Control 1/2 DIN Process Controller

Data SheetSS/C501_5Control IT1/2 DIN Process ControllerC501■ PID control with easily programmedstandard templates– single loop, heat/cool, motorized valve, auto/manual station, indicator, analog backup■ Clear process display and color-coordinatedswitches– process visibility, ease of operation■ Comprehensive input/output capabilities– up to three analog inputs, two analog outputs, fourrelays and four digital inputs■ Process security and plant safety– loop-break alarm, processor watchdog, passwordprotectionand intelligent power recovery■ Unique Control Efficiency Monitor (CEM)– two Autotune algorithms plus manual fine-tuningusing CEM■ PC configuration for ease of setup– easy access to advanced features and standardsettings■ IP66/NEMA4X front face– reliability in the harshest environments■ RS485 Modbus serial communication– SCADA, PLC and open system integrationC501 – stand-alone controller in ashort-case, 6 x 3 format forbasic applications

1/2 DIN Process ControllerC501SS/C501_5C501The C501 is a versatile single-loop controller with advancedcontrol features built-in as standard, e.g. gain scheduling,process optimization, alarm logic, maths and linearizers.The instrument can be commissioned using a built-inlibrary of application templates and advanced autotunefacilities. Configurations can also be edited and stored offlineusing our Windows-based PC Configurator.A wide range of process connections is included in thestandard instrument; a choice of option cards providesadditional input/output for complex applications. Modbusserial communications are available for integration withfactory automation systems.IP66 (NEMA 4X) front panel protection makes the C501 anextremely robust controller, suitable for use in a wide varietyof industrial environments.2

1/2 DIN Process ControllerC501SS/C501_5Process ConnectionsUniversal Process Input• Thermocouple• RTD• mA• Volts, mVPrimary Outputs1 x Analog/Logic2 x Relay OutputsPID ControlAlarmsRetransmissionTransmitter PowerSupply (45mA)Fixed Process Input• mA• mV• THC *AdditionalOutputs2 x Relays1 x Analog/LogicPID ControlAlarmsRetransmission2 x Digital InputsKEY: * Only if standard universal input is THCAdditional Inputs• 2 x Digital• Universal Process Input• Transmitter PowerSupply (23mA)Serial CommunicationsRS485 Modbus RTUSCADA Systems (on PC)3

1/2 DIN Process ControllerC501SS/C501_5Process Visibility and OperationThree high-visibility, colored digital displays show ProcessVariable, Set Point and Controller Output simultaneously. Dual,40-segment bargraphs give an instant indication of processstatus. For clarity, function keys are color-coded to match theircorresponding displays.Eight individual tactile front panel keys make the controller veryoperator-friendly, with one-touch access to local/remote setpoint adjustment, alarm acknowledgment, auto/manual andoutput adjustment.Secret-til-lit LED indicators display controller modes and alarmstatus, and provide extensive controller and plant diagnostics.All of these features ensure that the controller is operator-friendlyand no specific training is required for operational use.Custom LinearizerThe C501 has two separate 15-breakpoint linearizers which canbe programmed via the PC configurator and applied to eitherinputs or outputs. These can be used for non-standardthermocouples, non-linear tank levels or any non-linear input.The output linearizer accommodates any non-linear controlelements.Maths and Soft-WiringFour individual math blocks, each having up to 7 operators andoperands, provide functions such as average, maximum andminimum calculations. Square root, relative humidity andarithmetic functions are also included as standard. Inputs can beselected or switched in and out of calculations by digital signals.This allows both simple and advanced calculations to beprocessed and these can be soft-wired to control functions.58.862.415.0Control Efficiency Monitor (CEM)CEM measurements are designed to help you fine-tune yourprocess manually. Six key-performance parameters aremeasured and displayed, allowing you to vary your PID settingsto match the process needs and measure the results of yourinvestment.PVx 1 x 2+2%Process Security and Self-diagnosticsTo keep your process stable and secure, the C501 has intelligentdiagnostics and responses, which can be used for processsafety to initiate an action or to indicate a fault. A processorwatchdog monitors the processor continuously; a unique loopbreakalarm detects analog output failure; and there is an opencircuit detector on the input. Using these signals, safetyshutdown strategies can be initiated.For configuration data security, there are three levels ofpassword protection plus front panel function key lockouts,ensuring total process security.95%ySet Point2Start ofCalculationtapproachy 1tperiod5%tsettlet–2%4

