Emerson NELSON CM-2201 Installation And Operating Instructions Manual Download Page 19 | Manualshive

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CM-2201 Troubleshooting

19

©2015 Nelson Heat Tracing Systems

www.nelsonheaters.com GA2497 Rev. 2

9.3.7 GFI Alarm Continued

Cause of Alarm:
• Trip setting too close to normal leakage current
• Damaged cable insulation and/or moisture present
• Moisture in junction box
• Poor splice or termination
• Moisture provides conductive ground path, which allows

ground fault current

9.3.8 High Voltage Warning/Alarm

This warning/alarms voltage levels that are greater than the
HIGH VOLTAGE WARNING/ALARM setting.

Cause of Warning/Alarm:
• Warning/Alarm setting too close to normal operating voltage
• Incorrect wiring
• Power surge

9.3.9 Low Voltage Warning/Alarm

This warns/alarms of voltage levels that are less than the
LOW VOLTAGE WARNING/ALARM setting.

Cause of Warning/Alarm:
• Warning/Alarm setting too close to normal operating
voltage
• Damaged power cable
• Incorrect VOLTAGE TURNS RATIO
• “Brown-out” conditions
• Loss of power to the circuit

9.3.10 Overcurrent Trip

If the controller is unable to start the cable due to high
current, or after attempting to soft-start it, the controller
will trip its output switch off.

Cause of Alarm:
• Excessive in-rush current
• Incorrect CM-2201 settings
• Incorrect wiring
• Damaged cable

9.3.11 Switch Failure

This alarm indicates that the controller senses current flow
when the output switch should be off.

Cause of Alarm
• Some other device energized heat trace
• Output switch has failed “closed”

9.3.12 Power Limiting (Current Limiting)

This alarm indicates that the solid state relay is limiting the
average amount of power that is applied to the trace circuit
as defined by the MAXIMUM POWER setting.

Cause of Alarm:
• Power applied to trace circuit is being limited to the

MAXIMUM POWER setting

9.3.13 EEPROM Data Failure

This alarm indicates that the controller has detected a
failure in its non-volatile memory (this is where all of the
controller’s configuration and calibration settings are
stored). This indicates an internal problem, and the CM2201
should be replaced and returned to the factory for repair.

Cause of Alarm:
• The CM-2201 cannot bypass the failed area of its memory
and has loaded factory defaults into this failed area.

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Summary of Contents for NELSON CM-2201

Page 1: ...NELSON CM 2201 HEAT TRACE CONTROLLER Installation and Operating Instructions ...

Page 2: ...t up 4 1 Display Modes 4 2 Password Protection 4 3 Security Levels 5 0 General Operation 7 5 1 Display 5 2 Keypad 5 3 LED Functions 5 4 Monitoring 5 5 Alarm Management 5 6 Soft Start Feature 5 7 Current Limiting Feature 5 8 Ground Faults 6 0 Control Modes 8 6 1 On Off Control 6 2 Proportional Control 6 3 Forced Control Feature 7 0 Programming 9 7 1 Setpoints 7 2 Heater Setup 7 3 System Setup 8 0 C...

Page 3: ...at Tracing Systems www nelsonheaters com GA2497 Rev 2 Appendix A Specifications 21 Appendix B Wiring Diagrams 22 Appendix C Typical Installation Diagram 23 Appendix D Modbus Parameters 24 Appendix E RTD Tables 29 Appendix F Warranty 38 ...

Page 4: ...on 2 Class I Zone 2 and Zone 2 hazardous locations This manual provides information pertaining to the installation operation testing communications and maintenance of this device See Appendix A for additional details 1 1 Getting Started The CM 2201 should be connected to external RTDs power and communication based on Appendix B and C If any problems occur call Nelson technical support or follow th...

Page 5: ... can control resis tive loads of 30A continuous 40 C ambient The CM 2201 is designed to control one heating circuit by monitoring one or two temperature inputs via industry standard 3 wire 100Ω Platinum RTDs Two separate RTDs may be utilized to customize the temperature control inputs Several different modes are user selectable as well as the sensor failure operational mode The CM 2201 assembly is...

Page 6: ... parameter to be changed after the up or down arrow is pressed the controller will ask to type the password and after that the parameter can be changed and saved The password will stay disabled for 15 min then be auto matically re enabled During the 15 min period when the password is disabled other parameters can be changed and saved 3 0 Installation The CM 2201 must be installed only in areas for...

Page 7: ...gulating cables decreases as these cables get colder which results in higher current draw 5 6 Soft Start Feature Continued This can result in breaker trips if temperatures are very cold and the installed length of cable is high 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 u...

