MKS 49 Series Installation and operating instructions

Technology for Productivity
SERIES 49 THERMAL
MANAGEMENT
SYSTEM
User’s Manual &
Installation Guide

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C January 2020
Warranty Information
MKS Instruments, Inc., warrants the Series 49 Heater System and its accessories to be free from defects in materials
and workmanship for a period of two (2) years from the date of shipment by MKS or authorized representative to the
original purchaser (PURCHASER). Any product or parts of the product repaired or replaced by MKS under this
warranty are warranted only for the remaining unexpired part of its two (2) year original warranty period. After
expiration of the applicable warranty period, the PURCHASER shall be charged MKS current prices for parts and
labor, plus any transportation for any repairs or replacement.
ALL EXPRESSED AND IMPLIED WARRANTIES, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE WARRANTY PERIOD. NO WARRANTIES,
EXPRESSED OR IMPLIED, WILL APPLY AFTER THIS PERIOD.
Warranty Service
The obligations of MKS under this warranty shall be at its option: (1) to repair, replace, or adjust the product so that it
meets the applicable product specifications published by MKS; or (2) to refund the purchase price.
What Is Not Covered
The product is subject to the above terms only if located in the country of the seller from whom the product was
purchased. The above warranties do not apply to:
I. Damages or malfunctions due to failure to provide reasonable and necessary maintenance in accordance
with MKS operating instructions.
II. Damages or malfunctions due to chemical or electrolytic influences or use of the product in working
environments outside the specification.
III. Fuses and all expendable items, which by their nature or limited lifetime may not, function for two (2) years.
If such items fail to give reasonable service for a reasonable period of time within the warranty period of the
product; they will, at the option of MKS, be repaired or replaced.
IV. Defects or damages caused by modifications and repairs affected by the original PURCHASER or third
parties not authorized in the manual.
V. Improper Use or Operation:
a. High temperature operation or exposure, either by high set point or external heat source.
Operation outside the recommended temperatures resulting in damage to the system.
b. Poor thermal contact between heater and heated surface.
c. Operating a ripped or torn heater jacket.
d. Operating a heater jacket with punctures or cuts in the external jacket surface.
e. Tampering with control electronics, power cords, or warranty tags.
f. Removing or cutting the snaps, straps, or connectors.
g. Operating the system from an incorrect or unstable supply voltage.
h. Chemical exposure or contamination.
i. Modifications to any component of the system without direct approval from MKS.
j. Return of heaters that have failed during the warranty period, but not reported or returned to MKS during
the warranty period.
k. This list should not be construed to be all-inclusive.
Condition of Returned Products
MKS will not accept for repair, replacement, or credit any product which is asserted to be defective by the
PURCHASER, or any product for which paid or unpaid service is desired, if the product is contaminated with
potentially corrosive, reactive, harmful, or radioactive materials, gases, or chemicals.
When products are used with toxic chemicals, or in an atmosphere that is dangerous to the health of humans, or is
environmentally unsafe, it is the responsibility of the PURCHASER to have the product cleaned by an independent
agency skilled and approved in the handling and cleaning of contaminated materials before the product will be
accepted by MKS for repair and/or replacement.

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C January 2020
Copyright Information
All rights reserved MKS Instruments 2019. No part of this work is to be reproduced by any method
including photocopying and recording or by any information or retrieval system without written permission
of MKS Instruments.

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
Contents
Warranty Information ........................................................................................................................................ 1
1. Agency Listing .......................................................................................................................................... 4
2. Standards and Symbols ........................................................................................................................... 5
3. General Safety Precautions ..................................................................................................................... 6
4. Storage and Cleaning .............................................................................................................................. 7
5. General Specifications ............................................................................................................................. 8
6. S49UL System ......................................................................................................................................... 9
7. S49UL Installation .................................................................................................................................. 12
8. S49UL Heater Controller ........................................................................................................................ 17
9. S49UL LTA+ Controller .......................................................................................................................... 22
10. S49UL User Interface Software .............................................................................................................. 26
11. S49UL Basic Communications ............................................................................................................... 29
12. Troubleshooting ..................................................................................................................................... 31
13. Accessories and Component Parts ........................................................................................................ 36
14. Appendix ................................................................................................................................................ 37
15. Contact .................................................................................................................................................. 44

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
1. Agency Listing
The Series 49UL Thermal System complies with the requirements of the following
directives:
Electromagnetic Conformance: EN 61326-1
Safety: EN 61010-1
RoHS Compliant
UL Component Recognition
UL File E510879
Refer to the Series 49 Declaration of Conformity MKS P/N 20003858-001 for additional
compliance information.

