Emerson NELSON HEAT TRACE CM-2201 User manual

NELSON

™

CM-2201/CM-2202

HEAT TRACE CONTROLLERS

Installation and Operating Instructions

Contents

CM-2201/CM-2202

www.nelsonheaters.com

GA2497 Rev.5

1.0

Introduction 4

1.1GettingStarted

2.0

General Application Information 5

3.0

Installation 6

3.1

Selecting Installation Location

3.2

Mounting

3.3

Wiring

4.0

Initial Set-up

4.1

Display Modes

4.2

Password Protection

4.3

Security Levels

5.0

General Operation

5.2

Display

5.3

Keypad

5.4

LED Functions

5.5

Monitoring

5.6

Alarm Management

5.7

Current-Limiting Feature

5.8

GroundFaults

5.9

Soft Start Feature

6.0

Control Modes

6.1

On-Off Control

6.2

Proportional Control

6.3

Forced Control Feature

7.0

Programming

7.1

Setpoints

7.2

Heater Setup

7.3

System Setup

8.0 Communications

9.0 Troubleshooting

10.0 Maintenance

CM-2201/CM-2202

Contents

www.nelsonheaters.com

GA2497 Rev.5

Appendix A – Specifications

Appendix B – Wiring Diagrams

Appendix C – Typical Installation Diagram

Appendix D – Modbus Parameters

Appendix E – RTD Tables

Appendix F – Warranty

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GA2497 Rev.5

Introduction

CM-2201/CM-2202

1.1

Introduction

The Nelson Heat Trace CM-2201 is designed to monitor and

control one heating circuit in ordinary and Class I, Division

Class I, Zone 2, and Zone 2 hazardous locations.

The CM-2202 can monitor/control two heating circuits in

those

same locations.

This manual provides information pertaining to the Installation,

operation, testing, communications and

maintenance of these

controllers. See Appendix A for

detailed specifications

1.2

Getting Started

The CM-2201/CM-2202 is typically connected to external

RTDs,

power or communication based on Appendix B and

C. Detailed set-

up of the operating/control/monitoring

program is entered

throughout the following sections.

For addition help, call Nelson Technical Support or follow

the

Troubleshooting section.

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GA2497 Rev.5

CM-2201/CM-2202

Application Information

2.0 General Application Information

The CM-2201/CM-2202 are designed to operate on input

voltages between 100 and 277 Vac and 50/60Hz. Load

switching is handled by a 2-Pole solid-state relay and

can

control resistive loads of 30A continuous @ 40°C

ambient.

The CM-2201/CM-2202 are designed tocontrol heating

circuits bymonitoring one ortwo temperature inputsfor

each circuit via industry standard 3-wire, 100Ω,

Platinum

RTDs. The twoseparateRTDs for each

circuit maybe

utilized to customizethe temperature control inputs.

Several different modes are user

selectable aswell as the

sensor failure operational

mode.

The CM-2201 and CM-2202 can be operated in

temperatures of-40°Ft o+104°F(-40°Cto +40°C).

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GA2497 Rev.5

InstallationandInitialSetup CM-2201/CM-2202

3.1

Installation

The CM-2201/CM-2202 must be installed only in areas for

which it has been approved and in accordance with all

applicable electrical codes and ordinances. All conduit

entry

holes must be appropriately installed and sealed to

maintain

ingress protection rating.

Do not install this unit prior to functional testing if shipping

container or internal packaging shows signs of damage.

Notify the appropriate individuals immediately if damage is

suspected.

3.2

Selecting Installation Location

The CM-2201/CM-2202 should be installed in an area

protected from the elements as much as possible. It is

possible to install the unit in unprotected areas but such

often limits maintenance/access. Further, installation in

unprotected areas must becarefully considered to ensure

is always in operating conditions consistent with

specifications. See Appendix A for additionaldetails.

3.3

Mounting

The CM-2201/CM-2202 should be mounted at a

convenient

height to suit operator interaction.Conduit

entriesshould

be madeinthe bottomofthe enclosureto

preventdamageto

the internal electronics from moisture

intrusion. Conduit

entries should be drilled and the use of suitable bushings is

required to maintain the environmental ratings.

