ABB ControlMaster CM10 User manual

Category
Measuring, testing & control
Type
User manual

This manual is also suitable for

User Guide – Standard Functionality IM/CM/S–EN Rev. R
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN
The Company
We are an established world force in the design and manufacture of instrumentation for industrial process control,
flow measurement, gas and liquid analysis and environmental applications.
As a part of ABB, a world leader in process automation technology, we offer customers application expertise, service
and support worldwide.
We are committed to teamwork, high quality manufacturing, advanced technology and unrivalled service and
support.
The quality, accuracy and performance of the Company’s products result from over 100 years experience, combined
with a continuous program of innovative design and development to incorporate the latest technology.
Language
Operator Templates
Page 1 (4) Template
Operator Functions
Autoscroll
Soft Key Function
Auto Manual Enable
Local Remote Enable
Alarm Ack. Enable
SP Adjust Enable
Settings
Brightness
Contrast*
Date & Time
Date Format
Time & Date
Daylight Saving
SP Adjust Enable
Analog Inputs
Anlg Input 1 (4)
Analog Outputs
Analog Output 1 (2)
Digital I/O
Digital IO 1 (6)
Relays
Relay 1 (4)
Loop 1 Setpoints
Low Limit
High Limit
No. of Local SP’s
Local Setpoint 1
Track Mode
RSP Ratio
RSP Bias
RSP Fault Action
Default Setpoint
Ramp Mode
Ramp Rate
Select Sources
Loop 1 Control
Control Type
Control Action
On/Off Hysteresis
Autotune
PID
Loop 1 Output
Limits
Failure Actions
A/M Select Sources
Slew Rate
Tracking
Loop 1 Split O/P
Min Input 1
Min OP 1
Max Input 1
Max OP 1
Min Input 2
Min OP 2
Max Input 2
Max OP 2
Loop 1 Time Prop
Cycle Time 1
Cycle Time 2
Basic Device Setup Display Input/Output Control
Menu
Menu
Menu
Exit Select Exit Select
Exit Select Exit Select Exit Select
Initial Setup
App. Template
Loop 1 Output Type
Loop 1 Split O/P
Instrument Tag
Mains Freq.
Config Action
Custom Template
Reset to Defaults
Security Setup
Basic Password
Advanced Password
Reset Passwords
Custom Config
Note. When in Advanced Level (configuration) mode, press and hold the key to return to the standard Operator page – see Fig. 3.1, page 5
*Enabled for CM30 and CM50 only
Refer to Section 7.2, page 39 Refer to Section 7.3, page 43 Refer to Section 7.4, page 51Refer to Section 6, page 27 Refer to Section 7.1, page 36
Menu Menu
See
Back
Cover
Loop 1 Setpoints
Local Setpoint 1 (4)
RSP Ratio
RSP Bias
Ramp Mode
Ramp Rate
Loop 1 Control
On/Off Hysteresis
Mode
Autotune
PID
Loop 1 Mot Valve
Ratio
Bias
Deadband
Travel Time
Loop 1 Time Prop
Cycle Time 1
Cycle Time 2
Alarm 1 (8)
Trip
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN Contents
IM/CM/S–EN Rev. R 1
Contents
1 Safety .......................................................................... 3
1.1 Electrical Safety ..................................................... 3
1.2 Symbols ................................................................ 3
1.3 Health & Safety ..................................................... 4
2 Introduction ................................................................ 4
2.1 EC Directive 89 / 336 / EEC .................................. 4
2.2 End of Life Disposal ............................................... 4
3 Displays, Icons and Keys .......................................... 5
3.1 CM10 Operator Page, Icons and Keys .................. 5
3.2 CM30 and CM50 Operator Page, Icons & Keys .... 6
4 Installation ................................................................... 8
4.1 Siting and Environmental Requirements ................. 8
4.2 Dimensions ............................................................ 9
4.3 Mounting ............................................................. 11
4.4 Jumper Links for Relay Outputs ........................... 12
4.4.1 Removing the Controller from its Case ...... 12
4.4.2 Resetting Jumper Links ............................. 13
4.5 Electrical Connections ......................................... 14
4.5.1 CM10 Electrical Connections ..................... 15
4.5.2 CM30 Electrical Connections ..................... 16
4.5.3 CM50 Electrical Connections ..................... 17
4.5.4 Analog Inputs ........................................... 18
4.5.5 Frequency / Pulse Input ............................. 20
4.5.6 Digital Input / Output ................................. 20
5 Operator Level Menus .............................................. 22
5.1 Diagnostic Status Bar .......................................... 24
5.2 Diagnostic View ................................................... 25
5.3 Security Options .................................................. 25
5.4 Access Level ....................................................... 26
6 Basic Level ................................................................ 27
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN Contents
2 IM/CM/S–EN Rev. R
7 Advanced Level ........................................................ 36
7.1 Device Setup ....................................................... 36
7.2 Display ................................................................ 39
