INSTRUCTION MANUAL Multi-Loop Process Controller 53MC5000 PROCESS CONTROL STATION PN24950 Rev.
MicroMod Automation, Inc. The Company MicroMod Automation is dedicated to improving customer efficiency by providing the most ost-effective, application-specific process solutions available. We are a highly responsive, application-focused company with years of expertise in control systems design and implementation. We are committed to teamwork, high quality manufacturing, advanced technology and unrivaled service and support.
Contents Table of Contents 1.0 INTRODUCTION 1.1 1.2 1.3 1.4 1.5 PRODUCT OVERVIEW . . . . SCOPE OF BOOK . . . . . . . MODEL NUMBER BREAKDOWN SPECIFICATIONS . . . . . . . RELATED DOCUMENTATION . . 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0 INSTALLATION 2-1 2.1 2.2 2.3 2.4 2.5 2.
53MC5000 Process Control Station 3.12 ENGINEERING MODE OVERLAYS . . . . . . . . . . . . . . . . . 3.12.1 PASSWORD FUNCTION PROMPT . . . . . . . . . . . . . 3.12.1.1 PROCEDURE TO ENTER A KEY PASSWORD . . . . 3.12.2 DISPLAYING A DATAPOINT . . . . . . . . . . . . . . . . 3.12.2.1 PROCEDURE TO DISPLAY A DATAPOINT . . . . . . 3.12.3 DISPLAYING A MODULE . . . . . . . . . . . . . . . . . 3.12.3.1 PROCEDURE TO DISPLAY A MODULE . . . . . . . 3.12.4 CONFIGURE A DATAPOINT . . . . . . . . . . . . . . . . 3.12.4.
Contents 5.11 5.12 5.13 5.14 5.15 5.16 PARAMETER DISPLAY MODULES . . . . TREND MODULES . . . . . . . . . . . TOTALIZER MODULES . . . . . . . . . COMMUNICATION MODULE . . . . . . SYSTEM AND MISCELLANEOUS MODULE CONFIGURATION SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53MC5000 Process Control Station 13.0 CS22 - TWO LOOP OVERRIDE CONTROLLER 13.1 13.2 13.3 13.4 CS22 CS22 CS22 CS22 - TWO LOOP OVERRIDE CONTROLLER . . CONTROL SIGNALS . . . . . . . . . . . STANDARD DISPLAYS . . . . . . . . . DATAPOINT CONFIGURATION SELECTIONS . . . . . . . . 13-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.0 CS40 - DUAL TWO LOOP CASCADE CONTROLLER 14.1 14.2 14.3 14.
Contents APPENDIX B.0 COMMUNICATIONS B.1 STANDARD COMMUNICATIONS . . . . . . . . . . B.1.1 CONFIGURATION . . . . . . . . . . . . . B.1.2 PROTOCOL . . . . . . . . . . . . . . . B.1.3 MESSAGE TYPES . . . . . . . . . . . . B.1.4 COMMUNICATION TRANSACTION EXAMPLES B.1.5 CALCULATING DATA ADDRESSES . . . . . B.1.6 SOFTWARE CHARACTERISTICS . . . . . B.1.7 HARDWARE CHARACTERISTICS . . . . . B.1.8 DATALINK NODE LIST . . . . . . . . . . B.1.9 INITIALIZATION MESSAGE . . . . . . . . APPENDIX C.0 REMOTE KEYPAD C.
Contents List of Tables Table Table Table Table Table Table Table Table Table 1-1. 1-2. 1-3. 1-4. 1-5. 1-6. 1-7. 1-8. 1-9. 53MC5000 Process Control Station Specifications . . . . . . . 6 Digital Input/4 Digital Output Option Specifications . . . . . . Dual Relay ITB Specifications . . . . . . . . . . . . . . . . 16 Digital Input/Digital Output Option Board and ITB Specifications OPTO 22 Module Specifications for 16 DI/DO ITB . . . . . . . Single Channel Analog Input Option (ANI8) Specifications . . . .
53MC5000 Process Control Station Table 7-1. CS2 Control Signals . . . . . . . . . . . . . . . . . . . . . . . . . . Table 7-2. CS2 Standard Displays . . . . . . . . . . . . . . . . . . . . . . . . . Table 7-3. CS2 Analog Backup Controller Datapoints . . . . . . . . . . . . . . . . . 7-2 7-3 7-5 Table 8-1. CS3 Control Signals . . . . . . . . . . . . . . . . . . . . . . . . . . Table 8-2. CS3 Standard Displays . . . . . . . . . . . . . . . . . . . . . . . . . Table 8-3. CS3 Ratio Controller Datapoints . .
Contents Table Table Table Table Table B-1. B-2. B-3. B-4. B-5. Communication Module . . . . . Message Field Definitions . . . . Controller Memory Address Scheme Node List Assignment Codes . . . Network D Node List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents List of Figures Figure 1-1. Typical Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Figure 1-2. Information Layout of Book . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 2-1. Packing Bolt . . . . . . . . . . . . . . . . . . . . .
53MC5000 Process Control Station Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 4-1. Display 1 - Alarm Summary . . . . . . . . . . . . . 4-2. Display 2 - System Status . . . . . . . . . . . . . 4-3. Point Displays 3, 4, 5, and 6 (CDM = 0, Standard PID) . 4-4. Point Display 3 (CDM = 1, Indicator) . . . . . . . . . 4-5. Point Display 3 (CDM = 2, Manual Loader) . . . . . . 4-6. Point Display 3 (CDM = 3, Ratio Controller) . . . . . . 4-7.
Contents Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 18-1. Illustrated Parts Breakdown . . . . . . . . . . . . . 18-2. Hand Held Configurer and Valve Holder Pin Assignments 18-3. Cord Set Connector Pin Assignments . . . . . . . . . 18-4. Cord Set ITB Schematic . . . . . . . . . . . . . . 18-5. Dual Relay ITB Schematic . . . . . . . . . . . . . 18-6. 6 Digital Input/4 Digital Output ITB Schematic . . . . . 18-7.
53MC5000 Process Control Station READ FIRST WARNING INSTRUCTION MANUALS Do not install, maintain, or operate this equipment without reading, understanding and following the proper MicroMod Automation Inc. instructions and manuals, otherwise injury or damage may result. Read these instructions before starting installation; save these instructions for future reference. Contacting MicroMod Automation Inc. Should assistance be required with any MicroMod Automation Inc.
Section 1. Introduction 1.0 INTRODUCTION 1.1 PRODUCT OVERVIEW The MicroMod Automation 53MC5000 Process Control Station is a controller that is available in one, two, and four loop versions. It can function as a stand-alone unit or as part of a distributed controller network. The controller’s functionality is determined by the Function Index (FIX), which is used to select a broad range of resident control strategies that are common to industrial process applications.
53MC5000 Process Control Station If the controller has extended functionality (optional), additional performance capabilities are included. The extended functionalities include Flexible Control Interconnection Modules (F-CIM) and Flexible TRANslator language (F-TRAN). Both can be used to create more personalized control strategies (F-TRAN can also be used to create personalized displays).
Section 1. Introduction The MicroMod 53MC5000 Process Control Station provides a variety of standard displays to give a multiperspective presentation of the controlled process. Unlike many other controllers that have a singular bar graph display, the 53MC5000 Process Control Station has trend, parameter, status, totalizer, and multi-bar graph displays (2 and 4 loop versions). A display locator grid identifies the current display suite.
53MC5000 Process Control Station 1.2 SCOPE OF BOOK The information layout of the book is illustrated in Figure 1-2 and described as follows: • Section 1, Introduction - This section contains product overview information, a product model number breakdown, product specifications, and a list of related documentation. • Section 2, Installation - This section provides information to physically mount the controller in a panel and information to mount the ITBs.
Section 1. Introduction • Appendix A, Discrete Contact Output DOs - This appendix illustrates various circuit layouts for the Discrete Contact Outputs (DOs). • Appendix B, Communications - This appendix provides reference information for binary serial communication. Both, the RS-232 front port communications and the standard Datalink communications are described. • Appendix C, Remote Keypad - This appendix provides information to use the 6DI/4DO ITB for remote keypad operation.
1-6 6. CS1 - Single Loop PID Controller 53MC5000 PROCESS CONTROL STATION 7. CS2 - Analog Backup Controller 3. Product Description 2. Installation 1. Introduction .......... 4. Operator Displays 5. Configuration Parameters 16. Tuning PID Parameters 10. CS5 - Ratio Automatic/ Manual Station 11. CS20 - Two Loop Controller 12. CS21 - Two Loop Cascade Controller 17. EASY-TUNE 13. CS22 - Two Loop Override Controller ALTERNATE PATH INDICATED BY DOTS ( . . . ) 14.
Section 1. Introduction 1.
53MC9015 53MC5000 PLC and Printer Interfaces 53MC5 _ _ Base Model Number Control Loops 1 One Loop 2 Two Loops 4 Four Loops Power Requirements AC (120/240) 1 DC (24) 2 Functional Requirements Standard Extended (Programmable) Standard w/Factory Configuration Extended w/Factory Programming Standard w/Configuration by Subsidiary or Field Integration Extended w/Programming by Subsidiary or Field Integration Design Level _ _ _ _ _ _ 1 2 3 4 5 6 A B Type Bezel (Design Level "B" Only) DIN 72 x 144 mm Bez
Section 1.
53MC5000 Process Control Station 1.4 SPECIFICATIONS Table 1-1. 53MC5000 Process Control Station Specifications Item Power requirements (as specified) 1 of 4 Specification(s) 21 to 28 V dc 90-132 V rms 180-264 V rms 50/60 Hz Power consumption ac/dc operation 20 VA maximum. Internal power supply: Available power output for 25 V dc ± 1 V dc @ 80 mA maximum, short circuit protected. transmitters Output Ripple 200 mV p-p maximum.
Section 1. Introduction Table 1-1. 53MC5000 Process Control Station Specifications 2 of 4 Item Analog outputs (cont) Accuracy: Contact closure outputs Quantity 2 Type Solid state switch output. Configuration Solid state equivalent of single pole single throw, N.O. or N.C. contacts referenced to common. Voltage 30 V dc maximum. Current Datalink communication 50 mA dc maximum.
53MC5000 Process Control Station Table 1-1. 53MC5000 Process Control Station Specifications 3 of 4 Item Specification(s) Enclosure classification/environment Rated for installation in a "Pollution Degree 2" location per (cont) U.L. 508-1989/"Controlled Environment" per CSA C22.2 No. 142-M1987. An indoor, temperature controlled location (control room or shop floor) where normally, only nonconductive pollution occurs; however, temporary conductivity caused by condensation may be expected.
Section 1. Introduction Table 1-1. 53MC5000 Process Control Station Specifications Item Lithium battery: MicroMod Automation part number 4 of 4 Specification(s) 167B024U01 Manufacturer Eagel Picher Industries, Inc. Box 130 Bethel Road Seneca, MO 64865 Manufacturer’s part number LTC-7P Battery type Inorganic, liquid lithium thionyl chloride. Voltage 3.5 Capacity 750 mAh Storage temperature 150° C (302° F). Operating temperature -40° to 125° C (-40° to 257° F).
53MC5000 Process Control Station Table 1-2. 6 Digital Input/4 Digital Output Option Specifications Item Safety classification Dimensions Number of inputs Operational type Input connections: Voltage input mode Contact input mode Recognition level: Voltage input mode Contact input mode Specification(s) FM Approved: Nonincendive for Class 1, Div. 2, Groups A, B, C & D hazardous locations. 8.25 in. (210 mm) long, 2.740 in. (70 mm) wide.
Section 1. Introduction Table 1-3. Dual Relay ITB Specifications Item Safety classification Specification(s) FM Approved: Nonincendive for Class 1, Div. 2, Group A, B, C, & D hazardous locations. WARNING For use in Division 2 locations, the energy to relay contacts 8 and 11 must be limited to < 3 VA, < 28 V and 250 mA, resistive loads only.
53MC5000 Process Control Station Table 1-5. OPTO 22 Module Specifications for 16DI/DO ITB 1 of 2 Safety classification: FM Approved: Nonincendive for Class 1, Div. 2, Group A, B, C, & D hazardous locations as part of the 16DI/DO ITB. WARNING It is the user’s responsibility to install all associated switches and load apparatus in accordance with ANSI/NFPA 70, National Electrical Code.
Section 1. Introduction Table 1-5.
53MC5000 Process Control Station Table 1-7. Multichannel Analog Option Specifications 1 of 2 Item Saftey classification Specification(s) FM Approved: Nonincendive for Class 1, Div. 2, Group A, B, C, & D hazardous locations. Non-Isolated Analog Inputs (AI4 - AI7) Quantity 4 Connection type Track mounted ITB. Transmitter power Supplied by user to ITB. Current to voltage resistors Provided on ITB (250 ohm ± 0.1% tolerance). Current signals: Signal Range 0 - 21.84 mA ± 0.
Section 1. Introduction Table 1-7. Multichannel Analog Option Specifications Item Quantity Signal range Load range Accuracy 2 of 2 Specification(s) Non-Isolated Current Outputs (AO2 and AO3) 2 0 to 21.84 mA dc (4 to 20 mA dc typically). 0 - 640 ohms. ± 0.2% span. Table 1-8. Group 5B Isolation Module Specifications 1 of 4 Item Specification(s) Saftey classification for all Group 5B FM Approved: Nonincendive for Class 1, Div. 2, Group A, Isolation Modules B, C, & D hazardous locations.
53MC5000 Process Control Station Table 1-8. Group 5B Isolation Module Specifications 2 of 4 Item Specification(s) Isolation Module: 5B31 Group - Isolated Voltage Inputs ± 0.05% span ± 0.2 mV RTI Accuracy (Includes the combined ± 0.05% V z (A nominal voltage that results in a 0 V output.) effects of repeatability, hysteresis, and nonlinearity. It also assumes a very high load resistance.) ± 0.
Section 1. Introduction Table 1-8. Group 5B Isolation Module Specifications 3 of 4 Item Specification(s) Isolation Module: 5B32 Group - Isolated Current Inputs (Cont) Stability versus Ambient Temperature: ± 0.0025%/°C of Iz (A nominal value of input current that Module offset results in an output of 0 V.) ± 0.0025%/°C of reading/°C Module Gain ± 0.001%/°C Stability of supplied input resistor Noise: 10 nA rms RTI Input, 0.
53MC5000 Process Control Station Table 1-8. Group 5B Isolation Module Specifications Item 4 of 4 Specification(s) Isolation Module: 5B34 Group - Isolated RTD (Cont) CMV, input to output: Continuous 240 V rms Transient Meets IEEE - STD 472 (SWC). CMR (50 or 60 Hz): 1 k ohms in either or both input leads 160 db (all ranges) NMR (50 or 60 Hz) 60 db Sensor excitement current: 100 ohms Pt, 120 ohms Ni 0.25 mA 10 ohms Cu 1.0 mA Lead resistance effect: ± 0.02°C/ohm 100 ohms Pt, 120 ohms Ni ± 0.
Section 1. Introduction Table 1-9. SCADA Board Specifications Item Safety classification Dimensions Power requirements Modem baud rate Data protocol Modem parity Modem delay Datalink baud rate LEDs on SCADA board: CTS - Clear to Send RTS - Request to Send M_R - Modem Receive M_T - Modem Transmit D_R - Datalink Receive D_T - Datalink Transmit Specification(s) FM Approved: Nonincendive for Class 1, Div. 2, Group A, B, C, & D hazardous locations. 10 in. (254 mm) long, 2.740 in. (70 mm) wide.
