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Nextron MASTERTRACE MS-2102 Operator's Manual

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MASTER TRACE MS-2102
HEAT TRACING CONTROL
OPERATOR'S MANUAL

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Summary of Contents for Nextron MASTERTRACE MS-2102

  • Page 1 MASTER TRACE MS-2102 HEAT TRACING CONTROL OPERATOR’S MANUAL...

  • Page 2: Table Of Contents

    MS-2102 Contents 1 Product Overview ........................1.1 Introduction ................................. 1.1 Specifications ................................1.2 Summary of Features ..............................1.3 Use of this Manual ..............................1.3 Conventions ................................1.3 Shipping Content ............................... 1.3 Theory of Operation ..............................1.4 2 Installation ........................... 2.1 Unpacking the Controller ............................
  • Page 3 MS-2102 Contents 7 Alarms ............................7.1 Overview ..................................7.1 Trip or Failure Alarms ..............................7.1 Process Alarms ................................7.2 Warning Alarms ................................7.2 Reset Alarms ................................7.3 8 Communications ......................... 8.1 Overview ..................................8.1 Physical Layer ................................8.1 Modbus Protocol ................................ 8.1 Modbus Memory Map ..............................

  • Page 4: Product Overview

    MS-2102 Chapter 1 Product Overview Introduction A MS2102 Control Module is mounted near the pipes The MS-2102 two-point heat tracing controller uses a being traced to monitor the heater points. This Control microprocessor and is intended for stand-alone heat trace applications.

  • Page 5: Specifications

    MS-2102 Chapter 1 Product Overview Specifications Enclosure Type: Nema-4X steel, painted black Temperature Input Size: 10”Hx8”Wx6”D Range: -50 to +500°C (-58 to 932°F) Features: Quick release latches to open door Accuracy: ±2°C Flat aluminum plate to act as heatsink Repeatability: ±1°C and mounting flange for mounting on RTD:...

  • Page 6: Summary Of Features

    MS-2102 Chapter 1 Product Overview Summary of Features Inputs Control 2-RTD Sensors, one per circuit Temperature (On/Off- Deadband) 1-Override Temperature -Proportional PowerLimiting Monitoring RTD Temperatures Early Warning (TraceCheck) Heater Current Low and High Current Heater Voltage GF Alarm GF Current GF Trip Alarms Communications...

  • Page 7: Theory Of Operation

    MS-2102 Chapter 1 Product Overview Theory of Operation Current, Ground Fault and Voltage Sensing Controller functions are controlled by a microprocessor that measures all analog signals and logic inputs, control Current transformers and high impedance voltage dividers heater outputs and alarm contacts, and reads all user are used to scale-down the incoming heater current, input including communications and outputs to the ground fault current and voltage.
  • Page 8 MS-2102 Chapter 1 Product Overview ≤ Cycle modulating the current through the heater has the effect of turning the heater on and off rapidly and < < DB(t) therefore, power output is reduced in the long run. Since the switching is zero-cross controlled, the controller ≥...
  • Page 9 MS-2102 Chapter 1 Product Overview On/Off Control with Deadband The default control mode of the controller is deadband control or simply on/off control with the proportional control setting turned off. On/off control without deadband (that is deadband set to 0 C° or 0 F°; note that these units denote the temperature differential with “°”...
  • Page 10 MS-2102 Chapter 1 Product Overview Figure 1.5 Hardware Block Diagram...

  • Page 11: Installation

    MS-2102 Chapter 2 Installation Unpacking the Controller Check the shipping cartons for damage, or other signs of • T5 Earth Ground: (terminal 1). rough handling or abuse. If damaged, notify the shipping • T6 Heater 1 Power Input: 85-280Vac/30A max carrier at once.
  • Page 12 MS-2102 Chapter 2 Installation Figure 2.1 Main Board Layout Figure 2.2 Power Board Layout...

  • Page 13: Mounting The Controller

    MS-2102 Chapter 2 Installation Mounting the Controller Ground Connection Mount the control panel with Unistrut brackets using 1/2” Connect the controller grounding stud directly to a bolts. The Unistrut (or equivalent) mounting allows air ground bus using the shortest, practical path. Use a circulation to cool the heat-sink.

  • Page 14: Communication Wiring

    MS-2102 Chapter 2 Installation You must install the RTD sensor on the pipe surface or number of devices over 32. Avoid star or stub thermal well before the pipe insulation to ensure proper connections. thermal contact. The RTD position should be 180° from Terminate the first and last device in the daisy-chain loop.
  • Page 15 MS-2102 Chapter 2 Installation Figure 2.6 Mounting Dimensions Figure 2.7 Typical Wiring Diagram Warning - Explosion Hazard - Do not Warning - Explosion Hazard - Substitution disconnect equipment unless power has of components may impair suitability for been switched off or the area is known to be Class 1, Division 2 or Class 1, Zone 2.

  • Page 16: Getting Started

    MS-2102 Chapter 3 Getting Started Introduction Selecting the Heater The MS-2102 has many features that provide trouble-free To select the heater circuit, operation of heat tracing installations. 1. Press [SETPOINTS] once to access the Setpoints An example is presented to illustrate MS-2102 setup and Operating Values group of messages.
  • Page 17 MS-2102 Chapter 3 Getting Started to 16 characters to the name of a heater. Now that the MS-2102 control is ready for programming. For further information about the organization of all the To assign a heater name, messages or for details on the range and application of 1.Press [SETPOINTS] twice to enter the Heater Setup each message see Chapter 6 Setpoint Values.

  • Page 18: Testing Heater & Alarms

    MS-2102 Chapter 3 Getting Started followed by the new name that has been stored: heater is now set to 50 °C. 4. Press [MESSAGE ] after each setpoint to access the HTR 1-2 NAME: next setpoint. HEAVY OIL LINE 5. Hold [VALUE ] down until the word OFF appears to defeat any setpoint not required.

  • Page 19: Monitoring System Status

    MS-2102 Chapter 3 Getting Started 4. Press [STORE] to save the value. This is the temperature value that the controller will use 5. With the heater forced on, verify that the expected with the heater setpoint to determine the heater output. current is flowing using the actual current message, The 2 heaters in MS-2102 use the actual temperatures of located in ACTUAL\OPERATING VALUES\HEATER...
  • Page 20 MS-2102 Chapter 3 Getting Started Press [MEASURED] then [MESSAGE ] 6 times to Set the PROGRAM ENABLE dip switch to DISABLE to display: prevent accidental setpoint changes or tampering. By following this procedure, it should be fairly easy to install a similar control application.

  • Page 21: Front Panel Operation

    MS-2102 Chapter 4 Front Panel Operation Overview The front panel provides the local operator with LCD Status Lights alphanumeric display and keypad. The display and status Refer to Figure 4.1 Display, Front View. indicators update alarm and status information automati- •...
  • Page 22 MS-2102 Chapter 4 Front Panel Operation Figure 4.1 Display, Front View Figure 4.2 Contrast Control...

  • Page 23: Startup Messages

    Startup messages are displayed when power is applied to the controller. MASTERTRACE HEAT This message displays the controller model. TRACING CONTROL NEXTRON This message displays company name of the supplier. CORPORATION FIRMWARE VERSION This messages displays the firmware version number.

  • Page 24: Flash Messsages

    MS-2102 Chapter 4 Front Panel Operation This message appears when the user has scrolled through all alarms. NO MORE ALARMS Flash Messages Flash messages are warnings, errors or general informa- SETUP\SCAN TIME. The factory default is three tion displayed in response to a key press. The duration of seconds.

  • Page 25: Measured Values

    MS-2102 Chapter 5 Measured Values Overview Values of the selected heater in the control module. Access values and statistics in the Measured Values The Measured Values Menu is arranged in two groups. mode. The messages are organized into groups for easy Pressing [MEASURED] twice quickly access the top of reference as shown below.

  • Page 26: Operating

    MS-2102 Chapter 5 Measured Values Operating MESSAGE NO: M1-01 APPLIES TO: Control Module MEASURED: DEFAULT VALUE: N/A VALUE RANGE: N/A OPERATING VALUES DISPLAY MODE: All RESTRICTIONS: None MESSAGE NO: M1-02 APPLIES TO: Control Module DEFAULT VALUE: HT M-1 VALUE RANGE: HT M-1 to M-2 SELECT HT M-1 NONAME DISPLAY MODE:...
  • Page 27 MS-2102 Chapter 5 Measured Values MESSAGE NO: M1-07 APPLIES TO: Selected Heater HEATER AT 100% DEFAULT VALUE: N/A VALUE RANGE: 0 to 100% POWER DISPLAY MODE: Advanced RESTRICTIONS: None The displayed value is the percentage duty cycle of the heater circuit. For example, with PROPORTIONAL CONTROL and/or POWERLIMIT on, a percentage duty cycle of 30% means that the circuit is energized for 3 out of 10 power cycles.
  • Page 28 MS-2102 Chapter 5 Measured Values Statistics MESSAGE NO: M2-13 APPLIES TO: Control Module MEASURED: DEFAULT VALUE: N/A VALUE RANGE: N/A STATISTICS DISPLAY MODE: Advanced RESTRICTIONS: None MESSAGE NO: M2-14 APPLIES TO: Control Module DEFAULT VALUE: HT M-1 VALUE RANGE: HT M-1 to M-2 SELECT HT M-1 NONAME DISPLAY MODE:...

