Appleton CM-2201, CM-2202 Installation Manual
NELSON
HEAT TRACE
™
NELSON
CM-2201/CM-2202
HEAT TRACE CONTROLLERS
Installation and Operating Instructions
Table of Contents CM-2201/CM-2202
1.0
Introduction
1.1 Getting Started
4
2.0
3.0
4.0
5.0
General Application Information
Installation
Initial Set-up
5
3.1
Selecting Installation Location
3.2
Mounting
3.3
Wiring
5
4.1 Display Modes
4.2
Password Protection
4.3
Security Levels
General Operation
5.1 Display
5.2 Keypad
5.3 LED Functions
5.4 Monitoring
5.5
Alarm Management
5.6
Current-Limiting Feature
4
6
5.7 Ground Faults
5.8 Soft Start Feature
6.0
7.0
Control Modes
6.1
On-Off Control
6.2
Proportional Control
6.3
Forced Control Feature
Programming
7.1 Setpoints
7.2
7.3 System Setup
Heater Setup
8.0
Communications
8
9
15
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CM-2201/CM-2202 Table of Contents
9.0 T
10.0
roubleshooting
9.1 Operator Checks
9.2 Ground Faults
9.3 RTDs
9.4 Common Warnings/Al ar ms
Maintenance
Appendix A – Specifications 21
Appendix B – Wiring Diagrams 22
Appendix C – Typical Installation Diagram
Appendix D – Mounting Details 25
Appendix E – Modbus Address List 26
16
20
24
Appendix F – ASCII Table 38
Appendix G – RTD Tables 39
Appendix H – Warranty 48
©2018 Nelson H eat Tracing Systems www.nelsonheaters.com GA2497 Rev.6
Introduction CM-2201/CM-2202
1.0
Introduction
The Nelson Heat Trace CM-2201 is designed to monitor and
control one heating circuit in ordinary and Class I, Division 2,
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
1.1
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.
General Application Information CM-2201/CM-2202
2.0
General Appl i cati o n Inf or ma tio n
The CM-2201/CM-2202 are designed to operate on input
voltages between100and277Vacand50/60Hz. 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 to control heating
circuits by monitoring one or two temperature inputs for
each circuit via industry standard 3-wire, 100Ω,
RTDs. The two separate RTDs for each
utilized to customize the temperature control inputs.
Several different modes are user
sensor failure operational
TheCM-2201 and CM-2202 can be operated in
temperatures of -40°F to +104°F (-40°C to +40°C)
circuit maybe
selectable as well as the
mode.
Platinum
.
©2018 Nelson H eat Tracing Systems www.nelsonheaters.com GA2497 Rev.6
4
CM-2201/CM-2202 Installation and Initial Setup
3.0
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
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.
3.1
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 be carefully considered to ensure it
is always in operating conditions consistent with
specifications. See Appendix A for additional details.
3.2
Mounting
The CM-2201/CM-2202 should be mounted at a convenient
height to suit operator interaction.
(See Appendix D for mounting details.)
Conduit entries should be made in the bottom of the
enclosure to
from moisture
and the use of suitable bushings is required to maintain the
environmental ratings.
3.3
Wiring
Electrical wiring diagrams and schematics are provided in
Appendix B and C of this manual. Ensure that all wiring
and connections are in accordance with applicable wiring
codes. Enclosure grounding must be in accordance with
applicable wiring codes for non-metallic devices.
The power supply for the CM-2201 is derived from the
power provided for the load. However, the power supply for
the CM-2202 can be provided independent of the
supply for the loads being controlled. For
power supply for the CM-2202 can be 120 VAC while the
loads being controlled can be 277 VAC.
supply for the CM-2202 may also be
the loads being controlled – this is
connecting appropriate jumpers.
maintain
prevent damage to the internal electronics
intrusion. Conduit entries should be drilled
power
example, the
Further, the power
derived from either of
implemented by
4.0
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. Default settings are set to disable
heating cables, (See 7.0 Pro gr ammin g to ena ble he ater s
and program set points.)
4.1
Display Modes
This feature determines what messages and functions
are displayed during normal operations. If set to “normal
user,” only basic information is displayed. If set to
“advanced user,” all controller information is displayed.
Each parameter shown in this manual will list the Display
Mode required to view information and access each function
during programming.
