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  3. ControlIT 53MC5000

ABB ControlIT 53MC5000 User manual

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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
ï››
F-TRAN
ï››
EASY-TUNE
ï››
MICRO-DCI
ï››
MicroLink
ï››
SUPERVISOR-PC
ï››
Flexible Control
Strategy
ï››
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.
Copyright 2000 ABB Automation Inc. [December 2000]
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
i
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
iv
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
ï››
, 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
ï››
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
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.
ALTERNATE PATH INDICATED BY DOTS ( . . . )
53MC5000 Process Control Station
Figure 1-2. Information Layout of Book
1-6
/