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MASTER

TRACE

MS-2102

OPERATOR’S MANUAL

HEAT TRACING CONTROL

Summary of Contents for MASTERTRACE MS-2102

Page 1: ...MASTERTRACE MS 2102 OPERATOR S MANUAL HEAT TRACING CONTROL ...

Page 2: ...Alarm Wiring 2 4 3 Getting Started 3 1 Introduction 3 1 Selecting the Heater 3 1 Enabling the Heater 3 1 Entering Setpoints 3 1 Testing Heater Alarms 3 3 Monitoring System Status 3 4 4 Front Panel Operation 4 1 Overview 4 1 Operating the Keypad 4 1 Status Lights 4 1 Alphanumeric Display 4 1 Keypad 4 1 Display Contrast 4 1 Heater Numbering 4 1 Startup Messages 4 3 Status Messages 4 3 Flash Messsage...

Page 3: ... 1 Physical Layer 8 1 Modbus Protocol 8 1 Modbus Memory Map 8 4 9 Commissioning 9 1 Overivew 9 1 Requirements 9 1 RTD Input Test 9 1 Heater Voltage and Current Test MS2102 controller only 9 2 Ground Fault Current Test 9 3 Alarm Output Test 9 3 Override Input Test 9 3 Placing the Controller in Service 9 4 Completing the Installation 9 5 Warranty Back Cover ...

Page 4: ... to ensure that the device is still operating as intended This can be a tedious labour intensive job A MS2102 Control Module is mounted near the pipes being traced to monitor the heater points This Control Module can communicate with a single master unit to give complete system monitoring and control from a conven ient location Up to 32 Control Modules can be monitored on a RS485 data highway to a...

Page 5: ...s I Div 2 Groups A B C D Class I Zone 2 Groups IIC Class II Div 2 Groups F and G Class III Operating Temperature 40 C to 50 C LCD 20 C to 50 C Conformal Coating Boards conformal coated for hostile environments Enclosure Type Nema 4X steel painted black Size 10 Hx8 Wx6 D Features Quick release latches to open door Flat aluminum plate to act as heatsink and mounting flange for mounting on Uni Strut ...

Page 6: ...atherproof NEMA 4X Enclosure y 40 C to 50 C OperatingTemperature Range LCD 20 Cto 50 C User Interface y 32 Character LCD Display y LED Indicators on Faceplate y Clear English Language Messages y Intuitive Message Structure y Tactile Keys y Access Security Summary of Features Using This Manual Detailed information relating to switch and output ratings accuracy and so forth are detailed in Chapter 1...

Page 7: ...sequently some means are needed to convert the input voltage to a linear and useful range The CPU applies gain offset and non linearity corrections through a linearization algorithm Current Ground Fault and Voltage Sensing Current transformers and high impedance voltage dividers are used to scale down the incoming heater current ground fault current and voltage All three signals are then passed th...

Page 8: ...to the difference between actual temperature and heater setpoint The relationship is expressed as follows actual temperature heater setpoint x k heater output where k is the proportional gain To partially turn on the heater the proportional control function uses cycle modulation in the powerlimit function By incorporating cycle modulation into the proportional control equation the algorithm is exp...

Page 9: ...te oscillations hysterisis is applied to the on off control by a deadband value The on off control with deadband operation is described by the hysterisis curve in figure 1 4 Assume that actual temperature is well below setpoint deadband setting the controller calls for heat As the actual temperature rises the controller continues to call for heat until the actual temperature has reached setpoint d...

Page 10: ...MS 2102 1 7 Chapter 1 Product Overview Figure 1 5 Hardware Block Diagram ...

Page 11: ... Setpoints are set to OFF In this case the heaters are turned on The logic of this input allows either ambient temperature override or load shedding on all or selected heaters terminals 24 and 25 T4 RTD1 and RTD2 Inputs 3 wire RTD input Ground terminal connects to shield or case Lead resistance compensated terminals 6 13 T5 Earth Ground terminal 1 T6 Heater 1 Power Input 85 280Vac 30Amax continuou...

Page 12: ...2 2 MS 2102 Chapter 2 Installation Figure 2 2 Power Board Layout Figure 2 1 Main Board Layout ...

Page 13: ...e power supply range of 85 280Vac and rated voltage range of the heat trace cable Wiring methods must conform to Class I Division 2 or Class I Zone 2 requirements Heater Wiring Connect the two heating cables wiring to terminals 4 5 and 28 29 respectively See Figure 2 7 If the heating cable has a braid it should be terminated to the ground stud using a ring terminal suitable for 10 stud Ground Conn...

Page 14: ...ashion The total length of this daisy chain should not exceed 4 000 feet The maximum number of devices connected is 32 to avoid exceeding driver capability You can use commercially available repeaters to increase the number of devices over 32 Avoid star or stub connections Terminate the first and last device in the daisy chain loop Each controller is equipped with a termination jumper as shown in ...

Page 15: ...e 2 7 Typical Wiring Diagram Warning Explosion Hazard Substitution of components may impair suitability for Class 1 Division 2 or Class 1 Zone 2 Warning Explosion Hazard Do not disconnect equipment unless power has been switched off or the area is known to be non hazardous ...

Page 16: ...ater Entering Setpoints Accessing the Program Since the heater control display and keypad are normally accessible to passers by who may wish to read measured values a program disable feature is used to prevent accidental changes to the setpoints So before any setpoints can be entered the PROGRAM ENABLE dip switch located on the bottom of the board behind the enclosure door must be set in the ENABL...

Page 17: ... To assist operators in troubleshooting you can program each heater in the MS 2102 control with a heater name You can assign up to 16 characters to the name of a heater To assign a heater name 1 Press SETPOINTS twice to enter the Heater Setup group of setpoints 2 Press the MESSAGE ò key until the heater name message appears HTR1 2NAME NONAME Note The heater default name when MS 2102 is shipped fro...

Page 18: ...er is now set to 50 C 4 Press MESSAGE ò after each setpoint to access the next setpoint 5 Hold VALUE ñ down until the word OFF appears to defeat any setpoint not required For example if a high current alarm is not required set the value to off A detailed description of each message is found in Chapter 6 Setpoint Values Testing Heater Alarms You can force heater and alarm outputs on using the test ...

Page 19: ...l Values Monitoring Heater Temperature To monitor the heater temperature 1 Press MEASURED once to display HEATERCONTROLTEMP 55 C This is the temperature value that the controller will use with the heater setpoint to determine the heater output The 2 heaters in MS 2102 use the actual temperatures of RTD1 RTD2 as their control temperatures respectively If no RTD sensor is connected or a lead is brok...

Page 20: ...way displays a brief message to indicate the start of the statistics page followed by the first value message MEASURED STATISTICS Since this is a new installation any random data should be cleared 2 Press MESSAGE ò in this group until the message appears RESET STATISTICS yes 3 Reset statistics for a new measurement interval The MS 2102 keeps track of when the measurement interval started See Chapt...

Page 21: ...s you to clear alarms that are no longer active Status Lights Refer to Figure 4 1 Display Front View L10 Power The green Power light should be on at all times indicating that control power is applied to the Module If the light is off either there is no control power or the display has a malfunction and requires servicing L11Heater The green Heater light is on if the heater is energized L12 Communi...

Page 22: ...4 2 MS 2102 Chapter 4 Front Panel Operation Figure 4 1 Display Front View Figure 4 2 Contrast Control ...

Page 23: ...N CORPORATION MASTERTRACEHEAT TRACINGCONTROL FIRMWAREVERSION D2 00 00 SELF CHECK PASSED SELF CHECK FAILED Status Messages Status messages are automatically displayed for any active conditions in the controller such as trips and alarms These messages provide an indication of the current state of the controller Some messages prompt you to press MESSAGE ò to scroll through messages to provide additio...

Page 24: ...hen a setpoint has been stored This message indicates that the alarm cannot be reset because the alarm condition is still present This message appears when the heater name has been stored This message indicates that the program enable dip switch or program access function is set to disable and programming is not allowed Refer to Chapter 6 Section 6 3 for details on Setpoint Access Security SETUP S...