Page 8: ...e monitored temperature reaches the upper limit However the residual heat in the cable continues to transfer to the pipe and this will cause the pipe temperature to increase slightly above the upper limit Similarly there can be some temperature undershoot 6 2 Proportional Control This control method uses the typical proportional control algorithm wherein the cable is cycled on and off at a rate pr...

Page 9: ... sets the High Temperature Alarm setpoint It must be greater than the maintain temperature plus deadband To disable this alarm set the value to Off When the measured temperature of either RTD A or RTD B if activated is greater than or equal to this setpoint the High Temperature Alarm is activated and a HIGH TEMP ALARM message is added to the alarm stack The alarm deactivates when the temperature f...

Page 10: ...e circuit may be energized by the manual reset function 1 Display Mode All 2 Range Ground Fault Alarm to 500mA Off 3 Default 50mA 7 1 9 Low Voltage Alarm This value sets the Low Voltage Alarm setpoint It must be less than the high voltage alarm setpoint To disable this alarm set the value to Off When the Line Voltage is less than or equal to this setpoint the Low Voltage Alarm is activated and a L...

Page 11: ...Display Mode Advanced 2 Range 1 C to 5 C 1 F to 10 F 3 Default 2 C or 5 F 4 Note Deadband is disabled for Proportional Control mode 7 2 6 Control Type This selection determines the type of control method used by the controller either On Off Deadband or Proportional Control The On Off control mode is available for all heating devices Proportional Control mode is only available for series type heati...

Page 12: ... is based on RTD A but if the temperature from RTD B exceeds the high temperature alarm the heater is turned Off and a high temperature alarm is activated The High Temperature cutoff mode will operate in One RTD mode if the high temperature alarm is turned Off 7 2 10 RTD Operation Continued Functions requiring two RTDs to operate such as Average Lowest Highest and High Temperature Cutoff will oper...

Page 13: ... required to see the message Advanced only indicates that the display mode must be set to advanced user to view the message 1 Display Mode All 2 Range Normal Advanced 3 Default Advanced 7 3 7 Default Display This function specifies the information that will be displayed when no key has been pressed for the Display Timeout interval as described below VALUE INFORMATION DISPLAYED System status Alarm ...

Page 14: ...sets controller memory parameters to factory default values If the controllers memory becomes corrupt resetting the module will force the controller to overwrite each register and may correct any problems that exist 1 Display Mode Advanced 2 Range yes no 3 Default no 7 4 Program System Test 7 4 1 System Test This message displays the name of the sub menu when entered 1 Display Mode Advanced 2 Rang...

Page 15: ... control functions using Read 03 and Write 05 06 register commands 8 1 General Information Serial Port Select the serial port that corresponds to your RS 485 adapter USB to Serial adapter may be used for devices without serial connections Baud Rate User Defined at 1200 2400 4800 9600 or 19200 Data Bits 8 Stop Bits 1 Parity None Device Address User Defined between 1 and 255 8 2 Modbus Registers For...

Page 16: ...WHT lead of the RTD at the controller should be between 60 and 330 Ω depending on the temperature and the lead resistance Verify that the RTD is wired correctly the heat tracing controllers will always be terminated in the order source RED common WHT sense RED When wiring to the CM2201 the terminals are marked as follows Terminal No Description GND Bus Shield R1 RTD 1 Source RED W1 RTD 1 Common WH...

Page 17: ... the RTD actually measures This again is normally not a problem since the controller compensates for all but the worst cases of this 3 Unstable Temperature Continued d Check one by one if the all RTD leads are connected to the connector e Lastly it is possible for the RTD itself to fail on an intermittent basis but this failure mode should be considered unusual This kind of failure is probably the...

Page 18: ... 4 High Current Warning Alarm This warning alarm activates when current levels are greater than the HIGH CURRENT WARNING ALARM setting for the application 9 3 4 High Current Warning Alarm Continued Cause of Warning Alarm Warning Alarm setting too close to normal operating current High in rush current from cold start of self regulating cable Damaged or partially shorted heating cable As built cable...

Page 19: ... to start the cable due to high current or after attempting to soft start it the controller will trip its output switch off Cause of Alarm Excessive in rush current Incorrect CM 2201 settings Incorrect wiring Damaged cable 9 3 11 Switch Failure This alarm indicates that the controller senses current flow when the output switch should be off Cause of Alarm Some other device energized heat trace Out...