4.2
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 may also replace
the default password value (1234) with their own unique
value for greater protection of operational parameters.
4.3
Security Levels
CM-2201/CM-2202 has two levels of security. The high
level
(Advanced Display) requires password protection.
Disabling
menu will
parameter can
At this level all
are open.
The low level (Normal Level) does not give access to
parameters settings, but certain parameters (such as
temperature, current, GFI, etc.) are open for monitori ng.
If the password is “Enabled”, going directly to the
parameter to be changed, and pressing the ‘up’ or ‘down’
arrow, will cause the controller to ask for the password. If
correctly entered then
saved. The password will
automatically re-enabled. When disabled the password does
not need to be entered to change and save parameters.
the password from the Password Enable/Disable
keep the password disabled indefinitely – any
be changed without the use of a password.
the functions and monitoring parameters
:
the parameter can be changed and
stay disabled for 15 min, then be
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5
General Operation CM-2201/CM-2202
5.1
Display
The CM-2201/CM-2202 utilizes a 2-line x 16-character
alphanumeric display viewable from the front keypad. The top
line is reserved for the function or operation and the
bottom line displays the value range.
5.1.1
The CM2201 monitors one heating circuit consisting of load
(typically a heating cable) and controls the load
temperature of the item being heated
provided via one or two RTD’s
connected to the controller.
Actual
Right
To review the statistics that have been collected, press
until “Statistics” is displayed then press
scroll through the various statistics.
To change the control and monitoring settings (including
alarm settings), press the
Left
arrow to scroll through the various settings. Any
setting can be altered by pressing the
Note that a 4-digit password may
certain settings – when
leftmost digit –
or the
second leftmost digit using the
will flash until adjusted using
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
To view alarms, press the
Left
arrow to scroll through the various alarms. Alarms
that are not active can be erased
key.
Navigation for CM2201
until “Operating Values” is displayed, then press
or
Left
arrow to scroll through the various values.
required, the cursor will flash on the
Down
use the
arrow to decrease it. Move the cursor to the
Up
based on the
(typically a pipe) as
attached to the pipe and
To monitor the load, press
Right or
Program
arrow to increase this digit value
Alarms
key and then
Up
be required to change
Right
or
Up/Down
Enter
key to store it.
key and then Right
by pressing the
or
Down
Left
arrow and it
Left
Reset
Actual
arrow to
Right
arrow.
or
or
5.1.2
Navigation for CM2202
The CM2202 can monitor/control two separate heating
circuits (channels). The controller defaults to Channel 1
upon first start-up. All par am eter s for Chann el 1 can be
displayed and modified using standard techniques
as described for the CM2201 in Section 5.2.1.
To change to Channel 2, simply press the “Actual”
key and then Right arrow – the active channel will
be displayed. To change the channel, press the Up
arrow.
In general, when the active channel is displayed (e.g.
"CH.2"), the ch annel can be chan ged by pr essin g the
Up or Down arrow.
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CM-2201/CM-2202 General Operation
5.2
Keypad
The keypad is “capacitive” touch sensitive and keys are
activated by simply touching the area of the 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
The power LED will be illuminated when the
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 “
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 alar m s 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. (See 7.2.12 for f urther
information on the Alarm contacts setting).
Actual”
functions.
controller is
button follow the arrow and
Power-Limiting Feature
The Power-Limiting feature operates similarly to the
Start in that it restricts the amount of time the cable is
energized 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% of the time.
5.7
Ground Faults
Ground faults typically are the result of damaged or
improperly installed cables which allow current-carrying
conductors/ surfaces/pa rt s to b e in co nta ct wi th gr ou nd ed
objects.
For example, if a heating cabl e has bee n secur ed to a pipe
with a clamp, and if the clamp has bee n overtig hte ned,
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 the cable and/or the pipe itself. This type of
fault can eventually become serious, resulting
overheating/fire/shoc k hazar ds. Current leakage to
can be monitored by electronic circuitry and the SPC/DPC can
be programmed to either alarm or trip when leakage
current exceeds the specified maximum
allowable amount.
