Emerson NELSON HEAT TRACE CM-2201 Installation And Operating Instructions Manual Download Page 1 | Manualshive

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NELSON

™

CM-2201/CM-2202

HEAT TRACE CONTROLLERS

Installation and Operating Instructions

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Summary of Contents for NELSON HEAT TRACE CM-2201

Page 1: ...NELSON CM 2201 CM 2202 HEATTRACECONTROLLERS Installation and Operating Instructions ...

Page 2: ... Set up 4 1 Display Modes 4 2 Password Protection 4 3 Security Levels 5 0 General Operation 8 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 11 6 1 On Off Control 6 2 Proportional Control 6 3 Forced Control Feature 7 0 Programming 12 7 1 Setpoints 7 2 Heater Setup 7 3 SystemSetup 8 ...

Page 3: ... Heat Tracing Systems www nelsonheaters com GA2497 Rev 5 3 Appendix A Specifications 25 Appendix B Wiring Diagrams 26 AppendixC TypicalInstallationDiagram 28 Appendix D Modbus Parameters 29 Appendix E RTD Tables 39 Appendix F Warranty 48 ...

Page 4: ...ating 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 detailedspecifications 1 2 Getting Started The CM 2201 CM 2202 is typically connected to external RTDs power orcommunication based onAppendixBand C Detailed set up of the operating control monitoring programi...

Page 5: ...ay and can control resistive loads of 30A continuous 40 C ambient The CM 2201 CM 2202 are designed to control heating circuits bymonitoringone ortwo temperature inputsfor each circuit via industry standard 3 wire 100Ω Platinum RTDs The twoseparateRTDsfor each circuit maybe utilized to customize the temperature control inputs Several different modes are user selectable aswellasthe sensor failure op...

Page 6: ... specifications See AppendixAfor additionaldetails 3 3 Mounting TheCM 2201 CM 2202shouldbemountedata convenient heightto suit operator interaction Conduit entriesshould be madeinthebottomoftheenclosureto 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 Ele...

Page 7: ...ures Theusermayalsoreplace the default password value 1234 withtheirownunique value for greater protection of operational parameters 4 4 Security Levels CM 2201 CM 2202hastwo levelsofsecurity Thehigh level AdvancedDisplay requires passwordprotection Disabling the password from the Password Enable Disable menu will keep the password disabled indefinitely any parameter can be changedwithouttheuseofa...

Page 8: ... setting can be altered by pressing the Up or Down arrow Note that a 4 digit password may berequiredtochange certain settings when required thecursorwillflash 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 l...

Page 9: ...e 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...

Page 10: ...ult in breaker trips if temperatures are very cold and the installed length of cable is long TheSoft 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 an...

Page 11: ...cal proportional control algorithmwherein thecableiscycledonandoffatarate proportional to the difference between the setpoint value and the actual monitored temperature As the difference betweenthesetpointvalueandtheactualmonitored temperatureincreases theamountoftimethecableis energized increases proportionately This helps reducethe overshoot and undershoot commonly associated with On Off control...

Page 12: ...atureissetto Off 7 2 4 High Temp Alarm ThisvaluesetstheHighTemperature Alarm setpoint Itmustbegreaterthanthemaintaintemperatureplus deadband Todisablethisalarmsetthevalueto Off WhenthemeasuredtemperatureofeitherRTDAorRTDB if activated isgreaterthanorequaltothisset point the High TemperatureAlarmisactivatedanda HIGHTEMP ALARM message is added to thealarm stack The alarm deactivates when the tempera...

Page 13: ...nction 1 DisplayMode All 2 Range GroundFaultAlarmto500mA Off 3 Default 50mA 7 1 9 Low VoltageAlarm ThisvaluesetstheLowVoltageAlarmsetpoint Itmustbe lessthan the highvoltage alarmsetpoint Todisable this alarmsetthevalueto Off WhentheLineVoltageisless thanorequaltothissetpoint theLowVoltageAlarmis activatedanda LOWVOLTAGEALARM messageisadded tothealarmstack ThealarmdeactivateswhentheLine Voltagerise...

