Nextron MASTERTRACE MS-2101 Manuel utilisateur

MASTERTRACE MS-2101

OPERATOR’S MANUAL

HEAT TRACING CONTROL

MS-2101 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 .......................................................................................................................... 2.1

Control Module ......................................................................................................................................... 2.1

Mounting the Controller ............................................................................................................................ 2.3

Wire Sizing ............................................................................................................................................... 2.3

Conduit and Cabling ................................................................................................................................. 2.3

Power Wiring ........................................................................................................................................... 2.3

Heater Wiring ........................................................................................................................................... 2.3

Ground Connection .................................................................................................................................. 2.3

RTD Sensor Wiring .................................................................................................................................. 2.3

Communication Wiring ............................................................................................................................. 2.4

Alarm Wiring ............................................................................................................................................ 2.4

3 Getting Started.............................................................................................................. 3.1

Introduction .............................................................................................................................................. 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 Messsages ..................................................................................................................................... 4.4

5 Measured Values .......................................................................................................... 5.1

Overview .................................................................................................................................................. 5.1

Operating ................................................................................................................................................. 5.2

Statistics ................................................................................................................................................... 5.3

6 Setpoint Values............................................................................................................. 6.1

Overview .................................................................................................................................................. 6.1

Setpoints Entering .................................................................................................................................... 6.2

Setpoint Access Security .......................................................................................................................... 6.2

Operating ................................................................................................................................................. 6.2

Heater Setup ............................................................................................................................................ 6.5

System Setup ........................................................................................................................................... 6.8

Setpoint Tests......................................................................................................................................... 6.11

ContentsMS-2101

7 Alarms ........................................................................................................................... 7.1

Overview .................................................................................................................................................. 7.1

Trip or Failure Alarms ............................................................................................................................... 7.1

Process Alarms ........................................................................................................................................ 7.2

Warning Alarms ........................................................................................................................................ 7.3

Reset Alarms............................................................................................................................................ 7.3

8 Communications .......................................................................................................... 8.1

Overview .................................................................................................................................................. 8.1

Physical Layer .......................................................................................................................................... 8.1

Modbus Protocol ...................................................................................................................................... 8.2

Modbus Memory Map .............................................................................................................................. 8.4

Modbus Map Data Format ....................................................................................................................... 8.6

9 Commissioning ............................................................................................................ 9.1

Overview .................................................................................................................................................. 9.1

Requirements ........................................................................................................................................... 9.1

RTD Input Test ......................................................................................................................................... 9.1

Heater Voltage and Current Test .............................................................................................................. 9.2

Ground Fault Current Test ........................................................................................................................ 9.3

Alarm Output Test .................................................................................................................................... 9.3

Override Input Test ................................................................................................................................... 9.4

Placing the Controller in Service .............................................................................................................. 9.4

Completing the Installation ....................................................................................................................... 9.6

Warranty .............................................................................................................Back Cover

1.1

MS-2101 Chapter 1 Product Overview

Introduction

The MS-2101 single-point heat tracing controller uses a

microprocessor and is intended for stand-alone heat trace

applications. It can be for use with mineral-insulated, self-

regulating or constant-wattage cable for freeze protection,

process control and instrument tracing. The MS-2101 is

intended for indoor or outdoor installations in ordinary or

hazardous locations.

MS-2101 offers many advantages over other heat tracing

control schemes, which generally use some combination

of mechanical thermostats, custom-built panels or pro-

grammable controls to provide control, monitoring and

alarm functions. Budgetary constraints usually limit the

degree of system fault monitoring to less than optimal

levels. This results in periodic costly process shutdowns

due to process or hardware malfunctions. Equipment

reliability concerns often force plant procedures to

include annual thermostat performance checks to ensure

that the device is still operating as intended. This can be

a tedious, labour intensive job.

