ABB C505, User Manual

Page 1: ...ControlIT 1 2 DIN Advanced Process Controller C505 User Guide IM C505_6 ...

Page 2: ...noted 1 The relevant sections of these instructions must be read carefully before proceeding 2 Warning labels on containers and packages must be observed 3 Installation operation maintenance and servicing must only be carried out by suitably trained personnel and in accordance with the information given 4 Normal safety precautions must be taken to avoid the possibility of an accident occurring whe...

Page 3: ...le inputs and outputs default to the settings shown in Table B on the rear fold out C If you are not using 4 to 20mA inputs then select Level 7 using the upper and keys and set up Analog Inputs I P1 to I P3 to suit your process see Section 4 3 D Controller templates only Select Level 2 using the upper and keys and set the tune parameters Analog or Motorized Valve Control set the Proportional Integ...

Page 4: ...the template number and the output configuration details Your COMMANDER 500 is now ready for operation Step 1 Application Template and Output Configuration Choose the Template which best suits your application from the list in Table A located on the rear fold out Choose the Control Output Type required from the list of options in Table B on the rear foldout Step 2 Electrical Connections Using the ...

Page 5: ...rs Ratio Station Controller Set Up Mode Levels 2 to 5 Level 2 Tuning Level 3 Set Points Level 4 Alarm Trip Points Level 5 Valve Setup 8 Configuration Mode Levels 6 to E Level 6 Basic Configuration Level 7 Input Configuration Level 8 Alarm Configuration Level 9 Set Point Configuration Level A Control Configuration Level B Operator Configuration Level C Output Configuration Level D Serial Communicat...

Page 6: ... Level 9 Set Point Configuration 60 4 6 Level A Control Configuration 63 4 7 Level B Operator Configuration 68 4 8 Level C Output Assignment 70 4 9 Level D Serial Communications 76 4 10 Level E Calibration 77 Section Page 5 INSTALLATION 80 5 1 Mechanical Installation 80 5 2 Electrical Installation 85 5 3 Relays 87 5 4 Digital Output 87 5 5 Control or Retransmission Analog Output 87 5 6 Motorized V...

Page 7: ... Introduction The COMMANDER 500 front panel displays function keys and LED indicators are shown in Fig 1 1 Function Keys Auto manual Raise Local Remote L L R Parameter Advance Alarm Acknowledge Lower Up Down 100 80 60 40 20 0 M OP1 OP2 FF MST SLV COMMANDER 500 58 8 62 4 15 0 L L R R ...

Page 8: ...vel Note This key also stores any changes made in the previous frame LEV2 tUnE CYCl 5 0 Frame 2 Frame 1 top of level B Up and Down Keys and bIAS 50 0 51 0 49 0 LEV1 OPEr LEV2 tUnE move between frames within a Setup or Configuration level Any changes made on the current frame are stored when the next frame is selected LEV2 tUnE CYCl 5 0 Frame 2 Frame 1 top of level Press and hold LEVx 1001 1002 100...

Page 9: ...ive the first enabled alarm is displayed 1 The lower display shows alarm status ACt Alarm active and unacknowledged ACK Alarm active and acknowledged CLr Cleared or Inactive alarm LAt Unacknowledged latched alarm 2 Note The time of the power failure PF t is shown in the set point display High Process PV High Output Low Process PV Low Output High Latch PV Power Failure Time Low Latch PV Maths Block...

Page 10: ...l flash to indicate local set point ratio still selected Process variable and local set point ratio displayed on red and green displays 1 2 Remote set point ratio selected 3 Remote selection aborted R 450 2 350 0 70 When the MST indicator see Fig 1 3 is lit the key can be used to switch between the Master local and remote set points 1 2 L L R 450 2 350 0 70 When the SLV indicator see Fig 1 3 is li...

Page 11: ...or or Setup levels to the first page of the Configuration level LEVA CntL LEV1 OPEr LEV6 APPL Press simultaneously and hold for 3 seconds Press and hold to move from the Operator Level to the Security Code Frame and then to other levels Tune Level See Section 2 13 3 Set Up Level See Fig 3 1 Configuration Level See Fig 4 1 COdE 0 Note This Short cut key operates only when the configuration password...

Page 12: ... alarms active Local set point in use ON All active alarms acknowledged Master controller parameters displayed Slave controller parameters displayed Remote or Cascade set point in use Flashing One or more alarms active and unacknowledged A Upper Display B Lower Display 450 2 350 0 150 M OP1 OP2 FF 150 R MST SLV 450 2 350 0 MST SLV R 1 4 Character Set Fig 1 4 A B C D E F G H I J K L M N O P R S T U...

Page 13: ...n sensor is faulty or has not been fitted correctly Remote Set Point or External Ratio Failed Remote set point input value is over or under range Only appears if the remote set point or external ratio is displayed or in use Valve Sticking Motorized valve not moving at the speed expected Valve may be sticking Position Feedback Fail Input value is over or under range Only appears if output type set ...

Page 14: ... D 1 P S L e u l a V 1 t n i o P t e S l a c o L 3 i d 3 t u p n I l a t i g i D 2 P S L e u l a V 2 t n i o P t e S l a c o L 4 i d 4 t u p n I l a t i g i D 3 P S L e u l a V 3 t n i o P t e S l a c o L 1 o a 1 t u p t u O g o l a n A 4 P S L e u l a V 4 t n i o P t e S l a c o L 2 o a 2 t u p t u O g o l a n A t P S C e u l a V t n i o P t e S l o r t n o C 1 o d 1 t u p t u O l a t i g i D t P...

Page 15: ...on Analog backup station Indicator manual loader station Single loop with feedforward control Cascade control Cascade with feedforward Ratio controller Ratio station Note Only the frames relevant to the selected template are displayed see Section 4 In addition frames used to view the Control Efficiency Monitor and operate motorized valve and heat cool output types are also described 2 OPERATOR LEV...

Page 16: ...asic feedback control system using three term PID or on off control with either a local set point template 1 or remote set point template 2 PID Control Loop PID O P CSPt I P2 PV I P1 Manual Output OP1 Remote Set Point Input Process Variable Input 1 Template 2 Only 1 LSPt I P2 x rAtO bIAS RSPt L L R Local Set Point Control Output ...

Page 17: ...60s cycle time e g 25 15s on 45s off Remote Set Point Ratio 0 001 to 9 999 Remote set point value ratio x remote set point input bias Remote Set Point Bias In engineering units Return to top of page 1 With the Ramping Set Point function enabled see Section 3 3 Set Points Ramp Rate the bargraph shows the actual ramping set point value and the digital display shows the target set point value 2 Only ...

Page 18: ...nalog output follows the master controller s output value A fault in the master system can be identified either by detecting a low signal on the master output template 3 or via a digital signal template 4 When a fault is detected the COMMANDER 500 goes into manual mode with its output either set to the last valid master output value or to a configured output value see Section 4 6 Control Configura...

Page 19: ...uto Manual switch is overridden by the digital input signal 2 Template 3 only see Section 4 2 Basic Configuration Template Application 3 Template 4 only see Section 4 2 Basic Configuration Template Application Auto Mode Process Variable Master Output I P2 Control Output Master Output Master Output 0 to 100 Manual Mode Control Output under COMMANDER 500 control 0 to 100 2 OPERATOR LEVEL 2 3 Auto Ma...

Page 20: ...0 s current output follows the master controller s output value A fault in the master system can be identified either by detecting a low signal on the master output template 5 or via a digital signal template 6 When a fault is detected the COMMANDER 500 switches into local control mode and the process is controlled by the PID output of the COMMANDER 500 The COMMANDER 500 PID algorithm tracks the m...

Page 21: ...de only 2 OPERATOR LEVEL 2 4 Analog Backup Templates 5 and 6 1 Template 5 only see Section 4 2 Basic Configuration Template Application 2 Template 6 only see Section 4 2 Basic Configuration Template Application 55 0 50 0 Set Point Process Variable 70 OP1 R 55 5 50 0 50 OP1 Set Point Process Variable or Restored Master Output Digital Input Inactive or 1 2 or Low Master Output Value Digital Input Ac...

Page 22: ...nalog output the lower display indicates its value which can be adjusted by the user 1 Only displayed if template 8 selected see Section 4 2 Basic Configuration Template Application 2 Only displayed if control output type is analog output is assigned to Analog Output 1 Process Variable PV1 Process Variable PV2 Output Value 10 to 110 55 0 50 0 Process Variable PV2 Process Variable PV1 50 OP1 1 1 2 ...

Page 23: ... to SPHI see Section 4 5 Adjustable in Local control only Control Output 0 to 100 Adjustable in Manual control only Feedforward Note To disable feedforward action e g during system tuning set the Feedforward Gain parameter to 0FF see Section 3 2 Tune Level 2 Tune 0 to 100 Feedforward disturbance variable signal Continued CSPt I P3 I P1 I P2 OP1 Local Set Point Remote Set Point input PV input Feedf...

Page 24: ...ator Ratio Display and Operator Bias Display Remote Set Point Ratio 0 001 to 9 999 Remote set point value ratio x remote set point input bias Remote Set Point Bias In engineering units Return to Process Variable display 2 6 Single Loop with Feedforward Templates 9 and 10 bIAS 0 0 rAtO 1 000 Set Point Process Variable Set Point Process Variable 70 OP1 70 OP1 1 1 ...

Page 25: ...oint values Slave Process Variable SPV Slave Set Point SSPt SPLO to SPHI see Section 4 5 Adjustable in manual or local slave set point modes only Note The L L R key can be used in this frame to change between cascade and local slave set points Continued 1 With the Ramping Set Point function enabled see Section 3 3 Set Points Ramp Rate the bargraph shows the actual ramping set point value and the d...

Page 26: ... ouput bias in engineering units Continued 1 Only displayed if template 12 selected and ratio bias display enabled see Section 4 2 Basic Configuration and Section 4 7 Operator Configuration 2 Only displayed if ratio bias display enabled see Section 4 7 Operator Configuration C rtO 1 000 70 OP1 Slave Set Point SSPt SLV bIAS 0 0 rAtO 1 000 70 OP1 70 OP1 Master Set Point MSPt Master Process Variable ...

Page 27: ...d 12 Cascade Slave Set Point Bias In engineering units Return to Master Process Variable MPV display 1 Only displayed if ratio bias display enabled see Section 4 7 Operator Configuration C bIA 0 0 70 OP1 Slave Set Point SSPt Slave Process Variable SPV SLV 1 ...

Page 28: ...ion 4 5 Adjustable in Local control only Slave Control Output 0 to 100 10 to 110 for analog outputs Adjustable in Manual mode only Slave Process Variable SPV Slave Set Point SSPt SPLO to SPHI see Section 4 5 Adjustable in Manual mode only Note The L L R key can be used in this frame to change between cascade and local slave set points Continued 1 With the Ramping Set Point function enabled see Sec...

Page 29: ...splayed if enabled in Level B Operator Configuration see Section 4 7 Feedforward Disturbance Variable Note To disable feedforward action e g during system tuning set the Feedforward Gain parameter to 0FF see Section 3 2 Tune 0 to 100 Feedforward disturbance variable input Cascade Slave Set Point Ratio 0 001 to 9 999 Slave set point CSP2 value ratio x master ouput bias in engineering units Cascade ...

Page 30: ... process variable 2 OPERATOR LEVEL 1 Only displayed if enabled in Level B Operator Configuration see Section 4 7 Actual Ratio Desired Ratio Adjustable in Local control only Control Set Point WV x Ratio Bias Control Output 0 to 100 10 to 110 for analog outputs Adjustable in manual mode only Bias in engineering units Return to Actual Ratio display Fig 2 8 Ratio Controller WV x rAtO bIAS PID Control ...

Page 31: ...ee Section 4 7 Actual Ratio Desired Ratio Adjustable in local control only Ratio Setpoint Output WV x Ratio Bias 10 to 110 Adjustable in manual control only Bias In engineering units Return to Actual Ratio display bIAS 0 0 55 0 50 0 Wild Variable WV Process Variable PV 70 OP1 70 OP1 Process Variable PV 1 Wild Variable WV WV x rAtO bIAS I P3 Manual Output I P2 WV rAtO L L R Local Ratio 1 Template 1...

Page 32: ...hich output is changing Output Positive Heat Output Active Heat output 0 to 100 0 to 110 in manual mode with analog outputs Adjustable in manual mode only Output Negative Cool Output Active Cool output 100 to 0 110 to 0 in manual mode with analog outputs Adjustable in manual mode only OP2 cool OP1 heat Y2 St Y1 St PID O P 0 100 100 100 450 2 500 0 50 OP1 50 OP2 Fig 2 10 Typical Response Reverse Di...

