Emerson NELSON HEAT TRACE CM-2201, NELSON HEAT TRACE CM-2202 Installation And Operating Instructions Manual

™

NELSON

CM-2201/CM-2202

HEAT TRACE CONTROLLERS

Installation and Operating Instructions

Contents

CM-2201/CM-2202

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1.0

Introduction 4

1.1 Getting Started

2.0

3.0

4.0

5.0

General Application Information 5

Installation 6

3.1 Selecting Installation Location

3.2 Mounting

3.3 Wiring

Initial Set-up

4.1 Display Modes

4.2 Password Protection

4.3 Security Levels

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 Ground Faults

5.9 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 Heater Setup

7.3 System Setup

8.0 Communications

9.0 Troubleshooting

10.0 Maintenance

GA2497 Rev.5

CM-2201/CM-2202

Contents

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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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Introduction

1.1

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

1.2

Getting Started

The CM-2201/CM-2202 is typically connected to external RTDs, power or communication based on Appendix B and C. Detailed setup of the operating/control/monitoring throughout the following sections.

For addition help, call Nelson Technical Support or follow the Troubleshooting section.

program is entered

CM-2201/CM-2202

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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 to control heating circuits by monitoring one or two temperature inputs for each circuit via industry standard 3-wire, 100Ω, Platinum RTDs. The two separate RTDs for each circuit maybe utilized to customize the temperature control inputs. Several different modes are user sensor failure operational

The CM-2201 and CM-2202 can be operated in temperatures of -40°F t o +104°F (-40°C to +40°C).

mode.

selectable as well as the

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Installation and Initial Set up 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 be carefully considered to ensure it is always in operating conditions consistent with specifications. See Appendix A for additional details.

implemented by connecting appropriate jumpers. Refer to Wiring Diagram in Appendix B for details.

3.3

Mounting

The CM-2201/CM-2202 should be mounted at a convenient height to suit operator interaction. Conduit entries should be made in the bottom of the enclosure to prevent damage to 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 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 power supply for the loads being controlled. For example, the power supply for the CM-2202 can be 120 VAC while the loads being controlled can be 277 VAC. Further, the power supply for the CM-2202 may also be derived from either of the loads being controlled – this is

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CM-2201/CM-2202

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 displayed during normal operations. If set to “normal user” only basic information i controller information is 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 may also replace the default password value (1234) with their own unique value for greater protection of operational parameters.

determines what messages and functions are

s displayed. If set to “advanced user” all

Installation and Initial Set up

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 the use of a password. At this level all the functions and monitoring parameters are open. The low level (Normal Level) does not give access to parameters settings, but is open for few parameters monitoring like temperature, current, GFI, etc.

If the password is “Enabled”, when going directly to the parameter to be changed, after the ‘up’ or ‘down’ arrow is pressed, the controller will ask for the password. Then the parameter can be changed and saved. The password will disabled for 15 min, then be automatically re-enabled. the 15 min period when the password is disabled, parameters can be changed and saved.

stay

During

other

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CM-2201/CM-2202

5.1

General Operation

5.2

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.

General Operation

5.2.2 Navigation for CM2202

The CM2202 can monitor/control two separate heating circuits (channels). The controller defaults to Channel 1 upon first start-up. All parameters for Channel 1 can be displayed and modified using standard techniques as described for the CM2201 in Section 5.2.1.

5.2.1 Navigation for CM2201

The CM2201 monitors one heating circuit consisting of load (typically a heating cable) and controls the load 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 Values” is displayed, then press scroll through the various values. To review the statistics that have been collected, press Actual

Right

statistics.

To change the control and monitoring settings (including alarm settings), press the then

Right

settings. Any setting can be altered by pressing the

or may be required to change 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.

until “Statistics” is displayed then press

Left

arrow to scroll through the various

Left

arrow to scroll through the various

Down

arrow. Note that a 4-digit password

Actual

Right

until “Operating

Left

Program

arrow to

key and

To change to Channel 2, simply press the “ key and then displayed. To change the channel, press the Up

In general, when the active channel is displayed (eg. "CH.2"), the channel can be changed by pressing the Up or Down arrow.

right

arrow – the active channel will be

Actual”

arrow.

To view alarms, press the or

Left

arrow to scroll through the various alarms. Alarms that are not active can be erased by pressing the

Reset

key.

Alarms

key and then Right

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General Operation

CM-2201/CM-2202

5.3 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 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 activeparameters.

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.

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 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% ofthetime.

5.8

Ground Faults

Ground faults typically are the result of damaged or improperly installed cables which allow currentcarrying 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 the cable and/or the pipe itself. This type of fault can eventually become serious, resulting in overheating/fire/shock hazards. Current leakage to ground can be monitored by electronic circuitry and the SPC can be programmed to either alarm or trip when leakage

cu r r e n t e x c e e ds t he s p e c i f i e d

ma x i m u m a l l ow a bl e a m o u n t .

The alarm contacts function as follows:

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CM-2201/CM-2202

General Operation

5.9 Soft-Start Feature

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 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.

