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Warranty

The manufacturer warrants each control that it manufactures to be free from
defective material or workmanship for a period of 12 months from date of
purchase.

Under this warranty, the obligation of the manufacturer is limited to repairing or
replacing the defective control at its option, when returned to the manufactur-
er’s factory with shipping charges prepaid.

If failure has been caused by misuse, incorrect application or alteration of the
control, this warranty will be void.

UNLESS SPECIFICALLY 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-

TION OF THE CONTROL WILL BE UNINTERRUPTED OR
ERROR FREE; AND

c). ANY IMPLIED WARRANTY OR CONDITION OF

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PUR-
POSE.

The user shall be made aware that if the equipment is used in a manner not
specified by the manufacturer, the protection provided by the equipment may
be impaired.

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Summary of Contents for MASTERTRACE

Page 1: ...MASTERTRACE TM OPERATOR S MANUAL HEAT TRACING CONTROL ...

Page 2: ...ontrol Power Wiring 4 2 4 9 Commissioning 4 2 5 Operation 5 1 5 1 Control Modules 5 1 5 2 Interface Modules ML100 MR100 5 6 5 3 Responding to Alarms 5 9 5 4 Setpoint Values Menu Single Phase Modules 5 10 5 5 Setpoint Values Menu Three Phase Modules 1 and 5 point only 5 11 5 6 Measured Values Menu Single Phase Modules 5 12 5 7 Measured Values Menu Three Phase Modules 5 13 5 8 Interface Module MR100...

Page 3: ...Display Message Detail Measured B 1 Measured Values Operating Values B 1 Measured Values Statistics Menu B 3 Appendix C Summary of Alarms and their Causes C 1 Appendix D Typical Wiring Diagrams D 1 MS 1DXH0 D 1 MS 1DIN2 D 1 MS 1TXH0 D 1 MS 2DXH0 D 2 MS 2DIN2 D 2 MS 5ADXH0 D 2 MS 5ADIN2 D 3 MS 5ATXH0 D 3 MS 10ADXH0 D 4 MS 10ADIN2 D 4 MS 10ADIN2T D 5 MS 10ADIN2X D 5 Driving Contactors D 6 Serial Com...

Page 4: ...sssssssssssssss sssss s ssssssstsssssspssssssssssss sssss r sssss sssssssssssssssssssssss sssspsssssssssssssssss ssssssssssssssssssssssss pp 0 httt s pp0 tttsssss pptt htttssspsspsss sssssssspsssss s ssssssssssspssssssssssssssssssssss ssssspssssssssssssssssssspsssss psspsssssssssssssssssssss sssssssssssssssssss sssssssss sssssssss ssssssssssssssssssssssssss sssssssspssssssssssss sssssssssssssssssp...

Page 5: ...ssssssss ssssssss s sss ss ssssssssssss ss ssssssssssspssssssssssssssssssssssssssssss ssssssssstsssssssssssssss ggggggggggggggggggggggggggggggggggggggggg ssssssssssss sssssssssssssssssssssssssspssssssssspsssss ssssssssssssssssspssssssssssssssssssssssssssssssss sssssss ssssssssssssssssspssssss s ssssssssssssssssssss ssssssssssssssssssssss sssssspsssssss ssssssss ssssssss spsssssssh sssssss s sssh s...

Page 6: ...ssssssssssssssssssssssssssssss ssssssspssssss ssssssssssssssssssssssssssssssssssssss s ssssssssssssssssss s sssssssssss ssssss sssssssssssssssssss ssssssssssssssss s s s ssssssssssssss ssssss sssssssssssssssssssssssss ssssssssssssssssssssssssssssss sssssssssssssssssssssssss ssssssssssssssssssssssssssssssssssssssssssssssss sssssss assssssssssssssssssssssssssssssssssssssssssssssssssssss ssssssssstss...

Page 7: ...ssssssssssssss sssssssssssssssssssssssss ssssssgs ssssssssspsssssssspsssspssss s sssssgs ssssssssssssssssspssssssssssssssssssssssspssspsssss sssssssssssssspsssss sssssst h s sssssssssssssssss sssssssssssssssssssspsssss ssssssssspssssspsssssssssss sssssssssssssssssssss sssssss s ssssssssssssssssssssssss sssss ssssssssssssssssssssssssssssssssss sssssssssssssssss sssssssssssssssssssssssssssssss sssss...

Page 8: ...tion 2 3 STEP 3 Test heater and alarm operation Section 2 4 STEP 4 Monitor system status Section 2 5 2 2 Enable Heaters After each control has been programmed with it s unique address it is necessary to indicate which units are con nected to the system and should be controlled This is done by enabling a heater circuit To enable a heater circuit the operator must specify the heater number Note When...

Page 9: ...he ENABLE position the setpoint will not be saved and this message will flash on the screen NOTSTORED PROGDISABLED Now that the MasterTrace control is ready for program ming we will enter the setpoints for this example For fur ther information about the organization of all the messages or for details on the range and application of each message see Appendix A It is not necessary to enter setpoints...

Page 10: ... the displayed message with the error Now press MESSAGE or MESSAGE Ø to exit and return to the 1st character position Then press STORE until the cursor is under the incorrect character Proceed as before until new letters are entered Press the STORE key to skip over the correct letters until on the last character position Now press STORE to save the corrected message Setpoint information for system...

Page 11: ... until DISABLE appears and then store this value Holding the VALUE keyuntilthe word ON CON TINUOUSLY appears leaves the heater always ener gized until the MasterTrace control is manually powered off or until this setpoint is set to DISABLE Consequently selecting a value of ON CONTINUOUSLY should be used with caution since it overrides normal control operation and could lead to excessive heating or...