53MC5000 Process Control Station displays, perform current trending, historical trending, create historical data files, and centralize data logging; and how a personal computer can be used to configure controllers online, compile F-TRAN programs, download F-TRAN programs, edit recipes, and produce controller configuration documentation. • Publication Number 24368, Instruction Bulletin 53HC3300D, Custom Program Interface (MICRO-DCI Instrument to MS-DOS® Personal Computer).
Section 1. Introduction • Publication Number 24829, Operator’s Manual 53PW6000, Micro-PWC The Micro-PWC Operator’s Manual describes the operations required to use a configured Micro-PWC. It is designed to provide instructions on how to perform operational tasks on the Micro-PWC, provide suggestions and examples for operator activities as well as providing additional operational information.
53MC5000 Process Control Station 2.3 LOCATION The 53MC5000 Process Control Station is supplied with an enclosure designed specifically for indoor mounting in a dry, vibration free location. The location ambient temperature should be stable and maintained within the specified temperature limits listed in specifications Table 1-1. 2.4 MOUNTING It is not necessary to remove the controller from its case to install it.
Section 2. Installation Figure 2-2.
53MC5000 Process Control Station Table 2-2. Controller Panel Mounting Step Procedure 1 Ensure the through-case shipping bolt is removed as described in Table 2-1. 2 Slip the trim collar (mounting frame) over the rear of the case and slide it forward to the front of the case. For Single Mounted Case(s) 3a Slide the controller through the panel opening. 4a Support the weight of the case and attach the top and bottom mounting brackets. Tighten the bracket screws.
Section 2. Installation MOUNTING BRACKET ROD FOOT EXTENDS THROUGH NOTCH TOP OR BOTTOM OF CONTROLLER SITE MOUNTING PANEL TRIM COLLAR (SUPPLIED WITH CONTROLLER) CONTROLLER BEZEL 1. SLIDE TRIM COLLAR FROM REAR OF CONTROLLER TOWARD FRONT BEZEL. 2. SLIDE CONTROLLER THROUGH SITE PANEL CUT-OUT. 3. INSERT UPPER MOUNTING BRACKET FOOT INTO NOTCH. 4. POSITION CASE AND TURN ROD WITH SCREWDRIVER UNTIL IT MEETS PANEL. 5. FOR LOWER MOUNT- Figure 2-4. Bracket Rods Figure 2-5.
53MC5000 Process Control Station 2.5 MOUNTING THE INTERCONNECTION TERMINAL BOARDS (ITBs) The Interconnection Terminal Boards (ITBs) (and SCADA Adapter) are designed for snap-mounting into non-conductive, 2.9 inch (74 mm) wide PVC track that is either direct surface mounted (wall mounted) or mounted on DIN rail (32 or 35 mm) with adapters. The 2.9 inch (74 mm) wide PVC track is available from MicroMod Automation in 4 foot (1.2 m) lengths as part number 129A003U03 for wall mounting and for DIN rail mounting.
Section 2. Installation 2-7 Figure 2-6.
Section 2. Installation 2-9 Figure 2-8.
2-10 53MC5000 Process Control Station Figure 2-9.
Section 2. Installation 2.6 REMOVABLE PLUG-IN CONNECTORS The controller with standard rear terminal board (not the cord set option) has a vertical terminal strip (TB1) for signal connections and a horizontal terminal strip (TB2) for power input wiring. Both terminal strips have removable plug-in connectors. As shown in Figure 2-10, the upper signal connector for TB1 has screw lugs 1 through 12 and the lower signal connector has screw lugs 13 through 22.
53MC5000 Process Control Station 2.7 POWER CONNECTIONS FOR CONTROLLER AND ITBs An overview illustration of power connections to the controller and ITBs is provided in Figure 2-11. The Comm ITB does not require power; therefore, it is not shown in the illustration.
DUAL RELAY ITB CORD SET ITB TB2 9 10 TB1 1 2 ANALOG ITB* + 1 TB2 - ▼ 2 3 6 DIGITAL INPUT/4 DIGITAL OUTPUT ITB (6DI/4DO)*** TB3 + - ▼ 16 DIGITAL INPUT/DIGITAL OUTPUT ITB (16DI/DO)** TB2 1 2 SCADA ADAPTER BOARD 1 3 OR •• *EITHER ANALOG ITB OR HART ITB. (BOTH CANNOT COEXIST.) **EITHER 16DI/DO ITB OR HART MODEM ITB. (BOTH CANNOT COEXIST.) ALSO, ASSUMES 24 V MODULES INSTALLED ON THE 16DI/DO ITB. ***EITHER 6DI/4DO ITB OR HART MODEM ITB. (BOTH CANNOT COEXIST.
2-14 53MC5000 Process Control Station Figure 2-12.
Section 2. Installation 2-15 Figure 2-12.
2-16 53MC5000 Process Control Station Figure 2-12.
Section 2. Installation 2-17 Figure 2-12.
53MC5000 Process Control Station 2.7.1 SINGLE +24 V DC POWER SOURCE TO CONTROLLER AND ITBS The procedure to connect the controller TB2 screw lugs to a +24 V dc power source is provided in Table 2-3. This procedure assumes the power supply, controller, and ITBs are negatively grounded (negative ground system). Table 2-3. Single +24 V dc Power Source to Controller and ITBs Step Procedure See Figure 1 Connect the positive (+) 24 V input line, via a remote SPST switch, to TB2-4 (L1).
Section 2. Installation MC5000 1 MC5000 2 MC5000 3 PC L3 L2 L1 G PC L3 L2 L1 G PC L3 L2 L1 G SPST SPST SPST CONTROLLERS AND ITBs ARE WIRED SAME AS CONTROLLER 3. SCADA +24 V TB1 CORD SET TB2109 DUAL RELAY 1 TB1 2 ANALOG 1 TB2 2 16DI/DO** TB212 24 V DC P/S*** + - 24 V DC DISTRIBUTION TERMINAL STRIP* COMMON BUS BAR* AC EARTH GROUND *DISTRIBUTION TERMINAL STRIP AND COMMON BUS BAR NOT PROVIDED BY MicroMod Automation. **ASSUMES 24 V MODULES INSTALLED ON 16DI/DO. *** P/S IS NEGATIVE GROUND.
53MC5000 Process Control Station 2.7.2 SEPARATE 24 V DC POWER SOURCES TO CONTROLLER AND ITBs The procedure to connect the controller TB2 screw lugs to a controller-dedicated 24 V dc power source is provided in Table 2-4. The ITB power source must be negatively grounded; the controller power source can float, be positively grounded, or negatively grounded. Table 2-4.
Section 2. Installation MC5000 1 MC5000 2 PC L3 L2 L1 G PC L3 L2 L1 G SPST SPST SPST ONLY ONE SPST SWITCH PER CONTROLLER IS NEEDED. (SEE TABLE 2-4.) THE CONTROLLER P/S CAN BE TO A POSITIVE GROUND, NEGATIVE GROUND, OR FLOAT. ITBs ARE WIRED SAME AS THOSE UNDER CONTROLLER 2.
53MC5000 Process Control Station 2.7.3 110/120 V AC POWER SOURCE TO CONTROLLER The procedure to connect the controller TB2 screw lugs to a 110/120 V ac power source is provided in Table 2-5. Table 2-5. 110/120 V ac Power Source to Controller Step Procedure See Figure 1 Connect the phase or hot input line, via a remote SPST switch, to TB2-4 (L1). Figure 2-17 2 Connect the neutral input line to TB2-3 (L2 ).
Section 2. Installation MC5000 1 MC5000 2 MC5000 3 PC L3 L2 L1 G PC L3 L2 L1 G PC L3 L2 L1 G SPST CONTROLLERS AND ITBs ARE WIRED SAME AS CONTROLLER 3. SPST SPST SCADA TB1+24 V CORD SET TB2109 DUAL RELAY TB112 ANALOG 1 TB22 AC BREAKER BOX 16DI/DO** TB212 24 V DC P/S + - 24 V DC DISTRIBUTION TERMINAL STRIP* COMMON BUS BAR* AC EARTH GROUND *DISTRIBUTION TERMINAL STRIP AND COMMON BUS BAR NOT PROVIDED BY MicroMod Automation. •* *ASSUMES 24 V MODULES INSTALLED ON 16DI/DO. Figure 2-18.
53MC5000 Process Control Station 2.7.4 220/240 V AC POWER SOURCE TO CONTROLLER The procedure to connect the controller TB2 screw lugs to a 220/240 V ac power source is provided in Table 2-6. Table 2-6. 220/240 V ac Power Source to Controller Step Procedure See Figure 1 Connect the phase or hot input line, via a remote SPST switch, to TB2-4 (L1). Figure 2-19 2 Connect the neutral input line to TB2-2 (L3 ).
Section 2. Installation MC5000 1 MC5000 2 PC L3 L2 L1 G 1 2 3 4 MC5000 3 PC L3 L2 L1 G PC L3 L2 L1 G 5 1 2 3 4 5 SPST CONTROLLERS AND ITBs ARE WIRED SAME AS CONTROLLER 3. 1 2 3 4 5 SPST SPST SCADA TB1 +24 V CORD SET 9 TB2 10 DUAL RELAY TB1 1 2 ANALOG 1 TB2 2 AC BREAKER BOX 16DI/DO** TB2 24 V DC P/S 1 2 + - 24 V DC DISTRIBUTION TERMINAL STRIP* COMMON BUS BAR* AC EARTH GROUND *DISTRIBUTION TERMINAL STRIP AND COMMON BUS BAR NOT PROVIDED BY F&P.
53MC5000 Process Control Station 2.7.5 220/240 V AC (NO NEUTRAL) POWER SOURCE TO CONTROLLER The procedure to connect the controller TB2 screw lugs to a 220 (208)/240 V ac (no neutral) power source (208 V ac ± 10% variance) is provided in Table 2-7. Table 2-7. 220/240 V ac (No Neutral) Power Source to Controller Step Procedure See Figure 1 Connect the hot input line, via a remote DPST switch, to TB2-4 (L1 ). Figure 2-21 2 Connect the second hot input line, via a remote DPST switch to TB2-2 (L3 ).
Section 2. Installation MC5000 1 MC5000 2 MC5000 3 PC L3 L2 L1 G PC L3 L2 L1 G PC L3 L2 L1 G DPST CONTROLLERS AND ITBs ARE WIRED SAME AS CONTROLLER 3. DPST DPST SCADA TB1 +24 V CORD SET TB2109 DUAL RELAY TB1 12 ANALOG TB2 AC BREAKER BOX 1 2 16DI/DO** TB2 24 V DC P/S 1 2 + - 24 V DC DISTRIBUTION TERMINAL STRIP* COMMON BUS BAR* AC EARTH GROUND *DISTRIBUTION TERMINAL STRIP AND COMMON BUS BAR NOT PROVIDED BY MicroMod Automation. •* *ASSUMES 24 V MODULES INSTALLED ON 16DI/DO.
53MC5000 Process Control Station 2.8 SIGNAL CONNECTIONS TO STANDARD REAR TERMINAL BOARD Under ideal conditions shielded cable may not be required; however, in noisy locations two-wire shielded signal cable should be used. Also, signal transmission distance must not exceed the limit specified for the particular transmitter (refer to the applicable technical literature provided with the respective device), and correct polarity must be observed when connecting remote transmitters to the controller.
Section 2. Installation 2-29 Figure 2-24.
53MC5000 Process Control Station TB1 + - PIN 2 AI0 PIN 3 SIGNAL COMMON CABLE FROM TRANSMITTER PIN 4 +24 VOLTS PIN 5 AI1 + - PIN 6 SIGNAL COMMON CABLE FROM TRANSMITTER CHASSIS SAFETY GROUND NO. 6 SCREW WIRED AS SHOWN EACH TRANSMITTER HAS ITS OWN POWER SOURCE AND DOES NOT REQUIRE +24 V FROM THE CONTROLLER Figure 2-25.
Section 2. Installation TB1 PIN 6 SIGNAL COMMON PIN 7 AI2 PIN 8 SIGNAL COMMON PIN 9 AI3 R3 CHASSIS SAFETY GROUND + CABLE FROM TRANSMITTER + CABLE FROM TRANSMITTER CHASSIS SAFETY GROUND R4 NO. 6 SCREW NO. 6 SCREW RESISTORS ARE 250 OHM ± 0.1 % WIRED AS SHOWN EACH TRANSMITTER HAS ITS OWN POWER SOURCE AND DOES NOT REQUIRE +24 V FROM THE CONTROLLER Figure 2-27.
Section 2. Installation AI AO DI DO Note: The above illustrations are graphical representations of the signal conditioning that occurs on the controller main board. They are provided for reference purposes only. Figure 2-29.
2-34 53MC5000 Process Control Station Figure 2-30.
Section 2. Installation 2.10 SIGNAL CONNECTIONS FOR THE ITBS In noisy locations, two-wire shielded signal cable should be used and the routing of signal cable bundles close to power wires should be avoided. Each wire lead should be stripped to expose 1/4 inch (6.4 mm) conductor. All wiring to the ITB terminal board screw lugs is supplied by the customer. 2.10.
53MC5000 Process Control Station 2.10.4 DUAL RELAY ITB SIGNAL CONNECTIONS The Dual Relay ITB provides two interposing relays for use with the controller Contact Closure Outputs (DOs). Each relay can be wired directly to a controller standard rear terminal board (see Figure 2-24), to a Cord Set ITB (see Figure 2-34), or to a 6DI/4DO ITB (see Figure 2-35). The Dual Relay ITB enhances DO performance by extending the switching tolerances to accommodate larger loads.
Section 2. Installation 2-37 Figure 2-31.
Section 2. Installation 2-41 Figure 2-35.
2-42 53MC5000 Process Control Station Figure 2-36.
Section 2. Installation 2.11 DATALINK CONNECTIONS TO THE CONTROLLER Figure 2-32 illustrates a Datalink network daisy-chain installation for controllers with the standard rear terminal board. Four of the cable leads are connected to TB1 screw lugs 19 through 22, and the shield is connected to a #6 backpanel screw. The installation is terminated with a Comm ITB. Terminal board wire connections for the controller and Comm ITB are defined in Table 1 of the illustration.
Section 3. Product Description 3.0 PRODUCT DESCRIPTION As shown in Figure 3-1, the 53MC5000 Process Control Station contains a graphical dot matrix display; horizontal and vertical keypads; a mini-DIN configuration port connector concealed behind the faceplate pull-down door; and a compact instrument case that protects the instrument Main Board and internal power supply. The Main Board with attached power supply is shown in the upper left of the illustration.
Section 3. Product Description 3.4 CONTROLLER POWER SUPPLY The internal power supply provides power to the Main Board, Expansion Board with its installed option cards, display, and output power for transmitters (24-26 V dc, 80 mA total available output for controller and transmitters). 3.5 MAIN PRINTED CIRCUIT BOARD The Main Board contains the necessary circuitry, firmware, and memory for 53MC5000 Process Control Station functionality.
53MC5000 Process Control Station If the BACKGROUND SCAN INDEX is left at one, the display will be updated with each control algorithm execution because it will be determined solely by the SCAN INDEX. A number greater than one configured into the BACKGROUND SCAN INDEX causes that many control algorithm updates to occur before the display is updated with new data. There is a standard display algorithm for each display of the 53MC5000 Process Control Station.
