Nextron tracemate User manual

TRACE MATE
OPERATOR’S MANUAL
ELECTRONIC THERMOSTAT

TRACE MATE Contents
1 Product Overview .................................................................................................................... 1.1
Introduction........................................................................................................................................................................ 1.1
Using this Manual ............................................................................................................................................................. 1.1
Features and Benefits....................................................................................................................................................... 1.1
Conventions....................................................................................................................................................................... 1.1
Specifications .................................................................................................................................................................... 1.2
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
Alarm Wiring ..................................................................................................................................................................... 2.4
3 Applications .............................................................................................................................3.1
Mechanical Thermostat Replacement............................................................................................................................. 3.1
Alarm Annunciator ............................................................................................................................................................ 3.1
Switching Requirements................................................................................................................................................... 3.1
4 Operation .................................................................................................................................4.1
Alarms................................................................................................................................................................................ 4.1
Status Indicators ............................................................................................................................................................... 4.1
Alarm Reset....................................................................................................................................................................... 4.1
Heater Setpoint and Alarm Setpoints ............................................................................................................................. 4.1
5 Testing...................................................................................................................................... 5.1
Troubleshooting/System Integrity .................................................................................................................................... 5.1
Calibration ......................................................................................................................................................................... 5.1
Ground Fault Testing ........................................................................................................................................................ 5.2
Repairs............................................................................................................................................................................... 5.2
Warranty ....................................................................................................................... Back Cover

TRACE MATE
1.1
Product Overview
Introduction
The TraceMate solid state heat tracing control is an
electronicthermostat designed tomaintain a singleheater
at a desired setpoint temperature. It is suitable for use
with mineral-insulated, self-regulating or constant-
wattage cable in applications such as freeze protection,
process control and instrument tracing. The TraceMate is
intended for indoor or outdoor installation in ordinary or
class 1, division 2 hazardous locations.
TraceMate offersmanyadvantagesover other heat tracing
control schemes, which generally use some combination
of mechanical thermostats, custom-built panels or
programmable controls to provide control, monitoring
and alarm functions.Wiring costs are minimized by
mounting the control in close proximityto the heat tracing
cable and pipe. ANEMA 4X enclosure and wide tempera-
ture range electronic components are used to make
mounting possiblein most locations.Temperature
sensing is achieved bymounting a 100 ohm platinum
(DIN 43760) RTD sensor on the pipe. Heater current is
controlled bya solid state switch rated 30A. The
temperature setpoint is digital for fast non-ambiguous
setting over a wide range. Maximum system reliabilityis
obtained from a comprehensive alarm package which
includes indicators for quick fault identification and a
ground fault trip tominimize fire hazards.
Bycombining the control, system monitoring and testing
requirements of a heat tracecontrol system into a general
purpose control, the TraceMate makes it possible to
significantly upgrade systems at low installed cost. In
addition, it is very flexible in its application to adapt to
specific user requirements. Using dip switch and jumper
connection, TraceMate provides users a comprehensive
method to adjust heater setpoint, lowtemperature alarm
setpoint,high temperaturealarmsetpoint, currentfail
alarm setpoint, and ground fault trip alarm setpoint. Their
respective factory default values are:
Heater setpoint: 20°C
Low temp alarm: 5°C
High temp alarm: 100°C
Current fail alarm: 0.3 A
Ground fault trip alarm: 30 mA
Using This Manual
Detailed information relating to switch and output
ratings, accuracy etc. are detailed in Chapter 1, Product
Overview.Chapter 2, Installation discusses important
mounting and wiring issues for reliable operation.
Chapter 4, Operation describes how to setup and operate
the controller. The remainder of this manual should be
read and kept for reference for optimal performance of
the TraceMate.
Features and Benefits
Requirements TraceMate Features
Temperature
Control
*
*
*
*
0-511°C/0-511°F setpoint
Non-ambiguous, digital temperature
setpoint
100 ohm platinum RTD sensor
3-wire, lead resistance compensation
System Fault
Alarms
*
*
*
*
*
*
Breaker left off or tripped
Heater continuity or low current
Ground fault trip
Low temperature
High temperature
Broken sensor
Early Warning
*
*
*
Tracecheck exercises dormant
systems every 24 hours for early
warning to prevent shutdowns
Status indicators show cause of
alarms
Separate fail-safe local and remote
alarms
Remote
Monitoring *
*
Form C alarm dry contact output for
digital alarm interface
LED Alarm indicator viewable on
door
Hazardous/
Ordinary Area
Mounting
*
*
*
*
CSA approved for ordinary or Class
1, Division 2, Grps A,B,C,D
hazardous area
-40° to +50°C operating range
30 amps @120, 208 or 240VAC
rating
Weatherproof, Nema-4X enclosure
Easy retrofit replacement for
mechanical thermostat
Low Installed
Cost
*
*
*
*
Competitively priced
Self contained, no control panel to
build
Ground fault trip eliminates expensive
ground fault circuit breaker
Standard model simplifies spare
parts stocking
WarningStatement
VDC(DC Volatge)
Conventions
Thefollowing conventionsareused in thismanual:
V~ VAC(AC Volatge)