5.9 Soft-Start Feature
The Soft-Start feature enables self-regulating cables to
be ener gized at low temperatur es without causing excessive
load on the electrical system and extending cable life by
reducing cable internal heat ing due to inrush cu r rent s . The
resistance of self-regulating cables decreases as the
cables get colder, which results in higher current and can
result in brea ker trips if temp eratures are ve ry cold and
the instal led le ngt h of c ab le 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 du ring
this period, the period is usually short enough to reduce
average load on the elect rical syste m .
This short energizatio n p eriod 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 c an be conti nuou s ly
energized.
Soft-
in
ground
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7
Control Modes CM-2201/CM-2202
6.0
Control Modes
The CM-2201/CM-2202 allows the user to select different
control modes based on their individual process control
parameters.
6.1
On-Off Control
This control method simply energizes the cable until the
actual monitored temperature rises to the setpoint value
plus half the deadband value (upper limit). The cable is then
de-energized until the actual monitored temperature
setpoint value minus half the deadband value. Note that this
type of control can result in some temperature “overshoot;”
this is because the cable is de-energized
temperature reaches the upper limit.
in the cable continues to transfer
the pipe temperature to
Similarly, there can
6.2
Proportional Control
This control method uses the typical proportional
control algorithm wherein the cable is cycled on and off at a
rate
proportional to the difference between the setpoint value
and the actual monitored temperature. As the difference
between the setpoint value and the actual
monitored
cable is
reduce the
assoc iated with
energized increases proportionately. This helps
drops to the
when the monitored
However, the residual heat
to the pipe, and this will cause
increase slightly above the upper limit.
be some temperature “undershoot.”
temperature increases, the amount of time the
“overshoot” and “undershoot” commonly
On/Off control.
6.4 Forced Control Feature
This control me thod sim pl y allow s the user to for ce the cab le on or
off as desired using an external signal (e.g. +5 VDC or 24 VAC)
applied to the IN and G terminals or an external dry contact across
the +5V and IN terminals. The External Disable must be set to
“ON” to allow for external control, at which point the controller
operates as follows:
A) If the Temperature setpoint is “OFF” or “None”, then the
heater gets energized by applying the external signal or closing the
external contact.
B) If the Temperature setpoint is a specific value (ex. 55C),
then the setpoint will be maintained as per normal operation ONLY
when the external signal is present, or the external contact is
closed – otherwise, the heater will be disabled.
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8
CM-2201/CM-2202 Programming
7.1 Program-Setpoints
7.1.1
Setpoint Value
This message displays the name of the sub-menu when
entered.
7.1.2
This value sets the control setpoint temperature for
all operating modes. For On-Off control, the circuit is
energized if the control temperature is less than the
maintain temperature minus the deadband. The circuit
is
greater than the maintain temperature plus the
deadband. If maintain temp
heater circuit will have temperature
control temperature. If the maintain
then the heater circuit will have no
monitoring or control.
7.1.3
This value sets the Low Temperature Alarm setpoint. It must
be less than the maintain temperature minus the
To disable this alarm set the value to “Off’.
measured temperature of either RTDA or RTD
activated) is less than or equal to this setpoint, the
Low Temperature Alarm is activated and a “LOW TEMP
ALARM” message is added to the alarm stack. This alarm
deactivates when the temperature rises above the alarm
setpoint value.
1.
Display Mode: All
2.
Range: N/A
3.
Default: N/A
Maintain Temp
de-energized if the control temperature is
1.
Display Mode: All
2.
Range: -50 to 500°C, none or -58°F to 932°F,
none, Off
3.
Default: 10° or 50°F
Low Temp Alarm
1.
Display Mode: All
2.
Range: -50C to Maintain Temperature, Off, -58°F to
Maintain Temperature, Off
3.
Default: 5°C or 41°F
4.
Restrictions: Message does not exist if Maintain
Temperature is set to Off.
is set to None then the
monitoring with no
temp is set to Off
temperature
Deadband.
When the
B (if
7.1.4
High Temp Alarm
This value 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 RTDA or RTDB
(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 falls below this alarm
setpoint.
7.1.5
This value sets the Low Current Alarm setpoint. It must
be less than the high current alarm setpoint. To disable
this
is
Alarm
message is
deactivates when
alarm setpoint. Note:
heater at 100% power. If
Current Limiting is enabled, all
will be scaled to 100% power, based
resistive load, before being compared to the
setpoint.
1.
Display Mode: All
2.
