ABB ControlIT 53MC5000 User manual

INSTRUCTION MANUAL

Control

IT

Multi-Loop Process Controller

53MC5000

PROCESS CONTROL STATION

PN24950

✶ ✶

RETAIN THE INSTRUMENT CALIBRATION SHEET

✶ ✶

The factory set calibration constants for the analog inputs and analog

outputs are recorded on the instrument calibration sheet. This sheet

should be retained in the event one or more of the constants is

inadvertently changed.

TRADEMARKS:

The following are trademarks of ABB Automation Inc.: F-CIM



F-TRAN



EASY-TUNE



MICRO-DCI



MicroLink



SUPERVISOR-PC



Flexible Control

Strategy



The following is a registered trademark of General Electric Company: ULTEM 1000

®

The following is a registered trademark of the HART Communication HART

®

Foundation

The following is a registered trademark of Scada Software Corporation SCADA

®

The following are registered trademarks of Microsoft Corporation MS-DOS

®

WINDOWS®

The following is a registered trademark of Reed Devices, Inc. SNAPTRACK

®

All software, including design, appearance, algorithms and source

codes, is copyrighted by ABB Automation and is owned by ABB

Automation or its suppliers.

NOTICE

The instructions given in this manual cover generally the description,

installation, operation, and maintenance of the subject product.

ABB Automation reserves the right to make engineering refinements

that may not be reflected in this bulletin. Should any questions arise

which may not be answered specifically by these instructions, the

questions should be directed to ABB Automation for further detailed

information and technical assistance. The material in this manual is for

informational purposes and is subject to change without notice. ABB

Automation assumes no responsibility for any errors that may appear in

this manual.

Table of Contents

1.0 INTRODUCTION 1-1

1.1 PRODUCT OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 SCOPE OF BOOK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1.3 MODEL NUMBER BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1.4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

1.5 RELATED DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

2.0 INSTALLATION 2-1

2.1 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 PACKING BOLT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.3 LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.4 MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.5 MOUNTING THE INTERCONNECTION TERMINAL BOARDS (ITBs) . . . . . . . . . . 2-6

2.6 REMOVABLE PLUG-IN CONNECTORS . . . . . . . . . . . . . . . . . . . . . 2-11

2.7 POWER CONNECTIONS FOR CONTROLLER AND ITBs . . . . . . . . . . . . . 2-12

2.7.1 SINGLE +24 V DC POWER SOURCE TO CONTROLLER AND ITBs . . . . . 2-18

2.7.2 SEPARATE 24 V DC POWER SOURCES TO CONTROLLER AND ITBs . . . 2-20

2.7.3 110/120 V AC POWER SOURCE TO CONTROLLER . . . . . . . . . . . 2-22

2.7.4 220/240 V AC POWER SOURCE TO CONTROLLER . . . . . . . . . . . 2-24

2.7.5 220/240 V AC (NO NEUTRAL) POWER SOURCE TO CONTROLLER . . . . 2-26

2.8 SIGNAL CONNECTIONS TO STANDARD REAR TERMINAL BOARD . . . . . . . . 2-28

2.8.1 ANALOG INPUTS 0-3 (ANI0-3) . . . . . . . . . . . . . . . . . . . . 2-28

2.8.2 ANALOG OUTPUTS 0 AND 1 (ANO0&1) . . . . . . . . . . . . . . . . 2-32

2.8.3 CONTACT CLOSURE INPUTS 0 AND 1 (CCI0&1) . . . . . . . . . . . . 2-32

2.8.4 CONTACT CLOSURE OUTPUTS 0 AND 1 (CCO0&1) . . . . . . . . . . . 2-32

2.9 SIGNAL CONNECTIONS FOR SINGLE CHANNEL ANALOG OPTION (ANI8) . . . . . 2-32

2.10 SIGNAL CONNECTIONS FOR THE ITBS . . . . . . . . . . . . . . . . . . . 2-35

2.10.1 SCADA ADAPTER SIGNAL CONNECTIONS . . . . . . . . . . . . . . 2-35

2.10.2 ANALOG ITB SIGNAL CONNECTIONS . . . . . . . . . . . . . . . . 2-35

2.10.3 CORD SET ITB SIGNAL CONNECTIONS . . . . . . . . . . . . . . . 2-35

2.10.4 DUAL RELAY ITB SIGNAL CONNECTIONS . . . . . . . . . . . . . . 2-36

2.10.5 6 DIGITAL INPUT/4 DIGITAL OUTPUT (6DI/4DO) ITB . . . . . . . . . . 2-36

2.10.6 16 DIGITAL INPUT/DIGITAL OUTPUT (16DI/DO) ITB . . . . . . . . . . 2-36

2.11 DATALINK CONNECTIONS TO THE CONTROLLER . . . . . . . . . . . . . . . 2-43

2.12 MICROLINK CONNECTIONS TO THE CONTROLLER . . . . . . . . . . . . . . 2-43

3.0 PRODUCT DESCRIPTION 3-1

3.1 DOT MATRIX DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 MINI-DIN CONFIGURATION PORT CONNECTOR . . . . . . . . . . . . . . . . . 3-1

3.3 REAR TERMINAL BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.4 CONTROLLER POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.5 MAIN PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.6 EXPANSION BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.7 SAMPLING TIME INTERVALS . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.8 DATALINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.9 FUNCTION INDEXES (FIXs) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3.10 DATABASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3.11 KEYPADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Contents

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3.12 ENGINEERING MODE OVERLAYS . . . . . . . . . . . . . . . . . . . . . . 3-9

