ABB ControlMaster CM15 Training manual

—
ABB MEASUREMENT & ANALYTICS | COMMISSIONING INSTRUCTION | CI/CM15-EN REV. A
ControlMaster CM15
Universal process indicator,  DIN
Measurement made easy

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Further publications for the ControlMaster CM15 indicator are available for free download from:
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Data sheet



User guide
 IM/CM/I-EN
Communications supplement
 

IM/CM/C-EN

CONTROLMASTER CM15 | UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A 3
Contents
1 Health & Safety ............................................................4
Document symbols .........................................................4
Safety precautions.......................................................... 4
Potential safety hazards................................................ 5
Electrical .................................................................... 5
Safety standards ............................................................. 5
EC Directive 89/336/EEC............................................... 5
End-of-life disposal ........................................................ 5
Cleaning ............................................................................. 6
Symbols.............................................................................. 6
Restriction of Hazardous Substances (RoHS) ......... 6
2 Specification................................................................7
3 Installation ...................................................................9
Siting .................................................................................. 9
Mounting ......................................................................... 10
4 Electrical connections..............................................12
Accessing the connection terminals ........................ 13
Standard analog inputs (1 and 2)............................... 15
5 Front panel keys ........................................................16
6 Operator level menus ............................................... 17
7 Access levels and security options ........................18
Security options ............................................................ 18
8 Diagnostics messages .............................................19
9 Instrument menus.....................................................22
Notes...................................................................................26

4CONTROLMASTER CM15 |UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A
1 Health & Safety
Document symbols
Symbols that appear in this document are explained
below:
WARNING
The signal word ‘WARNING’ indicates an imminent
danger. Failure to observe this information may
result in death or severe injury.
NOTICE
The signal word ‘NOTICE’ indicates potential
material damage.
Note.
‘Note’ indicates useful or important information about
the product.
Safety precautions
Be sure to read, understand and follow the instructions
contained within this manual before and during use of
the equipment. Failure to do so could result in bodily
harm or damage to the equipment.
WARNING
Installation and maintenance of this product must
only be conducted by personnel authorized to work
on electrical installations and in accordance with
relevant local regulations.

CONTROLMASTER CM15 | UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A 5
Potential safety hazards
Electrical
WARNING
To ensure safe use when operating this equipment,
the following points must be observed:
• Up to 240 V AC may be present. Be sure to isolate
the supply before removing the terminal cover.
• 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 Material
Safety Data Sheets (where applicable) can be
obtained from the Company, together with servicing
and spares information.
Safety standards
This product has been designed to satisfy the
requirements of IEC61010-1:2010 3rd edition 'Safety
Requirements for Electrical Equipment for
Measurement, Control and Laboratory Use' and
complies with US NEC 500, NIST and OSHA.
EC Directive 89/336/EEC
Electrical – In order to meet the requirements of the EC
Directive 89/336/EEC for EMC regulations, this
product must be used in an industrial environment.
End-of-life disposal
The indicator contains a small lithium battery that
must be removed and disposed of responsibly in
accordance with local environmental regulations.
The remainder of the indicator does not contain
any substance that causes undue harm to the
environment and must be disposed of in
accordance with the Directive on Waste Electrical
and Electronic Equipment (WEEE). It must not be
disposed of in Municipal Waste Collection.

6CONTROLMASTER CM15 |UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A
…1 Health & Safety
Cleaning
The indicator can be hosed down if it has been installed
to IP66/NEMA 4X standards. Warm water and a mild
detergent can be used.
Symbols
Symbols that appear on this product are shown below:
Protective earth (ground) terminal.
Both direct and alternating current supply.
This symbol, when noted on a product, indicates a
potential hazard that could cause serious personal
injury and/or death. The user must refer to this
commissioning instruction for operation and/or
safety information.
This symbol, when noted on a product enclosure or
barrier, indicates that a risk of electrical shock
and/or electrocution exists. Only individuals
qualified to work with hazardous voltages should
open the enclosure or remove the barrier.
Recycle separately from general waste under the
WEEE directive
Restriction of Hazardous Substances (RoHS)
The European Union RoHS Directive and
subsequent regulations introduced in member
states and other countries limits the use of six
hazardous substances used in the manufacturing
of electrical and electronic equipment. Currently,
monitoring and control instruments do not fall
within the scope of the RoHS Directive, however
ABB has taken the decision to adopt the
recommendations in the Directive as the target for
all future product design and component
purchasing.