This short energization period is repeated and eventually increased; after a few minutes, the cable is usually warm enough current decreased to the point where it can be continuously energized.

such that the resistance has increased and the

resistance

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Control Modes

CM-2201/CM-2202

6.1

Control Modes

The CM-2201/CM-2202 allows the user to select different control modes based on their individual process control parameters.

6.2

On-Off Control

This control method simply energizes the cable until the actual monitored temperature rises to the set point value plus half the deadband value (upper limit). The cable is then de-energized until the actual monitored temperature

drops to the 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 when the 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.”

6.3

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 set point value and the actual monitored temperature increases, the amount of time the cable is energized increases proportionately. This helps reduce the

“overshoot”and“undershoot”commonly associated with

On/Off control.

B) If the Temperature setpoint is a specific value

(eg 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.

6.4

Forced Control Feature

This control method simply allows the user to force the cable on or off as desired using an external signal (eg +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:

If the Temperature setpoint is “OFF” or “None”,

then the heater gets energized by applying the external signal or closing the external contact.

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Programming

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7.1 Programming

7.2 Program-Setpoints

7.2.1 Setpoint Value

This message displays the name of the sub-menu when entered.

7.2.2 Maintain Temp

This value sets the control setpoint temperature for all operating modes. For On-Offcontrol, the circuit is energized if the control temperature is less than the maintain temperature minus the deadband. The circuit is de-energized if the control temperature is greater than the maintain temperature plus the deadband. If maintain temp is set to None then the heater circuit will have temperature monitoring with no control temperature. If the maintain temp is set to Off then the heater circuit will have no temperature monitoring or control.

7.2.3 Low Temp Alarm

This value sets the Low Temperature Alarm setpoint. It must be less than the maintain temperature minus the Deadband. To disable this alarm set the value to “Off’. When the measured temperature of either RTDA or RTD B (if 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.

Display Mode: All

Range: N/A

Default: N/A

Display Mode: All

Range: -50 to 500°C, none or -58°F to 932°F, none, Off

Default: 10° or 50°F

Display Mode: All

Range: -50C to Maintain Temperature, Off, -58°F to Maintain Temperature, Off

Default: 5°C or 41°F

Restrictions: Message does not exist if Maintain Temperatureis set to Off.

7.2.4 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 set point, 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

Display Mode: All

Range: Maintain Temperature to +500°C, Off, Maintain Temperature to +932°F, Off

Default: Off

Restrictions: Message does not exist if Maintain Temperatureis set to Off.

7.2.5 Low Current Alarm

This value sets the Low Current Alarm setpoint. It must be less than the high current alarm setpoint. To disable this alarm set the value to “Off’. When the heater current is less than or equal to this setpoint, the Low Current Alarm is activated and a “LOW CURRENT ALARM” message is added to the alarm stack. The alarm deactivates when the Heater Current rises abovethis alarmsetpoint. Note: This set point is based on the heater at 100% power. If Proportional Control or Current Limiting is enabled, all current measurements will be scaled to 100% power, based on a constant resistive load, before being compared to the alarm setpoint.

7.2.6 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 Alarm is activated and a “HIGH CURRENT ALARM” message is added to the alarm stack. The alarm deactivates when the heater current falls below this alarm set point. This

is based on the heater at 100% power.

Display Mode: All

Range: 0.1A to High Current Alarm, Off

Default: Off

set point.

setpoint

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Programming

CM-2201/CM-2202

7.1.6 High Current Alarm Continued

If Proportional Control or Current Limiting is enabled, all current measurements will be scaled to 100% power, based on a constant resistive load, before being compared to the alarm setpoint.

Display Mode: All

Range: Low Current Alarm to 30.0A, Off

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

greater than or equal to this setpoint, the Ground Fault Alarm is activated and a "GROUND FAULT ALARM" message is added to the alarm stack. The alarm deactivates when the Ground Fault Current falls below this alarm setpoint.

Display Mode: All

Range: 10 to Ground Fault Trip, Off

Default: 30mA

Low Voltage Alarm Continued

Display Mode: All

Range: 85VAC to High Voltage Alarm, Off

Default: Off

7.1.10 High Voltage Alarm

This value sets the High Voltage Alarm setpoint. It must begreater 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 deactivates when the Heater Voltage drops below this alarm

7.2

setpoint.

Display Mode: All

Range: Low Voltage Alarm to 280VAC, Off

Default: Off

Program- Heater Setup

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 heater circuit is de-energized, the Ground Fault TripAlarm is activated and a “GROUND FAULT TRIP” message is added to the alarm stack.This is a latching alarm and trip. When the cause of the alarm has been corrected, the circuit may

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.

be energized by the manual reset function.

Display Mode: All

Range: Ground Fault Alarm to 500mA, Off

Default: 50mA

7.2.1 Heater Setup

This message displays the name of the sub-menu when entered.

7.2.2 Enable Heater

This selection enables control and monitoring of the heater circuit. Setpoints and measured value messages cannot be accessed unless the heater is enabled. Select “No” if the circuit is not used.

