Nextron MASTERTRACE MS-2102 Manuale utente

MASTER

TRACE

MS-2102

OPERATOR’S MANUAL

HEAT TRACING CONTROL

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 ........................................................................................................................................... 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

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 Messsages ...................................................................................................................................................... 4.4

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

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

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

Statistics ..................................................................................................................................................................... 5.4

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

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

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

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

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

Heater Setup .............................................................................................................................................................. 6.7

System Setup ............................................................................................................................................................. 6.9

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

ContentsMS-2102

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 ................................................................................................................................................. 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

MS-2102

1.1

Chapter 1 Product Overview

Introduction

The MS-2102 two-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-2102 is

intended for indoor or outdoor installations in ordinary or

hazardous locations.

MS-2102 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 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 centrally located master. By

connecting Control Modules to a data highway, the MS-

2102 can immediately flag alarms caused by heat tracing

malfunctions, altered setpoints and monitor actual values

from a central location. Each local Control Module 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. Additional 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 operational as soon as it

is installed.

Figure 1.1 Typical MS-2102 Installation

1.2

MS-2102 Chapter 1 Product Overview

Specifications1

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: Two circuit, single-pole, one SCR per

circuit, 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 (only for heater 1)

Control Power

Power Requirement: Control power from heater 1 voltage

85-280VAC, 10VA max

Protection: Control power from heater 1 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 30A

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 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 switch-protected

Environment

Approvals: CSA C/US

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: Mechnical 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: Low Voltage Alarm

Hardware: Self-Check Failure

Relay Failure

RTD Open

RTD Short

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

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

Low Voltage Alarm: 85V to 300V, off

RTD Fail-safe: Heater On or Heater Off

Override: On or Off

Alarm Contacts: NO or NC for mechanical contact

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

then on, Flash during alarm then off

Ground Fault

Maximum Trip Time: 7.4 seconds

1. This is a pricise specification for MS2102 controller. For

MS2102 panels, there could be some variations.

MS-2102

1.3

Chapter 1 Product Overview

Inputs

y2-RTD Sensors, one per circuit

y1-Override

Monitoring

yRTD Temperatures

yHeater Current

yHeater Voltage

yGF Current

Alarms

yLow and High Current

yLow and High Temperatures

yGFAlarm

yGF Trip

yRelay Failure

ySensor Failure

ySelf-Test Failure

Outputs

y1-Mechnical (dry) Contact

y1-LEDAlarm Indicator

Statistics

yMinimum and Maximum Temperatures

yMaximum Current

yMaximum Ground Fault

yEnergy (MWh)

yEnergy Cost

Control

yTemperature (On/Off- Deadband)

yTemperature -Proportional

yPowerLimiting

Early Warning (TraceCheck)

yLow and High Current

yGFAlarm

yGF Trip

Communications

y1-RS485

yModbus Protocol

Environment

yCSA Certified 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-2102.

Conventions

The following conventions are used in this manual.

"User Changeable Values

Retrieved Data

[ ] Key Press

Shipping Content

MS-2102 Heat Trace Controller

MS-2102 Instruction Manual with Warranty Card

1.4

MS-2102 Chapter 1 Product Overview

Theory of Operation

Controller functions are controlled by a microprocessor

that measures all analog signals and logic inputs, control

heater outputs 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 1.5 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

(designated to heater 1) or RTD2 (designated to heater 2)

terminals 10-12 also includes the resistance of the inter-

connecting wiring to the RTD, which varies with wire

length, size and ambient temperature. 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 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 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 and

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-2102 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

MS-2102

1.5

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.

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

Equation 1.

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

secondsintime

C)(

C)(peratureheater tem

C)(emperaturesetpoint theater

cycle)C/duty(infactordeadband)(

cycleduty)(Where

)()(1)(

(1))()(0

)(

0)(0)(

°==

°=

≥=

<<=

≤=

∆TTs-T(t)e(t)

T(t)

tDB

tDBteiftd

tDBteif

DB(t)

teiftd

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 1.3 shows the relationship between the proposed

heater on duty cycle and the temperature difference for

different deadband factors used.

Figure 1.3 Proportional Control

Duty Cycle vs. Temperature Difference

1.6

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 “°”

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 1.4. 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 + 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.

Figure 1.4 On/Off Control with Deadband

MS-2102

1.7

Chapter 1 Product Overview

Figure 1.5 Hardware Block Diagram

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