CONTROLMASTER CM15 | UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A 7
2 Specification
Mechanical data
Protection
• Front face IP66/ NEMA 4X
• Rear panel IP20
Dimensions
• Height – 50 mm (2.0 in)
• Width – 97 mm (3.8 in)
• Depth behind panel – 120 mm (4.8 in)
Materials of construction
Glass filled polycarbonate
Weight
0.38 kg (0.84 lb)
Electrical
Power supply ranges
• 100 to 240 V AC ±10 % (90 V min. to 264 V max.)
50/60 Hz
• 10 to 36 V DC (optional)
Power consumption
10 W max.
Inputs/Outputs
Analog inputs
• 1 universal
• 1 process
Analog outputs
• 1 standard
• 1 optional
• Galvanically isolated from the rest of the circuitry,
500V for up to 1 minute. Range programmable

@ 20 mA.
Relay outputs
• 1 standard
• 3 optional
• Fully programmable. Contacts rated at 5 A @ 240 V.
Standard relays are changeover. Optional relays are
selectable NO or NC by jumper.

8CONTROLMASTER CM15 |UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A
…2 Specification
Digital inputs/outputs
2 optional, user programmable as input or output.
Minimum input pulse duration: 125 ms
Input
• Volt free
• 24 V DC (1 signal 15 to 30 V, 0 signal -3 to 5 V)
Output
• Open collector output
• 30 V, 100 mA max. switched
• Conforms to IEC 61131-2
Update Rate
125 ms
Environmental data
Ambient operating temperature
0 to 55 °C (32 to 131 °F)
Ambient operating humidity
5 to 95 % RH non-condensing
Storage temperature
–20 to 70 °C (–4 to 158 °F)
Approvals, certification & general safety
• EN-61010-1
• cULus
• Overvoltage class III on mains, Class II on
inputs and outputs
• Pollution category 2
• Insulation category 2
Emissions and Immunity
Meets the requirements of IEC 61326 for an industrial
environment

CONTROLMASTER CM15 | UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A 9
3 Installation
• Locate the indicator in a position where its operating temperature and humidity limits will not be exceeded and
ensure that it is suitably protected from direct sunlight, rain, snow and hail.
• Select a location away from strong electrical and magnetic fields. If this is not possible (particularly in
applications where mobile communications equipment is used), use screened cables within flexible, earthed
metal conduit.
Siting
At eye level Close to the sensor
Sensor
Avoid vibration
Figure 1 Siting
Temperature limits Humidity limits Use screened cable
IP66/NEMA4X (front panel), IP20 (rear)
0 to 95 % RH
55 °C
(131 °F)
max.
0 °C
(32 °F)
min.
Figure 2 Environmental requirements

10 CONTROLMASTER CM15 |UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A
…3 Installation
Mounting
ControlMaster CM15 is designed for panel mounting.
For NEMA4X protection, a panel thickness of 2.5 mm
(0.1 in) is required.
Referring to Figure 3:
1 Cut a hole of the correct size for the indicator in the
panel.
2 Insert the indicator into the panel cut-out.
97 (3.8)
50
(2.0)
120 (4.8)
140 (5.5)
44.8
(1 .7 )
20 (0.8)
14 (0.55)
≥30 (1.18)
45
(1.8 )
+0.6
–0
+0.02
–0
92
(3.6 )
+0.8
–0
+0.03
–0
Panel cut-out dimensions
Figure 3 Mounting dimensions

CONTROLMASTER CM15 | UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A 11
Referring to Figure 4:
1 Position one panel clamp Aat the side of the case
against the panel.
2 Locate the panel clamp anchor Bin slot C.
3 Tighten the panel clamp anchor screw Duntil
panel clamp Ais lightly touching the panel
4 Repeat steps 1 to 3 to fit the remaining panel clamp
Eand panel clamp anchor F
5 Torque tighten both panel clamp anchor screws to
0.1 N⋅m (0.9 lbf⋅in).
NOTICE
Do not over-tighten the screws.
D
A
B
C
E
F
Figure 4 Panel clamp assembly

