Cemline Corporation CEM-TROL User manual

$5.00

P. O. Box 55, Cheswick, PA, 15024
Phone: [phone] •FAX [phone]
www.cemline.com
Installation, Operation, and Maintenance Manual
CEMLINE CORPORATION®
CEM-TROL Solid State Control Module
and Electronic Control Valves

i
Table of Contents
Section Page
Disclaimers ..................................................................................................................... 1
Contact Information........................................................................................................ 1
General Notes and Warnings .......................................................................................... 2
Notes ................................................................................................................... 2
Warnings............................................................................................................. 2
Connection Electrical Power Source .................................................................. 3
The Controller Overview ................................................................................................ 4
Contractor Wiring ........................................................................................................... 7
Ratings ............................................................................................................................ 7
Control Screens............................................................................................................... 8
Setting the Controller...................................................................................................... 9
Home Screen....................................................................................................... 10
Alternative Home Screen.................................................................................... 11
Set Point Degree F .............................................................................................. 11
Primary High Limit Temperature ....................................................................... 12
Primary High Limit Temperature Reset Differential.......................................... 13
Secondary High Limit Temperature ................................................................... 14
Secondary High Limit Temperature Reset Differential...................................... 14
Control Valves .................................................................................................... 15
PID Gain Kp (Proportional)................................................................................ 16
PID Gain Ki (Integral) ........................................................................................ 16
PID Gain Kd (Derivative)................................................................................... 17
Remote Control .................................................................................................. 17
Control Output ................................................................................................... 18
Maximum Output ............................................................................................... 20
Initial Settings ..................................................................................................... 20
Diagnostics.......................................................................................................... 20

LL
About................................................................................................................... 21
Quit...................................................................................................................... 21
Terminal Board Layout ................................................................................................... 22
Building Automation Control Interface .......................................................................... 23
Remote On-Off ................................................................................................... 23
Remote Temperature Read Out........................................................................... 24
Remote Temperature Set Point ........................................................................... 24
Testing the Temperature Sensor ..................................................................................... 25
Wiring Diagram for Self-Contained Temperature Pilot Operated Control Valves ........ 26
Wiring Diagram for Pneumatically Operated Control Valves........................................ 27
Wiring Diagram for Warren Controls with AmurAct Actuator...................................... 28
Wiring Diagram for MXG and MFX Valves.................................................................. 29
Wiring Diagram for M2H and M3P Valves ................................................................... 30
Wiring Diagram for MVF Valves................................................................................... 31
MXG and MXF Valve Information ............................................................................... 32
M3P and M2H Valve Information.................................................................................. 34
MVF Valve Information................................................................................................. 35
General Valve Information............................................................................................. 37
Magnetic Coil Resistance Information........................................................................... 38
Warren ControlsAmurAct Actuator Valve Information................................................ 39
2011 Cemline Corporation. All Rights Reserved.
All trademarks in this manual are property of Cemline Corporation, unless otherwise noted or in
any other way set forth as a third party rights. Unauthorized use of these trademarks, as well as the
materials presented in this manual, is expressly prohibited and constitutes a violation of the
intellectual property rights of Cemline Corporation.

