Nelson Installation and Maintenance Manual: GA-2490, CM-3-32 Heat Trace Circuit Management System Manuals & Guides
CM3-32 Installation and Operations Manual
TABLE OF CONTENTS
I. FEATURES .................................................................................................................. 3
Control & Monitoring ............................................................................................................. 3
II. INSTALLATION .......................................................................................................... 5
Location .................................................................................................................................... 5
Control Power ......................................................................................................................... 5
Ventilation ................................................................................................................................ 5
Conduit Routing ..................................................................................................................... 5
III. OPERATION .............................................................................................................. 8
Channel Select ........................................................................................................................ 8
Channel Display ...................................................................................................................... 8
Individual Channel Enable/Disable .................................................................................... 9
Trip Reset Function ............................................................................................................... 9
Alarm Indication ................................................................................................................... 10
Output Alarm Reset ............................................................................................................. 10
Alarm Log Display ................................................................................................................ 11
Advanced Operations - Maintenance Alerts ................................................................. 12
Maintenance Alert Log ........................................................................................................ 12
Maintenance Alert Status ................................................................................................... 13
IV. START-UP ............................................................................................................... 14
Turning the System On ....................................................................................................... 14
Programming System Parameters ................................................................................... 14
Temperature Units ............................................................................................................... 14
Ground Fault Delay .............................................................................................................. 15
Automatic Test Cycle .......................................................................................................... 16
Programming Individual Channels (Circuits) ............................................................... 16
Sensor Failure Mode ........................................................................................................... 17
Ground Fault Control .......................................................................................................... 18
Global Programming of Channels (Circuits) ................................................................. 19
Advanced Setup Features .................................................................................................. 20
Ambient Control ................................................................................................................... 20
Maintenance Alerts .............................................................................................................. 21
Event Log and Display Settings ....................................................................................... 21
User Login and Passwords ............................................................................................... 23
Changing User Passwords ................................................................................................ 24
Changing Modbus Slave Address (-EC Option) ........................................................... 25
V. TROUBLESHOOTING.............................................................................................. 27
System Operation ................................................................................................................ 27
Section I .................................................................................................................................. 28
Communications Alarm ...................................................................................................... 28
Section II ................................................................................................................................. 29
Temperature Alarm .............................................................................................................. 29
Section III ................................................................................................................................ 30
Load Current Alarm ............................................................................................................. 30
Section IV ............................................................................................................................... 31
Ground Fault Alarm ............................................................................................................. 31
VI. SPECIFICATIONS ................................................................................................... 32
VII. GENERAL COMMUNICATION INFORMATION (-EC OPTION) ............................. 33
VIII. COMMUNICATIONS ............................................................................................. 33
PO Box 726 Tulsa, OK 74101 918-627-5530 Fax 918-641-7336 www.nelsonheaters.com
©2010 Nelson Heat Tracing Systems GA-2490 Rev. 3
August 2012
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CM3-32 Installation and Operations Manual
I. FEATURES
Control & Monitoring
The CM3-32 Circuit Management System is a microprocessor based control and
monitoring system utilizing standard industrial automation products specifically integrated
for use with electrical heat tracing systems. The system provides temperature and current
monitoring for each heat tracing circuit while communicating additional information to
operations personnel such as temperature alarms, sensor failures, electrical circuit faults,
and overall operational conditions.
The CM3-32 Circuit Management System is mounted in a NEMA 12, 4, or 4X free-standing
industrial enclosure. The system is available in standard configurations up to a maximum
of 32 control circuits per enclosure. The CM3-32 is configured from standard PLC
automation components interfaced with specialized current modules and power handling
devices designed for this specific application. Individual CM3-32 systems can be network
connected through the provided Modbus® RTU communications protocol.