Range: Maintain Temperature to +500°C,
Off,
Maintain Temperature to +932°F, Off
3.
Default: Off
4.
Restrictions: Message does not exist if
Maintain
Low Current Alarm
alarm set the value to “Off’. When the heater current
less than or equal to this setpoint, the Low Current
is activated and a “LOW CURRENT ALARM”
added to the alarm stack. The alarm
1.
Display Mode: All
2.
Range: 0.1A to High Current Alarm value, Off
3.
Default: Off
Temperature is set to Off.
the Heater Current rises above this
This setpoint is based on the
Proportional Control or
current measurements
on a constant
alarm
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9
Programming CM-2201/CM-2202
7.1.6
High Current Alarm
This value sets the High Current Alarm setpoint. It must
be greater than the low current alarm setpoint. To
disable this alarm set the value to “Off’. When the
heater current is greater than or equal to this setpoint,
the High Current
CURRENT ALARM” message
stack. The alarm deactivates when
falls below this alarm setpoint. This
on the heater at 100% power.
If Proportional Control or Current Limiting is enabled,
current measurements will be scaled to 100%
all
power, based on a constant resistive load, before being
compared to the
1.
Display Mode: All
2.
Range: Low Current Alarm value to 30.0A, Off
3.
Default: Off
7.1.7
Ground Fault Alarm
This value sets the Ground Fault Alarm setpoint. It must be
less than the ground fault trip setpoint. To disable this
alarm set the value to "Off'. When the Ground Fault Current is
greater than or equal to this setpoint, the Ground Fault
is activated and a "GROUND FAULT ALARM" message
added to the alarm stack. The alarm deactivates when
Ground Fault Current falls below this alarm setpoint.
1.
Display Mode: All
2.
Range: 10 to Ground Fault Trip, Off
3.
Default: 30mA
7.1.8
Ground Fault Trip
This value sets the Ground Fault Trip setpoint. It must be
greater than the ground fault alarm setpoint. To disable this
trip alarm set the value to “Off’. When the Ground Fault Current
is greater than or equal to this setpoint, the
de-energized, the Ground Fault Trip Alarm
“GROUND FAULT TRIP” message is added
stack. This is a latching alarm and trip. When
of the alarm has been corrected, the circuit may
energized by the manual reset function.
1.
Display Mode: All
2.
Range: Ground Fault Alarm to 500mA, Off
3.
Default: 50mA
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Alarm is activated and a “HIGH
alarm setpoint.
is added to the alarm
the heater current
setpoint is based
Alarm
is
the
heater circuit is
is activated and a
to the alarm
the cause
be
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 “LOW VOLTAGE ALARM” message is added
to the alarm stack. The alarm deactivates when the Line
Voltage rises above this alarm setpoint.
Low Voltage Alarm Continued
1.
Display Mode: All
2.
Range: 85VAC to High Voltage Alarm, Off
3.
Default: Off
7.1.10
High Voltage Alarm
This value sets the High Voltage Alarm setpoint. It must
be greater than the Low Voltage Alarm setpoint. To
disable this alarm set the value to “Off’. When the Heater
Voltage is greater than or equal to this setpoint, the High
Voltage Alarm is activated and a “HIGH VOLTAGE ALARM”
Message is added to the alarm stack messages. The
alarm
this alarm
deactivates when the Heater Voltage drops below
setpoint.
1.
Display Mode: All
2.
Range: Low Voltage Alarm to 280VAC, Off
3.
Default: Off
7.2
Program- Heater Setup
7.2.1
Heater Setup
This message displays the name of the sub-menu when
entered.
7.2.2
This selection enables control and monitoring of the
heater circuit. Setpoints and measured value messages
cannot be
“No” if the
1.
Display Mode: Advanced
2.
Range: N/A
3.
Default: N/A
Heater Enable
accessed unless the heater is enabled. Select
1.
Display Mode: All
2.
Range: Yes, No
3.
Default: No
circuit is not used.
10
CM-2201/CM-2202 Programming
7.2.3
Heater ID
This selection allows for user defined Heater
Identification.
for each heater
alphanumeric
from left to right. The cursor indicates which character is
selected. Press the [SELECT UP/DOWN] arrow keys
being
to change the character. Move to the next character by
pressing [NEXT] arrow. Press [ENTER] in the last character
position to save
1.
