ABB ControlMaster CM50 User manual

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

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

At Eye Level

Close to the Sensor

Avoid Vibration

Sensor

Temperature Limits

55°C

(131°F)

Max.

0°C

(32°F)

Min.

Humidity Limits

0 to 95% RH

IP66/NEMA4X (front panel) IP20 (rear)

Use Screened Cable

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)

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

LK1

LK2

LK3

N/O

N/C

LK1

LK2

N/O

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

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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