ABB C505 User Manual
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ABB C505 User Manual

ABB C505 User Manual

Control it 1/2 din advanced process controller, industrial it enabled
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User Guide
Control
IM/C505_6
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DIN
Advanced Process Controller
2
C505

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  • Page 1 User Guide Control IM/C505_6 Advanced Process Controller C505...
  • Page 2 Cert. No. Q5907 As a part of ABB, a world leader in process automation technology, we offer customers application expertise, service and support worldwide. We are committed to teamwork, high quality manufacturing, advanced EN 29001 (ISO 9001) technology and unrivalled service and support.
  • Page 3 GETTING STARTED Step 3 – Setting the Parameters (Fig. GS.1) Power-up the instrument. Press the keys simultaneously and hold for 3 seconds to advance directly to Level 6 – Basic Configuration. Set the appropriate application template, output type and control action. Use the key to advance between frames and upper keys to adjust the default values –...
  • Page 4 GETTING STARTED The COMMANDER 500 can be configured and made ready for operation in three easy steps. This 'Getting Started' guide provides an overview of these steps and, where necessary, refers to the relevant section of the manual. Step 1 – Decide on the Application Template and the Output Configuration required Step 2 –...

  • Page 5: Overview

    OVERVIEW This manual is divided into 5 sections which contain all the information needed to install, configure, commission and operate the COMMANDER 505 Advanced Process Controller. Each section is identified clearly by a symbol as shown in Fig. 1. Displays and Controls Configuration Mode (Levels 6 to E) •...

  • Page 6: Table Of Contents

    CONTENTS Section Page Section Page OVERVIEW ............ 1 5 INSTALLATION ........80 5.1 Mechanical Installation ....80 1 DISPLAYS AND FUNCTION KEYS ..3 5.2 Electrical Installation ....... 85 1.1 Introduction ........3 5.3 Relays ..........87 1.2 Use of Function Keys ....... 4 5.4 Digital Output ........

  • Page 7: Displays And Function Keys

    1 DISPLAYS AND FUNCTION KEYS 1.1 Introduction The COMMANDER 500 front panel displays, function keys and LED indicators are shown in Fig. 1.1. COMMANDER 500 58. 8 62. 4 MST SLV 15. 0 OP2 FF Function Keys Raise Lower Alarm Parameter Advance Acknowledge Local/Remote...
  • Page 8 …1 DISPLAYS AND FUNCTION KEYS 1.2 Use of Function Keys A – Raise and Lower Keys LEV2 bIAS tUnE 50. 0 51. 0 LEV1 OPEr – 49. 0 Use to change/set a parameter value… and… …move between levels B – Up and Down Keys LEV2 Frame 1 2.

  • Page 9: Use Of Function Keys

    1 DISPLAYS AND FUNCTION KEYS… …1.2 Use of Function Keys E – Alarm Acknowledgement (Flashing) (On continuously) (Off) 450. 2 500. 0 All active No active Any active, alarms alarms present unacknowledged acknowledged alarms 1. H P1 1HP1 2. x xx 450.
  • Page 10 …1 DISPLAYS AND FUNCTION KEYS …1.2 Use of Function Keys F – Local / Remote Key Changing between Local and Remote Set Points 450. 2 500. 0 450. 2 450. 2 400. 0 400. 0 Process variable and local set point (ratio) displayed on red and green displays. Remote set point (ratio) value is displayed.
  • Page 11 1 DISPLAYS AND FUNCTION KEYS… …1.2 Use of Function Keys G – Short-cut Keys Press simultaneously and hold for 3 seconds LEVA LEV6 CntL APPL LEV1 450. 2 OPEr 350. 0 Press to move from anywhere in Press to move from the Configuration level to the first anywhere in the Operator frame in the Operator level...

  • Page 12: Secret-Til-Lit Indicators

    …1 DISPLAYS AND FUNCTION KEYS 1.3 Secret-til-Lit Indicators Flashing 450. 2 One or more No alarms active All active alarms alarms active and acknowledged unacknowledged Master controller 350. 0 parameters displayed MST SLV Slave controller parameters displayed Local set point Remote or in use Cascade set...

  • Page 13: Error Messages

    1 DISPLAYS AND FUNCTION KEYS… 1.5 Error Messages Error/Action To clear the display: Display Calibration Error Press the Turn mains power off and on again (if the error persists contact the Customer Support Organization). Non-volatile Memory Error Press the x = 1, 2: Motherboard Memory x = 3: Option Board Memory Turn mains power off and on again (if the error persists, check...

  • Page 14: Processor Watchdog

    …1 DISPLAYS AND FUNCTION KEYS 1.6 Processor Watchdog The instrument's processor activity is monitored by an independent watchdog device. When the output of the watchdog is assigned to a relay or digital output, the relay/digital output de-energizes if the instrument fails to function correctly. 1.7 Loop Break Monitor Both analog outputs are monitored continuously to detect a loop break.