12 CONTROLMASTER CM15 |UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A
4 Electrical connections
WARNING
• The indicator 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 fitted in close proximity
to the indicator within easy reach of the
operator and must be marked clearly as the
disconnection device for the indicator. A fuse
must be fitted in accordance with Figure 6 on
page 14.
• Remove all power from the supply, relay and any
powered control circuits and high common
mode voltages before accessing or making any
connections.
• Use cable appropriate for the current loads:
3-core cable rated 3 A and 90 °C (194 °F)
minimum, that conforms to either IEC 60227 or
IEC 60245. The terminals accept cables from 0.8
to 2.5 mm2(18 to 14 AWG).
• The indicator conforms to installation category
II of IEC 61010.
• All connections to secondary circuits must have
basic insulation.
• After installation there must be no access to live
parts, for example, terminals.
• Terminals for external circuits are for use only
with equipment with no accessible live parts.
• If the indicator is used in a manner not specified
by the company, the protection provided by the
equipment may be impaired.
• All equipment connected to the indicator’s
terminals must comply with local safety
standards (IEC 60950, EN601010-1)

CONTROLMASTER CM15 | UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A 13
NOTICE
• Always route signal leads and power cables
separately, preferably in earthed (grounded)
metal conduit.
• Use screened cable for signal inputs and relay
connections.
• Replacement of the internal battery (type Varta
CR1620 3V lithium cell) must be carried out by an
approved technician only
Accessing the connection terminals
Referring to Figure 5, press terminal cover release
catch Aand pull the terminal cover Baway from the
indicator body.
A
B
Figure 5 Removing the terminal cover

14 CONTROLMASTER CM15 |UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A
…4 Electrical connections
1
2
3
4
5
6
7
8
9
10
11
12
19
20
21
22
23
24
25
26
27
28
29
30
13
14
15
16
17
18
25
26
Rear view
Tx
PSU
NC
C
NO
**
C
**
C
**
C
**
C
Line ***
Neutral
100 to
240 V AC
10W
Analog input 1
Analog output 2
Digital output + external
Digital input/output 1
Digital input/output 2
Digital input/output –
Relay output 1
Relay output 2
Relay output 2
Relay output 3
Relay output 4
* Refer to the Communications Supplement (IM/CM/C-EN) for MODBUS
connection details
** N/O or N/C contact selection is made via internal jumper links.
N/O is the factory default setting.
*** 200 mA type T fuse (mains AC) or 2 A type T fuse (120 V DC max.) and
external isolating switch. For UL-marked indicators the fuse must be UL
recognized.
**** Provides 24 V digital output (observe + and – connections).
Analog input 2
Analog/digital output 1 ****
10 to
36 V DC
Comms *
Rear viewStandard connections Option board 1
Option board 1A

CONTROLMASTER CM15 | UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A 15
Standard analog inputs (1 and 2)
1
2
3
4
5
Tx
Tx
* 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 with THC inputs only if analog input 1 is also used as a THC input.
**** For mA input types, to ensure loop continuity when the indicator is switched off, fit a 2V7
Zener diode as shown.
Note. 
THC
THC***
Milliamps*
Milliamps*
Analog input 1
Analog input 2 mA****, mV, V
digital input
mA****,
mV, V
digital
input
Transmitter PSU
RTD+ RTD+
3rd lead
3-lead RTD
2-lead RTD
+ resistance
RTD–
RTD–
RTD–
CJ**
CJ sensor

16 CONTROLMASTER CM15 |UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A
5 Front panel keys
Operation is performed using the keys on the front
panel. These enable local navigation and selection of
software options on all displays, acknowledgment of
alarms and error messages, monitoring and access to
all menus.
All diagnostics messages are displayed within the
Diagnostics View.
Prompts associated with active keys are displayed on
each screen. Diagnostic and display icon descriptions
are included in this document.
Key functions for the indicator overlay are described
below:
A
B
C
Navigation key (upper)/programmable
soft key.
Up/Down keys – navigate up/down menu
items and increase/decrease displayed
values.
Navigation key (lower)/operator level
access key.
Note. When a soft key option is assigned to key A, the
Advanced Level (see page 18) must be accessed
using key C.