1.2
TRACE MATE Product Overview
Temperature Range
Range: -50°C to 500°C, -58°F to 932°F
Hysteresis: ±2°C, ±3.2°F
Absolute Accuracy: ±2.5°C, ±4.5°F
Repeatability: ±1°C, ±1.8°F
RTD: 100 ohm platinum, 3-wire 20 ohms
maximum lead resistance
Heater Switching
Configuration Single-pole
Dual-pole, Dual SCR, one per phase
Ratings: Single-pole, 120Vac @ 30 amps
Dual-pole, 208-240Vac @30amps
250 amp 1/2 cycle inrush
Line Frequency 50 or 60Hz
Control Power
Power Requirements Control power from heater voltage
Single-pole, 120Vac, 10VA
Dual-pole, 208-240VacC, 10VA
Protection Control power from heater voltage
protected by 2A fuse.
MOV transient protection and RC
snubber
User Interface
Heater Setpoint 12 position dip switch
Reset/Heater Test dip switch
Panel Indicators Power on
Heater on
Low temperature alarm
High temperature alarm
Current fail alarm
Ground fault trip alarm
RTD fail alarm
Environment
Approvals: CSA NRTL/C and FM
Class I, Div.2, Groups A,B,C,D
Class I, Zone 2, Groups IIC
Operating Range: Single-pole: -40°C to +50°C
Dual-pole: -40°C to +40°C
Heater current derated
Conformal Coating: Boards conformal coated for hostile
environments.
User-Definable Options
Heater Setpoint:
Low Temperature Alarm Setpoint:
High Temperature Alarm Setpoint: 0°C-511°C, 1°C steps
0°F-511°F, 1°F steps
Temperature Units: 0°C or °F
Current Fail Alarm Setpoint: 0.0A-30.0A, 1 A steps
Ground Fault Trip Alarm Setpoint: 0mA-511mA, 1 mA steps
Enclosure
Type: E5: Nema-4X steel, painted black
Size: Single-pole: 8”Hx6”Wx4”D
Dual-pole: 10”Hx8”Wx4”D
Features: Quick release latches to open door
One 3/4” conduit knockout for power
and two 1/2” conduit knocks for RTD
and signal wiring.
Alarms
Low Temperature: Actual temperature < low temperature
alarm setpoint
High Temperature: Actual temperature > high temperature
alarm setpoint
Current Fail: Heater current < current fail alarm
setpoint
Ground Fault Trip: Ground fault current > Ground fault trip
alarm setpoint
RTD Fail: RTD Open, RTD Short
Hardware: No incoming voltage
TraceCheck: Current Fail Alarm
Configurationt: NC/NO Contacts
Alarm Output Rating: Form C dry contact: 12-277Vac@ 0.5A,
30VDC/0.1A.
LED Indicator: 6VDC/50mA
Alarm Function
Temperature: Low Temperature Alarm
High Temperature Alarm
Current: Current Fail Alarm
Ground Fault Ground Fault Trip
Hardware RTD Open, RTD Short
Specifications
Heater Current Rating
1 and 2-Pole Switching
0
5
10
15
20
25
30
35
-10 0 10 20 30 40 50
Ambient Air Temp (°C)
Heater Current (Amps)
1-Pole
2-Pole