Section 3. Product Description 3.9 FUNCTION INDEXES (FIXs) The controller’s functionality is determined by the Function Index (FIX), which is used to select a broad range of control strategies and operations. A FIX is selected by entering its number into the database System Module Function Index datapoint B000. (The database description and data entry procedures follow in this section of the book.
53MC5000 Process Control Station • FIX 98 Default Database - The database of the controller can be set to a predetermined condition by entering a 98 into datapoint B000. This causes the entire database except for the analog I/O calibration constants, the FCS wirelist, and some text strings to be set to the default values. It should be noted that any pre-loaded database configuration will also be overwritten with the default values by FIX 98.
Section 3. Product Description 3.11 KEYPADS To the right of the display is the vertical keypad and directly beneath the display is the horizontal keypad. Both keypads have functioning push buttons that are dependent on the instrument mode of operation which can be either operator/control mode or engineer mode . Mode selection is made with the Mode ( ● ) push button on the horizontal keypad.
53MC5000 Process Control Station Engineer Mode Display Module Datapoint Display Module Datapoint Display Operations Mode [Sec. 3.12.2] [Sec. 3.12.3] Configure Program * Key? ** [Sec 3.12.1] Key? ** [Sec 3.12.1] Datapoint Configure Datapoint Operations [Sec. 3.12.4] Module View Build Module Configure Mode [Sec. 3.12.5] *See 53MC5000 Customization Guide ** If configured Blocks shown shaded only appear when using the Hi-Resolution display Figure 3-2.
Section 3. Product Description 3.12 ENGINEER MODE OVERLAYS The Engineer Mode Overlays are used to view (Display) or make necessary changes (Configure) to the controller database parameters. Standard viewing/change entries are made by addressing single parameters by their datapoint specification on a single line overlay at the bottom of the display. On units with HiRes displays (53MC5xxxB4xxxxxxxxx) either the datapoint method or the module method may be used to perform viewing/change operations.
53MC5000 Process Control Station • The screen should now appear as shown on the right. • If the required key-code is "222222", follow the following procedure. • Press the entry line. key until the digit "2" appears on the • Press the the left. key to shift the first entry one position to • Press the entry line. key until the next "2" appears on the • Press the left.
Section 3. Product Description 3.12.2 DISPLAYING A DATAPOINT The following procedure illustrates how to display the contents of datapoint B012, which is the display brightness index.Note that B12 is shown being entered instead of B012 , since leading zeros are not required when specifying datapoints. 3.12.2.1 Procedure to Display a Datapoint • Press the Mode button to enter the ENGINEER mode indicated by the appearance of either CONFIGURE, DISPLAY or PROGRAM at the bottom of the display.
53MC5000 Process Control Station • The display shows the POINT entry line at the bottom of the display, as shown on the right. • Press the the entry line. • Press the the left. key until the character "B" appears on key to shift the first entry one position to • Press the key until "1" appears on the entry line. • Press the left. key to shift this entry one position to the • Press the key until "2" appears on the entry line. • The entry-line should now appear as shown on the right.
Section 3. Product Description 3.12.3 DISPLAYING A MODULE Refer to Section 3.11 for Keypad function in Module Mode The navigational sequence would be the following (Refer to Table 3-5): • Select Module Type (then Module, if there’s more than one Module) • Select Page (Skipped when there’s only a single page) • Select Parameter 3.12.3.
53MC5000 Process Control Station 3.12.4 CONFIGURE A DATAPOINT The following procedure illustrates how to alter the contents of datapoint C115 (CONTROL module & Span parameter) from 100 to 200. 3.12.4.1 Procedure to Configure a Datapoint • Press the Mode button to enter the ENGINEER mode indicated by the appearance of either CONFIGURE, DISPLAY or PROGRAM at the bottom of the display. • If CONFIGURE does not appear, press F2 until CONFIGURE appears at the bottom of the display.
Section 3. Product Description • The existing contents of DATAPOINT C115 are displayed (shown as 100.000 in this example). • To change the value of C115, first shift the C115 contents all the way right by pressing and holding the button. • Replace the "1" with a "2" by pressing the button until a "2" appears on the entry line, as shown in the screen to the right. • Enter the two additional zeros by using the buttons as discussed previously. and • The screen should now look as shown on the right.
53MC5000 Process Control Station 3.12.5 CONFIGURE A MODULE Refer to Section 3.11 for Keypad function in Module Mode The navigational sequence would be the following (Refer to Table 3-5): • Select Module Type (then Module, if there’s more than one Module) • Select Page (Skipped when there’s only a single page) • Select Parameter 3.12.5.
Section 3. Product Description • The existing contents of DATAPOINT C115 are displayed (shown as 100.000 in this example). • To change the value of C115, first shift the C115 contents all the way right by pressing and holding the button. • Replace the "1" with a "2" by pressing the button until a "2" appears on the entry line, as shown in the screen to the right. • Enter the two additional zeros by using the buttons as discussed previously. and • The screen should now look as shown on the right.
53MC5000 Process Control Station Numeric and Datapoint Data • The current value and an editable value are displayed, as shown in the screen to the right. • Use the buttons to select the desired character position on the edit line • Use the buttons to change the character value on the edit line. • Once the new value has been entered, press F3 to accept the new value on the edit line and change the parameter’s value or press F1 to abort the changes and retain the current value.
Section 3. Product Description When the Module Mode configuration is complete, the controller may be returned to the operator mode either by pressing the F1 key to step backwards through the menus or by pressing the MODE key .
3-20 CONFIGURE-MODULE MODE MENU ORGANIZATION SYSTEM EXECUTE TAG FIX FXM SCAN BACK BSCAN PWRUP LLD COUNTER ANALOG OUT 0 to 3 BASE TAG DISCRETE IN 0 to 11 INV TAG DISCRETE OUT 0 to 11 INV TAG EXTERNAL 0 to 11 RPT LPT SCAN MODE CONTROL 0 to 3 GENERAL TAG IR IRL CTR CTM CDM EU SETPOINT SP RSP STV SH SL SSR B1 K1 SPM * Only appears in Module numbers 4 through 7 STATUS 0&1 NAME STA STB STC STD STE STF STG STH TAG PL1 PL2 ADB AIX AK IA BR CP CB DLD SMA SMB SMC SMD SME SMF SMG SMH ALARM SAA SAB SAC SAD S
Section 3. Product Description 3.13 KEYPAD ALTERNATIVES There are six alternative methods other than the faceplate push buttons for accessing and changing database parameters. All six methods to display and/or alter database parameters are listed as follows: 1. Using a personal computer running the MC5FIG.EXE configuration program that is supplied as part of the 53HC3300 software package. This procedure is included in the Instruction Bulletin (IB 53HC3300) with the software. 2.
3-22 53MC5000 Process Control Station Figure 3-6.
Section 3. Product Description 3.13.1.1 HAND HELD CONFIGURER SET UP The Hand Held Configurer is shipped pre-configured to operate with the instrument. If the HHC does not operate correctly, check the configuration by entering set up mode. To enter HHC set up mode, hold CONTROL and SHIFT, and press F1. The correct configuration is shown below. Option Selection Baud 9600 Data Bits* 7 Parity** Space *Not applicable for U02 version. **Parity = None for U02 version.
53MC5000 Process Control Station Data Type B L C&H A F Data Format Are three digit characters 000-255. Is a one digit character 0 or 1. Are ten digit characters including digits, decimal point and sign (when negative). Zero = 0.0. Are ten characters or less. Are five characters or less. Pressing ENTER after pressing D automatically recalls the last datapoint number that was accessed. Pressing N after pressing D causes the next datapoint of the same data type to be displayed.
Section 3. Product Description 3.13.1.5 HHC MEMORY MODULE ASSEMBLY TRANSFER The procedure to save or load the controller database and/or calibration constants using the HHC with memory module (part number 698B182U02) is as follows: 1. Insert the memory module containing the desired database in the HHC. The memory module is inserted by placing it into the recess at the back of the HHC with the memory module label facing outward and up, then sliding it down until it is firmly seated.
53MC5000 Process Control Station Based on the selection made from this menu, one of the following operations can occur: • F2- DATABASE: This operation copies the entire database, all B, L, C, H, and A, datapoint values, in the controller to the memory module. This transfer takes approximately 12 seconds. • F3- PROGRAM: This selection copies the F-TRAN programs and F-CIM module sequences from the controller to the memory module. This transfer takes approximately 20 seconds.
Section 3. Product Description 3.13.2 USING A PC TERMINAL EMULATOR 3.13.2.1 Microsoft Windows Hyperterminal This procedure describes the use of the Microsoft Windows HyperTerminal program to emulate the 53MC5000 Handheld terminal. This procedure is based on configuring this function for the first time. Once configured, handheld terminal emulation may be started by double-clicking on the icon created in Step 5 of this procedure. 1.
53MC5000 Process Control Station 7. Select OK to continue. 8. The next window is used to configure the PC COM port communications parameters. The front port of the 53MC5000 has fixed communication parameters of 9600 baud, 8 Data Bits, 1 Stop Bit, and no Parity. 9. When the proper settings have been made, select OK to accept the settings. 10. Select File Properties from the HyperTerminal tool bar.
Section 3. Product Description 11. In the Properties window, select the Settings tab as pictured below. Choose the VT100 option from the Emulation pull down list. Click OK to continue. 12. The terminal mode setup is now complete. If the cable is connected between the controller and the PC, the basic handheld functions may now be performed using the terminal mode. 13. Displaying database values: Any database location within the controller can be displayed. To display a database location type D.
53MC5000 Process Control Station 3.14 ENGINEER MODE LOCKOUT Access to Engineer mode operation through the ACK/SEL (●) faceplate push button can be disabled. This can be accomplished by configuring password datapoint Q000 to the three character sequence %Z$ using the Hand Held Configurer. To remove the character sequence, press 0 (hold CTRL and press the zero key) on the Hand Held Configurer, which enters a NULL character string into the addressed datapoint.
Section 4. Operator Displays 4.0 OPERATOR DISPLAYS Standard displays are provided by the 53MC5000 Process Control Station (controller) and additional displays can be designed using F-TRAN if the controller has extended functionality. Typical display types are point, parameter, summary, status, and totalizer. There is one unique display, called the Locator Grid, which is not common to any one of these types. Point displays are bar graphs with setpoint indicators and alphanumeric tags.
53MC5000 Process Control Station The display handler may be configured manually by entering the appropriate values into datapoints of the System Module (see Section 5, Table 5-15). The datapoints are Number of Groups (B017), Number of Displays per Group (B018), and Display List (B021 through B084). Displays are updated at intervals determined by the Scan Index (B003) and Background Scan Index (B006), which are configurable parameters.
Section 4. Operator Displays Table 4-1.
53MC5000 Process Control Station Table 4-2. Generated Display Lists Display Number 3 9 13 14 2 Title Applicable Control Strategies Single Loop Flexible Control Strategies Single List Single Loop CON0* CS1 Single Loop PID Controller, CS2 Analog Backup Controller, Single Loop CON0 with Horizontal Trend CS3 Ratio Controller, Parameter Module 0 CS4 Automatic/Manual Station, and Parameter Module 1 CS5 Ratio Automatic/Manual Station.
53MC5000 Process Control Station 4.2 DISPLAY 2 - SYSTEM STATUS The System Status Display provides information indicating the functionality, operation, and communication status of the controller. The display is composed of two pages. The second page is accessed by pressing the F3 push button. Releasing the F3 push button causes the first page to reappear. The low-resolution version System Status Display is illustrated in Figure 4-2.
53MC5000 Process Control Station 4.3 DISPLAYS 3, 4, 5, AND 6 - POINT DISPLAYS (CON0-3) Displays 3, 4, 5, and 6 are point displays (see Figure 4-3). A point display provides loop control information with bar graphs and digital readouts. The type of bar graphs presented can be selected by the value loaded into the Control Display Mode (CDM0-3) datapoint (B339, B344, B349, or B354, as applicable) of the CON module for the point display.
Section 4. Operator Displays Ratio Auto/Manual Station). Also, many of the faceplate push button operator functions are Not Applicable (N/A) for the Indicator (CDM = 1) and Manual Loader (CDM = 2) graphical presentations as shown in Table 4-4, which follows. Table 4-4. Faceplate Push Buttons (Operator Functions) Push Button R/L A/M F1 F2 F3 ● Title Function Remote/Ratio/Computer Selects the Remote or Local setpoint modes for displays of or Local all control strategies except CS2, CS3, and CS5.
53MC5000 Process Control Station 4.3.1 POINT DISPLAYS 3, 4, 5, AND 6 (CDM = 0, STANDARD PID) The control module tag name (e.g., CON-0) appears at the top of the display. The left side of the Standard PID Display (CDM = 0) contains a fifty segment vertical axis. Above and below the vertical axis are the numerical values indicating its upper and lower ranges. Left of the vertical axis is the process variable bar.
53MC5000 Process Control Station CONTROL MODULE TAG NAME (A004) CONTROLLER SPAN (C187) + CONTROLLER LOWER RANGE (C188) ENGINEERING UNITS LEGEND (A005) LOW ALARM LIMIT INDICATOR CON2 ALARM LIMIT 1 (C175) (ALSO CONTROL ALARM MODE, B345 = 5) LO-LO ALARM LIMIT INDICATOR CON2 ALARM LIMIT 2 (C176) CONTROLLER LOWER RANGE (C188) C = CLOSE VALVE (SEE REVERSE VALVE L157) O = OPEN VALVE HORN OVERLAY (A009 = ’wALARMx’, L065 = 1, AND L063 = 0) LO-LO ALARM OVERLAY LO-LO ALARM LIMIT INDICATOR CON2 ALARM LIMIT 2 (C176)
Section 4.
53MC5000 Process Control Station 4.3.2 POINT DISPLAY 3 (CDM = 1, INDICATOR) The Indicator display is illustrated in Figure 4-4 In the illustration the control module tag name appears at the top of the display. The left side of the Indicator display (CDM = 1) contains a fifty segment vertical axis. Above and below the vertical axis are the numeric values indicating the upper and lower ranges. Left of the vertical axis is the process variable bar.
Section 4. Operator Displays 4.3.3 POINT DISPLAY 3 (CDM = 2, MANUAL LOADER) The Manual Loader Display is illustrated in Figure 4-5. In the illustration the control module tag name appears at the top of the display. The left side of the Manual Loader Display (CDM = 2) contains a fifty segment vertical axis. Above and below the vertical axis are the numerical values indicating its upper and lower ranges. Left of the vertical axis is the process variable bar.
53MC5000 Process Control Station 4.3.4 POINT DISPLAY 3 (CDM = 3, RATIO CONTROLLER) The Ratio Controller Display is illustrated in Figure 4-6. In the illustration the control module tag name appears at the top of the display. The left side of the Ratio Controller Display (CDM = 3) contains a fifty segment vertical axis with numerical values above and below it indicating its upper and lower ranges. Left of the vertical axis is the process variable bar.
Section 4. Operator Displays 4.3.5 POINT DISPLAY 3 (CDM = 4, AUTO/MANUAL STATION) The Auto/Manual Station Display is illustrated in Figure 4-7. In the illustration the control module tag name appears at the top of the display. The left side of the Auto/Manual Station Display (CDM = 4) contains a fifty segment vertical axis with numerical values above and below it indicating its upper and lower ranges. Left of the vertical axis is the alarmed variable indicator bar.