Page 12: ...pe has been installed 100 OHM platinumDIN 43760 and that the three RTD wires are wired to the correct terminals 2 5 2Actual Current Press MESSAGE Ø from the heater temperature message or the MEASURED keythen MES SAGE Ø several times to display HEATERCURRENT 5 5A This value is the actual measured current of the heater Resolution is to 0 5 amp over a range of 0 0 to 100 0 amps Above 100 0 amps the v...

Page 13: ... will be cleared However if you clear statistics us ing MR100 only the statistics of the selected heater is cleared This completes setpoint programming and system testing Set the PROGRAM ENABLE dip switch to DISABLE to prevent accidental setpoint changes or tampering By fol lowing this sequence and message explanation it should be fairly easy to install a similar control application Refer to Appen...

Page 14: ...he many standard features incorporated into each con trol Each heater point is monitored by a control mounted near the pipe being traced Up to 300 points can be monitored by a single master conveniently located to allow quick system monitoring and fault diagnosis Asecond RS485 port can be used for communication between controls and centralized monitoring Each local control is completely independen...

Page 15: ...toring English character graphics display of all values Local or remote display and programming RS485 communication to remote monitor Alarm contacts for PC interface or remote indicator alarm Verification Measured temperature displayed and easily verified in the field Heater on indication for setpoint accuracy checking Precision components No mechanical parts for calibration drift Hazardous Ordina...

Page 16: ...40 C to 60 C Conformal Coating Boards conformal coated for hostile environments Alarm Alarm Output Programmable for NO or NC contacts One DC opto isolated contact One dry mechanical contact Alarm Output Rating DC contact 30Vdc 0 1A 500mW max Dry mech contact 120Vac 1 0A max Alarm Light Output LED Indicator 12Vdc 30mA Alarm Messages Temperature High Temperature Alarm Low Temperature Alarm Current L...

Page 17: ... Class1 Div II Groups A B C D Class1 Zone 2 Group IIC Operating Range 40 C to 60 C Conformal Coating Boards conformal coated for hostile environments Alarm Alarm Output Programmable for NO or NC contacts One DC opto isolated contact One dry mechanical contact Alarm Output Rating Hazardous Areas DC contact 30Vdc 0 1A 500mW max Dry mech contact 30Vdc 10mA max Ordinary Areas DC contact 30Vdc 0 1A 500...

Page 18: ...A B C D Class1 Zone 2 Group IIC Operating Range 40 C to 60 C Conformal Coating Boards conformal coated for hostile environments Alarm Alarm Output Programmable for NO or NC contacts One DC opto isolated contact One dry mechanical contact Alarm Output Rating Hazardous Areas DC contact 30Vdc 0 1A 500mW max Dry mech contact 30Vdc 10mA max Ordinary Areas DC contact 30Vdc 0 1A 500mW max Dry mech contac...

Page 19: ...g Range 40 C to 60 C Conformal Coating Boards conformal coated for hostile environments Alarm Alarm Output Programmable for NO or NC contacts One DC opto isolated contact One dry mechanical contact Alarm Output Rating DC contact 30Vdc 0 1A 500mW max Dry mech contact 120Vac 1 0A max Alarm Light Output LED Indicator 12Vdc 30mA Alarm Messages Temperature High Temperature Alarm Low Temperature Alarm C...

Page 20: ...ng Cost 0 to 1 000 000 00 Environment Approval CSA NRTL C Class1 Div II Groups A B C D Class1 Zone 2 Group IIC Operating Range 40 C to 60 C Conformal Coating Boards conformal coated for hostile environments Alarm Alarm Output Programmable for NO or NC contacts One DC opto isolated contact One dry mechanical contact Alarm Output Rating Hazardous Areas DC contact 30Vdc 0 1A 500mW max Dry mech contac...

Page 21: ... conformal coated for hostile environments Alarm Alarm Output Programmable for NO or NC contacts One DC opto isolated contact One dry mechanical contact Alarm Output Rating DC contact 30Vdc 0 1A 500mW max Dry mech contact 120Vac 1 0A max 30Vdc 0 1A max Alarm Light Output LED Indicator 12Vdc 30mA Alarm Messages Temperature High Temperature Alarm Low Temperature Alarm Current High Current Alarm Low ...

Page 22: ...IIC Operating Range 40 C to 60 C Conformal Coating Boards conformal coated for hostile environments Alarm Alarm Output Programmable for NO or NC contacts One DC opto isolated contact One dry mechanical contact Alarm Output Rating Hazardous Areas DC contact 30Vdc 0 1A 500mW max Dry mech contact 30Vdc 10mA max 250Vac 0 5A max not subject to a corrosive environment Ordinary Areas DC contact 30Vdc 0 1...

Page 23: ...up IIC Operating Range 40 C to 60 C Conformal Coating Boards conformal coated for hostile environments Alarm Alarm Output Programmable for NO or NC contacts One DC opto isolated contact One dry mechanical contact Alarm Output Rating Hazardous Areas DC contact 30Vdc 0 1A 500mW max Dry mech contact 30Vdc 10mA max 250Vac 0 5A max not subject to a corrosive environment Ordinary Areas DC contact 30Vdc ...

