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Manuals and User Guides for ABB ControlIT 53MC5000. We have
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ABB ControlIT 53MC5000 manual available for free PDF download: Instruction Manual
ABB ControlIT 53MC5000 Instruction Manual (406 pages)
Multi-Loop Process Controller
Brand:
ABB
| Category:
Controller
| Size: 11.78 MB
Table of Contents
Table of Contents
3
1 Introduction
15
Product Overview
15
Figure 1-1. Typical Displays
17
Scope of Book
18
Figure 1-2. Information Layout of Book
20
Model Number Breakdown
21
Specifications
24
Table 1-1. 53MC5000 Process Control Station Specifications
24
Table 1-2. 6 Digital Input/4 Digital Output Option Specifications
28
Table 1-3. Dual Relay ITB Specifications
29
Table 1-4. 16 Digital Input/Digital Output Option Board and ITB Specifications
29
Table 1-5. OPTO 22 Module Specifications for 16DI/DO ITB
30
Table 1-7. Multichannel Analog Option Specifications
32
Table 1-8. Group 5B Isolation Module Specifications
33
Related Documentation
37
Table 1-9. SCADA Board Specifications
37
2 Installation
40
Inspection
40
Packing Bolt Removal
40
Table 2-1. Packing Bolt Removal
40
Figure 2-1. Packing Bolt
40
Location
41
Mounting
41
Figure 2-2. Outline Dimensions and Panel Cut-Out Requirements
42
Table 2-2. Controller Panel Mounting
43
Figure 2-3. Single or Multiple Panel Mounting
43
Figure 2-4. Bracket Rods
44
Figure 2-5. Intercase Spacing
44
MOUNTING the INTERCONNECTION TERMINAL BOARDS (Itbs)
45
Figure 2-6. ITB Snap-Mounting
46
Figure 2-7. Controller Rear Terminal ITB Connectors
47
Figure 2-8. Potential ITB Complement to Controller with Standard Rear Terminal Board
48
Figure 2-9. Potential ITB Complement to Controller with Cord Set Connector Board
49
Removable Plug-In Connectors
50
Figure 2-10. Removable Plug-In Connectors from Standard Rear Terminal Board
50
POWER CONNECTIONS for CONTROLLER and Itbs
51
Figure 2-11. Power Connections Overview
52
Figure 2-12. Assigned Power Input Terminals
53
Figure 2-13. Single +24 V DC Power Source to Controller and Itbs
57
SINGLE +24 V DC POWER SOURCE to CONTROLLER and Itbs
57
Table 2-3. Single +24 V DC Power Source to Controller and Itbs
57
Figure 2-14. Wiring Example for Single+24 V DC Power Supply to Controller and Itbs (Negative Ground System)
58
Figure 2-15. Controller Dedicated 24 V DC Power Source
59
SEPARATE 24 V DC POWER SOURCES to CONTROLLER and Itbs
59
Table 2-4. Controller Dedicated 24 V DC Power Source
59
Figure 2-16. Wiring Example of Separate 24 V DC Power Sources for Controller and Itbs (Controller Positive, Negative, or Floating Ground)
60
110/120 V Ac Power Source to Controller
61
Figure 2-17. 110/120 V Ac Power Source to Controller
61
Table 2-5. 110/120 V Ac Power Source to Controller
61
Figure 2-18. 110/120 V Ac Power Wiring Example
62
220/240 V Ac Power Source to Controller
63
Figure 2-19. 220/240 V Ac Power Source to Controller
63
Table 2-6. 220/240 V Ac Power Source to Controller
63
Figure 2-20. 220/240 V Ac Power Wiring Example
64
220/240 V Ac (no Neutral) Power Source to Controller
65
Figure 2-21. 220/240 V Ac (no Neutral) Power Source to Controller
65
Table 2-7. 220/240 V Ac (no Neutral) Power Source to Controller
65
Figure 2-22. 220/240 V Ac (no Neutral) Power Wiring Example
66
Signal Connections to Standard Rear Terminal Board
67
Analog Inputs 0-3 (Ani0-3)
67
Figure 2-23. Rear Terminal Board Resistors R1 and R2
67
Figure 2-24. Controller Standard Rear Terminal Board Signal Connections
68
Analog Outputs 0 and 1 (Ano0&1)
71
Contact Closure Inputs 0 and 1 (Cci0&1)
71
Contact Closure Outputs 0 and 1 (Cco0&1)
71
Signal Connections for Single Channel Analog Option (Ani8)
71
Signal Connections for the Itbs
74
Scada Adapter Signal Connections