TRACE MATE
2.1
Chapter 2 Installation
Unpacking the Controller
Check the shipping cartons for damage, or other signs of
rough handlingor abuse. Ifdamaged, notifytheshipping
carrier at once.
Carefullyremove theTraceMate from the shipping box.
Inspect face plate for shipping damage and check
electronics for loose wiring or damage. Report any
damage to the carrier at once.
Control Module
See Figure 2.1 TraceMate Controls and Indicator Layout
to locate the following:
Switches and Jumpers
•S1-9Setpoint Number:
S1-9 consists of 9 switches.Theyare S1, S2, S3, S4,
S5, S6, S7, S8 and S9. These 9 switches generate a
Setpoint Number in a range of 0-511.The exact value
of this Setpoint Number equals the sum of the
contributions by each switch. If a switch is in OFF
position, its contribution is zero. If it is in ON position,
its contribution equals the value labeled on the board.
Ex. 1: If all 9 switches are in the ON position,
SetpointNumber=1+2+4+8+16+32+64+128
+ 256 = 511.
Ex. 2: If only switches 4 and 16 are in the ON position,
SetpointNumber=0+0+4+0+16+0+0+0+0
= 20.
•S10Temperature Units:
°C if S10 is on °C side.
°F if S10 is on °F side.
•S11RESET: Latched “Current fail” or “Ground Fault
Trip” alarms are cleared when S11 isswitched towards
the RESET sidemomentarilyif the alarm conditions
are no longer exist.
•S12TEST: Manually forces heater on when S12 is on
TEST side. Noeffect if the ground fault trip is active.
•JP1Setpoint Configuration:
LT: Setpoint Number generated byS1-9 is interpreted
as lowtemperature alarm setpoint in °C or °F.
HT: Setpoint Number generated by S1-9 is interpreted
as high temperature alarm setpoint in °C or °F.
GF: Setpoint Number generated byS1-9 is interpreted
as ground fault trip alarm setpoint in mA.
AMP: Setpoint Number generated by S1-9 is divided
by10 and interpreted as current fail alarm setpoint in
A.
SP: Setpoint Number generated byS1-9 is interpreted
as heater setpoint in °C or °F.
NONE: Setpoint Number generated by S1-9 has no
effects on any setpoints.
Warning -The ground fault trip function is
intended for equipment protection only and
should not be used in place of ground fault
protection for personnel protection where
thisis required.
There are no consumable components contained in any of
the models covered in this manual.
There is no cleaning requirements for anyof the modules
covered in this manual.
Terminals
Refer to Figure 2.2 Typical Wiring Diagram, for
power, heater and RTD field connections.
•T1Form C Alarm Dry Contacts: Both NO (terminals
10 and 11) and NC (terminals 12 and 11) are rated
277V[email protected] and [email protected].
•T2Alarm Light Output: The output is configured as
normally closed. Output is rated 6 Vdc @ 50 mA for
an LED type lamp (terminals 8+ and 9-).
•T3RTD Input: 3 wire RTD input. Lead resistance
compensated. (terminals 5,6,7).
•T4Ground Stud.
•T5Heater Power Input: 120VAC/30Amax for TM-
1SIH1-xx and 208-240VAC/30Afor TM-1DIH2
(terminals 1 and 2).
•T6Heater Power Output: 30A max (terminals 3 and 4).
StatusLights:
•L1HTR ON: Light is on calling for heat.
•L2RTD FAIL: Light is on when controller detects
open or short RTD inputs.
•L3LO TEMP: Light is on when controller detects a
lowtemperature alarm.
•L4HI TEMP: Light is on when controller detects a
hightemperaturealarm.
•L5AMPFAIL: Light is on when controller detects a
current fail alarm.
•L6GF: Light is on when controller detects a ground
faulttripalarm.
•L7PWRON: Lightisonwhencontrolpoweris
present.
Warning - During installation, disconnect
power supply.