Page 33: ...tion Display 0 to 100 of travel Note In manual mode the and keys can be used to drive the valve open and valve close relays directly 2 12 2 Motorized Valve without Feedback Boundless Valve State Display OPN Valve opening StP Valve stopped CLS Valve closing Note In manual mode the and keys can be used to drive the valve open and valve close relays directly OP2 cool OP1 heat Y2 St Y1 St PID O P OP2 ...

Page 34: ... process using the new PID parameters If an error occurs during the auto tune the COMMANDER 500 reverts to manual mode with the control output set to the default output value An error message is displayed in the operator level see Table 2 1 2 OPERATOR LEVEL 2 2 t A Stable process before auto tune SPT PV B Process response during auto tune t PV 1 4 wave damping Controlling to Set Point Auto tune co...

Page 35: ...the set point at set point tuning is carried out At set point tuning manipulates the control output to produce a controlled oscillation of the process A step change of 10 of the starting output value is applied initially This is adjusted to give an amplitude of oscillation 3 times the noise level Once the amplitude and period of oscillation are consistent minimum 2 cycles maximum 4 cycles PID para...

Page 36: ...e type B b Type B MSt A Master type A MSt b Master type B Auto tune is started automatically when the key is pressed Auto tune can be stopped at any time by pressing the key Note Slave control loops only place the slave into local set point mode and adjust the set point to the required value prior to autotuning Note P I control only set the derivative term to OFF in the Tuning Level see Section 3 ...

Page 37: ...ontrol parameters General guidelines are shown in Table 2 2 Action Decrease proportional band Decrease integral time Increase derivative time Increase proportional band Increase derivative time Increase proportional band Increase integral time Increase proportional band Decrease integral time If large overshoot and oscillatory then Increase proportional band Increase integral time Increase derivat...

Page 38: ...onal Band until decay ratio 0 25 If the decay ratio 0 25 decrease the Proportional Band until decay ratio 0 25 f Leave the proportional band at the setting which gives 0 25 decay ratio and using the Control Efficiency Monitor note the period between peaks g Calculate and set the following parameters Integral action time Period 1 5 Derivative action time Period 6 Note The manual tuning facility mus...

Page 39: ...shoot The maximum error expressed as a percentage of the set point Overshoot Decay Ratio The ratio of the amplitude of the first and second overshoots Ratio X2 X1 Period The time in seconds between the first two peaks tperiod Settling Time The time taken in minutes for the process variable to settle within 2 of the set point value tsettle Error Integral The integral of the error value until the pr...

Page 40: ...Manual reset value Feedforward gain and bias Control deadband Heat Cool Output 1 2 Start LEV3 Set Points Local set point values 1 to 4 Slave set point value Remote set point ratio bias Cascade set point ratio bias Ramp rate LEV4 Alarm Trip Points Alarm 1 to 8 trip points LEV5 Motorized Valve Set Up With feedback Feedback ratio bias Deadband Regulator travel time Boundless Deadband Regulator travel...

Page 41: ...utput 2 PID Output Hys 2 3 4 Set Point Reverse Acting Control Output PV OFF ON Hysteresis Value Set Point Direct Acting Control Output PV OFF ON Hysteresis Value Level 2 Tune Note To select this frame from anywhere in this page press and hold the key for a few seconds Cycle Time Output 1 1 0 to 300 0 seconds for time proportioning or OnOF for on off control Note On off Control is not available on ...

Page 42: ...n Template Application Integral Action Time 2 3 and 4 1 to 7200 seconds or OFF IAt 2 is the integral action time for the slave controller if a cascade template is selected see Section 4 2 Basic Configuration Template Application Derivative Action Time 1 0 1 to 999 9 seconds or OFF drV 1 is the derivative action time for the master controller if a cascade template is selected see Section 4 2 Basic ...

Page 43: ...al action enabled 0 0 to 100 Note Manual reset is applied whether or not an integral action time is set Manual Reset Value 2 As Manual Reset Value 1 but applied to the slave output 0 0 to 100 Note Manual reset is applied whether or not an integral action time is set Feedforward Gain The feedforward value applied to the control output is disturbance variable x feedforward gain bias When set to OFF ...

Page 44: ...put 2 cool becomes active 0 0 to Y1st see Heat Cool Output 1 Return to top of page 3 SET UP MODE 2 20 2 23 3 2 Level 2 Tune 50 0 Y2 St 2 23 50 0 Y1 St 2 22 OFF Cbnd 2 21 Deadband Set Point LEV2 tUNE 0 0 FFbS 2 20 1 Process Variable Control Output 2 2 1 Only displayed if a feedforward template is selected see Section 4 2 Basic Configuration Template Application Not applied to Control Output when Fe...

Page 45: ...nual mode Remote Set Point Ratio The remote set point value is ratio x remote set point input bias 0 001 to 9 999 Remote Set Point Bias In engineering units Continued SEtP LEV 3 3 00 1 000 rAtO 0 BIAS 3 06 3 07 400 LSP4 3 04 200 LSP2 3 02 500 LSP1 3 01 1 2 4 4 1 2 300 S SPt 3 05 3 1 3 SET UP MODE 1 Not displayed for ratio controller or ratio station templates 2 Displayed only if a local set point ...

Page 46: ...ontrol output when the set point value is changed The rate set applies to both the local and the remote set points Return to top of page 3 3 Level 3 Set Points 3 SET UP MODE 3 08 3 10 1 Displayed only if a Cascade template is selected see Section 4 2 Basic Configuration Template Application 1 000 C rtO 3 08 OFF r rtE 3 10 0 C bIA 3 09 1 1 Actual Ramping Set Point Value used by PID Algorithm 0 100 ...

Page 47: ... Trip Points Note Level 4 is not applicable if all alarm types are set to None see Section 4 4 Alarms Alarm Type y a l p s i D n o i t p i r c s e D y a l p s i D n o i t p i r c s e D E N O N e n o N 3 P L 3 P I s s e c o r P w o L V P H V P s s e c o r P h g i H O H t u p t u O h g i H 2 V P L V P s s e c o r P w o L O L t u p t u O w o L 2 P L H V P h c t a L h g i H 1 b H h g i H 1 k c o l B s...

Page 48: ...dband is between 48 and 52 Regulator Travel Time The time entered is compared with the actual travel time If the valve is sticking an error message is generated 0 to 5000 seconds 0 no check Return to top of page U LU E LEV 5 5 00 1 0 d bnd 5 03 0 VbIA 5 02 0 VrAt 5 01 30 r trU 5 04 Position Required valve position Deadband centered around required position LEV 5 VLVE PID Control Terms PV SPt Proce...

Page 49: ...viation is within the deadband setting 3 SET UP MODE Proportional Step Time Control Deviation Raise Lower Time Integral Action Pulses Proportional Step Proportional Step Integral Action Pulses Calculation for Control Pulses Boundless Control The following calculations are shown for guidance when setting deadband proportional and integral values They can be used to check the suitability of boundles...

Page 50: ...or a few seconds Boundless Deadband In engineering units Regulator Travel Time The time taken for the regulator to travel from the fully open to the fully closed position 1 to 5000 seconds Return to top of page U LU E LEV 5 5 00 0 r trU 5 03 5 04 0 d bnd Position Control Set Point Deadband centered around Set Point LEV 5 VLVE 3 SET UP MODE ...

Page 51: ...gs LEVC Output Assignment Outputs 1 and 2 type Digital output Assignment source Polarity Analog output Assignment source Electrical range Engineering range Relay outputs 1 to 4 Assignment source Polarity LEVd Serial Communications 2 4 wire connection 2400 9600 19200 baud rate Parity MODBUS address LEVE Calibration Offset span adjustment Motorized valve feedback APPL INPt SEt P ALr CNtL OPEr ASSN S...

Page 52: ...h option board fitted y a l p s i D n o i t p i r c s e D e t a l p m e T L S 1 0 y l n o t n i o p t e s l a c o l h t i w p o o l e l g n i S L S 2 0 t n i o p t e s e t o m e r h t i w p o o l e l g n i S M A 3 0 n o i t c e l e s l a n g i s w o l h t i w n o i t a t s l a u n a M o t u A M A 4 0 n o i t c e l e s l a t i g i d h t i w n o i t a t s l a u n a M o t u A b A 5 0 n o i t c e l e ...

Page 53: ...ve without feedback is not available with templates 9 10 and 13 y a l p s i D e p y T t u p t u O E n O n e n o N G L n A 1 o a t u p t u o l o r t n o C t u p t u o g o l a n A Y L r 1 Y L R t u p t u o l o r t n o C t u p t u o y a l e R G I d 1 o d t u p t u o l o r t n o C t u p t u o l a t i g i D b F P k c a b d e e f h t i w e v l a v d e z i r o t o M 2 Y L R e s o l C 1 Y L R n e p O 2 3 ...

Page 54: ...orized Valve Output with Feedback PFb Output Type C Motorized Valve Output without Feedback Boundless Process Open relay Close relay Valve Controller Control Algorithm PV SPt bNd Output Type HC rr HC rd HC dr HC dd HC Ar HC Ad HC AA Output Types D Heat cool Output PV Relay or Digital or Analog Output Process Heat Output Cool Output Relay or Digital or Analog Output Control Algorithm SPt Note Only ...

Page 55: ... templates 2 Only displayed if a Cascade template is selected 3 Not displayed if Heat Cool output types selected see parameter 6 02 4 Only displayed if Heat Cool output types selected see parameter 6 02 50 F rEJ 6 06 rEU C ACt 6 03 1 LEV 6 APPL rEV Act1 6 04 rEV Act2 6 05 2 2 4 CONFIGURATION MODE p o o L e l g n i S 1 t u p t u O 3 V E r e s r e v e R 3 r i d t c e r i D l o o C t a e H t a e H 1 ...

Page 56: ...X XXX Continued 4 CONFIGURATION MODE INPt LEV 7 7 00 0 dP 1 7 03 C UNt 1 7 02 2 tYP 1 7 01 1 1 Only displayed if THC or RTD input types are selected y a l p s i D n o i t p i r c s e D y a l p s i D n o i t p i r c s e D F F O d e s U t o N P D T R 0 0 1 T P b B e p y T C H T 1 A m 0 2 o t 0 E E e p y T C H T 2 A m 0 2 o t 4 J J e p y T C H T 3 V 5 o t 0 K K e p y T C H T 4 V 5 o t 1 L L e p y T C...

Page 57: ...remain valid UP Input driven to the maximum upscale value 999 dN Input driven to the minimum downscale value 999 In the event of a fault being detected on the input the input is driven in the direction selected Input Filter Time Constant I P1 The input values are averaged over the time set 0 to 60 seconds Continued 4 CONFIGURATION MODE THC RTD Type C F Min Max Min Span Min Max Min Span Type B 18 1...

Page 58: ...able 4 1 Broken Sensor Drive I P2 NONE No action Actual input values remain valid UP Input driven to the maximum upscale value 999 dN Input driven to the minimum downscale value 999 Filter Time Constant I P2 The input values are averaged over the time set 0 to 60 seconds Continued 4 CONFIGURATION MODE 1 Frames 7 09 to 7 14 are not displayed if Analog Input Type 2 is set to OFF 2 Only displayed if ...

Page 59: ... values are averaged over the time set 0 to 60 seconds Return to top of page 4 CONFIGURATION MODE 1 Frames 7 16 to 7 21 are not displayed if Analog Input Type 3 is set to OFF 2 Only displayed if THC or RTD input types are selected 1000 En3 H 7 18 0 dP 3 7 17 C UNt3 7 16 2 tYP 3 7 15 0 En3 L 7 19 1 2 UP bSd 3 7 20 0 FLt 3 7 21 LEV7 INPt y a l p s i D n o i t p i r c s e D y a l p s i D n o i t p i ...

Page 60: ...ff rLY x ACK x RLY x Horn Relay assigment frame in Level C Output Assignment Alarm On Alarm Off Negative Trip Value Positive Trip Value Low Deviation Alarm Control Set Point Hysteresis Low Deviation ve Trip Value Alarm On Alarm Off Hysteresis Low Deviation ve Trip Value Process Variable High Deviation ve Trip Value Hysteresis Alarm On Alarm Off Control Set Point Alarm On Alarm Off Positive Trip Va...