53MC5000 Process Control Station 4.3.6 POINT DISPLAY 3 (CDM = 5, RATIO AUTO/MANUAL STATION) The Ratio Auto/Manual Station Display is illustrated in Figure 4-8. In the illustration the control module tag name appears at the top of the display. The left side of the Ratio Auto/Manual Station Display (CDM = 5) contains a fifty segment vertical axis with numerical values above and below it indicating its upper and lower ranges. Left of the vertical axis is the alarmed variable indicator bar.
Section 4. Operator Displays 4.6 DISPLAYS 13 TO 20 - PARAMETER MODULE DISPLAYS Parameter Module Displays provide access to any datapoint for display or configuration purposes without entering engineer mode. Each display allows access to view and/or alter three parameter datapoint values in operator/control mode. As shown in Figure 4-11, a Parameter Display has seven information lines. There is a tag name at the top of the display. Beneath the tag name are three descriptive point names.
Section 4. Operator Displays 4.7 DISPLAYS 21 AND 22 - DISCRETE STATUS DISPLAYS There are two Discrete Status Displays, SDT0 and SDT1, that show the current state of sixteen logical parameters in the controller (eight parameters per display - see Figure 4-12).
53MC5000 Process Control Station M A S K 0 0 1 MODIFY DISABLE 0 (L320) = 1 INHIBITING POINTER AT ALARM A. POINTER APPEARS FOR ALARMS B - H. ALARM C = 1 - 10 CHARACTERS REVERSE VIDEO. TAG NAME (A063) SELECTION POINTER (MODIFY DISABLE 0 (L320) = 0; THEREFORE, SELECTION POINTER IS NOT INHIBITED AT ALARM A.) M A S (F3) K 1 0 0 1 - 5 CHARACTERS NORMAL VIDEO M A S (F3) K 1 0 1 6 - 10 CHARACTERS NORMAL VIDEO POINT 1 NAME FOR SDT-1 (A064) = OPEN CLOSE*. F3 IS PRESSED TO TOGGLE OPEN, THEN CLOSE, ON DISPLAY.
Section 5. Configuration Parameters 5.0 CONFIGURATION PARAMETERS The configuration parameters provide the latitude to define the controller’s personality attributes, so that while still functioning within its designed specifications, it can perform application requirements with greater refinement.
53MC5000 Process Control Station Multi I/O Analog Option Single Channel Analog Input Option Input Modules AI0 AI1 AI2 AI3 AI4 AI5 AI6 AI7 AI8 General Modules CON0 CON1 CON2 CON3 SDT0 SDT1 PAR0 PAR1 PAR2 PAR3 PAR4 PAR5 PAR6 PAR7 TREND0 TREND1 TREND2 TREND3 TREND4 TREND5 TREND6 TREND7 Output Modules TOT0 TOT1 TOT2 TOT3 TOT4 TOT5 TOT6 TOT7 AO0 AO1 AO2 AO3 Multi I/O Analog Option Control Algorithms 6DI/4DO Option 16DI/DO Option (16 Modules Maximum on ITB) DI0 DI1 DI2 DI3 DI4 DI5 DI6 DI7 DI8 DI9 DI
Section 5. Configuration Parameters 5.3 CONFIGURING THE DATABASE MODULES The datapoints in the database modules must be changed to reflect required alterations in the factory standard configuration or when the controller is re-configured. There are generally six datapoint parameter types contained in the eleven database modules. The parameter types affect network communications, display indications, input-output signals, trending, totalizing, and responsiveness of the controller.
53MC5000 Process Control Station Table 5-3. Database Modules Name 2 of 2 Purpose See Table Discrete Out Modules These modules allow the action of a DOs to be reversed (normally a closed contact = 1, but can be changed to = 0). The 18 Contact Closure Output (DO0-17) Modules can be configured separately. 5-7 External Module This module provides the ability to transfer data to/from other MICRODCI controllers or instruments through the MicroLink peer-to-peer communications network.
5.4 ANALOG INPUT MODULES (AI0-8) The Analog Input Modules (AI0-8) are used to configure the characteristics of each input. Inputs AI4 through AI8 are active only if the appropriate hardware option is installed. The nine Analog Input Modules are listed in Table 5-4. Each module can be configured separately. Table 5-4.
5-6 Table 5-4. Analog Input Modules (AI0-8) Atom SQRT (0-8) AI0 L440 AI1 AI2 L441 L442 AI3 L443 CIZ (0-8) B263 B264 B265 B266 CIS (0-8) C296 C297 C298 C299 FREQ (0-8) AI4 L444 AI5 L445 AI6 L446 AI7 AI8 Default L447 L448 0 L468 L469 L470 L471 53MC5000 Process Control Station Title Definition Square Root This value specifies the Signal characteristics of the signaling input as either linear or square root.
Table 5-4. Analog Input Modules (AI0-8) Title Scan Pulse Count Tag Name Engineering Units Atom AIPI (5-7) AI0 AI1 AI2 AI3 AI4 AIPC (5-7) AI5 AI6 AI7 C066 C065 C064 AI8 H066 H065 H064 TAG A224 A225 A226 A227 A228 A229 A230 A231 A232 EU A298 A299 A300 A301 A302 A303 A304 A305 A306 Default 0 0 Section 5.
5-8 5.5 ANALOG OUTPUT MODULES (AO0-3) The Analog Output Modules (AO0-3) are used to configure the characteristics of each output. Outputs AO2 and AO3 are active only if the appropriate hardware option is installed. The four Analog Output Modules are provided in Table 5-5. Each one can be configured separately. Table 5-5.
5.6 DISCRETE INPUT MODULES (DI0-17) The Discrete Input Modules (DI0-17) generate logic levels based on the applied voltages or contact condition on the associated terminals. Inputs DI2-17 are active only when the appropriate hardware options are installed. The 18 Discrete Input Modules are provided in Table 5-6. Each one can be configured separately (total combined DIs and DOs for controller cannot exceed 18). Table 5-6.
5-10 5.7 DISCRETE OUTPUT MODULES (DO0-17) The Discrete Output Modules (DO0-17) convert a logic level to a hardware contact condition. Outputs DO2-17 are active only when the appropriate hardware options are installed. The 18 Discrete Output Modules are provided in Table 5-7. Each one can be configured separately (total combined DIs and DOs for controller cannot exceed 18). Table 5-7. Discrete Output Modules (DO0-17) Title Definition Discrete Output Output Invert Tag Name Same as above.
5.8 EXTERNAL MODULE (TASKS 0-23) The External Module provides a total of 24 (0-23) tasks that are used to transfer data between the controller and networked devices. Each task is capable of performing a read, write, or bidirectional operation.
5-12 Table 5-8. External Module (Tasks 0-23) Title Remote Point Scan Mode Status The Remote Point and Local Point parameters must specify identical data types. This parameter specifies the datapoint within the controller or instrument that is accessed by the task. The Remote Point and Local Point parameters must specify identical data types. Specifies the rate at which the task is executed. The time in seconds (0-255) that the task is to be repeated is loaded into this datapoint.
Table 5-8. External Module (Tasks 0-23) Title Remote Point Local Point Scan Definition Same as above. Status Title Remote Point Local Point Scan Mode Status Definition Same as above.
5-14 5.9 CONTROLLER MODULES (CON0-3) These modules affect the action of the control algorithms, the control loop displays, and control related functions (e.g., Auto Enable, etc.). There are four Controller Modules (CON0-3) that can be configured separately, one for each control loop display. The number of control loops provided by a controller is model number dependent. Table 5-9.
Table 5-9. Controller Modules (CON0-3) Title Alarm Examples: B335 PV PL1 PL2 Alarm (C103) (C104) >60 <40 >60 <40 >60 <40 >60 >70 <40 <30 >50 <30 Trend Rate Trend Mode 60 40 60 40 60 40 60 70 40 30 10 -10 HIGH LOW HIGH N/A N/A LOW HIGH HI-HI LOW LO-LO HI-DEV LO-DEV Definition Setpoint 40 40 Atom CON0 CON1 CON2 CON3 Default Notes Alarm Limit 1 is set for 60. If PV exceeds 60 = HIGH alarm. Alarm Limit 2 is set for 40. If PV falls below 40 = LOW alarm. Alarm Limit 1 is set for 60.
5-16 Table 5-9.
Table 5-9. Controller Modules (CON0-3) Title Alarm B Active See Control Alarm Mode (AIX). Auto Switch This parameter is used in conjunction with Auto Enable (AE) to allow the Control Output (OUT) to become the auto/manual generator result Output (OUT). This parameter is used in conjunction with Remote Setpoint Enable (RE) to allow the modified Remote Setpoint to become the setpoint value to the setpoint generator.
5-18 Table 5-9. Controller Modules (CON0-3) Title Remote Setpoint Enable Output Track Switch See Output Track Enable (OTE). SP Track Enable When this parameter is configured to a 1, the controller’s setpoint can be forced to match Setpoint Track Value (STV) whenever the Setpoint Track Switch (SWSPT) is a 0 .
Table 5-9. Controller Modules (CON0-3) Title Manual Fallback Disable Definition Control Alarm Acknowledge Used internally by the controller. Alarm AA Past State Used internally by the controller. Alarm AB Past State Used internally by the controller. Process Variable The process variable used in the PID algorithm. Setpoint The output of the setpoint generator. Output The output of the Auto/Manual Selector.
5-20 Table 5-9. Controller Modules (CON0-3) Title Alarm Dead Band Proportional Band Rate Time Output High Limit Output Low Limit Manual Reset Remote SP Bias Remote SP Ratio This parameter determines the position of the valve (output) when the instrument is in Automatic mode and the error is zero. (only in effect when TR = 0.) This parameter and Remote SP Ratio (K1) allow the remote setpoint to be modified prior to input at the setpoint generator.
Table 5-9. Controller Modules (CON0-3) 8 of 9 Definition This parameter defines a gap or dead band on either side of the setpoint. When the process variable is within this gap, proportional and integral output changes are suppressed. Note that derivative changes are based on the PV and are therefore not affected. Atom CZ (0-3) Controller Span These two parameters set the upper and lower values on the controller display.
5-22 Table 5-9. Controller Modules (CON0-3) Title Partial Output Term Used internally by the controller Setpoint High Limit These two parameters are configured to indicate the maximum and minimum controller setpoint values allowed. They are applied to the final output of the setpoint generator and therefore affect the remote and track setpoint results.See Remote Setpoint Enable (RE) and Setpoint Tracking Enable (STE).
5.10 STATUS MODULES (SDT0 AND SDT1) There are two Status Modules (SDM) that can be configured separately. The two Status Modules each provide indication and push button access control for eight logical points in the controller. How the indicators appear for given conditions and alarms is dependent upon the configuration selections entered in the Status Modules. The display handler index numbers for the discrete status displays are 21 and 22, which correspond to status modules SDT0 and SDT1 respectively.
5-24 Table 5-10. Status Modules (SDT0 and SDT1) Title Point 0 Mode Point 1 Mode 2 of 4 Definition Mode (SM) indicates how the Point Name is displayed, which is also affected by three other parameters: SDT Alarm Enable (SA), SDT State (SS), and SDT Alarm Acknowledge (SK).
Table 5-10. Status Modules (SDT0 and SDT1) Definition When this value is a 1, the Horn bit (L065) is set when the corresponding SDT State changes from 0 to 1 . The displayed Point Name flashes as long as SDT State = 1 and SDT Alarm Acknowledge = 0. 0 - OFF 1 - ON 0 1 2 3 4 5 6 7 This parameter is set to 1 whenever State (SS) changes from 0 to 1. It indicates an unacknowledged alarm and must be cleared to 0 to acknowledge the alarm. This parameter is used internally by the Controller.
5-26 Table 5-10. Status Modules (SDT0 and SDT1) Display Definition When set to a 1, this parameter inhibits the operator from modifying the state of the corresponding individual points with the push buttons. (The arrow indicator on the SDT display skips over the inhibited points when the up/down faceplate push buttons are pressed.) When set to a 0, the operator can alter the state of the individual corresponding points with the push buttons.
5.11 PARAMETER MODULES These modules provide quick operator access to any three selected datapoints (e.g., Alarm Limits 1 & 2 and Alarm Dead Band) without the necessity of entering Engineer mode and addressing the datapoints. There are eight Parameter Modules (0-7) that can be configured separately. Table 5-11.
5-28 5.12 TREND MODULES There are eight configurable Trend Modules that can be configured separately. Each Trend Module provides storage of the last 80 samples of the specified input (the last 40 samples are displayed on the point trend line). The first four Trend Modules are attached to the CON Modules if the Trend Rate datapoint in the CON Module is non-zero.
Table 5-12. Trend Modules Title Trend Mode Trend Zero Atom TRM (0-7) 0 1 2 3 4 5 6 7 Default B356 B359 B362 B365 B368 B371 B374 B377 0 TRH (0-7) B357 B360 B363 B366 B369 B372 B375 B378 47 TRZ (0-7) C302 C304 C306 C308 C310 C312 C314 C316 0 Section 5. Configuration Parameters Trend Height 5-29 Definition This parameter specifies the sampling method used to record the selected datapoint.
5-30 5.13 TOTALIZER MODULES There are eight Totalizer Modules that can be configured separately. Each module provides a totalization (integration) of a specified input. Sampling occurs once a second whenever the input parameter contains a valid datapoint specification. Table 5-13. Totalizer Modules Parameter Rollover Value Dropout Value Reset This parameter specifies the maximum value of the totalizer. When the total reaches this value it is reset to 0.0; however, totalizing continues.
Table 5-13. Totalizer Modules Parameter Actual Total Output Pulse Display Definition This parameter indicates the integer value of the total accumulation. This value is pulsed to a 1 for one scan each time the actual total reaches the rollover value. This is the index number for the display that provides access through the totalizer module.
5-32 5.14 SYSTEM MODULE This module controls and monitors the loading, scheduling and execution of the operations algorithms; as well as the display appearance, network communications, counter/timer settings and hardware status indicators. Table 5-14. System Module Title Unit Tag Name Function Index Match Scan Index Scan File Overrun Counter Background Program Definition This parameter indicates the name that is displayed as the Controller Name and should not be confused with the loop tag names.
Table 5-14. System Module Title Background Scan Index Power-Up Status Link List Load Model Number Low Model Number High Unit Identifier Definition This parameter directs how often the display is renewed and when activated with Background Program (BACK - B008), the period for executing the EASY-TUNE algorithm. The period realized equals B006 X B003 X 50 mS.
5-34 Table 5-14. System Module Title Slot 1 3 of 6 Definition The value in each of these datapoints identifies the option card type occupying that slot. The value codes are: Slot 2 Slot 3 Slot 5 Seconds Minutes Hours Day Month Year Counter Mode Instrument Address Run time counter/clock. These values increment in the time-units specified. This parameter controls the operation of the RTC (run-time counter).
Table 5-14. System Module Title 4 of 6 Definition Atom Datapoint Default BR B002 253 CP L256 0 CB L258 0 DLD L257 0 IMA IMB A188 A189 NULL NULL This datapoint value designates the baud rate (data transfer rate) of the Datalink network. The baud rate must be the same for all of the instruments connected to the same Datalink network. Datapoint values and their corresponding baud rates are as follows: No Parity No Byte Stuffing Datalink Disable Initialization Message Section 5.
5-36 Table 5-14. System Module Title Display Program Display Brightness Alarm Line Display List Definition This value is the current display program index number. This parameter controls the display screen intensity. For Model 53MC5000A controllers and Model 53MC5000B controllers with the Low-Res display, index values from 0 to 7 determine brightest (0) to dimmest (7) intensity. This parameter has negligible effect on display brightness in 53MC5000B controller models with the Hi-Res display.
Table 5-14. System Module Title Number of Groups Loop Select Definition This parameter dictates the number of groups that the display list represents. In the pop-up locator grid, this parameter represents the number of columns in the matrix. Valid numbers are from 1 to 8. When B017 contains a 1, F1 is the page forward push button and F2 is the page backward push button. When B017 contains a number greater than 1, F1 is the next group push button and F2 is the next display push button.
5-38 Table 5-14. System Module Title Definition Atom Datapoint Default PLIM L520 1 APLD L522 0 ESTAT B387 0 Enable Tuning Parameter Limits 0 - no limits checked, 1 - limits below apply Parameter Modify Status lowest % PB highest % PB lowest TR (minutes) highest TR (minutes) lowest TD (minutes) highest TD (minutes) Automatic Tuning Parameter 1 - upon successful completion of the EASY-TUNE sequence, new tuning parameters will be entered.
Table 5-14. System Module Title Definition EASY-TUNE Unsuccessful Status Display B387 = Description 51 Controller output was saturated. 52 54 55 Status (Cont.) 56 57 58 59 60 61 Controller output was changed externally, i.e. deliberately or accidentally. A time-out had occurred when B387 was 1. A time-out had occurred when B387 was 2. A time-out had occurred when B387 was 3. A time-out had occurred when B387 was 4. A time-out had occurred when B387 was 5. L521 was set to 1.
53MC5000 Process Control Station 5.16 CONFIGURATION SUMMARY Figure 5-2 illustrates the general approach to customizing and configuring the controller. INSTALL CONTROLLER PER SECTION 2, INSTALLATION. CHOOSE A CONTROL STRATEGY AS DESCRIBED IN SECTIONS 6 - 15.
Section 6. CS1 - Single Loop Controller 6.3 CS1 STANDARD DISPLAYS Loading CS1 preconfigures the System Module display list for five displays. The five displays are listed in Table 6-2 with appropriate reference sections, figure numbers, and configuration tables. A configuration table is not listed for the Single Loop CON0 display, as that information is provided in this section.
Section 6. CS1 - Single Loop Controller Table 6-3. CS1 Single Loop CON0 Datapoints Datapoint C256 C276 B269 L416 L440 L115 C112 1 of 5 DeTitle and Function fault AI0 - Process Variable 5-4 AI0 Engineering Span - Enter a value, that when added to the 100 Engineering Zero value, will produce an upper range value in engineering units that represents the PV transducer upper range signal value.
53MC5000 Process Control Station Table 6-3. CS1 Single Loop CON0 Datapoints Datapoint L441 C258 C278 B271 L418 L442 L119 DeTable Module Title and Function fault AI1 - Remote Setpoint (Is affected by the Setpoint Related Datapoints.) (Cont) 5-4 AI1 Square Root Signal - It is used if the Remote Setpoint input 0 is a squared signal value that must be linearized. 0 = input is already linear; 1 = square root to restore linearization.
Section 6. CS1 - Single Loop Controller Table 6-3. CS1 Single Loop CON0 Datapoints Datapoint Table Module L122 5-9 CON0 C109 5-9 CON0 C110 5-9 CON0 C118 5-9 CON0 C106 5-9 CON0 C107 5-9 CON0 C108 5-9 CON0 C111 5-9 CON0 L106 5-9 CON0 L114 5-9 CON0 C115 5-9 CON0 C116 5-9 CON0 L473 5-5 AO1 L264 5-6 DI0 Title and Function AO0 - Control Out (Cont) Hard Manual Limit - 1 = apply output limits to the final output of the Auto-Manual Generator.
53MC5000 Process Control Station Table 6-3. CS1 Single Loop CON0 Datapoints Datapoint Table Module L265 5-6 DI1 L288 5-7 DO0 L289 5-7 DO1 B335 5-9 CON0 C103 5-9 CON0 C104 5-9 CON0 C105 5-9 CON0 C114 5-9 CON0 C125 5-9 CON0 C126 5-9 CON0 C117 5-9 CON0 L118 5-9 CON0 6-8 Title and Function DI1 - Remote Setpoint Enable Contact Input Invert - Normally, Remote Setpoint Enable is permitted if DI1 is closed (datapoint L115 - Remote Setpoint Enable is set to 1 by DI1).
Section 6. CS1 - Single Loop Controller Table 6-3. CS1 Single Loop CON0 Datapoints Datapoint Table Module A000 5-9 CON0 Title and Function Miscellaneous Datapoints Tagname - Assignable 10 character name. A001 5-9 CON0 Engineering Units - Assignable 10 character designator. L109 5-9 CON0 Reverse Valve - Bottom of display output valve action indicators: 1 = [O] [C] display order, 0 = [C] [O] display order.
53MC5000 Process Control Station 6.5 CS1 SOFT-WIRE LIST MODIFICATIONS Table 6-4 lists values that can be entered into designated soft-wire list datapoints to alter CS1 functionality. Table 6-4. CS1 Soft-Wire List Modifications To force control to manual on a momentary contact closure of DI0: Set B133 = 97 To set controller output to a fixed value while DI0 is an open contact: Set B160 = 129 and Set C129 to desired value.
Section 7. CS2 - Analog Backup Controller 7.0 CS2 - ANALOG BACKUP CONTROLLER 7.1 CS2 - ANALOG BACKUP CONTROLLER The Analog Backup Controller is used in operations where a remote computer is normally controlling the final element directly. In this process configuration, the controller functions as a signal selector and automatic backup unit to the computer. The controller assumes process control in the event of a signaled computer failure.
53MC5000 Process Control Station Figure 7-2. DO Output Diverter Circuit 7.2 CS2 CONTROL SIGNALS Loading CS2 connects the 53MC5000 Controller function blocks for operation as an Analog Backup Controller. As shown in Figure 7-1, up to nine control signals are available. Table 7-1 below describes the nine signals in CS2. Table 7-1. CS2 Control Signals Control Signal AI0 - Process Variable Definition This analog input signal represents the value of the process to be manipulated by the controller.
Section 7. CS2 - Analog Backup Controller Table 7-1. CS2 Control Signals Control Signal 2 of 2 Cord Set ITB DO0 When open, the computer output path is through TB2-5 (+) Computer the diverter circuit diode to the final element TB2-6 (-) Output Diverter (valve). DO1 - Backup When open, the controller output path is through TB2-7 (+) Output Diverter the diverter circuit diode to the final element TB2-8 (-) (valve). Definition Rear Term Board 16 (+) 17 (-) DO0 PC 18 (+) 17 (-) DO1 PC Signal 7.
Section 7. CS2 - Analog Backup Controller Table 7-3.
53MC5000 Process Control Station Table 7-3. CS2 Analog Backup Controller Datapoints Datapoint Table Module C109 5-9 CON0 C110 5-9 CON0 C118 5-9 CON0 C106 5-9 CON0 C107 5-9 CON0 C108 5-9 CON0 C111 5-9 CON0 L106 5-9 CON0 L114 5-9 CON0 C115 5-9 CON0 C116 5-9 CON0 L473 5-5 AO1 L264 5-6 DI0 L265 5-6 DI1 L024 5-7 DO0 7-6 Title and Function AO0 - Backup Control Output (Cont) Output High Limit - Sets maximum Control Output signal value in engineering units.
Section 7. CS2 - Analog Backup Controller Table 7-3. CS2 Analog Backup Controller Datapoints Datapoint Table Module L025 5-7 DO1 B335 5-9 CON0 C103 5-9 CON0 C104 5-9 CON0 C105 5-9 CON0 C114 5-9 CON0 C125 5-9 CON0 C126 5-9 CON0 C117 5-9 CON0 A000 5-9 CON0 A001 5-9 CON0 L109 5-9 CON0 3 of 3 DeTitle and Function fault DO1 - Backup Output Diverter When open, the controller output path is through the diverter 0 circuit diode to the final element.
53MC5000 Process Control Station NOTES: 7-8
Section 8. CS3 - Ratio (PID) Controller 8.0 CS3 - RATIO (PID) CONTROLLER 8.1 CS3 - RATIO (PID) CONTROLLER The Ratio (PID) Controller is used where one variable, called the controlled variable, must be automatically maintained in definite proportion to another variable, called the wild variable. Field transmitters (e.g, flow meters) must be installed in each variable line.
53MC5000 Process Control Station 8.2 CS3 CONTROL SIGNALS Loading CS3 connects the 53MC5000 Controller function blocks for operation as a Ratio (PID) Controller. As shown in Figure 8-1, CS3 provides nine control signals which are described in Table 8-1: Table 8-1.
Section 8. CS3 - Ratio (PID) Controller 8.3 CS3 STANDARD DISPLAYS Loading CS3 preconfigures the System Module display list for five displays. The five displays are listed in Table 8-2 with appropriate reference sections, figure numbers, and configuration tables. A configuration table is not listed for the Ratio Controller Single Loop CON0 display, as that information is provided in this section.
Section 8. CS3 - Ratio (PID) Controller Table 8-3.
53MC5000 Process Control Station Table 8-3.
Section 8. CS3 - Ratio (PID) Controller Table 8-3. CS3 Ratio Controller Datapoints Datapoint Table Module C118 5-9 CON0 C106 5-9 CON0 C107 5-9 CON0 C108 5-9 CON0 C111 5-9 CON0 L106 5-9 CON0 L114 5-9 CON0 C115 5-9 CON0 C116 5-9 CON0 L264 5-6 DI0 L265 5-6 DI1 L288 5-7 DO0 L289 5-7 DO1 Title and Function AO0 - Control Out (Cont) Output Slew Rate - It is a rate limit applied to the output value.
53MC5000 Process Control Station Table 8-3. CS3 Ratio Controller Datapoints Datapoint Table Module B335 5-9 CON0 C103 5-9 CON0 C104 5-9 CON0 C105 5-9 CON0 C114 5-9 CON0 C125 5-9 CON0 C126 5-9 CON0 C117 5-9 CON0 A000 5-9 CON0 A001 5-9 CON0 L109 5-9 CON0 8-8 4 of 4 DeTitle and Function fault Alarms Related Datapoints Control Alarm Mode - Used to select one of six alarm types 1 or none. See Table 5-9 for details and examples.
Section 9. CS4 - Automatic/Manual Station 9.0 CS4 - AUTOMATIC/MANUAL STATION 9.1 CS4 - AUTOMATIC/MANUAL STATION The Automatic/Manual Station operates as a standard auto/manual selector and a manual loader. Automatic throughput is enabled when DI1 is closed, DI0 is closed (no Output Tracking), and A (Auto) is selected with the A/M faceplate push button. Automatic throughput is overridden when DI1 is open. In automatic, the signal on AI0 is passed through to the station’s output.
53MC5000 Process Control Station 9.2 CS4 CONTROL SIGNALS Loading CS4 connects the 53MC5000 Controller function blocks for operation as an Automatic/ Manual Station. As shown in Figure 9-1, CS4 provides eight control signals which are described in Table 9-1: Table 9-1.
Section 9. CS4 - Automatic/Manual Station 9.3 CS4 STANDARD DISPLAYS Loading CS4 preconfigures the System Module display list for five displays. The five displays are listed in Table 9-2 with appropriate reference sections, figure numbers, and configuration tables. A configuration table is not listed for the Auto/Manual Point Display 3, as that information is provided in this section.
Section 9. CS4 - Automatic/Manual Station Table 9-3.
53MC5000 Process Control Station Table 9-3. CS4 Automatic/Manual Station Datapoints Datapoint Table L419 5-4 L443 5-4 L472 5-5 L120 5-9 L122 5-9 C109 5-9 C110 5-9 C115 5-9 C116 5-9 L264 5-6 L265 5-6 L288 5-7 L289 5-7 9-6 Module Title and Function AI3 - Tracking Input (Output Tracking) (Cont) AI3 0-5 V Input - Enter a value that matches the signal voltage range of the tracking input signal. 1 = 0 - 5 V input range; 0 = 1 - 5 V input range.
Section 9. CS4 - Automatic/Manual Station Table 9-3. CS4 Automatic/Manual Station Datapoints Datapoint Table Module B335 5-9 CON0 C103 5-9 CON0 C104 5-9 CON0 C105 5-9 CON0 A000 5-9 CON0 A001 5-9 CON0 3 of 3 DeTitle and Function fault Alarms Related Datapoints Control Alarm Mode - Used to select one of six alarm types 1 or none. See Table 5-9 for details and examples.
53MC5000 Process Control Station NOTES: 9-8
Section 10. CS5 - Ratio Automatic/Manual Station 10.0 CS5 - RATIO AUTOMATIC/MANUAL STATION 10.1 CS5 - RATIO AUTOMATIC/MANUAL STATION The Ratio Automatic/Manual Station operates as a combination auto/manual selector, a manual loader, and a ratio station. Transfer from automatic to manual is bumpless after which the output may be manipulated with the faceplate output push buttons. In automatic, the signal on AI0 is modified by the ratio value, then passed through to the station’s output at AO0.
53MC5000 Process Control Station 10.2 CS5 CONTROL SIGNALS Loading CS5 connects the 53MC5000 Controller function blocks for operation as a Ratio Automatic /Manual Station. As shown in Figure 10-1, CS5 provides nine control signals which are described in Table 10-1: Table 10-1.
Section 10. CS5 - Ratio Automatic/Manual Station 10.3 CS5 STANDARD DISPLAYS Loading CS5 preconfigures the System Module display list for five displays. The five displays are listed in Table 10-2 with appropriate reference sections, figure numbers, and configuration tables. A configuration table is not listed for the Ratio Auto/Manual Point Display 3, as that information is provided in this section.
Section 10. CS5 - Ratio Automatic/Manual Station Table 10-3.
53MC5000 Process Control Station Table 10-3. CS5 Ratio Automatic/Manual Station Datapoints Datapoint Table Module L418 5-4 AI2 L442 5-4 AI2 L119 5-9 CON0 C259 5-4 AI3 C279 5-4 AI3 B272 5-4 AI3 L419 5-4 AI3 L443 5-4 AI3 L472 5-5 AO0 L120 5-9 CON0 L122 5-9 CON0 C109 5-9 CON0 C110 5-9 CON0 C115 5-9 CON0 C116 5-9 CON0 10-6 Title and Function AI2 - Alarmed Variable (Cont) 0-5 V Input - Enter a value that matches the voltage range of the Alarmed Variable signal.
Section 10. CS5 - Ratio Automatic/Manual Station Table 10-3. CS5 Ratio Automatic/Manual Station Datapoints Datapoint Table Module L264 5-6 DI0 L265 5-6 DI1 L288 5-7 DO0 L289 5-7 DO1 B335 5-9 CON0 C103 5-9 CON0 C104 5-9 CON0 C105 5-9 CON0 A000 5-9 CON0 A001 5-9 CON0 3 of 3 DeTitle and Function fault DI0 - Force Output Tracking Contact Input Invert - Normally, Force Output Tracking is 0 enabled if DI0 is open (and datapoint L119 - Enable Output Tracking = 1).
53MC5000 Process Control Station NOTES: 10-8
Section 11. CS20 - Two Loop Controller 11.0 CS20 - TWO LOOP CONTROLLER 11.1 CS20 - TWO LOOP CONTROLLER A two loop 53MC5000 Controller is configured at the factory for CS20 operation to provide the standard displays listed in Table 11-2 and the default datapoint settings listed in Table 11-3.
53MC5000 Process Control Station 11.2 CS20 CONTROL SIGNALS Loading CS20 connects the 53MC5000 Controller function blocks for operation as two standard PID controllers. As shown in Figure 11-1, up to ten control signals are available; however, only two are essential for each loop controller: they are the Process Variable and the Control Output. If the other six control signal functions are not needed, then their respective datapoints should be left at the default values.
Section 11. CS20 - Two Loop Controller Table 11-1. CS20 Control Signals Control Signal DO1 - Process Alarms Loop 2 2 of 2 Cord Set ITB This contact is closed when the Loop 2 Process TB2-7 (+) Variable value is not within the C139 and C140 TB2-8 (-) datapoint values (Loop 2 Alarm Limits 1 and 2); otherwise, the contact is open. Definition Rear Term Board 18 (+) 17 (-) Signal DO1 PC 11.3 CS20 STANDARD DISPLAYS Loading CS20 preconfigures the System Module display list for ten displays.
53MC5000 Process Control Station Table 11-3.
Section 11. CS20 - Two Loop Controller Table 11-3. CS20 Two Loop Controller Datapoints 2 of 6 DataDepoint Table Module Title and Function fault AI2 - Remote Setpoint Loop 1 (Is affected by Setpoint Related Datapoints) (Cont) C112 5-9 CON0 Remote Setpoint Bias (B1) - This datapoint and Remote 0 Setpoint Ratio (K1) allow the Remote Setpoint input to be modified by the Setpoint Generator.
53MC5000 Process Control Station Table 11-3. CS20 Two Loop Controller Datapoints 3 of 6 DataDepoint Table Module Title and Function fault AI3 - Remote Setpoint Loop 2 (Is affected by Setpoint Related Datapoints) (Cont) C279 5-4 AI3 Engineering Zero - Enter a value that represents in 0 engineering units the Loop 2 Remote Setpoint lower range signal value. B272 5-4 AI3 Digital Filter Index - This is a first order filter that can be 3 applied to the Loop 2 Remote Setpoint signal.
Section 11. CS20 - Two Loop Controller Table 11-3. CS20 Two Loop Controller Datapoints Datapoint Table Module Title and Function CON0 Control Loop 1 Related Datapoints (Cont) CON0 Controller Span - Enter a value, that when added to the Loop 1 Controller Lower Range value, will produce the Loop 1 control upper range value in engineering units. CON0 Controller Lower Range - Enter a value that represents in engineering units the Loop 1 control lower range value.
53MC5000 Process Control Station Table 11-3. CS20 Two Loop Controller Datapoints Datapoint Table Module Title and Function DI0 - Remote Enable Loop 1 Contact Input Invert - Normally, Remote Enable Loop 1 is permitted if DI0 is closed (datapoint L115 - Remote Setpoint Enable is set to 1 by DI0). Set to 1 to reverse the DI0 condition required to permit Remote Enable Loop 1 (DI0 open = Remote Enable Loop 1).
Section 11. CS20 - Two Loop Controller Table 11-3. CS20 Two Loop Controller Datapoints Datapoint Table C117, C153 5-9 A000, A002 A001, A003 5-9 L109, L133 5-9 5-9 Module Title and Function Setpoint Related Datapoints (Loop 1, Loop 2) (Cont) CON0, Setpoint Slew Rate - It is a rate limit applied to the setpoint. CON1 When configured to a non-zero value, the setpoint used in the PID algorithm is only allowed to change by this amount each scan time.
53MC5000 Process Control Station NOTES: 11-12
Section 12. CS21 - Two Loop Cascade Controller 12.0 CS21 - TWO LOOP CASCADE CONTROLLER 12.1 CS21 - TWO LOOP CASCADE CONTROLLER The Two Loop Cascade Controller provides two standard PID controllers that function as a primary and secondary controller in one unit. The output of the primary controller, based on its setpoint and process variable, becomes the setpoint input to the secondary controller.
53MC5000 Process Control Station 12.2 CS21 CONTROL SIGNALS Loading CS21 connects the 53MC5000 Controller function blocks for operation as a Two Loop Cascade Controller. As shown in Figure 12-1, CS21 provides ten control signals which are described in Table 12-1. Table 12-1.
Section 12. CS21 - Two Loop Cascade Controller Table 12-1. CS21 Control Signals Control Signal DO1 - Process Alarms Primary 2 of 2 Definition This contact is closed when the primary loop Process Variable value is not within the C139 and C140 datapoint values (primary loop Alarm Limits 1 and 2); otherwise, the contact is open. Cord Set ITB TB2-7 (+) TB2-8 (-) Rear Term Board 18 (+) 17 (-) Signal DO1 PC 12.
53MC5000 Process Control Station Table 12-3. CS21 Two Loop Cascade Controller Datapoints Datapoint C256 C276 B269 L416 L440 L115 C112 Table Module Title and Function AI0 - Process Variable Primary 5-4 AI0 Engineering Span - Enter a value, that when added to the Engineering Zero value, will produce an upper range value in engineering units that represents the PV Primary transducer upper range signal value.
Section 12. CS21 - Two Loop Cascade Controller Table 12-3. CS21 Two Loop Cascade Controller Datapoints 2 of 6 DataDepoint Table Module Title and Function fault AI1 - Remote Setpoint Primary (Is affected by Setpoint Related Datapoints) (Cont) L441 5-4 AI1 Square Root Signal - It is used if the Primary Remote 0 Setpoint is a squared signal value that must be linearized. 0 = input is already linear; 1 = square root to restore linearization.
53MC5000 Process Control Station Table 12-3. CS21 Two Loop Cascade Controller Datapoints Datapoint Table Module Title and Function AO0 - Control Output (Secondary) (Cont) Manual Fallback Disable - 0 = always power up in manual for Secondary Control Output; 1 = auto/manual selector unchanged at power up. Hard Manual Limit - 1 = apply output limits to the final output of the Loop 1 Auto-Manual Generator. Affects both the manual push buttons and the controller’s result. 0 = do not apply limits.
Section 12. CS21 - Two Loop Cascade Controller Table 12-3. CS21 Two Loop Cascade Controller Datapoints Datapoint C148 Table 5-9 Module Title and Function CON1 Control Related Datapoints (Secondary) (Cont) CON1 Remote Setpoint Bias (B1) - This datapoint and Remote Setpoint Ratio (K1) allow the primary CON0•OUT input to be modified by the CON1 Setpoint Generator.
53MC5000 Process Control Station Table 12-3. CS21 Two Loop Cascade Controller Datapoints Datapoint L106 L114 C115 C116 L264 L265 L288 L289 B335, B340 C103, C139 C104, C140 C105, C141 12-10 Table Module Title and Function CON0 Control Related Datapoints (Secondary Setpoint Transmit) (Cont) 5-9 CON0 Reverse Switch - 0 = Secondary Setpoint Transmit ↑ if Primary PV ↑; 1 = Secondary Setpoint Transmit↓ if Primary PV↑.
Section 12. CS21 - Two Loop Cascade Controller Table 12-3. CS21 Two Loop Cascade Controller Datapoints Datapoint Table C114, C150 5-9 C125, C161 C126, C162 C117, C153 5-9 A000, A002 A001, A003 L109, L133 5-9 5-9 5-9 5-9 5-9 Module Title and Function Setpoint Related Datapoints (Primary, Secondary) CON0, Control Zone - A gap on both sides of setpoint. When PV is CON1 within this gap, the proportional and integral output changes are suppressed. Derivative output is unaffected.
53MC5000 Process Control Station NOTES: 12-12
Section 13. CS22 - Two Loop Override Controller 13.0 CS22 - TWO LOOP OVERRIDE CONTROLLER 13.1 CS22 - TWO LOOP OVERRIDE CONTROLLER The Two Loop Override Controller provides two standard PID controllers that function as two interdependent variables, Primary and Limiting, to control a single final element (e.g., valve). Neither variable may exceed a safe limit. The outputs of both PIDs are fed into a high/low selector that determines which output will drive the final element.
53MC5000 Process Control Station 13.2 CS22 CONTROL SIGNALS Loading CS22 connects the 53MC5000 Controller function blocks for operation as two standard PID controllers. As shown in Figure 13-1, CS22 provides ten control signals which are described in Table 13-1. Table 13-1. CS22 Control Signals Control Signal AI0 - Primary Variable Loop Definition This analog input signal represents the value of the primary loop process to be manipulated by the controller.
Section 13. CS22 - Two Loop Override Controller Table 13-1. CS22 Control Signals Control Signal 2 of 2 Definition DO1 - Process This contact is closed when the Limiting Alarms Limiting Variable value is not within the C139 and C140 datapoint values (Loop 2 Alarm Limits 1 and 2); otherwise, the contact is open. Cord Set ITB TB2-7 (+) TB2-8 (-) Rear Term Board 18 (+) 17 (-) Signal DO1 PC 13.3 CS22 STANDARD DISPLAYS Loading CS22 preconfigures the System Module display list for ten displays.
53MC5000 Process Control Station Table 13-3.
Section 13. CS22 - Two Loop Override Controller Table 13-3. CS22 Two Loop Override Controller Datapoints 2 of 5 DataDefault point Table Module Title and Function AI1 - Remote Setpoint Primary (Is affected by Setpoint Related Datapoints) (Cont) L441 5-4 AI1 Square Root Signal - It is used if the Primary Variable Loop 0 Remote Setpoint signal is a squared nonlinear value. 0 = input is already linear; 1 = square root to restore linearization.
53MC5000 Process Control Station Table 13-3. CS22 Two Loop Override Controller Datapoints 3 of 5 DataDefault point Table Module Title and Function AI3 - Remote Setpoint Limiting (Is affected by Setpoint Related Datapoints) (Cont) B272 5-4 AI3 Digital Filter Index - This is a first order filter that can be 3 applied to the Limiting Variable Loop Remote Setpoint signal. See Table 5-4 for input values.
Section 13. CS22 - Two Loop Override Controller Table 13-3. CS22 Two Loop Override Controller Datapoints Datapoint Table Module C116 5-9 CON0 C142 5-9 CON1 C143 5-9 CON1 C144 5-9 CON1 C147 5-9 CON1 L130 5-9 CON1 L138 5-9 CON1 C151 5-9 CON1 C152 5-9 CON1 L473 5-5 AO1 L264 5-6 DI0 L265 5-6 DI1 Title and Function CON1 Control Related Datapoints Controller Lower Range - Enter a value that represents in engineering units the Primary Control Lower Range value.
53MC5000 Process Control Station Table 13-3. CS22 Two Loop Override Controller Datapoints Datapoint Table L288 5-7 L289 5-7 B335, B340 C103, C139 5-9 5-9 C104, C140 5-9 C105, C141 5-9 C114, C150 5-9 C125, C161 C126, C162 C117, C153 5-9 5-9 5-9 A000, A002 A001, A003 5-9 L109, L133 5-9 13-10 5-9 Title and Function DO0 - Process Alarms Primary DO0 Contact Output Invert - Normally, Process Alarms Primary is enabled if DO0 is closed.
Section 14. CS40 - Dual Two Loop Cascade Controller 14.0 CS40 - DUAL TWO LOOP CASCADE CONTROLLER 14.1 CS40 - DUAL TWO LOOP CASCADE CONTROLLER The Dual Two Loop Cascade Controller provides four standard PID controllers that function as two cascade pairs. Each cascade pair is arranged with a primary and related secondary controller.
53MC5000 Process Control Station 14.2 CS40 CONTROL SIGNALS Loading CS40 connects the 53MC5000 Controller function blocks for operation as a Dual Two Loop Cascade Controller. As shown in Figure 14-1, CS40 provides ten control signals which are described in Table 14-1 as follows: Table 14-1.
Section 14. CS40 - Dual Two Loop Cascade Controller Table 14-1. CS40 Control Signals Control Signal DO1 - #2 Secondary Process Alarms 2 of 2 Definition This contact is closed when the #2 Secondary Process Variable value is not within the C211 and C212 datapoint values (#2 Secondary Alarm Limits 1 and 2); otherwise, the contact is open. Cord Set ITB TB2-7 (+) TB2-8 (-) Rear Term Board 18 (+) 17 (-) Signal DO1 PC 14.
Section 14. CS40 - Dual Two Loop Cascade Controller Table 14-3.
53MC5000 Process Control Station Table 14-3. CS40 Dual Two Loop Cascade Controller Datapoints Datapoint Table B271 5-4 L418 5-4 L442 5-4 C259 5-4 C279 5-4 B272 5-4 L419 5-4 L443 5-4 L120 5-9 L122 5-9 C109 5-9 C110 5-9 L106 5-9 L114 5-9 14-8 2 of 7 DeModule Title and Function fault AI2 - #1 Secondary Process Variable (Cont) AI2 Digital Filter Index - This is a first order filter that can be 3 applied to the #1 Secondary Variable transducer signal.
Section 14. CS40 - Dual Two Loop Cascade Controller Table 14-3. CS40 Dual Two Loop Cascade Controller Datapoints Datapoint Table C106 5-9 C107 5-9 C108 5-9 C111 5-9 C115 5-9 C116 5-9 C118 5-9 L472 5-5 L168 5-9 L170 5-9 C181 5-9 C182 5-9 C190 5-9 C178 5-9 C179 5-9 C180 5-9 Module Title and Function CON0 •OUT (Setpoint from Loop 1 to Loop 3) (Cont) CON0 Proportional Band - Is the percent of error required to move the CON0•OUT full scale for proportional action.
53MC5000 Process Control Station Table 14-3. CS40 Dual Two Loop Cascade Controller Datapoints Datapoint C183 L154 L162 C187 C188 C184 C185 L144 L146 C145 C146 C154 C142 C143 C144 L130 14-10 Table Module Title and Function CON 2 #1 Secondary Control Output (LOOP 3) Related Datapoints (Cont) 5-9 CON2 Manual Reset - It determines output valve position when the controller Loop 3 is in Auto and the error = 0. It is mutually exclusive with Reset Time.
Section 14. CS40 - Dual Two Loop Cascade Controller Table 14-3. CS40 Dual Two Loop Cascade Controller Datapoints Datapoint Table C147 5-9 L138 5-9 C115 5-9 C152 5-9 L473 5-5 L192 5-9 L194 5-9 C217 5-9 C218 5-9 C226 5-9 C214 5-9 C215 5-9 C216 5-9 C219 5-9 L178 5-9 L186 5-9 C221 5-9 Module Title and Function CON1 •OUT (Setpoint from Loop 2 to Loop 4) (Cont) CON1 Manual Reset - It determines output valve position when the controller Loop 2 is in Auto and the error = 0.
53MC5000 Process Control Station Table 14-3. CS40 Dual Two Loop Cascade Controller Datapoints Datapoint C223 C224 C220 Table Module Title and Function CON 3 #2 Secondary Control Output (LOOP 4) Related Datapoints (Cont) 5-9 CON3 Controller Span - Enter a value, that when added to the Loop 4 Control Lower Range value, will produce the Control upper range value in engineering units. 5-9 CON3 Controller Lower Range - Enter a value that represents in engineering units the Loop 4 Control lower range value.