2.2
TRACE MATE Chapter 2 Installation
Figure 2.1 TraceMate Controls and Indicators
Figure 2.2Typical Wiring Diagram

TRACE MATE
2.3
Chapter 2 Installation
Mounting the Controller
Mount the control panel with Unistrut brackets using 3/
8” bolts. The Unistrut (or equivalent) mounting allows
air circulation to cool the heat-sink. This is important to
ensure proper operation of the Tracemate. Mounting
dimensions are shown in Figure 2.5.
Wire Sizing
Conduit and Cabling
TraceMate comes with one 3/4” and 1/2” conduit
knockouts located on the bottom of the enclosure.
Conduit hubs should be NEMA-4X rated, such as T&B
H050-0.5 and H075-0.75 or Myers equivalent, to
maintain a watertight seal. Unused knockouts should be
sealed using NEMA-4X rated seals.
Power Wiring
The power input terminals supply power to both the heat
trace and controller. Size power input wires appropriately
tothe breaker size andmaximum ambientoperating
temperatures.Maximum breaker size is30A. Connect
power wires to input terminals 1 and 2. See Figure 2.2.The RTD probe is delicate and should not
be bent or used as a tool to puncture
insulation.
Wiring methods should comply with Canadian
Electrical or National Electrical Code and
local codes. Power and signal wires should not
be run in the same conduit system. Wiring
should be rated at least 90 °C.
Wire Size (AWG) Current Load (A) Max. Ambient
Tempera ture (°C)
63050
83040
10 24 50
12 16 50
The supply voltage must be 120VAC forTM-
1SIH1-E5-RTD ( Single-pole ) or 208-240VAC
for TM-1DIH2-E5-RTD ( Dual-pole ) and
rated voltage range of the heat trace cable.
Wiring methods must conform to Class 1,
Division II or Class 1, Zone II requirements.
Heater Wiring
Connect heating cablewiring to terminals 3 and 4. See
Figure 2.2. If the heating cable has a braid, it should be
terminated tothe ground stud using a ring terminal
suitable for #10 stud.
Figure 2.3 Ground Connection
Ground Connection
Connect the controller grounding stud directlyto a ground
bus using the shortest, practical path. Use a tinned copper,
braided bonding cable such as Belden 8660. As a guide-
line, the ground cablesshould be minimum 96 strands,
number 34AWGeach.
To install the ground connection, remove theoutside nut,
washer and #8 ring lug provided on the ground stud.
Crimp theground cableonto the ring lug and re-assemble
onto the ground stud using the washer and nut.
Figure 2.4 RTD Mounting
RTD Sensor Wiring
RTD sensors should be 3-wire, 100 ohm, platinum to
DIN standard 43760. Mount the RTD element on the
pipe, away from the heat trace and 30° to 45° from the
bottom of the pipe. The total circuit resistance per
conductor from the RTD to the control panel must be
less than 10 ohm. Exceeding this resistance will result in
a non-linear temperature measurement. Belden cable
8770 or equivalent allows RTDs to be placed up to 1,000
feet from the control panel. Complete all RTD wiring
according to Figure 2.2 Typical Wiring Diagram.

2.4
TRACE MATE Chapter 2 Installation
You must install the RTD sensor on the pipe surface or
thermal well before the pipe insulation to ensure proper
thermal contact. The RTD position should be 180° from
the electric heat trace cable which is the coldest spot of
thepipe.TheRTDsensormaybesecuredtothepipeby
fiber-glass tape. Ifadditional wiring is required for the
RTD, shielded 3-lead wire sized 18 or 20AWG must be
used for the RTD sensor to minimize the effects of noise
pickup. Atypical RTD installation is shown in Figure 2.4.
Alarm Wiring
TraceMate has a form c dry alarm contact and an active
alarm output for driving an LED alarm indicator. The
alarm LED output is configured to turn on the alarm
indicator when there is no alarm. Refer to Figure 2.2for
contact and alarm output terminals.
The form c dry alarm contact is rated 0.5A 277Vac/0.1A
30Vdc.
The alarm LED output is rated 6Vdc, 50mA. It can drive
a 6Vdc LED indicator.
These alarm contact and output are designed as interface
to annunciator, PLC, DCS, or panels.
Figure 2.5 Enclosureand Mounting Dimensions
Warning - Explosion Hazard - Substitution
of components may impair suitability for
Class 1, Division 2 or Class 1, Zone 2.
Warning - Explosion Hazard - Do not
disconnect equipment unless power has
been switched off or the area is known to be
non-hazardous.