Page 61: ...e Trip Point Alarm On Alarm Off Alarm Latched Alarm acknowledged by operator Hysteresis Process Variable High Latch Alarm Action Low Latch Alarm Action Trip Point Alarm On Alarm Off Alarm On Alarm Off High Process Low Process Hysteresis Hysteresis Process Variable Fig 4 5 High and Low Process Alarm Action Fig 4 6 High and Low Latch Alarm Action ...

Page 62: ...ed 8 00 8 03 4 CONFIGURATION MODE 1 Applies to the PID output with single or heat cool output types selected see Section 3 4 y a l p s i D n o i t p i r c s e D y a l p s i D n o i t p i r c s e D E N O N e n o N 3 P L 3 P I s s e c o r P w o L V P H V P s s e c o r P h g i H O H t u p t u O h g i H 1 V P L V P s s e c o r P w o L O L t u p t u O w o L 1 P L H V P h c t a L h g i H 1 b H h g i H 1...

Page 63: ...re at issue 4 and later All active and unacknowledged alarms can be acknowledged by a single digital input Set the source required to acknowledge all alarms See Rear Fold out Table C Digital Sources Return to top of page 4 4 Level 8 Alarms 4 CONFIGURATION MODE 8 04 8 25 0 trP x 8 05 8 06 8 07 NONE tYPx 8 04 8 10 8 13 8 16 8 19 8 22 8 08 8 11 8 14 8 17 8 20 8 23 0 HYS x 8 09 8 12 8 15 8 18 8 21 8 2...

Page 64: ...efine the maximum and minimum values to which the local and or remote set points can be adjusted The set point limits do not apply when in Manual mode with local set point tracking enabled If the set point is outside its limits when Automatic mode is selected the set point value can only be adjusted towards its limits Once within the limits they apply as normal Control Set Point CSPT or Master Set...

Page 65: ... Sources Local Set Point Source 2 The source required to select local set point 2 LSP2 as the current local set point See Rear Fold out Table C Digital Sources Local Set Point Source 3 The source required to select local set point 3 LSP3 as the current local set point See Rear Fold out Table C Digital Sources Local Set Point Source 4 The source required to select local set point 4 LSP4 as the curr...

Page 66: ...ired to select local set point mode or remote ratio mode when the ratio controller template is selected See Rear Fold out Table C Digital Sources Remote Set Point or Ratio Selection Source The source required to select remote set point mode or remote ratio mode when the ratio controller template is selected See Rear Fold out Table C Digital Sources Return to top of page NONE Lr 5r 9 12 NONE r SrC ...

Page 67: ... 1 A 00 A 02 y a l p s i D g n i t t e S y a l p s i D g n i t t e S 0 e d o m t s a L 5 e d o m o t u A t e s e r m r e t l a r g e t n i 1 e d o m l a u n a M t u p t u o t s a l g n i s u 6 e d o m o t u A m r e t l a r g e t n i t s a l g n i s u 2 h t i w e d o m l a u n a M t u p t u o 0 0 7 e g a t u o r e w o P o t u A e m i t y r e v o c e R e g a t u o r e w o P e d o m l a u n a M e m i...

Page 68: ...ent output value becomes the low limit until the value rises above the limit set 0 0 to 100 0 Output 1 Heat High Limit Heat Cool Control Limits the high level of control output 1 in automatic mode If the control output is above this limit when automatic mode is selected the current output value becomes the high limit until the value falls below the limit set 0 0 to 100 0 Output 2 Cool High Limit H...

Page 69: ...he control output or both control outputs for heat cool 0 01 to 99 99 change per second or OFF Note The default slew rate setting is applied to both increasing and decreasing output values The slew rate setting can be applied to either increasing values only or decreasing values only using the PC Configurator Slew Rate Disable Source The digital source required to disable slew rate control of the ...

Page 70: ...auto manual station The source required to lock into manual mode with Configured Output 3 Switching from manual to auto is not possible via the front panel See Rear Fold out Table C Digital Sources Note If template 3 is selected the source is assigned to alarm 1 If template 4 is selected the source is assigned to digital input 1 Configured Output 3 The control output value required when manual mod...

Page 71: ... proportional 3 and integral 3 terms as the tuning parameters See Rear Fold out Table C Digital Sources Tune Parameter Source 4 Gain Scheduling Determine the digital source used to select the proportional 4 and integral 4 terms as the tuning parameters See Rear Fold out Table C Digital Sources Return to top of page OFF A SrC A 18 OFF t4 Sr A 22 OFF t3 Sr A 21 OFF t2 Sr A 20 OFF t1 Sr A 19 2 2 2 Se...

Page 72: ...NO Bias setting for Remote and Cascade set point not displayed in operator level Continued 4 CONFIGURATION MODE 1 Not displayed if the Indicator template in use 2 Only displayed if a template with remote set point or cascade control is selected 3 Cascade templates only OPEr LEVb b 00 NO r d15 NO b d15 b 05 b 06 YES S AdJ b 04 YES FPAK b 03 Lr FPLr b 02 YES FP AM b 01 1 1 1 1 2 1 2 b 00 b 06 y a l ...

Page 73: ...s 2 3 4 and 5 and the autotune facility 0 to 9999 default 0 Configuration Password Enables access to the configuration levels set up levels and the autotune facility 0 to 9999 default 0 Day Setting Use to set the weekday of the on board clock 1 to 7 1 Sunday 7 Saturday Hour Setting Use to set the hour of the on board clock 0 to 23 Minute Setting Use to set the minute of the on board clock 0 to 59 ...

Page 74: ... Analog Output 1 Assignment Source Press to advance to Digital Output 1 Assignment Source C 00 C01 C07 C08 4 CONFIGURATION MODE 4 8 1 Digital Output 1 Digital Output 1 do1 Assignment Source Select the source required to activate Digital Output 1 See Rear Fold out Table C Digital Sources Digital Output 1 do1 Polarity The output can be set to energize for either an active or inactive digital signal ...

Page 75: ... to 22 0mA Retransmission 1 Engineering High The engineering range value at which maximum output is required In engineering units Retransmission 1 Engineering Low The engineering range value at which minimum output is required In engineering units Continued tYP1 ANLG NONE AnI A 100 0 r1 H C 02 C 05 0 0 r1 L C 06 20 0 AN1 H C 03 4 0 AN1 L C 04 tYP 2 ANLG 1 2 2 1 If the output is assigned to a contr...