Section 14. CS40 - Dual Two Loop Cascade Controller Table 14-3. CS40 Dual Two Loop Cascade Controller Datapoints Datapoint C114, C150, C186, C222 C125, C161, C197, C233 C126, C162, C198, C234 C117, C153, C189, C225 Table 5-9 5-9 5-9 5-9 A008 A000, A002, A004, A006 A001, A003, A005, A007 5-9 5-9 Module Title and Function Setpoint Related Datapoints (Loops 1, 2, 3, 4) CON0, Control Zone - A gap on both sides of setpoint.
53MC5000 Process Control Station NOTES: 14-14
Section 15. CS41 - Four Loop Controller 15.0 CS41 - FOUR LOOP CONTROLLER 15.1 CS41 - FOUR LOOP CONTROLLER A four loop 53MC5000 Controller is configured at the factory for CS41 operation to provide the standard displays listed in Table 15-2 and the default datapoint settings listed in Table 15-3.
53MC5000 Process Control Station 15.2 CS41 CONTROL SIGNALS Loading CS41 connects the 53MC5000 Controller function blocks for operation as four standard PID controllers. As shown in Figure 15-1, CS41 provides 24 control signals which are described in Table 15-1 as follows: Table 15-1. CS41 Control Signals Control Signal Definition AI0 - Process This analog input signal represents the value Variable Loop 1 of the Loop 1 process to be manipulated by the controller.
Section 15. CS41 - Four Loop Controller Table 15-1.
53MC5000 Process Control Station Table 15-1. CS41 Control Signals Control Signal 3 of 3 Definition CCO2 This contact is closed when the Loop 3 PV Process Alarms value is not within Alarm Limits 1 and 2 (C175 Loop 3 and C176); otherwise, the contact is open. CCO3 This contact is closed when the Loop 4 PV Process Alarms value is not within Alarm Limits 1 and 2 (C211 Loop 4 and C212); otherwise, the contact is open.
Section 15. CS41 - Four Loop Controller Table 15-3.
53MC5000 Process Control Station Table 15-3. CS41 Four Loop Controller Datapoints 2 of 13 DataDepoint Table Module Title and Function fault AI2 - Remote Setpoint Loop 1 (Is affected by Setpoint Related Datapoints) (Cont) C112 5-9 CON1 Remote Setpoint Bias (B1) - This datapoint and Remote 0 Setpoint Ratio (K1) allow the Remote Setpoint input to be modified by the Setpoint Generator.
Section 15. CS41 - Four Loop Controller Table 15-3. CS41 Four Loop Controller Datapoints 3 of 13 DataDepoint Table Module Title and Function fault AI3 - Remote Setpoint Loop 2 (Is affected by Setpoint Related Datapoints) (Cont) C279 5-4 AI3 Engineering Zero - Enter a value that represents in 0 engineering units the Loop 2 Remote Setpoint lower range signal value. B272 5-4 AI3 Digital Filter Index - This is a first order filter that can be 3 applied to the Loop 2 Remote Setpoint signal.
53MC5000 Process Control Station Table 15-3. CS41 Four Loop Controller Datapoints Datapoint Table Module L421 5-4 AI5 L445 5-4 AI5 L163 4 of 13 Title and Function AI5 - Process Variable Loop 4 (Cont) 0-5 V Input - Enter a value that matches the signal voltage range of the Loop 4 PV transducer. 1 = 0 - 5 V range; 0 = 1 5 V range. Square Root Signal - It is used if the Loop 4 PV transducer is a nonlinear differential pressure (DP) cell that provides a squared signal value.
Section 15. CS41 - Four Loop Controller Table 15-3. CS41 Four Loop Controller Datapoints Datapoint L187 C220 C221 C263 C283 B276 L423 L447 L472 L120 L122 C109 C110 5 of 13 DeTable Module Title and Function fault AI7 - Remote Setpoint Loop 4 (Is affected by Setpoint Related Datapoints) 5-9 CON3 Remote Setpoint Enable - This datapoint is controlled by 0 CCI3.
53MC5000 Process Control Station Table 15-3. CS41 Four Loop Controller Datapoints Datapoint C118 Table 5-9 Module CON0 C106 5-9 CON0 C107 5-9 CON0 C108 5-9 CON0 C111 5-9 CON0 L106 5-9 CON0 L114 5-9 CON0 C115 5-9 CON0 C116 5-9 CON0 L473 5-5 AO1 L144 5-9 CON1 L146 5-9 CON1 C145 5-9 CON1 C146 5-9 CON1 C154 5-9 CON1 15-14 6 of 13 Title and Function AO0 - Control Output Loop 1 (Cont) Output Slew Rate - It is a rate limit applied to the output value.
Section 15. CS41 - Four Loop Controller Table 15-3.
53MC5000 Process Control Station Table 15-3. CS41 Four Loop Controller Datapoints Datapoint Table Module Title and Function CON2 Control Loop 3 Related Datapoints (Cont) CON2 Manual Reset - It determines Loop 3 output valve position when the controller is in Auto and the error = 0. It is mutually exclusive with Reset Time. CON2 Reverse Switch - 0 = Loop 3 Control Output ↑ if Loop 3 PV ↑; 1 = Loop 3 Control Output ↓ if Loop 3 PV ↑.
Section 15. CS41 - Four Loop Controller Table 15-3. CS41 Four Loop Controller Datapoints Datapoint Table C223 5-9 C224 5-9 L264 5-6 L265 5-6 L266 5-6 L267 5-6 L268 5-6 C129 5-6 C128 5-6 Module Title and Function CON3 Control Loop 4 Related Datapoints (Cont) CON3 Controller Span - Enter a value, that when added to the Loop 4 Controller Lower Range value, will produce the Loop 4 control upper range value in engineering units.
53MC5000 Process Control Station Table 15-3.
Section 15. CS41 - Four Loop Controller Table 15-3.
53MC5000 Process Control Station Table 15-3. CS41 Four Loop Controller Datapoints Datapoint L290 L291 Table 5-7 5-7 Module CCO2 CCO3 12 of 13 Title and Function CCO2 - Process Alarm Loop 3 Contact Output Invert - Normally, Process Alarm Loop 3 is enabled if CCO2 is closed. Set to 1 to reverse the CCO2 condition required to activate Process Alarm Loop 3 (CCO2 open = the Loop 3 PV value is not within the C175, C176 Alarm Limits).
Section 15. CS41 - Four Loop Controller Table 15-3. CS41 Four Loop Controller Datapoints Datapoint C117, C153, C189, C225 Table 5-9 A008 A000, A002, A004, A006 A001, A003, A005, A007 5-9 5-9 13 of 13 Module Title and Function Setpoint Related Datapoints (Loops 1, 2, 3, 4) (Cont) CON0, Setpoint Slew Rate - It is a rate limit applied to the setpoint. CON1, When configured to a non-zero value, the setpoint used in CON2, the PID algorithm is only allowed to change by this amount CON3 each scan time.
53MC5000 Process Control Station NOTES: 15-22
Section 16. Tuning PID Parameters 16.0 TUNING PID PARAMETERS Tuning the controller is an iterative process to refine the Proportional Band (PB), Integral (also called Reset Time [TR]), and Derivative (TD) parameters of each active Control Module (CON-0 through CON-3). The number of active CON Modules is determined by the Control Strategy selected (e.g.
53MC5000 Process Control Station 16.3 DERIVATIVE ACTION (TD) Derivative action augments proportional action by responding to the rate of change of the process variable. It is used to make each controller PID loop more responsive to sudden process disturbances. The datapoints to set the Rate parameters for CON0 through CON3 are C108, C144, C180, and C216; they each have a default value of 0 minutes. The minimum value for derivative action is 0.01 minutes and the maximum value is 8 minutes; 0 is off.
Section 16. Tuning PID Parameters Table 16-3. Proportional Cycle Method Step Procedure 1 Set the process to approximately normal conditions in Manual mode. 2 Set TR first to minimum value (0.02 minutes) for several moments, then set it to the extreme maximum (200 minutes) to lock in a fixed reset value. 3 Set P.B. to the widest value (1000%). 4 Set TD to the lowest value (0.01 minutes). 5 Switch to Auto mode .. 6 Slowly reduce P.B. until process cycling starts.
53MC5000 Process Control Station Figure 16-1.
Section 17. EASY-TUNE 17.0 EASY-TUNE The EASY-TUNE algorithm is used to help determine the optimal tuning values for the Proportional Band (PB), Integral (TR), and Derivative (TD) parameters (called PID constants) of each Controller Module 0 through 3 (CON0-3). The datapoints for these parameters are summarized in Table 17-1 as follows: Table 17-1. Summary Information for Tuning Parameters Abbr. Datapoint (CON0, 1, 2, 3) Min. Affect Max. Affect Parameter P.B.
53MC5000 Process Control Station Table 17-2.
Section 17. EASY-TUNE 17.4 EASY-TUNE SEQUENCE STATUS Once initiated, the algorithm sets the controller to Manual mode. After a period of settling time, a step change in controller output is applied and the resulting process response is observed. As summarized in Tables 17-3 and 17-4, datapoint B387, EASY-TUNE Status, will numerically show the result of the EASY-TUNE algorithm. Figure 17-1 illustrates this event sequence and correlates it to the numeric codes in B387.
17-4 53MC5000 Process Control Station Figure 17-1.
Section 17. EASY-TUNE 17.5 MODIFICATIONS TO TUNING CRITERIA During EASY-TUNE sequence execution, each of the three algorithm variables: Time Constant (TP ), Process Gain (K P), and Dead-Time (WP) are altered by 10% in the conservative direction (controller operating characteristics would be slower response, but less chance of oscillation and instability) before the tuning parameters are computed using the ITAE equations listed in Table 17-5.
53MC5000 Process Control Station Note: The approximation of a process step response curve by a first order time lag plus dead-time model is done by equating their values at 0.2835 and 0.6321 fraction of the total excursion. Figure 17-2.
Section 17. EASY-TUNE 17.6 ABORTING THE EASY-TUNE SEQUENCE If the EASY-TUNE sequence is active and the controller output is deliberately changed, the sequence will be aborted. The original controller output and Manual or Auto mode will be restored. Datapoint B387, EASY-TUNE Status, will be set to 54. If the EASY-TUNE sequence is active and datapoint L521, EASY-TUNE Abort Switch, is set to 1 , the sequence is immediately aborted. The original controller output and Manual or Auto mode will be restored.
53MC5000 Process Control Station NOTES: 17-8
Section 18. Maintenance and Parts List 18.0 MAINTENANCE AND PARTS LIST ✶ ✶ RETAIN THE INSTRUMENT CALIBRATION SHEET ✶ ✶ The factory set calibration constants for the analog inputs and analog outputs are recorded on the instrument calibration sheet. This sheet should be retained in the event one or more of the constants is inadvertently changed to the wrong value and field recalibration is necessitated. 18.
Section 18. Maintenance and Parts List Table 18-1. Parts Replacement 1 of 4 Front Display Panel The 53MC5000B controller can be equipped with one of two display types, Low Resolution (48 x 96 pixels) and High Resolution (96 x 192 pixels). The two display types may be interchanged, provided proper procedures are followed. When removing, replacing and/or exchanging face plate displays, it is always recommended to remove power from the controller.
Section 18. Maintenance and Parts List OFF ON SW1 SW1 Location MAIN PCB ASSEMBLY Table 18-1. Parts Replacement Step 12 13 14 15 16 17 18 19 20 2 of 4 Procedure Replacing a 53MC5000B Hi-Res Display with a Low-Res Display Follow Steps 1-4 to remove the front display panel. Follow Steps 30-33 to remove the Main PCB. On the Main PCB, switch SW1 (Refer to the figure above for SW1 location) is used to apply power to the Low Resolution Display continuously.
Section 18. Maintenance and Parts List Table 18-1. Parts Replacement 3 of 4 Step Procedure 21 Continue to slide the expansion board from the cabinet. To replace the expansion board: Reconnect the expansion ribbon cable to the new expansion board J11; and slide the board fully into the cabinet. Seat the board into its 22 socket. See step 4 to install the front display panel.
Section 18. Maintenance and Parts List Table 18-1. Parts Replacement Step 33 34 35 Note 36 37 No te 38 39 40 41 42 4 of 4 Procedure To replace the main PCB with power supply module: Connect the display ribbon cable to the edge connector and the expansion ribbon cable to P6. Slide the main PCB into the cabinet and seat the board into the rear terminal board socket. See step 22 to install the expansion board. Reference steps 5 & 6 to install the front display panel.
18-6 Section 18. Maintenance and Parts List Figure 18-1.
Section 18. Maintenance and Parts List When replacing parts, should technical assistance be required, contact the nearest MicroMod Automation field office. NECESSARY ORDERING INFORMATION When communicating with MicroMod for replacement of the main PCB, reference the unit’s serial number to ensure the correct replacement assembly is supplied. The necessary ordering information is provided on the instrument data tag and on the manufacturing specification sheet supplied with that particular controller.
Section 18. Maintenance and Parts List Table 18-2.
Section 18. Maintenance and Parts List Table 18-2. Controller Parts List Item 14 15 Part Number 177A128U12 177A128U13 177A128U14 177A128U15 177A128U16 177A128U17 177A128U18 177A128U19 177A128U20 177A128U21 177A128U22 177A128U23 177A128U24 177A128U25 686B625U01 686B625U02 161M417U05 Description 0 to +120° C (10 ohms @ 25° C) (Analog Devices Inc. 5B34-C-02) 120 ohms ni, 0 to +300° C (Analog Devices Inc. 5B34-N-01) Type J, 0 to +760° C (Analog Devices Inc.
Section 18. Maintenance and Parts List Table 18-3.
Section 18. Maintenance and Parts List Table 18-4. Isolated Discrete I/O Modules for the 16DI/DO ITB OPTO 22 Part Number G4IDC5 G4IDC5G G4IAC5 G4IAC5A G4IDC24 G4IAC24 G4OAC5 G4OAC5A G4OAC5A5 (NC) G4OAC24 G4OAC24A G4IDC5 G4IDC5B G4IDC5D G4IDC5G G4IAC5 G4IAC5A G4IDC24 G4IAC24 G4ODC5 G4ODC5A G4ODC24 ITB Voltage Max. Input Current OPTO 22 AC Input Modules 5 V dc 25 mA 5 V dc 25 mA 5 V dc 11 mA 5 V dc 6.
Section 18. Maintenance and Parts List AI4-7, AO2, and AO3 optional inputs and outputs are configured on the controller expansion board with the Multichannel Analog Option card. The calibration constants for these inputs and outputs reside in the board memory and not the controller memory. Consult MicroMod for the option card calibration procedures. AI8 is configured on the controller expansion board with the Single Channel Analog Input Option card or the Multichannel Analog Option card.
Section 18. Maintenance and Parts List Step 1 2 3 4 Procedure Press the F2 push button and DO NOT RELEASE IT. While the F2 push button is still held pressed, use a paper clip to press the reset button. DO NOT RELEASE the F2 push button. The display goes all black and then the default display appears. Release the F2 push button. (The database is reset to the default values with the default display present on the controller.