1/2 DIN Process ControllerC501SS/C501_5Out-of-the-Box and Installed-in-MinutesThe C501 has been designed to minimize your configuration andcommissioning time, as you need only enter values that relate toyour process. Application templates, offering preconfiguredcustomized control strategies, allow rapid setup of the controller.Templates are selected via the PC configurator or the front panelkeys. Alternatively the unit may be supplied preconfigured. Oncea template is selected only three key settings are required andthe controller is ready-to-run.Complete configurations can be created, edited and storedoff-line, using the PC configuration editor. A dedicated cableconnects the PC to a jack socket on the top of the controller forrapid upload, or download, of configurations. Copies of theconfigurations can be saved and produced as hard copy.A dual mode, intelligent autotune requires no prior knowledge ofPID settings and offers a choice of fast response or minimumovershoot strategies.Process AlarmsThe C501 has eight internal processalarms. These can be soft-wired to controlstrategies, logic equations and outputrelays.Each alarm can have a separate hysteresisvalue, programmable in engineering unitsor time. Alarms can also be enabled ordisabled via digital inputs and can beconfigured as annunciators, so the alarmmay be disabled once acknowledged.58.862.415.05

1/2 DIN Process ControllerC501SS/C501_5Customized Application TemplatesTemplates are provided to make the basic configuration for aparticular application as simple as possible. When a template isselected the C501 assumes the preset form for that template(see below). The inputs and software blocks are soft-wiredautomatically to perform the selected function.Configuration time is greatly reduced as 90% of the choices youwould normally need to make in similar products are alreadypreconfigured.The C501 offers the following templates:1 Single loop controller with local set point2 Single loop controller with remote set point3 Auto manual station (low signal detection)4 Auto manual station (digital signal selection)5 Analog backup station (low signal detection)6 Analog backup station (digital signal selection)7 Single indicator/manual loader station8 Dual indicator/manual loader stationSequencing and Logic ControlThe C501 offers comprehensive sequencing, to complement itsadvanced analog control features, and six logic equations, withup to fifteen elements per equation. These logic equations, whencombined with delay timers, real-time alarms and extensive I/O,make the C501 a powerful interlocking controller.ABCDA . BC . DQ = (A . B) . (C . D)Intelligent Adjustable Power RecoveryTwo forms of plant power failure recovery are availableprogrammable between 0 and 9999s for recovery time:‘HOT’ restart – if the power is restored within the recovery timethe C501 defaults to Auto mode, allowing the process to be upand-runningwithout delay.‘COLD’ restart – if the power is not restored within the presetrecovery time, the controller defaults to Manual mode, or apredetermined control output. This ensures that after powerfailure the controller does not start to control the process withoutoperator acknowledgment.Industrial Robust DesignThe front face has been designed to meet IP66/NEMA4X ratingwith a unique moulded case and panel seal. A chemical resistantpolyester front panel ensures a secure investment for anyenvironment.Single Loop Control Template – ExampleSteamLocal Set PointLSPtLLRSteamConstant HeadReservoirRemote Set Point InputIP2RSPtWater/SteamInterfaceLTDrum LevelTransmitterProcess Variable InputIP1CSPtPVPIDControl LoopPID O/PWater withSteam BubblesBoilerDrumI/PFeedwaterControl ValveFeedwaterControl OutputOP1Manual Output6