1
Disclaimers
This Installation, Operation, and Maintenance Manual is intended to be as complete and up to date
as possible. It covers the installation, operation, and maintenance procedures for CEMLINE
CORPORATION’s CEM-TROL control module and electronic control valves. CEMLINE®
reserves the right to update this manual and other product information concerning installation,
operation, and/or maintenance, at any time and without obligation to notify product owners of such
changes.
CEMLINE is not responsible for inaccuracies in specifications, procedures and/or the content of
other product literature, supplied by the manufacturers of components used in CEMLINE CEM-
TROL control module. CEMLINE strives to use only the highest quality components; however,
CEMLINE has no direct control over their manufacture, or their consistent quality.
CEMLINE is not responsible for injury to personnel or product damage due to the improper
installation, operation, and/or maintenance of CEMLINE Electronic Controls. All installation,
operation, and maintenance procedures should only be performed by trained/certified personnel. All
personnel performing these procedures should completely and carefully read and understand all
supplied materials before attempting the procedures. All personnel should pay strict attention to all
Notes, Cautions, and Warnings that appear within the procedures detailed in this manual.
CEMLINE welcomes user input as to suggestions for product or manual improvement.
Contact Information
For information concerning warranties, or for questions pertaining to the installation,
operation or maintenance of CEMLINE products, contact:
CEMLINE CORPORATION
P.O. Box 55
Cheswick, PA 15024
USA Phone: [phone]
USA Fax: [phone]
www.cemline.com
To order replacement parts, contact CEMLINE CORPORATION at the address listed above, or call
toll free:
USA/Canada/Caribbean Phone: [phone]
Note: Please include the model and serial number of the unit for which the parts are being
ordered. If ordering by phone, please have this information readily available.

2
General Notes and Warnings
Notes
This manual is intended to cover installation, operation, and maintenance procedures for
CEMLINE CORPORATION CEM-TROL control module and electronic control valves.
If questions are not answered by this manual, or if specific installation, operation, and/or -
maintenance procedures are not clearly understood, contact CEMLINE CORPORATION for
clarification before proceeding.
All installation, operation, and maintenance procedures should be performed only by
experienced, trained and certified personnel. Personnel should be trained in and familiar with
correct piping and electrical procedures and methods, and should be experienced in working
with hot/boiler water systems and steam systems.
CEMLINE CORPORATION CEM-TROL control module and other electronic controls are
designed for indoor use only, unless otherwise required by design specifications.
If the unit is damaged during installation, operation, or maintenance, complete the following
steps:
1. Turn off and lock out the electric power supply to the unit in an approved manner.
2. Turn off all incoming steam/hot water valves.
3. Contact in-house maintenance personnel or CEMLINE CORPORATION for
instructions.
Warnings !
As with any piece of equipment that utilizes hot/boiler water or steam and electricity, the potential
exists for severe personal injury if proper installation, operation, and maintenance procedures are
not followed. Listed on the following pages are specific warnings pertaining to CEMLINE
Electronic Controls. All warnings should be carefully read and understood. All precautions
contained in the warnings should be carefully followed to reduce the chance of injury.
Note: Throughout this manual, warnings will be denoted by the symbol .
All documentation for each major component has been included with the unit. It is strongly
recommended that each document be reviewed before attempting any installation, operation, or
maintenance procedures.
The documentation for each major component may also contain warnings and cautions identified by
the manufacturer of each component. These warnings and cautions may be specific for the
particular component, and therefore not covered in this general Installation, Operation, and
Maintenance Manual. They should also be carefully reviewed before attempting installation,
operation, or maintenance procedures.

3
The combination of electricity and water can pose a very dangerous situation. Assure that all
power has been shut off/disconnected and locked out in an appropriate manner, before
attempting any installation or maintenance procedures.
Areas of potential danger:
1. all electric power leads and connections;
2. all hot/boiler water lines, steam lines, joints, valves, and relief valves; and
3. all joints at valve, gauges, etc.
Before attempting any installation, operation, or maintenance procedures pertaining to the unit.
1. Assure that the electric power supply has been turned off and locked out in an approved
manner;
Hot/boiler water and steam present a situation that can be very dangerous due to the fact it
is under pressure and at very high temperatures. To avoid possible injury or death, use
common sense and follow all accepted and recommended procedures when performing
installation, operation, and maintenance procedures.
Connecting the Electric Power Source
All installation procedures involving electric power connection should only be performed by
trained, certified electricians.
Hot/boiler water and steam present a situation that can be very dangerous because of the high
temperatures and pressures. Use common sense and follow all accepted and recommended
procedures when performing installation, operation, and maintenance procedures to avoid
possible injury or death.
The combination of electricity and water can pose a very dangerous situation. Assure that all
power has been shut off/disconnected and locked out in an approved manner, before
attempting any installation or maintenance procedures.
The CEMLINE Packaged Water Heaters have been wired during assembly. Connecting the electric
power supply to the unit consists of connecting the correct voltage, phase, and amperage power
leads to the terminal strip or circuit breaker. The exact voltage, phase, and amperage requirements
for the unit can be determined from the rating plate affixed to the jacket of the unit, or from the
Submittal Sheet and Wiring Diagrams supplied with the unit.

4
The Controller - Overview
Cemline CEM-TROL control module is a solid state controller designed to control temperatures and
limit(s) on Cemline Packaged Water Heaters.
The CEM-TROL is supplied with a LED backlit LCD display. LED pilot lights are supplied to
indicate On-Off, primary high limit temperature, and secondary high limit temperature. The CEM-
TROL control module allows the owner to set the operating temperature, primary high temperature
limit and the secondary temperature high limit on the display screen. The CEM-TROL control
module has over temperature alarm lights and an alarm horn with built in alarm silence relay. The
CEM-TROL control module is supplied with dry contact closure outputs to indicate to building
automation system (BAS): power on, primary high temperature, secondary high temperature, and
any alarm. The CEM-TROL control module allows the BAS to turn the Cemline Packaged Water
Heater on or off through a remote relay suitable for 24 VAc, 1 amp. The control module allows the
BAS to remotely monitor the operating temperature and remotely set the operating temperature.
The control module is supplied with an on-off switch and is mounted in a NEMA 4 enclosure.
Built in remote start stop: This feature allows the Packaged Water Heater to be started or stopped
from a remote location. Typically this would be accomplished from the Building Automation
System (BAS) . Requires a dry contact suitable for 24 VAc and 1 amp. Terminal block P1
terminals 1 – 2 on the panel is where the BAS on-off is wired.
Built in On-Off Switch: Allows for local on-off and is convenient for service in the unlikely event
service is required. This switch is mounted in the side of the panel.
Built in Alarm Horn: The alarm horn will sound and LED will light red on primary high
temperature limit and/or secondary high temperature limit. If either high temperature limits are
exceeded the alarm horn will also sound and the alarm light(s) will light red. The CEM-TROL also
features an alarm silence relay which will silence the alarm but not the fault light when the
generator is being serviced. When the fault is cleared both the alarm and fault light(s) will
automatically reset.
Built in PID controller: The PID control in the CEM-TROL allows the user to easily select the
operating temperature set point of the water heater. The controller reads the temperature of the
heated water from a temperature sensor in the water heater. Based upon the water temperature, the
controller then sends a 0 –10 VDC output signal to the control valve to open or close the valve
accordingly. In order to use this functionality of the CEM-TROL must be wired to either a
pneumatic control valve with an I-P transducer or an electronic control valve. This feature is not
functional when using a pilot operated valve with a self-contained temperature pilot.
The CEM-TROL is designed with the P-I-D control logic.
P is proportional. The proportional is used to handle the present. Proportional is a constant used to
send a signal to the output. Proportional control with a set point of 140 oF and a proportional band
of 10 would have a 100% (10 VDC) output at 130 deg F, 50% (5 VDC) output at 135 oF and 10%
(1 VDC) output at 139 deg F oF.

5
I is integral. The integral measures error over a short period of time to develop a constant used to
send a signal to the output. The integral is then added to the proportional to eliminate error.
D is derivative. The derivative is often referred to as rate. Derivative is used to respond to a
change in the system. The larger the derivative the more rapidly the controller can respond to
changes within the system.
Built in operating temperature readouts: The CEM-TROL features an easy to read LED digital
readout of the water temperature in the water heater.
Built in primary high temperature cut off and alarm: In the event of high temperature, the CEM-
TROL will close the source steam, boiler water, or HTHW supply valve and sound an alarm.
Built in secondary high temperature limit and alarm: In the event of secondary high temperature set
point is exceeded the CEM-TROL will open an optionally supplied domestic water solenoid valve
to relieve the vessel of overheated water and sound an alarm.
Built in remote temperature set point: The BAS can remotely set the operating temperature of the
water heater. This requires the use of a pneumatic control valve with an I-P transducer or an
electronic control valve. This feature is not functional when using a pilot operated valve with a
self-contained temperature pilot.
Built in LED/LCD display of functions and alarms: The CEM-TROL is designed for the user to tell
at a glance how the system is operating. The built in LED displays make troubleshooting simple.
Function LED Indicator 1 LED Indicator 2
Power ON Green = Power On Blank = No power
Primary High Limit Blank = Temperature below
primary high limit set point.
Red = Primary high limit set
point has been exceeded.
Secondary High Limit Blank = Temperature below
secondary high limit set point.
Red = Secondary high limit set
point has been exceeded.
CEM-TROL units version 2.0 and higher will display the below alarm status on the LCD screen if
the temperature sensor(s) are not attached or are defective. In order to determine the version of the
CEM-TROL please refer to the ‘About’ section on page 21 of this manual
LCD Display Description
Sensor Loss 1 The primary sensor wired to terminal block P2 - terminals 1 & 2 is not
connected and needs to be connected or the sensor is faulty or defective
and needs to be replaced.
Sensor Loss 2 The secondary sensor wired to terminal block P2 - terminals 3 & 4 is not
connected and needs to be connected or the sensor is faulty or defective
and needs to be replaced.
Sensor Loss 3 Both the primary sensor wired to terminal block P2 - terminals 1 & 2 and
the secondary sensor wired to terminal block P2 - terminals 3 & 4 are not
connected and need to be connected or the sensors are faulty or defective
and need to be replaced.

6
Built in contacts to notify BAS (Building Automation System) of functions and alarms: This
control allows for simple and reliable interface from a remote location. The BAS can also start and
stop the packaged water heater. BAS can remotely read the temperature in the packaged water
heater via a 4 – 20 mA signal whereby 4 mA= 32 oF and 20 mA = 212oF. BAS can remotely set
the temperature of the packaged water heater between 50 and 160 oF using a 4 – 20 mA signal
whereby 4 mA= 32 oF and 20 mA = 212 oF.
Power ON
Primary High Limit
Secondary High Limit
Alarm
Operating temperature (via a 4-20 mA signal)
(4 mA = 32 oF: 20 mA = 212 oF)

7
Contractor Wiring
All Power Connections should be performed by a trained , certified electrician. Be sure the
factory supplied on-off switch is in the OFF position before connecting to building power.
Field wiring: Installer must run feed wires to terminals on panel mounted on-off disconnect switch
and green ground wire to ground lug. Units are normally wired for 120 volt single phase input.
Warning: Before drilling hole in panel for conduit connection of power carefully open door
and verify that nothing in panel will be interfered with. BE CAREFUL not to get any drill
shavings or metal slug on board or transformer or disconnect switch.
Panel is normally factory shipped for 120
Volt/ 1 phase/60/50 Hz. If so desired
220/1/50 or 60 Hz power can be used. To
convert to 220 volt input it is necessary to
reconfigure the 24 volt output transformer.
Below is the wiring diagram for 120 volt
and 220 volt input.
CAUTION: Before attempting to rewire the transformer be sure power coming to the
unit is turned off and locked out in an approved manor.
Ratings
Input: selectable 120/220 VAC –50/60 Hz @120 Vac min 90 volt max 130 volt
Output Contacts: 1 amp at 24 Vac
Building Automation outputs: Dry contacts, NO .5 amp maximum, non inductive
Display: LED display with resolution of
.3 % of scale
Available temperature set range:
50 – 160 oF
Operating ambient temperature:
Min 32 Deg F max 140 deg F
Operating Humidity:
5% to 95% relative humidity (RH)
non condensing
Alarm approximately 103 db.
NEMA 4 enclosure
The Cemline CEM-TROL is a self contained board and can not be field repaired. For a replacement
board contact Cemline Corporation at the address shown on page one of this manual.