ABB C505 User Manual

User Guide

IM/C505_6

Control

/2 DIN Advanced Process Controller

C505

ABB

The Company

We are an established world force in the design and manufacture of instrumentation for industrial process control, flow measurement, gas and liquid analysis and environmental applications.

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 technology and unrivalled service and support.

The quality, accuracy and performance of the Company’s products result from over 100 years experience, combined with a continuous program of innovative design and development to incorporate the latest technology.

The UKAS Calibration Laboratory No. 0255 is just one of the ten flow calibration plants operated by the Company, and is indicative of our dedication to quality and accuracy.

BS EN ISO 9001:2000

Cert. No. Q5907

EN 29001 (ISO 9001)

Lenno, Italy – Cert. No. 9/90A

Use of Instructions

✶

Warning.

An instruction that draws attention to the risk of injury or death.

Caution.

An instruction that draws attention to the risk of damage to the product, process or surroundings.

Although

Warning hazards are related to personal injury, and Caution hazards are associated with equipment or

property damage, it must be understood that operation of damaged equipment could, under certain operational conditions, result in degraded process system performance leading to personal injury or death. Therefore, comply fully with all

Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this manual for any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval of the Technical Communications Department.

Warning and Caution notices.

Note.

Clarification of an instruction or additional information.

Information.

Further reference for more detailed information or technical details.

Health and Safety

To ensure that our products are safe and without risk to health, the following points must be 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 when operating in conditions of high pressure and/or temperature.

5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry. Normal safe handling procedures must be used.

6. When disposing of chemicals ensure that no two chemicals are mixed.

Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets (where applicable) may be obtained from the Company address on the back cover, together with servicing and spares information.

GETTING STARTED

Step 3 – Setting the Parameters (Fig. GS.1)

Pow er-up the instrument. Press the and keys simultaneously and hold f or 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 and keys to adjust the

default values – see Section 4.2 for further information.

Note. When the output type has been selected, the availab le inputs and outputs

default to the settings shown in Table B on the rear fold-out.

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.

Controller templates only: Select Level 2 using the upper and keys and set the tune parameters:

• Analog or Motorized Valve Control – set the Proportional, Integral and

Derivative terms.

• Time Proportioning Control – set the Cycle Time, Hysteresis and P, I & D Terms

• Heat/Cool Outputs – set the points at which the Output 1 and Output 2

become active.

Press to return to the Operating displays.

Adjust the set point to the required value.

Your COMMANDER 500 is now in operation

50.1

50.5

LEV.6 APPL

LEV.7 INPt

LEV2 tUNE

50.1

50.5

t.APP

C D

01.SL

O.tYP ANLG

C.ACt rEV

FrEJ

50.1

50.5

Note. With the above configuration, no alarms or limits have been set and advanced functionality (gain scheduling, set point sources etc.) has not been enabled.

Fig. GS.1 Setting the Parameters

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 – Connect the process inputs and outputs Step 3 – Power up the instrument, set 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 labels on the back of the instrument as a guide, connect the process inputs, outputs and power supplies. Refer to Section 5.2 of this man ual (Electrical Installation) for more information.

Continued…

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

• Displays and Function Keys

• LED Indication

• Error Messages

Operator Mode (Level 1)

• Single Loop Controller

• Motorized Valve Controller

• Auto/Manual & Backup Stations

• Feedforward Controllers

• Cascade Controllers

• 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

Fig. 1 Overview of Contents

Getting Started

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 Communications

• Level E – System Calibration

Installation

• Siting

• Mounting

• Electrical Connections

Table A – Template Applications

B – Output Sources

Getting Started

Shunt Resistors

2 x 100Ω

(+1 optional)

Process Labels

Fig. 3 Accessories

Fig. 2 Foldouts

Panel Clamps

Table C – Digital Sources

D – Analog Sources

CJ Sensor

(+1 optional)