7.3 Input/Output ........................................................ 43
7.4 Control ................................................................ 51
7.5 Process Alarm ..................................................... 63
7.6 Profile .................................................................. 66
7.6.1 Ramp Types .............................................. 67
7.6.2 Guaranteed Ramp / Soak .......................... 68
7.6.3 Set Point Start Condition – Current PV ...... 70
7.6.4 Profile Parameters ..................................... 71
7.7 Functions ............................................................ 80
7.8 Communication ................................................... 93
7.9 Diagnostics .......................................................... 94
7.9.1 Diagnostic Messages ................................ 96
7.10 Device Info ....................................................... 100
8 Templates and Functionality .................................. 101
8.1 Basic Templates ............................................... 101
8.1.1 Single Loop / Single Loop with
Remote Setpoint ..................................... 101
8.2 Standard Templates ......................................... 103
8.2.1 Auto / Manual Station (Low Signal
Selection / Digital Signal Selection) .......... 103
8.2.2 Analog Backup Station (Low Signal
Selection / Digital Signal Selection) .......... 104
8.2.3 Single Indicator ....................................... 106
8.2.4 Dual Indicator ......................................... 106
9 PC Configuration .....................................................107
10 Specification ..........................................................108
Appendix A – Digital and Analog Sources .................116
A.1 Digital Sources ...................................................116
A.2 Analog Sources .................................................117
Appendix B – Error Codes ..........................................118
B.1 Configuration Error Codes ................................. 118
B.2 Profile Error Codes .............................................121
Appendix C – Analog Input (Engineering) Units ........122
Appendix D – Output Type Assignments .................. 124
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 1 Safety
IM/CM/S–EN Rev. R 3
1Safety
Information in this manual is intended only to assist our
customers in the efficient operation of our equipment. Use of
this manual for any other purpose is specifically prohibited
and its contents are not to be reproduced in full or part
without prior approval of the Technical Publications
Department.
1.1 Electrical Safety
This equipment complies with the requirements of CEI / IEC
61010-1:2010 3
rd
edition 'Safety Requirements for Electrical
Equipment for Measurement, Control and Laboratory Use'
and complies with US NEC 500, NIST and OSHA.
If the equipment is used in a manner NOT specified by the
Company, the protection provided by the equipment may be
impaired.
1.2 Symbols
One or more of the following symbols may appear on the
equipment labelling:
Warning – Refer to the manual for instructions
Caution – Risk of electric shock
Functional earth (ground) terminal
Protective earth (ground) terminal
Direct current supply only
Alternating current supply only
Both direct and alternating current supply
The equipment is protected
through double insulation
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 2 Introduction
4 IM/CM/S–EN Rev. R
1.3 Health & Safety
2Introduction
This manual provides details for the ControlMaster
CM10 (
1
/8 DIN), CM30 (
1
/4 DIN) and CM50 (
1
/4 DIN)
controllers with Standard functionality.
2.1 EC Directive 89 / 336 / EEC
In order to meet the requirements of the EC Directive 89/336/
EEC for EMC regulations, this product must not be used in a
non-industrial environment.
2.2 End of Life Disposal
Controllers with Standard functionality contain a small lithium
battery that must be removed and disposed of responsibly in
accordance with local environmental regulations.
Health and Safety
To ensure that our products are safe and without risk to health,
the following points must be noted:
The relevant sections of these instructions must be read
carefully before proceeding.
Warning labels on containers and packages must be
observed.
Installation, operation, maintenance and servicing must
be carried out only by suitably trained personnel and in
accordance with the information given.
Normal safety precautions must be taken to avoid the
possibility of an accident occurring when operating in
conditions of high pressure and / or temperature.
Safety advice concerning the use of the equipment described in
this manual or any relevant hazard data sheets (where applicable)
may be obtained from the Company, together with servicing and
spares information.
Note.
Read all relevant sections of this guide before configuring the
system or modifying system parameters.
Install and use associated equipment in accordance with the
relevant national and local standards.
System configuration must be carried out only by users or
personnel with approved access rights (user privileges).
