MICRO-DCI™ Process Control Station

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MICRO-DCI™ Process Control Station | Manualzz
MICRO-DCI™ Process Control Station
Series 53MC5000
„
High Visibility CRT-type dot matrix
operator display
„
Family of configurable process graphic
displays and standard Controller
Templates
„
One, Two or Four loops of control
„
Modular design enables user selection of
many expansion options both software
and hardware
„
Easy implementation using library of
preconfigured Flexible Control Strategies
(FCS)
„
Configurable Control Interconnection
Modules (F-CIM) for more complex
applications
„
F-TRAN high level programming available
to solve difficult applications
„
Easy-Tune™ PID self-tuning algorithm
standard in all product version
„
Standard Micro-DCI™ DataLink
communication port (RS-422/485)
„
Standard RS-232C configuration port
„
Compact standard DIN case
(72 x 144 mm Bezel), only 12" in length
„
Optional Dual high speed (2 Mb) highway
with Peer-to-Peer communication
„
Optional PLC and Printer communications
interface
Series 53MC5000
Process Control Station
Specification Sheet
S-DCI-53MC5000_1
Micro-DCI Process Control Station Series 53MC5000
Micro-DCI™ PROCESS CONTROL
STATION
The 53MC5000 is MicroMod Automation’s state-ofthe-art Process Control Station designed to perform
any process application, from simple PID to the most
complex control strategy. Its sophisticated design
includes an embedded microprocessor Application
Specific Integrated Circuit (ASIC) and Surface Mount
Technology, providing superior performance and
reliability. The 53MC5000 is the cornerstoneof the
Micro-DCITM generation of modular control systems.
The 53MC5000 operator interface incorporates a
high visibility dot matrix graphic display. This display
supports both standard and customized screens for
maximum user flexibility.
The 53MC5000 is available in One, Two, or Fourloop control versions, and is designed for expansion
on multiple levels; Functionality, Hardware, and
Software. This allows the user to select only the
functions required for a given application. Option
boards expand the controller hardware as required;
discrete inputs & outputs, analog inputs & outputs, or
communication ports. Software may be extended to
permit the configuration method that best fits the
application; the prewritten and configurable Flexible
Control Strategy (FCS), configurable F-CIMs (Control
Interconnection Modules), or F-TRAN, MicroMod
Automation's high-level control language.
53MC5000 Overview
The 53MC5000 can handle a wide variety of control
applications. At the operator interface level, this is
achieved using multiple screens to provide full
process variable and alarm display of all data. The
high visibility dot matrix display permits many
operator screens of both digital and graphical data in
a single unit. The use of standard and/or customized
displays enhances the operator interface to the
process. A display hierarchy is included to minimize
operator keystrokes. The controller is able to scan all
inputs, solve PID algorithms, generate outputs and
update screens in less than 100 milliseconds. At the
same time, multiple self-diagnostics verify
performance.
2
S-DCI-53MC5000_3
At the process Input/Output level, the 53MC5000
modular hardware provides a standard I/O mix and
allows for expansion capability. Standard I/O includes
four analog inputs, two analog outputs, two discrete
inputs, and two discrete outputs. Option boards
enable the 53MC5000 to support the following
additional I/O: four analog inputs and two analog
outputs; a universal input (high level, thermocouple or
RTD); discrete inputs/ outputs (6 DI/4DO or 16
assorted DI/DO).
Control Strategies are implemented in the
53MC5000 using one of the following methods:
• Select a Flexible Control Strategy (FCS)
configuration from a library resident in the
53MC5000
• Select and modify pre-written FCS configurations
for custom applications
• F-CIM connection of standard or custom modules
for special applications
• F-TRAN high level language for complex
applications and/or custom displays
Control Strategy configuration can be generated or
modified using any of the following methods:
• Database parameters, FCS, or F-CIM
configuration through controller faceplate keys
• Database parameters or FCS configuration
through the Hand-Held Configurer (HHC) ASCII
keypad
• Database parameters, FCS, F-CIM, or F-TRAN
configuration using the MicroTools™ configuration
tool kit 53MT6000 configuration software running
in a personal computer (PC)
• Database parameters, FCS, F-CIM, or F-TRAN
configuration using the Micro-DCI Personnel Work
Center (Micro-PWC)model 53PW6000
The 53MC5000 includes a standard Micro-DCI
communication port (RS-422/485 at 28.8 Kbaud)
called DataLink. DataLink allows monitoring and
configuration over a network from the Micro-PWC
operator station or using the Custom Program
Interface software. The 53MC5000 is easily
implemented in new or existing networks of MicroDCI™ products. As an option, the controller can be
equiped with a 2 Mbaud highway called MicroLink.