TRACE MATE Chapter 3 APPLICATIONS
3.1
Mechanical Thermostat Replacement
Mount the control unit near the pipe being traced in a
location with easy access. Replace the thermostat
capillary tube with an RTD mounted on the pipe and
connect the existing heater and power wires to the
TraceMate as shown in Figure 3.1. A green alarm status
light, visible to maintenance personnel, is connected to
the TraceMate LED alarm output and should be always
on. If the light goes off, the following may have oc-
curred: (1) bulb burnt out (fail-safe indication); (2) no
control power available; (3) system fault. Examine the
LEDs inside the TraceMate to determine the cause of the
alarm.
Advantage of this scheme over mechanical thermostats
is: easy setpoint adjustment and early warning of system
faults with TraceCheck system exercising every 24 hours
and rapid fault diagnosis in the event of a problem.
Alarm Annunciator
If an alarm annunciator or programmable controller is
available, terminal 10, 11 &12 can be used as a low cost
digital interface. These terminals are form C dry con-
tacts. A separate voltage source must be connected across
these terminals as shown in Figure 3.2 for the annuncia-
tor to sense the alarm logic
Switching Requirements
Two different TraceMate models are available to accom-
modate different power configuration of electric heat
trace. The single pole switching model is used for phase
to neutral power feed such as 120VAC. 208 and 240VAC
are both phase to phase power feed and will require a two
pole switching model to ensure both lines are switched
off. Not only is this an electrical code requirement, but to
ensure both connections to the heater are not hot when
the controller is not calling for heat. This is especially
important for the ground fault function to operate
properlysince switching onlyone line there is a 50%
chance that the heater output is properlytripped.
Figure 3.1 Thermostat Replacement
Figure 3.2 Alarm Annunciator