Page 76: ... Output 2 do2 Assignment Source Select the source required to activate Digital Output 2 See Rear Fold out Table C Digital Sources Digital Output 2 do2 Polarity The output can be set to energize for either an active or inactive digital signal POS Output energized when source is active NEG Output energized when source is inactive Continued 1 Only displayed if optional ouput is fitted If the output i...

Page 77: ... High The engineering range value at which maximum output is required In engineering units Retransmission 2 Engineering Low The engineering range value at which minimum output is required In engineering units Continued 0 0 r2L C 14 NONE AN2 A C 10 20 0 AN2H C 11 4 0 AN2 L C 12 100 0 r2H C 13 rLY1 NONE tYP 2 ANLG 1 1 1 1 1 2 2 4 8 5 Analog Output 2 1 Only displayed if optional ouput is fitted If th...

Page 78: ...NEG Relay energized when source is inactive Relay 3 Assignment Source Select the source required to activate relay output 3 See Rear Fold out Table C Digital Sources Relay 3 Polarity The relay can be set to energize for either an active or inactive digital signal POS Relay energized when source is active NEG Relay energized when source is inactive Continued POS rL2 P C 20 NONE rL2 A POS rL1 P C 18...

Page 79: ... Relay energized when source is active NEG Relay energized when source is inactive Return to top of page NONE rL4 A C 23 POS rL4 P C 24 1 2 3 LEVC ASSN 4 4 1 If the output is assigned to a control output by the control type the setting displayed cannot be changed see Section 4 2 Basic Configuration Control Output Type 2 Not displayed if relay is assigned to a control output signal 3 Not applicable...

Page 80: ...nection 2400 baud rate 3 2 wire connection 9600 baud rate 4 4 wire connection 9600 baud rate 5 2 wire connection 19200 baud rate 6 4 wire connection 19200 baud rate Parity NONE None Odd Odd EVEN Even MODBUSTM Address Each slave on a MODBUS link must be assigned a unique address see IM C500 MOD 1 to 99 Return to top of page 4 9 Level D Serial Communications Configuration Note Level D is only applic...

Page 81: ...ering Units Span Adjustment 0 750 to 1 250 If the and keys are not operated for three seconds the display reverts to the span value only Analog Input 2 Offset Calibration Analog Input 2 Value in Engineering Units Offset In engineering Units If the and keys are not operated for three seconds the display reverts to the offset value only Analog Input 2 Span Calibration Analog Input 2 Value in Enginee...

Page 82: ...on _AN Manual Calibration Regulator Travel Time 0 to 5000 seconds Ensure that the value entered is compatible with the regulator motor as this is used to determine the length of travel of the feedback mechanism Motorized Valve Feedback Fully closed Position NO No action YES Fully closes the valve automatically and sets the electrical input to low range value Note Input value flashes when calibrati...

Page 83: ...a Value This value should only be changed if a new CJ sensor is supplied with a CJ Beta value different to 3977 The beta value of the CJ sensor Cold Junction Reading I P1 and I P2 The temperature measured by the cold junction sensor is displayed in C Cold Junction Reading I P3 The temperature measured by the cold junction sensor is displayed in C Return to top of Calibration Level 100 0 Fb LO E11 ...

Page 84: ...ent However the unit contains a small lithium battery This should be removed and disposed of responsibly in accordance with local environmental regulations The remainder of the unit can be safely considered as normal waste and disposed of accordingly 6 1 Mechanical Installation 5 1 1 Siting Figs 5 1 and 5 2 Fig 5 2 Environmental Requirements Fig 5 1 General Requirements 55 C Max 0 C Min IP66 NEMA4...

Page 85: ... 4 Overall dimensions are shown in Fig 5 3 Note For NEMA4X protection a minimum panel thickness of 2 5mm is recommended Fig 5 3 Overall Dimensions 149 5 5 87 137 5 5 41 137 8 5 43 18 0 71 76 2 99 5 0 0 2 148 5 83 Dimensions in mm in 68 0 7 0 2 68 0 03 0 30 1 18 14 0 55 Panel Cutout 138 1 0 5 43 0 04 0 ...

Page 86: ...panel see Fig 5 3 Insert the case and instrument if assembled into the panel cut out 3 Secure the instrument using the panel clamp retaining screws The rubber friction sleeves prevent overtightening 4 2 3 3 Fit the panel clamps to the case ensuring that the lugs are correctly located in their slots ...

Page 87: ... from the Case Note Refitting is the reversal of removal 5 1 2 Mounting Figs 5 3 to 5 5 Remove the instrument from the case 3 Unclip the process label cover and remove the process label if fitted Loosen the captive screw securing the instrument to the case 1 2 ...

Page 88: ...Fig 5 6 PROCESS LABEL Inscribe the process label with the desired text Unclip the process label cover from the front panel Insert the process label into the recess Refit the cover over the process label 2 1 4 3 Fig 5 6 Fitting Process Labels ...

Page 89: ... cables up to 14AWG 2 5mm2 5 2 1 Electrical Connections Figs 5 7 to 5 9 Caution The Power Supply ground cable must be connected to the Ground Stud and NOT to terminal 18 Fig 5 7 Electrical Connections General RTD2 NO NC C NO NC C C RTD1 NO NC C NO NC C 13 14 15 16 17 18 25 26 27 28 29 30 1 2 3 4 5 6 7 8 9 10 11 12 See Fig 5 8 85 to 265V a c 31 32 33 34 35 36 19 20 21 22 23 24 Ground Stud Vs 0V Ear...

Page 90: ...istor Fit the CJ sensor supplied if I P1 or I P2 are THC inputs I P2 can only be used with THC inputs if I P1 is also used as a THC input 19 20 21 22 THC milliVolts and Volts RTD 3rd lead RTD 3 lead RTD 2 lead RTD and Resistance RTD RTD RTD milliAmps 100Ω 100Ω Tx 2 wire Transmitter milliAmps CJ Sensor I P3 Analog Input 3 THC millivolts and volts RTD 3rd lead RTD 3 lead RTD Milliamps 1 2 3 4 Millia...