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 3 Displays, Icons and Keys
IM/CM/S–EN Rev. R 5
3 Displays, Icons and Keys
3.1 CM10 Operator Page, Icons and Keys
Fig. 3.1 ControlMaster CM10 Display and Icons
CM10
47.46
35.00
47.6%
gal/h
PV
SP
OP
ControlMaster
B
C
A
PV Value
Setpoint Value
Icons
Access
Level
Manual Control
Mode
Local Setpoint
Remote Setpoint
Output Value
Auto Control
Mode
Operator
Level
Icons
See Table 3.1
for key functions
Alarm
Status
A
Navigation (left) / Operator Level access key – see
page 22.
B
Up / Down keys – navigate up / down menus and
increase / decrease displayed values.
C
Navigation key (right) / programmable Soft Key
see page 40.
Table 3.1 CM10 Front Panel Key Functions
Note. When a Soft Key option is assigned to key C,
the Advanced Level (see page 36) must be accessed
using the Operator Level access key A.
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 3 Displays, Icons and Keys
6 IM/CM/S–EN Rev. R
3.2 CM30 and CM50 Operator Page, Icons & Keys
The ControlMaster CM30 and CM50 displays and icons are shown in Fig. 3.2.
Fig. 3.2 ControlMaster CM30 and CM50 Displays and Icons
CM50
1000.0
0.0
479.2
500.0
74.9
AUTO
LOCAL
PSI
PV
SP
OP
ControlMaster
CM30
PSI
PV
SP
OP
ControlMaster
479.2
500.0
74.9
%
PV Value
Bargraph
Setpoint
Value
Icons
Access
Level
Manual
Mode
Local Setpoint
Remote
Setpoint
Output
Value
Auto
Mode
Operator
Level
Menu
Icons
Adjust
– Indicates which value is adjusted
by the / keys
Process
Alarm
Autotune
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 3 Displays, Icons and Keys
IM/CM/S–EN Rev. R 7
The ControlMaster CM30 and CM50 front panel keys are shown in Fig. 3.3.
Fig. 3.3 ControlMaster CM30 / CM50 Front Panel Keys
B D
E
A
C
A
Navigation (left) / Operator Level access key – see
page 22.
B Local / Remote setpoint mode selection key.
C
Up / Down keys – navigate up / down menus and
increase / decrease displayed values.
D Auto/Manual control mode selection key.
E
Navigation key (right) / programmable Soft Key –
see page 40.
Table 3.2 CM30 / CM50 Front Panel Key Functions
Note. When a Soft Key option is assigned to key E, the
Advanced Level (see page 36) must be accessed using
the Operator Level access key A.
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 4 Installation
8 IM/CM/S–EN Rev. R
4 Installation
4.1 Siting and Environmental Requirements
Fig. 4.1 Siting and Environmental Requirements
+
CM30 CM30 CM30
CM30 CM30
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 4 Installation
IM/CM/S–EN Rev. R 9
4.2 Dimensions
Fig. 4.2 ControlMaster CM10 and CM30 Dimensions
CM10 CM30
Dimensions in mm (in.)
Panel Cut-out
Dimensions
97 (3.81)
97
(3.81)
121 (4.76)
141 (5.55)
91.8
(3.6)
20 (0.78)
92
(3.62)
+0.03
–0
+0.8
–0
92 (3.62)
14 (0.55)
14 (0.55)
30 (1.18)
+0.8 –0
+0.03 –0
50 (1.97)
45 (1.77)
+0.6
–0
+0.02
–0
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 4 Installation
10 IM/CM/S–EN Rev. R
Dimensions in mm (in.)
Fig. 4.3 ControlMaster CM50 Dimensions
Controllers can be
close-stacked to
DIN 43835
144
(5.67)
123 (4.84)
146 (5.74)
138
(5.43)
23 (0.9)
138
(5.43)
30 (1.18)
14 (0.55)
(+0.04 –0)
+1.0 –0
68 +0.7
–0
(2.67 +0.03
–0
)
76 (3.0)
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 4 Installation
IM/CM/S–EN Rev. R 11
4.3 Mounting
ControlMaster is designed for panel mounting. For NEMA4X
protection, a panel thickness of 2.5 mm (0.1 in.) is required.
To panel-mount the controller:
1. Cut a hole of the correct size for the controller in the
panel – see Section 4.2, page 9 for dimensions.
2. Insert the controller into the panel cut-out.
Referring to Fig. 4.4:
3. Position the upper panel clamp A at the top front of
the case against the panel.
4. Locate the panel clamp anchor B in slot C.
5. Tighten the panel clamp anchor screw D until panel
clamp A is secured against the panel.
