Nelson Installation and Maintenance Manual: GA-2500, CM-3-SSR Heat Trace Circuit Management System Manuals & Guides
CM3
SSR Versions
HEAT TRACE CIRCUIT MANAGEMENT SYSTEM
INSTALLATION AND OPERATIONS MANUAL
CM3-SSR Installation and Operations Manual
www.emerson.com
©2018 Nelson Heat Tracing Systems GA-2500 Rev. 1
April 2018
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TABLE OF CONTENTS
TABLE OF CONTENTS .................................................................................................. 2
I. FEATURES .................................................................................................................. 4
Control & Monitoring................................................................................................. 4
II. INSTALLATION .......................................................................................................... 6
Location ........................................................................................................................ 6
Control Power ............................................................................................................. 6
Conduit Routing ......................................................................................................... 6
III. OPERATION ............................................................................................................ 10
Channel Select .......................................................................................................... 10
Channel Display ....................................................................................................... 10
Individual Channel Enable/Disable ..................................................................... 11
Trip Reset Function ................................................................................................. 11
Alarm Indication ....................................................................................................... 12
Output Alarm Reset ................................................................................................. 12
Alarm Log Display ................................................................................................... 13
Advanced Operations - Maintenance Alerts ..................................................... 14
Maintenance Alert Log ............................................................................................ 14
Maintenance Alert Status ....................................................................................... 15
IV. START-UP ............................................................................................................... 16
Turning the System On........................................................................................... 16
Programming System Parameters ...................................................................... 16
Temperature Units ................................................................................................... 16
Ground Fault Delay .................................................................................................. 17
Automatic Test Cycle .............................................................................................. 18
Programming Individual Channels (Circuits) ................................................... 18
Cable Type ................................................................................................................. 19
Softstart ...................................................................................................................... 19
Control Mode ............................................................................................................. 20
Current Limit ............................................................................................................. 21
Temperature Control Settings .............................................................................. 21
Sensor Failure Mode ............................................................................................... 22
Ground Fault Control .............................................................................................. 23
Global Programming of Channels (Circuits) .................................................... 23
Advanced Setup Features ..................................................................................... 24
Ambient Control ....................................................................................................... 25
Maintenance Alerts .................................................................................................. 25
Event Log and Display Settings ........................................................................... 26
User Login and Passwords ................................................................................... 28
Changing User Passwords .................................................................................... 29
Changing Modbus Slave Address (-EC Option) .............................................. 30
V. TROUBLESHOOTING.............................................................................................. 32
System Operation .................................................................................................... 32
Section I ...................................................................................................................... 33
Communications Alarm .......................................................................................... 33
Section II ..................................................................................................................... 34
Temperature Alarm .................................................................................................. 34
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Section III .................................................................................................................... 35
Load Current Alarm ................................................................................................. 35
Section IV ................................................................................................................... 36
Ground Fault Alarm ................................................................................................. 36
VI. SPECIFICATIONS ................................................................................................... 37
VII. GENERAL COMMUNICATION INFORMATION (-EC OPTION) ............................. 38
VIII. COMMUNICATIONS ............................................................................................. 38
CM3-SSR Installation and Operations Manual
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©2018 Nelson Heat Tracing Systems GA-2500 Rev. 1
April 2018
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I. FEATURES
Control & Monitoring
The CM3-SSR 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 and control 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-SSR Circuit Management System is mounted in a NEMA 12, 4, or 4X, freestanding industrial enclosure. The system is available in standard configurations up to a
maximum of 32 control circuits per enclosure. The CM3-SSR is configured from standard
PLC automation components interfaced with specialized current modules and power
handling devices suitable for this specific application. Individual CM3-SSR systems can be
network connected through the optional 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 Alarm
▪ Ground Fault Trip
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©2018 Nelson Heat Tracing Systems GA-2500 Rev. 1
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Programmable Operational Features – direct programming of the following features is
provided:
▪ Temperature Units
▪ Ground Fault Delay Option
▪ Automatic Test Cycle Function and Time Intervals
▪ Heater Cable Type
▪ Control Mode
▪ Softstart Function and Duration
▪ Current Limiting Function and Limit Value
▪ Sensor Failure Mode
▪ Ground Fault Trip Control Function
▪ Ambient Control Function and Channel Identification
▪ Maintenance Alert Function and Settings
▪ System Override Option
Global Programming – allows programming of all control setpoint values from a single
input screen
Modbus® Communications (EC Suffix Only) – 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
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II. INSTALLATION
Location
The CM3-SSR 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 CM3-SSR is designed for use in both ordinary, non-classified locations and Class I,
Division 2 hazardous, classified locations. Protecting electrical equipment in hazardous,
classified, locations requires special considerations. Enclosures located in hazardous
locations must not be opened unless power is removed from the equipment and the area is
known to be non-hazardous.