Page 24: ...0 C to 60 C Conformal Coating Boards conformal coated for hostile environments Alarm Alarm Output Programmable for NO or NC contacts One DC opto isolated contact One dry mechanical contact Alarm Output Rating DC contact 30Vdc 0 1A 500mW max Dry mech contact 120Vac 1 0A max 30Vdc 0 1A max Alarm Light Output LED Indicator 12Vdc 30mA Alarm Messages Temperature High Temperature Alarm Low Temperature A...

Page 25: ... 40 C to 60 C Conformal Coating Boards conformal coated for hostile environments Alarm Alarm Output Programmable for NO or NC contacts One DC opto isolated contact One dry mechanical contact Alarm Output Rating DC contact 30Vdc 0 1A 500mW max Dry mech contact 120Vac 1 0A max 30Vdc 0 1A max Alarm Light Output LED Indicator 12Vdc 30mA Alarm Messages Temperature High Temperature Alarm Low Temperature...

Page 26: ...rmal Coating Boards conformal coated for hostile environments Alarm Alarm Output Programmable for NO or NC contacts One DC opto isolated contact One dry mechanical contact Alarm Output Rating DC contact 30Vdc 0 1A 500mW max Dry mech contact 120Vac 1 0A max 30Vdc 0 1A max Alarm Light Output LED Indicator 12Vdc 30mA Alarm Messages Temperature High Temperature Alarm Low Temperature Alarm Current High...

Page 27: ...ult Maximum Trip Time 24 5 seconds Environment Approval CSA NRTL C for Ordinary areas Operating Range 40 C to 60 C Conformal Coating Boards conformal coated for hostile environments Alarm Alarm Output Programmable for NO or NC contacts One DC opto isolated contact One dry mechanical contact Alarm Output Rating DC contact 30Vdc 0 1A 500mW max Dry mech contact 120Vac 1 0A max 30Vdc 0 1A max Alarm Li...

Page 28: ...iv II Groups A B C D Class1 Zone 2 Group IIC Operating Range 40 C to 60 C Conformal Coating Boards conformal coated for hostile environments Alarm Alarm Output Programmable for NO or NC contacts One DC opto isolated contact One dry mechanical contact Alarm Output Rating Hazardous Areas DC contact 30Vdc 0 1A 500mW max Dry mech contact 30Vdc 10mA max 250Vac 0 5A max not subject to a corrosive enviro...

Page 29: ... Div II Groups A B C D Class1 Zone 2 Group IIC Operating Range 40 C to 60 C Conformal Coating Boards conformal coated for hostile environments Alarm Alarm Output Programmable for NO or NC contacts One DC opto isolated contact One dry mechanical contact Alarm Output Rating Hazardous Areas DC contact 30Vdc 0 1A 500mW max Dry mech contact 30Vdc 10mA max 250Vac 0 5A max not subject to a corrosive envi...

Page 30: ...l network connections Type RS485 Protocol Modbus RTU Transmission Rate 600 1200 2400 4800 9600 baud Interconnect 2 wire shielded twisted pair Highway Distance 4 000 feet without repeater Modules per Highway 1 MR100 and 30 Control Modules Environment Approval CSA NRTL C Class1 Div II Groups A B C D Class1 Zone 2 Group IIC Operating Range 40 C to 60 C LCD Display 20 C to 60 C VFD Display 40 C to 60 ...

Page 31: ... EN 55024 and EN 60950 1 UL 508 CSA C22 2 Class1 Div II Groups A B C D ISA 12 12 01 UL1604 Operating Range 30 C to 70 C Storage 40 C to 85 C Sealing Nema 4X IP66 front panel only Alarm Alarm Output One NO dry mechanical contact Alarm Output Rating Hazardous Areas Dry mech contact 30Vdc 10mA max 250Vac 0 25A max not subject to a corrosive environment Ordinary Areas Dry mech contact 120Vac 0 5A max ...

Page 32: ...Pole External Solid State DXH 3 Pole External Solid State TXH Switch Rating No Switches 0 30A 240Vac 2 50A 240Vac 3 100A 240Vac 4 30A 600Vac 5 50A 600Vac 6 100A 600Vac 7 Additional Options A1 Green LED Alarm Indicator A2 Red LED Alarm Indicator Bx Distribution Panel with x Amp Main RTD 7ft RTD Sensor SP Special Modification X1 Control Transformer 208VAC Input X2 Control Transformer 240VAC Input X3...

Page 33: ...5 11nnngngnnnnngnnnggnngnnnnn e e e e e e ee e e e e e e e e e e r e e e e e e e e ee e ee t e e e e e e e e e e ee D e e e e r e e e e 111nngngnnnnngnnnRgnnnng 5 e e e e e 5 e NN e e e e e e e e e e D dNeD e e e e e e NDN e NDN e e e e e e e5 e e e e Dt e e ee 5 Dt e e e e e e e ee e e ee 5 m m m m m Dmm D D e e ee 11gngngggnnnnnggnnggngngnng e e e e e e e e e e m m m m me N e e e e ee e e e e e ...

Page 34: ...hhhhhhhhhhhhhhhhhhhhhhshhhhhhhlhlhh h h l hhhhlhlhhh h hhhh hhh hhhhhhhhhl 11gnRnnggngngnng 5NNN e N e ee er e e e O Ne e e ee e e mr5 e e D e m m e e e e e e e e mr5 e e e r e e e e e e e e e e e ee 5 e mr5 e e e e e e e e e ee e e e ee 5 e m m D m Dmm D D e e e ee 5 e e e e NNee NNeD D5Ne Ne5D D e e e e NDNe ND 11gngnggnnnnnnnng e ee ee e m m e e r e e e e e e e e e e e e e e e e e e e ee e e e ...

Page 35: ...e e e e e e e e e e e e e r e e e e 5 e e e e e ee 5ede5 e e 555 N m e r e r e e e e 555e r e e 555 e e ee 5 555 5 555 e e e e e e e e e e e e e T N e e e e e e e e e e e e e e 555e hlhhhhhhnhlnhhhhhhhhnlnlhhhnhnhthhhhhhhhh hshhhhhhhhhhhhhlhhhhhlhhhhhhhlthhhhhhhshh lhlhhh h h hhhhhh hhhhlhlhhh h hhhh l hlhhhhhhnhlnhhhhhhhhnlnlhhhnh hhhhh hhhhhhhhhhhh hhhhhhhhhhhhhhhhhhhhhhlh thhhhhhhhhhhhhhsshhhhh...

Page 36: ...111 RRRRRREEEEE 4444444444nnnnnnnnnnnn llNsNNlhlNNlNNNsNNl e 5 e5N T 5 e e T 5 e ee N ee e e e e 5e 5 e N e e N e 5 N 1 112 5 e e ee N ee ...

Page 37: ...ated dc output is rated 30Vdc 0 1A terminals 4 5 and the dry mechanical output is rated 30Vdc 10mA 250Vac 0 5A terminals 6 7 In ordinary areas the opto isolated dc output is rated the same as hazardous but the dry mechanical output is rated 120Vac 1A 30Vdc 0 1A Contacts are configurable for normally open or closed T2 Alarm Light Output The output is configurable for normally open closed or flash O...

Page 38: ...wired to the RTD Transmitter and the transmit ter can be located up to 7km away from the control mod ule Model MS 10ADIN2X only T17 15Vdc Power Output Model MS 10ADIN2X only 5 1 4 Communications Ports C1 ML100 Interface Standard connection to a Dedi cated Interface Module via a ribbon cable Maximumca ble length is 4 feet C2 Serial Port 1 Standard connection to an RS 485 data highway via a 2 conduc...

Page 39: ...MASTERTRACE 5 3 Chapter 5 Operation Figure 5 3 MS 1DXH0 MS 2DXH0 Control Modules Figure 5 2 MS 1TXH0 Control Module ...

Page 40: ...5 4 MASTERTRACE Chapter 5 Operation Figure 5 5 MS 5ADIN2 MS 10ADIN2 Control Modules Figure 5 4 MS 5ADXH0 MS 5ATXH0 MS 10ADXH0 Control Modules ...

Page 41: ...MASTERTRACE 5 5 Chapter 5 Operation Figure 5 7 MS 10ADIN2X Control Module Figure 5 6 MS 10ADIN2T Control Module ...

Page 42: ...nsmitterfortemperaturemeasurement 913 15V is dc current source terminal and 914 is dc current return terminal To connect with an RTD Transmitter use 18 AWG wires to connect terminal 913 to the I terminal on RTDTransmitter and terminal 914 to the I terminal on RTD Transmitter The actual RTD sensor is to be locally wired to the RTD Transmitter and the transmitter can be locatedupto7kmawayfromMR100 R...

Page 43: ...e user to move up through the selected menu The MESSAGE ò key allows the user to move down through the selected menu The VALUE ñ key allows the user to increase the value of the displayed selected item The VALUE ò key allows the user to decrease the value of the displayed selected item The STORE key allows the user to save the changed value of the selected item The RESET key allows the user to cle...

Page 44: ...5 8 MASTERTRACE Chapter 5 Operation Figure 5 9 ML100 Dedicated Interface Module Rear View Figure 5 10 MR100 Group Interface Module Rear View ...

Page 45: ...splayed 2ALARMS PRESS MSSG DOWN Pressing MESSAGE ò displays the alarm detail screens for each alarm as shown LOWTEMPERATURE ALARM HEATER2 1 NONAME ACTUAL 3 C SETPOINT 5 C The first screen shows what the alarm is the second shows where the alarm is and the third screen shows why there is an alarm The Scan Time determines the rate at which these screens are displayed If there no more alarms this mes...

Page 46: ...GEô STAGGER START off MESSAGEô NUM OF AMB SENSE HTRS 0 MESSAGEô SETPOINTS SYSTEM SETUP MESSAGEô MODULE RANGE 1 30 MESSAGEô MODULE LIST MOD 1 SEL yes MESSAGEô SETPOINT ò 6 MANUAL SYSTEM ALARM disabled MESSAGEô GF TEST test now MESSAGEô go to 1 SETPOINTS SETPOINTS TEST MESSAGEô MANUALALARM disabled MESSAGEô MANUAL HEATER disabled MESSAGEô BAUD RATE MR100 1200 MESSAGEô BAUD RATE 1 1200 MESSAGEô go to...

Page 47: ...led MESSAGEô GF TEST test now MESSAGEô go to 1 SETPOINTS SETPOINTS TEST MESSAGEô MANUALALARM disabled MESSAGEô MANUAL HEATER disabled MESSAGEô RESET CONTROL MODULE no MESSAGEô RESET MR100 no MESSAGEô MANUALVERSION 1501 0006_1 MESSAGEô FORASSISTANCE 403 735 9555 MESSAGEô go to 6 5 Restrictions 1 5 10 point Modules 2 MR100 Interface Module Advanced User Mode 2 2 2 2 2 READ MODULE NUMBER 1 MESSAGEô A...

Page 48: ...ED ò 1 MEASURED ò MEASURED STATISTICS MESSAGEô SELECT HT 1 1 NONAME MESSAGEô MIN TEMPERATURE 3 C MESSAGEô MAX TEMPERATURE 25 C MESSAGEô MAX HEATER CURRENT 4 7A MESSAGEô MAX GROUND FAULT CURRENT 6mA MESSAGEô go to 3 2 3 ENERGY USED LAST DAY 2 1 kWh MESSAGEô TOTALENERGY USED 42 2 kWh MESSAGEô ENERGY COST LAST DAY 1 70 MESSAGEô TOTALENERGY COST 33 92 MESSAGEô HEATER ON TIME 80 hrs MESSAGEô HEATER IS ...

Page 49: ... 1 NONAME MESSAGEô MIN TEMPERATURE 3 C MESSAGEô MAX TEMPERATURE 25 C MESSAGEô A MAX HEATER CURRENT 4 7A MESSAGEô MAX GROUND FAULT CURRENT 6mA MESSAGEô go to 3 2 3 ENERGY USED LAST DAY 2 1 kWh MESSAGEô TOTALENERGY USED 42 2 kWh MESSAGEô ENERGY COST LAST DAY 1 70 MESSAGEô TOTALENERGY COST 33 92 MESSAGEô HEATER ON TIME 80 hrs MESSAGEô HEATER IS ON 17 OF THE TIME MESSAGEô TIME SINCE RESET 48 hrs MESSA...

Page 50: ... keyboard can be activated or hidden through a simple click on the iCon located atthe bottom Quite often in the operation of MR100 for Win dows CE keyboard is needed to input the digital values for heater setpoints and text characters for heater names 5 8 2 Terminals Jumper Refer to the Typical Wiring Diagrams for power field connections T1 Alarm Contact terminals A1 and A2 In hazardous areas the ...

Page 51: ...MASTERTRACE 5 15 Chapter 5 Operation Figure 5 13 MR100 for Windows CE Group Interface Module RearView ...

Page 52: ...ch Control Module must be Selected for the MR100 to com municate with it Any Control Module not selected will be skipped by the SELECT HT functions msg M1 02 M2 02 S1 02 S2 02 For MR100 for Windows CE interface module the Commu nication Map panel selects all the Control Modules for com munication To select a Control Module for communication simply check the check box beside the module number Note ...

Page 53: ...y Connect the Control Module to the existing data highway by daisy chaining RS 485 cable to the serial port Note that only the last Control Module on the data highway should have its RS485 120 jumpers set to IN 7 4 2 Check the Module Number Check the Programming Sheet for Control Panel or Modules that came with the new Control Module for the Module Number It must be a unique number for the data hi...

Page 54: ...MASTERTRACE Chapter 7 Networking Modules 7 2 Figure 7 1 MASTERTRACE System Network ...

Page 55: ... use it as the Master in the network You can program the Master according to MasterTrace Modbus Communication Protocol to write read data to from MasterTrace control modules over Ethernet from anywhere in the plant as long as the Ethernet port on the PLC or Automation system is Modbus TCP supported and is assigned to an IP address that is different to the IP addresses of the gateway and other devi...

Page 56: ...nstalled on the PC that is the master in the RS485 communication network Its functionalities are two folded First it has the physical links with all heat tracing controllers and uses these links to query data from the controllers in the RS485 network Secondly it is the server in the internet communication network and upon request it will pass all information obtained from the RS485 network to its ...

Page 57: ...s ured The displayed current should equal the measured cur rent within the accuracy of the devices used If there is a significant discrepancy return the Control Module to the factory for calibration 8 2 3 Alarm Output Test If an external alarm signal is inte gral to the system operation the alarm output should be tested regularly The alarm output on each control module is tested using the MANUAL A...

Page 58: ...plete the fol lowing steps Turn off power to the affected heater circuits Locate the failed relay and disconnect the wires ensure that all wires are adequately labeled Remove the two 6 32 screws that secure the relay re move the failed relay and discard the thermal conductive pad Use Nextron part number 1007 0003 Berquist Q2 101 for replacement thermal conductive pad Use Nextron part number from t...

Page 59: ...ntrol Module which is connected to the ML100 Disconnect the ribbon cable from the Interface Module Remove the four Nylock nuts labeled A in Figure 5 9 that secure the Interface Circuit Board Assembly Disconnect the ribbon cable connector to the Keypad and remove the Interface Circuit BoardAssembly Replace the ML100 Dedicated Interface Circuit Board Assembly with Nextron part number 1303 0002_2 Tor...

Page 60: ...le Disconnect power wires to the 12Vdc power supply To replace the Programmed QTERM A7 touch screen terminal remove the terminal from the panel enclosure then replaced with Nextron part number 9003 0062_1 To replace the Cable for QTERM A7 remove the cable by disconnecting all its wire connections then replaced with Nextron part number 9003 0063 To replace the 12Vdc power supply remove the power su...

Page 61: ... F none off DISPLAYMODE All RESTRICTIONS None This function sets the maintain temperature For on off control the circuit is energised if the Heater Control Temperature is less than the Heater Setpoint minus the DEADBAND The circuit is de energised if the Heater Control Temperature is greater than the Heater Setpoint plus the DEADBAND Both PROPORTIONAL CONTROL and POWER LIMIT affect heater switchin...

Page 62: ...r DEFAULTVALUE off VALUERANGE 0 5 to 100 0A off DISPLAYMODE All RESTRICTIONS Three Phase Modules This function sets the phase A Low Current Alarm setpoint It must be less than the phase A High Current Alarm setpoint To disable this alarm set the value to off When the Heater Current A is less than or equal to this setpoint the Low Current AAlarm is activated and a LOW CURRENT AALARM message is adde...