6. Repeat steps 3 to 5 to fit the lower panel clamp E
and panel clamp anchor F.
Caution. Do not overtighten the screw.
Fig. 4.4 Mounting Details
E
A
C
F
D
B
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 4 Installation
12 IM/CM/S–EN Rev. R
4.4 Jumper Links for Relay Outputs
The factory-set default for relay action is N/O.
4.4.1 Removing the Controller from its Case
The ControlMaster inner assembly must be removed from its
case to access the relay contact jumper links.
Referring to Fig. 4.5:
1. Insert the bezel release tool A (supplied) into the front
panel slot B below the function keys.
2. Press the bezel release tool A fully in and then down
C until the shoulder on the tool engages with the
notch behind the controller front plate.
3. Pull the bezel release tool A to withdraw the inner
assembly from the case D.
Note. If the bezel release tool is mislaid, 2 small flat-
headed screwdrivers (4 mm [0.15 in.]) can be used as
alternative tools, one inserted into the front panel slot and
the second for leverage in the notch on the underside of
the controller front plate. The notch is the only area that
can be used as a leverage point – do not attempt to lever
the front panel from any other area.
Fig. 4.5 Removing the Controller from the Case
A
C
D
B
A
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 4 Installation
IM/CM/S–EN Rev. R 13
4.4.2 Resetting Jumper Links
1. The links associated with the relay outputs are shown
in Fig. 4.6.
2. If necessary, move the link to select the relay action
required (N/O or N/C).
Note. The factory-set default for all jumper links is N/O.
Fig. 4.6 Jumper Links for Relay Outputs
N/C N/O
N/C N/O
N/C N/O
LK1
LK2
LK3
N/O
N/O
N/C
N/C
LK1
LK2
N/O
N/O
N/C
N/C
LK2
LK1
CM10 and CM30
Option Board 1 / 1a
CM50 Option
Board 1
CM50 Standard
Board 1
LK1 = Relay O/P 3
LK2 = Relay O/P 4
LK1 = Relay O/P 1
LK2 = Relay O/P 2
LK1 = Relay O/P 2
LK2 = Relay O/P 3
LK3 = Relay O/P 4
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 4 Installation
14 IM/CM/S–EN Rev. R
4.5 Electrical Connections
Warning.
The controller is not fitted with a switch therefore a disconnecting device such as a switch or circuit breaker conforming to local safety
standards must be fitted to the final installation.
It must be mounted in close proximity to the controller within easy reach of the operator and must be marked clearly as the disconnection
device for the instrument.
Remove all power from supply, relay and any powered control circuits and high common mode voltages before accessing or making any
connections.
Use cable appropriate for the load currents. The terminals accept cables from 18 to 14 AWG (0.8 to 2.5mm
2
).
Always route signal leads and power cables separately, preferably in earthed (grounded) metal conduit.
It is strongly recommended that screened cable is used for signal inputs and relay connections.
The instrument conforms to Mains Power Input Overvoltage Category 2, Pollution Degree 2 (EN601010–1).
(This equipment is protected through double insulation – Insulation Class II.)
Analog / digital inputs and outputs, transmitter power supply and DC power supply are SELV (Safety Extra Low Voltage) circuits.
All connections to secondary circuits must have basic insulation.
After installation, there must be no access to live parts, e.g. terminals.
Terminals for external circuits are for use only with equipment with no accessible live parts.
If the controller is used in a manner not specified by the Company, the protection provided by the equipment may be impaired.
All equipment connected to the controller's terminals must comply with local safety standards (IEC 60950, EN601010–1).
Note. Terminal screws must be tightened to a torque of 0.1 Nm (0.9 lbf/in.).