Page 25: ...er circuit mode 2 3 phase heater in MS2102 1TXHx panel 3 HTR SET VOLTAGE is set to measured Advanced User Mode Ø Ø Values of the selected heater in the control module The Measured Values Menu is arranged in two groups Pressing MEASURED twice quickly access the top of the second group MESSAGE allows you to move up through the selected menu MESSAGE Ø allows you to move down through the selected menu...

Page 26: ...STRICTIONS Heater Setpoint must not be offor none MS 2102 calculates the displayed value based on the actual measured temperature of the selected heater s RTD MS 2102 controls the selected heater circuit by comparing the Heater Control Temperature to the Heater Setpoint If the tempera ture is outside the value range then RTD OPEN or RTD SHORT is displayed MESSAGENO M1 05 APPLIESTO Selected Heater ...

Page 27: ...EFAULTVALUE N A VALUERANGE 0 to 100 0A O L DISPLAYMODE All RESTRICTIONS MS2102 1TXHxpanel The displayed value is the actual phase C current of the heater circuit If the heater is off this value is zero If the current exceeds the value range then O L is displayed The use of PROPORTIONALCONTROLor POWERLIMIT functions can reduce the current from its nominal rating MESSAGENO M1 11 APPLIESTO Selected H...

Page 28: ...t If the displayed value is RTD OPEN a value greater than the maximum range was recorded To reset the displayed value press RESET To reset with all statistics use RESETSTATISTICS MESSAGENO M2 17 APPLIESTO Selected Heater DEFAULTVALUE N A VALUERANGE 0 1to30 0 100 0A O L DISPLAYMODE Advanced RESTRICTIONS None The displayed value is the highest heater phase A current since the last reset If the displ...

Page 29: ...M2 23 APPLIESTO Selected Heater DEFAULTVALUE N A VALUERANGE 0to 100 000 00 DISPLAYMODE Advanced RESTRICTIONS None The displayed value is the energy cost in the last day Energy cost is calculated from the Energy Used times the COST PER kWh This value is automatically updated once every 24 hours It cannot be reset MESSAGENO M2 24 APPLIESTO Selected Heater DEFAULTVALUE N A VALUERANGE 0to 100 000 00 D...

Page 30: ...depends on the process but large changes could be an indication of degradation of the heater or the insulation To reset use RESETSTATISTICS MESSAGENO M2 28 APPLIESTO Control Module DEFAULTVALUE N A VALUERANGE 0 to 999 999 hours DISPLAYMODE Advanced RESTRICTIONS None The displayed value is the total time since the last reset It is useful for maintenance purpose To reset use RESET STATISTICS MESSAGE...

Page 31: ... to 3 LOW VOLTAGE ALARM 120V MESSAGE DISPLAY MODE normal user MESSAGE DEFAULT DISPLAY system status MESSAGE DISPLAYTIMEOUT 60 seconds MESSAGE SCAN TIME 3 seconds MESSAGE TEMPERATURE UNITS celcius MESSAGE ALARM LIGHT MODE alarm off MESSAGE Restrictions 1 3 phase heater in MS2102 1TXHx panel 2 Dual RTD per circuit mode 3 HTR SET VOLTAGE is set to measured Advanced User Mode 2 allows you to program a...

Page 32: ... Module and N is the heater circuit within the Control Module Press VALUE or VALUE and then press STORE to select a heater circuit For convenience and to reduce human error the Heater Name is also displayed MESSAGENO S1 03 APPLIESTO Selected Heater DEFAULTVALUE yes VALUERANGE yes no DISPLAYMODE Advanced RESTRICTIONS None This function enables control and monitoring for the heater circuit You canno...

Page 33: ...must be less than the High Current Alarm setpoint To disable this alarm set the value to off When the Heater Current is less than or equal to this setpoint the Low Current Alarm is activated and a LOW CURRENTALARM message is added to the System Status messages The alarm deactivates when the Heater Current rises above this alarm setpoint The value range is in 0 5Aincrements Note This setpoint is ba...