Color Touch Screen Graphics Terminal – 5.7” Color LED analog touch pad, resolution
1024 x 1024, compact flash card memory for user application
Process Temperature Display – actual pipe/vessel temperature is displayed with alarm
indication by animation and color change
Load Current Display – actual heater load current is displayed with alarm indication by
animation and color change
Ground Fault Leakage Display – actual ground fault leakage is displayed with alarm
indication by animation and color change
Heater Status, Condition, and Alarm Displays – real time status of individual channel
control is displayed by alarm banners, animated light bars and/or animated backgrounds
Programmable Setpoint Values – direct programming of the following values is provided:
Maintain Temperature
Deadband
Hi Temperature Alarm
Lo Temperature Alarm
Hi Current Alarm
Lo Current Alarm
Ground Fault Alarms, Alarm and Trip Values
Programmable Operational Features – direct programming of the following features is
provided:
Temperature Units
Ground Fault Delay Option
Automatic Test Cycle Function and Time Intervals
Sensor Failure Mode
Ground Fault Trip Control Function
Ambient Control Function and Channel Identification
Maintenance Alert Function and Settings
System Override Option
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©2010 Nelson Heat Tracing Systems GA-2490 Rev. 3
August 2012
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CM3-32 Installation and Operations Manual
Global Programming – allows programming of all control setpoint values from a single
input screen
Modbus® Communications – remote monitoring capabilities provided via Modbus® RTU
protocol using simple 2-wire, RS-485 hardware
Web Gate and Web Page Server (ET Suffix Only) – direct control and monitoring is
provided through Ethernet connection to the Graphics Terminal, Web Gate server with
remote terminal diagnostics from the navigator on your PC
Maintenance Alerts – trend analysis of each channel’s electrical characteristics is
provided with actual value indication and alert messaging for use by operations personnel
to focus periodic maintenance efforts more efficiently
PO Box 726 Tulsa, OK 74101 918-627-5530 Fax 918-641-7336 www.nelsonheaters.com
©2010 Nelson Heat Tracing Systems GA-2490 Rev. 3
August 2012
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CM3-32 Installation and Operations Manual
II. INSTALLATION
Location
The CM3-32 should be located in a suitable location on a flat and level surface. The
enclosure should be bolted to the base and/or wall surface, or adequately supported by
other methods to prevent unsafe installation and/or operational conditions.
NEMA Type 12 (IP55)
Enclosures are intended for indoor use primarily to provide a degree of protection
against dust, falling dirt, and dripping non-corrosive liquids.
NEMA Type 4 (IP66)
Enclosures are intended for indoor or outdoor use primarily to provide a degree
of protection against windblown dust and rain, splashing water, and hose
directed water, undamaged by the formation of ice on the enclosure.
NEMA Type 4X (IP66)
Enclosures are intended for indoor or outdoor use primarily to provide a degree
of protection against corrosion, windblown dust and rain, splashing water, and
hose directed water, undamaged by the formation of ice on the enclosure.
The basic CM3-32 is designed for use in ordinary, non-classified locations. Protecting
electrical equipment in hazardous, classified, locations requires special considerations.
NEMA 4 and 4X Panels supplied with a P Suffix are provided with Type Z Purge equipment
to ensure safe operation within a hazardous location. The protective gas purge supply
must be clean, dry, and free of hydrocarbons or corrosive materials. All protective gas
purge supply pressures must be set correctly and all enclosure doors must be closed
securely. Purged enclosures must not be opened unless power is removed from the
equipment and the area is known to be non-hazardous.
Control Power
The CM3-32 accepts universal voltages of 100-240VAC single phase, 60/50Hz. The panel
is equipped with (2) Form C Alarm Relays that are energized during normal operation.
Should the panel lose control power or activate an alarm, the relays will de-energize
indicating an alarm condition.
Ventilation
The CM3-32 is provided with continuously operating internal circulation fans. These fans
are used for static ventilation and aid heat dissipation from the enclosure by passive
radiation and convection. The accumulation of heat in an enclosure is potentially damaging
to electrical and electronic devices. Overheating can shorten the life expectancy of costly
electrical components or lead to premature failure.
Conduit Routing
When routing conduit to the CM3-32 enclosure, clear space is provided on the top, right
side, and bottom areas. Top entry should be avoided if possible. Top entry provides a
potential moisture path to the electronics and interconnecting wiring. If top entry cannot be
avoided, do not locate conduit entries directly over any exposed electrical equipment. Drip
loops are recommended for all top and/or side entry. A drip loop is a dip or bend in the
wiring to block or shed moisture that may follow a wire to the connection point.