  • Page 15: Operator Level

    2 OPERATOR LEVEL 2.1 Introduction The Operator level (Level 1) is the normal day-to-day mode of the COMMANDER 500. This section describes the operator facilities available on each frame depending on the control template and output type selected. The template types detailed in this section are: •...
  • Page 16 …2 OPERATOR LEVEL 2.2 Single Loop Controller (Templates 1 and 2) The single loop controller is a basic 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). Local Set Point LSPt RSPt...
  • Page 17 2 OPERATOR LEVEL… …2.2 Single Loop Controller (Templates 1 and 2) •1 Process Variable Set Point 450. 2 Process 500. 0 Control Set Point •1 Variable ['SPLO' to 'SPHI' – see Section 4.5] Adjustable in Local Control Only Control Output [0 to 100% (digital/relay outputs), –10 to 110% (analog outputs)] Adjustable in manual mode only.
  • Page 18 …2 OPERATOR LEVEL 2.3 Auto/Manual Station (Templates 3 and 4) Note. Refer also to Appendix A2.1 – Series and Parallel Operation. The auto/manual station provides a backup for a master controller. In normal operation the COMMANDER 500’s analog 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).

  • Page 19: Auto/Manual Station (Templates 3 And 4)

    2 OPERATOR LEVEL… …2.3 Auto/Manual Station (Templates 3 and 4) Master Auto Mode 55. 0 output 50. 0 Process Variable Master Output (I/P2) Process Variable Control Output = Master Output [Master Output, 0 to 100%] •1 •1 Restored •2 Low Master •2 Master Output Output Value...
  • Page 20 …2 OPERATOR LEVEL 2.4 Analog Backup (Templates 5 and 6) Note. Refer also to Appendix A2.1 – Series and Parallel Operation. The analog backup station provides a backup for a master controller. In normal operation (remote control mode selected) the COMMANDER 500’s current output follows the master controller’s output value.

  • Page 21: Analog Backup (Templates 5 And 6)

    2 OPERATOR LEVEL… …2.4 Analog Backup (Templates 5 and 6) Set Point Remote Mode 55. 0 Process 50. 0 Process Variable Variable Set Point ['SPLO' to 'SPHI' – see Section 4.5] Control Output = Master Output [Master Output, 0 to 100%] •1 Low Master Restored...

  • Page 22: Indicator/Manual Loader Station (Templates 7 And 8)

    …2 OPERATOR LEVEL 2.5 Indicator/Manual Loader Station (Templates 7 and 8) One or two process variables can be displayed on the digital and bargraph displays. If the control output is assigned to an analog output, the lower display indicates its value which can be adjusted by the user.
  • Page 23 2 OPERATOR LEVEL… 2.6 Single Loop with Feedforward (Templates 9 and 10) These templates provide three-term PID control with feedforward. The disturbance variable is weighted by the feedforward gain (FFGn) and the feedforward bias (FFbS) values and added to the controller output value.

  • Page 24: Single Loop With Feedforward (Templates 9 And 10)

    …2 OPERATOR LEVEL …2.6 Single Loop with Feedforward (Templates 9 and 10) Set Point •1 Remote Set Point Ratio rAtO Process 1. 0 00 Variable [0.001 to 9.999] Remote set point value = (ratio x remote set point input) + bias Set Point •1 Remote Set Point Bias...
  • Page 25 2 OPERATOR LEVEL… 2.7 Cascade Control (Templates 11 and 12) For cascade control, two internally-linked PID controllers are used, with the first (master) PID controller providing the set point for the second (slave) controller. The master output is weighted using the cascade ratio (C.rtO) and bias (C.bIA) values to create the slave set point value. Local Slave Set Set Point...

  • Page 26: Cascade Control (Templates 11 And 12)

    …2 OPERATOR LEVEL …2.7 Cascade Control (Templates 11 and 12) Master •1 Remote Set Point Ratio rAtO Set Point (MSPt) 1. 0 00 [0.001 to 9.999] Master remote set point value = Master (ratio x remote set point input) + bias Process Variable (MPV)
  • Page 27 2 OPERATOR LEVEL …2.7 Cascade Control (Templates 11 and 12) Slave •1 Cascade Slave Set Point Bias C. b IA Set Point (SSPt) 0. 0 [In engineering units] Slave Process Variable (SPV) Return to display Master Process Variable (MPV) •1 Only displayed if ratio/bias display enabled – see Section 4.7, Operator Configuration.
  • Page 28 …2 OPERATOR LEVEL 2.8 Cascade with Feedforward (Template 13) For cascade control, two internally-linked PID controllers are used, with the first (master) PID controller providing the set point for the second (slave) controller. The feedforward disturbance variable signal is added to the master output (slave set point). The disturbance signal is weighted by the feedforward gain (FFGn) and the feedforward bias (FFbs) values.