MicroLink provides peer-to-peer communication and
can be purchased in redundant configurations. The
53MC5000 and the Micro-PWC provide a total
system solution to solve a broad range of application
problems.
Micro-DCI Process Control Station Series 53MC5000
Operator Interface
The 53MC5000 Process Control Station’s dot matrix
display provides unequaled presentation of
information to the user in a stand alone controller or
in combination with an Operator/Engineer
Workstation. The combination of displays and front
panel keys provides a broad range of operator
interaction; far beyond the capabilities of the
traditional panel-mounted controller. To assist the
user, a set of pre-configured displays and a display
handler are provided as standard. Each display
includes three general areas of information:
• The entire display screen is available to
configure static data and/or dynamic points.
• The top line of the display is used as an alarm
line. The “ALARM” message will be displayed
when an alarm occurs regardless of the current
user display.
• The bottom line of the display is used as a
scratch pad area when configuring in the
Engineering Mode. Single line menu options and
User entered data are displayed for operator
convenience.
Function Keys
S-DCI-53MC5000_3
OUT arrows - The two (2) output pushbuttons are
used by the control loop displays to adjust the
output of the controller when the controller is in
manual. In Engineering Mode these keys are used
to highlight, change or set values.
MODE Button - The “MODE” button is used to
acknowledge an alarm or enter Engineering Mode
(once alarms have been acknowledged). Pressing
the MODE key while in Engineering Mode will return
the user to the normal Controller Mode.
F1 - The F1 key is normally used to page through
groups in the display hierarchy. In Engineering
Mode, the F1 key moves the user back to the
previous menu level.
F2 - The F2 key is normally used to advance to the
next display within a group. In Engineering Mode,
the F2 key is used to advance through the various
choices (Display - Configure - Program).
F3 - The F3 key is used as a “SELECT” and
“ENTER” key by the Status, Parameter, and
Summary displays. In the TWO and FOUR LOOP
display, it toggles between the loops. In Engineering
Mode, the F3 key is used as “ENTER” to choose
the current menu selection or to complete an entry.
The controller front panel has ten (10) functional
pushbuttons (see Figure 2). The function of each of
these pushbuttons is determined by the type of
display currently selected and the mode of
operation.
The 53MC5000 has two standard operating modes:
Controller Mode (normal operating mode) and
Engineering Mode (configuration mode).
The keys and their functions are described below.
Unless specified as an Engineer Mode function, the
functions listed are for Controller Mode.
R/L - This key is used with the Control loop displays
(Point, Group , or Point Trend) to switch between
REMOTE and LOCAL setpoint modes.
SP arrows - The two (2) setpoint pushbuttons are
used to adjust the setpoint of control loop displays
when in local and to highlight various selections in
other displays. In Engineering Mode these keys are
used to highlight, change or set values.
Figure 2: MC5000 Operator Keys
A/M - This button is used by the control loop
displays to switch between AUTOMATIC and
MANUAL control Mode.
3
S-DCI-53MC5000_3
Micro-DCI Process Control Station Series 53MC5000
Figure 3: Single Loop
Figure 4: Single Loop with
PV Trending
Figure 5: Two Loop
Displays
A dot matrix gas discharge display provides the
operator window to the process. A family of
standard preconfigured displays incorporating
dynamic bargraphs, trends, and digital data are
stored in the 53MC5000. These include; Single
Loop, Single Loop with PV Trending, Two Loop,
Four Loop, Parameter, Point Status, and System
Status (diagnostic) displays. Additional custom
displays of dynamic and static data can be
developed by the user or MicroMod Automation for
specific process application requirements. Displays
are oriented in a configurable hierarchy for easy
selection. The display hierarchy may be modified
for any user applications. Examples of the standard
displays are presented in Figures 3 through 11.
(Note: Images in the figures are captured from
the Hires display.)