3.12.1 PASSWORD FUNCTION PROMPT . . . . . . . . . . . . . . . . . . 3-9

3.12.1.1 PROCEDURE TO ENTER A KEY PASSWORD . . . . . . . . . 3-9

3.12.2 DISPLAYING A DATAPOINT . . . . . . . . . . . . . . . . . . . . . 3-11

3.12.2.1 PROCEDURE TO DISPLAY A DATAPOINT . . . . . . . . . . . 3-11

3.12.3 DISPLAYING A MODULE . . . . . . . . . . . . . . . . . . . . . . 3-13

3.12.3.1 PROCEDURE TO DISPLAY A MODULE . . . . . . . . . . . . 3-13

3.12.4 CONFIGURE A DATAPOINT . . . . . . . . . . . . . . . . . . . . . 3-14

3.12.4.1 PROCEDURE TO CONFIGURE A DATAPOINT . . . . . . . . . 3-14

3.12.5 CONFIGURE A MODULE . . . . . . . . . . . . . . . . . . . . . . . 3-16

3.12.5.1 MODULE-MODE CONFIGURATION PROCEDURE . . . . . . . 3-16

3.13 KEYPAD ALTERNATIVES . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

3.13.1 USING THE HAND HELD CONFIGURER . . . . . . . . . . . . . . . . 3-21

3.13.1.1 HAND HELD CONFIGURER SET UP . . . . . . . . . . . . . 3-23

3.13.1.2 DISPLAYING A CONTROLLER DATAPOINT . . . . . . . . . . 3-23

3.13.1.3 ALTERING A CONTROLLER DATAPOINT . . . . . . . . . . . 3-24

3.13.1.4 SETTING OR CHANGING A CONTROLLER PASSWORD KEY . . 3-24

3.13.1.5 HHC MEMORY MODULE ASSEMBLY TRANSFER . . . . . . . . 3-25

3.13.1.6 SAMPLE HAND HELD CONFIGURER COMMANDS . . . . . . . 3-26

3.13.2 USING A PC TERMINAL EMULATOR . . . . . . . . . . . . . . . . . 3-27

3.13.2.1 MICROSOFT WINDOWS HYPERTERMINAL . . . . . . . . . . 3-27

3.14 ENGINEERING MODE LOCKOUT . . . . . . . . . . . . . . . . . . . . . . . 3-30

4.0 OPERATOR DISPLAYS 4-1

4.1 DISPLAY 1 - ALARM SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.2 DISPLAY 2 - SYSTEM STATUS . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.3 DISPLAYS 3, 4, 5, AND 6 - POINT DISPLAYS (CON0-3) . . . . . . . . . . . . . . 4-8

4.3.1 POINT DISPLAYS 3, 4, 5, AND 6 (CDM = 0, STANDARD PID) . . . . . . . 4-10

4.3.2 POINT DISPLAY 3 (CDM = 1, INDICATOR) . . . . . . . . . . . . . . . 4-16

4.3.3 POINT DISPLAY 3 (CDM = 2, MANUAL LOADER) . . . . . . . . . . . . 4-17

4.3.4 POINT DISPLAY 3 (CDM = 3, RATIO CONTROLLER) . . . . . . . . . . . 4-18

4.3.5 POINT DISPLAY 3 (CDM = 4, AUTO/MANUAL STATION) . . . . . . . . . 4-19

4.3.6 POINT DISPLAY 3 (CDM = 5, RATIO AUTO/MANUAL STATION) . . . . . . 4-20

4.4 POINT DISPLAYS 7 AND 8 - TWO LOOP DISPLAYS . . . . . . . . . . . . . . . 4-21

4.5 POINT DISPLAYS 9, 10, 11, AND 12 - SINGLE LOOP WITH

HORIZONTAL TREND . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

4.6 DISPLAYS 13 TO 20 - PARAMETER MODULE DISPLAYS . . . . . . . . . . . . . 4-25

4.7 DISPLAYS 21 AND 22 - DISCRETE STATUS DISPLAYS . . . . . . . . . . . . . . 4-27

4.8 DISPLAYS 23 TO 30 - TOTALIZER DISPLAYS . . . . . . . . . . . . . . . . . . 4-29

4.9 DISPLAY 31 - LOCATOR GRID . . . . . . . . . . . . . . . . . . . . . . . . 4-30

4.10 POINT DISPLAY 32 - FOUR LOOP DISPLAY . . . . . . . . . . . . . . . . . . 4-31

5.0 CONFIGURATION PARAMETERS 5-1

5.1 READY TO USE CONTROL STRATEGIES . . . . . . . . . . . . . . . . . . . . 5-1

5.2 DATAPOINT TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3 CONFIGURING THE DATABASE MODULES . . . . . . . . . . . . . . . . . . . 5-3

5.4 ANALOG INPUT MODULES (ANI0-8) . . . . . . . . . . . . . . . . . . . . . . 5-5

5.5 ANALOG OUTPUT MODULES (ANO0-3) . . . . . . . . . . . . . . . . . . . . 5-8

5.6 CONTACT CLOSURE INPUT MODULES (CCI0-17) . . . . . . . . . . . . . . . . 5-9

5.7 CONTACT CLOSURE OUTPUT MODULES (CCO0-17) . . . . . . . . . . . . . . 5-10

5.8 EXTERNAL I/O MODULE (TASKS 0-23) . . . . . . . . . . . . . . . . . . . . . 5-11

5.9 CONTROLLER MODULES (CON0-3) . . . . . . . . . . . . . . . . . . . . . . 5-14

5.10 STATUS DISPLAY MODULES (SDT0 AND SDT1) . . . . . . . . . . . . . . . . 5-24

53MC5000 Process Control Station

ii

5.11 PARAMETER DISPLAY MODULES . . . . . . . . . . . . . . . . . . . . . . 5-27

5.12 TREND MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

5.13 TOTALIZER MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

5.14 COMMUNICATION MODULE . . . . . . . . . . . . . . . . . . . . . . . . 5-32

5.15 SYSTEM AND MISCELLANEOUS MODULE . . . . . . . . . . . . . . . . . . 5-33

5.16 CONFIGURATION SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . 5-37

6.0 CS1 - SINGLE LOOP CONTROLLER 6-1

6.1 CS1 - SINGLE LOOP (PID) CONTROLLER . . . . . . . . . . . . . . . . . . . . 6-1

6.2 CS1 CONTROL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.3 CS1 STANDARD DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.4 CS1 DATAPOINT CONFIGURATION SELECTIONS . . . . . . . . . . . . . . . . 6-3

6.5 CS1 SOFT-WIRE LIST MODIFICATIONS . . . . . . . . . . . . . . . . . . . . 6-10

7.0 CS2 - ANALOG BACKUP CONTROLLER 7-1

7.1 CS2 - ANALOG BACKUP CONTROLLER . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 CS2 CONTROL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7.3 CS2 STANDARD DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.4 CS2 DATAPOINT CONFIGURATION SELECTIONS . . . . . . . . . . . . . . . . 7-3

8.0 CS3 - RATIO (PID) CONTROLLER 8-1

8.1 CS3 - RATIO (PID) CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.2 CS3 CONTROL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.3 CS3 STANDARD DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

8.4 CS3 DATAPOINT CONFIGURATION SELECTIONS . . . . . . . . . . . . . . . . 8-3

9.0 CS4 - AUTOMATIC/MANUAL STATION 9-1

9.1 CS4 - AUTOMATIC/MANUAL STATION . . . . . . . . . . . . . . . . . . . . . . 9-1

9.2 CS4 CONTROL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.3 CS4 STANDARD DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