CONTENTS

Section Page

OVERVIEW....................................................1

1 DISPLAYS AND FUNCTION KEYS ........3

1.1 Introduction .......................................3

1.2 Use of Function Keys .......................4

1.3 Secret-til-Lit Indicators......................8

1.4 Character Set ....................................8

1.5 Error Messages ................................9

1.6 Processor Watchdog ......................10

1.7 Loop Break Monitor ........................10

1.8 Glossary of Abbreviations...............10

2 OPERATOR LEVEL............................... 11

2.1 Introduction ..................................... 11

2.2 Single Loop Controller

(Templates 1 and 2)........................1 2

2.3 Auto/Manual Station

(Templates 3 and 4)........................1 4

2.4 Analog Backup

(Templates 5 and 6)........................1 6

2.5 Indicator/Manual Loader Station

(Templates 7 and 8)........................1 8

2.6 Single Loop with Feedforward

(Templates 9 and 10)......................19

2.7 Cascade Control

(Templates 11 and 12) .................... 21

2.8 Cascade with Feedforward

(Template 13) ..................................24

2.9 Ratio Controller

(Templates 14 and 15)....................26

2.10Ratio Station

(Templates 16 and 17)....................27

2.11 Heat/Cool Output Types .................28

2.12Motorized Valve Output Types .......29

2.13Auto-tune ........................................30

2.14Control Efficiency Monitor ..............33

3 SET UP MODE .......................................36

3.1 Introduction .....................................36

3.2 Level 2 – Tune ................................ 37

3.3 Level 3 – Set Points........................41

3.4 Level 4 – Alarm Trip Points.............43

3.5 Level 5 – Valve Setup.....................44

4 CONFIGURATION MODE ..................... 47

4.1 Introduction...................................... 47

4.2 Level 6 – Basic Configuration ........48

4.3 Level 7 – Analog Inputs ..................52

4.4 Level 8 – Alarms .............................56

4.5 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

4.10Level E – Calibration ......................77

Section Page

5 I NSTALLATION......................................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 Valve Connections .........88

5.7 Input Connections ...........................89

5.8 Output Connections ........................89

5.9 Power Supply Connections.............89

SPECIFICATION .........................................90

APPENDIX A – CONTROL TEMPLATES ..94

A1 Single Loop Controller

(Templates 1 and 2) ........................94

A2 Auto/Manual Station and

Analog backup Station.................... 95

A3 Indicator/Manual Loader Station

(Templates 7 and 8) ........................98

A4 Single Loop Controller with

Feedforward (Templates 9 and 10). 99

A5 Cascade Controllers

(Templates 11 and 12)..................100

A6 Cascade Controller with

Feedforward (Template 13)...........101

A7 Ratio Controller

(Templates 14 and 15)..................102

A8 Ratio Station

(Templates 16 and 17)..................103

APPENDIX B – COMMANDER

CONFIGURATION EDITOR......................104

B1 Introduction ...................................104

B2 Analog Input Customization ......... 104

B3 Programmable Maths Blocks........104

B4 Logic Equations ............................104

B5 Process Alarm Customization ......104

B6 Real Time Alarms .........................104

B7 Delay Timers .................................105

B8 Custom Linearizers.......................105

B9 Template Customization ...............105

B10 Connecting the COMMANDER

PC Configurator ............................105

FRAMES INDEX .......................................106

INDEX ......................................................109

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

100

58.8

Raise

Alarm

Acknowledge

M OP1 OP2 FF

Function Keys

62.4

MST SLV

15.0

Lower

Parameter Advance

Local/Remote

Fig. 1.1 Front Panel Displays and Function Keys

Up Down

Auto/manual

…1 DISPLAYS AND FUNCTION KEYS

1.2 Use of Function Keys

A – Raise and Lower Keys

bIAS

50.0

Use to change/set a parameter value… …move between levelsand…

B – Up and Down Keys

700

Use to adjust the output value…

C – Parameter Advance Key

LEV2 tUnE

CYCl

51.0

49.0

–

710

690

–

and…

Frame 1 (top of level)

Frame 2

…move between frames within a Setup or Configuration level. Any changes made on the current frame are stored when the next frame is selected.