TRACE MATE Chapter 4 Operation
4.1
Alarms
When an alarm condition occurs, the form c dry alarm
contact reacts and the corresponding alarm LED comes
on to indicate the cause of the alarm. Fault diagnosis for
these alarms is listed below.
RTD Fail: If the RTD sensor is not connected or
shorted, RTD FAIL alarm LED will turn on. Check that
the RTD sensor is properly connected. This alarm is not
latched and will be reset as soon as the RTD is properly
connected. In the event of an RTD failure, the heater
output isturned offto prevent a runawayheating
situation.
LowTemperature: Once the actual temperature is below
thelow temperature alarm setpoint, LOTEMPalarm
LED will turn on. This will normally indicate that the
heater circuit is not providing enough heat tomaintain the
setpoint. When a system is first turned on this alarm may
be activated. It is particularlyuseful in taking corrective
action in freezeprotection systems to prevent a burst
pipe. This alarm is not latched and will be reset as soon as
thealarm condition disappears.
High Temperature: Once the actual temperature is above
thehigh temperature alarm setpoint, HITEMPalarm
LED willturn on. This alarm is not latched and will be
reset as soon asthe alarm condition disappears.
Current Fail:This alarm is activated when the TraceMate
control calls for heat and a heater current less than the
current fail alarm setpoint flows. Either the continuity of
the wiring and heat tracing cable is defective or a very
small heater is being switched. In order to detect faults on
dormantsystems with theTraceCheck feature, which
turns on the heaters for several secondsevery24 hours,
this alarm is latched. Thus, once the condition is detected,
the alarm will remain on until it is reset.
Ground Fault Trip: This alarm is activated when the
ground fault current is above the ground fault trip alarm
setpoint. Aground fault is a current to ground caused by
moisture,corrosion or insulation breakdown. Often the
amount ofground fault current is not enough to trip the
heater circuit breaker but could result in a serious fire
hazard, especiallywith self-regulating cable.
When a ground fault is detected, the heater will be
switched off, even if the control is calling for heat. This
eliminates the need for an expensive ground fault circuit
breaker. Largeground fault currentswill trip theheater
circuit breaker, so an intentional time delayis allowed for
the breaker to clear high fault currents, which can occur
on solidly grounded systems.
Since the heater maybe shut off after a ground fault, it is
very important that the alarm outputs beused so
corrective action can be taken quicklyenough to prevent
a process shutdown due to the loss of heat to a pipe.
Ground fault detection only works with resistance or
solidly grounded systems. If the system is ungrounded, it
must be grounded or an artificial ground must be created
bymeans of a zip-zag transformer. Oncea ground fault
condition isdetected, it remains latched until it is reset.
Status Indicators
Power On Indicator: When incoming voltage is applied
to the TraceMate, the green PWR ON indicator LED
should be on. If this LED is not on, check that the
appropriate voltage is present by connecting a meter
across terminals 1 and 2. If voltage is present and the
LED is off, the controller should be replaced and sent to
the factory for service.
Heater On Indicator: Whenever the heater is on, the green
HTR ON indicator LED will be on. This is useful for
checking correct operation of the control. If the ground
fault alarm light or RTD fail alarm light is on, the heater
will not switch on even if the actual temperature is below
the setpoint.
Alarm Reset
The low/high temperature and RTD fail alarms reset as
soon asthe condition disappears.The ground fault trip
and current fail alarm arelatchedalarms.Alatchedalarm
will remain even if the alarm condition disappears. To
reset the latched alarms, remove incoming power for a
few seconds by opening and reclosing the circuit breaker.
Provided the alarm conditions are no longer present, the
alarms should all be reset when power is re-applied to the
TraceMate. It is also possible to reset the latched alarms
bymomentarilyswitching S11 towards itsON position (
refer to Figure 2.1 ) even if the TraceMate is at control
with power applied.
Heater Setpoint andAlarm Setpoints
As stated in chapter 2, five setpoints can be adjusted by
properlysetting up S1-9 and JP1 ( refer to Figure 2.1 ).
S1-9 consisits of 9 switches. Theyare S1, S2, S3, S4, S5,
S6, S7, S8 and S9. These 9 switches generate a Setpoint
Number in a range of0-511. The exact value of this
Setpoint Number equals the sum of the contributions by
each switch. Ifa switch isin ON position, its contribution
to the Setpoint Number equals its labelled value on the
board. Otherwise, its contribution is zero. For example, if
all 9 switches are in ON position, Setpoint Number =
1+2+4+8+16+32+64+128+256 = 511. If only switches
S3 and S5 are in ON position, Setpoint Number =
0+0+4+0+16+0+0+0+0 = 20.
Depending on the jumper position of JP1, the Setpoint
Number generated by S1-9 can beinterpreted as either
heater setpoint,or lowtemperature alarm setpoint, or high
temperature alarm setpoint, or ground fault trip alarm
setpoint, or current fail alarm setpoint.

TRACE MATE Chapter 4 Operation
4.2
Heater Setpoint: If the jumper on JP1 is at SP position,
the Setpoint Number generated by S1-9 is interpreted as
the heater setpoint. Whether the setpoint is in °C or °F
depends on the position of S10 ( refer to Figure 2.1 ).
The factory default value is 20°C.
LowTemperatureAlarm Setpoint: If the jumper on JP1 is
at LT position, the Setpoint Number generated byS1-9 is
interpreted as the low temperature alarm setpoint in °C or
°F. The factory default value is 5°C.
High TemperatureAlarm Setpoint: If the jumper on JP1
is at HT position, the Setpoint Number generated by S1-9
isinterpreted as thehigh temperaturealarm setpoint in °C
or °F. The factory default value is 100°C.
Ground Fault TripAlarm Setpoint: If the jumper on JP1
is at GF position, the Setpoint Number generated byS1-9
is interpreted as the ground fault trip alarm setpoint in
mA. The factory default value is 30 mA.
Current FailAlarm Setpoint: If the jumper on JP1 is at
AMP position, the Setpoint Number generated byS1-9 is
divided by10 and interpreted as the current fail alarm
setpoint in A. The factorydefault value is 0.3A.
NONE: If the jumper on JP1 is at NONE position, the
Setpoint Number generated byS1-9 has no effects on any
setpoints.
Once the jumper is at NONE position, all the adjusted
setpoints will be saved in EEPROM which means that
their values will not be changed even after power off.