A controller is mounted near the pipe being traced to

monitor the heater point. This controller can communi-

cate with a single master unit to give complete system

monitoring and control from a convenient location. Up to

32 controllers can be monitored on a RS485 data highway

to a centrally located master. By connecting controls to a

data highway, the MS-2101 can immediately flag alarms

caused by heat tracing malfunctions, altered setpoints and

monitor actual values from a central location. Each local

control is completely independent and will continue to

function if the master fails or if the communication link

fails. This ensures maximum reliability and minimizes

vulnerability in the event of a hardware failure. Addi-

tional points can easily be added at any time as easily as a

mechanical thermostat can be installed. Unlike control

schemes using programmable controllers, no software

development is required. The complete system is opera-

tional as soon as it is installed.

Figure 1.1 Typical MS-2101 Installation

1.2

MS-2101 Chapter 1 Product Overview

Specifications

Temperature Input

Range: -50 to +500°C (-58 to 932°F)

Accuracy: ±2°C

Repeatability: ±1°C

RTD: Two, 100 ohm platinum, 3-wire RTD

20 ohms maximum lead resistance

Heater Switching

Configuration: One circuit, Two-pole, one SCR per

phase, 800 amp 1 cycle inrush

Ratings: 85-280Vac, 30A continuous

Line Frequency: 50 or 60Hz

Current Measurement: 0.1 to 30A 3%±0.2A

GF Measurement: 10 to 1000mA 5%±2mA

Voltage Measurement: 0 to 300Vac 3%±2V

Control Power

Power Requirement: Control power from heater voltage

85-280VAC, 10VA max

Protection: Control power from heater voltage

protected by 2A fuse

MOV transient protection

Communications

Port: (1) Serial network connection

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: 32 Control Modules.

Measured Values

Temperature: -50 to 500°C (-58 to 932°F)

Minimum Temperature: -50 to 500°C (-58 to 932°F)

Maximum Temperature: -50 to 500°C (-58 to 932°F)

Heater Current: 0.1 to 60A

Ground Fault Current: 10 to 1000mA

Min. Heater Voltage: 85 to 300Vac

Max. Heater Voltage: 85 to 300Vac

Power Consumption: 0 to 1,000 MWh

Operating Cost: 0 to $1,000,000.00

User Interface

Display: 16-character x 2-line LCD Alpha-

numeric display

Keypad: 9 tactile keys, polyester faceplate

- Setpoint, measured, status

- Message Up, Message Down

- Value Up, Value Down

- Reset

- Store

Contrast: Adjustable by potentiometer

Panel Indicators: Power on

Heater on

Serial communication active

System fail

Process alarm

Security: Controller parameters password protected

Environment

Approvals: CSA NRTL/C and FM

Class 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.

One 3/4” conduit knockout for power

and three 1/2” conduit knockouts for RTD

and signal wiring.

Alarm Output

Alarm: Programmable for NO or NC contact

One Mechanical (dry) contact

Alarm Rating: Mechanical contact: 30Vdc/100mA,

120Vac/0.52A, 62.5W Max

Alarm Output: LED Indicator: 5Vdc/50mA

Alarm Function

Temperature: High Temperature Alarm

Low Temperature Alarm

Current: Low Current Alarm

High Current Alarm

Ground Fault Current: Ground Fault Current Alarm

Ground Fault Current Trip

Voltage: High Voltage Alarm

Low Voltage Alarm

Hardware: Self-Check Failure

Switch Shorted

RTD Open

RTD Shorted

Continuity

User-Definable Options

Heater Status: Enable or Disable

Heater Name or Tag: 16 Character Alphanumeric

Temperature Units: °C or °F

Proportional Control: on or off

Deadband: 1 to 50C° (2 to 90F°)