Control Power
The CM3-SSR 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 deenergize indicating an alarm condition.
Conduit Routing
When routing conduit to the CM3-SSR enclosure, clear space is provided for bottom entry.
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 entries. 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.
CM3-SSR Installation and Operations Manual
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©2018 Nelson Heat Tracing Systems GA-2500 Rev. 1
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!
WARNING:
Moisture intrusion can damage the
CM-3 electronics.
Do not place conduit entry on top of CM3
in conditions where precipitation may
occur.
Processor, Power
Supply and I/O
Module Assembly
RTD Input
Modules
Common Alarm Relays
Power Supply
Control Power
Terminal Blocks
Line Out
Terminal Blocks
(Typical)
Line In
Terminal Blocks
(Typical)
Sensor Wire
Trough
Line In/Out
Wire Trough
Heat Sinks
(4-6 Circuits Each)
GF Modules
(GC0710)
Power Switch
Ground Bus
CM3-SSR
Figure 1
Note: Model CM3404XSSR shown,
Placement and number of components may
differ between models.
Control Signal
Terminal Blocks
Processor, Power
Supply and I/O
Module Assembly
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April 2018
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CM3 Field wiring
Figure 2
CM3-SSR Installation and Operations Manual
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©2018 Nelson Heat Tracing Systems GA-2500 Rev. 1
April 2018
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RTD Interface Module
Figure 4
RTD Interface Module
Part No. 2900774
Instrument Wire for Sensor
Connections (Typical)
D25SUB Connector
High Density Connections
to PLC Input Modules
Note:
Refer to Assembly and Wiring
Diagrams supplied with panel for
specific connection details
PLC Module Details
Figure 3
Power Supply
Display
OK LED (green)
24 V LED (green)
Processor Module
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
missing or faulty
Discrete I/O Module (Alarm and Load Relays)
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
Analog I/O Module (RTD Sensors)
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
High density cable
connections to RTD
Interface Modules
USB cable
connection to
Graphics Display
RS-485 Internal
communications cable
connection
Flash Memory card
Serial Module (EC Option)
Display
RUN LED (green) Normal Status
ERR LED (red) Fault Status
SER COM (green) ON=Activity,
Flashing=Device Communicating
Backplane Extension Module
RUN LED (green) Normal Status
ERR LED (red) Fault Status
SER COM (green) ON=Activity,
Flashing=Device Communicating
CM3-SSR Installation and Operations Manual
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©2018 Nelson Heat Tracing Systems GA-2500 Rev. 1
April 2018
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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 pushbutton labeled
CONTROL. 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-black. 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
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programmed value for Ground Fault Trip, the background will reverse and
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 the < CONTROL > pushbutton to toggle to be ENABLED for
automatic control of the individual channel by the programmed set point
temperature. Press the
< CONTROL > pushbutton again to disable the displayed channel. When
indicating DISABLED, 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 ENABLED, a tripped
condition will be indicated by the flashing arrow above the TRIP RESET
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 < TRIP RESET >.
CM3-SSR Installation and Operations Manual
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©2018 Nelson Heat Tracing Systems GA-2500 Rev. 1
April 2018
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If the Ground Fault Trip function is programmed to be DISABLED, the reset
switch will be replaced by the GROUND FAULT TRIP DISABLED
indication.
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 CM3-32-SSR, the RESET pushbutton
and 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. The RESET pushbutton will
remain visible until the output alarm relays are cleared.
Output Alarm Reset
The CM3-32-SSR 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.
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