PO Box 726 Tulsa, OK 74101 918-627-5530 Fax 918-641-7336 www.nelsonheaters.com
©2010 Nelson Heat Tracing Systems GA-2490 Rev. 3
August 2012
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CM3-32 Installation and Operations Manual
WARNING:
Modul
e Assembly
Alarm Relays
Terminal Blocks
Wire Trough
Terminal Blocks
Terminal Blocks
Trough
Module Assembly
Alarm Relays
Terminal Blocks
Wire Trough
Terminal Blocks
Contactors
Moisture intrusion can damage the
modules,
relays
or con
trol wiring.
Processor and I/O
Power Supply
RTD Input
Modules
Sensor Wire
Control Power
Line In
Processor and I/O
Power Supply
RTD Input
Modules
Sensor Wire
Trough
Control Power
Line In
Line In
Terminals
Line In
CM3-32-R2
Figure 1
CM3-32-C
Figure 2
Ventilation Fans
Line Out
Line Out
Wire Trough
Power Relays
(GC-695)
Communications
Interface Modules
CT Modules
(GC0710)
!
CM-3 electronics. Do not place
conduit entry directly over the control
Ventilation Fans
Line Out
Line Out
Wire Trough
Voltage Drivers
(GC0577X01)
CT Modules
(GC0710)
PO Box 726 Tulsa, OK 74101 918-627-5530 Fax 918-641-7336 www.nelsonheaters.com
©2010 Nelson Heat Tracing Systems GA-2490 Rev. 3
August 2012
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CM3-32 Installation and Operations Manual
Note:
Power Supply
Processor Module
missing or faulty
Discrete I/O Module
(Alarm Relays)
Analog
I/O Module
(RTD Sensors)
Display
RUN LED (green) Processor running
ERR LED (red) Processor or system fault
I/O LED (red) I/O module fault
SER COM LED (yellow) Activity present
CARD ERR LED (red) Memory card
Display
OK LED (green)
24 V LED
(green)
Flash Memory card
RS-485 Internal
communications cable
connection
D25SUB Connector
High Density Connections
to PLC Input Modules
Refer to Assembly and Wiring
Diagrams supplied with panel for
specific connection details
Display
RUN LED (green) Normal
ERR LED (red) On=Internal fault, Flashing=Comm fault
I/O LED (red) On=External fault, Flashing=Terminal
block fault
Channel LED’s (green) On=Normal, Off=Alarm
Display
RUN LED (green) Normal
ERR LED (red) On=Internal fault, Flashing=Comm
fault
I/O LED (red) On=External fault, Flashing=Cable fault
Channel LED’s (green) On=Normal, Flashing=Sensor
failure or no sensor connected
USB cable
connection to
Graphics Display
PLC Module Details
Figure 3
RTD Interface Module
Figure 4
High density cable
connections to RTD
Interface Modules
RTD Interface Module
Part No. 2900774
Instrument Wire for Sensor
Connections (Typical)
PO Box 726 Tulsa, OK 74101 918-627-5530 Fax 918-641-7336 www.nelsonheaters.com
©2010 Nelson Heat Tracing Systems GA-2490 Rev. 3
August 2012
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CM3-32 Installation and Operations Manual
III. OPERATION
Channel Select
To view the current status of each individual control channel, press
< CHANNEL SELECT > found in the lower left corner of the Home page.
This action will access the CHANNEL SELECT page allowing the direct
selection of each individual channel. Press the channel number to access
the specific page required.
Press < Home > on any displayed page to return to the Home page screen.
Channel Display
Individual channel pages display the current status of all operational
conditions. Actual values are compared to programmed values and
indicated by color and/or animation. The actual values are only shown
when the heater is energized. These values will be shown as 0’s during any
de-energized condition.
The status of each heater output control is shown by the switch labeled
STATUS. The HEATER indication bar light will notify the operator as to
whether the heat tracing is currently Off (Green) or On (Red).