PowerLimit: 0.1 to 30A, off

SoftStart: 10 to 999s, off

TraceCheck: 1 to 24hrs, off

Temperature Setpoint: -50 to 500°C (-58 to 932°F), off, none

High Temp Alarm: -50 to 500°C (-58 to 932°F), off

Low Temp Alarm: -50 to 500°C (-58 to 932°F), off

High Current Alarm: 0.1 to 30A, off

Low Current Alarm: 0.1 to 30A, off

Ground Fault Alarm: 10 to 1000mA, off

Ground Fault Trip: 10 to 1000mA, off

High Voltage Alarm: 85V to 300V, off

Low Voltage Alarm: 85V to 300V, off

RTD Definition: Single, Backup, Highest, Lowest,

Average or High Temperature Cutout

RTD Fail-safe: Heater On or Heater Off

Heat Trace Curve: disable, user, LT3, 5, 8, 10

HLT3, 5, 8, 10, 12, 15, 18, 20

Override: On or Off

Alarm Contacts: NO or NC for each contact

Alarm Light: Alarm on, Alarm off, Flash during alarm

then on, Flash during alarm then off

Ground Fault

Maximum Trip Time: 3.7 seconds

1.3

MS-2101 Chapter 1 Product Overview

Inputs

y2-RTD Sensors

y1-Override

Monitoring

yRTD Temperatures

yHeater Current

yHeater Voltage

yGF Current

Alarms

yLow and High Current

(Compensated by heat trace curve for

Self-regulating cable)

yLow and High Temperatures

yContinuity

yGF Alarm

yGF Trip

ySwitch Failure

ySensor Failure

ySelf-Test Failure

Outputs

y1-Mechanical (dry) Contact

y1-LEDAlarm Indicator

Statistics

yMinimum and Maximum Temperatures

yMaximum Current

yMaximum Ground Fault

yMinimum and Maximum Voltage

yEnergy (MWh)

yEnergy Cost

Control

yTemperature (On/Off- Deadband)

yTemperature -Proportional

yPowerLimiting

ySoftstart

Early Warning (TraceCheck)

yLow and High Current

yContinuity

yGF Alarm

yGF Trip

Communications

y1-RS485

yModbus Protocol

Environment

yCSA Certified and FM Approved for Hazardous

Locations

yWeatherproof, NEMA-4X Enclosure

y-40°C to +50°C Operating Temperature Range

(LCD: -20°C to +50°C)

User Interface

y32 Character LCD Display

yLED Indicators on Faceplate

yClear, English Language Messages

yIntuitive Message Structure

yTactile Keys

yAccess Security

Summary of Features

Using This Manual

Detailed information relating to switch and output ratings,

accuracy and so forth are detailed in Chapter 1 Specifica-

tions.Chapter 2 Installation discusses important mount-

ing and wiring issues for reliable operation. Chapter 3

Getting Started provides a step-by-step tutorial for a heat

trace application. The remainder of this manual should be

read and kept for reference to provide the maximum

benefit of the MS-2101.

Conventions

The following conventions are used in this manual.

"User Changeable Values

Retrieved Data

[ ] Key Press

Shipping Content

MS-2101 Heat Trace Controller

MS-2101 Instruction Manual with Warranty Card

1.4

MS-2101 Chapter 1 Product Overview

Theory of Operation

Controller functions are controlled by a Intel 80C32 8-bit

microprocessor that measures all analog signals and logic

inputs, control heater output and alarm contacts, and

reads all user input including communications and outputs

to the faceplate display and LEDs. Consult the hardware

block diagram in figure 1.8 for details. The remainder of

this chapter describes the algorithms and operation of

some of the controller functions.

RTD Sensing

An RTD changes its resistance in a precision relationship

to temperature. This resistance is sensed by passing a

constant current through the RTD and measuring the

resulting voltage across the RTD (resistance = voltage/

current). The voltage appearing across RTD1 terminals

6&8 and RTD2 terminals 10&12 also includes the

resistance of the inter-connecting wiring to the RTD,

which varies with wire length, size and ambient tempera-

ture. By using a three-wire sensing scheme and a lead

resistance compensation circuit, the lead resistance is

cancelled out to give a voltage proportional to the true

RTD sensor temperature.