Page 14: ...tchingfrequency 1 DisplayMode Advanced 2 Range 1C to5C 1F to10F 3 Default 2C or5F 4 Note DeadbandisdisabledforProportionalControl mode Control Type This selection determines the type of control method used by the controller either On Off Deadband or Proportional Control TheOn Offcontrolmodeisavailable forall heating devices ProportionalControlmodeis only available for series type heating devices W...

Page 15: ... theheateristurned Offanda high temperature alarm is activated TheHigh Temperature cutoffmodewilloperateinoneRTDmodeif thehigh temperature alarm is turned Off RTD Operation Continued Functions requiring two RTDs to operate such as Average Lowest HighestandHighTemperatureCutoff will operate in One RTD mode if one of the two RTDsfail 1 Display Mode Advanced 2 Range OneRTD Backup Average Lowest Highe...

Page 16: ...ge 0 01 to 1 00 3 Default 0 05 7 3 6 Display Mode Thisselectiondetermineswhatmessagesaredisplayedby the controller for operations personnel If set to advanced user all messages are displayed Ifsetto normaluser only the basic messages are displayed Each message listed throughoutthismanualshowstheDisplayMode required toseethemessage Advancedonly indicates thatthe displaymodemustbesetto advanceduser ...

Page 17: ...disable Ifa period oftime is selected the heater is forcedOn orOffforthe selectedinterval If continuous isselectedtheheateris forced OnorOffuntil disable isselected 1 DisplayMode Advanced 2 Range 1 24hours Disabled OnContinuously 3 Default disabled Ground Fault Test Thisfunctionwilltestthegroundfaulttripfunctionofthe controller to ensure proper operation When selected the controller will generate ...

Page 18: ... Modbus number 03 Modbus function code 3 0046 start reading from data address 70 0026 the next 38 addresses 2590 CRC 2 The controller will answer with value 0x02 High Temperature Alarm active Alarm 3 Once the alarm condition has been resolved the alarm can be cleared by sending the following instruction 04 05 0045 FF00 9C4C 04 controller Modbus number 05 Modbus function code 5 0045 writing to data...

Page 19: ...w alarm To erase all alarms on alarm log see below 7 To erase all alarms on the Alarm log from the remote terminal send the following instruction 04 05 0097 FF00 3D83 04 controller Modbus number 05 Modbus function code 0097 data address 151 to write FF00 command to erase all memory log 3D83 CRC 19 CM 2201 CM 2202 Communications ...

Page 20: ...sistancebetweenthesource RED or sense RED lead and the common 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 iswiredcorrectly the heat tracing conrtrollers will always be terminated in the order source RED common WHT sense RED When wiring to theCM2201 CM2202 theterminalsaremarked asfollows Terminal No De...

Page 21: ...etween what the controller reads and whatthe RTDactuallymeasures This againis normally notaproblemsincethecontrollercompensates forall buttheworstcases ofthis 3 Unstable Temperature Continued d CheckonebyoneiftheallRTDleadsareconnectedto the connector e Lastly it is possible for the RTD itself to fail on an intermittentbasisbutthisfailuremodeshouldbe consideredunusual Thiskindoffailureisprobablyth...

Page 22: ...se terminals Damagedorinoperativetemperaturesensors 9 4 4 HighCurrentWarning Alarm ThisWarning alarmscurrentlevelsthataregreaterthanthe HIGHCURRENTWARNING ALARMsettingfortheapplication HighCurrentWarning Alarm Continued CauseofWarning Alarm Warning Alarmsettingtooclosetonormaloperating current Highin rushcurrentfrom coldstart ofselfregulating cable Damagedorpartiallyshortedheatingcable Asbuilt cab...

Page 23: ...pitsoutputswitchoff CauseofAlarm Excessivein rushcurrent IncorrectCM 2201 CM2202 settings Incorrect wiring Damagedcable Switch Failure Thisalarmindicatesthatthecontrollersensescurrentflow whentheoutputswitchshould beoff Cause of Alarm Some other device energized heat trace Outputswitchhasfailed closed 9 3 11 Power Limiting Current Limiting This alarm indicates that the solid state relay is limitin...

Page 24: ...rgasketandadjustasrequired Clean door gasket b Verifythatmoistureisnotenteringenclosure repairas required c Checkterminalstoensureconnectionsaresecure d Checkwiringforanysignsofoverheating e Cleanfrontpanelwithmildsoapondampcloth Donotuseanyclothfromsyntheticmaterialorsimilar On thecleaning processthefrontlabelmaycharge electrostatic andby touching the front panel may generate sparks 24 ...