Display Mode: Advanced
2.
Range: 16 Characters (CM-2201)
12 Character s (CM-2202)
3.
Default: Blank
7.2.4
Heater Type
This selection allows the user to set which type of
heati ng cable is b e ing used. Self regu la ting heat ing cable
should not be used with proportional control, soft-start
mode, or Power limiting; for this reason these options
are unavailable when heater type is set to self
regulating. When heater type is set to fixed resistance all
control options are available. Display Mode: Advanced
1.
Display Mode: Advanced
2.
Range: Self Regulatin g, Fixed Resistance
3.
Default: Fixe d Resistance
7.2.5
External Disable
This selection sets the response of the heater circuit to the
Override inputs. The Override inputs respond to contact
closure. If the Override is set to “Disable”, the override inputs
are ignored, and control of the heater circuit operates
normally based on the measured temperature and maintain
temperature setpoint. If the Override is set to
“Enable”, an
the heater Off.
closed, the heater control resumes in normal manner.
1.
Display Mode: Advanced
2.
Range: Enable, Disable
3.
Default: Disable
It provides a unique, identifiable tag or label
circuit. The Heater Name allows up to 16
characters which are entered one at a time
the Heater ID.
open contact on the override inputs forces
When the contact on the override input is
7.2.6
Deadband
The Deadband is defined as the difference between the set
point temperature and the actual maximum temperature
that is ideally allowed in excess of the setpoint
temperature Decreasing the deadband increases the
temperature control
switching frequency.
1.
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
7.2.7
Control Type
This selection determines the type of control
method used
or Proportional
available for all heating
mode is only available for
devices.
7.2.8
This selection sets the maximum average current limit
allowed for the heater circuit. It is useful for reducing
the
will
for a
draw to the
1.
Display Mode: Advanced
2.
Range: On-Off, Proportional
3.
Default: On-Off
4.
Selection does not exist if Heater type is set to
Self regulating.
5.
Selection does not exist if Maintain Temperature
set to Off.
is
Power Limit
power output of fixed resistance heaters. The load
be turned on for a period of time and then turned off
period of time to maintain the average current
1.
Display Mode: Advanced
2.
Range: 20% - 100%, Off
3.
Default: Off
4.
Note: The value range is in 10% increments.
accuracy but also increases the heater
mode.
by the controller, either On-Off (Deadband)
Control. The On-Off control mode is
devices. Proportional Control
series type heating
value set.
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Programming CM-2201/CM-2202
7.2.9
Soft Start Mode
This function ramps the heater output from Off to nominal
current of the heater over the set soft start cycle
time. It
regulating
the load will
function.
7.2.10
This selection determines how the control temperature is
utilized by the RTD inputs.
−
−
−
−
−
−
is useful for reducing inrush currents of self-
heaters. At the end of the soft start cycle time,
no longer be controlled by the soft start
1.
Display: Advanced
2.
Range:10 to 999 seconds, Off
3.
Default: Off
RTD Operation
In One RTD Mode, the temperature is based on the
measured temperature from RTD-A.
In Backup Mode, control temperature is based on RTD-A.
for any reason RTD-A fails, then RTD-B takes over.
If
In Average Mode, the control temperature is based on the
average of RTD-A and RTD-B measured temperatures.
In Lowest Mode, control temperature is based on the
lowest
In Highest Mode, control temperature is based on the
highest of the two temperature measurem ents.
In High Temp er ature Cut off Mode, contr ol temperature is
based on RTD-A, but if the temperature from RTD-B
exceeds
turned Off and a
activated. The High Temperature
operate in one RTD mode if the high
is turned Off.
Functions requiring two RTDs to operate, such as Average, Lowest, Highest and High Temperature Cut off, will operate in One RTD mode if one of the two RTDs fail.
1.
2.
3.
Restrictions
Temperature is set to Off.
of the two temperature measurements.
the high temperature alarm, the heater is
Display Mode: Advanced
Range: One RTD, Backup, Average, Lowest,
Highest,
Default: One RTD
high temperature alarm is
cut off mode will
temperature alarm
High Temperature Cut off
: Message does not exist if Maintain
during this
“ALARM
System Status
alarm,
and press
value to “Off”. The
heater is forced off for
trip. Auto Test decreases
warning of problems that
until the heater was needed.
