ABB ControlMaster CM50 User manual

—
ABB MEASUREMENT & ANALYTICS | COMMISSIONING INSTRUCTION | CI/CM30/50-EN REV. C
ControlMaster CM30 and CM50
Universal process controllers, ¼ and ½ DIN
Measurement made easy

For more information
Further publications for the ControlMaster CM30
and CM 50 controllers are available for free
download from:
www.abb.com/measurement
or by scanning these codes:
CM30 CM50
Search for or click on:
Data sheet
 
Data sheet
 
User guide (basic functionality)
 IM/CM/B-EN
User guide (standard functionality)
 IM/CM/S-EN
User guide (extended/dual functionality)
 IM/CM/ED-EN
Communications supplement
 

IM/CM/C-EN
To access the IAMA help & support portal please
scan the following code:

CONTROLMASTER CM30 & CM50 | PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C 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) ......... 7
2 Specification................................................................8
3 Installation .................................................................10
Siting .................................................................................11
Mounting ......................................................................... 12
4 Electrical connections..............................................15
Accessing the connection terminals ........................ 16
CM30 electrical connections.......................................17
CM50 electrical connections...................................... 18
Standard analog inputs (1 and 2)............................... 19
5 Front panel keys ....................................................... 20
6 Operator level menus ...............................................21
Profile operator page................................................... 22
7 Access levels and security options ........................23
Security options ............................................................ 23
8 Diagnostics messages ............................................ 24
9 Instrument menus.................................................... 30

4CONTROLMASTER CM30 & CM50 |PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C
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

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 CM30 & CM50 | PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C 5
Potential safety hazards
Electrical
WARNING

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

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


EC Directive 89/336/EEC
Electrical – In order to meet the requirements of the EC

product must be used in an industrial environment.
End-of-life disposal
The controller contains a small lithium battery that
must be removed and disposed of responsibly in
accordance with local environmental regulations.
The remainder of the controller 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 CM30 & CM50 |PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C
…1 Health & Safety
…End-of-life disposal
ABB is committed to ensuring that the risk of any
environmental damage or pollution caused by any
of its products is minimized as far as possible. The
European Waste Electrical and Electronic
Equipment (WEEE) Directive that initially came into
force on 13 August 2005 aims to reduce the waste
arising from electrical and electronic equipment;
and improve the environmental performance of all
those involved in the life cycle of electrical and
electronic equipment.
In conformity with European local and national

above symbol may not be disposed of in European
public disposal systems after 12th August 2005.
Cleaning
The controller 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.

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.


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

CONTROLMASTER CM30 & CM50 | PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C 7
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

monitoring and control instruments do not fall

ABB has taken the decision to adopt the
recommendations in the Directive as the target for
all future product design and component
purchasing.

8CONTROLMASTER CM30 & CM50 |PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C
2 Specification
Mechanical data
Protection
• Front face IP66/ NEMA 4X
• Rear panel IP20
CM30 dimensions
• Height – 97 mm (3.8 in)
• Width – 97 mm (3.8 in)
• Depth behind panel – 121 mm (4.8 in)
CM50 dimensions
• Height – 144 mm (5.6 in)
• Width – 76 mm (3.0 in)
• Depth behind panel – 123 mm (4.9 in)
Materials of construction
Glass filled polycarbonate
CM30 weight
0.5 kg (1.1 lb)
CM50 weight
0.58 kg (1.3 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.
Analog inputs
Universal process inputs
Number 
Non-universal process inputs
Number 

CONTROLMASTER CM30 & CM50 | PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C 9
Outputs
Controls/retransmission outputs
Number 
Type Configurable as analog or digital pulse
Isolation Galvanically isolated from the rest of

Analog
range
0 to 20 mA programmable
Load 
Accuracy 0.25 % of output or ±10 µA
Relays
Number CM30: 
CM50: 
Type CM30: Standard with changeover
contacts
Optional contacts selectable as
NO or NC (by jumper)
CM50: Selectable as NO or NC (by jumper)
Contact
ratings

Update
rate
125 ms

10 CONTROLMASTER CM30 & CM50 |PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C
…2 Specification
Digital input/output
Number 
Type User-programmable as input or output
Minimum input pulse duration – 125 ms
Input Volt-free or 24 V DC
1-signal 15 to 30 V
0-signal –3 to 5 V
Conforms to IEC 61131-2
Output Open collector output

Conforms to IEC 61131-2
Update
rate
125 ms
Environmental data
Operating temperature range
0 to 55 °C (32 to 131 °F)
Operating humidity range
5 to 95 % RH (non-condensing)
Storage temperature range
–20 to 70 °C (–4 to 158 °F)
Approvals, certification & general safety
• EN-61010-1
• cULus
• 
inputs and outputs
• Pollution category 2
• Insulation category 2
Emissions and Immunity
Meets the requirements of IEC 61326 for an industrial
environment
3 Installation
• Locate the controller in a position where its
operating temperature and humidity limits will not
be exceeded and ensure that it is suitably protected

