Emerson NELSON HEAT TRACE CM-2201 User manual

NELSON
™
CM-2201/CM-2202
HEAT TRACE CONTROLLERS
Installation and Operating Instructions

Contents
CM-2201/CM-2202
©2017 Nelson Heat Tracing Systems
www.nelsonheaters.com
GA2497 Rev.5
2
1.0 Introduction 4
1.1GettingStarted
2.0 General Application Information 5
3.0 Installation 6
3.1 Selecting Installation Location
3.2 Mounting
3.3 Wiring
4.0 Initial Set-up
4.1 Display Modes
4.2 Password Protection
4.3 Security Levels
5.0 General Operation 8
5.2 Display
5.3 Keypad
5.4 LED Functions
5.5 Monitoring
5.6 Alarm Management
5.7 Current-Limiting Feature
5.8 GroundFaults
5.9 Soft Start Feature
6.0 Control Modes 11
6.1 On-Off Control
6.2 Proportional Control
6.3 Forced Control Feature
7.0 Programming 12
7.1 Setpoints
7.2 Heater Setup
7.3 System Setup
8.0 Communications 18
9.0 Troubleshooting 20
10.0 Maintenance 24

CM-2201/CM-2202
Contents
©2017 Nelson Heat Tracing Systems
www.nelsonheaters.com
GA2497 Rev.5
3
Appendix A – Specifications 25
Appendix B – Wiring Diagrams 26
Appendix C – Typical Installation Diagram 28
Appendix D – Modbus Parameters 29
Appendix E – RTD Tables 39
Appendix F – Warranty 48

©2017 Nelson Heat Tracing Systems
www.nelsonheaters.com
GA2497 Rev.5
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Introduction CM-2201/CM-2202
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 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.

©2017 Nelson Heat Tracing Systems
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GA2497 Rev.5
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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 tocontrol heating
circuits bymonitoring one ortwo temperature inputsfor
each circuit via industry standard 3-wire, 100Ω, Platinum
RTDs. The twoseparateRTDs for each circuit maybe
utilized to customizethe temperature control inputs.
Several different modes are user selectable aswell as the
sensor failure operational mode.
The CM-2201 and CM-2202 can be operated in
temperatures of-40°Ft o+104°F(-40°Cto +40°C).

©2017 Nelson Heat Tracing Systems
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GA2497 Rev.5
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InstallationandInitialSetup 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 becarefully considered to ensure it
is always in operating conditions consistent with
specifications. See Appendix A for additionaldetails.
3.3 Mounting
The CM-2201/CM-2202 should be mounted at a convenient
height to suit operator interaction.Conduit entriesshould
be madeinthe bottomofthe enclosureto preventdamageto
the internal electronics from moisture intrusion. Conduit
entries should be drilled and the use of suitable bushings is
required to maintain the environmental ratings.
3.4 Wiring
Electrical wiring diagrams and schematics are provided in
Appendix B andC of this manual. Ensure that all wiring
and connections are in accordance with applicable wiring
codes. Enclosure grounding must be in accordance with
applicablewiringcodes fornon-metallic devices.
The power supply for the CM-2201 isderived from the
power provided for the load. However, the power supply
forthe CM-2202 can be provided independentofthe
powersupply for the loads being controlled.For
example, the powersupply forthe CM-2202 can be120
VAC whilethe loads being controlled canbe277 VAC.
Further,the power supplyforthe CM-2202 may also be
derived from either oftheloads being controlled –thisis
implemented by connecting appropriate jumpers.
Refer to Wiring Diagram in Appendix B for details.

©2017 Nelson Heat Tracing Systems
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GA2497 Rev.5
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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 determines what messages and functions
are
displayed during normal operations. If set to “normal user” only
basic information i
sdisplayed. If set to “advanced user” all
controllerinformationis 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 mayalsoreplace the default
password value (1234) with their own unique value for greater
protection of operational parameters.
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 be
changed without theuse ofa password. At this level all the
functionsand monitoring parameters are open.The low
level (Normal Level) does not give accesstoparameters
settings,butis open for fewparameters monitoring like
temperature, current, GFI, etc.
If the password is“Enabled”,whengoingdirectlyto the
parameter to be changed,afterthe‘up’ or‘down’ arrowis
pressed,the controller willask for the password. Then the
parameter can be changed and saved.The password will stay
disabled for 15 min, then be automatically re-enabled. During
the15min period whenthepassword is disabled, other
parameters can be changed and saved.
CM-2201/CM-2202
InstallationandInitialSetup

©2017 Nelson Heat Tracing Systems
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GA2497 Rev.5
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CM-2201/CM-2202 General Operation
5.1 General Operation
5.2 Display
The CM-2201/CM-2202 utilizes a 2 line x 16 character
alphanumeric displayviewable fromthe front keypad.
The toplineis reserved for the function or operation
and the bottom line displays the value range.
5.2.1 Navigation for CM2201
The CM2201 monitors one heating circuit consisting of
load (typically a heating cable) and controls theload
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 Actual until “Operating
Values” is displayed, then press Right or Left arrow to
scroll through thevarious values.
To review the statistics that have been collected,
press Actual until “Statistics” is displayed then press
Right or Left arrow to scroll through the various
statistics.
To change the control and monitoring settings
(including alarm settings), press the Program key and
then Right or Left arrowto scroll through the various
settings. Any setting can be altered by pressing the
Up or Down arrow. Note that a 4-digit password
may berequiredtochange 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.
To view alarms, press the Alarms key and then Right
or Left arrowto scroll through the various alarms.
Alarms that are not active can be erased bypressing
the Reset key.
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 inSection 5.2.1.
To changeto 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
(eg. "CH.2"), the channel can be changed by
pressing the Up or Down arrow.

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GA2497 Rev.5
General Operation CM-2201/CM-2202
5.3 Keypad
The keypad is “capacitive” touch sensitive and keys
are activated by simply touching the area ofthe
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 active parameters .
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.
The alarm contacts function as follows:
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 isenergized 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
improperlyinstalledcableswhichallowcurrent-
carrying 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 thecable and/or the pipe itself. This
type of fault can eventually become serious, resulting
in overheating/fire/shock hazards. Current leakage to
ground can bemonitored by electronic circuitryand
the SPC can be programmed to either alarm or trip
when leakage c u r r e n t e x ce e d s t h e s p e c i f i e d
m a x i mu m a l l o wa b l e a m o u n t .

©2017 Nelson Heat Tracing Systems
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GA2497 Rev.5
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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 resistance
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.
5.9 Soft-Start Feature
This short energization period 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 can be continuously
energized.
CM-2201/CM-2202 General Operation