MASTER
TRACE
8.1
Chapter 8
Service & Testing
8 Service & Testing
8.1 Troubleshooting Hints
8.1.1 Disable Advanced Functions: When you are trying to
determine the problem on a heater circuit it can be helpful to
turn off the advanced functions for the heater circuit or
control module being checked. These include PROPOR-
TIONAL CONTROL (msg. S2-05), POWER LIMIT CUR-
RENT (msg. S1-19), TRACECHECK™ CYCLE (msg. S1-22)
and STAGGER START (msg. S3-10).
8.1.2 Use MANUAL HEATER Function: It may be neces-
sary to force the heater circuit on to take measurements.
The MANUAL HEATER function (msg. S4-02) is provided
for this purpose and eliminates the need to change the heater
setpoint to force the heater circuit on.
8.2 Field Tests
8.2.1 RTD Input Test: The RTD input can be tested by con-
necting a known resistance of sufficient accuracy. A decade
Resistance Box or RTD Simulator is recommended. Discon-
nect the RTD(s) from the control module ensuring that the
leads are adequately labeled. Connect the Resistance Box
as shown in Figure 8.3. If the module has dual RTD inputs,
set the RTD MODE function (msg. S2-08) to “2 RTDs, aver-
aged” and connect the second RTD input in parallel with
the first as shown. Select a temperature from Figure 8.1 or
Figure 8.2 that is close to the maintain temperature and set
the Resistance Box to the equivalent resistance. The dis-
played HEATER CONTROL TEMPERATURE (msg. M1-04)
should equal the selected temperature within the accuracy
of the devices used. If there is a significant discrepancy,
return the Control Module to the factory for repair. When
testing is complete, reconnect the RTD(s).
8.2.2 Current Input Test: The current inputs can be tested
by using an ammeter. A clamp-on CT is recommended to
eliminate the need to disconnect the heater leads. To meas-
ure phase current, place the clamp-on CT around a single
heater phase wire. For three-phase loads, this means around
three phase conductors and a neutral (for 4-wire systems).
Using the Interface Module, display the current being meas-
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 ALARM function (msg. S4-
03). The alarm output on the MR100 Interface Module is
tested using the MANUAL SYSTEM ALARM function
(msg. S4-04). There is no MANUAL SYSTEM ALARM func-
tion on MR100 for Windows CE Interface Module. Its alarm
C°)smho(RC°)smho(RC°)smho(R
04-72.480898.03100248.571
03-22.880907.43101215.971
02-61.2900105.83102271.381
01-90.6901192.24103228.681
000.00102160.64104264.091
0109.30103128.94105280.491
0297.70104185.35106296.791
0376.11105123.75107203.102
0446.51106140.16108288.402
0593.91107167.46109264.802
0642.32108174.86100330.212
0770.72109161.271
F°)smho(RF°)smho(RF°)smho(R
04-72.4806105.72106392.961
03-74.6807126.92107343.171
02-66.8808147.13108393.371
01-58.0909168.33109334.571
030.3900279.53100484.771
0122.5901280.83101415.971
0293.7902281.04102455.181
0375.9903292.24103485.381
0447.10104283.44104416.581
0509.30105284.64105436.781
0660.60106275.84106456.981
0722.80107266.05107476.191
0883.01108247.25108486.391
0935.21109228.45109496.591
00186.41100309.65100596.791
01138.61101379.851
02179.81102340.161
03101.12103311.361
04142.32104371.561
05173.52105332.761
Figure 8.1 Resistance versus Temperature in °C
(DIN 43760 RTD)
Figure 8.2 Resistance versus Temperature in °F
(DIN 43760 RTD)
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