Single Loop - This display is available for each
control loop in the controller (up to four). Each
control loop’s alphanumeric tagname is displayed at
the top of the screen. The loop Process Variable
(PV) is displayed both digitally and in bargraph
form. The loop SetPoint (SP) is displayed digitally
and an indicating arrow. Process alarms are also
displayed as “TIC” marks to the left of the PV
bargraph. When in alarm condition, the PV
bargraph will flash and a text message (alarm line)
will flash indicating the
4
type of alarm. The PV bargraph is displayed with a
scale including the minimum and maximum range
values. Process variable engineering units are also
displayed. The control Output (OP) is represented
as a horizontal bargraph and a digital value. 0%
output may be either Open (O) or Closed (C) as
required. Auto/Manual and Remote/Local status
indications are displayed at the bottom of the screen
(see Fig. 3).
Single Loop with PV Trending - This display is
available for each control loop in the controller (up
to four). Each control loop’s alphanumeric tagname
is displayed at the top of the screen. The loop
Process Variable (PV) is displayed digitally (with
Engineering Units), bargraph, and current trend
form.The PV bargraph is displayed with a scale
including the minimum and maximum range values.
The setpoint (SP) is displayed digitally and as an
arrow to the right of the PV scale. Alarm limits are
displayed as “TIC” marks to the left of the PV
bargraph when configured. When in alarm
condition, the alarm line and PV bargraph flash. The
output (OP) is digitally displayed. The trend displays
the maximum time base in seconds or minutes.
Auto/Manual and Remote/Local status indications
are displayed at the bottom of the screen (see Fig.
4)
S-DCI-53MC5000_3
Micro-DCI Process Control Station Series 53MC5000
Figure 6: Four Loop
Display
Figure 7: Parameter Display
Two-Loop - This display shows two abbreviated
single loop bargraph displays simultaneously. The
screen displays both alphanumeric tagnames at the
top of the screen, left and right justified as required.
The loop PV and OP are displayed in bargraph form
with a SP arrow. Control pushbuttons (R/L, A/M, and
INC/DEC) are active only for the selected loop,
indicated by a square cursor below the bargraph.
Alarm limits, alarm displays, scales, controller
mode, and the output bargraph are similar to Single
Loop displays (see Fig. 5).
Four-Loop - This display shows four abbreviated
single loop bargraph displays simultaneously. The
screen displays the tagname of the selected loop at
the bottom of the screen along with the digital
values of the loop PV, OP and SP. The bargraph
display includes the PV bargraph, the SP indicating
arrow and controller mode (R/L,A/M). Control
pushbuttons (R/L, SP increase/decrease, A/M, and
output increase/decrease) are active for the
selected loop only, indicated by a triangular cursor
below the bargraph (see Fig. 6).
Parameter - Eight Parameter Displays are provided
for user access to controller databse locations
normally accessible through engineering mode
Figure 8: Alarm/Status Display
(Password Protected). Parameter displays provide
the display and modifiaction of any three (3)
database parameters such as alarm limits or tuning
constants. Each Parameter Display module has its
own user configurable alphanumeric legend
displayed at the top of each screen. Each database
location assigned to the parameter display also has
a user configurable alphanumeric label. (see Fig. 7)
Alarm/Status Display - Two Alarm/Status displays
can be configured to display alarm information,
contact status information or a variety of other
logical data information. Each display has a user
configurable alphanumeric legend that appears at
the top of the screen and alphanumeric legends for
each of eight (8) status points assigned to the
display. Each legend represents the value of a
single logical in the controller. If the status value
equals zero (0), the tagname will be displayed in
standard video. If the status value equals one (1),
the legend will be displayed in reverse video. Each
assigned logical value may also be designated as
an alarm. The legend will flash, in alternating direct/
reverse video, for logical values whose alarms are
enabled and the status is one (1). Status Displays
allow operator input as well. This operator access
allows motors and pumps to be started and stopped
from the display screen, (see Fig. 8).
5
S-DCI-53MC5000_3
Micro-DCI Process Control Station Series 53MC5000
Figure 9: Custom
Figure 10:
Configuration Menus
Custom - The controller incorporates the ability for
the user to develop special displays of static and/or
dynamic data presentation for his application.
These displays are developed using MicroMod’s
Display F-TRAN statements. The statements
provide the ability to print text, draw lines, draw
bargraphs, and draw trends. Lines, bargraphs, and
trends may be either vertical or horizontal.
Bargraphs and trends use “live” data for display (an
example of a custom display is shown in Fig. 9).