1.
2.
3.
7.2.11
This selection sets the controllers fail-safe mode. The
controller detects if RTD-A has failed and will use RTD-B
available. If RTD-B is not installed or has also
if
failed, the
as selected in this
where there is no hazard from
may select “On” to operate the heater
and prevent freeze up.
potential hazard from
to de-energize the circuit
available.
1.
2.
3.
7.2.12
This selection sets the operating mode of the external
alarm indicator.
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:
period, the Auto Test Alarm is activated and an
DURING AUTO TEST” message is added to the
messages. This is a latching alarm. To clear the
locate the alarm message in the Alarm menu
[ENTER]. To disable this feature, set the
Auto Test Cycle does not operate if
any reason, including ground fault
maintenance by providing an early
would otherwise go undetected
Display Mode: Advanced
Range:1 to720 hours, Off
Default: 24 hours
RTD Failure Mode
heater will be set to its fail-safe state
mode. For freeze protection
For processes where there is a
overheating, you may select “Off”,
Display Mode: Advanced
Range: On, Off
Default: Off
Restrictions:
Temperature is set to Off.
Alarm Contact
Message does not exist if Maintain
By setting the contacts to NC, these contacts
overheating, you
continuously
until one of the RTD’s becomes
7.2.11
Auto Test Cycle
This value sets the frequency at which the Auto Test Cycle is
activated. Auto Test is a feature that exercises the system by
automatically applying power to the heater at
specified time intervals. If an alarm condition is detected
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1.
Display Mode: Advanced
2.
Range: Normally Open, Normally Closed
3.
Default: Normally Open
12
Programming CM-2201/CM-2202
7.3 Program– System Setup
7.3.1 System Setup
This message displays the name of the sub-menu
when entered.
1. Display Mode: Advanced
2. Range: N/A
3. Default: N/A
7.3.2
Password
This selection determines if password protection is
required
show “disable” if program access is currently enabled
and show “enable” if program access is currently
disabled.
7.3.3
This selection allows the user to change the default
password. The user is prompt to re-enter the old
password, press [ENTER]. If correct, the user is prompt to
enter the new password, press [ENTER]. The user is then
prompt to re-enter the new password. If the user does
not enter the new password and press [ENTER] then the
password does not change.
7.3.4
This selection determines the unit of measure for
temperature values. All temperatures are displayed in
the
Fahrenheit degrees (F°).
for programming changes. The display will
1. Display Mode: All
2. Range: Enable or Disable
3. Default: Enable
Change Password
1. Display Mode: All
2. Range: Yes, No
3. Default: No
Units
selected units of either Celsius degrees (C°) or
1. Display Mode: Advance
2. Range: Celsius, Fahrenheit
3. Default: Celsius
7.3.5 Operational Costs
This value sets the cost per kWh of electrical power. This is
used to calculate energy costs for operating this control
circuit.
7.3.6 Display Mode
This selection determines what messages are displayed by
the controller for operations personnel. If set to
“advanced
“normal user”, only the basic messages are displayed.
Each message listed throughout this manual shows the
Display Mode required
to see the message. “Advanced only” indicates that the
display mode must be set to “advanced user” to view the
message.
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
System status
Heater status Alarm status of
Heater temp Temperature of
1. Display Mode: Advance
2. Range: $0.01 to 1.00
3. Default: $0.05
user”. all messages are displayed. If set to
1. Display Mode: All
2. Range: Normal, Advance
3. Default: Advance
1. Range: System Status, Heater Status, Heater Temp
2. Default: system status
3. Restrictions: Temperature messages are
not
displayed if Maintain Temperature is set
to Off.
INFORMATION
DISPLAYED
Alarm status of
all the heaters
the heater
the
heater
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13
Programming CM-2201/CM-2202
7.3.8 Display Timeout
This function sets the length of time from the last key
press, to automatically return to the Default Display
information.
1. Display Mode: Advance
2. Range:5 to 600 seconds, Off
3. Default: 120 seconds
7.3.9 Modbus Address
This selection sets a unique address to ensure only one
CM- 2201 attempts communications with the master unit
at any time. See Section 8.0 for complete information on
Modbus communications.
1. Display Mode: Advance
2. Range: 1 to 255 to accommodate multiple
3. Default: 1
Selecting “Off’ disables this function.
devices on same network.