5.0

2.00

2.01

LEV1

OPEr

LEV2 tUnE

CYCl

5.0

LEVx 1001 1002 1003

Frame 1 (top of level)

Frame 2

Press and hold

LEV2

tUnE

Note. This key also stores any changes made in the previous frame

D – Auto/Manual Key

Use to advance to the next frame within a level…

Auto Manual

450.2

500.0

Use to select Auto or Manual control mode

Fig. 1.2a Use of Function Keys

or…

…select the top (LEV.x) frame from within a level

450.2

500.0

Process Variable Control Set Point

Control Output (%)

…1.2 Use of Function Keys

E – Alarm Acknowledgement

Any active,

unacknowledged

alarms

All active

alarms

acknowledged

(Flashing)

450.2

500.0

200.3

1.HP1 2003

1HP1

ACt

ACK

LAt

CLr

ACK

LAt

200.3

2.xxx

ACt

Unacknowledged

alarms only

450.2

500.0

(On continuously) (Off)

No active

alarms present

Pressing again acknowledges the displayed alarm. Lower display changes to reflect new status.

Next active and unacknowledged alarm is displayed. If no alarms are active, the next enabled alarm is displayed.

The first active and unacknowledged alarm is displayed (or if no alarms are active, the first enabled alarm is displayed)

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

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 1 High High Deviation Maths Block 1 Low Low Deviation Maths Block 2 High High Process I/P1 Maths Block 2 Low Low Process I/P1 Maths Block 3 High High Process I/P2 Maths Block 3 Low

Low Process I/P2 Maths Block 4 High High Process I/P3 Maths Block 4 Low Low Process I/P3

HPV HO LPV LO HLP PF.t LLP Hb1 Hd Lb1 Ld Hb2 HP1 Lb2 LP1 Hb3 HP2 Lb3 LP2 Hb4 HP3 Lb4 LP3

Note. If no alarms have been enabled in the Set Up level, pressing

the key has no effect.

1 DISPLAYS AND FUNCTION KEYS…

Fig. 1.2b Use of Function Keys

…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

Process variable and local set point (ratio) displayed on red and green displays. Remote set point (ratio) value is displayed. The value and symbol flash to

450.2

400.0

450.2

400.0

indicate local set point (ratio) still selected.

Remote set point (ratio) selected.

Remote selection aborted.

Note. When an Analog Backup Station template is selected, the key

is used to switch between local and remote mode – see Sections 2.4 and 4.2.

Selecting Local Set Points 1 to 4

450.2

350.0

Process variable and local set point 1 displayed.

Process variable and local set point 2 displayed

Process variable and local set point 3 displayed

3 4

Process variable and local set point 4 displayed

450.2

400.0

450.2

475.0

450.2

475.0

Selecting Master and Slave Set Points – Cascade Mode

Abbreviations are

detailed in Section 1.8.

Slave PID

Control Loop

When the SLV indicator (see Fig 1.3) is lit, the key can be used to switch between the local slave set point and the cascade

LSPt RSPt

M.PV S.PV

M.SPt

Master

Control Loop

450.2

When the MST indicator

350.0

(see Fig 1.3) is lit, the

key can be used to switch between the Master

local and remote set points

PID

Local S.SPt

M.OP x CrtO + CbIA

S.SPt

450.2

350.0

slave set point generated from the master output.

OP1

Fig. 1.2c Use of Function Keys

…1.2 Use of Function Keys

G – Short-cut Keys

1 DISPLAYS AND FUNCTION KEYS…

Press simultaneously and hold for 3 seconds

LEVA

CntL

LEV1

OPEr

Press to move from anywhere in the Configuration level to the first frame in the Operator level

450.2

350.0

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

LEV6

APPL

450.2

350.0

Press to move from anywhere in the Operator or Setup levels to the first page of the Configuration

Note. This Short-cut key operates only when the configuration password is set to ‘0’

level

Fig. 1.2d Use of Function Keys

…1 DISPLAYS AND FUNCTION KEYS

1.3 Secret-til-Lit Indicators

450.2

350.0

MST SLV

450.2

350.0

150

M OP1 OP2 FF

MST

SLV

OP1

OP2

Flashing

One or more alarms active and unacknowledged

A – Upper Display

Flashing

Autotune in progress

All active alarms acknowledged

Master controller parameters displayed

Slave controller parameters displayed

Remote or Cascade set point in use

Manual control selected

Output 1 (heat) value displayed

Output 2 (cool) value displayed

Feedforward disturbance variable displayed

Valve opening Valve stopped Valve closing

B – Lower Display

OFF

No alarms active

Local set point in use

OFF

Auto control selected

1.4 Character Set – Fig. 1.4

A B C D E F G H

Fig. 1.3 Secret-til-lit Indicators

A b C d E F G H

Fig. 1.4 Character Set

1.5 Error Messages

1 DISPLAYS AND FUNCTION KEYS…

Display

CAL Err

Err NVx

A-d Err

9999

t.Err 1

CJ.F 1

rSP.F 9999

rAt.F 9999

Error/Action Calibration Error

Turn mains power off and on again (if the error persists contact the Customer Support Organization).