Display Mode: Advanced

Range: N/A

Default: N/A

Display Mode: All

Range: yes, no

Default: yes

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Programming

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7.2.3 Heater ID

This selection allows for user defined Heater Identification. It provides a unique, identifiable tag or label for each heater circuit. The Heater Name allows up to 20 alphanumeric characters which are entered one at a time from left to right. The cursor indicates which character is being selected. Press the [SELECT UP/DOWN] arrow keys to change the character. Move to the nextcharacter by pressing [NEXT] arrow. Press [ENTER] in the last character position to save the Heater ID.

Display Mode: Advanced

Range: 20 Characters

Default: Blank

7.2.4 Manual Override

This selection sets the response of the heater circuit to the Override inputs. The Override inputs respond to contact closure. If the Over ride is set to “Off”, the over ride 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“On”, an open contact on the Override inputs forces the heater Off. When the contact on the Override input is closed, the heater control resumes in normal manner.

Display Mode: Advanced

Range: On, Off

Default: Off

7.2.5 Deadband

The Deadband is defined as the difference between the setpoint temperature and the actual maximum temperature that is ideally allowed in excess of the setpoint temperature. Decreasing the deadband increases the temperature control accuracy but also increases the heater switching frequency.

Display Mode: Advanced

Range: 1 C° to 5 C°, 1 F° to 10 F°

Default: 2 C° or 5 F°

Note: Deadband is disabled for Proportional Control mode.

Control Type

This selection determines the type of control method used by the controller, either On-Off (Deadband) or Proportional for all heating devices. Proportional Control mode is only available for series type heating devices.

Warning:

for use with self-regulating heating cable types due to the constantly changing characteristics of self-regulating cables – this will cause the control to be unstable. Further, the continual cycling associated with Proportional Control result in internal heating of the cable and lead to reduced life expectancy.

Display Mode: Advanced

Range: On-Off, Proportional

Default: On-Off

Selection does not exist if Maintain Temperature is set to Off.

7.2.6 Current Limiting

This selection sets the maximum average current limit allowed for the heater circuit. It is useful for reducing the power output of constant wattage heaters. The load will be turned on for a period of time and then turned off for a period of time to maintain the average current draw to the value set.

Display Mode: Advanced

Range: 0.5 to 30.0 A, Off

Default: Off

Note: The value range is in 0.5A increments.

7.2.7 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 is useful for reducing inrush currents of self-regulating heaters. At the end of the soft start cycle time, the load will no longer be controlled by the soft start function.

Display: Advanced

2. Range: 10 to 999 seconds, Off

Default: Off

Control. The On-Off control mode is available

Proportional Control should never be selected

can

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Programming

CM-2201/CM-2202

7.2.8 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 during this period the Auto Test Alarm is activated and an “ALARM DURING AUTO TEST” message is added to the System Status messages. This is a latching alarm. To clear the alarm,

locate the alarm messsage in the Alarm Menu and press [ENTER].

The Auto Test Cycle does not operate if heater is forced off for any reason, including ground fault trip. Auto Test decreases maintenance by providing an early warning of problems that would otherwise go undetected until the heater was needed.

7.2.9 RTD Operation

This selection determines how the control temperature is utilized by the RTD inputs.

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. If for any reason RTD-A fails, then RTD-B takes over.

To disable this feature, set the value to “Off”.

Display Mode: Advanced

2. Range: 1 to 720 hours, Off

Default: 24 hours

Functions requiring two RTDs to operate, such as Average, Lowest, Highest and High Temperature Cutoff, will

operate in One RTD mode if one of the two

7.2.10

This selection sets the controllers fail-safe mode. The controller detects if RTD-A has failed and will use RTD-B if available. If RTD-B is not installed or has also failed, the heater will be set to its fail-safe state as selected in this mode. For freeze protection where there is no

hazard from overheating, you may select "On" to operate the heater continuously and prevent freeze up.

For processes where there is a potential hazard from overheating, you may select “Off”, to de-energize the circuit until one of the RTD’sbecomes available.

RTD Operation Continued

Display Mode: Advanced

Range: One RTD, Backup, Average, Lowest, Highest, High Temperature Cutoff

Default: One RTD

Restrictions: Message does not exist if Maintain Temperature is set to Off.

RTD Failure Mode

Display Mode: Advanced

Range: On, Off

Default: Off

Restrictions: Message does not exist if Maintain Temperature is set to Off.

RTDs fail.

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 basedon the lowest of the two temperature measurements.

In Highest Mode, control temperature is based on the highest of the two temperature measurements.

In High Temperature Cutoff Mode, control temperature 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.

7.3

Program– System Setup

7.3.1 System Setup

This message displays the name of the sub-menu when entered.

7.3.2 Password

This selection determines if password protection is required for programming changes. The display will show “disable” if program access is currently enabled and show “enable” if program access is currently disabled.

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Display Mode: Advanced

Range: N/A

Default: N/A

Display Mode: All

Range: Enable or Disable

Default: Enable

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Emerson NELSON HEAT TRACE CM-2201, NELSON HEAT TRACE CM-2202 Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual