—
ABB ME A SUREMENT & ANALY TICS | COMMISSIONING INSTRUC TION | CI/CM10 - EN RE V. A
ControlMaster CM10
Universal process controller, ꢀ DIN
Measurement made easy
CONTROLMASTER CM10ꢀ |ꢀ UNIVERSALꢀPROCESSꢀCONTROLLER ,ꢀꢁꢀDINꢀ |ꢀ CI/CM10 -ENꢀRE V.ꢀA
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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
5
6
7
Front panel keys ........................................................16
Operator level menus ............................................... 17
Access levels and security options ........................18
Security options ............................................................ 18
8
9
Diagnostics messages .............................................19
Instrument menus.................................................... 24
2
3
Specification................................................................7
Installation ...................................................................9
Siting ..................................................................................9
Mounting ......................................................................... 10
4
Electrical connections..............................................12
Accessing the connection terminals ........................ 13
Standard analog inputs (1 and 2)............................... 15
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1
Health & Safety
Document symbols
Safety precautions
Symbols that appear in this document are explained
below:
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
The signal word ‘WARNING’ indicates an imminent
danger. Failure to observe this information may
result in death or severe injury.
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.
NOTICE
The signal word ‘NOTICE’ indicates potential
material damage.
Note.
‘Note’ indicates useful or important information about
the product.
CONTROLMASTER CM10ꢀ |ꢀ UNIVERSALꢀPROCESSꢀCONTROLLER ,ꢀꢁꢀDINꢀ |ꢀ CI/CM10 -ENꢀRE V.ꢀA
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Potential safety hazards
Electrical
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.
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.
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.
•
Normal safety precautions must be taken to
avoid the possibility of an accident occurring
when operating in conditions of high pressure
and/or temperature.
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.
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.
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.
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…1 Health & Safety
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.
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.
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
CONTROLMASTER CM10ꢀ |ꢀ UNIVERSALꢀPROCESSꢀCONTROLLER ,ꢀꢁꢀDINꢀ |ꢀ CI/CM10 -ENꢀRE V.ꢀA
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2
Specification
Mechanical data
Protection
Inputs/Outputs
Analog inputs
• Front face IP66/ NEMA 4X
• Rear panel IP20
• 1 universal
• 1 process
Dimensions
Analog outputs
• Height – 97 mm (3.8 in)
• Width – 50 mm (2.0 in)
• Depth behind panel – 121 mm (4.8 in)
Materials of construction
Glass filled polycarbonate
Weight
• 1 standard
• 1 optional
• Galvanically isolated from the rest of the circuitry,
500V for up to 1 minute. Range programmable
source and range 0 to 22 mA, maximum load 750 Ω
@ 20 mA.
0.38 kg (0.84 lb)
Relay outputs
• 1 standard
• 3 optional
Electrical
Power supply ranges
• 100 to 240 V AC ±10 % (90 V min. to 264 V max.)
50/60 Hz
• Fully programmable. Contacts rated at 5 A @ 240 V.
Standard relays are changeover. Optional relays are
selectable NO or NC by jumper.
• 10 to 36 V DC (optional)
Power consumption
10 W max.
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…2 Specification
Digital inputs/outputs
2 optional, user programmable as input or output.
Minimum input pulse duration: 125 ms
Approvals, certification & general safety
• EN-61010-1
• cULus
Input
• Volt free
• Overvoltage class III on mains, Class II on
inputs and outputs
• 24 V DC (1 signal 15 to 30 V, 0 signal -3 to 5 V)
• Pollution category 2
Output
• Insulation category 2
• Open collector output
• 30 V, 100 mA max. switched
• Conforms to IEC 61131-2
Update Rate
Emissions and Immunity
Meets the requirements of IEC 61326 for an industrial
environment
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)
CONTROLMASTER CM10ꢀ |ꢀ UNIVERSALꢀPROCESSꢀCONTROLLER ,ꢀꢁꢀDINꢀ |ꢀ CI/CM10 -ENꢀRE V.ꢀA
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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 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
Sensor
At eye
level
Avoid
vibration
Close to the sensor
Figure 1 Siting
55 °C
(131 °F)
max.
0 to 95 % RH
IP66/NEMA4X
(front panel),
IP20 (rear)
0 °C
(32 °F)
min.
Use
screened
cable
Humidity limits
Temperature limits
Figure 2 Environmental requirements
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…3 Installation
Mounting
ControlMaster CM10 is designed for panel mounting.
For NEMA4X protection, a panel thickness of 2.5 mm
(0.1 in) is required.
20 (0.8)
121 (4.8)
50 (2.0)
97
(3.8)
91.8
(3.6)
1
Cut a hole of the correct size for the controller in the
panel.
2
Insert the controller into the panel cut-out.
141 (5.5)
+0.6
–0
45
(1.8+0.02
)
–0
91.8+0.8
–0
(3.6+0.03
)
–0
≥30 (1.18)
14 (0.55)
Panel cut-out dimensions
Figure 3 Mounting dimensions
CONTROLMASTER CM10ꢀ |ꢀ UNIVERSALꢀPROCESSꢀCONTROLLER ,ꢀꢁꢀDINꢀ |ꢀ CI/CM10 -ENꢀRE V.ꢀA
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1
Position one panel clamp A at the top of the case
against the panel.
2
3
Locate the panel clamp anchor B in slot C.
Tighten the panel clamp anchor screw D until
panel clamp A is lightly touching the panel
4
5
E and panel clamp anchor F
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
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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 Figure 6 on
•
•
•
•
•
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
parts, for example, 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.
•
•
Remove all power from the supply, relay and any
powered control circuits and high common
mode voltages before accessing or making any
connections.
•
All equipment connected to the controller’s
terminals must comply with local safety
standards (IEC 60950, EN601010-1)
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).
CONTROLMASTER CM10ꢀ |ꢀ UNIVERSALꢀPROCESSꢀCONTROLLER ,ꢀꢁꢀDINꢀ |ꢀ CI/CM10 -ENꢀRE V.ꢀA
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NOTICE
Accessing the connection terminals
•
Always route signal leads and power cables
separately, preferably in earthed (grounded)
metal conduit.
catch A and pull the terminal cover B away from the
controller body.
•
•
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
A
B
Figure 5 Removing terminal cover
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…4 Electrical connections
Rear view
Standard connections
Option board 1
Rear view
Tx
PSU
13
14
15
16
17
1
2
19
Analog output 2
20
21
Analog input 1
3
Digital output + external
Digital input/output 1
Digital input/output 2
Digital input/output –
4
22
23
24
25
26
27
28
29
30
Analog input 2
5
18
6
Analog/digital output 1 ****
7
**
Relay output 2
8
NC
C
C
Relay output 1
100 to
9
**
Relay output 3
NO
C
10
11
12
**
Line ***
Neutral
10 to
36 V DC
240 V AC
10W
Relay output 4
C
Option board 1A
*
connection details
** N/O or N/C contact selection is made via internal jumper links.
N/O is the factory default setting.
**
C
25
26
Relay output 2
*** 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).
Figure 6 Electrical connections
CONTROLMASTER CM10ꢀ |ꢀ UNIVERSALꢀPROCESSꢀCONTROLLER ,ꢀꢁꢀDINꢀ |ꢀ CI/CM10 -ENꢀRE V.ꢀA
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Standard analog inputs (1 and 2)
2-lead RTD
+ resistance
3-lead RTD
3rd lead
THC
RTD–
1
Milliamps*
Milliamps*
mA****,
mV, V
digital
input
2
RTD+
RTD–
RTD+
Analog input 1
Analog input 2
CJ**
Tx
3
RTD–
4
mA****, mV, V
digital input
THC***
Tx
5
Transmitter PSU
*
Using internal transmitter power supply.
CJ sensor
** 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 controller is switched off, fit a 2V7
Zener diode as shown.
Note. 3-lead RTD leads must have equal resistance, not exceeding 20 Ω each.
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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.
Key functions for the controller overlay are described
below:
A
B
C
All diagnostics messages are displayed within the
Diagnostics View.
A
B
Navigation key (left)/operator level access key.
Up/Down keys – navigate up/down menu items
and increase/decrease displayed values.
Prompts associated with active keys are displayed on
each screen. Diagnostic and display icon descriptions
are included in this document.
C
Navigation key (right)/programmable soft key.
Note. When a soft key option is assigned to key C, the
using key A.
Operator level menus
CONTROLMASTER CM10ꢀ |ꢀ UNIVERSALꢀPROCESSꢀCONTROLLER ,ꢀꢁꢀDINꢀ |ꢀ CI/CM10 -ENꢀRE V.ꢀA
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Operator level menus are used to adjust setpoint(s) and output(s), select setpoints,
select the view and to enter Basic and Advanced modes (via the Access Level).
To access Operator Level menus:
1
2
3
From the Operator Page, press
to view the available menus.
keys to scroll through the menus and menu options.
to expand menu levels and to select menu options or press to return
Use the
and
Autotune
Adjust
Setpoint Select
Alarm Acknowledge
Press
to the previous menu.
Autotune
Adjust
Used to start or stop an Autotune routine.
This menu is enabled only if Autotune mode is On.
Enables a value to be adjusted using the
and
keys.
The icon next to a value indicates the current adjustable selection.
