ABB CM 16 User manual

CM 16 Temperature controllers with
compact dimensions
Manual 42/61-72 EN Rev. 01

Table of contents
Page
Remarks .................................. 2
Installation and commissioning
1. Identifying the instrument ..................... 3
2. Selecting installation site and
mounting the instrument ...................... 3
3. Connecting signals .......................... 4
4. Connecting the power supply .................. 4
5. Commissioning the instrument ................. 4
Operation
Front panel ................................... 5
Display ...................................... 5
Parameter definition ........................ 6
Parameter-definition principle ...................... 6
Complete parameter-definition ...................... 8
Selftune
Automatic selftune ............................. 12
Manual adjusting of a PID controller ................. 12
Ramps and alarms
Ramps ...................................... 13
Alarms ...................................... 13
Example ..................................... 13
Calibration ................................ 14
Error messages ........................... 14
Maintenance .............................. 15
Conversion ............................... 16
Appendix
Application ................................... 17
Description ................................... 17
Technical data ................................ 18
Packaging for transport or
for return to manufacturer ........................ 19
Important instructions
for your safety!
Please read and observe!
Correct and safe operation of the controller calls for ap-
propriate transportation and storage, expert installation
and commissioning as well as correct operation and me-
ticulous maintenance.
Only those persons conversant with the installation, com-
misioning, operation and maintenance of similar appara-
tuses and who possess the necessary qualifications are
allowed to work on the controller.
Please take note of
− the contents of this Operating Manual,
− the safety regulations affixed to the controller and
− the safety regulations pertaining to the installation and
operation of electrical systems.
The directives, norms and guidelines mentioned in this
Operating Manual are applicable in the Federal Republic
of Germany. When using the controller in other countries,
please observe the national regulations prevailing in the
respective country.
The controller has been designed and tested in accor-
dance with DIN VDE 0411Part 1„Safety requirements for
electronic measuring apparatuses“, and has been supplied
in a safe condition. In order to retain this condition and to
ensure safe operation, the safety instructions in this Ope-
rating Manual bearing the headline „Caution“ must be ob-
served. Otherwise, persons can be endangered and the
controller itself, as well as other equipment and facilities
can be damaged.
If the information in this Operating Manual should prove
to be insufficient in any point, the Service Department will
be delighted to give you more information.
Remarks on symbols
, , , means that the respective key on the controller
front panel should be pressed.
R-18797
2Table of contents • Remarks

Installation and commissioning
1. Identifying the instrument
The unit is identified by its rating plate. The rating plate is located
on the side of the case. It contains the following information:
−voltage range of the built-in power supply unit
−type of sensor input for which the controller has been adap-
ted to at the factory: thermocouple (“T/C”), Pt100 resistance
thermometer (“RTD”) or mA input
−type of output: 0/4...20 mA or relay output
−Alarm output (always available)
2. Selecting the installation site and mounting the unit
Fig. 1 Dimensional diagram
Z-18799 left Panel cutout
right Depth behind panel
1Panel
Caution
To maintain protection against shocks, the device may only
be operated when fully installed.
The controller is designed for front-panel mounting in machines,
devices, control cabinets and control rooms. The installation site
should be selected in such way that relevant environmental and
mechanical capability requirements are fulfilled (see “Technical
Data”).
Installation •Commissioning 3

3. Connecting the signals
Fig. 2 Wiring diagram
Z-18800 1, 2 Alarm
3, 4, 5 Sensor input (RTD, TC, mA)
6, 7 Power supply
8, 9, 10 Control output (relay, mA)
Caution
When selecting the lead material as well as when installing
and connecting the power leads, the local specifications for
installation of power current systems are to be observed.
The controller is ex works either equipped with a measuring input
for thermocouple, Pt100-resistance thermometer or for mA uni-
form signals.
The type of thermocouple or Pt100 can be modified per software.
Changing the measuring input between the thermocouple, Pt100
and mA is however not possible without changing the hardware
(“Conversion”).
Connect sensors, control and alarm outputs in accordance
with fig. 2.
4. Connecting the power supply
(see fig. 2)
Caution
When selecting the lead material as well as when installing
and connecting the power leads, the local specifications for
installation of power current systems are to be observed.
Note
The controllers are fully insulated according to protection class
category II. There is no grounding conductor to connect.
1. Install an external mains isolator, which completely discon-
nects all power.
2. Connect the power supply as illustrated in fig. 2.
5. Commissioning the instrument
Caution
Before switching on the instrument, make sure that the ad-
justed operating voltage corresponds to the mains voltage. Switch on the instrument using the external mains isolator.
After switch-on, the identification of the microprocessor and the
software version are first displayed. Then follows an activation of
all segments of LED displays, including the status LEDs for out-
puts and alarms in self-test.
4Installation • Commissioning