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
2. Standards and Symbols
Electrical shock hazard warning
Hot surface hazard warning
General warning or critical instruction,
important procedure, practice, or
condition
Failure to follow instruction will void
warranty and may result in product or
personal damage
Contact MKS

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
3. General Safety Precautions
Failure to follow instruction will void warranty and may result in product or personal
damage.
Use in an Explosive Environment may lead to direct ignition of explosive vapor or
particulate in the environment.
Standard systems are designed for use on steel piping. Designed power output
and/or operating temperatures may not be suitable for use with other materials.
Installation and use of system with other materials may result in irreversible damage
to those materials and/or the S49UL Thermal System.
For product installed on metal piping, ground the piping system in accordance with
U.S NEC standard, local governing standard, or both.
Areas near the S49UL Thermal System may be hot, and caution should be
observed when touching these areas
A Ground Fault Equipment Leakage Circuit Interrupter (GFELCI) should be used
with the S49UL Thermal System. Although grounded piping is not required for
system functionality, grounding will allow for full performance of the GFELCI and
greatly reduce the risk of electrical shock.
Individual components of the S49UL Thermal System meet the requirements of
reinforced and double insulation and are not required to carry an individual ground.
For standard systems, individual devices must be installed and secured to the
piping or material to be heated before being powered.
Running a device without the proper thermal load (whether due to improper
installation, application, failure to properly secure, use on geometry other than the
design intent etc.) may result in overheating of the device leading to permanent
irreversible damage.
For applications where devices are directly or indirectly heating hazardous
materials, follow the hazardous material safety procedures specified by local
governing body or chemical supplier
MKS offers custom system design for a wide array of applications, is there is any
questions on system design or use consult MKS customer service for guidance.

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
4. Storage and Cleaning
Devices should be stored in their original packaging in a dry, mild temperature
environment out of exposure to direct sunlight.
Internal electronics are sensitive and may be damage by exposure to high humidity
or ambient temperatures in excess of 50°C
The external surfaces of System components may be cleaned with a damp cloth
and mild detergent
Do not immerse in liquid. Immersion in water or other liquid may result in electric
shock or irreversible damage to the device
Do not use solvents. Materials used in manufacture of the system may be
irreversibly damaged by exposure to solvents
Do not open or remove control housing in an attempt to clean internal features.
Opening of the control housing will void product warranty and may lead to risk of
electrical shock or irreversible damage.

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
5. General Specifications
Controller Parameter
Specification
Housing Material
Polycarbonate
Electrical Rating
100-120 VAC, 50/60 Hz
200-240 VAC, 50/60 Hz
Maximum Supply Current
10 Amps
Maximum Output Current
5 Amps Resistive Load
Environment
0°C to 50°C Indoor Use Only
Relative Humidity
0% to 95% non-condensing
Temperature Setting Range
35°C to 200°C **
Temperature Setting Resolution
1C Increments
Enclosure Rating
Unvented
Digital Communications
Modbus RTU over RS485 Half-Duplex
Communication Data Rate
115200 Baud
**Temperature setting range is dependent on heater jacket construction
Operating heater jacket above rated temperature will void all warranties
LTA Parameter
Specification
Housing Material
Polycarbonate
Electrical Rating
100-120 VAC, 50/60 Hz
200-240 VAC, 50/60 Hz
Maximum Supply Current
10 Amps
Maximum Contact Output
30VDC 1A Resistive Load
Environment
0°C to 50°C Indoor Use Only
Relative Humidity
0% to 95% non-condensing
Enclosure
Unvented
Digital Communications
Modbus RTU over RS485 Half-Duplex
Communication Data Rate
115200 Baud
Heater Jacket
Specification
Jacket Material
PTFE Coated Polyimide (Tan Jacket)
PTFE Woven Cloth (White Jacket)
Insulating Material
Polyimide Foam (Tan Jacket)
Fiberglass Batting (White Jacket)
Maximum Supply Current
5 Amps
Maximum Power Output
600 Watts @ 120VAC
1200 Watts @ 240VAC
Maximum Operating
Temperature
200°C Continuous
Environment
0°C to 60°C Indoor Use Only
Relative Humidity
0% to 95% non-condensing
Contact Information MKS Instruments, Inc.
Telephone
[phone]
5330 Sterling Dr.
Toll-Free
[phone] (USA Only)
Boulder, Co. 80301

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
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6. S49UL System
S49UL System Description:
The MKS S49UL Thermal Management System is the 6th generation of MKS thermal
product. The focus of S49UL is product Safety (UL Certification, improved insulation),
simple and robust communications (out of box RS485 Modbus ready), and high
temperature heating (200°C continuous). The new heater jacket construction options
are polyimide (polyimide fabric woven shell with open cell polyimide foam insulation)
and PTFE (polytetrafluoroethylene woven fabric shell with fiberglass batting insulation).
Both products offer continuous operation up to 200°C.
S49UL Thermal System Components:
1. S49UL Heater Controller: Regulates power to the heater jacket.
2. S49UL Heater Jacket: Generates active heat.
3. Power Adapter. Supplies power to the chain of heaters and provides for
communications pass thru (adjacent upstream and downstream chain of heaters).
4. Input Power cable. Standard IEC input cable, supplies input power to the Power
Adapter.
5. LTA+ Controller (optional): Provides centralized visual indication and Digital Process
Control Output for the Heater Network.
6. Communications cable (optional). Provides access to the RS485 network
communications, terminating in either 2 wire flying leads or a USB Type A
connection.
7. Network terminator Plugs (optional). Installed at the ends of the S49UL network to
provide termination of the RS485 bus. Recommended for use anytime active Modbus
Communications or a LTA+ controller is installed on the network.
8. Tablet or Peripheral device (User Supplied). Connected to the S49UL Communications
Network via the Communications Cable and Power Adapter.
Figure 1: Typical Series 49 System Components

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
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All interconnects within the system use custom hybrid connectors (Power + Signal).
Because of the proprietary connectors to power the Series 49UL System a MKS supplied
Power Kit is required. The S49UL Power Kit allows for power injection and communications
pass thru, this feature allows for continuous communications on large or high-power
installations that require multiple power drops.
Each Power Kit includes the following items:
1. Power Adapter (10 amp fused)
2. Input Power Cable
3. Upstream terminating plug
4. Downstream terminating plug
Figure 2: Power Adapter Kit Contents
The pass thru for RS-485 communications on the Power Adapter is shown below in Figure
3. Note that there is no connection to AC voltage passed to the male pins- its purpose is
solely to provide communications connectivity upstream of the power injection block.
Figure 3: Power Adapter Power Injection and RS-485 Communications Pass Thru
The S49UL Heater Controller manages temperature regulation thru a basic On/Off
control algorithm. Overtemperature protection is handled by redundant temperature
sensing and power switching circuitry with a failsafe hardware backup. Control status,
alerts, and error conditions are indicated by a set of LEDs.
4

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
The S49UL Thermal Management System also includes an optional Line Temperature
Alert or LTA+. This device is similar in function to the legacy MKS Low Temperature Alert
or LTA. Installed at the front end of the controller network the S49UL LTA+ aggregates
network information providing the user with single point Visual and Analog Process Control
indication of network status.
The S49UL Heater Control and S49UL LTA+ Control carry a 50°C ambient environmental
temperature rating. Should the internal temperature of the controller exceed 50oC, normal
operation will continue however relay endurance (cycle life) and general system performance
may suffer.
Note: The device will enter the Lock State if the internal temperature of the control assembly
exceeds 85oC.
The S49UL Heater Control offers several user adjustable parameters that are accessed
through RS485 Modbus RTU communication. The adjustable parameters include
temperature control set-point, alarm set-points, an overtemperature safety limit, and other
advanced features. For a comprehensive list of available user adjustable parameters and
diagnostic data information refer to the Modbus Register Map in the Appendix.
To access the RS485 communications terminals two communications kits are available.
The first kit terminates in flying leads and is intended for customers requiring a direct
connection to an existing customer supplied communications system. The second kit
terminates in a Type A USB and is intended for use with the MKS supplied Android App.
The Android based user interface application is the only MKS supported S49UL software
interface, no other MKS supported software is available at this time.
The S49UL Thermal Management System is plug and play out of box. For the average
installation there is no calibration, configuration, or setup required aside from connecting
to mains power. The S49UL Thermal System is not intended to be field serviceable.
Opening the control housing, modifying the heater jackets, or altering other system
hardware in any way will void all product warranties.

