm conditions Low / high temperature, low / high current, low / high voltage, low / high resistance,
ground-fault alarm / trip, RTD failure, loss of programmed values, EMR or SSR failure,
equipment protection trip, attached device alarm, contactor lifetime exceeded
RTD failure, loss of programmed values, or SSR failure
Alarm modes Normal (solid on), flash (on & off), toggle (re-ring new alarms)
Equipment protection Ground fault trip, low / high temperature limit, Soft-Start features, (tube bundle heat trace
output limiting, SSR overcurrent protection, circuit breaker nuisance trip prevention)
Network Automatic network configuration with DHCP, or static IP configuration
Other English, French, German, Spanish, Russian
Password protection, text tags / identifiers for controller and temperature sensors

Connection Terminals
Power supply input Screw terminals, 24 – 5 AWG (0.2 – 16.8mm2)
Heating cable output Screw terminals, 24 – 5 AWG (0.2 – 16.8mm2)
Ground Three box lugs, 14 – 2 AWG (2.0 – 33.6 mm2)
Sensor/Other Terminals Cage clamp terminals, 28 – 12 AWG (0.08 – 3.3 mm2)

Communications
RS-485 Modbus RTU: 2-wire RS-485 shielded twisted pair, maximum length 4,000 ft (1,200 m)
Data Rate: 9600, 19.2k,38.4k,57.6k baud, none, even or odd parity, 0,1 or 2 stop bits
Ethernet Modbus/TCP, DHCP, 10/100 Base-T, maximum length 328 ft (100 m)
Data Rate: 10 or 100 MB/s
Connections: Shielded 8-pin RJ-45

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Ordering Details

Description Part # Weight lb (kg)

1038 Controller in an 8” X 10” FRP enclosure with window. 10380-002 14.6 (6.6)
2-pole 32A 277V SSR. Controls a single circuit with a 2-pole solid-state relay

1038 Controller in an 8” X 10” 304SS enclosure with window. 10380-004 19.0 (8.6)
2-pole 32A 277V SSR. Controls a single circuit with a 2-pole solid-state relay

1038SC-002 T/C Signal Converter in 7”H X 4.5”W X 3.5”D FRP enclosure 10380SC-004 8.0 (3.6)
Required for factory installed or SensorTube bundles with J or K thermocouples

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OB-DAT-1038-20R1