74
Analog Itb Signal Connections
74
Cord Set Itb Signal Connections
74
Dual Relay Itb Signal Connections
75
Digital Input/4 Digital Output (6Di/4Do) Itb
75
Digital Input/Digital Output (16Di/Do) Itb
75
Figure 2-31. SCADA Adapter Connections
76
Figure 2-32. Comm ITB Datalink Connections
77
Figure 2-33. Analog ITB Connections
78
Figure 2-34. Cord Set ITB Connections
79
Figure 2-35. 6DI/4DO ITB Connections
80
Figure 2-36. 16DI/DO ITB Connections
81
Datalink Connections to the Controller
82
Microlink Connections to the Controller
82
Figure 2-37. Datalink Installation to Controllers with Cord Set Option
83
3 Product Description
84
Dot Matrix Display
84
Rear Terminal Boards
84
Figure 3-1. Process Control Station Illustrated Overview
85
Controller Power Supply
86
Main Printed Circuit Board
86
Expansion Board
86
Sampling Time Intervals
86
Datalink
87
Table 3-1. Sampling Time Intervals
87
FUNCTION INDEXES (Fixs)
88
Database
89
Keypads
90
Engineering Mode Overlays
92
Password Function Prompt
92
Procedure to Enter a Key Password
92
Displaying a Datapoint
94
Procedure to Display a Datapoint
94
Displaying a Module
96
Procedure to Display a Module
96
Configure a Datapoint
97
Procedure to Configure a Datapoint
97
Configure a Module
99
Module-Mode Configurationprocedure
99
Keypad Alternatives
104
Using the Hand Held Configurer
104
Figure 3-6. Front Panel Configuration Port Connections
105
Displaying a Controller Datapoint
106
Hand Held Configurer Set up
106
Altering a Controller Datapoint
107
Setting or Changing a Controller Password Key
107
Hhc Memory Module Assembly Transfer
108
Sample Hand Held Configurer Commands
109
Using a Pc Terminal Emulator
110
Microsoft Windows Hyperterminal
110
Engineering Mode Lockout
113
4 Operator Displays
114
Table 4-1. Standard Displays
116
Table 4-2. Generated Display Lists
117
Display 1 - Alarm Summary
118
Figure 4-1. Display 1 - Alarm Summary
118
Display 2 - System Status
119
Figure 4-2. Display 2 - System Status
119
Displays 3, 4, 5, and 6 - Point Displays (Con0-3)
121
Table 4-3. Status Indicators
121
Table 4-4. Faceplate Push Buttons (Operator Functions)
122
Point Displays 3, 4, 5, and 6 (CDM = 0, Standard Pid)
123
Figure 4-3. Point Displays 3, 4, 5, and 6 (CDM = 0, Standard PID)
124
Figure 4-4. Point Display 3 (CDM = 1, Indicator)
129
Point Display 3 (CDM = 1, Indicator)
129
Figure 4-5. Point Display 3 (CDM = 2, Manual Loader)
130
Point Display 3 (CDM = 2, Manual Loader)
130
Figure 4-6. Point Display 3 (CDM = 3, Ratio Controller)
131
Point Display 3 (CDM = 3, Ratio Controller)
131
Figure 4-7. Point Display 3 (CDM = 4, Auto/Manual Station)
132
Point Display 3 (CDM = 4, Auto/Manual Station)
132
Figure 4-8. Point Display 3 (CDM = 5, Ratio Auto/Manual Station)
133
Point Display 3 (CDM = 5, Ratio Auto/Manual Station)
133
Point Displays 7 and 8 - Two Loop Displays
134
Figure 4-9. Two Loop Point Displays 7 and
134
Point Displays 9, 10, 11, and 12 - Single Loop with Horizontal Trend
136
Figure 4-10. Point Displays 9 - 12, Single Loop with Horizontal Trend
136
Displays 13 to 20 - Parameter Module Displays
138
Table 4-5. Editing a Parameter Value in Operator/Control Mode
138
Figure 4-11. Displays 13 to 20 - Parameter Module Displays
139
Displays 21 and 22 - Discrete Status Displays
140
Table 4-6. Status Indicator Display Modes
140
Figure 4-12. Displays 21 and 22 - Discrete Status Displays
141
Displays 23 to 30 - Totalizer Displays
142
Figure 4-13. Displays 23 to 30 - Totalizer Displays
142
Display 31 - Locator Grid
143
Figure 4-14. Display 31- Locator Grid
143
Point Display 32 - Four Loop Display
144
Figure 4-15. Point Display 32 - Four Loop Display
144
5 Configuration Parameters
146
Ready to Use Control Strategies
146
Datapoint Types
146