Setpoint Select
Selects the local setpoint to be used
(displayed only if more than 1 local setpoint is configured).
Alarm Acknowledge
View Select
Acknowledges any active but unacknowledged alarms.
Selects the Operator view to be displayed.
Enter Advanced Level Displays the Access Level selection views.
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6
Access levels and security options
Access Level
The access level menus are used to enter the Basic and Advanced menus, view all
Logout
parameters in read only mode and to logout (return to operator view mode).
Read Only
Basic
To view Access Level menus:
1
From the operator view mode, press
Advanced
Service
OR
press
scroll to Enter Config. Mode, then press . The Access Level menu is displayed.
Use the and keys to scroll to the required/permitted level of access
(basic or advanced), then press
to display the available operator menus and use the
and
keys to
2
.
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
Basic
Enables all parameter settings to be viewed.
Enables access to the basic level and adjustment of totalizer count settings and alarm trip points.
Enables configuration access to all parameters.
Advanced
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 CM10ꢀ |ꢀ UNIVERSALꢀPROCESSꢀCONTROLLER ,ꢀꢁꢀDINꢀ |ꢀ CI/CM10 -ENꢀRE V.ꢀA
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Diagnostics messages
The controller is programmed to display diagnostics
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.
messages that provide information on servicing
requirements and any other conditions that develop
during operation.
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.
NAMUR (NE107) status icon
Failure
High process alarm
Low process alarm
High latch alarm
High latch alarm
Maintenance
Out of spec
Check function
Diagnostic description/alarm tag
Alarm
icon
High Temp
PV1 Failed
High Temp
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…7 Diagnostics messages
Icon
Number/
Message
Possible cause
Suggested action
Temporary or permanent failure of analog to Cycle power to controller.
242.004
digital converter on the main I/O board.
If problem persists replace main I/O board.
Contact local service organization.
Check wiring.
ADC 1 Failed
Problem with input assigned to Loop 1 PV.
Broken sensor leads, defective input source Check input source.
or input signal out of permitted range.
250.000
PV 1 Failed
Check if input signal is outside permitted limits.
Problem with Input assigned to Loop 1
Remote Setpoint. Broken sensor leads,
defective input source or input signal out of Check if input signal is outside permitted limits.
permitted range.
Check wiring.
Check input source.
246.002
RSP 1 Failed
Error in Cold junction measurement
associated with AIN1. Wiring fault or
defective sensor.
Check cold junction device is correctly fitted.
Ensure I/P 2 is turned off.
Replace CJ sensor.
222.014
CJ 1 Failed
Problem with input assigned to Loop 1 wild Check wiring.
230.010
WV 1 Failed
variable. Broken sensor leads, defective
Check input source.
input source or input signal out of permitted Check if input signal is outside permitted limits.
range.
CONTROLMASTER CM10ꢀ |ꢀ UNIVERSALꢀPROCESSꢀCONTROLLER ,ꢀꢁꢀDINꢀ |ꢀ CI/CM10 -ENꢀRE V.ꢀA
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Icon
Number/
Message
Possible cause
Suggested action
Problem with input assigned to Loop 1
position feedback. Broken sensor leads,
defective input source or input signal out of Check if input signal is outside permitted limits.
permitted range.
Check wiring.
Check input source.
234.008
PFB 1 Failed
Failure of non-volatile memory on processor/ Check all configuration parameters and correct any errors.
display board or permanent corruption of its Acknowledge error.
216.016
NV Error
Proc Bd
data.
If problem persists contact local service organization.
Failure of non-volatile memory on main
board or permanent corruption of its data.
Check calibration of AIN1, AIN2 and AO1.
Recalibrate if necessary.
Acknowledge error.
214.017
NV Error
Main Bd
If problem persists contact local service organization.
212.018
NV Error
Opt Bd 1
Failure of non-volatile memory on option
Recalibrate If necessary.
board 1 or permanent corruption of its data. Acknowledge error.
If problem persists contact local service organization.
Acknowledge error.
Failure of non-volatile memory on
communications board or permanent
corruption of its data.
208.020
NV Error
Comm Bd
Check communications board is correctly identified by controller.
If problem persists contact local service organization.
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…7 Diagnostics messages
Icon
Number/
Message
Possible cause
Suggested action
The configuration contains a source that is
no longer present or valid.
Check invalid sources in Diagnostics menu.
Config Error
Check configuration, check I/O required for configuration is
present and correct any illegal use of the invalid signal by
changing configuration or fitting additional option cards.
Autotune has failed to complete its sequence Check process response.
054.044
Tune Lp1 Fail
or has calculated values outside of its
permitted range.
Consider changing the Autotune dynamic setting.
Ensure process is stable and repeat autotune.