7.3.10 Baud Rate
Sets the communication baud rate for the RS485 serial
port. All controllers connected to the same data highway
must operate on the same baud rate.
1. Display Mode: Advance
2. Range: 2400, 4800, 9600, 19200
3. Default: 9600
7.3.11 Reset Module
This selection resets controller memory parameters to
factory default values. If the controller’s memory
becomes corrupt, resetting the module will force the
controller to overwrite each register and may correct
any problems that
1. Display Mode: Advance
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.
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1. Display Mode: Advanced
2. Range: N/A
3. Default: N/A
exist.
7.4.2 Alarm Output Test
This function is used for testing and commissioning
purposes allowing the alarm output to be forced On either
for a short period of time or continuously. At the end of the
specified time duration, the testing option is
automatically
operate if the alarm configuration is set to disable and the
message “ALARM DISABLED” will appear.
1. Display Mode: Advanced
2. Range: 1-24 hours, Disabled, Continuously
3. Default: disabled
disabled. The alarm test function will not
7.4.3 Heater Test
This function overrides heater control for
maintenance purposes. For normal operation, set to
“disable”. If a period of time is selected, the heater is
forced On or Off for the selected interval. If “continuous” is
selected the heater is forced On until “disable” is selected.
1. Display Mode: Advanced
2. Range: 1-24 hours, Disabled, On Continuously
3. Default: disabled
7.4.4 Ground Fault Test
This function will test the ground fault trip function of
the controller to ensure proper operation. When
selected, the controller will generate an artificial
ground fault current; if
sensed as being greater than 30
The GF test function will verify actual ground fault
current and heater trip. Status of the test will be
displayed as pass or fail. If this test has been
invoked by the “Now” option and it passes, the user is
prompted to
the load is capable of being re-energized as required. If
this test has been invoked by the “Autotest” option
and it passes, the load is allowed to be reenergized as
required. If this test has been invoked by the Autotest
cycle and it fails, an Autotest alarm is generated but
the load is allowed to be re-energized as required.
1. Display Mode: Advanced
2. Range: Autotest cycle, Now, Disabled
3. Default: Disabled
the ground fault current is
mA, the test passes.
reset the ground fault trip, at which time
14
CM-2201/CM-2202 Communications
8.0 Communications
The Nelson Heat Trace CM-2201 supports a subset of the Modbus® RTU protocol format that provides monitoring,
programming, and control functions using Read (03) and Write (05-06) register commands.
General Information
Serial Port:
Baud Rate: User Defined at 2400,
Data Bits: 8
Stop Bits: 1
Parity:
Device Address:
Modbus Registers
For all Modbus register addresses,
Example of checking alarms via Modbus from a remote
terminal.
Controller SETTINGS and Status used on this example:
a. Modbus address 04
b. Baud rate 19200; non-parity; Stop bit 1.
c. High Temperature alarm active
1.
To check if any alarm is activated, send the
following instruction:
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”
At this point the controller enters the alarm into
the alarm log memory and clears the active
alarm. To check the alarm log memory, see
below.
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Select the serial port that corresponds to your RS-485 adapter.
USB to Serial adapter may be used for devices without serial connections.
4800, 9600 or 19200
None
User Defined between 1 and 255
see Appendix E.
04 03 0046 0026 2590
04 = controller Modbus number
03 = Modbus function code 3
0046 = start reading from data address
70
0026 = the next 38 addresses
2590 = CRC
04 =controller Modbus number
05 = Modbus function code 5
0045 = writing to data address 165
FF00 = erase command
9C4C = CRC
4.
If the command to check if any alarm is
activated (as shown in (1) above) is now sent to
the controller, and assuming no other alarms
have since been activated, the controller will
answer with 0x0000 (no active alarms).
5.
To check the alarm log memory, issue the
following instructions:
04 03 006E 0026 A598
04 = controller Modbus number
03 = Modbus function code 3
006E = start reading from data address
110
0026 = the next 38 addresses
A598 = CRC
6.
The High Temperature Alarm will be listed
here, so the controller will answer 0x02. The
Alarm log can hold 20 alarms. After 20 alarms
the oldest alarm will be erased to allow for
storage of the new 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
Note: The DPC can read up to 45 addresses per command
15
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