Page 91: ...rd and the option board if fitted 5 4 Digital Output 15V d c min at 20mA Min load 750Ω 5 5 Control or Retransmission Analog Output Max load 15V 750Ω at 20mA Isolated from analog input dielectric strength 500V for 1 minute 5 INSTALLATION Fig 5 10 Relay Links Note The default setting for the relay links is Normally Open N O Processor Board LK3 LK4 Normally open Normally closed LK1 LK2 Option Board L...

Page 92: ...volt inputs and the appropriate thermocouple linearizer is selected This is only possible via the PC configurator 5 INSTALLATION 0 100 Motorized Valve Drive N N L L Motorized Valve Drive Valve Positioner Power Supply 100 0 Link 0 100 20 19 21 A Relay Connections Motorized Valve Drive B Feedback Connections V mA or mV Input Types C Feedback Slidewire Connection 100Ω mA inputs only 19 20 21 D Altern...

Page 93: ...y l l a c i s n i r t n i r o f e u l B e s a C L n o C e F 0 1 7 3 4 N I D 0 1 7 3 4 N I D e u l B d e r e u l B e u l B 5 7 2 3 lead Resistance Thermometer RTD Inputs The three leads must have equal resistance not exceeding 50Ω each 5 7 3 2 lead Resistance Thermometer RTD Inputs If long leads are necessary it is preferable to use a 3 lead RTD If the RTD is to be used in a hazardous area a 3 lead...

Page 94: ...o Manual Station Analog Backup Indicator Manual Loader Cascade Feedforward Ratio Output Types Current proportioning Time proportioning On off Motorized valve with and without feedback Heat cool Control Parameters Four sets of PID settings selectable via digital signals Set Points Local remote and four local set points selectable via digital signals Configured Outputs Three preset output values sel...

Page 95: ... a F 2 9 3 C F E 0 0 9 o t 0 0 1 0 5 6 1 o t 0 4 1 r o 1 0 5 0 9 0 C F J 0 0 9 o t 0 0 1 0 5 6 1 o t 0 4 1 r o 1 0 5 0 9 0 C F K 0 0 3 1 o t 0 0 1 0 5 3 2 o t 0 4 1 r o 1 0 5 0 9 0 C F L 0 0 9 o t 0 0 1 0 5 6 1 o t 0 4 1 r o 1 0 5 1 7 2 C F N 0 0 3 1 o t 0 0 2 0 5 3 2 o t 5 2 3 r o 1 0 5 0 9 0 C F R 0 0 7 1 o t 8 1 0 0 0 3 o t 0 r o 1 0 5 0 9 0 C 0 0 3 e v o b a F 0 4 5 C F S 0 0 7 1 o t 8 1 0 0 0...

Page 96: ...selected Delay Timers Number 2 Programmable Delay and Duration in seconds Logic Equations Number 6 Elements 15 per equation Operators OR AND NOR NAND NOT EXOR Custom Linearizers Number 2 Breakpoints 15 per linearizer Accessed via PC Configurator Options Analog Inputs Number 1 Isolation Galvanically isolated from the rest of the circuitry Type Universal see Universal Process Inputs on page 11 Analo...

Page 97: ...ic Strength 500V DC to earth Analog digital output 1 to rest of the circuitry 500V DC for 1 minute Analog digital output 2 to rest of the circuitry 500V DC for 1 minute Analog input 3 IP3 to rest of the circuitry 500V DC for 1 minute Serial communications to rest of the circuitry 500V DC for 1 minute Environmental Operating Limits 0 to 55 C 32 to 130 F 5 to 95 RH non condensing Temperature stabili...

Page 98: ...s Variable Input 1 Template 2 Only Set Point Ramp 1 I P 2 x rAtO bIAS I P1 Local Set Point Single Loop Control provides basic feedback control using three term PID or On off control The controller output is calculated from the difference between the process variable and the control set point The control set point can be a fixed value entered by the user or from a remote source ...

Page 99: ...ATES Process Variable di 1 Master Output ao1 Digital Select I P2 PV Output Status Relay 1 External Relay I P1 ao1 Master Output Actuator Process Master Controller C500 Process Variable di 1 Master Output ao1 Digital Select I P2 PV Output Status I P1 ao1 Actuator Process Master Controller C500 Series Connection Parallel Connection Fig A1 Series and Parallel Operation ...

Page 100: ... the master signal is restored or the digital input returns to its normal state the COMMANDER 500 switches back to auto mode i e COMMANDER 500 output master output The auto manual station can be used in series or in parallel with the master output signal see Fig A1 Parallel operation is achieved by using relay 1 in the COMMANDER 500 to energize an external relay with suitable changeover contacts f...

Page 101: ...mode operation When the master signal is restored or the digital input returns to its normal state the COMMANDER 500 switches back to remote control mode i e COMMANDER 500 output master output The analog backup station can be used in series or in parallel with the master output signal See Fig A1 Parallel operation is achieved by using relay 1 in the COMMANDER 500 to energize an external relay with...

Page 102: ...nalog output the lower display indicates its value which can be adjusted by the user This output can be used to manually control a process or to provide a set point value for another controller A3 Indicator Manual Loader Station Templates 7 and 8 PV1 PV2 I P2 I P1 Manual Output ao1 1 Template 8 Only 1 2 Not applicable if Control Output Type is set to None see Section 4 2 Basic Configuration 2 ...

Page 103: ...ation is disabled by setting FFGn to 0FF Single Loop Controller with Feedforward A disturbance variable is weighted by the feedforward gain FFGn and the feedforward bias FFbs values and then added to the controller output value Multiplication of the feedforward signal with the control output instead of addition can be selected using the configurator When in Manual mode the PID output tracks the di...

Page 104: ...r the second slave controller The two controllers are linked internally The master output can be weighted using the cascade ratio C rto and bias C bia values to create the slave set point value When the auto manual mode is changed from the front panel or by a digital signal both the master and slave controllers change mode In manual the slave set point can be adjusted by the user and the value is ...

Page 105: ...nt can be adjusted by the user and the value is tracked by the master controller taking account of the feedforward signal to ensure bumpless transfer back into auto The slave can also be taken out of cascade mode using the front panel L L R switch when the slave values are displayed LSPt MSPt M OP x C r tO C b IA L L R I P1 Slave Set Point I P2 OP1 Master Process Variable Input Slave Process Varia...

Page 106: ...tio Controller enables a controlled process variable to be maintained automatically in definite proportion to another variable known as the wild variable The wild variable weighted by ratio rAtO and bias bIAS values forms the control set point for the process variable The ratio value applied to the wild variable can be either a local value set on the front panel or a remote signal on an analog inp...