Page 34: ...below 100 duty cycle to prevent erroneous alarms at low duty cycles MESSAGENO S1 11 APPLIESTO Selected Heater DEFAULTVALUE off VALUERANGE 0 5 to 30 0 100 0A off DISPLAYMODE All RESTRICTIONS MS2102 1TXHxpanel This function sets the phase B High Current Alarm setpoint It must be greater than the phase B Low Current Alarm setpoint To disable this alarm set the value to off When the phase B Heater Cur...

Page 35: ...cate the alarm message in the Status Menu and press RESET Note This setpoint is based on the heater at 100 power If proportional control or Power Limit is enabled all current measurements will be converted to to 100 power based on a constant resistive load before being compared to the alarm setpoint MESSAGENO S1 15 APPLIESTO Selected Heater DEFAULTVALUE off VALUERANGE 0 5 to 30 0 100 0A off DISPLA...

Page 36: ... is a feature that exercises the system by automatically applying power to the heater if off for about 30 seconds If an alarm condition is detected during this period the TraceCheck Alarmisactivatedanda ALARMDURINGTRACECHECKmessage is added to the System Status messages If a ground fault is detected the heater circuit is opened This is a latching alarm To clear the alarm locate the alarm message i...

Page 37: ...UE off VALUERANGE on off DISPLAYMODE Advanced RESTRICTIONS None This feature sets the response of the heater circuit to the Control Module s Master Override input The Master Override input responds to a contact closure If the Master Override is set to off or the Master Override inputs are shorted control of the heater circuit operates normally based on the Heater Control Temperature and the Heater...

Page 38: ...ENO S2 08 APPLIESTO Selected Heater DEFAULTVALUE off VALUERANGE on off DISPLAYMODE Advanced RESTRICTIONS Heater Setpoint must not be off This function sets the heater fail safe state The Control Module detects if the temperature sensor has failed In this case it will set the heater to its fail safe state For freeze protection where there is no hazard from over heating set to on to prevent freeze u...

Page 39: ... off Heater temp Control temperature MESSAGENO S3 04 APPLIESTO Control Module DEFAULTVALUE 60 s VALUERANGE 5 to 600 s off DISPLAYMODE Advanced RESTRICTIONS None This function sets the length of time from the last key press to automatically return to the Default Display information To disable this function set the value to off MESSAGENO S3 05 APPLIESTO Control Module DEFAULTVALUE 3 s VALUERANGE 1 t...

Page 40: ...alarm flash on flashes the alarm light when alarms are present and turns on the alarm light when there are no alarms Value alarm flash off flashes the alarm light when alarms are present and turns off the alarm light when there are no alarms MESSAGENO S3 11 APPLIESTO Control Module DEFAULTVALUE MECH NC VALUERANGE MECH NOSS N A SS N A MECH NOSS N A MECH NCSS N A MECH NCSS N A DISPLAYMODE Advanced R...

Page 41: ...MODE Advanced RESTRICTIONS None This function manually controls of the alarm output for maintenance purposes For normal operation set to disable If you select a period of time the alarm output is forced into alarm state for the selected interval If you select on continuously the alarm output is forced into alarm state until you select disabled Alarm state is determined byALARM CONTACTS function se...

Page 42: ... off ü Check SCRs for failure in short circuit state ü Controller may be faulty and needs repair The temperature derived from the RTD resistance has exceeded 500 C or dropped below 50 C ü Check for damaged RTD cable or open short connection ü Check middle lead of RTD terminal 7 or 11 for open connection ü Pipe temperature has exceeded 500 C ü Pipe temperature has dropped below 50 C ü Test the RTD ...

Page 43: ...e heater circuit is on is less than or equal to the Low Current Alarm setpoint ü Check that the alarm setpoint is correct ü For self regulating heating cable the current varies substantially with tempera ture Check that the alarm setpoint accounts for this variation or use the heat trace curve function ü Test for correct current measurement ü For parallel resistance heating cable check for broken ...

Page 44: ...atching The alarm remains on the display even after the alarm condition has gone away Latch alarms require you to acknowledge or reset the alarm To reset alarms 1 Press STATUS 2 Press MESSAGE ò to locate the alarm message 3 Press RESET The alarm should be cleared from the display unless the alarm condition is still present ...

Page 45: ...he module number must be unique for each controller on the data highway to avoid bus contention The module number is user defineable from 1 to 250 refer to Chapter 6 Setpoint Values for details Only the addressed slave responds to a packet that starts with its module number Function Code The function code tells the slave what action to perform Refer to supported functions in this section for detai...

Page 46: ...essages Function code 06 Store a Value into one Variable Register Modbus implementation Preset Single Register MS 2102implementation Store a value into one variable register In Modbus Preset Single Register places a specific binary value into a holding register For the MS 2102 mplementation of Modbus this function is used to store a value into one variable register with Memory Location Index in Mo...

Page 47: ...ample Assign a module to a new address 230 Here are transmis sion and response messages MS 2102 Error Responses If a MS 2102 module receives a transmission in which an error is indicated by framing format overrun or the CRC calculation the module will not respond to the n o i s s i m s n a r T r e t s a M s e t y B l a m i c e D s t n e t n o C e g a s s e M s s e r d d A e v a l S 1 1 1 e v a l s...

Page 48: ...error other than CRC error will be The MS 2102 implements the following exception re sponse codes 01 ILLEGAL FUNCTION The function code transmitted by the master is not one of the functions supported by MS 2102 02 ILLEGAL MEMORY LOCATION INDEX The index transmitted by the master is not allowable 08 ILLEGALADDRESS ENABLE DIP SWITCH POSITION The address enable dip switch on MS 2102 controller is in ...

Page 49: ...xceed the name plate ratings 3 Check that the grounding stud is properly connected to ground RTD Input Test Equipment Two Resistance Decade Boxes or RTD Simulator To test RTD Input 1 Disconnect the RTD s from the control module ensuring that the leads are adequately labelled 2 Connect the resistance box as shown in figure 9 3 C s m h o R C s m h o R C s m h o R 0 4 7 2 4 8 0 8 9 8 0 3 1 0 0 2 4 8 ...

Page 50: ...e variac outputs to terminals 2 and 3 Connect the input supply of the variac to either 208 or 240VAC 120VAC will work but will not provide an effective test range for voltage testing 3 Connect the load bank to terminals 4 and 5 4 Connect the voltmeter across terminals 2 and 3 5 Connect a clamp on ammeter around one of the load cables 6 Set the variac control for 120VAC and turn on the power 7 Forc...

Page 51: ...he variac control to simulate various levels of ground fault currents through the load and compare readings from the display with the ammeter Readings should be within the accuracy of the controller and test equipment 8 If there is a significant discrepancy consult the factory for service 9 Disconnect the load bank after the test The test procedures for heater 2 ground fault current are as same as...

Page 52: ...g Check the heat trace design to make sure the breaker rating is appropriately sized Trun on the STAGGER START function to reduce the inrush current Ground Faults Check ground fault current MEASURED OPERATING VALUES GROUND FAULT CURRENT on the display Ground fault current should not be over 15mA otherwise ground fault trip or alarm appears on the display To troubleshoot ground faults check heat tr...

Page 53: ...oller supports two types of control scheme on off and proportional The default is on off switching which is used for majority of the applications When on off switching is used the deadband setting determines the heater turn off temperature above the heater setpoint and the heater turn on temperature below the heater setpoint The deadband setting is user definable located at SETPOINTS HEATER SETUP ...

Page 54: ...PROVIDED FOR IN WRITING IN THIS WAR RANTY EACH CONTROL IS PROVIDED WITHOUT ANY WARRANTY OF ANY KIND EITHER EXPRESSED OR IMPLIED IN PARTICULAR WITHOUT LIMITING THE GENERALITY OF THE FOREGOING THE FOLLOWING IMPLIED WARRANTIES AND CONDITIONS ARE EXPRESSLY DIS CLAIMED a ANY IMPLIED WARRANTY OR CONDITION THAT THE CON TROL WILL MEET YOUR REQUIREMENTS b ANY IMPLIED WARRANTY OR CONDITION THAT THE OPERA TI...

Page 55: ...MASTERTRACE TM HEAT TRACING CONTROL P N 1501 0019 MS 2102 04 18 Printed in Canada Nextron Limited 14 6120 11th Street S E Calgary Alberta T2H 2L7 Tel 403 735 9555 Fax 403 735 9559 ...

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