If problem persists tune the loop manually.
Autotune has been aborted by the user.
Abnormal oscillations in the control loop.
070.040
Tuner 1 Abort
Check process.
Perform new manual or Autotune.
086.036
Oscillation 1
Motorized valve travel time is significantly
slower than configured time.
Check valve to identify reason for sticking.
Check correct travel time is entered in configuration.
094.034
Valve 1
Sticking
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Icon
Number/
Message
Possible cause
Suggested action
Autotune is in progress.
Autotune can be aborted if required by selecting Manual control
mode.
168.026
(166.027)
(164.028)
Tuner 1
Phase 1..3
162.029
(154.033)
Autotune has completed successfully and
calculated new control parameters.
Acknowledge diagnostic.
Tuner 1 Pass
The device is currently in the configuration
mode.
This is for use with remote access via digital communications.
178.025
In
Configuration
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8
Instrument menus
Basic level
Advanced level
Menu
Menu
Menu
Basic Setup
Device Setup
Display
Exit
Select
Exit
Select
Exit
Select
Loop 1 Setpoints
Local Setpoint 1 (4)
RSP Ratio
Initial Setup
Language
App. Template
Operator Templates
Page 1 (4) Template
Loop 1 Output Type
Loop 1 Split O/P
Instrument Tag
Mains Freq.
RSP Bias
Operator Functions
Autoscroll
Ramp Mode
Ramp Rate
Soft Key Function
Auto Manual Enable
Local Remote Enable
Alarm Ack. Enable
SP Adjust Enable
Config Action
Loop 1 Control
On/Off Hysteresis
Mode
Reset to Defaults
Security Setup
Basic Password
Advanced Password
Reset Passwords
Autotune
PID
Settings
Loop 1 Time Prop
Cycle Time 1
Brightness
Cycle Time 2
Alarm 1 (8)
Trip
Note. When in Advanced Level (configuration) mode, press and hold the
key to return to the standard Operator page
CONTROLMASTER CM10ꢀ |ꢀ UNIVERSALꢀPROCESSꢀCONTROLLER ,ꢀꢁꢀDINꢀ |ꢀ CI/CM10 -ENꢀRE V.ꢀA
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Menu
Menu
Input/Output
Control
Continued
overleaf
Exit
Select
Exit
Select
Analog Inputs
Analog Input 1 (2)
Loop 1 Setpoints
Low Limit
Control Type
Control Action
On/Off Hysteresis
Autotune
Loop 1 Split O/P
Min Input 1
Min OP 1
High Limit
Analog Outputs
Analog Output 1
No. of Local SP’s
Local Setpoint 1
Track Mode
Max Input 1
Max OP 1
PID
Min Input 2
Min OP 2
Digital I/O
Loop 1 Output
Limits
RSP Ratio
Digital IO 1 (2)
RSP Bias
Max Input 2
Max OP 2
Failure Actions
A/M Select
Sources
Relays
RSP Fault Action
Default Setpoint
Ramp Mode
Relay 1 (4)
Loop 1 Time Prop
Cycle Time 1
Slew Rate
Ramp Rate
Cycle Time 2
Select Sources
Loop 1 Control
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…8 Instrument menus
…Advanced level
Menu
Menu
Menu
Communications
Process Alarm
Diagnostics
Exit
Select
Exit
Select
Exit
Select
Alarm 1 (8)
Type
Refer to the
Diagnostic History
Communications
Source Analysis
Analog Source
Digital Source
Invalid Sources
Tag
for Communication
parameter details.
Source
Trip
Hysteresis
Time Hysteresis
Display Enable
Acknowledge Source
Enable Source
Note. When in Advanced Level (configuration) mode, press and hold the
key to return to the standard Operator page
CONTROLMASTER CM10ꢀ |ꢀ UNIVERSALꢀPROCESSꢀCONTROLLER ,ꢀꢁꢀDINꢀ |ꢀ CI/CM10 -ENꢀRE V.ꢀA
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Menu
Device Info
Exit
Select
Instrument Type
I/O Build
No. Analog Inputs
No. Analog Outputs
No. Relays
No. Digital I/O
Functionality
Serial No.
Hardware Revision
Software Revision
Sales
Service
Software
—
ABB Limited
Measurement & Analytics
Howard Road, St. Neots
Cambridgeshire, PE19 8EU
UK
Tel: +44 (0)1480 475 321
Fax: +44 (0)1480 217 948
Email: [email protected]
ABB Inc.
Measurement & Analytics
125 E. County Line Road
Warminster, PA 18974
USA
Tel: +1 215 674 6000
Fax: +1 215 674 7183
—
We reserve the right to make technical changes
or modify the contents of this document without
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