When actual conditions are within programmed parameters, the specific
value will be shown in steady-white. If the actual condition is outside of the
programmed parameters, the specific value and ALARM indication bar light
will flash slow off-and-on. If the current condition exceeds the
PO Box 726 Tulsa, OK 74101 918-627-5530 Fax 918-641-7336 www.nelsonheaters.com
©2010 Nelson Heat Tracing Systems GA-2490 Rev. 3
August 2012
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CM3-32 Installation and Operations Manual
programmed value for Ground Fault Trip, the specific value will change to
flash fast off-and-on.
To view a different channel, press < Back > to access the Channel
Selection page.
Press < Home > on any displayed page to return to the Home page screen.
Individual Channel Enable/Disable
Press < ON > side of the STATUS switch to automatically control the
individual channel by the programmed set point temperature. Press the
< OFF > side of the STATUS switch to disable the displayed channel.
When the STATUS switch is in the < OFF > position, the channel will not be
included during the System Override function or the Auto Test-Cycle
function and all alarms will be disabled.
Press < Home > on any displayed page to return to the Home page screen.
Trip Reset Function
If the Ground Fault Trip function is programmed to be < ON >, a tripped
condition will be indicated by the flashing background around the RESET
GF TRIP button. All ground fault trip conditions must be manually reset.
This operational parameter will disable the heater output device until the
condition is corrected and the reset button is pressed. To reset the tripped
circuit, press < RESET GF TRIP >.
If the Ground Fault Trip function is programmed to < OFF >, the reset switch
will be replaced by the GROUND FAULT TRIP DISABLED indication.
PO Box 726 Tulsa, OK 74101 918-627-5530 Fax 918-641-7336 www.nelsonheaters.com
©2010 Nelson Heat Tracing Systems GA-2490 Rev. 3
August 2012
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CM3-32 Installation and Operations Manual
Safety Warning:
The system will still reflect ground fault alarm conditions, but the
heater will not be de-energized during any high ground leakage
conditions.
Press < Home > on any displayed page to return to the Home page screen.
Alarm Indication
When an alarm is triggered by the CM-3, a banner will appear at the top of
the Home page and begin scrolling each active alarm condition. This
indication gives the operator the current active alarm(s) and channel
number(s). The Alarm Banner will remain active until the alarm condition is
corrected.
Output Alarm Reset
The CM-3 is equipped with two separate alarm output relays, one is used
for Common Alarm indication and the other is specific to any Ground Fault
conditions only. To clear these alarm outputs, press < RESET OUTPUT
ALARM >. Additional alarm conditions will activate these alarm outputs
accordingly. These alarm contacts are designed to be used for external
indication of alarm status.
PO Box 726 Tulsa, OK 74101 918-627-5530 Fax 918-641-7336 www.nelsonheaters.com
©2010 Nelson Heat Tracing Systems GA-2490 Rev. 3
August 2012
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CM3-32 Installation and Operations Manual
Alarm Log Display
To view all current alarms, press < CHANNEL STATUS > in the lower left
corner of the page. This will display the Channel Summary page. Any
channels that are currently in alarm will be represented by the Alarm Banner
on the lower portion of the page and the specific channel number will be
flashing off-and-on. Acknowledge specific Channel Alarms by pressing
the appropriate channel number. Press < Alarm Log > to directly access
the stored list of alarms.
This page will show all current alarms and their status. Alarm messages
shown in Red are active, those shown in Green have returned to normal.
All alarms are stamped with the Date and Time. You can directly select a
specific alarm message by pressing the block directly to the left of the
message as shown by the black and white arrow above.
These icons move the cursor up or down one row. Cursor Up moves the
cursor up one row. Cursor Down moves the cursor down one row.
These icons scroll one page up or down. Page Up and Page Down are
useful when there are too many alarms to fit on a single page of the alarm
summary. Page Up moves the display up one page. Page Down moves
the display down one page.
PO Box 726 Tulsa, OK 74101 918-627-5530 Fax 918-641-7336 www.nelsonheaters.com
©2010 Nelson Heat Tracing Systems GA-2490 Rev. 3
August 2012
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