Page 63: ...off DISPLAY MODE All RESTRICTIONS Three Phase Modules This function sets the phase A High Current Alarm setpoint It must be greater than the Low Current A Alarm setpoint To disable this alarm set the value to off When the Heater Current A is greater than or equal to this setpoint the High Current AAlarm is activated and a HIGH CURRENT AALARM message is added to the System Status messages The alarm...

Page 64: ...orrected locate the alarm message in the Status Menu and press RESET The value range is in 0 5A increments MESSAGENO S1 17 APPLIESTO Selected Heater DEFAULTVALUE off VALUERANGE 0 5 to 100 0A off DISPLAY MODE Advanced RESTRICTIONS Three Phase Modules This function sets the phase B High Current Trip setpoint It must be greater than the Low Current B Alarm and the High Current B Alarm setpoints To di...

Page 65: ... DEFAULT VALUE 25 mA VALUE RANGE 10 to 1000 mA off DISPLAYMODE All RESTRICTIONS None This function sets the Ground Fault Alarm setpoint It must be less than the Ground Fault Trip setpoint To disable this alarm set the value to off When the Ground Fault Current is greater than or equal to this setpoint the Ground Fault Alarm is activated and a GROUND FAULT ALARM message is added to the System Statu...

Page 66: ...ff When the Heater Voltage is less than or equal to this setpoint the Low Voltage Alarm is activated and a LOW VOLTAGE ALARM message is added to the System Status messages The alarm deactivates when the Heater Voltage rises above this alarm setpoint Setpoints Heater Setup Menu MESSAGE NO S2 01 APPLIES TO Interface Module DEFAULT VALUE N A VALUE RANGE N A DISPLAY MODE Advanced RESTRICTIONS None Thi...

Page 67: ...verride input will have full control over the heater circuit It means that the heater will be turned on if the inputs are shorted and off if the inputs are open MESSAGE NO S2 05 APPLIES TO Selected Heater DEFAULT VALUE off VALUE RANGE on off DISPLAY MODE Advanced RESTRICTIONS Solid State Modules This functions minimizes temperature overshoot and undershoot for tighter temperature control For criti...

Page 68: ...es all the setpoints of the selected heater to all the other heaters in the system The copied setpoints are heater enabled heater setpoint low high temperature alarm low high current alarm high current trip power limit ground fault trip ground fault alarm tracecheck cycle time tracecheck htr on time heater voltage heater name master override proportional control deadband heater fail safe state and...

Page 69: ...ll the heaters Heater status Heater status of selected heater Heater temp Temperature of the selected heater Scan heater All measured values of the selected heater Scan temps Temperatures of all enabled heaters Scan currents Phase currents of all enabled heaters Scan gnd faults Ground fault currents of all enabled heaters Scan all heaters All measured values of all enabled heaters MESSAGE NO S3 06...

Page 70: ... 1 HT 2 1 to HT30 1 MR100 DISPLAYMODE Advanced RESTRICTIONS MR100 Interface Module This function sets the global ambient RTD for the heaters selected for freeze protection applications Refer to Appendix E for the operation details of this message MESSAGENO S3 13 APPLIESTO Interface Module DEFAULTVALUE N A VALUERANGE 50 Cto500 C 58 Fto932 F DISPLAYMODE Advanced RESTRICTIONS MR100 Interface Module T...

Page 71: ...d to If the display interface is an MR100 the baud rate applies to serial port 1 of the module selected MESSAGENO S3 17 APPLIESTO Interface Module DEFAULTVALUE 1200 VALUERANGE 600 1200 2400 4800 9600 DISPLAYMODE Advanced RESTRICTIONS None This function sets the communication baud rate for serial port 2 of the control module that the ML100 display is connected to If the display interface is an MR10...

Page 72: ...ce MESSAGENO S3 21 APPLIESTO Address Enabled Control Module DEFAULT VALUE no VALUE RANGE yes no DISPLAYMODE Advanced RESTRICTIONS MR100 Interface Module This function resets all values of the Control Module which has been placed in Address Enabled mode Select yes to proceed Select yes again to confirm This message asks you to confirm that the Control Module Address is enabled The Control Module Ad...

Page 73: ...odule DEFAULT VALUE no VALUE RANGE yes no DISPLAY MODE Advanced RESTRICTIONS MR100 Interface Module This function changes the Module Number of a connected Control Module which has been placed in Address Enabled mode Select yes to proceed Select yes again to confirm Enter the new Module Number The Module Number of each Control Module on a data highway or connected to a MR100 Interface Module must b...

Page 74: ...9c is displayed PRESS MSSG DOWN TO CONTINUE MODULE 1 ALREADY EXISTS CHECKING MODULE NUMBER 1 ô ô MESSAGENO S3 22c APPLIESTO Address Enabled Control Module DEFAULT VALUE None VALUE RANGE None DISPLAY MODE Advanced RESTRICTIONS MR100 Interface Module This message provides a last chance to confirm the Module Number Change Press MSSG ò to proceed This message indicates that the SET MODULE Number funct...

Page 75: ...e on Press MSSG ò to proceed Refer to Chapter 5 1 2 ô MESSAGENO S3 23a APPLIESTO Address Enabled Control Module DEFAULTVALUE None VALUERANGE None DISPLAY MODE Advanced RESTRICTIONS MR100 Interface Module If you receive the message NO RESPONSE check that the Control Module Address is enabled or refer to Appendix C Summary of Alarms and their Causes NO RESPONSEALARM Press MSSG ò to proceed MESSAGENO...