Non-volatile Memory Error

x = 1, 2: Motherboard Memory x = 3: Option Board Memory Turn mains power off and on again (if the error persists, check configuration/setup settings).

A to D Converter Fault

The analog to digital converter is not communicating correctly.

Input Value Over/Under Range

Auto-tune Error

The number displayed indicates the type of error present – see Table 2.1 on page 30.

Cold Junction Failed

Cold junction 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.

To clear the display:

Press the key

Contact the Customer Support Organization

Restore valid input

Press the key

Check connections or replace if faulty.

Restore valid input

StK

999

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 to 'PFb' – motorized valve with feebac k.

Check that the correct Regulator Travel Time has been set – see Section 3.5. Check the valve.

Restore valid input

…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. A warning signal or other action can be initiated by assigning the loop break signals to relays or digital outputs.

1.8 Glossary of Abbreviations

noitaiverbbAnoitpircseDnoitaiverbbAnoitpircseD

VPelbairaVssecorP1id1tupnIlatigiD

tPSLeulaVtnioPteSlacoL2id2tupnIlatigiD 1PSLeulaV1tnioPteSlacoL3id3tupnIlatigiD 2PSLeulaV2tnioPteSlacoL4id4tupnIlatigiD 3PSLeulaV3tnioPteSlacoL1oa1tuptuOgolanA 4PSLeulaV4tnioPteSlacoL2oa2tuptuOgolanA

tPSCeulaVtnioPteSlortnoC1od1tuptuOlatigiD

tPSReulaVtnioPteSetomeR2od2tuptuOlatigiD

P/ODIPmhtiroglADIPehtfotuptuOVP.MelbairaVssecorPretsaM 1PO)taeh(1tuptuOrellortnoCtPS.MtnioPteSlortnoCretsaM 2PO)looc(2tuptuOrellortnoCPO.MtuptuODIPretsaM

1P/I1tupnIgolanAtPS.StnioPteSevalS 2P/I2tupnIgolanAVP.SelbairaVssecorPevalS 3P/I3tupnIgolanAVWelbairaVdliW

VDelbairaVecnabrutsiD

Table 1.1 Glossary of Abbreviations

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:

• Single loop controller

• Auto/Manual station

• 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.

C501

01.SL

2001

Fig. 2.1 Power-up Displays

Model – C501

Template (see rear fold-out)

Software series

Software version

…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

Remote Set Point Input

•1

I/P2

Process Variable Input

I/P1

•1 Template 2 Only

I/P2 x rAtO + bIAS

RSPt

CSPt

Manual Output

PID

Control Loop

Fig. 2.2 Single Loop Controller

PID O/P

Control Output

OP1

…2.2 Single Loop Controller (Templates 1 and 2)

2 OPERATOR LEVEL…

Set Point

Process Variable

Set Point

Process Variable

OP1

•1

Process Variable

450.2

500.0

rAtO

•1

•2

Control Set Point

['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. With on/off control selected, 0% = control output off, 100% = control output on. In manual mode, intermediate values can be selected. These use 'time proportioning' with a 60s cycle time, e.g. 25% = 15s on, 45s off.

Remote Set Point Ratio

1.000

[0.001 to 9.999] Remote set point value = (ratio x remote set point input) + bias

Set Point Process

Variable

bIAS

1.000

•3

Remote Set Point Bias

[In engineering units]

OP1

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 displayed if template 2 selected and Ratio Display is enabled – see Section 4.2, Basic Configuration and Section 4.7, Operator Configuration.

•3 Only displayed if template 2 selected and Bias Display is enabled – see Section 4.2, Basic Configuration and Section 4.7, Operator Configuration.

…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). 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 Configuration/ Configured Output 1. When the master output is restored or the digital input returns to its inactive state, the COMMANDER 500 switches back to auto mode.

Note. The Alarm A1 Trip value must be set when using template 3.