1/2 DIN Process ControllerC501SS/C501_5SpecificationSummary8 application templates: Single loop, Auto/Manual,Analog backup, IndicatorTwo Autotune optionsControl Efficiency MonitorPC configurationIP66/NEMA4X front faceOperationDisplay2 x 100mm 40-segment LED bargraphs2 x 10mm 4-digit LED indicators1 x 10mm 3-digit LED indicatorsDisplay range –1999 to +9999ConfigurationBasic configuration via front panel keysAdvanced feature configuration by PC onlySecurityInternal security switch and password-protected menusStandard FunctionsControl StrategiesSingle-loop, Auto/manual Station, Analog Backup,Indicator/Manual LoaderOutput TypesCurrent proportioning, Time proportioning, On/off, Motorized valve(with and without feedback), Heat/cool.Control ParametersFour sets of PID settings, selectable via digital signalsSet PointsLocal, remote and four local fixed set points,selectable via digital signalsConfigured OutputsThree preset output values, selectable via digital signalsAutotuneOn demand for 1 /4 wave or minimal overshootAnalog InputsUniversal Process InputsNumber1 standard1 optionalTypeUniversally configurable to provide:Thermocouple (THC)Resistance thermometer (RTD)mVVoltsmAResistanceInput ImpedancemA 100ΩmV, V 10MΩLinearizer FunctionsTHC types B, E, J, K, L, N, R, S, T, PT100, √, 3 /2, 5 /2Broken Sensor ProtectionProgrammable for upscale or downscale driveSample Interval125ms (1 input)Digital filterProgrammableCold Junction CompensationAutomatic CJC incorporated as standardStability 0.05°C/°C change in ambient temperatureInput ProtectionCommon mode rejectionSeries mode rejection>120dB at 50/60Hz with300Ω imbalance resistance>60dB at 50/60HzTransmitter Power SupplyNumber 1 standard, 1 optionalVoltage 24V DC nominalDrive Up to 45mA as standard,up to 23mA on option boardNon-universal Process InputNumber1 standardInput typesmA, mV only (THC only if IP1 is also THC)Linearization B, E, J, K, L, N, R, S, T, √, 3 /2, 5 /27

1/2 DIN Process ControllerC501SS/C501_5...SpecificationEMCEmissionsMeets requirements of EN50081-2ImmunityMeets requirements of EN50082-2OutputsControl/Retransmission OutputsNumber 1 standard, 1 optionalType Programmable as analog orlogic (digital) outputIsolation Galvanically isolated from the rest of the circuitryAnalog range 0 and 20mA (programmable), accuracy: 0.25%Digital voltage 17V @ 20mARelay OutputsNumber 2 standard, 2 optionalType SPST, rated 5A at 115/230V ACStandard Analog Input RangesDigital InputsNumberTypeMinimum pulse2 standard, 2 optionalVolt-free200msAdvanced FeaturesMaths Blocks *Number 4Operators +, –, x, ÷, Average, Maximum, Minimum,High select, Low select, √, Median select,Relative HumidityInput multiplexer (digitally selected)Delay Timers *Number 2Programmable Delay and Duration in secondsLogic Equations *Number 6Elements 15 per equationOperators OR, AND, NOR, NAND, NOT, EXORCustom Linearizers *Number 2Breakpoints 15 per linearizer* Accessed via PC ConfiguratorThermocoupleB 0E 0J 0K 0L 0N 0R 0S 0T 0* For B, R and S thermocouples, accuracy is not guaranteed below value statedM in. span below zero Type T 70ºC (126ºF)Type N 105ºC (189ºF)M aximum Range°C M aximum Range°F Accuracy (% of reading)– 18 to 1800 to 32700 .1% or±1° C (1. 8° F ) [above 200° C (392° F )]*– 100 to 90– 140 to 16500 .1% or± 0 . 5° C (0. 9° F)– 100 to 90– 140 to 16500 .1% or± 0 . 5° C (0. 9° F)– 100 to 130– 140 to 23500 .1% or± 0 . 5° C (0. 9° F)– 100 to 90– 140 to 16500 .1% or± 1 . 5° C (2. 7° F)– 200 to 130– 325 to 23500 .1% or± 0 . 5° C (0. 9° F)– 18 to 1700 to 30000 .1% or± 0 . 5° C (0. 9° F ) [above 300° C (540° F )]*– 18 to 1700 to 30000 .1% or± 0 . 5° C (0. 9° F ) [above 200° C (392° F )]*– 250 to 30– 400 to 5500 .1% or± 0 . 5° C (0. 9° F)THC standards DIN 43710IEC 584RTDt100platinum, 100P 0**RTD, 3-wireΩ perDIN 437600M aximum Range°C M aximum Range°F Accuracy (% of reading)* *– 200 to 60– 325 to 11000 .1% or± 0 . 5° C (0. 9° F)standard (IEC 751), with range of 0 to 40 ΩLinearInputsMillivoltsMilliampsVoltsesistanceR 0R angeAccuracy (% of reading)0 to 500mV0 .1% or± 10µA0 to 50mA0 .2% or±2µA0 to 5V0 .2% or± 2mV0 to 500 Ω 0 .2% or± 0.08Ω8