Page 76: ...he MR100 Interface Module was reset MESSAGENO S3 25 APPLIESTO Interface Module DEFAULTVALUE N A VALUERANGE N A DISPLAYMODE Advanced RESTRICTIONS None This message displays the firmware version number FIRMWARE VERSION D1 02 01 MESSAGENO S3 26 APPLIESTO Interface Module DEFAULTVALUE N A VALUERANGE N A DISPLAY MODE Advanced RESTRICTIONS None This message displays the operation manual version or reord...

Page 77: ...E NO S4 04 APPLIES TO Interface Module DEFAULT VALUE disabled VALUE RANGE enabled disabled DISPLAY MODE All RESTRICTIONS MR100 Interface Module This function manually controls of the alarm output for maintenance purposes For normal operation set to disabled If enabled is selected the alarm output is forced on until disabled is selected MESSAGE NO S4 05 APPLIES TO Selected Control Module DEFAULT VA...

Page 78: ...s in manual override if man on is displayed See MANUAL HEATER function MESSAGE NO M1 04 APPLIES TO Selected Heater DEFAULTVALUE N A VALUERANGE 50 to 500 C 58 to 932 F DISPLAY MODE All RESTRICTIONS None For single RTD modules the displayed value is the actual measured temperature of the RTD sensor for this heater circuit For dual RTD modules the displayed value is calculated from the actual measure...

Page 79: ...cing the circuit voltage MESSAGE NO M1 09 APPLIES TO Selected Heater DEFAULT VALUE N A VALUE RANGE 0 to 100 0 A DISPLAY MODE All RESTRICTIONS Three Phase Modules The displayed value is the actual phase A current of the heater circuit If the heater is off this value will be zero If the current exceeds the value range then O L is displayed The use of PROPORTIONAL CONTROL or POWER LIMIT functions can...

Page 80: ...t is the Module Number and the second part is the heater circuit within the Control Module Press VALUE ñ or VALUE ò and then press STORE to select a heater circuit For convenience and to reduce human error the Heater Name is also displayed MESSAGE NO M2 03 APPLIES TO Selected Heater DEFAULTVALUE N A VALUERANGE 50 to 500 C 58 to 932 F DISPLAY MODE Advanced RESTRICTIONS None The displayed value is t...

Page 81: ...as recorded To reset the displayed value press RESET To reset with all statistics use RESET STATISTICS function MESSAGE NO M2 08 APPLIES TO Selected Heater DEFAULT VALUE N A VALUE RANGE 0 to 100 0 A DISPLAY MODE Advanced RESTRICTIONS Three Phase Modules The displayed value is the highest Heater Current C since the last reset If the displayed value is O L a value greater than the maximum range was ...

Page 82: ...ted Heater DEFAULT VALUE N A VALUE RANGE 0 to 1 000 000 hours DISPLAY MODE Advanced RESTRICTIONS None The displayed value is the elapsed time since last reset To reset use RESET STATISTICS function MESSAGE NO M2 15 APPLIES TO Selected Heater DEFAULT VALUE N A VALUE RANGE 0 to 999 999 hours DISPLAY MODE Advanced RESTRICTIONS None The displayed value is the accumulated time that the heater circuit h...

Page 83: ...VALUE N A VALUE RANGE yes no DISPLAY MODE Advanced RESTRICTIONS None This function resets all the statistical values except Total Run Time Energy Used Last Day and Energy Cost Last Day Select yes and then press STORE You are asked to confirm your request Again select yes and then press STORE The statistical values are now cleared If the display interface is an ML100 this function resets the statis...

Page 84: ...e check for failed zones The measured Heater Current when the heater circuit is on is greater than or equal to the High Current Alarm setpoint or the Heater Current is greater than the maxi mum value range For three phase Control Modules the individual phase A B or C is identified ü Check that the alarm setpoint is correct ü For self regulating heating cable the current varies substantially with t...

Page 85: ... Test the RTD input ü RTD ShortAlarm can indicate RTD Board RTD Sampler RTDTransmitter failure ü RTD Open Alarm can indicate that a spare heater circuit is enabled The phase current is greater than or equal to 0 1 A when the heater circuit is off ü Check for switch failure ü Test the switch input or coil voltage When the heater circuit is off the input or coil voltage should be 0 Vdc Otherwise the...

Page 86: ...MASTERTRACE D 1 Appendix D Typical Wiring Diagrams MS 1DXH0 MS 1DIN2 MS 1TXH0 Appendix D Typical Wiring Diagrams ...

Page 87: ...D 2 MASTERTRACE Appendix D Typical Wiring Diagrams MS 2DXH0 MS 2DIN2 MS 5ADXH0 ...

Page 88: ...MASTERTRACE D 3 Appendix D Typical Wiring Diagrams MS 5ADIN2 MS 5ATXH0 ...

Page 89: ...D 4 MASTERTRACE Appendix D Typical Wiring Diagrams MS 10ADIN2 MS 10ADXH0 ...

Page 90: ...MASTERTRACE D 5 Appendix D Typical Wiring Diagrams MS 10ADIN2X MS 10ADIN2T ...

Page 91: ...D 6 MASTERTRACE Appendix D Typical Wiring Diagrams Driving Contactors Serial Communication 1 ...

Page 92: ...MASTERTRACE D 7 Appendix D Typical Wiring Diagrams Serial Communication 2 ...