RTDs respond in a known but non-linear fashion to

temperature, which if uncorrected could lead to signifi-

cant errors over the temperature range of the controller.

Consequently, some means is 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 through a full wave rectifier and filter to obtain a

DC signal. The DC signals are then converted to digital

values by a 10 bit A/D converter before finally being

passed on to the CPU for analysis.

Each of the three DC signals are sampled 300 times with

zero cross synchronization so that the sampling covers an

exact span of ten power cycles. This is to ensure that

heater current values are consistently measured when the

heater output cycle is modulated by the powerlimit,

softstart or proportional control functions.

Powerlimit

The powerlimit function allows the heater to operate

below its rated power by cycle modulation. Cycle

modulation is accomplished by controlling the integral

number power cycles into the heater over a periodic time

frame. The MS-2101 uses a ten cycle time frame. The

integral number of power cycles per time frame is called a

duty cycle. With a ten cycle time frame, there are ten duty

cycles possible. For each duty cycle, there is a fixed

pattern that defines the number of power cycles in which

the heater is on and off. This is shown in figure 1.2:

Figure 1.2 Cycle Modulation - 10 Cycle Frame

1.5

MS-2101 Chapter 1 Product Overview

Cycle modulating the current through the heater has the

effect of turning the heater on and off rapidly and

therefore, power output is reduced in the long run. Since

the switching is zero-cross controlled, the controller

knows exactly when power cycles start and finish. Zero-

cross switching also helps reduce power harmonics that

generate unnecessary interference.

The heater current (average current) measured by the

controller while cycle modulation is in effect may be

approximated as follows:

Heater Current at 100% x Duty Cycle = Average Current

When powerlimit is enabled, a powerlimit current is set

by the user. This is essentially the desired average current.

The powerlimit control algorithm ensures that the actual

current will not exceed the powerlimit setting while

optimizing the maximum duty cycle possible. When the

average current exceeds the powerlimit setting, the duty

cycle is reduce by 10%. When the average current is

below the powerlimit setting, the duty cycle is increased

by 10%. Before the algorithm increases or decreases the

duty cycle, the controller waits until the heater current has

reached steady-state at the current duty cycle setting. If

the heater is initially off and the controller calls for heat,

the duty cycle starts at zero and increases by 10%

increments until it reaches a steady-state value. This

ramping up effect provides a current-driven softstart

whenever the controller calls for heat unlike the softstart

function, which is time driven.

Softstart

During cold temperature startups with self-regulating heat

trace cables, the current driven softstart built into the

powerlimit function may not be long enough to overcome

the inrush current. The softstart function is separate from

powerlimit and is time driven where for when you set the

softstart period. Having the two separate functions is

desirable when powerlimit may not be required by the

application but softstart is essential to avoid nuisance

breaker trips during cold startups. The controller applies

the softstart function initial startup when the controller is

powered up.

Operation of the softstart function varies depending on

whether or not powerlimit and/or proportional control are

enabled. When powerlimit and proportional control are

off, operation is simplified. The softstart function uses

cycle modulation to gradually increase power output over

the softstart period. Since most circuit breakers are the

thermal type, the cycle modulated output appears as a

reduced load to the circuit breaker.

During controller power-up and assuming the controller is

calling for heat, the duty cycle starts at 10% and incre-

ments by 10% until full power is reached. Since there are

ten duty cycle increments, the time that the controller

maintains each duty cycle setting is the softstart setting

(softstart period) divided by 10. The softstart operation

powerlimit and proportional control off is shown by the

curve in figure 1.3.

Figure 1.3 Softstart Curve with Powerlimit and

Proportional Control Disabled

With powerlimit enabled, the only difference is that

instead of the duty cycle ramping to 100%, it stops at the

value determined by the powerlimit function such that the

average current does not exceed the powerlimit current

set by the user. The maximum duty cycle setting is

approximated by the controller initially so that the time

period for each duty cycle increment can be determined.