9.4 CS4 DATAPOINT CONFIGURATION SELECTIONS . . . . . . . . . . . . . . . . 9-3

10.0 CS5 - RATIO AUTOMATIC/MANUAL STATION 10-1

10.1 CS5 - RATIO AUTOMATIC/MANUAL STATION . . . . . . . . . . . . . . . . . 10-1

10.2 CS5 CONTROL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

10.3 CS5 STANDARD DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

10.4 CS5 DATAPOINT CONFIGURATION SELECTIONS . . . . . . . . . . . . . . . 10-3

11.0 CS20 - TWO LOOP CONTROLLER 11-1

11.1 CS20 - TWO LOOP CONTROLLER . . . . . . . . . . . . . . . . . . . . . . 11-1

11.2 CS20 CONTROL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

11.3 CS20 STANDARD DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . 11-3

11.4 CS20 DATAPOINT CONFIGURATION SELECTIONS . . . . . . . . . . . . . . 11-3

12.0 CS21 - TWO LOOP CASCADE CONTROLLER 12-1

12.1 CS21 - TWO LOOP CASCADE CONTROLLER . . . . . . . . . . . . . . . . . 12-1

12.2 CS21 CONTROL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

12.3 CS21 STANDARD DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . 12-3

12.4 CS21 DATAPOINT CONFIGURATION SELECTIONS . . . . . . . . . . . . . . 12-3

Contents

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13.0 CS22 - TWO LOOP OVERRIDE CONTROLLER 13-1

13.1 CS22 - TWO LOOP OVERRIDE CONTROLLER . . . . . . . . . . . . . . . . . 13-1

13.2 CS22 CONTROL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

13.3 CS22 STANDARD DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . 13-3

13.4 CS22 DATAPOINT CONFIGURATION SELECTIONS . . . . . . . . . . . . . . . 13-3

14.0 CS40 - DUAL TWO LOOP CASCADE CONTROLLER 14-1

14.1 CS40 - DUAL TWO LOOP CASCADE CONTROLLER . . . . . . . . . . . . . . . 14-1

14.2 CS40 CONTROL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

14.3 CS40 STANDARD DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . 14-3

14.4 CS40 DATAPOINT CONFIGURATION SELECTIONS . . . . . . . . . . . . . . . 14-3

15.0 CS41 - FOUR LOOP CONTROLLER 15-1

15.1 CS41 - FOUR LOOP CONTROLLER . . . . . . . . . . . . . . . . . . . . . . 15-1

15.2 CS41 CONTROL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2

15.3 CS41 STANDARD DISPLAYS . . . . . . . . . . . . . . . . . . . . . . . . 15-4

15.4 CS41 DATAPOINT CONFIGURATION SELECTIONS . . . . . . . . . . . . . . . 15-4

16.0 TUNING PID PARAMETERS 16-1

16.1 PROPORTIONAL ACTION (PB) . . . . . . . . . . . . . . . . . . . . . . . . 16-1

16.2 INTEGRAL ACTION (TR) . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

16.3 DERIVATIVE ACTION (TD) . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2

16.4 CONTROLLER PID LOOP TUNING . . . . . . . . . . . . . . . . . . . . . . 16-2

17.0 EASY-TUNE 17-1

17.1 GENERAL CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . 17-1

17.2 INITIATING THE EASY-TUNE SEQUENCE . . . . . . . . . . . . . . . . . . . 17-1

17.3 EASY-TUNE PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . 17-1

17.4 EASY-TUNE SEQUENCE STATUS . . . . . . . . . . . . . . . . . . . . . . 17-3

17.5 MODIFICATIONS TO TUNING CRITERIA . . . . . . . . . . . . . . . . . . . 17-5

17.6 ABORTING THE EASY-TUNE SEQUENCE . . . . . . . . . . . . . . . . . . . 17-7

17.7 EASY-TUNE SEQUENCE COMPLETION . . . . . . . . . . . . . . . . . . . . 17-7

18.0 MAINTENANCE AND PARTS LIST 18-1

18.1 SERVICE APPROACH . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1

18.2 PARTS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1

18.3 PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-4

18.4 CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-9

18.5 ERROR AND HARDWARE MALFUNCTION MESSAGES . . . . . . . . . . . . 18-10

18.6 RESETTING THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . 18-10

18.7 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . 18-11

APPENDIX A.0 DISCRETE CONTACT OUTPUT CCOs A-1

A.1 CCO EQUIVALENT CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . A-1

A.2 POWER FOR CCO OPERATION . . . . . . . . . . . . . . . . . . . . . . . . A-2

A.3 CCO WITH SOLID STATE RELAY . . . . . . . . . . . . . . . . . . . . . . . A-2

A.4 OPERATING CCOs IN PARALLEL . . . . . . . . . . . . . . . . . . . . . . . A-3

A.5 CASCADING A CCO TO A CCI . . . . . . . . . . . . . . . . . . . . . . . . A-3

53MC5000 Process Control Station

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APPENDIX B.0 COMMUNICATIONS B-1

B.1 STANDARD COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . B-1

B.1.1 CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

B.1.2 PROTOCOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3

B.1.3 MESSAGE TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . B-4

B.1.4 COMMUNICATION TRANSACTION EXAMPLES . . . . . . . . . . . . . B-5

B.1.5 CALCULATING DATA ADDRESSES . . . . . . . . . . . . . . . . . . . B-6

B.1.6 SOFTWARE CHARACTERISTICS . . . . . . . . . . . . . . . . . . . B-8

B.1.7 HARDWARE CHARACTERISTICS . . . . . . . . . . . . . . . . . . . B-8

B.1.8 DATALINK NODE LIST . . . . . . . . . . . . . . . . . . . . . . . . B-8

B.1.9 INITIALIZATION MESSAGE . . . . . . . . . . . . . . . . . . . . . B-10

APPENDIX C.0 REMOTE KEYPAD C-1

C.1 REMOTE KEYPAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

APPENDIX D.0 DATABASE D-1

APPENDIX E.0 FM APPROVALS E-1

Contents

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List of Tables

Table 1-1. 53MC5000 Process Control Station Specifications . . . . . . . . . . . . . . 1-9

Table 1-2. 6 Digital Input/4 Digital Output Option Specifications . . . . . . . . . . . . 1-13

Table 1-3. Dual Relay ITB Specifications . . . . . . . . . . . . . . . . . . . . . . 1-14

Table 1-4. 16 Digital Input/Digital Output Option Board and ITB Specifications . . . . . . 1-14

Table 1-5. OPTO 22 Module Specifications for 16 DI/DO ITB . . . . . . . . . . . . . 1-15

Table 1-6. Single Channel Analog Input Option (ANI8) Specifications . . . . . . . . . . 1-16