1/2 DIN Process ControllerC501SS/C501_5OptionsAnalog InputsNumber 1Isolation Galvanically isolated from the rest of the circuitryTypeUniversal (see above)Analog/Digital outputNumber 1Isolation Galvanically isolated from the rest of the circuitryTypeProgrammable 0 to 20mA analog or17V @ 20mA digitalRelay OutputsNumber 2TypeSPST, rated 5A at 115/230V ACDigital InputsNumber 2TypeVolt-freeMinimum pulse 200msSerial CommunicationsConnections RS485, 2- or 4-wireProtocol Modbus RTUIsolation Galvanically isolated from the rest of thecircuitryPhysicalSize76mm x 148mm x 149.5mm(2.99 in. x 5.83 in. x 5.87 in.)Weight750g (1.6lb)ElectricalVoltage85 to 265V AC 50/60Hz24V DCPower consumption

1/2 DIN Process ControllerC501SS/C501_5Overall DimensionsDimensions in mm (in.)137.5 (5.41)18(0.71)76 (2.99)68+0.7–0+0.03(2.68–0)137.8(5.43)148(5.83)Panelcut-out138 +1–0+0.04(5.43 )–014 (0.55)149.5 (5.87)5.0(0.2)30 (1.18)Electrical ConnectionsMilliamps(Using on-boardtransmitter power supply)192022456IP3 IP2 IP1Milliamps(Using externaltransmitter power supply)1920IP33-Lead RTD192021IP3123122-Lead RTDand Resistance192021IP345IP2IP1123IP1612IP1RedRedWhiteRedWhite100 Ω–Tx+100Ω(–)(+)SeeadjacentThermocouple.Millivolts and Volts19202145123IP3 IP2* IP1*THC only if IP1 is THCAnalog Input 3 (–)Analog Input 3 (+)Analog Input 3 (RTD2)Transmitter PSU (+)Digital / Analog Output 2 (+)Digital / Analog Output 2 (–)Digital Input Common 2 (–)Digital Input 3 (+)Digital Input 4 (+)Relay 3 (NO/NC)Relay 3 Common (C)Relay 4 (NO/NC)Relay 4 Common (C)(–)(+)Modbus Connections+ 32Tx– 33RS485 + 34Tx/ Rx– 35Common 36RS485 TX (+)RS485 TX (–)RS485 TX/RX (+)RS485 TX/RX (–)RS485 Common (C)1920212223242526272829303132333435361234567891011121314151617181AAnalog Input 1 (–)Analog Input 1 (+)Analog Input 1 (RTD1) SeeAnalog Input 2 (–) adjacentAnalog Input 2 (+)Transmitter PSU (+)Digital / Analog Output 1 (+)Digital / Analog Output 1 (–)Digital Input Common (–)Digital Input 1 (+)Digital Input 2 (+)Relay 2 (NO/NC)Relay 2 Common (C)Relay 1 (NO/NC)Relay Common (C)Live (+)Neutral (–)Ground85 to265VAC+Vs (+)OV (–)Ground24VDC10

1/2 DIN Process ControllerC501SS/C501_5Ordering InformationC5011/2 DIN Process ControllerC501Option Board0 None2 x digital input + 2 x relay1 x analog input + 1 xRS485 Modbus1 x analog inputanalogoutput + 2 x digital inputs + 2 x relay+ 1 x analog output + 2 x digital inputs + 2 x relays + RS485 ModbusPower Supply85V to 265V AC24V DCBuildABB StandardCSA approval (pending)UL approval (pending)Programming/Special FeaturesConfigured to factory standardConfigured to customer requirementsSpecial features/ X X X X / X X X X* If configuring a C501 for motorized valve control with feedback, or dual analog output on heat/cool, either option 02 or 04 must be fitted.00000012*34*01012SCSTUPDSXXAccessoriesPC Configurator Kit (part no. C100/0700)Licensing, Trademarks and CopyrightsModbus is a trademark of Modicon, Inc.Windows is a trademark of the Microsoft Corp.11

1/2 DIN Process ControllerC501SS/C501_5ABB has Sales & Customer Supportexpertise in over 100 countries worldwidewww.abb.comThe Company’s policy is one of continuous productimprovement and the right is reserved to modify theinformation contained herein without notice.Printed in UK (06.02)© ABB 2002SS/C501 Issue 5ABB LimitedHoward Road, St NeotsCambridgeshirePE19 8EUUKTel: +44 (0)1480 475321Fax: +44 (0)1480 217948ABB Inc.125 E. County Line RoadWarminsterPA 18974USATel: +1 215 674 6000Fax: +1 215 674 7183