Operation
Front panel
Fig. 3 Front panel
Z-18798 1Process variable
2Setpoint
3Status LED for alarm relay
4Status LED for output relay
5Status display „manual mode“
6Status display „selftune active“
7Key „increase“
8Key „menü“
9Key „start selftune“or „back to main operator level“
10 Key „decrease“
Key Function description
switches to the next parameter within a menu
level.
if pressed for at least 6 s, switches to the next
menu level (only possible if the last parameter of
the previous menu is indicated).
increases the parameter value.
decreases the parameter value.
returns to the standard mode (exits a submenu,
aborts selftune and returns from “Manual”to
“Automatic”).
if pressed for at least 6 s, starts selftune.
+ switches the lower display from setpoint to per-
centage value of output 1.
+ if pressed for at least 6 s, switches over to manu-
al operation mode.
Display
In the standard mode, the process variable is indicated in the up-
per display. In the lower display the setpoint, or after pressing
+ the percentage value ot the output is indicated.
The setpoint can be adjusted with and .
When scrolling through the menu levels, in the upper display a
short text describing the parameter appears, whose value is
shown in the lower display and which can be modified with
and .
The status LEDs for the outputs and alarms light up respectively
anytime the relays are switched on.
The manual operation is shown in the lower display by an illumi-
nated point in the lower right corner.
Operation 5
12
6
5
9
107
8
4
3

Parameter definition
Parameter-definition principle
Fig. 4 Flow diagram
Z-18796
6Parameter definition

1. Display the first parameter accessible at the main operator
level:
Remarks
At the main operator level, only those parameters are accessi-
ble, which were defined in parameter (see page 9). The fac-
tory setting for is 0, i.e. no additional parameters can be se-
lected at the main operator level.
If parameter has the value 1, parameters can only be dis-
played but not changed (see page 9).
2. Change parameter:
,
3. Display the next parameter:
4. Change the parameter:
,
etc. until
5. Last parameter is displayed:
6. Change parameter:
,
7. Access the first menu level:
for at least 6 s
8. Change parameter:
,
9. Display the next parameter:
etc. up to the last parameter of the first menu level .
10. Either return to the main operator level:
or
proceed further to the second menu level:
for at least 6 s
11. Change parameter:
,
12. Display the next parameter:
13. Change parameter:
,
etc. up to the last parameter of the second menu level .
14. Either return to the main operator level:
or
proceed further to the third menu level:
for at least 6 s
15. Calibrate controller: see section on “Calibration”
or
return to the main operator level:
Remarks
The complete parameter-definition, the parameters and their
adjustment possibilities as well as their factory settings are listed
on pages 8 to 11.
With it is possible to return to the main operator level at any
time.
Modified parameters become immediately effective.
Parameter definition 7

Complete parameter-definition
In order to parameter-define the controller completely, the steps
provided below must be processed consecutively.
Key Display Parameter Parameter values
underlined or FS = Factory Setting
change
Main operator level
for at
least 6 s
defines the alarm setpoint value for the alarm con-
figured under . Depending on the type of alarm
defined for the parameter , this can be either an
absolute alarm value or a deviation alarm value (see
also Section on “Alarms”).
•absolute alarm value in the range
... , if = 0, 1, 4, 5
•relative alarm value in the
range ... , if = 2, 3, 6,
7, 8, 9, 10, 11
•time value in the range 0... 3600 min,
if =12or13
FS 200 °C
,
defines the setpoint ramp rate to allow the process to
reach the new setpoint via a linear ramp after setpoint
change.
•0...200 °C/min (360 °F/min), if =
0to9
•0...3600 digit/min, if = 10
,
defines the offset value for manual reset (= operating
point), if = 0, i.e. the output signal of the controller
is shifted by .
Notice
This parameter is only required when the controller
does not use any integral component (integral action
time ).
0.0...100 % ,
defines the offset shift for the process variable in the
display (measured value correction).
Example
The display shows 1 °C less than the actual
temperature. This can be corrected with an input of
+1 °C.
−111...0...+111 °C ,
defines the proportional range of output 1 (heating)
Notice
Changing this parameter has decisive effects on the
control action.
0...10...200 °C (0 for ON/OFF control) ,
8Parameter definition