3.4

Wiring

Electrical wiring diagrams and schematics are provided in

Appendix B andC of this manual. Ensure that all wiring

and connections are in accordance with applicable wiring

codes. Enclosure grounding must be in accordance with

applicablewiringcodes fornon-metallic devices.

The power supply for the CM-2201 isderived from the

power provided for the load. However, the power supply

forthe CM-2202 can be provided independentofthe

powersupply for the loads being controlled.For

example, the powersupply forthe CM-2202 can be120

VAC whilethe loads being controlled canbe277 VAC.

Further,the power supplyforthe CM-2202 may also be

derived from either oftheloads being controlled –thisis

implemented by connecting appropriate jumpers.

Refer

to Wiring Diagram in Appendix B for details.

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GA2497 Rev.5

4.1

Initial Set-Up

Upon initial power-up, the CM-2201/CM-2202 display will

run self-check, display the software version and then start

the main program.

4.2

Display Modes

This feature determines what messages and functions

are

displayed during normal operations. If set to “normal

user” only

basic information i

sdisplayed. If set to

“advanced user” all

controllerinformationis displayed.

Each parameter shown in

this manual will list the Display

Mode required to view

information and access each function

duringprogramming.

4.3

Password Protection

The CM-2201/CM-2202 may have password protection

enabled

to ensure that sensitive operating parameters are

not

inadvertently adjusted. If password protection is

enabled,

the user will be prompted to enter a valid value to

access any

protected features. The user mayalsoreplace

the default

password value (1234) with their own unique

value for greater

protection of operational parameters.

4.4

Security Levels

CM-2201/CM-2202 has two levels of security. The high level

(Advanced Display) requires password protection. Disabling

the password from the Password Enable/Disable menu will keep

the password disabled indefinitely –any parameter can

changed without theuse ofa password. At this level all

the

functionsand monitoring parameters are open.The low

level (Normal Level) does not give accesstoparameters

settings,butis open for fewparameters monitoring like

temperature, current, GFI, etc.

If the password is“Enabled”,whengoingdirectlyto the

parameter to be changed,afterthe‘up’ or‘down’ arrowis

pressed,the controller willask for the password. Then

the

parameter can be changed and saved.The password will

stay

disabled for 15 min, then be automatically re-enabled.

During

the15min period whenthepassword is disabled,

other

parameters can be changed and saved.

CM-2201/CM-2202

InstallationandInitialSetup

www.nelsonheaters.com

GA2497 Rev.5

CM-2201/CM-2202

General Operation

5.1

General Operation

5.2

Display

The CM-2201/CM-2202 utilizes a 2 line x 16 character

alphanumeric displayviewable fromthe front keypad.

The toplineis reserved for the function or operation

and

the bottom line displays the value range.

5.2.1

Navigation for CM2201

The CM2201 monitors one heating circuit consisting of

load (typically a heating cable) and controls theload

based on the temperature of the item being heated

(typically a pipe) as provided via one or two RTD’s

attached to the pipe and connected to the controller.

To monitor the load, press

Actual

until “Operating

Values” is displayed, then press

Right

Left

arrow to

scroll through thevarious values.

To review the statistics that have been collected,

press

Actual

until “Statistics” is displayed then press

Right

Left

arrow to scroll through the various

statistics.

To change the control and monitoring settings

(including alarm settings), press the

Program

key and

then

Right

Left

arrowto scroll through the various

settings. Any setting can be altered by pressing the

Down

arrow. Note that a 4-digit password

may

berequiredtochange certain settings –when

required, the cursor will flash on the left most digit –

use the Up arrow to increase this digit value or

the Down arrow to decrease it. Move the cursor to

the second leftmost digit using the Right or Left

arrow and it will flash until adjusted using Up/

Down arrows. When the last digit has been

selected, press Enter and then changes will be

allowed to the setting. Once the setting is

adjusted, press the Enter key to store it.

To view alarms, press the

Alarms

key and then

Right

Left

arrowto scroll through the various

alarms.

Alarms that are not active can be erased

bypressing

the

Reset

key.