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
7. S49UL Installation
The following guidelines are based on a typical installation of S49UL Thermal
System, some installations could be different.
Caution- The PTFE heater utilizes a fiberglass insulation. While the insulation is
contained by the heater shell, use caution if shell is damaged.
Caution- The internal surface of the heater (equipment contact side) may be hot.
Caution- Do not operate heaters unless they are properly installed and in good
thermal contact with part to be heated. Operating the device on a system with a
different thermal load than intended could result in damage to the product or
user system.
Caution- The element inside the heater can become a shock hazard if the heater
jacket is damaged. Visually confirm the integrity of the heater jacket before
installation.
Caution- Never place combustibles, sensitive equipment or parts that may be
damaged by excessive heat in close proximity to the internal surface of the
heater jacket.
Caution- powering a damaged device may create a safety hazard.
Each power adapter is capable of providing a maximum of 10 amps to a
particular heater chain. Do not connect heaters which result in current draw in
excess of 10A.
Follow all local wiring standards when connecting mains power to this
product.
Disposal of this product must conform to all appropriate local codes.

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
The Series 49 Thermal Management System is not field-serviceable. Do not attempt to install or
operate any component with visible damage. Unpack and verify that there is no damage to any
of the heater jackets, controllers, or cables and accessories. If there is any question as to the
quality or construction of the product contact MKS immediately.
Installation area
Inspection of parts and area to be heated for combustibles, sensitive equipment or parts that
may be damaged by excessive heat.
Inspect areas where heaters will be installed. Look for sharp metal edges or protrusions such
as ground lugs, bolts, burrs or brackets that could abrade or tear the heater jacket.
Features that may inhibit performance such as un-even surfaces or profiles that do not match
the profile of the heater jacket should be avoided.
The external surface of the heaters remains below 80C during normal operation. Check for
surrounding parts that could potentially be damaged if contacting the heater outer shell.
Power connections
Each heater jacket has a label clearly marking the design full load current draw. A series
of heaters (add current draw values together) should not exceed 10 amps for a single
power drop. Verify with the local electric authority any limitations on current supply at the
facilities connection. Again, the full load current (experienced when the controller is
supplying power to the heater jacket) is listed on the label of the heater jacket.
Figure 4: Image of Heater Label Indicating Design Voltage and Current Draw
Installation of S49UL Heater Jacket
The S49UL Heater Assembly typically ships with the heater jacket and heater controller
already mated. The heater jacket is tailor fit to the shape of the heated part. When
installed the fit of the heater on the part should be snug ensuring full and uniform contact
and good thermal distribution. Poor contact or improper fit of the heater jacket may lead
to poor performance and premature heater failure.

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
Un-fasten the securing straps and gently open the heater jacket along the parting line(s).
Install the jacket onto the part to be heated fastening the securing straps. The securing straps
are designed for moderate compression of the jacket insulation and some force may be
required to properly secure the straps.
Under no circumstances should devices other than those supplied with the heater be
used to secure the heater jacket on the part.
It is acceptable to slightly compress the insulation to ensure proper installation, but
never cut or modify the heater jacket.
Heaters for bellows, flexible hose, and flanges as well as some custom application
heaters are designed for a loose fit to allow for flex and movement of the bellows and for
rotation in the case of the flange heaters.
Connection of Series 49 Heater System
To ensure performance and UL Compliance use only MKS supplied cables to connect the
heater system. Failure to use MKS supplied cables may result in damage or failure of the
heater system and will void any and all warranty claims.
Individual control devices are designed to be daisy chained together, however care should be
taken to ensure the current draw on a single power adapter does not exceed 10 Amps. MKS
provided power adapters use a 10 Amp slow blow inline fuse.
Begin connecting the system at the first power adapter and ensure the power adapter is not
connected to facilities power supply. The female socket connections will transmit power to the
first heater in the line, power is then transmitted thru each additional controller connected to the
chain until the last heater is reached or another power adapter is installed (required anytime
more than 10Amps of current is needed). The labels of the power adapter clearly mark the
power output connection and the communications connection with ISO standard symbols
Figure 5: Power Adapter with Communications and Power Connection Callouts

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
All S49UL interconnections are designed with a keying feature
and positive twist lock engagement. When mating connections ensure the male and
female connectors are properly aligned, axially rotate the male and female connectors
while applying a slight lateral force to locate the keying position. Once aligned press the
connectors together while turning the twist locking bale. Turn the bale until you hear or
feel a click, this will ensure the bale is locked in place and a full connection is made.
Figure 6: Align keys as close as
possible and gently push and rotate
the connectors until the two halves
engage. Figure 7: Twist the bale on the
female connector until it locks into
place.
Take the first heater in the heater system and connect the male (power accepting) connector of
the heater jacket into the female (power output) connector of the Power Adapter. (Refer to
section 7.2.2. for power adapter details.)
Figure 8: Mate Input power block to the first heater in the line
For daisy chain applications continue by taking the male (power accepting) connector of the
next heater in the chain and connecting it to the female (power output) connector of the
previous heater.
Continue connecting the heaters in this manner until either the last heater in the chain is
reached or the chain nears the 10 Amp per power adapter limit.
Note that the power adapter contains a 10 Amp fuse.