Key Display Parameter Parameter values
underlined or FS = Factory Setting
change
defines integral (reset) time. This action component
prevents stationary control deviations.
Notice
Changing this parameter has decisive effects on the
control action. A big integral action time in a slow
control, whereas a too small value can lead to over-
shooting and even to a destabilisation of the entire
control process.
0...120...3600 s ,
defines the derivative (rate) time for the differential
component. This component enables quicker reaction
to changes in the stationary status.
Notice
A modification of this parameter has decisive effects
on the control action. A too small derivative time ini-
tially produces drastic overhooting, whereas a too big
value produces oscillations and even destabilisation
of the entire control process.
0...30...1000 s ,
PV back to the main operator level
or to 1. menu level
for at
least 6 s
determines if the keys are disabled for making
modifications on parameter values
Notice
The keyboard is disabled with immediate effect!
0 activated
1 deactivated
,
defines the parameters which can be directly
accessed on the main operator level
0 no parameter
1
2
3
4,
5,
6,
7,,
,
defines proportional cycle time for relay output 1
Example
Cycle time duration 10 s and calculated output signal
40 %:
Output relay closes for 4 s and opens afterwards for
6s
0...120 s
FS relay: 20 s
analog: 0 s
,
Parameter definition 9

Key Display Parameter Parameter values
underlined or FS = Factory Setting
change
defines the type of sensor
Remarks
Modification of the signal type (TC, Pt100, linear)
requires a hardware change (see Section on
“Conversion”)!
When modifying the measuring sensor, the
parameters and for the measuring range
must be matched accordingly.
0 thermocouple type J
1 thermocouple type K
2 thermocouple type T
3 thermocouple type E
4 thermocouple type B
5 thermocouple type R
6 thermocouple type S
7 thermocouple type N
8 Pt100 (DIN 43 760)
9 Pt100 (JIS C1604-1981)
10 linear (−10...60 mV, 0/4...20 mA)
FS depends on the instrument ordered:
TC: 0, RTD: 8, mA: 10
,
defines alarm mode of the alarm (see also section on
“Alarms”)
0 overshooting of the alarm value
1 undershooting of alarm value
2 overshooting of SP +
3 undershooting of -
4 like 0, however with suppression of
the initial alarm
5 like 1, however with suppression of
the initial alarm
6 like 2, however with suppression of
the initial alarm
7 like 3, however with suppression of
the initial alarm
8 leaving range SP +/-
9 entering range SP +/-
10 like 8, however with suppression of
the initial alarm
11 like 9, however with suppression of
the initial alarm
12 alarm relay OFF, when timer expires
13 alarm ON, when timer expires
,
defines the hysteresis of alarm 1 (see also Section on
“Alarms”)
0...0.5...20 % of the range ,
defines the dimension
Notice
The controller subsequently converts all values
accordingly.
0°F
1°C
,
10 Parameter definition

Key Display Parameter Parameter values
underlined or FS = Factory Setting
change
defines the number of decimal points 0 No decimal places
1 One decimal place
2 Two decimal places (only when
= 10)
3 Three decimal places (only when
= 10)
,
defines the control action for the output 0 direct (cool)
1 inverse (heat)
,
defines the reaction in case of sensor break Output Alarm
0 Off Off
1 Off On
2 On Off
3On On
,
defines the hysteresis for On/Off control 0...0.5...20 % of the measuring range ,
defines the lower-range value (low limit) depends on the sensor
FS depends on the sensor
,
defines the upper-range value (high limit) depends on the sensor
FS depends on the sensor
,
or PV return to the main operator level
or to 2. menu level
for at
least 6 s
lower calibration point for recalibration depends on the sensor
FS depends on sensor
,
upper calibration point for recalibration depends on sensor
FS depends on sensor
,
return to the main operator level
Parameter definition 11