  • Page 29: Cascade With Feedforward (Template 13)

    2 OPERATOR LEVEL… …2.8 Cascade with Feedforward (Template 13) Master Feedforward Disturbance Variable 450. 2 Set Point (MSPt) 500. 0 Note. To disable feedforward action (e.g. during system tuning), set the Feedforward Gain parameter to – see Section 3.2, Tune. Master [0 to 100%] Process...

  • Page 30: Ratio Controller (Templates 14 And 15)

    …2 OPERATOR LEVEL 2.9 Ratio Controller (Templates 14 and 15) Ratio control 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. Local Ratio rAtO •1...

  • Page 31: Ratio Station (Templates 16 And 17)

    2 OPERATOR LEVEL… 2.10 Ratio Station (Templates 16 and 17) The ratio station provides a set point for a subsequent slave controller. The wild variable (WV) is weighted by ratio (rAtO) and bias (bIAS) values and is then retransmitted as an analog output value. Local Ratio Manual Output Analog...

  • Page 32: Heat/Cool Output Types

    …2 OPERATOR LEVEL 2.11 Heat/Cool Output Types 2.11.1 Reverse (Heat)/Direct (Cool) or Direct (Heat)/Reverse (Cool) The active output, either OP1 (Heat) or OP2 (Cool) is displayed and may be adjusted in manual mode. The OP1 and OP2 l.e.d.s indicate which output is changing. +100% –100% OP1 (heat)

  • Page 33: Motorized Valve Output Types

    2 OPERATOR LEVEL… 2.11.2 Reverse (Heat)/Reverse (Cool) or Direct (Heat)/Direct (Cool) It is not possible to view or adjust the heat/cool outputs directly. The PID output (0 to 100%), used to calculate the heat (OP1) and cool (OP2) outputs, is displayed and may be adjusted in manual mode. The OP1 and OP2 l.e.d.s indicate which output is changing.

  • Page 34: Auto-Tune

    …2 OPERATOR LEVEL 2.13 Auto-tune Note. Auto-tune is not available for Auto/Manual Station, Indicator or Ratio Station templates, or when boundless or heat/cool control types are selected. Information. • Auto-tune optimizes process control by manipulating the COMMANDER 500 output and then monitoring the process response.
  • Page 35 2 OPERATOR LEVEL… 2.13.2 'At Set Point' Auto-tune If the process variable is within 10% of 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.
  • Page 36 …2 OPERATOR LEVEL 2.13.3 Auto-tune Accessing the Auto-tune Facility 1. . x x xxxx From any operating frame, press and hold the xxxx until the 'COdE' frame is displayed. 1. x x COdE Set the correct auto-tune password. 1. x x AtNE Auto-tune Enable Select the type of auto-tune required.
  • Page 37 2 OPERATOR LEVEL… 2.14 Control Efficiency Monitor Note. With cascade control, the Control Efficiency Monitor is applicable only to the master controller. The Control Efficiency Monitor can be used either to compare the relative performance with different tuning parameters, or when fine tuning the PID settings, to give optimum control. When the set point is changed, auto mode is selected or following a power failure, input failure or a large load disturbance, the control monitor performs a series of measurements to indicate the effectiveness of the current control parameters.

  • Page 38: Control Efficiency Monitor

    …2 OPERATOR LEVEL …2.14 Control Efficiency Monitor period Set Point –2% approach settle Start of Calculation Fig. 2.14 Control Efficiency Monitor Parameters 2.14.1 Manual Tuning The Control Efficiency Monitor may be used for manually tuning the PID parameters. The following method describes how to tune the controller for wave damping: a) Set the integral and derivative action times to OFF.
  • Page 39 2 OPERATOR LEVEL… 2.14.2 Using the Control Efficiency Monitor 450. 2 500. 0 Press and hold the lower keys for 2 seconds. Note. If the front panel keys are not operated for 60 seconds whilst any Control Efficiency Monitor frame is being displayed, the instrument reverts to the first operating frame.

  • Page 40: Set Up Mode

    3 SET UP MODE 3.1 Introduction To access the Set Up mode (Levels 2 to 5) the correct password must be entered in the security code frame. Press and hold LEV1 COdE AtNE 450. 2 500. 0 OPEr Invalid password Valid Set Up or 450.

  • Page 41: Level 2 – Tune

    3 SET UP MODE… 3.2 Level 2 – Tune 2.00...2.04 Note. Level 2 is not applicable if an Auto/Manual Station, Indicator or Ratio Station template is selected. 2. 0 0 Level 2 – Tune LEV. 2 tUNE Note. To select this frame from anywhere in this page, press and hold the key for a few seconds.