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 4 Installation
IM/CM/S–EN Rev. R 15
4.5.1 CM10 Electrical Connections
Fig. 4.7 ControlMaster CM10 Electrical Connections
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
+
+
+
+
+
19
20
21
22
23
24
25
26
27
28
29
30
25
26
Option Board 1
Comms*
Tx PSU
Analog / Digital
Output 1****
Analog Input 1
Analog Input 2
Relay Output 1
Neutral
Line***
100 to
240 V AC
10 W
10 to
36 V DC
NC
C
NO
Analog Output 2
Digital Input / Output 1
Digital Input / Output 2
Digital Input / Output –
Relay Output 2
Relay Output 3
Relay Output 4
Digital Output + External
**
C
**
C
**
C
Standard Connections
* See rear panel for MODBUS connections
** N/O (factory default) or N/C contact selection made via internal jumper links – see page 12
*** 200 mA Type T fuse (mains AC) or 2 A Type T fuse (120 V DC max.) and external
isolating switch. For UL-marked controllers the fuse must be UL recognized
**** Provides 24 V digital output (observe + and – connections)
Rear View Rear View
Relay
Output 2
**
C
Option Board 1a
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 4 Installation
16 IM/CM/S–EN Rev. R
4.5.2 CM30 Electrical Connections
Fig. 4.8 ControlMaster CM30 Electrical Connections
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
+
+
+
+
+
29
30
31
32
33
34
35
36
37
38
39
40
+
+
41
42
43
44
45
46
47
48
49
50
51
52
47
48
Rear
View
Analog Input 3
Analog Input 4
Tx PSU
Digital Output + External
Digital Input / Output 1
Digital Input / Output 4
Digital Input / Output 5
Digital Input / Output 6
Digital Input / Output –
Comms*
Tx
PSU
Analog Output 2
Rear
View
Option Board 1 Option Board 2Standard Connections
Digital Input / Output 2
Digital Input / Output –
**
C
**
C
**
C
Relay Output 2
Relay Output 3
Relay Output 4
Digital Output + External
Digital Input / Output 3
Analog
Input 1
Analog Input 2
Relay Output 1
Neutral
Line***
100 to
240 V AC
10 W
10 to
36 V DC
NC
C
NO
Analog / Digital
Output 1****
Rear
View
* Refer to rear panel for MODBUS connections
** N/O (factory default) or N/C contact selection made via internal jumper links – see page 12
*** 200 mA Type T fuse (mains AC) or 2 A Type T fuse (120 V DC max.) and external
isolating switch. For UL-marked controllers the fuse must be UL recognized
**** Provides 24 V digital output (observe + and – connections)
**
C
Relay
Output 2
Option Board 1a
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 4 Installation
IM/CM/S–EN Rev. R 17
4.5.3 CM50 Electrical Connections
Fig. 4.9 ControlMaster CM50 Electrical Connections
+
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
+
+
+
24
25
26
27
28
29
30
31
32
33
34
35
+
19
20
21
22
23
36
37
38
39
40
41
+
+
Rear View
Rear View
Digital Output + External
Tx PSU
Digital Input / Output 5
Digital Input / Output 6
Digital Input / Output –
Digital Input / Output 3
Digital Input / Output 4
Relay Output 3
Relay Output 4
Analog Output 2
Option Board 1
**
C
**
C
Analog Input 1
Analog Input 2
Comms*
Standard Connections
Neutral
Line***
Digital Output + External
Digital Input / Output 1
Digital Input / Output 2
Digital Input / Output –
Analog / Digital Output 1****
Relay Output 1
Relay Output 2
**
C
**
C
Tx PSU
*Refer to rear panel for
MODBUS connections
**N/O (factory default) or N/C
contact selection made via
internal jumper links – see
page
12
***200 mA Type T fuse
(mains AC) or 2 A Type T
fuse (120 V DC max.) and
external isolating switch. For
UL-marked controllers the
fuse must be UL recognized
****Provides 24 V digital
output (observe + and –
connections)
Analog Input 3
Analog Input 4
100 to
240 V AC
10 W
10 to
36 V DC
ControlMaster CM10, CM30 and CM50
Universal process controllers,
1
/8,
1
/4 and
1
/2 DIN 4 Installation
18 IM/CM/S–EN Rev. R
4.5.4 Analog Inputs
Fig. 4.10 Standard Analog Inputs (1 and 2)
mA
mV
V
Digital Input
Milliamps*
THC
CJ**
THC***
3-lead RTD
mA, mV, V,
Digital Input
2-lead RTD
+ Resistance
RTD +
RTD –
RTD +
RTD –
Tra ns m i t t e r P S U
Analog
Input 2
Analog
Input 1
Milliamps*
RTD –
3rd lead
CJ
Sensor
* Using internal transmitter power supply.
** Fit the CJ sensor supplied if Analog Input 1 or 2 are THC inputs.
(Alternatively, it is possible to use an external fixed cold [reference] junction, if the controller
is programmed for use with millivolt inputs and the appropriate thermocouple linearizer is selected.)
*** Analog Input 2 can be used only with THC inputs if Analog Input 1 is also used as a THC input.
**** For mA input types, to ensure loop continuity when the controller is switched off, fit a 2V7 Zener diode as shown.
Note. 3-lead RTD: 3 leads must have equal resistance, not exceeding 20 each.
****
****
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ABB ControlMaster CM10 User manual

Category
Measuring, testing & control
Type
User manual
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