Selftune
Automatic selftune
Remarks
The existing PID parameters are replaced.
If the controller is operating in on/off control, automatic selftune
is aborted with the message. Selftune is also aborted when
setpoint and process variable are very close initially or when the
heating/cooling power is not enough to reach the adjusted set-
point.
Depending on the system’s response time, the selftune process
may require more than 2 hours.
1. Ensure that the controller is adjusted appropriately (type of
sensor, °C/°F, resolution, lower- and upper-range values).
2. Ensure that the parameters for the proportional ranges
and are not equal to zero (On/Off control), since no self-
tuning can otherwise take place.
3. Wait until the current process variable is clearly different from
the adjusted setpoint.
Notice
Selftune is at its best if the system is started from the onset
(“cold start”).
4. Start the selftune process by pressing for at least 6 s.
During the active selftuning phase, a LED flashes on the right
side of the upper display.
5. If necessary, abort the selftune process with .
As soon as selftune is terminated, the LED stops flashing. The
PID parameters found are taken over automatically.
Manual adjusting of a PID controller
In some cases, it may be necessary or useful to manually opti-
mise the parameters.
Remarks
Since the control parameters , and are not independent
of each other, only one parameter should be changed in small
steps at a time whilst observing the control action, before making
any further changes.
Tab. 1
Control Control action Remedy
Proportional
component
too slow reaction
drastic overshooting, oscil-
lation
decrease Pb
increase Pb
Integral
component
too slow reaction
instability, oscillation
decrease ti
increase ti
Differential
component
too slow reaction
drastic overshooting, oscil-
lation
increase td
decrease td
Manual setting of a PID controller according to the
Ziegler-Nichols method
If the selftune possibility is not utilised, the Ziegler-Nichols me-
thod can be applied to manually define the control parameters of
a PID controller.
1. To switch off the parameter, set integral action time and
derivative action time to 0.
2. Set the proportional range at a high start value and ob-
serve or record the control action.
3. Reduce parameters until a stable oscillation of the control
variable is achieved. Note the value adjusted for it as
P(oscillate).
4. Measure the period duration Tc of the oscillation in seconds
(see fig. 5).
Fig. 5
Z-18818
5. The control parameters can be calculated from this measured
value according to the following formula:
Proportional range = 1.7 ×P(oscillate)
Derivate time (rate) = 0.5 ×P(oscillate)
Integral time (reset) = 0.125 ×Tc
6. Enter the parameters into the controller.
12 Parameter definition

Ramps and alarms
Ramps
If a ramp rate was configured, the process reaches the setpoint
via a linear ramp.
The ramp rate is set within range 0 to 200 °C with parameter
. The ramp function is disabled when the parameter set
to 0.
Alarms
The alarm can be used for a minimum or maximum value moni-
toring of the process variable or of the control deviation.
Optionally, the first alarm signal can be suppressed, e.g. when
starting up a furnace and a minimum nominal value is monitored,
due to a low initial temperature. No alarm is signalled at this
stage, but signalling occurs when the temperature first exceeds
the minimum value and falls back to a value below the alarm set
point.
Timer (time alarm)
The alarm relay can also be configured for a timer function.
To do this, the value 12 or 13 is set for parameter . A time
between 0 and 3600 min is preset for parameter .
After switching on the supply voltage, the time function of the
alarm relay is activated. The timer starts when the process vari-
able has reached the setpoint. After the run out of the preset
time the alram relay is switched on ( = 13) in order to send
a signal or switch on a device. Alternatively the alram relay is
switched off ( = 12) after the run out of time in order to
switch off a device (e.g. even the power supply of the controller
itself).
Example
Fig. 6
Z-18817
The value for the ramp rate of the setpoint was set to 5 °C/min
and a timer function was configured ( = 12, = 15).
At the time t = 0 the control begins by connecting the supply
voltage. Since a ramp rate was set, the temperature increases at
a speed of 5 °C/min to a setpoint of 125 °C. On reaching the
setpoint, the timer is started. After expiry of the preset 15 mi-
nutes, alarm relay 1 opens and can then switch off a unit, in-
cluding for instance the controller itself.
By using the 2nd timer function ( = 13), the alarm relay
function can be inversed: the alarm relay initially remains open
and closes upon reaching the setpoint and after expiry of the
preset time.
Ramps and Alarms 13