Page 25: ...2201 CM 2202 110 277Vac 30Amps Solid State Relays 30Amps per Channel 50or60Hz SolidStateRelay DPST Normally Open NO NEMA 4X Alarm Outputs 1 24VACto277VAC Max 0 5Amps Solid State Relay requires Min 100mA load 2 30VDC Max 0 1Amps SolidStateRelay requiresMin 50mAload Agency Approval for Hazardous Locations cCSAus Class1 DIV 2 GroupsA B C D Class1 Zone2 IIC TemperatureCode T4 135 C 25 ...

Page 26: ...1 SolidStateContact 2 InstallJumperat JP1 120 OHMResistor on both terminalsifCM 2201 is last device on network Elseinstall jumper on one terminal onlyof JP1 3 If Force feature isactivatedbyexternal drycontact use 5V and IN terminals Groundconnectionisnotrequired Ifactivatedbyexternalvoltagesignal use IN and G Ground terminalsasnoted 26 ...

Page 27: ...Output are SSR N O 2 All RTD s must have the Shield connected to Ground Bus 3 Remove Jumper JP1 only if the controller is in RS485 Network AND is not the last unit on the Network 4 Connect Power Supply Jumpers PJ1 PJ2 as follows CONTROL POWER SOURCE PJ1 L1 CONN3 PJ2 L2 N CONN3 INDEPENDENT NO CONNECTION CH 1 L1 CONN4 L2 N CONN4 CH 2 L1 CONN5 L2 N CONN5 27 ...

Page 28: ...ev 5 DRAFT CM2202 Appendices CM 2201 CM 2202 Appendix C TypicalInstallationDiagram RS485 Al ARM WIRING D CS POWER CONNECTION CONDUIT DRAIN R TIJA HEA TRACE CABLE POWER CONNECTION CKT1 POWE R CONNECTION CON ltJIT DRAIN HEAT TRACE CABL E CT2 R TIJA PAJ IEL BOARD e 28 ...

Page 29: ...CM 2201 CM 2202 Appendices 2017 Nelson Heat Tracing Systems www nelsonheaters com GA2497 Rev 5 DRAFT AppendixD 29 ...

Page 30: ...Appendices CM 2201 CM 2202 2017 Nelson Heat Tracing Systems www nelsonheaters com GA2497 Rev 5 DRAFT 30 ...

Page 31: ...CM 2201 CM 2202 Appendices 2017 Nelson Heat Tracing Systems www nelsonheaters com GA2497 Rev 5 DRAFT 31 ...

Page 32: ...Appendices CM 2201 CM 2202 2017 Nelson Heat Tracing Systems www nelsonheaters com GA2497 Rev 5 DRAFT 32 ...

Page 33: ...CM 2201 CM 2202 Appendices 2017 Nelson Heat Tracing Systems www nelsonheaters com GA2497 Rev 5 DRAFT 33 ...

Page 34: ...Appendices CM 2201 CM 2202 2017 Nelson Heat Tracing Systems www nelsonheaters com GA2497 Rev 5 DRAFT 34 ...

Page 35: ...CM 2201 CM 2202 Appendices 2017 Nelson Heat Tracing Systems www nelsonheaters com GA2497 Rev 5 DRAFT 35 ...

Page 36: ...Appendices CM 2201 CM 2202 2017 Nelson Heat Tracing Systems www nelsonheaters com GA2497 Rev 5 DRAFT 36 ...

Page 37: ...CM 2201 CM 2202 Appendices 2017 Nelson Heat Tracing Systems www nelsonheaters com GA2497 Rev 5 DRAFT 37 ...

Page 38: ...Appendices CM 2201 CM 2202 2017 Nelson Heat Tracing Systems www nelsonheaters com GA2497 Rev 5 DRAFT 38 ...

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Page 48: ...s information representation of operating conditionsor other data toAppletonGroup in the selection or designoftheGoodsandthepreparationofAppleton Group s quotation andintheeventthatactualoperatingconditionsor other conditions differ from those represented by you any warranties or other provisions contained herein which are affected by such conditions shall be null and void Ifwithinthirty 30 daysaf...

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