TRACE MATE Chapter 5 TESTING
5.1
Troubleshooting/SystemIntegrity
Amajor concern in heat tracing is knowing that the
control and heater cablearefunctioning normally. On
systems that sit idle for long periods, such as freeze
protection, faults usuallyshowup when the system is
needed most. Users often perform an annual check on
mechanical thermostats toensure that problems have not
developed. This is a tedious task because the controls are
often high off the ground in inaccessibleareas.
SincetheTraceMate controlusesanRTD,itcanbe
mounted in a convenient ground level location near other
controls for easy access. Indicator lights for HEATER ON
and POWER indicate the system status. If the RTD sensor
or wiring goes open/short circuit, the NO SENSOR LED
comes on indicating a fault. For this condition the actual
temperature output indicates a value out of the
temperaturemeasurement range, i.e. [-50°C-500°C] or
[-58°F-932°F].
The control can be forced on or off easily by changing the
heater setpoint switches to be above or below the actual
process temperature, noting the HEATER ON LED and
heater current with a clamp-on ammeter.
Calibration
Although theTraceMate control is constructed with
precision components and should give long service
without anyrecalibration necessary, users however may
wish to perform periodic calibration checks. When the
TraceMate control is first installed, or for periodic
maintenance checks, system operation can be verified by
adjusting the heater setpoint dip switch 2°C above and
below a known temperature on the RTD input to see if the
heater turns on and off . For example, if the RTD input
temperature is 25°C, setting the heater setpoint to 27°C
will force the heater on and conversely a 23°C setpoint
will forcethe heater off.
Bysubstituting a known resistor valuefor the RTD sensor
and looking up the equivalent temperature in tables 5.1
and 5.2, the calibration accuracyof the control can be
verified. This can be done in the field without removing
the controlusing a resistancesimulator box and a quality
digital multimeter.
Disconnect the incoming RTDwires andconnect a
resistance box. Simulatean RTD temperature using the
variable resistor or decade box and set the heater setpoint
dip switch 2°C above the simulated temperature. The
heater LED should turn on. Setting the heater setpoint dip
switch 2°C below the simulated temperature, heater LED
should turn off.
Table 5.1 Resistance versus Temperature in °F
(DIN 43760 RTD)
°F R (ohms) °F R (ohms) °F R (ohms)
-40 84.27 160 127.50 360 169.29
-30 86.47 170 129.62 370 171.34
-20 88.66 180 131.74 380 173.39
-10 90.85 190 133.86 390 175.43
0 93.03 200 135.97 400 177.48
10 95.22 210 138.08 410 179.51
20 97.39 220 140.18 420 181.55
30 99.57 230 142.29 430 183.58
40 101.74 240 144.38 440 185.61
50 103.90 250 146.48 450 187.63
60 106.06 260 148.57 460 189.65
70 108.22 270 150.66 470 191.67
80 110.38 280 152.74 480 193.68
90 112.53 290 154.82 490 195.69
100 114.68 300 156.90 500 197.69
110 116.83 310 158.97
120 118.97 320 161.04
130 121.10 330 163.11
140 123.24 340 165.17
150 125.37 350 167.23
Figure 5.1 RTD Simulation