Calibration
Notice
The units are precalibrated at the factory. They should be reca-
librated (according to the following steps) only when absolutely
necessary.
The existing calibration data is then unredeemable.
As a principle, recalibration means that suitable calibration equip-
ment is available.
1. It must be safeguarded that the controller is correctly adjus-
ted (type of sensor, °C/°F, resolution, lower-range value,
upper-range value).
2. Switch off the power supply.
3. Instead of sensor, connect a calibration unit to the input ter-
minals (ensure correct polarity!) and generate a calibration
signal which corresponds to the lower calibration value (e.g.
0 mV for 0 °C).
4. Switch on the power supply.
5. Select the parameter for the lower calibration value on
the 3rd menu level (see Section on “Parameter definition”).
6. Adjust the displayed value with and until this corres-
ponds with the calibration value.
7. Press for at least6sinorder to store this value.
8. Select the parameter for the upper calibration value on
the 3rd menu level (see Section on “Parameter definition”).
9. Generate a calibration signal which corresponds to the upper
calibration value (e.g. 46 mV for 800 °C).
10. Adjust the displayed value with and until this
corresponds to the calibration value.
11. For at least 6 s press to store this value.
12. Return to the standard level with .
13. Switch off the power supply.
14. Instead of the calibration unit, connect the sensor to the input
terminal (ensure correct polarity!).
15. Switch on the power supply.
Error messages
Error message Possible cause Remedy
sensor break, sensor incorrectly connected check the sensor connection, exchange sensor
lower-measuring range undershot check the setting of the parameter and correct
upper-measuring range overshot check the setting of the parameter and correct
analog output is defective look for external error sources (parasitic pulses),
consult your after-sales service
self-tuning unsuccessful, ON/OFF control configured
( =0)
repeat the self-tuning, set unequal to 0
manual operation is not allowed during ON/OFF
control
set unequal to 0
checksum error check control parameter and re-adjust
Tab. 2
14 Calibration •Error messages

Maintenance
Caution
When the instrument is connected to its supply, terminals
may be live and the opening of covers or removal of parts
except those to which access can be gained by hand is
likely to expose live parts.
The instrument shall be disconnected from all voltage
sources before it is opened for any operations. Operations
on the opened instrument under voltage must only be
performed by an expert who is aware of the hazard involved.
Capacitors inside the instrument may still be charged even
if the instrument has been disconnected from all voltage
sources.
Only fuses of the specified type and rated current may be
used as replacements. Makeshift fuses may not be used.
The fuse-holder may not be short-circuited.
Whenever it is likely that protection has been impaired, the
instrument shall be made inoperative and be secured
against any unintended operation.
It must be assumed that the protection has been impaired
when
− the instrument has visible signs of damage,
− the instrument no longer functions,
− the instrument has been stored in unfavorable
conditions for a long time
− the instrument has been subjected to adverse transport
conditions.
Maintenance 15

Conversion
Caution
When the instrument is connected to its supply, terminals
may be live and the opening of covers or removal of parts
except those to which access can be gained by hand is
likely to expose live parts.
The instrument shall be disconnected from all voltage
sources before it is opened for any operations. Operations
on the opened instrument under voltage must only be
performed by an expert who is aware of the hazard involved.
Capacitors inside the instrument may still be charged even
if the instrument has been disconnected from all voltage
sources.
Only fuses of the specified type and rated current may be
used as replacements. Makeshift fuses may not be used.
The fuse-holder may not be short-circuited.
Whenever it is likely that protection has been impaired, the
instrument shall be made inoperative and be secured
against any unintended operation.
It must be assumed that the protection has been impaired
when
−the instrument has visible signs of damage,
−the instrument no longer functions,
−the instrument has been stored in unfavorable
conditions for a long time
−the instrument has been subjected to adverse transport
conditions
Changing the measuring input
Bild 8 R1 resistor
Z-18827 G2 soldered jumper
G5 soldered jumper
If the controller is to be used for a measuring input other than the
one preset,
1. The soldered jumpers G2 and G5 must be closed or opened
in accordance with the following table or the resistor R1
should be installed or removed.
Tab. 3
Input G2 G3 R1 (1 %,
0.25 W)
Parameter
in
Thermocouple open closed no resistor 0, 1, 2, 3, 4,
5,6or7
Resistance
thermometer Pt100
open open no resistor 8or9
Current closed open or
closed
2.8 Ω 10
Voltage
(
− 10...60 mV)
closed open or
closed
no resistor 10
2. The sensor type (parameter ) and the measuring range
thresholds (parameter and ) must be readjusted
accordingly
3. The controller must be recalibrated (see Section on “Cali-
bration”).
16 Conversion