The softstart operation with powerlimit enable is shown

by the curve in figure 1.4.

Figure 1.4 Softstart Curve with Powerlimit Enabled

When proportional control is turned on, the maximum

duty cycle available to the controller is constrained by the

powerlimit current if enabled and softstart.

1.6

MS-2101 Chapter 1 Product Overview

Proportional Control

Unlike on/off control where the heater is fully on or off,

proportional control can partially turn on the heater. The

heater output is proportional 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 expressed using the

following equations:

secondsintime

C)(

C)(peratureheater tem

C)(emperaturesetpoint theater

cycle)C/duty(infactordeadband)(

cycleduty)(Where

)()(1)(

)()(0

)(

0)(0)(

°==

°=

≥=

<<=

≤=

∆TTs-T(t)e(t)

T(t)

tDB

tDBteiftd

tDBteif

DB(t)

teiftd

The deadband factor DB(t) is a time constant that

determines the slope of change of the proposed heater on

duty cycle with the temperature difference. It is adjusted

between 1 to 10 each hour to minimize the difference

between the measured temperature and the temperature

setpoint. Every hour after power up, the controller

calculates the absolute values of the temperature

differences e(t) and sums them during the hour. Then the

total absolute temperature difference is divided by the

number of temperature readings taken during the hour.

The result is called the Average Absolute Temperature

Difference (AATD) for the hour. If current AATD is

smaller than the AATD in the previous hour, the deadband

factor will be increased or decreased in the same

direction. If current AATD is larger than the AATD in the

previous hour, the deadband factor will be increased or

decreased in the reversed direction. At steady state, the

deadband factor used will fluctuate around a optimum

value.

Figure 1.5 shows the relationship between the proposed

heater on duty cycle and the temperature difference for

different deadband factors used.

Figure 1.5 Proportional Control

Duty Cycle vs. Temperature Difference

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 “°”

placed to the right of the unit) means that the heater turns

on when actual temperature is below setpoint and turns

off when above setpoint. However, this causes oscillations

when the actual temperature is very close to setpoint. To

eliminate 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 1.6. 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 + deadband setting). The controller no longer

calls for heat and the heater is off. As the actual

temperature cools, the controller does not call for heat

until the actual temperature reaches (setpoint – deadband

setting). The hysterisis effect is controlled by the

momentum of the actual temperature rather than the

temperature value itself.

1.7

MS-2101 Chapter 1 Product Overview

Figure 1.6 On/Off Control with Deadband

Heat Trace Curve

Monitoring low and high current alarms on self-regulating

heat tracing cable is difficult. Choosing a high current

alarm setting based on cable characteristics near the

heater setpoint temperature will produce nuisance alarms

during startup. Choosing a low current alarm setting other

than below the current draw of the cable at heater setpoint

temperature produces nuisance alarms. The heat trace

curve function allows you to program the cable character-

istics so that the controller can offset the current alarm

settings.

The heat trace curve is described by the following linear

equation:

W = aT + b

where, W is the Watt/ft at temperature T (in degree F), a

and b are the slope and offset of the linear curve.

If the Watt per foot value of the heat trace is Ws at

setpoint temperature Ts, and the Watt per foot value of the

heat trace is W at temperature T, the offset ratio to be

applied to the high/low current alarm level is Ws/W.

That is, if the high/low current alarm level is set to Is, the

current draw of the cable at setpoint temperature of Ts,

then the high/low current alarm level at operating tem-

perature T should be corrected to (Ws/W)*Is to compen-

sate the effect of operating temperature on the allowed

maximum/minimum heater current. The heat trace curve

is shown in figure 1.7.

If no heat trace curve is used, the offset ratio is set to 1

and no correction to the high/low current alarm level is

done.

Figure 1.7 Heat Trace Curve

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