TRACE MATE Chapter 5 TESTING
5.2
Table 5.2 Resistance versus Temperature in °C
(DIN 43760 RTD)
°C R (ohms) °C R (ohms) °C R (ohms)
-40 84.27 80 130.89 200 175.84
-30 88.22 90 134.70 210 179.51
-20 92.16 100 138.50 220 183.17
-10 96.09 110 142.29 230 186.82
0 100.00 120 146.06 240 190.46
10 103.90 130 149.82 250 194.08
20 107.79 140 153.58 260 197.69
30 111.67 150 157.32 270 201.30
40 115.64 160 161.04 280 204.88
50 119.39 170 164.76 290 208.46
60 123.24 180 168.47 300 212.03
70 127.07 190 172.16
Ground Fault Testing
It is possible to simulate a ground fault bycreating a
situation where the current from the two heater terminals
1and2isnotequal.Asshowninfigure5.2,thisisdone
byconnecting a resistor across terminals 1 and 4.
Followthese steps to test the ground fault circuit:
1. Turn on incoming power. Set thegound fault trip
alarm setpoint to 30mA ( default ).
2. Turn off incoming power.
3. Connect a resistor between terminals 1 and 4.
This allows ground fault current I
G
to flow,
which will be seen bythe ground fault sensor as
a ground fault. Sizethe resistor according to the
Heater Voltage 110 240 208 AC Volts
Resistance 2700 6200 5100 Ohms
Wattage 5 10 10 Watts
Voltage Rating 250 500 500 DC Volts
table to ensure sufficient ground fault current of
30mA± 25%.
4. Apply power. The ground fault indicator should
come on after a short delay. It should not be
possible to turn on the heater even if the actual
temperature is belowthe setpoint. The
TraceMate acts a ground fault circuit breaker.
5. Turn off incoming power.
6. Remove the ground fault resistor between
terminals 1 and 4.
7. Re-applypower.All alarm indicatorsshould be
off.
Repairs
In the event of a hardware failure, system operation can
be restored quicklyby following this procedure:
1. Turn off incoming heater and alarm power.
2. Ensure that all wires are correctlymarked for the
corresponding terminals.
3. Disconnectall wires to theterminals.
4. Remove any screws holding the TraceMate
controller and return it tothe factoryfor repair.
5. Install a replacement TraceMate controller.
6. Reconnect the wires, apply power and follow
the testing procedure for a new control.
Figure 5.2 Ground Fault Simulation

Warranty
The manufacturer warrantseach control that it manufactures to be free from
defective material or workmanship for a period of 12 months from date of
purchase.
Under this warranty, the obligation of the manufacturer is limited to repairing
or replacing the defective control at its option, when returned to the manufac-
turer’s factory with shipping charges prepaid.
If failure has been caused by misuse, incorrect application or alteration of the
control,thiswarranty will bevoid.
UNLESS SPECIFICALLY PROVIDED FOR IN WRITING IN THIS WAR-
RANTY, EACH CONTROL IS PROVIDED WITHOUT ANY WARRANTY OF
ANY KIND EITHER EXPRESSED OR IMPLIED. IN PARTICULAR, WITH-
OUT LIMITING THE GENERALITY OF THE FOREGOING, THE FOLLOW-
ING IMPLIED WARRANTIESAND CONDITIONSARE EXPRESSLY DIS-
CLAIMED:
a). ANY IMPLIED WARRANTYOR CONDITION THAT THE CON-
TROL WILL MEET YOUR REQUIREMENTS.
b). ANY IMPLIED WARRANTY OR CONDITION THAT THE OP-
ERATION OF THE CONTROL WILL BE UNINTERRUPTED OR
ERROR FREE; AND
c). ANY IMPLIED WARRANTY OR CONDITION OF
MERCHANTABILITY OR FITNESS FORAPARTICULAR
PURPOSE.
The user shall be made aware that if the equipment is used in a manner not
specified by the manufacturer, the protection provided by the equipment may
be impaired.

TRACE MATE
ELECTRONIC THERMOSTAT
P/N: 1501-0012_1 TMII 02/09 Printed in Canada
Nextron Limited 6120 11
th
Street S.E., Calgary, Alberta, T2H 2L7, Tel:[phone], Fax: [phone]