  • Page 29: Statistics

    MS-2102 Chapter 5 Measured Values MESSAGE NO: M2-20 APPLIES TO: Selected Heater MAX GROUND FAULT DEFAULT VALUE: N/A VALUE RANGE: 0, 10 to 1000 mA,O.L. CURRENT: 15mA DISPLAY MODE: Advanced RESTRICTIONS: None The displayed value is the highest Ground Fault Current since the last reset. If the displayed value is O.L., a value greater than the maximum range was recorded.
  • Page 30 MS-2102 Chapter 5 Measured Values MESSAGE NO: M2-27 APPLIES TO: Selected Heater HEATER IS ON DEFAULT VALUE: N/A VALUE RANGE: 0 to 100% 17% OF THE TIME DISPLAY MODE: Advanced RESTRICTIONS: None The displayed value is the percentage of time that the heater circuit has been on since the last reset.

  • Page 31: Setpoint Values

    MS-2102 Chapter 6 Setpoint Values Overview allows you to program and test the Control Module.The The MS-2102 has a considerable number of programming Setpoint Menu is arranged in four groups. Pressing setpoints for flexibility. Setpoint messages are organized [SETPOINT] twice quickly to access the top of the into groups for easy reference as shown below.

  • Page 32: Setpoints Entering

    MS-2102 Chapter 6 Setpoint Values Setpoints Entering Setpoint Access Security Prior to operating the heat trace, you must enter process The setpoint access security is achieved via the Program setpoints, alarm levels and alarm output configuration via Enable Dip Switch. You can program setpoints through front panel keypad and display, RS485 port or SCADA the keypad by setting the program enable dip switch to system running user written software.
  • Page 33 MS-2102 Chapter 6 Setpoint Values MESSAGE NO: S1-05 APPLIES TO: Selected Heater LOW TEMPERATURE DEFAULT VALUE: 5°C VALUE RANGE: -50 to 500 °C, off ALARM: 120°C 41°F -58 to 932 °F, off DISPLAY MODE: RESTRICTIONS: Heater Setpoint must not be off.
  • Page 34 MS-2102 Chapter 6 Setpoint Values MESSAGE NO: S1-09 APPLIES TO: Selected Heater C: LOW CURRENT DEFAULT VALUE: off VALUE RANGE: 0.5 to 30.0/100.0 A, off ALARM: 10.5A DISPLAY MODE: RESTRICTIONS: MS2102-1TXHx panel This function sets the phase C: Low Current Alarm setpoint. It must be less than the phase C: High Current Alarm setpoint.
  • Page 35 MS-2102 Chapter 6 Setpoint Values MESSAGE NO: S1-13 APPLIES TO: Selected Heater HIGH CURRENT DEFAULT VALUE: off VALUE RANGE: 0.5 to 30.0/100.0 A, off TRIP: 15.0A DISPLAY MODE: RESTRICTIONS: None This function sets the High Current Trip setpoint. It must be greater than the Low Current Alarm setpoint and the High Current Alarm setpoint.
  • Page 36 MS-2102 Chapter 6 Setpoint Values MESSAGE NO: S1-17 APPLIES TO: Selected Heater GROUND FAULT DEFAULT VALUE: 30 mA VALUE RANGE: 10 to 1000 mA,off TRIP: 100mA DISPLAY MODE: Advanced RESTRICTIONS: None This function sets the Ground Fault Trip setpoint. It must be greater than the Ground Fault Alarm setpoint.

  • Page 37: Heater Setup

    MS-2102 Chapter 6 Setpoint Values Heater Setup MESSAGE NO: S2-01 APPLIES TO: Control Module DEFAULT VALUE: N/A VALUE RANGE: N/A SETPOINTS: DISPLAY MODE: Advanced RESTRICTIONS: None HEATER SETUP This message displays the name of the sub-menu when entered. MESSAGE NO: S2-02 APPLIES TO: Control Module...
  • Page 38 MS-2102 Chapter 6 Setpoint Values MESSAGE NO: S2-06 APPLIES TO: Selected Heater AUTO TUNING DEFAULT VALUE: off VALUE RANGE: 1 to 24 hrs, off PERIOD: off DISPLAY MODE: Advanced RESTRICTIONS: Heater Setpoint must not be off. This function sets the Auto Tuning Period. Once the period is set, the controller would automatically adjust its proportional control gain constant based on the system performance data every Auto Tuning Period.

  • Page 39: System Setup

    MS-2102 Chapter 6 Setpoint Values System Setup MESSAGE NO: S3-01 APPLIES TO: Control Module SETPOINTS: DEFAULT VALUE: N/A VALUE RANGE: N/A SYSTEM SETUP DISPLAY MODE: All RESTRICTIONS: None This message displays the name of the sub-menu when entered. MESSAGE NO: S3-02 APPLIES TO: Control Module...
  • Page 40 MS-2102 Chapter 6 Setpoint Values MESSAGE NO: S3-08 APPLIES TO: Control Module STAGGER START: DEFAULT VALUE: off VALUE RANGE: on, off DISPLAY MODE: Advanced RESTRICTIONS: None This function staggers the power up of heater circuits to eliminate tripping of the main breaker.