  • Page 42: Level 2 - Tune

    …3 SET UP MODE …3.2 Level 2 – Tune 2.05...2.13 •1 Proportional Band 1 2. 0 5 Pb-1 100. 0 Enter the value for Proportional Band 1. [0.1% to 999.9%] 'Pb-1' is the default proportional band and is the proportional band for the master controller if a cascade template is selected –...
  • Page 43 3 SET UP MODE… …3.2 Level 2 – Tune 2.14...2.19 •1 2. 1 4 Derivative Action Time 2 drV2 [0.1 to 999.9 seconds or 'OFF'] The derivative action time for the slave controller if a cascade template is selected – see Section 4.2, Control Configuration/ Template Application. •2 2.
  • Page 44 …3 SET UP MODE …3.2 Level 2 – Tune 2.20...2.23 •1 2. 2 0 Feedforward Bias FFbS 0. 0 [–100.0% to 100.0%] 2. . 2 1 Control Deadband Cbnd When the process variable is in the deadband, changes to the control output due to proportional and integral action are suppressed.
  • Page 45 3 SET UP MODE… 3.3 Level 3 – Set Points 3.00...3.07 Note. Level 3 is not applicable if Auto/Manual Station or Indicator templates are selected. Level 3 – Set Points 3. 0 0 LEV. 3 SEtP Note. To select this frame from anywhere in this page, press and hold the key for a few seconds.

  • Page 46: Level 3 - Set Points

    …3 SET UP MODE …3.3 Level 3 – Set Points 3.08...3.10 •1 Cascade Set Point Ratio 3. 0 8 C. r tO In automatic mode, the slave set point value is: 1. 0 00 (ratio x master output) + bias. [0.001 to 9.999] •1 Cascade Set Point Bias...

  • Page 47: Level 4 - Alarm Trip Points

    3 SET UP MODE… 3.4 Level 4 – Alarm Trip Points 4.00...4.08 Note. Level 4 is not applicable if all alarm types are set to 'None' – see Section 4.4, Alarms/ Alarm Type. Level 4 – Alarm Trip Points 4. 0 0 LEV.

  • Page 48: Level 5 - Valve Setup

    …3 SET UP MODE 3.5 Level 5 – Valve Setup 5.00...5.04 Note. Level 5 is applicable only for a motorized valve output type – see Section 4.2, Basic Configuration/ Output Type. Valve Open relay Output (PID O/P x V. r At Control Process Controller...
  • Page 49 3 SET UP MODE… 3.5.2 Valve Setup (Boundless Types) – Fig. 3.4 A ‘boundless’ process controller provides an output that is effectively the time derivative of the required regulator position, i.e. the COMMANDER 500 signals the regulator, not where to go to (position derivative), but in which direction to travel and how far to move, by a series of integral action pulses.
  • Page 50 …3 SET UP MODE 5.00...5.04 …3.5.2 Valve Setup – Boundless 5. 0 0 LEV. 5 Level 5 – Valve Setup U. L U. E Note. To select this frame from anywhere in this page, press and hold the key for a few seconds. 5.

  • Page 51: Configuration Mode

    4 CONFIGURATION MODE 4.1 Introduction To access the Configuration mode (Levels 6 to E) the correct password must be entered in the security code frame. LEVE Valid Note. When in the configuration LEV6 Configuration mode, alternate bargraphs led's are APPL password illuminated, all relays and digital outputs Press...
  • Page 52 …4 CONFIGURATION MODE 4.2 Level 6 – Basic Configuration 6.00...6.01 Level 6 – Basic Configuration 6. 0 0 LEV. 6 APPL Note. To select this frame from anywhere in this page, press the key for a few seconds. Template Application 6.

  • Page 53: Level 6 - Basic Configuration

    4 CONFIGURATION MODE… …4.2 Level 6 – Basic Configuration 6.02 •1 6. 0 2 Control Output Type O. t YP The appropriate relays, digital outputs and analog outputs are assigned to AnLG the control output variables. The other hardware outputs are provisionally assigned to alarm and retransmission functions but these may be changed in the output assignment level –...
  • Page 54 …4 CONFIGURATION MODE …4.2 Level 6 – Basic Configuration Output Types: ANLG Relay Output Control Process Digital Output Algorithm Analog Output A – Single Output Output Type: Open relay Control Valve Process Algorithm Controller Close relay Position Feedback B – Motorized Valve Output with Feedback Output Type: Open relay Control...
  • Page 55 4 CONFIGURATION MODE… …4.2 Level 6 – Basic Configuration 6.03...6.06 •1 Control Action 6. 0 3 C. A Ct 3 • 3 • 4 • 4 • 4 • 4 • •2 Control Action (Master Loop) 6. 0 4 Act1 –...
  • Page 56 …4 CONFIGURATION MODE 4.3 Level 7 – Analog Inputs 7.00...7.03 Level 7 – Analog Inputs 7. 0 0 LEV. 7 INPt Note 1. Refer also to Table A – Template Applications on the rear fold-out. Note 2. To select this frame from anywhere in this page, press the key for a few seconds.
  • Page 57 4 CONFIGURATION MODE… … 4.3 Level 7 – Analog Inputs 7.04...7.07 Engineering High (I/P1) 7. 0 4 En1. H 1000 [–999 to 9999] Note. This parameter defaults to the maximum allowed value when THC or RTD inputs are selected – see Table 4.1. °C °F THC/RTD Type...

  • Page 58: Level 7 - Analog Inputs

    …4 CONFIGURATION MODE … 4.3 Level 7 – Analog Inputs 7.08...7.14 •1 7. 0 8 Analog Input Type & Electrical Range (I/P2) tYP2 Note. THC inputs can only be used on I/P2 if I/P1 is also set to THC. n i l •2 7.
  • Page 59 4 CONFIGURATION MODE… … 4.3 Level 7 – Analog Inputs 7.15...7.21 Analog Input Type & Electrical Range (I/P3) •1 7. 1 5 tYP. 3 n i l Temperature Units •2 7. . 1 6 UNt3 THC readings displayed in °C –...
  • Page 60 …4 CONFIGURATION MODE 4.4 Level 8 – Alarms Note. Any type of alarm can be used to sound an annunciator (klaxon/horn) which is disabled when the alarm is acknowledged. This is achieved by assigning the relay to the acknowledge state of the alarm instead of the actual alarm state.

  • Page 61: Level 8 - Alarms

    4 CONFIGURATION MODE… …4.4 Level 8 – Alarms Hysteresis Trip Point Hysteresis Process Variable Alarm On High Process Alarm Off Alarm On Low Process Alarm Off Fig 4.5 High and Low Process Alarm Action Trip Point Hysteresis Process Variable Alarm On Alarm Latched Alarm Off Alarm acknowledged...
  • Page 62 …4 CONFIGURATION MODE …4.4 Level 8 – Alarms 8.00...8.03 Level 8 – Alarms 8. 0 0 LEV. 8 ALMS Note. To select this frame from anywhere in this page, press the key for a few seconds. Alarm 1 Type 8. 0 1 tYP.
  • Page 63 4 CONFIGURATION MODE… … 4.4 Level 8 – Alarms 8.04...8.25 8. 0 4 Alarm Type 2 (Alarms 2 to 8) tYPx NONE 8. 0 7 8. 1 0 [see Alarm 1 Type] 8. 1 3 8. 1 6 8. 1 9 8.
  • Page 64 …4 CONFIGURATION MODE 4.5 Level 9 – Set Point Configuration 9.00...9.05 Note. Level 9 is not applicable when an Indicator template (templates 7 and 8) or an Auto/Manual station template (templates 3 and 4) is selected. 9. 0 0 Level 9 – Set Point Configuration LEV9 SEt.

  • Page 65: Level 9 - Set Point Configuration

    4 CONFIGURATION MODE… …4.5 Level 9 – Set Point Configuration 9.06...9.11 •1 Remote Set Point Fault Action 9. . 0 6 SP. F A The action required when a fault occurs with the remote set point. NONE NONE – No action –...
  • Page 66 …4 CONFIGURATION MODE …4.5 Level 9 – Set Point Configuration 9.12...9.14 •1 Local/Remote Set Point (or Ratio) Selection Source 9. 1 2 Lr. 5 r The source required to lock into remote set point mode or remote ratio NONE mode when the ratio controller template is selected. When the source is active the key does not operate.
  • Page 67 4 CONFIGURATION MODE… 4.6 Level A – Control Configuration A.00...A.02 Note. Level A is not displayed if an indicator template is selected. Level A – Control Configuration A. 0 0 LEVA CntL Note. To select this frame from anywhere in this page, press and hold key for a few seconds.

  • Page 68: Level A - Control Configuration

    …4 CONFIGURATION MODE …4.6 Level A – Control Configuration A.03...A.08 Process Variable Fail Action A. 0 3 PVFA Determines controller output when the process variable input fails. NONE No action NONE Put into Manual mode HOLd Put into Manual mode and select default output dFLt Default Output A.
  • Page 69 4 CONFIGURATION MODE… …4.6 Level A – Control Configuration A.09...A.12 •1 Output 2 (Cool) Low Limit – Heat/Cool Control A. 0 9 OP2L Limits the low level of control output 2 in automatic mode, when 'reverse- reverse' or 'direct-direct' control action is selected in the Basic Configuration level.
  • Page 70 …4 CONFIGURATION MODE …4.6 Level A – Control Configuration A.13...A.17 Configured Output 1 A. 1 3 C. O P1 The control output value required when manual is selected by manual 0. 0 mode source 1. [0 to 100% or LAST (non-heat/cool)] [–100 to 100% (heat/cool only)] Manual Mode Selection Source 2 A.
  • Page 71 4 CONFIGURATION MODE… …4.6 Level A – Control Configuration A.18...A.22 Auto Mode Selection Source A. 1 8 A. S rC Select the digital source used to activate auto mode. Auto •1 See Rear Fold-out/ Table C – Digital Sources. Manual •2 Tune Parameter Source 1 (Gain Scheduling) A.
  • Page 72 …4 CONFIGURATION MODE 4.7 Level B – Operator Configuration b.00...b.06 Level B – Operator Configuration b. 0 0 LEVb OPEr Note. To select this frame from anywhere in this page, press and hold key for a few seconds. •1 Front Panel Auto/Manual Key Enable b.

  • Page 73: Level B - Operator Configuration

    4 CONFIGURATION MODE… b.07...b.13 …4.7 Level B – Operator Configuration •1 Auto-tune Password b. 0 7 A. P A5 Enables access to the auto-tune facility in the operator level. [0 to 9999 (default 0)] Set Up Password b. 0 8 S.

  • Page 74: Level C - Output Assignment

    …4 CONFIGURATION MODE 4.8 Level C – Output Assignment Configuration C.00, C01, C07, C08 Note. The Output Assignment default settings are preconfigured to each template – see Table B, Output Sources on the rear fold-out. Level C – Output Assignment C.
  • Page 75 4 CONFIGURATION MODE… 4.8.2 Analog Output 1 C02...C06 tYP1 ANLG Analog Output 1 (ao1) Assignment Source •1 C. 0 2 AnI. A Select the source required to activate Analog Output 1 NONE See Rear Fold-out/ Table D – Analog Sources. Analog Output 1 (ao1) Electrical High C.
  • Page 76 …4 CONFIGURATION MODE 4.8.3 Output 2 Assignment C09, C15, C16 0. 0 dG1. P 0. 0 Analog/Digital Output 2 (ao2/do2) Type •1 C. 0 9 tYP. 2 Select the output type for Output 2. ANLG Analog ANLG – Digital – AN2.
  • Page 77 4 CONFIGURATION MODE… 4.8.5 Analog Output 2 C10...C14 tYP. 2 ANLG •1 C. 1 0 Analog Output 2 (ao2) Assignment Source AN2. A Select the source required to activate Analog Output 2 NONE See Rear Fold-out/ Table D – Analog Sources. •1 Analog Output 2 (ao2) Electrical High C.
  • Page 78 …4 CONFIGURATION MODE 4.8.6 Relay Outputs 1 to 4 C17...C22 0. 0 dG2. P 0. 0 •1 Relay 1 Assignment Source C. . 1 7 rL1. A Select the source required to activate relay output 1. NONE See Rear Fold-out/ Table C – Digital Sources. •2 Relay 1 Polarity C.
  • Page 79 4 CONFIGURATION MODE… …4.8.6 Relay Outputs 1 to 4 C23...C24 •1 Relay 4 Assignment Source C. . 2 3 rL4. A •4 Select the source required to activate relay output 4 NONE See Rear Fold-out/ Table C – Digital Sources. •2 Relay 4 Polarity C.

  • Page 80: Level D - Serial Communications

    …4 CONFIGURATION MODE 4.9 Level D – Serial Communications Configuration d.00...d.03 Note. Level D is only applicable if the serial communications option is fitted. d. 0 0 LEVd Level D – Serial Communications Configuration SErL Note. To select this frame from anywhere in this page, press and hold key for a few seconds.
  • Page 81 4 CONFIGURATION MODE… 4.10 Level E – Calibration E.00...E.04 Note. This page enables fine tuning of the inputs to eliminate system errors. Level E – Calibration E. 0 0 LEVE Note. To select this frame from anywhere in this page, press the key for a few seconds.

  • Page 82: Level E - Calibration

    …4 CONFIGURATION MODE …4.10 Level E – Calibration E.05...E.10 Analog Input 3 Offset Calibration •1 E. 0 5 OFF. 3 Analog Input 3 Value in Engineering Units 100. 3 8888 0. 0 Offset [In engineering Units] If the keys are not operated for three seconds the display reverts to the offset value only.
  • Page 83 4 CONFIGURATION MODE… …4.10 Level E – Calibration E.11...E.16 FCAL •1 Position Feedback Electrical Range Low Fb. L O Set the minimum electrical input value. 100. 0 [0.0 to 999.9] For resistance input types, no decimal places are displayed. For all other input types, 1 decimal place is displayed.

  • Page 84: Installation

    5 INSTALLATION EC Directive 89/336/EEC In order to meet the requirements of the EC Directive 89/336/EEC for EMC regulations, this product must not be used in a non-industrial 55°C environment. Max. End of Life Disposal 0°C This instrument does not contain any substance Min.
  • Page 85 5 INSTALLATION… 5.1.2 Mounting – Figs. 5.3 to 5.5 The instrument is designed for panel mounting (Fig. 5.4). Overall dimensions are shown in Fig. 5.3. Note. For NEMA4X protection, a minimum panel thickness of 2.5mm is recommended. Dimensions in mm (in.) 137.5 (5.41) 76 (2.99) (0.71)
  • Page 86 …5 INSTALLATION …5.1.2 Mounting – Figs. 5.3 to 5.5 Fit the panel clamps to the case, ensuring that the lugs are correctly located in their slots Cut a suitable hole in the panel (see Fig. 5.3) Insert the case (and instrument, if assembled) into the panel cut-out...
  • Page 87 5 INSTALLATION… …5.1.2 Mounting – Figs. 5.3 to 5.5 Unclip the process label cover and remove the process label, if fitted. Loosen the captive screw securing the instrument to the case Remove the instrument from the case Note. Refitting is the reversal of removal. Fig.
  • Page 88 …5 INSTALLATION 5.1.3 Process Labels – Fig. 5.6 Inscribe the process label with the desired text Unclip the process label cover from the front panel Refit the cover over the process label Insert the process label into the recess Fig. 5.6 Fitting Process Labels...

  • Page 89: Electrical Installation

    5 INSTALLATION… 5.2 Electrical Installation Refer to the Template Applications table and Output Sources table on the rear fold-out to determine the input and output connections to be made. Warning. Before making any connections, ensure that the power supply, any powered control circuits and high common mode voltages are switched off.
  • Page 90 …5 INSTALLATION …5.2.1 Electrical Connections – Figs. 5.7 to 5.9 3-lead 2-lead RTD Milliamps * Milliamps Voltage millivolts and Resistance and volts lead – RTD – – Analog **100Ω **100Ω Input 1 RTD – RTD – I/P 1 CJ Sensor# **** –...

  • Page 91: Relays

    5 INSTALLATION… 5.3 Relays 5.4 Digital Output 15V d.c. min. at 20mA Note. Refer to rear fold-out/ Table B – Min. load 750Ω Output Sources for default relay assigments. 5.5 Control or Retransmission Relay contacts are rated at: Analog Output 115/230V a.c.

  • Page 92: Motorized Valve Connections

    …5 INSTALLATION 5.6 Motorized Valve Connections – Fig. 5.11 5.7 Input Connections Make connections to each input – see Fig 5.8. Note. Relays used to drive the motorized Refer to rear fold-out/ Table A – Template valve must be set for 'Normally Open' operation – Applications for the default input assignment see Section 5.3.1.

  • Page 93: Output Connections

    5 INSTALLATION… 5.7.2 3-lead Resistance 5.8 Output Connections Thermometer (RTD) Inputs Make connections as shown in Fig 5.7. The three leads must have equal resistance, not Refer to rear fold-out/ Table B – Output exceeding 50Ω each. Sources for the default output assignment settings.

  • Page 94: Specification

    SPECIFICATION Standard Functions Summary Control Strategies 17 application templates: Single loop, Cascade, Single-loop, Auto/Manual Station, Analog Backup, Indicator/ Feedforward, Ratio, Auto/Manual Manual Loader, Cascade, Feedforward, Ratio Two Autotune options Output Types Current proportioning, Time proportioning, On/off, Motorized valve Control Efficiency Monitor (with and without feedback), Heat/cool.
  • Page 95 SPECIFICATION... Analog Inputs Sample Interval Universal Process Inputs 125ms (1 input) Number 1 standard Digital filter Programmable 1 optional Cold Junction Compensation Type Automatic CJC incorporated as standard Universally configurable to provide Stability 0.05°C/°C change in ambient temperature Thermocouple (THC) Resistance thermometer (RTD) Input Protection Common mode rejection...
  • Page 96 ...SPECIFICATION Options Outputs Analog Inputs Control/Retransmission Outputs Number Number 1 standard, 1 optional Isolation Galvanically isolated from the rest of the circuitry Type Programmable as analog or logic (digital) output Type Universal (see on page 11) Dielectric Galvanically isolated from the rest of the circuitry Universal Process Inputs Analog range 0 and 20mA (programmable), accuracy: 0.25%...
  • Page 97 (500V DC for 1 minute) Environmental Operating Limits 0° to 55°C (32° to 130°F) 5 to 95%RH (non-condensing) Temperature stability <0.02%/°C or 2µV/°C (<0.011%/°F or 1.11µV/°F) Long term drift <0.02% of reading or 20µV annually Front face NEMA4X (IP66) SS/C505 Issue 4...

  • Page 98: Appendix A - Control Templates

    APPENDIX A – CONTROL TEMPLATES A1 Single Loop Controller (Templates 1 and 2)

  • Page 99: A2 Auto/Manual Station And Analog Backup Station

    APPENDIX A – CONTROL TEMPLATES… A2 Auto/Manual Station and Analog Backup Station A2.1 Series and Parallel Operation Note. See Sections A2.2 and A2.3 for detailed templates. C500 Process Process Variable I/P1 Master Output Actuator I/P2 Output Master Controller Digital Select Status di.1 Series Connection...
  • Page 100 …APPENDIX A – CONTROL TEMPLATES …A2.2 Auto/Manual Station (Templates 3 and 4)
  • Page 101 APPENDIX A – CONTROL TEMPLATES… A2.3 Analog Backup (Templates 5 and 6)

  • Page 102: A3 Indicator/Manual Loader Station (Templates 7 And 8)