5.2.2

Navigation for CM2202

The CM2202 can monitor/control two separate heating

circuits (channels). The controller defaults to Channel

upon first start-up. All parameters for Channel 1 can

be displayed and modified using standard techniques

described for the CM2201 inSection 5.2.1.

To changeto Channel 2, simply press the “

Actual

”

key and then

right

arrow –the active channel will

displayed. To change the channel, press the

arrow.

In general, when the active channel is displayed

(eg. "CH.2"), the channel can be changed by

pressing the Up or Down arrow.

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GA2497 Rev.5

General Operation

CM-2201/CM-2202

5.3 Keypad

The keypad is “capacitive” touch sensitive and keys

are activated by simply touching the area ofthe

desired key with a finger, even when wearing gloves.

Note that a stylus or other item used to touch the

keypad will usually not activate the keys.

5.4

LED Functions

LED indicators will show the status of the respective

functions. The power LED will be illuminated when the

controller is connected to a source voltage.The heater

LED

will be illuminated when voltage is applied to any

heater.

The system LED will illuminate if there is an

internal

hardware issue with the controller.The comm

LED will

illuminate when the controller is sending data

through

external communication.The alarm LED will

flash when

there is a current active alarm condition or any

circuit;

the alarm LED will illuminate solid when an alarm

was

previously present but is not currently active.

5.5

Monitoring

By touching the“

Actual”

button follow the arrow

and the

controller will scroll through all

the active parameters .

5.6

Alarm Management

All alarm(s) will be saved in the alarm log. If no

alarms are active (alarm LED solid red) the Alarm

LED can be turned off by touching “Reset” once for

every alarm that previously occurred. If any alarm is

active (alarm LED flashing red) the user cannot reset

the alarm. The two alarm relays are SSR type. To set

the contacts of the relays go to Settings –Heater

Setup –Alarm contact. By choosing up/down arrow,

the contacts can be selected to function as Normally

Open or Normally Closed. Press “Enter” to save the

selection. Note: By setting the contacts to NC,

these contacts will be open when there is no power

applied to the unit (this can be useful for signaling

loss of power to the unit) OR there is an active

alarm OR there previously was an active alarm that

has not been acknowledged.

The alarm contacts function as follows:

5.7

Current-Limiting Feature

The Current-Limiting feature operates similarly to the

Soft-Start in that it restricts the amount of time the

cable

isenergized during any given period thereby

reducing the

average current draw of the cable

during that period. For

example, if a cable normally

draws 8 Amps, but current

limit is set to 6 Amps, then

the cable would be energized

only 75% ofthetime.

5.8

Ground Faults

Ground faults typically are the result of damaged or

improperlyinstalledcableswhichallowcurrent-

carrying conductors/surfaces/parts to be in contact

with grounded objects. For example, if a heating

cable has been secured to a pipe with a clamp, and

if the clamp has been overtightened, then the

ground braid and/or the pipe may come in contact

with current carrying parts within the cable. This

would result in current leakage to ground

through the

ground braid of thecable and/or the pipe itself.

This

type of fault can eventually become serious, resulting

in overheating/fire/shock hazards. Current leakage to

ground can bemonitored by electronic circuitryand

the SPC

can be programmed to either alarm or trip

when leakage

c u r r e n t e x ce e d s t h e s p e c i f i e d

m a x i mu m a l l o wa b l e a m o u n t .

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GA2497 Rev.5

The Soft-Start feature enables self-regulating cables to be

energized at low temperatures without causing excessive load

on the electrical system and extending cable life by reducing

cable internal heating due to inrush currents. The

resistance

of self-regulating cables decreases as the cables get

colder, which results in higher current and can result in

breaker trips if temperatures are very cold and the

installed length of cable is long. The Soft-Start feature

operates by initially only energizing the cable for a very short

period of time –while the current draw may be high during

this period, the period is usually short enough to reduce

average load on the electrical system.

5.9 Soft-Start Feature

This short energization period is repeated and eventually

increased; after a few minutes, the cable is usually warm

enough such that the resistance has increased and the

current decreased to the point where it can be continuously

energized.

CM-2201/CM-2202

General Operation

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