• Select a location away from strong electrical and
magnetic fields. If this is not possible (particularly in
applications where mobile communications



CONTROLMASTER CM30 & CM50 | PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C 11
Siting
At eye
level
Close to the sensor
Sensor
Avoid
vibration
Figure 1 Siting
Temperature limits Humidity limits
Use
screened
cable
IP66/NEMA4X

IP20 (rear)
0 to 95 % RH
55 °C
(131 °F)
max.
0 °C
(32 °F)
min.
Figure 2 Environmental requirements

12 CONTROLMASTER CM30 & CM50 |PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C
…3 Installation
Mounting
ControlMasters CM30 and CM50 are designed for panel

of 2.5 mm (0.1 in) is required.
Referring to Figure 3:
1 Cut a hole of the correct size for the controller in the
panel.
2 Insert the controller into the panel cut-out.

CONTROLMASTER CM30 & CM50 | PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C 13
123 (4.9)
146 (5.7)
76 (3.0)
23 (0.9)20 (0.8)
14 (0.55)
14 (0.55) ≥30 (1.18)
≥30 (1.18)
68
(2.7 )
+0.7
–0
+0.03
–0
138
(5.4 )
+1.0
–0
+0.04
–0
137.8
(5.4)
144
(5.6)
CM30 CM50
97 (3.8)
97
(3.8)
91.8
(3.6)
121 (4.8)
141 (5.5)
92
(3.6
)
+0.8
–0
+0.03
–0
92
(3.6 )
+0.8
–0
+0.03
–0
Panel cut-out
dimensions
Controllers can be
close-stacked to
DIN43835
Panel cut-out
dimensions
Figure 3 Mounting dimensions

14 CONTROLMASTER CM30 & CM50 |PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C
…3 Installation
…Mounting
Referring to Figure 4:
1 Position one panel clamp Aat the top 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.
Figure 4 Panel clamp assembly

CONTROLMASTER CM30 & CM50 | PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C 15
4 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 fitted in close proximity
to the controller within easy reach of the
operator and must be marked clearly as the
disconnection device for the controller. A fuse
must be fitted in accordance with CM30
electrical connections on page 17 and CM50
electrical connections on page 18.
• 
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)

IEC 60245. The terminals accept cables from 0.8
to 2.5 mm2(18 to 14 AWG).
• The controller 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

• 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

equipment may be impaired.
• All equipment connected to the controller’s
terminals must comply with local safety


16 CONTROLMASTER CM30 & CM50 |PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C
…4 Electrical connections
NOTICE
• Always route signal leads and power cables

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

catch Aand pull the terminal cover Baway from the
controller body.
B
A
Figure 5 Removing terminal cover

CONTROLMASTER CM30 & CM50 | PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C 17
CM30 electrical connections
Rear view
Tx
PSU
Tx PSU
NC
C
NO
**
C
**
C
**
C
**
C
Line ***
Neutral
100 to
240 V AC
10W
Analog input 1 Analog input 3
Analog output 2
Digital output + external
Digital input/output 3
Digital input/output 4
Digital input/output 5
Digital input/output 6
Digital input/output –
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 controllers the fuse must be UL
recognized.
**** Provides 24 V digital output (observe + and – connections).
Analog input 2 Analog input 4
Analog/digital
output 1 ****
10 to
36 V DC
Comms *
Rear viewRear view
Standard connections Option board 1 Option board 2
Option board 1A

18 CONTROLMASTER CM30 & CM50 |PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C
…4 Electrical connections
CM50 electrical connections
+
–
+
–
+
–
+
–
+
–
+
–
+
–
Rear view
Tx PSU Tx PSU
**
C
**
C
**
C
**
C
Line ***
Neutral
100 to
240 V AC
10W
Analog input 1 Analog input 3
Analog output 2
Digital output + external
Digital input/output 3
Digital input/output 4
Digital input/output 5
Digital input/output 6
Digital input/output –
Digital output + external
Digital input/output 1
Digital input/output 2
Digital input/output –
Relay output 1
Relay output 3
Relay output 4
Relay output 2
* 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
controllers the fuse must be UL recognized.
**** Provides 24 V digital output (observe + and – connections).
Analog input 2 Analog input 4
Analog/digital output 1 ****
10 to
36 V DC
Comms *
Rear view
Standard connections Option board 1

CONTROLMASTER CM30 & CM50 | PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C 19
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.

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.
 
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

20 CONTROLMASTER CM30 & CM50 |PROCESS CONTROLLERS, ¼ & ½ DIN | CI/CM30/50-EN REV. C
5 Front panel keys
Operation is performed using the keys on the front
panel. These enable local navigation and selection of


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 controller overlay are described
below:
ANavigation key (left)/operator level access key.
BLocal /Remote setpoint mode selection key.
CUp/Down keys – navigate up/down menu items
and increase/decrease displayed values.
DAuto/Manual control mode selection key.
ENavigation key (right)/programmable soft key.
Note. When a soft key option is assigned to key E
Advanced Level (see page 23) must be accessed
using key A.