Page 20: ...ed Clean door gasket b Verify that moisture is not entering enclosure repair as required c Check terminals to ensure connections are secure d Check wiring for any signs of overheating e Clean front panel with mild soap on damp cloth Do not use any cloth from synthetic material or similar During the cleaning process the front label may charge electrostatically and touching the front panel may gener...

Page 21: ...110 277 Vac 30 Amps Solid State Relays Maximum Current 30 Amps Frequency 50 or 60 Hz Switching Solid State Relay STDP Normally Open NO Enclosure NEMA 4X Alarm Outputs 1 24VAC to 277VAC Max 0 5 Amps 2 30VDC Max 0 1 Amps Agency Approval for Hazardous Locations cCSAus Class1 DIV 2 Groups A B C D Class 1 Zone 2 IIC Temperature Code T4 135 C ...

Page 22: ...tact 2 Install Jumper at JP1 120 OHM Resistor on both terminals if CM 2201 is last device on network Else install jumper on one terminal only of JP1 3 If Force feature is activated by external dry contact use 5V and IN terminals Ground connection is not required If activated by external voltage signal use IN and G Ground terminals as noted ...

Page 23: ...CM 2201 Appendices 23 2015 Nelson Heat Tracing Systems www nelsonheaters com GA2497 Rev 2 Appendix C Typical Installation Diagram ...

Page 24: ... 40008 7 2 Deadband in C x per 1 C 1 to 5 40009 8 2 Low Current Alarm x per 0 1A 1 to 300 32767 if Set to Off 40010 9 2 High Current Alarm x per 0 1A 1 to 300 32767 if Set to Off 40011 10 2 Ground Fault Alarm x per 1mA 10 to 500 32767 if Set to Off 40012 11 2 Ground Fault Trip x per 1mA 10 to 500 32767 if Set to Off 40013 12 2 Low Voltage Alarm x per 1V 85 to 280 32767 if Set to Off 40014 13 2 Hig...

Page 25: ...Fahrenheit 1 Celsius b1 Enable Heater 0 No 1 Yes b2 Manual Override 0 Off 1 On b3 Control Type 0 On Off 1 Proportional b4 b6 RTD Operation 000 Single RTD Mode 001 Backup 010 Average 011 Lowest 100 Highest 101 High Temp Cutout b7 RTD Failure Mode 0 Off 1 On b8 Enable Password 0 Disable 1 Enable b9 Display Mode 0 Normal 1 Advanced b10 b11 Default Display 00 System Status 01 Heater Status 10 Heater T...

Page 26: ...if RTD Open 32767 if RTD Shorted 40050 49 2 High Temp Alarm in C x per C 32765 if RTD Open 32767 if RTD Shorted 40051 50 2 Heater Power x per 10 40052 51 2 Reserved 40053 52 2 Current x per 0 1A 32766 as Out of Range 40054 53 2 GF Current 40055 54 2 Voltage x per 1V 32766 as Out of Range 40056 55 2 Reserved 40057 56 2 Max Temp in F x per F 32765 if RTD Open 32767 if RTD Shorted 40058 57 2 Max Temp...

Page 27: ...nt Alarm 8 High Current Alarm 16 GF Alarm 32 GF Trip 64 Low Voltage Alarm 128 High Voltage Alarm 256 Auto Test Alarm 512 Continuity Failure Alarm 1024 SSR Failed Shorted Alarm 2048 RTD A Open Alarm 4096 RTD A Shorted Alarm 8192 RTD B Open Alarm 16384 RTD B Shorted Alarm 32768 Self Check Failure 40072 71 2 Alarm Stack 02 40073 72 2 Alarm Stack 03 40074 73 2 Alarm Stack 04 40075 74 2 Alarm Stack 05 ...

Page 28: ...02 101 2 Reset Heater On Percentage Set to 1 to Reset 00103 102 2 Reset Statistics Set to 1 to Reset 00104 103 2 Reset Low Temp Set to 1 to Reset 00105 104 2 Reset High Temp Set to 1 to Reset 00106 105 2 Reset Low Current Set to 1 to Reset 00107 106 2 Reset High Current Set to 1 to Reset 00108 107 2 Reset GF Set to 1 to Reset 00109 108 2 Reset GF Trip Set to 1 to Reset 00110 109 2 Reset Low Voltag...

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Page 41: ...N FOR YOUR USE OR PURPOSE This warranty does not extend to any losses or damages due to misuse accident abuse neglect normal wear and tear negligence unauthorized modification or alteration use beyond rated capacity or improper installation maintenance or application To the extent that you or your agents have supplied specifications information representation of operating conditions or other data ...

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