Page 107: ...rovides a set point for a subsequent slave controller The wild variable is weighted by ratio rAtO and bias bIAS values and is then retransmitted as an analog output value The ratio value applied to the wild variable can be either a local value set on the front panel or a remote signal on an analog input The actual ratio of the process variable to the wild variable is also displayed A8 Ratio Statio...

Page 108: ... s n a i d e m s d n a r e p O s l a n g i s l a t i g i d r o g o l a n a y n a 0 r o 1 e u l a v e h t e v a h s l a n g i s l a t i g i d e g a r e v A l a t i g i d y b t e s e r d o i r e p e m i t e l b a t c e l e s a r e v o l a n g i s g o l a n a n a f o e u l a v e g a r e v a e h T l a n g i s n o i t c e t e d m u m i x a M l a n g i s l a t i g i d y b t e s e r l a n g i s g o l a n...

Page 109: ... blocks and custom linearizers to be added into the standard template format The following sources can be programmed process variable inputs set point inputs position feedback input input to ratio bias block ratio inputs bias inputs disturbance variable inputs input to feedforward block feedforward term add to or multiply with PID O P B10 Connecting the COMMANDER PC Configurator APPENDIX B COMMAND...

Page 110: ...Motorised Valve Ratio O Output 1 On off Hysteresis Value Output 2 On off Hysteresis Value P Proportional Band 1 Proportional Band 2 Proportional Band 3 Proportional Band 4 R Ramp Rate Regulator Travel Time Remote Set Point Bias Remote Set Point Ratio S Set Points T Tune V Valve Set Up Mnemonic Number 1 xxx 4 01 2 xxx 4 02 3 xxx 4 03 4 xxx 4 04 5 xxx 4 05 6 xxx 4 06 7 xxx 4 07 8 xxx 4 08 Ab 1 2 15 ...

Page 111: ...Output 2 Polarity Digital Output 2 Source F Feedback Range High Feedback Range Low I Input 1 Broken Sensor Input 1 Decimal Point Input 1 Engineering High Input 1 Engineering Low Input 1 Filter Time Constant Input 1 Temp Units Input 1 Type Input 2 Broken Sensor Input 2 Decimal Point Input 2 Engineering High Input 2 Engineering Low Input 2 Filter Time Constant Input 2 Temp Units Input 2 Type Input 3...

Page 112: ... 1 Polarity Relay 1 Source Relay 2 Polarity Relay 2 Source Relay 3 Polarity Relay 3 Source Relay 4 Polarity Relay 4 Source Remote Set Point Source RSPT Fault Action S Serial Communications Serial Configuration Set Point Configuration Set Point 1 Source Set Point 2 Source Set Point 3 Source Set Point 4 Source Set Point Default Value Set Point High Limit Set Point Low Limit Set Point Tracking Set up...

Page 113: ... 32 Character Set 8 Clock Setting 69 Cold Junction Compensation 79 86 89 Failed 9 C Configuration Error 9 Configuration Password 69 Configured Outputs 1 to 3 66 See Also Auto Manual and Backup Templates Control Action 51 Control Configuration Level A 63 Control Efficiency Monitor 33 Control Set Point see Set Points Control Output Deadband 40 Custom Linearizer 100 D Date and Time Setting 69 Deadban...

Page 114: ...B 68 Operating Displays 3 Operator Ratio Bias Display Enable 68 Operator Level 11 O Output Assignment Level C 70 Connections 85 87 88 Heat Cool 28 Limits 64 Slew Rate 65 Output Sources Rear Fold out Table B Types 49 Option Board 85 P Panel Clamps 2 82 PC Configurator 100 PID Parameters 38 39 See Also Gain Scheduling Power Fail Recovery 63 Power Supplies 85 89 Power Up Displays 11 Process Alarms 57...

Page 115: ...ler see Cascade Controllers Slave Set Point see Cascade Controllers Slew Rate 65 Soft start see Set Point Ramp Rate Output Slew Rate Span Adjustment see Calibration T Temperature Units 52 54 55 Template Applications 11 48 90 Rear Fold out Table A Terminals and Connections 85 Thermocouple 52 53 54 55 85 86 Time Setting 69 Real time alarms 100 Delay Timers 101 Tuning Automatic 30 Manual 34 Tune Para...

Page 116: ...112 NOTES ...

Page 117: ... u t s i D e l b a i r a V 4 1 C r r e l l o r t n o c o i t a R e l b a i r a V s s e c o r P e l b a i r a V d l i W k c a b d e e F 5 1 C r o i t a r e t o m e r h t i w r e l l o r t n o c o i t a R e l b a i r a V s s e c o r P e l b a i r a V d l i W o i t a r e t o m e R 6 1 S r n o i t a t s o i t a R e l b a i r a V s s e c o r P e l b a i r a V d l i W 7 1 S r o i t a r l a n r e t x e h...

Page 118: ... l a v d e z i r o t o M 3 N I F d e l i a f 3 t u p n I E S L C y a l e R e s o l C e v l a v d e z i r o t o M 1 K b L 1 t u p t u o g o l a n a k a e r b p o o L s s e c o r P s m r a l A 1 A e v i t c a 1 m r a l A 2 K b L 2 t u p t u o g o l a n a k a e r b p o o L 2 A e v i t c a 2 m r a l A G O d e v i t c a g o d h c t a W F P l i a f r e w o P 8 A e v i t c a 8 m r a l A c i g o L s n o i...

Page 119: ...tation pH conductivity and dissolved oxygen transmitters and sensors ammonia nitrate phosphate silica sodium chloride fluoride dissolved oxygen and hydrazine analyzers Zirconia oxygen analyzers katharometers hydrogen purity and purge gas monitors thermal conductivity Customer Support We provide a comprehensive after sales service via a Worldwide Service Organization Contact one of the following of...

Page 120: ...ained herein without notice ABB 2003 Printed in UK 11 03 ABB Inc 125 E County Line Road Warminster PA 18974 USA Tel 1 215 674 6000 Fax 1 215 674 7183 ABB Limited Howard Road St Neots Cambridgeshire PE19 8EU UK Tel 44 0 1480 475321 Fax 44 0 1480 217948 ABB has Sales Customer Support expertise in over 100 countries worldwide www abb com ...