Application
The controller is designed to solve simple, basic control tasks,
especially in the field of temperature control.
Description
The control task can be done with P, PI, PD, PID or a simple
On/Off action. The right controller parameters are traced with an
automatic self-tune function. In the ensuing operation, a Fuzzy
Logic feature is used to effect an indirect adaption of the con-
troller parameters, which have the effect of optimising and stabi-
lising the control action even outside the stationary condition (e.g.
during big setpoint jumps).
The alarm function is selectable. Apart from the minimum or ma-
ximum value monitoring of the process variable or of the control
deviation, it can also be used as a time relay. Additonally, a fur-
ther function such as ramp rate can be adjusted for the setpoint.
All settings can be stored in a non-volatile memory and thus
remain unaffected by any power supply interruptions.
Application •Description 17

Technical data
Input
Types
Sensor Measuring range Error
Thermocouple Type J −50...999 °C±2°C
Thermocouple Type K −50...1370 °C±2°C
Thermocouple Type T −270...400 °C±2°C
Thermocouple Type E −50...750 °C±2°C
Thermocouple Type B 300...1800 °C±3°C
Thermocouple Type R 0...1750°C±2°C
Thermocouple Type S 0...1750 °C±2°C
Thermocouple Type N −50...1300 °C±2°C
Pt100 (DIN or JIS) −200...400 °C±0,4 °C
Linear (−10...60 mV) −1999...9999 ±0,05 %
Reference junction compensation
0.1 % of the ambient temperature
Correction of process variable
adjustable
Option
0/4...20 mA input
Outputs
Control relay
3 A / 240 V AC resistive load
Alarm relay
2 A / 240 V AC resistive load
Optional
continuous output 0/4...20 mA (maximum load 500 Ω)
Display
Process variable
4-digit, red LED
Setpoint
4-digit, green LED
Green or red status LED for control or alarm relays
Power supply
90...264 V AC, 50/60 Hz
or
24 V UC (20...32 V AC/DC)
Power consumption
<5VA
Housing
Front
48 ×48 mm
Panel cutout
45 ×45 mm
Installation depth
86 mm
Mass
170 g
Type of protection
Front: IP 54
Electrical connection
with screw terminals (IP 00)
Enviromental conditions
Ambient temperature
−10...50 °C
Storage and transportation temperature
−20...70 °C
Relative humidity
0...90 %
no condensation
Insulation
20 MΩ(500 V DC)
Vibration immunity
10...55 Hz, 1 mm
Immunity to shock
20g
Electromagnetic compatibility / Safety
Interference immunity
according to EN 50 082-2
Interference emission
according to EN 55 011, class B
UL, CSA and CE certificate
CPU
Sampling rate
3/s
18 Technical data

Packaging for transport or for return to manufacturer
If the original packing is no longer available, the instrument must
be wrapped in an insulating air foil or corrugated board and
packed in a sufficiently large crate lined with shock absorbing
material (foamed material or similar) for the transportation. The
amount of cushioning must be adapted to the weight of the unit
and to the mode of transport.
The crate must be labelled “Fragile”.
For overseas shipment the unit must additionally be sealed
airtight in 0.2 mm thick polyethylene together with a dessicant
(e.g. silica gel). The quantity of the desiccant must correspond to
the packing volume and the probable duration of transportation
(at least 3 months). Furthermore, for this type of shipment the
crate should be lined with a double layer of kraft paper.
Packaging for ... 19

ABB Automation Products GmbH
Hoeseler Platz 2
D-42579 Heiligenhaus
Tel.: [phone] - 51 81
Fax: [phone] - 50 81
http://www.abb.com
Subject to technical changes.
Printed in the Fed. R. of Germany
42/61-72 EN Rev. 01
Edition 12.01
Subject to technical changes.
This technical documentation is protected by copyright. Translating, photocopying and diseminating it in any form whatsoever - even
editings or excerpts thereof - especially as reprint, photomechanical or electronic reproduction or storage on data processing systems or
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