Table 1-7. Multichannel Analog Option Specifications . . . . . . . . . . . . . . . . . 1-17

Table 1-8. Group 5B Isolation Module Specifications . . . . . . . . . . . . . . . . . 1-18

Table 1-9. SCADA Board Specifications . . . . . . . . . . . . . . . . . . . . . . 1-22

Table 2-1. Packing Bolt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Table 2-2. Controller Panel Mounting . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Table 2-3. Single +24 V dc Power Source to Controller and ITBs . . . . . . . . . . . . 2-18

Table 2-4. Controller Dedicated 24 V dc Power Source . . . . . . . . . . . . . . . . 2-20

Table 2-5. 110/120 V ac Power Source to Controller . . . . . . . . . . . . . . . . . 2-22

Table 2-6. 220/240 V ac Power Source to Controller . . . . . . . . . . . . . . . . . 2-24

Table 2-7. 220/240 V ac (No Neutral) Power Source to Controller . . . . . . . . . . . . 2-26

Table 3-1. Sampling Time Intervals . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Table 3-2. Entering a Key Password . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Table 3-3. Procedure to Display a Datapoint . . . . . . . . . . . . . . . . . . . . 3-11

Table 3-4. Procedure to Alter a Datapoint . . . . . . . . . . . . . . . . . . . . . . 3-12

Table 3-5. Procedure to Configure in Module Mode . . . . . . . . . . . . . . . . . . 3-14

Table 4-1. Standard Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Table 4-2. Generated Display Lists . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Table 4-3. Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Table 4-4. Faceplate Push Buttons (Operator Functions) . . . . . . . . . . . . . . . . 4-9

Table 4-5. Editing a Parameter Value in Operator/Control Mode . . . . . . . . . . . . 4-25

Table 4-6. Status Indicator Display Modes . . . . . . . . . . . . . . . . . . . . . 4-27

Table 5-1. Ready to Use Control Strategies . . . . . . . . . . . . . . . . . . . . . . 5-1

Table 5-2. Datapoint Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Table 5-3. Database Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Table 5-4. Analog Input Modules (ANI0-8) . . . . . . . . . . . . . . . . . . . . . . 5-5

Table 5-5. Analog Output Modules (ANO0-3) . . . . . . . . . . . . . . . . . . . . . 5-8

Table 5-6. Contact Closure Input Modules (CCI0-17) . . . . . . . . . . . . . . . . . . 5-9

Table 5-7. Contact Closure Output Modules (CCO0-17) . . . . . . . . . . . . . . . . 5-10

Table 5-8. External I/O Module (Tasks 0-23) . . . . . . . . . . . . . . . . . . . . 5-12

Table 5-9. Controller Modules (CON0-3) . . . . . . . . . . . . . . . . . . . . . . 5-14

Table 5-10. Status Display Modules (SDT0 and SDT1) . . . . . . . . . . . . . . . . 5-24

Table 5-11. Parameter Display Modules . . . . . . . . . . . . . . . . . . . . . . 5-27

Table 5-12. Trend Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Table 5-13. Totalizer Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30

Table 5-14. Communication Module . . . . . . . . . . . . . . . . . . . . . . . . 5-32

Table 5-15. System and Miscellaneous Module . . . . . . . . . . . . . . . . . . . 5-33

Table 6-1. CS1 Control Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Table 6-2. CS1 Standard Displays . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Table 6-3. CS1 Single Loop CON0 Datapoints . . . . . . . . . . . . . . . . . . . . . 6-5

Table 6-4. CS1 Soft-Wire List Modifications . . . . . . . . . . . . . . . . . . . . . 6-10

Contents

vi

Table 7-1. CS2 Control Signals . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Table 7-2. CS2 Standard Displays . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Table 7-3. CS2 Analog Backup Controller Datapoints . . . . . . . . . . . . . . . . . 7-5

Table 8-1. CS3 Control Signals . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

Table 8-2. CS3 Standard Displays . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Table 8-3. CS3 Ratio Controller Datapoints . . . . . . . . . . . . . . . . . . . . . 8-5

Table 9-1. CS4 Control Signals . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

Table 9-2. CS4 Standard Displays . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

Table 9-3. CS4 Automatic/Manual Station Datapoints . . . . . . . . . . . . . . . . . 9-5

Table 10-1. CS5 Control Signals . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

Table 10-2. CS5 Standard Displays . . . . . . . . . . . . . . . . . . . . . . . . 10-3

Table 10-3. CS5 Ratio Automatic/Manual Station Datapoints . . . . . . . . . . . . . . 10-5

Table 11-1. CS20 Control Signals . . . . . . . . . . . . . . . . . . . . . . . . . 11-2

Table 11-2. CS20 Standard Displays . . . . . . . . . . . . . . . . . . . . . . . . 11-3

Table 11-3. CS20 Two Loop Controller Datapoints . . . . . . . . . . . . . . . . . . 11-6

Table 12-1. CS21 Control Signals . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

Table 12-2. CS21 Standard Displays . . . . . . . . . . . . . . . . . . . . . . . . 12-3

Table 12-3. CS21 Two Loop Cascade Controller Datapoints . . . . . . . . . . . . . . 12-6

Table 13-1. CS22 Control Signals . . . . . . . . . . . . . . . . . . . . . . . . . 13-2

Table 13-2. CS22 Standard Displays . . . . . . . . . . . . . . . . . . . . . . . . 13-3

Table 13-3. CS22 Two Loop Override Controller Datapoints . . . . . . . . . . . . . . 13-6

Table 14-1. CS40 Control Signals . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

Table 14-2. CS40 Standard Displays . . . . . . . . . . . . . . . . . . . . . . . . 14-3

Table 14-3. CS40 Dual Two Loop Cascade Controller Datapoints . . . . . . . . . . . . 14-7

Table 15-1. CS41 Control Signals . . . . . . . . . . . . . . . . . . . . . . . . . 15-2

Table 15-2. CS41 Standard Displays . . . . . . . . . . . . . . . . . . . . . . . . 15-4

Table 15-3. CS41 Four Loop Controller Datapoints . . . . . . . . . . . . . . . . . . 15-9

Table 16-1. Summary Information for Tuning Parameters . . . . . . . . . . . . . . . 16-2

Table 16-2. Trial and Error Tuning Method . . . . . . . . . . . . . . . . . . . . . 16-2

Table 16-3. Proportional Cycle Method . . . . . . . . . . . . . . . . . . . . . . . 16-3

Table 16-4. Step Response Method (Ziegler-Nichols) . . . . . . . . . . . . . . . . . 16-3

Table 17-1. Summary Information for Tuning Parameters . . . . . . . . . . . . . . . 17-1

Table 17-2. EASY-TUNE Parameters . . . . . . . . . . . . . . . . . . . . . . . . 17-2

Table 17-3 Normal Successful Status Display . . . . . . . . . . . . . . . . . . . . 17-3

Table 17-4. EASY-TUNE Unsuccessful Status Display . . . . . . . . . . . . . . . . 17-3

Table 17-5. EASY-TUNE Equations . . . . . . . . . . . . . . . . . . . . . . . . 17-5

Table 18-1. Parts Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2

Table 18-2. Controller Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . 18-4

Table 18-3. Related Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-7

Table 18-4. Isolated Discrete I/O Modules for the 16DI/DO ITB . . . . . . . . . . . . . 18-9

53MC5000 Process Control Station

vii

Table B-1. Communication Module . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Table B-2. Message Field Definitions . . . . . . . . . . . . . . . . . . . . . . . . B-3

Table B-3. Controller Memory Address Scheme . . . . . . . . . . . . . . . . . . . . B-6

Table B-4. Node List Assignment Codes . . . . . . . . . . . . . . . . . . . . . . . B-8

Table B-5. Network D Node List . . . . . . . . . . . . . . . . . . . . . . . . . . . B-9

Table D-1. Datapoint Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Table D-2. Analog Input Modules . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Table D-3. Analog Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Table D-4. Contact Input Modules . . . . . . . . . . . . . . . . . . . . . . . . . . D-2

Table D-5. Contact Output Modules . . . . . . . . . . . . . . . . . . . . . . . . . D-3

Table D-6. External I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3

Table D-7. Controller (CON) Modules . . . . . . . . . . . . . . . . . . . . . . . . D-4

Table D-8. Status Display Modules . . . . . . . . . . . . . . . . . . . . . . . . . D-6

Table D-9. Parameter Display Modules . . . . . . . . . . . . . . . . . . . . . . . . D-7

Table D-10. Trend Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8

Table D-11. Totalizer Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-8

Table D-12. Communication Module . . . . . . . . . . . . . . . . . . . . . . . . . D-8

Table D-13. System and Miscellaneous Module . . . . . . . . . . . . . . . . . . . . D-9

Table D-14. Database - L Type Datapoints . . . . . . . . . . . . . . . . . . . . . D-10

Table D-15. Database - B Type Datapoints . . . . . . . . . . . . . . . . . . . . . D-17

Table D-16. Database - C Type Datapoints . . . . . . . . . . . . . . . . . . . . . D-22

Table D-17. Database - H Type Datapoints . . . . . . . . . . . . . . . . . . . . . D-29

Table D-18. Database - A Type Datapoints . . . . . . . . . . . . . . . . . . . . . D-31

Table D-19. Database - F Type Datapoints . . . . . . . . . . . . . . . . . . . . . D-37

Contents

viii

List of Figures

Figure 1-1. Typical Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Figure 1-2. Information Layout of Book . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Figure 2-1. Packing Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Figure 2-2. Outline Dimensions and Panel Cut-Out Requirements . . . . . . . . . . . . 2-3

Figure 2-3. Single or Multiple Panel Mounting . . . . . . . . . . . . . . . . . . . . . 2-4

Figure 2-4. Bracket Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Figure 2-5. Intercase Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Figure 2-6. ITB Snap-Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Figure 2-7. Controller Rear Terminal ITB Connectors . . . . . . . . . . . . . . . . . . 2-8

Figure 2-8. Potential ITB Complement to Controller with Standard Rear Terminal Board . . . 2-9

Figure 2-9. Potential ITB Complement to Controller with Cord Set Connector Board . . . . 2-10

Figure 2-10. Removable Plug-In Connectors from Standard Rear Terminal Board . . . . . 2-11

Figure 2-11. Power Connections Overview . . . . . . . . . . . . . . . . . . . . . 2-13

Figure 2-12. Assigned Power Input Terminals . . . . . . . . . . . . . . . . . . . . 2-14

Figure 2-13. Single +24 V dc Power Source to Controller and ITBs . . . . . . . . . . . 2-18

Figure 2-14. Wiring Example for Single +24 V dc Power Supply to Controller

and ITBs (Negative Ground System) . . . . . . . . . . . . . . . . . . 2-19

Figure 2-15. Controller Dedicated 24 V dc Power Source . . . . . . . . . . . . . . . 2-20

Figure 2-16. Wiring Example of Separate 24 V dc Power Sources for Controller

and ITBs (Controller Positive, Negative, or Floating Ground) . . . . . . . . 2-21

Figure 2-17. 110/120 V ac Power Source to Controller . . . . . . . . . . . . . . . . 2-22

Figure 2-18. 110/120 V ac Power Wiring Example . . . . . . . . . . . . . . . . . . 2-23

Figure 2-19. 220/240 V ac Power Source to Controller . . . . . . . . . . . . . . . . 2-24

Figure 2-20. 220/240 V ac Power Wiring Example . . . . . . . . . . . . . . . . . . 2-25

Figure 2-21. 220/240 V ac (No Neutral) Power Source to Controller . . . . . . . . . . . 2-26

Figure 2-22. 220/240 V ac (No Neutral) Power Wiring Example . . . . . . . . . . . . 2-27

Figure 2-23. Rear Terminal Board Resistors R1 and R2 . . . . . . . . . . . . . . . . 2-28

Figure 2-24. Controller Standard Rear Terminal Board Signal Connections . . . . . . . . 2-29

Figure 2-25. Current Input Signals to ANI0&1 (Transmitters Have Power Source) . . . . . 2-30

Figure 2-26. Current Input Signals to ANI0&1 (Transmitters Receive +24 V dc from Controller) 2-30

Figure 2-27. Current Input Signals to ANI2&3 (Transmitters Have Power Source) . . . . . 2-31

Figure 2-28. Current Input Signals to ANI2&3 (Transmitters Receive +24 V dc from Controller) 2-31

Figure 2-29. ANI, ANO, CCI, and CCO Graphical Illustrations . . . . . . . . . . . . . 2-33

Figure 2-30. Input Signals to ANI8 at TB3 . . . . . . . . . . . . . . . . . . . . . 2-34

Figure 2-31. SCADA Adapter Connections . . . . . . . . . . . . . . . . . . . . . 2-37

Figure 2-32. Comm ITB Datalink Connections . . . . . . . . . . . . . . . . . . . . 2-38

Figure 2-33. Analog ITB Connections . . . . . . . . . . . . . . . . . . . . . . . 2-39

Figure 2-34. Cord Set ITB Connections . . . . . . . . . . . . . . . . . . . . . . . 2-40