CONTROLMASTER CM15 | UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A 17
6 Operator level menus
Reset Statistics
To t alizer
View Select
Operator level menus are used to start, stop and reset totalizers, reset statistics,
select the view and to enter Basic and Advanced modes (via the Access Level).
To access Operator Level menus:
1 From the Operator Page, press to view the available menus.
2 Use the and keys to scroll through the menus and menu options.
3 Press to expand menu levels and to select menu options or press to return
to the previous menu.
Reset Statistics Resets current statistics.
Totalizer Start, stop and reset totalizers.
View Select Switches the view to an Operator Page or the Diagnostic View.
Enter Config. Mode Displays the Access Level selection views.

18 CONTROLMASTER CM15 |UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A
7 Access levels and security options
Access Level
Logout
Read O nly
Basic
Advanced
Service
The access level menus are used to enter the Basic and Advanced menus, view all
parameters in read only mode and to logout (return to operator view mode).
To view Access Level menus:
1 From the operator view mode, press
OR
press to display the available operator menus and use the and keys
to scroll to Enter Config. Mode, then press . The Access Level menu is
displayed.
2 Use the and keys to scroll to the required/permitted level of access
(basic or advanced), then press .
Logout Displayed after basic or advanced level are accessed.
Logs the user out of basic or advanced level.
If passwords are set, a password must be entered to access the levels again after selecting log out.
Read Only Enables all parameter settings to be viewed.
Basic Enables access to the basic level and adjustment of totalizer count settings and alarm trip points.
Advanced Enables configuration access to all parameters.
Service Reserved for use by authorized personnel.
Security options
Passwords can be set to enable secure end-user access
at 2 levels: Basic and Advanced. The Service level is
password protected and reserved for factory use only.
Passwords are set, changed or restored to their default
settings at the device setup/security setup parameter.

CONTROLMASTER CM15 | UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A 19
8 Diagnostics messages
The indicator is programmed to display diagnostics
messages that provide information on servicing
requirements and any other conditions that develop
during operation.
When a diagnostics condition is detected, the
associated NAMUR Icon, together with the highest
priority diagnostics message are displayed in the
status bar when in operator view. A list of all currently
active diagnostic alarm states are displayed in the
diagnostic view.
Failure
Maintenance
Out of spec
Check function
Description of diagnostic or alarm tag.
The highest priority diagnostic or alarm
is displayed. Other active diagnostic/
alarm states can be viewed on the
Diagnostic View – see below.
High process alarm
Low process alarm
High latch alarm
High latch alarm
NAMUR (NE107) status icon
Hig h Tem p
PV1 Failed
Hig h Tem p
Alarm
icon
Diagnostic description/alarm tag

20 CONTROLMASTER CM15 |UNIVERSAL PROCESS INDICATOR,  DIN | CI/CM15-EN REV. A
…8 Diagnostics messages
Icon Number/
Message
Possible cause Suggested action



Broken sensor leads, defective input source or
input signal out of permitted range.
Check wiring.
Check input source.
Check if input signal is outside permitted limits.



Broken sensor leads, defective input source or
input signal out of permitted range.
Check wiring.
Check input source.
Check if input signal is outside permitted limits.


Error in cold junction measurement associated

sensor.
Check cold junction device is correctly fitted.

Replace CJ sensor.


Error in cold junction measurement associated

sensor.
Check cold junction device is correctly fitted.
Replace CJ sensor.

NV Error
Proc Bd
Failure of non-volatile memory on processor
display board or permanent corruption of its
data.
Check all configuration parameters and correct any errors.
Acknowledge error.
If problem persists contact local service organization.

NV Error
Main Bd
Failure of non-volatile memory on main board or
permanent corruption of its data.

Recalibrate if necessary.
Acknowledge error.
If problem persists contact local service organization.

NV Error


or permanent corruption of its data.

Recalibrate If necessary.
Acknowledge error.
If problem persists contact local service organization.