Manual Output

Master Output

I/P2

Digital Select

di1

•1 Template 3 Only

•2 Template 4 Only

Low Signal Select

(Alarm A1)

•1

•2

Fig. 2.3 Auto/Manual Station

Analog Output

ao1

Auto / Manual

Select

…2.3 Auto/Manual Station (Templates 3 and 4)

2 OPERATOR LEVEL…

Master output

Process Variable

•1

•2

Low Master Output Value

•3

Digital Input Active

Master output

Process Variable

55.0

50.0

55.5

50.0

•1

•2

Restored Master Output

•3

Digital Input Inactive

Auto Mode

Process Variable Master Output (I/P2)

Control Output = Master Output

[Master Output, 0 to 100%]

Manual Mode

•1 In template 4 the Auto/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.

Control Output (under COMMANDER 500 control)

[0 to 100%]

…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. 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 master output value continuously in order to ensure bumpless transfer from remote to local mode operation. When the master output is restored or the digital input returns to its inactive state, the COMMANDER 500 switches back to remote control mode.

Note. The Alarm A1 Trip value must be set when using template 5.

Manual Output

Local Set Point

LSPt

Process Variable

I/P1

Master Output

I/P2

Digital Select

di1

•1 Template 5 Only

•2 Template 6 Only

PID

Control Loop

Low Signal Select

(Alarm 1)

Fig. 2.4 Analog Backup Station

•1

•2

Local/

Remote

Select

Analog Output

ao1

…2.4 Analog Backup (Templates 5 and 6)

2 OPERATOR LEVEL…

Set Point

Process Variable

•1

•2

Set Point

Process Variable

OP1

Low Master Output Value

Digital Input Active

55.0

50.0

55.5

50.0

•1

Restored Master Output

•2

Digital Input Inactive

Remote Mode

Process Variable

Set Point

['SPLO' to 'SPHI' – see Section 4.5]

Control Output = Master Output

[Master Output, 0 to 100%]

Local Mode

OP1

•1 Template 5 only – see Section 4.2, Basic Configuration/ Template Application.

•2 Template 6 only – see Section 4.2, Basic Configuration/ Template Application.

Control Output (under COMMANDER 500 control)

[0 to 100%] Adjustable in Manual Mode only.

…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.

Process Variable (PV2)

Process Variable (PV1)

OP1

•1

55.0

50.0

•1

•2

Process Variable PV1

Process Variable PV2

Output Value

[–10 to 110%]

•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).

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.

Local Set Point

LSPt

Manual Output

Remote Set Point input

•1 PV input

Feedforward Disturbance Variable

I/P2

•1 Template 10 Only

I/P3

I/P1

RSPt x rAtO + bIAS

Control Set Point

Process

•1

450.2

500.0

Variable

OP1

Control Set Point

Process

450.2

500.0

Variable

CSPt

∑

PID O/P +

(DV x FFGn + FFbS)

DV x FFGn + FFbS

MPV

PID

Control Loop

FFGN = 0

Fig. 2.5 Single Loop Controller with Feedforward

Process Variable

Control Set Point

•1

['SPLO' 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.

OP1

[0 to 100%]

Feedforward disturbance variable signal.

Continued…

…2 OPERATOR LEVEL

…2.6 Single Loop with Feedforward (Templates 9 and 10)

Set Point Process

Variable

Set Point Process

Variable

OP1

rAtO

1.000

bIAS

0. 0

•1

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

•1 Only displayed if template 10 selected – see Section 4.2, Basic Configuration/Template Application and Section 4.7, Operator Configuration/Operator Ratio Display and Operator Bias Display.

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 Set Point

LSPt

Remote Set Point input

•1

I/P3

Master PV Input

I/P1

Slave PV Input

I/P2

•1 Template 12 Only

Master Set Point (MSPt)

MST

Master Process Variable (MPV)

OP1

RSPt x

RSPt

rAtO + bIAS

•1

MPV

SPV

450.2

500.0

Slave Set Point

SSPt

Master

Control Loop

PID

M.OP

M.OP x CrtO + CbIA

Fig. 2.6 Cascade Controller

Master Process Variable (MPV)

•1

Master Control Set Point (MSPt)

['SPLO' to 'SPHI' – see Section 4.5] Adjustable in local control only.

Slave Control Output

[0 to 100%] (–10 to 110% for analog outputs) Adjustable in manual mode only.

to change between local/remote set point values.