Section 18. Maintenance and Parts List SI-6892 NOTES: 1. CONNECT A CURRENT METER BETWEEN PINS 1 AND 2 TO MEASURE AO0 CURRENT. 2. CONNECT A VOLTMETER BETWEEN PINS 4 AND 5 TO MEASURE AI0 VOLTAGE. 3. TO CONTROL THE VALVE FROM A CURRENT SOURCE OTHER THAN THE CONTROLLER, CONNECT A CURRENT SOURCE (0-20 mA, 0-5 V dc) BETWEEN PINS 1 AND 3. (ALLOWS CONTROLLER TO BE POWERED DOWN AND REMOVED FROM CASE WHILE STILL MAINTAINING AO0 VALVE CONTROL FOR PROCESS.) Figure 18-2.
Section 18. Maintenance and Parts List Figure 18-3.
Section 18. Maintenance and Parts List SC-53-1458 R0 (ITB Part Number 686B616U01) Figure 18-4.
Section 18. Maintenance and Parts List SC-53-1457 R1 (ITB Part Number 686B614U01) Figure 18-5.
SC-53-1456 R0 18-18 Section 18. Maintenance and Parts List (ITB Part Number 686B613U01) Figure 18-6.
SC-53-1466 (ITB Part Number 686B628U01) Section 18. Maintenance and Parts List 18-19 Figure 18-7.
SC-53-1460 R0 18-20 Section 18. Maintenance and Parts List (ITB Part Number 686B617U01) Figure 18-8.
SC-53-1463 R0 Section 18. Maintenance and Parts List (ITB Part Number 686B622U01) 18-21 Figure 18-9.
Section 18. Maintenance and Parts List SD-53-2560 6 Digital Input/4 Digital Output (6DI/4DO) PCB Option (686B600U01) 1. This option card occupies Expansion Board slot 4 (J connectors 3 and 4). 2. It provides 6 additional Contact Closure Inputs (6 DIs) and 4 additional Contact Closure Outputs (4 DOs). 3. The Contact Closure modules correspond to database locations for DI2-7 and DO2-5 (See Configuration Tables 5-6 and 5-7). 4.
Section 18. Maintenance and Parts List SD-53-2608 16 Digital Input/Digital Output (16DI/DO) PCB Option (686B625U01) 1. This option card occupies Expansion Board slot 4 (J connectors 3 and 4). 2. It provides 16 additional Contact Closure Inputs (DIs) or Contact Closure Outputs (DOs) in any mix. Each input or output can be conditioned using the OPTO-22 G4 modules or equivalent that are listed in the Specifications table of Section 1. 3.
Section 18. Maintenance and Parts List SD-53-2605 Single Channel Analog Input PCB Option (686B606U02) 1. This option card occupies Expansion Board slot 5 (J connectors 1 and 2). 2. It provides the ability to add Analog Input 8 (AI8). This option card requires one Group 5 Analog Device Module or equivalent that is listed in specifications Table 1-8. 3. This option corresponds to database locations for AI8 (See Configuration Table 5-4). 4. It does not require an ITB or an ITB cable.
Section 18. Maintenance and Parts List SD-53-2602 Multi I/O Analog PCB Option (686B612U02) 1. This option card occupies Expansion Board slot 5 (J connectors 1 and 2). 2. This option supports the capabilities of the Single Channel Analog Input (AI8) plus it adds 4 AIs (AI4-7) and 2 AOs (AO2 and 3). If used, AI8 of this option card requires one Group 5 Analog Device Module or equivalent that is listed in the Specifications table of Section 1. 3.
Section 18. Maintenance and Parts List SC-53-2565 High Speed Communications PCB Option (686B599U01) 1. These option cards occupy Expansion Board slots 1 (J connector 9 and 10) and 2 (J connectors 7 and 8). The MicroLink Network B High Speed Communications PCB occupies slot 1 and the MicroLink Network A High Speed Communications PCB occupies slot 2. The High Speed Communications PCBs provide controller rear connectors J6 through J9.
Appendix A. Discrete Output DOs APPENDIX A.0 DISCRETE OUTPUTS (DOs) The tolerance ratings for the DO output switches are provided in the specifications table of Section 1 (Table 1-1). The maximum open voltage is 30 V dc and the maximum closed current is 50 mA dc. A DO will operate any external device that can be made to switch if it does not require more than 50 mA of current to the (+) terminal.
Appendix A. Discrete Output DOs A.2 POWER FOR DO OPERATION If the 24 V dc supply of the controller is not already fully loaded (24 V dc, 80 mA maximum, net of internal controller requirements), it can be used as a source of power for a DO; otherwise, a separate, external 24 v dc supply must be used. In the upper circuit illustration of Figure A-2, the +24 V is obtained from TB1 screw lugs 1 or 4 (TB1-1 or TB1-4) of the controller standard rear terminal board.
Appendix A. Discrete Output DOs A.4 OPERATING DOs IN PARALLEL Figure A-4 illustrates two DOs connected in parallel to a single power source (controller rear terminal board 24V dc screw lug TB1-1 or TB1-4) so that any one of the two DOs can actuate the relay. Figure A-4.. Operating DOs in Parallel A.5 CASCADING A DO TO A DI In Figure A-5, the DO of one controller is applied directly to the DI of another controller. When the DO closes, the DI circuit of the second controller is complete.
Appendix A.
Appendix B. Communications APPENDIX B.0 COMMUNICATIONS B.1 STANDARD COMMUNICATIONS Two digital communication channels are provided with the controller: 1) There is a configuration port that is an RS-232 serial interface. It is accessed via a 5 pin mini-DIN connector located under the pull-down door on the front panel. It is used to configure controller parameters for selected operational characteristics.
53MC5000 Process Control Station B.1.1 CONFIGURATION To initialize the controller for binary communications, configure the controller as described in Table B-1, Column 3 (Set Up ). Table B-1. Communication Module Purpose: This module is used to configure the Datalink port parameters (e.g., baud rate, parity selection, etc.). Title Datapoint Set Up Default Controller Address B01 S 0 Baud Rate B02 S Attribute It identifies the address of this controller on the Datalink network.
Appendix B. Communications B.1.2 PROTOCOL The Datalink protocol requires the host or SUPERVISOR-PC to initiate all transactions. There are two basic categories for all of the Datalink message types: Interrogate , which is used to read data from an addressed controller, and Change , which is used to alter a value in an addressed controller. The addressed controller decodes the message and provides an appropriate response. The protocol definitions for the Datalink message types are provided in Table B-2.
53MC5000 Process Control Station B.1.3 MESSAGE TYPES The types of messages that are sent between the host or SUPERVISOR-PC and the Datalink network controller are formatted as follows: HOST OR SUPERVISOR-PC TO CONTROLLER: 1. INTERROGATE - This message requests up to 20H consecutively stored bytes, beginning at the specified memory address location of the addressed controller. 01111110 E0H + I.A. NUM LO ADD HI ADD LRC 2. CHANGE - This message sends up to 20H bytes of new data to the addressed controller.
Appendix B. Communications B.1.4 COMMUNICATION TRANSACTION EXAMPLES Transaction A Example - Host or SUPERVISOR-PC requests 9 bytes of data beginning at hexadecimal memory address 1000H from the controller at Datalink address 03. 1. Host or SUPERVISOR-PC sends INTERROGATE message. 01111110 11100011 00001001 00000000 00010000 11111100 SOH Command + I.A. NUM LO ADD HI ADD LRC 2. Controller sends RESPONSE message. 01111110 00100011 00001001 00000000 00010000 XXXXX XXXXX XXXXX SOH Command + I.A.
53MC5000 Process Control Station B.1.5 CALCULATING DATA ADDRESSES If communications software must be generated to accommodate unique Datalink applications requirements, then the controller memory address scheme must be known for proper data bit (e.g., L data type) and data byte (e.g., B, C, H, and A data types) memory location determination. Note: Numbers used in this section that are expressed in hexadecimal notation (base 16) are identified with a subscript H after the number.
Appendix B. Communications Table B-3. Controller Memory Address Scheme Data Type H Base Memory Address F00 H A (F)* 1400 H Byte Size 5 Data Format Represents high precision floating point values that have a resolution of one part in 2 billion (31 bits) and a dynamic range of ± 10 38 . The first four bytes represent a 2’s complement notation in fractional form (2-n) whose absolute value is between 0.5 and 0.9999. The fifth byte is the power of 2 in 2’s complement notation.
53MC5000 Process Control Station B.1.6 SOFTWARE CHARACTERISTICS 1. Transparency Rule - whenever 7E hexidecimal is transmitted as anything other than SOH, a 00 byte will be inserted directly following it (byte stuffing). 2. All transactions are initiated by the Host or SUPERVISOR-PC. 3. All controllers begin their response within 10 ms after the end of the transmission by the Host or SUPERVISOR-PC; otherwise, a faulty transmission may be assumed. 4. Illegal messages received by the controllers are ignored.
Appendix B. Communications The Network D Node List is as follows: Table B-5.
53MC5000 Process Control Station B.1.9 INITIALIZATION MESSAGE If datapoints A188 and A189 are configured to NON-NULL values, their contents will be transmitted onto the Datalink network at reset/power-up. Prior to transmitting, a delay based on the unit’s instrument address is observed. There is a one second delay between the transmission of datapoint A188 and datapoint A189 contents. Datapoints A188 and A189 can be configured as two NULL TERMINATED strings up to 10 characters each.
Appendix C. Remote Keypad APPENDIX C.0 REMOTE KEYPAD C.1 REMOTE KEYPAD Support for a remote keypad, that has the same functions as the 10 push buttons on the front display panel, is activated when datapoint L72 (Remote Keypad Enable [RMTK]) is set to a 1. Keypad entries can be made by either the front display panel push buttons or remotely via 10 normally open push buttons mounted on a board that is wired to the 6DI/4DO ITB. Figure C-1 illustrates the remote keypad wiring to the 6DI/4DO board.
53MC5000 Process Control Station NOTES: C-2
Appendix D. Database APPENDIX D.0 DATABASE The database contains six datapoint types. Each datapoint type represents a specific data format: whole integers, alphanumeric text strings, etc. The datapoint types are defined in Table D-1; the paste-up configuration tables are repeated in abbreviated form (no definitions) in Tables D-2 through D-13; and the database is listed in alphanumeric order in Tables D-14 through D-19. Middle gray tone shading in any cell means it is not applicable.
53MC5000 Process Control Station Table D-2.
Appendix D. Database Table D-5.
53MC5000 Process Control Station Table D-7. Controller (CON) Modules Page * General Name Atom CON0 CON1 CON2 CON3 Control Tagname TAG A000 C115 C151 C187 C223 100 C116 C152 C188 C224 0 Trend Rate CTR B336 B341 B346 B351 Trend Mode CTM B337 B342 B347 B352 0 Control Display Mode CDM B339 B344 B349 B354 0 EU A001 A003 A005 A007 PERCENT SPM B338 B343 B348 B353 0 B336 = 2, B341, B346, & B351 = 0.
Appendix D. Database Table D-7.
53MC5000 Process Control Station Table D-8.
Appendix D. Database Table D-8.
53MC5000 Process Control Station Table D-10.
Appendix D. Database Table D-13. System Module Page * Name Unit Tag Name Function Index Execute Comm.
53MC5000 Process Control Station Table D-13.
Appendix D. Database Table D-14.
53MC5000 Process Control Station Table D-14.
Appendix D. Database Table D-14.
53MC5000 Process Control Station Table D-14.
Appendix D. Database Table D-14.
53MC5000 Process Control Station Table D-14.
Appendix D. Database Table D-15.
53MC5000 Process Control Station Table D-15.
Appendix D. Database Table D-15.
53MC5000 Process Control Station Table D-15. Database - B Type Datapoints Datapoint B376 B377 B378 B379 B380 B381 B382 B383 B384 Name Rate Mode Height Database Identifier Product Identifier (0 = 53MC5000, 1 = 53SL5100A, 2 = 53IT5100A, 3 = 53ML5100A) For internal controller use.
Appendix D. Database Table D-15.
53MC5000 Process Control Station Table D-15.
Appendix D. Database Table D-16.
53MC5000 Process Control Station Table D-16.
Appendix D. Database Table D-16.
53MC5000 Process Control Station Table D-16.
Appendix D. Database Table D-16.
53MC5000 Process Control Station Table D-16.
Appendix D. Database Table D-16.
53MC5000 Process Control Station Table D-17.
Appendix D. Database Table D-17.
53MC5000 Process Control Station 1 of 6 Table D-18.
Appendix D. Database Table D-18.
53MC5000 Process Control Station 3 of 6 Table D-18.
Appendix D. Database Table D-18.
53MC5000 Process Control Station Table D-18.
Appendix D. Database Table D-18.
53MC5000 Process Control Station Table D-19.
Appendix D. Database Table D-19.
MODULAR CONTROLLER QUICK START APPENDIX E.0 - FM APPROVAL The following listed equipment is Factory Mutual approved as: Nonincendive for use in Class I, Division 2, Group A, B, C & D locations, Temperature Code T3C, 160 oC. Temperature Code T3C means that the highest component surface temperature at maximum line and load conditions, does not exceed 160o C (320o F) based on an ambient temperature of 40o C (104 oF).
MODULAR CONTROLLER QUICK START APPROVED OPTIONS The following optional accessories as listed in Chapter 1.0 of the Instruction Manual are suitable for use in Division 2. • 6DI/4DO, Contact Closure Input (CCI), Contact Closure Output (CCO). • Dual Relay ITB, CCO. WARNING For use in Division 2 locations, the energy to relay contacts 8 and 11 must be limited to <3 VA, <28 V and <250 mA, resistive loads only.
MODULAR CONTROLLER QUICK START APPROVED OPTIONS (cont’d) • Single Channel Analog Input Option. • Multi-Channel Analog I/O Option. • 5Bxx Group of mV, Voltage, Current, RTD and Thermocouple Input Isolation Modules. • SCADA Adapter ITB. NON-APPROVED OPTIONS The Hand Held Configurer (HHC) (Discussed in Chapter 3.0 of the 53MC5000 Instruction Manual) is a portable terminal designed to interface with the 53MC5000 through the "Configuration Port" connector located on the front panel of the 53MC5000.
MODULAR CONTROLLER QUICK START INSTALLATION DIAGRAMS A copy of each of the following interconnection diagrams is included in this Appendix. In Class I, Division 2 installations these drawings shall be used in place of the installation drawings provided in the 53MC5000 Instruction Manual and 53MC5000 Quick Start Installation Guide.
MODULAR CONTROLLER QUICK START LITHIUM BATTERY HANDLING PRECAUTIONS MicroMod Part. No. 167B024U01 Manufacturer: Eagle Picher Industries, Inc. Box 130 Bethel Road Seneca, MO 64865 Part Number: LTC-7P Type: Inorganic, Liquid Lithium Thionyl Chloride Voltage: 3.5 Capacity: 750 mAh Storage Temp.: 150 oC (302 oF) Operating Temp.: Sealing: -40 to 125 oC (-40 to 257 oF) Hermetic, Non-Venting WARNING REPLACE BATTERY WITH EAGLE PICHER P/N LTC-7P ONLY.
The Company’s policy is one of continuous product improvement and the right is reserved to modify the information contained herein without notice, or to make engineering refinements that may not be reflected in this bulletin. Micromod Automation assumes no responsibility for errors that may appear in this manual. © 2005 MicroMod Automation, Inc. Printed in USA MicroMod Automation, Inc. 75 Town Centre Drive Rochester, NY USA 14623 Tel. 585-321-9200 Fax 585-321-9291 www.micromodautomation.