  • Page 41: Setpoint Tests

    MS-2102 Chapter 6 Setpoint Values MESSAGE NO: S3-14 APPLIES TO: Control Module DEFAULT VALUE: N/A VALUE RANGE: N/A MANUAL VERSION 1501-0019 DISPLAY MODE: Advanced RESTRICTIONS: None This message displays the operator manual version or recorder number. MESSAGE NO: S3-15 APPLIES TO: Control Module DEFAULT VALUE: N/A VALUE RANGE: N/A...

  • Page 42: Alarms

    MS-2102 Chapter 7 Alarms Overview The MS-2102 is capable of generating many different section throughout this chapter. types of alarms. In this chapter, alarms are organized in Access alarms by pressing [STATUS] where the total three groups: trip or failure, heater and warning. Each number of alarms is displayed.

  • Page 43: Process Alarms

    MS-2102 Chapter 7 Alarms Process Alarms The Heater Control Temperature is greater than or equal to the High Temperature Alarm setpoint. HIGH TEMPERATURE Check that the alarm setpoint is correct. ALARM Test for correct RTD operation. Check the heat trace design. The Heater Control Temperature is less than or equal to the Low Temperature Alarm setpoint.

  • Page 44: Reset Alarms

    MS-2102 Chapter 7 Alarms Reset Alarms Some alarms such as TraceCheck type, Ground Fault Trip To reset alarms, and Ground Fault test are latching. The alarm remains on 1. Press [STATUS]. the display even after the alarm condition has gone away. 2.

  • Page 45: Communications

    MS-2102 Chapter 8 Communications Overview The MS-2102 heat trace controller communicates with from 1 to 250; refer to Chapter 6 Setpoint Values for computerized equipment such as programmable logic details. Only the addressed slave responds to a packet that controllers, desktop computers or man-machine interfaces starts with its module number.
  • Page 46 MS-2102 Chapter 8 Communications This command can access only the variable registers with Master Query: It consists of module address, function Memory Location Index between 0 (the first index in code, memory location index of the variable register, data Module Setup Group) and 164 (the last index in Heater value FF00 Hex and CRC error check.
  • Page 47 MS-2102 Chapter 8 Communications s " s " ) " r ) " ° 0 t s i 300 °C. Here are transmission and response messages: Module Commissioning & Addressing s " A MS-2102 module contains a whole set of setpoints and ) "...

  • Page 48: Modbus Memory Map

    MS-2102 Chapter 8 Communications transmission. When a MS-2102 module detects an error other than a framing, format, overrun or CRC error, a response will be sent to the master. The most significant bit of the FUNC- TION CODE byte will be set to 1 (that is the function code sent from the slave will be equal to the function code sent from the master plus 128).

  • Page 49: Commissioning

    MS-2102 Chapter 9 Commissioning Overview Figure 9.1 Resistance versus Temperature in °C You can use the procedures in this chapter to verify the (DIN 43760 RTD) proper operation of the MS-2102. Although not a com- plete functional verification, these tests will check major operating functions.

  • Page 50: Heater Voltage And Current Test (Ms2102 Controller Only)

    MS-2102 Chapter 9 Commissioning Choose a test temperature for each RTD input and either 208 or 240VAC. 120VAC will work but will not select corresponding resistances for each of the provide an effective test range for voltage testing. resistance decade boxes using the table of RTD 3.

  • Page 51: Ground Fault Current Test

    MS-2102 Chapter 9 Commissioning Ground Fault Current Test factory for service. Disconnect the load bank after the test. Internal GF Test The controller comes with a ground fault test function The test procedures for heater 2 ground fault current are that can be executed from the display as same as the above procedures except that the load (SETPOINTS\SETPOINT TEST\GF TEST).

  • Page 52: Placing The Controller In Service

    MS-2102 Chapter 9 Commissioning Heater 1 should now be off. Verify by checking the breaker rating is appropriately sized. Trun on the lamp is off. STAGGER START function to reduce the inrush current. 10. Short override input, terminals 24 and 25 with a short Ground Faults: piece of wire.

  • Page 53: Completing The Installation

    MS-2102 Chapter 9 Commissioning HEATER GOES. The choice of on or off depends on the the heat trace. For powerlimit to work properly, the application. powerlimit current should be below the nominal current rating of the heat trace. For example, if the heat trace Cost of Power draws 20A at its rated voltage and the application only requires 75% of its rated output, a powerlimit current of...

  • Page 54: Warranty

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

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