SSPt

Manual Output

Slave PID

Control Loop

Note. With template 12 the

key can be used

OP1

Slave Set Point (SSPt)

450.2

500.0

Slave Process Variable (SPV)

Slave Set Point (SSPt)

['SPLO' to 'SPHI' – see Section 4.5]

Slave Process Variable (SPV)

SLV

OP1

Adjustable in manual or local slave set point modes only.

Note. The

key can be used in this frame to

change between cascade and local slave set points.

Continued…

…2 OPERATOR LEVEL

…2.7 Cascade Control (Templates 11 and 12)

Master Set Point (MSPt)

Master Process Variable (MPV)

Master Set Point (MSPt)

Master Process Variable (MPV)

Slave Set Point (SSPt)

Slave Process Variable (SPV)

MST

OP1

MST

OP1

SLV

OP1

rAtO

1.000

bIAS

0. 0

C.rtO

1.000

•1

•2

Remote Set Point Ratio

[0.001 to 9.999] Master remote set point value = (ratio x remote set point input) + bias

Remote Set Point Bias

[in engineering units]

Cascade Slave Set Point Ratio

[0.001 to 9.999] Slave set point (SSPt) value = (ratio x master 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.

…2.7 Cascade Control (Templates 11 and 12)

2 OPERATOR LEVEL

Slave Set Point (SSPt)

Slave Process Variable (SPV)

SLV

OP1

C.bIA

0. 0

•1

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.

…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.

Local Set Point

LSPt

MSPt

Master PV Input

I/P1

Feedforward Disturbance Variable

I/P3

Slave PV Input

I/P2

Master Set Point (MSPt)

MST

MPV

SPV

•1

450.2

500.0

Master Process Variable (MPV)

OP1

FFGn

= 0

SSPt

∑

Master

PID

Control Loop

DV x FFGn + FFbS

Local Slave Set Point

SSPt

M.OP x

CrtO + CbiA

Fig. 2.7 Cascade Controller with Feedforward

Master Process Variable (MPV)

•1

Master Control Set Point (MSPt)

['SPLO' to 'SPHI' – see Section 4.5] Adjustable in Local control only

Slave Control Output

[0 to 100% (–10 to 110% for analog outputs)] Adjustable in Manual mode only.

Manual Output

Slave

PID

Control Loop

OP1

Slave Set Point (SSPt)

1997 2000

Slave Process Variable (SPV)

Slave Set Point (SSPt)

['SPLO' to 'SPHI' – see Section 4.5] Adjustable in Manual mode only

Note. The

key can be used in this frame to

change between cascade and local slave set points.

Slave Process Variable

SLV

(SPV)

OP1

Continued…

…2.8 Cascade with Feedforward (Template 13)

2 OPERATOR LEVEL…

Master Set Point (MSPt)

Master Process Variable (MPV)

Slave Set Point (SSPt)

Slave Process Variable (SPV)

Slave Set Point (SSPt)

Slave Process Variable (SPV)

MST

SLV

OP1

SLV

OP1

450.2

500.0

C.rtO

1.000

C.bIA

0. 0

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.

•1

Cascade Slave Set Point Ratio

[0.001 to 9.999] Slave set point (CSP2) value = (ratio x master ouput) + bias [in engineering units]

Cascade Slave Set Point Bias

[In engineering units]

Return to Master Process Variable (MPV) display.

•1 Only displayed if enabled in Level B, Operator Configuration – see Section 4.7.

…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

•1

Remote Ratio

I/P3

Wild Variable

I/P2

Process Variable input

I/P1

•1 Template 15 only

Control Set Point

Process Variable (PV)

OP1

Control Set Point

Process Variable (PV)

55.0

50.0

bIAS

0. 0

rAtO

rAtO +bIAS

Fig. 2.8 Ratio Controller

•1

Manual Output

Control

CSPt

PID

Control Loop

PID O/P

Output

OP1

Actual Ratio

Process Variable (PV) – Bias

Wild Variable (WV)

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]

OP1

Return to Actual Ratio display.

•1 Only displayed if enabled in Level B, Operator Configuration – see Section 4.7.

+ 90 hidden pages

ABB C505 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

OVERVIEW

1 DISPLAYS AND FUNCTION KEYS

2 OPERATOR LEVEL