    …APPENDIX A – CONTROL TEMPLATES A3 Indicator/Manual Loader Station (Templates 7 and 8)

  • Page 103: A4 Single Loop Controller With Feedforward (Templates 9 And 10)

    APPENDIX A – CONTROL TEMPLATES… A4 Single Loop Controller with Feedforward (Templates 9 and 10)

  • Page 104: A5 Cascade Controllers (Templates 11 And 12)

    …APPENDIX A – CONTROL TEMPLATES A5 Cascade Controllers (Templates 11 and 12)

  • Page 105: A6 Cascade Controller With Feedforward (Template 13)

    APPENDIX A – CONTROL TEMPLATES… A6 Cascade Controller with Feedforward (Template 13)

  • Page 106: A7 Ratio Controller (Templates 14 And 15)

    …APPENDIX A – CONTROL TEMPLATES A7 Ratio Controller (Templates 14 and 15)

  • Page 107: A8 Ratio Station (Templates 16 And 17)

    APPENDIX A – CONTROL TEMPLATES A8 Ratio Station (Templates 16 and 17)

  • Page 108: Appendix B - Commander Configuration Editor

    APPENDIX B – COMMANDER CONFIGURATION EDITOR B1 Introduction Using the COMMANDER Configurator the COMMANDER 500 can be programmed without using any of the front panel keys. In addition to the standard settings, the Configurator also gives access to more advanced features not accessible via the front panel keys.

  • Page 109: B9 Template Customization

    APPENDIX B – COMMANDER CONFIGURATION EDITOR B7 Two Delay Timers • Programmable delay and duration (0 to 9999 seconds) B8 Two Custom Linearizers • 15 breakpoints per linearizer • The source can be any analog signal B9 Template Customization Each template can be customized by changing the sources for various functions in the COMMANDER 500. This allows maths blocks and custom linearizers to be added into the standard template format.

  • Page 110: Frames Index

    FRAMES INDEX Set Up Frames Mnemonic Number Frame Title Pb-1 2. 0 5 Proportional Band 1 Pb-2 2. 0 6 Proportional Band 2 1. x xx 4. 0 1 Proportional Band 3 Pb-3 2. 0 7 Alarm 1 Trip 2. x xx 4.
  • Page 111 FRAMES INDEX… Configuration Frames Frame Title Mnemonic Number LEV6, APPL 6. 0 0 Basic Configuration b. d IS b. 0 6 Bias Display Enable Alarm 1 Hysteresis HYS. 1 8. 0 3 Alarm 1 Trip trP. 1 8. 0 2 Alarm 1 Type Calibration LEVE, CAL...
  • Page 112 …FRAMES INDEX LEV7 7. 0 0 Level Heading Serial Communications LEVd d. 0 0 LC. S r 9. 1 3 Local Set Point Source Serial Configuration S. C FG d. 0 1 Local/Remote Enable FPLr b. 0 2 Set Point Configuration LEV9, SEt.

  • Page 113: Index

    INDEX …C Accessories .............. 1 Configuration Error ........... 9 Alarms ............43, 56 Configuration Password ......... 69 Acknowledge ............. 5 Configured Outputs 1 to 3 ........66 Acknowledge enable ........68 See Also: Auto/Manual and Backup Templates Configuration ........... 56 Control Action ............
  • Page 114 …INDEX …O Heat/Cool ..............28 Output Control Action ........... 49, 51 Assignment – Level C ........70 Output limits ............ 64 Connections ........85, 87, 88 Start positions ..........40 Heat/Cool ............28 Hysteresis Limits ............... 64 Alarms ............ 56 to 59 Slew Rate ............
  • Page 115 INDEX Secret-til-Lit Indicators ..........8 Security Options ............. 69 Serial Communications – Level d ......76 Set Points Configuration – Level 9 ........60 Default Value ........... 61 Limits ............... 60 Operator Adjust enable ........68 Ramp Rate ............42 Scaling .............
  • Page 116 NOTES...
  • Page 117 REFERENCE TABLES Table A – Template Applications . 1 L S † . 2 L S † . 3 M A – . 4 M A i g i – . 5 b A – . 6 b A i g i –...
  • Page 118 REFERENCE TABLES Table C – Digital Sources e l i e l i e l i v i t v i t v i t l i a v i t i t l v i t i t l v i t v i t v i t...
  • Page 119 – Food & Beverage and Repair Centre. – Manufacturing – Metals and Minerals United Kingdom – Oil, Gas & Petrochemical ABB Limited – Pulp and Paper Tel: +44 (0)1480 475 321 Fax: +44 (0)1480 217 948 Drives and Motors •...
  • Page 120 ABB has Sales & Customer Support expertise The Company’s policy is one of continuous product in over 100 countries worldwide improvement and the right is reserved to modify the information contained herein without notice. www.abb.com © ABB 2003 Printed in UK (11.03) ABB Limited ABB Inc.

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