Figure 2-35. 6DI/4DO ITB Connections . . . . . . . . . . . . . . . . . . . . . . 2-41

Figure 2-36. 16DI/DO ITB Connections . . . . . . . . . . . . . . . . . . . . . . . 2-42

Figure 2-37. Datalink Installation to Controllers with Cord Set Option . . . . . . . . . . 2-44

Figure 3-1. Process Control Station Illustrated Overview . . . . . . . . . . . . . . . . 3-2

Figure 3-2. Engineer Mode Command Hierarchy . . . . . . . . . . . . . . . . . . . . 3-8

Figure 3-3. Engineer Mode Key Password Prompts . . . . . . . . . . . . . . . . . . 3-10

Figure 3-4. Displaying a Datapoint . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Figure 3-5. Altering a Datapoint . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Figure 3-6. Front Panel Configuration Port Connections . . . . . . . . . . . . . . . . 3-15

Contents

ix

Figure 4-1. Display 1 - Alarm Summary . . . . . . . . . . . . . . . . . . . . . . . 4-5

Figure 4-2. Display 2 - System Status . . . . . . . . . . . . . . . . . . . . . . . 4-6

Figure 4-3. Point Displays 3, 4, 5, and 6 (CDM = 0, Standard PID) . . . . . . . . . . . 4-11

Figure 4-4. Point Display 3 (CDM = 1, Indicator) . . . . . . . . . . . . . . . . . . . 4-16

Figure 4-5. Point Display 3 (CDM = 2, Manual Loader) . . . . . . . . . . . . . . . . 4-17

Figure 4-6. Point Display 3 (CDM = 3, Ratio Controller) . . . . . . . . . . . . . . . . 4-18

Figure 4-7. Point Display 3 (CDM = 4, Auto/Manual Station) . . . . . . . . . . . . . . 4-19

Figure 4-8. Point Display 3 (CDM = 5, Ratio Auto/Manual Station) . . . . . . . . . . . . 4-20

Figure 4-9. Two Loop Point Displays 7 and 8 . . . . . . . . . . . . . . . . . . . . 4-21

Figure 4-10. Point Displays 9 - 12, Single Loop with Horizontal Trend . . . . . . . . . . 4-23

Figure 4-11. Displays 13 to 20 - Parameter Module Displays . . . . . . . . . . . . . . 4-26

Figure 4-12. Displays 21 and 22 - Discrete Status Displays . . . . . . . . . . . . . . 4-28

Figure 4-13. Displays 23 to 30 - Totalizer Displays . . . . . . . . . . . . . . . . . . 4-29

Figure 4-14. Display 31- Locator Grid . . . . . . . . . . . . . . . . . . . . . . . . 4-30

Figure 4-15. Point Display 32 - Four Loop Display . . . . . . . . . . . . . . . . . . 4-31

Figure 5-1. Database Modules . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Figure 5-2. Configuration Summary . . . . . . . . . . . . . . . . . . . . . . . . 5-37

Figure 6-1. Typical CS1 Single Loop Controller Application . . . . . . . . . . . . . . 6-1

Figure 6-2. CS1 Single Loop CON0 Datapoints . . . . . . . . . . . . . . . . . . . 6-4

Figure 7-1. Typical CS2 Analog Backup Controller Application . . . . . . . . . . . . . 7-1

Figure 7-2. CCO Output Diverter Circuit . . . . . . . . . . . . . . . . . . . . . . . 7-2

Figure 7-3. CS2 Analog Backup Controller Datapoints . . . . . . . . . . . . . . . . . 7-4

Figure 8-1. Typical CS3 Ratio Controller Application . . . . . . . . . . . . . . . . . 8-1

Figure 8-2. CS3 Ratio Controller Datapoints . . . . . . . . . . . . . . . . . . . . . 8-4

Figure 9-1. Typical CS4 Automatic/Manual Station Application . . . . . . . . . . . . . 9-1

Figure 9-2. CS4 Automatic/Manual Station Datapoints . . . . . . . . . . . . . . . . . 9-4

Figure 10-1. Typical CS5 Ratio Automatic/Manual Station Application . . . . . . . . . . 10-1

Figure 10-2. CS5 Ratio Automatic/Manual Station Datapoints . . . . . . . . . . . . . 10-4

Figure 11-1. Typical CS20 Two Loop Controller Application . . . . . . . . . . . . . . 11-1

Figure 11-2. CS20 Two Loop Controller Datapoints . . . . . . . . . . . . . . . . . . 11-4

Figure 12-1. Typical CS21 Two Loop Cascade Controller Application . . . . . . . . . . 12-1

Figure 12-2. CS21 Two Loop Cascade Controller Datapoints . . . . . . . . . . . . . . 12-4

Figure 13-1. Typical CS22 Two Loop Override Controller Application . . . . . . . . . . 13-1

Figure 13-2. CS22 Two Loop Override Controller Datapoints . . . . . . . . . . . . . . 13-4

Figure 14-1. Typical CS40 Dual Two Loop Cascade Controller Application . . . . . . . . 14-1

Figure 14-2. CS40 Dual Two Loop Cascade Controller Datapoints . . . . . . . . . . . . 14-4

Figure 15-1. Typical CS41 Four Loop Controller Application . . . . . . . . . . . . . . 15-1

Figure 15-2. CS41 Four Loop Controller Datapoints . . . . . . . . . . . . . . . . . . 15-5

Figure 16-1. Typical Step Response Record . . . . . . . . . . . . . . . . . . . . . 16-4

Figure 17-1. EASY-TUNE Sequence Diagram . . . . . . . . . . . . . . . . . . . . 17-4

Figure 17-2. Process Step Response Curve . . . . . . . . . . . . . . . . . . . . . 17-6

53MC5000 Process Control Station

x

Figure 18-1. Illustrated Parts Breakdown . . . . . . . . . . . . . . . . . . . . . . 18-5

Figure 18-2. Hand Held Configurer and Valve Holder Pin Assignments . . . . . . . . . 18-12

Figure 18-3. Cord Set Connector Pin Assignments . . . . . . . . . . . . . . . . . . 18-13

Figure 18-4. Cord Set ITB Schematic . . . . . . . . . . . . . . . . . . . . . . . 18-14

Figure 18-5. Dual Relay ITB Schematic . . . . . . . . . . . . . . . . . . . . . . 18-15

Figure 18-6. 6 Digital Input/4 Digital Output ITB Schematic . . . . . . . . . . . . . . 18-16

Figure 18-7. 16 Digital Input/ Digital Output ITB Schematic . . . . . . . . . . . . . . 18-17

Figure 18-8. Multichannel Analog ITB Schematic . . . . . . . . . . . . . . . . . . . 18-18

Figure 18-9. Communication ITB Schematic . . . . . . . . . . . . . . . . . . . . . 18-19

Figure 18-10. 6 Digital Input/4 Digital Output (6DI/4DO) PCB Option . . . . . . . . . . 18-20

Figure 18-11. 16 Digital Input/ Digital Output (16DI/DO) PCB Option . . . . . . . . . . 18-21

Figure 18-12. Single Channel Analog Input PCB Option . . . . . . . . . . . . . . . . 18-22

Figure 18-13. Multi I/O Analog PCB Option . . . . . . . . . . . . . . . . . . . . . 18-23

Figure 18-14. High Speed Communications PCB Option . . . . . . . . . . . . . . . 18-24

Figure A-1. CCO Circuit and its Equivalent . . . . . . . . . . . . . . . . . . . . . . A-1

Figure A-2. Power For CCO Operation . . . . . . . . . . . . . . . . . . . . . . . . A-2

Figure A-3. CCO with Solid State Relay . . . . . . . . . . . . . . . . . . . . . . . A-2

Figure A-4.. Operating CCOs in Parallel . . . . . . . . . . . . . . . . . . . . . . . A-3

Figure A-5. Cascading a CCO to a CCI . . . . . . . . . . . . . . . . . . . . . . . . A-3

Figure C-1. Remote Keypad Wiring Schematic . . . . . . . . . . . . . . . . . . . . C-1

Contents

xi

READ FIRST

WARNING

INSTRUCTION MANUALS

Do not install, maintain, or operate this equipment without reading,

understanding and following the proper ABB Automation instructions

and manuals, otherwise injury or damage may result.

RETURN OF EQUIPMENT

All Flowmeters and/or Signal Converters being returned to ABB

Automation for repair must be free of any hazardous materials (acids,

alkalis, solvents, etc). A Material Safety Data Sheet (MSDS) for all

process liquids must accompany returned equipment. Contact ABB

Automation for authorization prior to returning equipment.

Read these instructions before starting installation;

save these instructions for future reference.

DOCUMENTATION SUBMISSIONS

Send photocopies of pages with marked corrections or comments to:

ABB Automation

Instrumentation Division

Department 261/A2

125 E. County Line Road

Warminster, PA 18974-4995

Please include a reference to the Publication Number (PN...) or

equipment Model Number when submitting corrections or comments.

Contacting ABB Automation

Should assistance be required with any ABB Automation product,

contact the following:

Telephone:

ABB Instrumentation Technical Support Center

1 (800) 697-9619

E-Mail:

[email protected]

Read First

I

1.0 INTRODUCTION

1.1 PRODUCT OVERVIEW

The ABB Automation 53MC5000 Process Control Station is a versatile controller that is available in

one, two, and four loop versions. It can function as a stand-alone unit or as part of a distributed

controller network. The controller’s functionality is determined by the Function Index (FIX), which is

used to select a broad range of resident control strategies that are common to industrial process

applications. Each version of the controller comes ready to install as a Single Loop Controller, Two

Loop Controller, or Four Loop Controller.

It is not necessary to have any programming knowledge or to analyze complex switch dia-

grams that represent the internal operation of the controller to implement a control strategy.

After the appropriate control strategy (CS) is selected, it is tailored to the user’s specific process

application requirements by entering process specific information into datapoint locations with the

keypad push buttons. For many datapoints, entries are simplified index values that represent

operating characteristics.

Every controller provides the capability to customize the existing Control Strategies or create new

ones using Flexible Control Strategy wire lists. Also included with every controller are Datalink

network capabilities; a front panel RS-232 configuration port; EASY-TUNE



, the instrument self

tuning algorithm; four analog inputs; analog input digital filtering; analog input square root extraction;

two contact closure inputs; two analog outputs; and two contact closure outputs. The standard

features are summarized in the table that follows:

CS Application or Feature 1 Loop 2 Loops 4 Loops

CS1

Single Loop (PID*) Controller

♦

**

••

CS2

Analog Backup (PID) Controller

•• •

CS3

Ratio (PID) Controller

•• •

CS4

Automatic/Manual Station

•• •

CS5

Ratio Automatic/Manual Station

•• •

CS20

Two Loop (PID) Controller

♦

**

•

CS21

Two Loop (PID) Cascade Controller

••

CS22

Two Loop (PID) Override Controller

••

CS40

Dual Two Loop (PID) Cascade Controller

•

CS41

Four Loop (PID) Controller

♦

**

RS-485 Datalink Network Capabilities

•• •

Front Panel RS-232 Configuration Port

•• •

EASY-TUNE

•••

Four Analog Inputs (AI0-3)

•• •

Analog Input Digital Filtering

•• •

Analog Input Square Root Extraction

•• •

Two Contact Closure Inputs (DI0&1)

•• •

Two Analog Outputs (AO0&1)

•• •

Two Contact Closure Outputs (DO0&1)

•• •

* Proportional, Integral, and Derivative control action, one PID algorithm per loop.

**

♦

= Ready to use as described in Sections 6 (CS1), 11 (CS20), and 15 (CS41).

Section 1. Introduction

1-1

If the controller has

extended functionality

(optional), additional performance capabilities are

included. The extended functionalities include

F

lexible

C

ontrol

I

nterconnection

M

odules (F-CIM) and

F

lexible

TRAN

slator language (F-TRAN). Both can be used to create more personalized control

strategies (F-TRAN can also be used to create personalized displays).

The hardware architecture of the controller allows for a diverse assortment of upgrades to meet the

unique needs of most process applications. The upgrades are implemented using an optional

Expansion board and associated option cards within the controller, and Interconnecting Terminal

Boards (ITBs) that are mounted external to the controller. A controller that contains an Expansion

Board is called

expansion ready

(model number 53MC5

♦♦♦

A2

♦

B

etc., where

♦

are other control-

ler selectable items). The following table lists the 53MC5000 Process Control Station hardware

expansion capabilities described in this book.

Expansion Board

Option Card

Required ITB Function

Single Channel Analog

Input Option

None Adds Analog Input 8 (AI8) which accepts one of

the Group 5 Analog Device Modules (e.g,

Isolated Linearized Thermocouple) that are

described in detail in specifications Table 1-8.

Multi I/O Analog PCB

Option

Analog ITB Adds Analog Inputs 4 through 7 (AI4-7), and

Analog Outputs 2 and 3 (AO2&3). Capabilities

for Frequency Input (AI4-7) and Pulsed Input

(AI5-7) are supported. This option also

supports the AI8 capabilities above.

6 Digital Input/4 Digital

Output (6DI/4DO) Option

6 Digital Input/4

Digital Output ITB

This option provides six additional Contact

Closure Inputs (DI2-7) and four additional

Contact Closure Outputs (DO2-5).

16 Digital Input/Digital

Output (16DI/DO) PCB

Option

16 Digital Input/

Digital Output

This option provides 16 additional Contact

Closures that can be a mix of inputs and outputs

from DI2-17 and DO2-17. The ITB is populated

with a variety of OPTO 22 or equivalent

modules. The OPTO 22 modules are described

in specifications Table 1-5.

High Speed

Communications PCB

Option

(MicroLink)

None The Expansion Board can accept two of these

option cards. Each one provides controller

access to a MicroLink peer-to-peer

communications network.

HART* Modem Option

Card and/or one or two

Auxiliary Processor

Boards (APBs)

HART ITB and/or

HART Modem ITBs

(two maximum)

Provides the capability to communicate with

HART instruments. See Publication Number

24526, IB 53MC9014, 53MC5000 HART



Interface.

One or two Auxiliary

Processor Boards

(APBs)

RS-232/485 ITB Provides controller-to-PLC communication

capabilities for Allen-Bradley, OPTO22, Modbus

RTU, Siemens S5, and Koyo. It also provides a

printer interface for outputting datalogs. See

Publication Number 24627, IB 53MC9015,

53MC5000 PLC and Printer Interface.

*

H

ighway

A

ddressable

R

emote

T

ransducer.

53MC5000 Process Control Station

1-2

The ABB Automation 53MC5000 Process Control Station provides a variety of standard displays to

give a multiperspective presentation of the controlled process. Unlike many other controllers that

have a singular bar graph display, the 53MC5000 Process Control Station has trend, parameter,

status, totalizer, and multi-bar graph displays (2 and 4 loop versions). A display locator grid identifies

the current display suite. User defined displays can be created with F-TRAN (requires extended

functionality). Typical

low-resolution

53MC5000 Process Control Station displays are shown in

Figure 1-1.

Single Loop

Display

Single Loop with

Horizontal Trend

Display

Parameter

Display

Status Display Four Loop

Display

Two Loop

Display

Figure 1-1. Typical Displays

Section 1. Introduction

1-3

1.2 SCOPE OF BOOK

The information layout of the book is illustrated in Figure 1-2 and described as follows:

•

Section 1, Introduction -

This section contains product overview information, a product

model number breakdown, product specifications, and a list of related documentation.

•

Section 2, Installation -

This section provides information to physically mount the controller

in a panel and information to mount the ITBs. It also provides power and signal connection

information for the controller and ITBs. Detailed controller power wiring example diagrams

are provided for a +24 V dc power source (negative ground), 24 V dc power source (control-

ler positive, negative, or floating ground), 110/120 V ac power source, 220/240 V ac power

source, and 220 (208)/240 V ac (no neutral) power source.

•

Section 3, Product Description -

This section provides a physical description of the prod-

uct. It explains the SCAN index sampling time intervals and sampling time intervals for

other various product functions such as trending and totalizing. It describes the function in-

dexes, database, and front display keypad functions. Also provided in this section are in-

structions to use the Hand Held Configurer (HHC) to configure the controller database

datapoints instead of using the controller keypad push buttons.

•

Section 4, Operator Displays -

This section describes the standard displays of the control-

ler. All of the displays described are available on every controller; however, some displays

may not be active, dependent on the controller version purchased (e.g., single loop, 2 loop,

or 4 loop versions).

•

Section 5, Configuration Parameters -

This section describes the datapoint types, pro-

vides a summary illustration of the controller database modules, and provides a definition of

each datapoint in the database modules.

•

Sections 6 through 15, Control Strategy 1 (CS1) - Control Strategy 41 (CS41) -

Each sec-

tion provides a brief description and illustration of a predefined control strategy application.

The applicable external control signals for each control strategy are defined and the control

strategy standard displays are listed. Also provided is a datapoint configuration illustration

followed by the specific datapoint definitions for each control strategy.

•

Section 16, Tuning PID Parameters -

This section provides three methods to tune the in-

strument: Trial and Error, Proportional Cycle, and Step Response (Ziegler-Nichols).

•

Section 17, EASY-TUNE -

This section provides information to initiate EASY-TUNE and to

modify the tuning parameters. EASY-TUNE is the controller self-tuning algorithm used to

help determine the optimal values for the Proportional Band, Integral, and Derivative control

action datapoints. This section also provides definitions of the tuning sequence status pa-

rameters.

•

Section 18, Maintenance and Parts List -

This section provides a parts replacement proce-

dure, an illustrated parts breakdown of the controller, a parts list, calibration information for

the analog input/output zero and span settings, hardware malfunction messages, a hardware

reset procedure, Hand Held Configurer (HHC) and Valve Holder pin assignments, schemat-

ics of the ITBs, and illustrations with descriptive summaries of the Expansion Board Option

Cards.

53MC5000 Process Control Station

1-4

•

Appendix A, Discrete Contact Output DOs -

This appendix illustrates various circuit lay-

outs for the Discrete Contact Outputs (DOs).

•

Appendix B, Communications -

This appendix provides reference information for binary se-

rial communication. Both, the RS-232 front port communications and the standard Datalink

communications are described.

•

Appendix C, Remote Keypad -

This appendix provides information to use the 6DI/4DO ITB

for remote keypad operation. A remote keypad wiring schematic is also provided.

•

Appendix D, Database -

This appendix lists all of the database parameters (datapoints).

Section 1. Introduction

1-5

2. Installation

4. Operator

Displays

16. Tuning PID

Parameters

6. CS1 - Single

Loop PID Controller

7. CS2 - Analog

Backup Controller

9. CS4 - Automatic/

Manual Station

10. CS5 - Ratio

Automatic/ Manual

Station

11. CS20 - Two

Loop Controller

12. CS21 - Two

Loop Cascade

Controller

13. CS22 - Two

Loop Override

Controller

14. CS40 - Dual

Two Loop Cascade

Controller

15. CS41 - Four

Loop Controller

53MC5000 PROCESS CONTROL STATION

8. CS3 - Ratio

Controller

17. EASY-TUNE

5. Configuration

Parameters

3. Product

Description

1. Introduction

Reference Information

18. Maintenance

and Parts List

A. Discrete

Contact Outputs

B. Communications

C. Remote Keypad

D. Database

HOW TO READ THIS BOOK

. . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

.

ALTERNATE PATH INDICATED BY DOTS ( . . . )

53MC5000 Process Control Station

Figure 1-2. Information Layout of Book

1-6

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ABB ControlIT 53MC5000 User manual

ABB ControlIT 53MC5000 User manual

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