Page 93: ... Heater 10 on the MS10 will use the local ambient RTD s temperature measurement as their temperature measurements This is a freeze protection application If NUM OF AMB SENSE HTRS Master 1 RTD1 on the MS10 will be the global ambient RTD Heater 1 on the MS10 will use the ambient RTD as its temperature sensor Heater 2 Heater 10 will use RTD2 RTD10 as their respective temperature sensors Also the MS10...

Page 94: ...TD sensors Using the special MS10 MR100 software this panel can be built in the following three configurations 1 Configuration 1 Panel without MR100 AMBI ENT SENSING HEATER HT 1 1 This configuration is illustrated in Figure E 1 In this configuration two MS10 modules are linked togather through a RS485 cable to form a network Three RTDs are equiped for temperature measurement RTD1 1 is the glo bal ...

Page 95: ...Appendix E Freeze Protection Figure E 1 Heat Tracing Panel Configuration 1 Panel without MR100 AMBIENT SENSING HEATER HT 1 1 Figure E 2 Heat Tracing Panel Configuration 2 Panel with MR100 AMBIENT SENSING HEATER HT 1 1 ...

Page 96: ...E 4 MASTERTRACE Appendix E Freeze Protection Figure E 3 Heat Tracing Panel Configuration 3 Panel with MR100 AMBIENT SENSING HEATER MR100 ...

Page 97: ...ments from RTD Sampler x to control heaters Here x is the address of the RTD Sampler The RTD Sampler is an independent temperature meas urement device and is usually located far away from the control module The address of an RTD Sampler can be set to a value between 0 to 15 by positions of the dip switches on board An RTD Sampler can measure either 10 or 20 RTD temperatures depending on the setup ...

Page 98: ... Appendix F FWireless and Wired RTD Figure F 1 On Board RTD Wiring Figure F 2 Transmit RTD Measurement via RS485 Cable RTD HEATTRACINGPANEL CONTROL MODULE RTD SAMPLER RTD RS485 CABLE HEAT TRACING PANEL 120VAC 4000 ft ...

Page 99: ...s and Wired RTD Figure F 3 Transmit RTD Measurement via RF Modem HEAT TRACING PANEL RTD SAMPLER RTD 120VAC 300 m Figure F 4 Transmit RTD Measurement via 18 AWG Wire RTD TRANSMITTER RTD 18 AWG WIRE HEAT TRACING PANEL 7 km CONTROL MODULE ...

Page 100: ...ides a graphical user interface to allow the operator to easily and quickly interpret the data collected from the field and program the controllers as required 2 QTERM A7 Touch Screen All human machine interface activities are through the 7 touch screen Figure G 1 is the typical desktop screen of QTERM A7 There are two iCons of critical importance to the operation of MR100 for Windows CE Figure G ...

Page 101: ...3 major parts 1 System pull up menu 2 Function page 3 Function page tap System pull up menu provides accesses to all operation tasks such as file open close password change etc Function page is MR100 s primary working area It displays all kinds of information which MR100 gathers from each heat tracing controller in the network It also provides a graphical user interface system for user to interfac...

Page 102: ...Vdc 30mA and can be directly wired to drive an LED type alarm indicator in Normally Open fashion The color of the indicator should agree with the jumper position on the Cable for QTERM A7 as shown in Figure G 3 On the System Setup Function Page there are 3 panels designed to setup the RS485 communication between MR100 and the heat tracing controllers They are Baud Rate Module Range and Communicati...

Page 103: ... C B GND C Cable for Mechanical Alarm NO Alarm Light Red On Alarm Jumper Green Off Alarm Jumper G G G 12Vdc 120Vac Power Supply MasterTrace Heat COM2 COM1 Windows CE Figure G 3 MR100 Overall System Communication Wiring Diagram 6 Setpoint Function Page Setpoint Function Page as shown in Figure G 4 displays all setpoint values of a selected heater It can be opened by a click on the Setpoint tap Figu...

Page 104: ...r Since the command could greatly alter the operation of the entire heat tracing panel an Are you sure window will pop up to get user s confirmation for the execution of this important command Baud Rate 1 and Baud Rate 2 located on lower portion of Setpoint Function Page are 2 drop down edit boxes designed to change the selected module s communication baud rates of serial port 1 and 2 respectively...

Page 105: ...green color on Measurement Statistics Function Page To use this command button to reset all the statistic data of the selected heater one must follow these procedures 1 Click the Reset Statistics button to start the reset action 2 Confirm Cancel the reset action by clicking the Yes No box on the confirmation box Figure G 6 Alarm Function Page ...

Page 106: ...uttons located on the right hand side of the table to view other alarms on different pages Some alarms are latched alarms Along with a latched alarm there is one Reset button displayed in green color on the right side of the alarm row To reset a latched alarm follow these procedures 1 Click on the Reset button to start the reset action 2 Confirm Cancel the reset action by clicking the Yes No box o...

Page 107: ... includes three operations They are 1 Reset Control Module It is designed to reset the setpoints of all heaters on a control module to their default values 2 Read Module Number It is designed to read the module number of a control module 3 Set Module Number It is designed to set the module number of a control module Each operation can be carried out if the following 2 conditions are met 1 MR100 s ...

Page 108: ...be started Note Upon completion of a Module Commissioning Addressing operation the target control module must get out of its listening new address mode This can be realized by setting the target control module s ADRESS dip switch to Disable position 11 Change Password Password if there is one is required if you want to change Program Enable in System Setup Function Page The default password is no ...

Page 109: ...ROVIDED 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 TIO...

Page 110: ...MASTERTRACE TM HEAT TRACING CONTROL P N 1501 0006_1 MT06 16 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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