Table 5-1. Ready to Use Control Strategies
146
Table 5-2. Datapoint Types
146
Figure 5-1. Database Modules
147
Configuring the Database Modules
148
Table 5-3. Database Modules
148
Analog Input Modules (Ani0-8)
150
Controller Modules (Con0-3)
159
Table 5-9. Controller Modules (CON0-3)
159
Table 5-12. Trend Modules
173
Table 5-13. Totalizer Modules
175
Status Display Modules (Sdt0 and Sdt1)
185
Figure 5-2. Configuration Summary
185
Figure 6-1. Typical CS1 Single Loop Controller Application
186
Table 6-1. CS1 Control Signals
187
Table 6-2. CS1 Standard Displays
188
Figure 6-2. CS1 Single Loop CON0 Datapoints
189
Table 6-3. CS1 Single Loop CON0 Datapoints
190
Table 6-4. CS1 Soft-Wire List Modifications
195
Figure 7-1. Typical CS2 Analog Backup Controller Application
196
Table 7-1. CS2 Control Signals
197
Table 7-2. CS2 Standard Displays
198
Figure 7-3. CS2 Analog Backup Controller Datapoints
199
Table 7-3. CS2 Analog Backup Controller Datapoints
200
Figure 8-1. Typical CS3 Ratio Controller Application
204
Table 8-1. CS3 Control Signals
205
Table 8-2. CS3 Standard Displays
206
Figure 8-2. CS3 Ratio Controller Datapoints
207
Table 8-3. CS3 Ratio Controller Datapoints
208
Figure 9-1. Typical CS4 Automatic/Manual Station Application
212
Table 9-1. CS4 Control Signals
213
Table 9-2. CS4 Standard Displays
214
Figure 9-2. CS4 Automatic/Manual Station Datapoints
215
Table 9-3. CS4 Automatic/Manual Station Datapoints
216
Figure 10-1. Typical CS5 Ratio Automatic/Manual Station Application
220
Table 10-1. CS5 Control Signals
221
Table 10-2. CS5 Standard Displays
222
Figure 10-2. CS5 Ratio Automatic/Manual Station Datapoints
223
Table 10-3. CS5 Ratio Automatic/Manual Station Datapoints
224
Figure 11-1. Typical CS20 Two Loop Controller Application
228
Table 11-1. CS20 Control Signals
229
Table 11-2. CS20 Standard Displays
230
Figure 11-2. CS20 Two Loop Controller Datapoints
231
Table 11-3. CS20 Two Loop Controller Datapoints
233
Figure 12-1. Typical CS21 Two Loop Cascade Controller Application
240
Table 12-1. CS21 Control Signals
241
Table 12-2. CS21 Standard Displays
242
Figure 12-2. CS21 Two Loop Cascade Controller Datapoints
243
Table 12-3. CS21 Two Loop Cascade Controller Datapoints
245
Figure 13-1. Typical CS22 Two Loop Override Controller Application
252
Table 13-1. CS22 Control Signals
253
Table 13-2. CS22 Standard Displays
254
Figure 13-2. CS22 Two Loop Override Controller Datapoints
255
Table 13-3. CS22 Two Loop Override Controller Datapoints
257
Figure 14-1. Typical CS40 Dual Two Loop Cascade Controller Application
262
Table 14-1. CS40 Control Signals
263
Table 14-2. CS40 Standard Displays
264
Figure 14-2. CS40 Dual Two Loop Cascade Controller Datapoints
265
Table 14-3. CS40 Dual Two Loop Cascade Controller Datapoints
268
Figure 15-1. Typical CS41 Four Loop Controller Application
276
Table 15-1. CS41 Control Signals
277
Table 15-2. CS41 Standard Displays
279
Figure 15-2. CS41 Four Loop Controller Datapoints
280
Table 15-3. CS41 Four Loop Controller Datapoints
284
Table 16-1. Summary Information for Tuning Parameters
299
Table 16-2. Trial and Error Tuning Method
299
Table 16-3. Proportional Cycle Method
300
Table 16-4. Step Response Method (Ziegler-Nichols)
300
Figure 16-1. Typical Step Response Record
301
Table 17-1. Summary Information for Tuning Parameters
302
Table 17-2. EASY-TUNE Parameters
303
Table 17-3 Normal Successful Status Display
304
Table 17-4. EASY-TUNE Unsuccessful Status Display
304
Figure 17-1. EASY-TUNE Sequence Diagram
305
Table 17-5. EASY-TUNE Equations
306
Figure 17-2. Process Step Response Curve
307
Table 18-1. Parts Replacement
312
Table 18-2. Controller Parts List
316
Table 18-3. Related Parts List
318
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