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
If the daisy chain nears 10 Amps of current draw, and there are still additional heaters to
be connected to the system, an additional Power Adapter is required. Multiple Power Adapters
may be used on a single Heater System or daisy chain line to add as many power drops as
necessary.
To install additional Power Adapters, make sure the Power Adapter is not connected to the
facilities supply power. Starting with the last heater in the previous power zone, mate the female
(power output) connector of that heater controller to the male (power accepting) connector of
the Power Adapter. Continue connecting the remaining heater controllers until the current draw
of this string approaches 10 amps, repeat the addition of Power Adapters as necessary
Note: For networks running a LTA+ Controller or RS485 Modbus Communications the network
must be limited to 64 heater controllers.
Note: To limit inrush current on networks with multiple Power Adapters the Power Adapters
should be connected to the mains power in sequence rather than powering all from a single
switch.
Figure 9: Daisy Chain Heater Application, Dual/Multiple Power Drops
If no external communications or alerts signals are required, the system is ready to be powered.
If desired, terminating plugs can be installed on the first power adapter and last heater in the
chain to prevent dust and debris from entering the interconnect connections. Terminating plugs
are supplied as part of the power kit (see Figure 2).
Ensure that the system is properly grounded. This is accomplished by verifying that a
ground line (user supplied) is connected from the ground lug on the power adapter to a
conductive metal part of the line to be heated.
Powering the Series 49 System
Before powering the system ensure that the correct facilities supply voltage for the heater
system is being used. Each S49UL controller is clearly marked with a silver label (see Figure 4)
showing the correct voltage and power requirements for the heater jacket. Connection of the
heater jacket to the wrong supply voltage will cause an Error at the S49UL Heater Controller
and the unit will not allow power to the heater jacket. With the supply voltage verified, connect
the Power Adapter to the input power cable then connect the input power cable to the facilities
mains supply power.

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
8. S49UL Heater Controller
Controller Architecture:
The S49UL Heater Controller utilizes single microprocessor control with a backup
hardware safety. During normal operation both the Primary Control Circuit and the
Hardware Safety Circuit are driven by the microprocessor. Downstream of the processor
there are two power control relays wired in series, the series configuration provides both
the Primary Control Circuit and the Hardware Safety Circuit the ability to directly cut power
to the heater jacket. While the Primary Control Circuit can command both the Control and
Safety Relay the Hardware Safety Circuit can only open the Safety Relay. In the event the
microprocessor has a catastrophic failure the Hardware Safety Circuit takes over and shuts
down power to the heater jacket by opening the Safety Relay. The main purpose of the
Hardware safety circuit is to provide protection from an over-temperature event, replacing
the thermal fuse or thermostat used in early generation products.
Figure 10: S49UL Controller Architecture

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
Wiring details
The S49UL Heater Controller utilizes a hybrid power and communications interconnect
cable. The cable contains the AC power delivery conductors as well as RS485
communications lines. The input and output connector pin outs for the hybrid power and
communications line are shown in Figure 11 below.
The S49UL Heater Controller connects to the heater jacket via a bulkhead connection.
Several embedded safety features exist preventing the controller from supplying power
unless the heater jacket is properly connected, see Table 4: S49UL Troubleshoot Guide
towards the end of the document for details on possible Error indication. The pin out for the
heater output connector is shown below.
Figure 11: Heater Controller pin-outs
Note: Interconnect and heater output connectors are keyed to prevent cross mating

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Series 49 Thermal Management System Instruction Manual #20009807-001 - Rev. C – January 2020
Visual Indication
The S49UL Heater Controller has two sets of LED indicators, the Status LEDs and the
Diagnostic LEDs. Status LED’s are located near the heater jacket connection and provide
indication of control status. Diagnostic LED’s are located towards the interconnect cable
and provide information related to control alerts and errors. The Status indicators are
visible from both sides of the controller allowing for 360° visibility.
Figure 12: LED Location on Series 49 controller
The most common display indications are shown in Figure 13 below, for a full list of
display indicators and definitions see Table 4: S49UL Troubleshoot Guide near the end
of the document
Figure 13: Series 49 LED 1 Display- most common conditions
Diagnostic LED
Status LED