Configuration Menus - Figures 10 and 11 are a
sample of the configuration menus supplied on the
High Resolution version of the 53MC5000
controller. These configuration menus allow the
user the ability to change the controller
configuration without requiring a knowledge of the
controllers database. A heirarchy of menus
provides access to more and more configuration
detail as well as fast access to specific database
parameters.
6
Figure 11:
Control Loop Configuration
Totalizer - Each 53MC5000 controller has eight (8)
totalizers as a standard feature. Each totalizer can
be customer configured to accept inputs from a
variety of sources including the normal analog input
signals or a calculated value from within the controller. Scaling parameters allow a wide range engineering units options (gallons, Kgallons, Mgallons,
etc.). Each totalizer also has a user definable rollover value and the ability to soft-wire the rollover to a
contact output. A momentary pulse is generated
each time the totalizer rolls-over. Refer to Fig. 12.
System Status - This two page screen displays
information useful for evaluating the controller
hardware configuration and performance.
Information on the two screens include the
configured Model Number, the Control Strategy
currently executing, the Control Strategy Scan rate,
the controller Instrument Address, the DataLink
communication baud rate and the Option card
status. Also available is the system Run Time
Counter (Design Level A or B) or Real Time Clock
(Design Level B). Refer to Figures 13 & 14.
S-DCI-53MC5000_3
Micro-DCI Process Control Station Series 53MC5000
Figure 12: Totalizers
Figure 13: System Status 1
Figure 14: System Status 2
Configuration And Programming
Flexible Control Strategy (FCS)
The 53MC5000 is offered in Single-Loop
(53MC5100), Two-Loop (53MC5200), and Four-Loop
(53MC5400) functional models with Standard and
Extended versions. The Single-Loop controller is
offered only in the Standard version. The Two-Loop
and Four-Loop controllers are available in both
Standard and Extended versions. All models have
pre-programmed control strategies stored in ROM.
Control strategies allow the user the ability to
implement standard control quickly and easily,
without the need to invest time in configuration.
The Flexible Control Strategy (FCS) is a sequence of
control modules that can be configured to fit most
process applications. A One-Loop 53MC5000 has
one set of these control modules. A Two-Loop
version has a second, independent set of control
modules and the Four-Loop version has four sets. A
library of commonly used control strategy
configurations is resident in the 53MC5000. These
control strategies include standard PID, Ratio, Twoloop, Cascade, and others. The user merely inputs
his specific process parameters to implement a
powerful control strategy. FCS permits the preconfigured strategy to be enhanced through the
implementation of standard Math, Logic, Totalization,
Control, and I/O Assign modules. FCS is very easy
to use, but is powerful enough to implement special
requirements.
The 53MC5000 Standard version includes the
Flexible Control Strategy (FCS). The user selects
preconfigured control strategies stored in ROM and
loads them into FCS. The Extended model allows
the user to modify both the functionality of the
modules, as well as the order of execution through
F-CIM (Control Interconnection Modules)
configuration. The user also has the ability to use
“F-TRAN”, which is a high level language for the
most complex applications. Configuration can be
performed in the manner preferred by the user;
controller data entry keys, an optional hand-held
configurer, an IBM-PC or compatible using HC3300C
software, or through a Supervisor-PC network.
7
Micro-DCI Process Control Station Series 53MC5000
Implementing a strategy simply involves loading
the set-up values from ROM to make FCS perform
the desired control strategy. For most process
applications, the unit can immediately be placed in
service utilizing these standard strategies. If a
specialized strategy is required, the user need only
modify the standard strategy to implement his
specific change, not develop the entire strategy.
Modifications are performed by changes to the
module “softwiring”. Softwiring involves pointing
the inputs of FCS modules at the outputs of other
FCS modules. This list of pointers or “wirelist” is
then stored as database parameters.
NOTE THAT NO PROGRAMMING IS REQUIRED
TO IMPLEMENT A STANDARD OR MODIFIED
FCS.
The following descriptions detail each of the ten
(10) standard Flexible Control Strategies.
The CS 1 - PID Controller is utilized in
conjunction with other devices to automatically
control a process variable (PV) at a predetermined
set point (SP). The proportional, integral and
derivative (PID) terms can be activated as needed.
The standard strategy may include multiple
supplementary functions like; remote setpoints,
additive or multiplicative feedforward, output
tracking, PV retransmission, etc.
The CS 2 - Analog Backup Controller is used in
operations where a remote computer is normally
controlling the final element directly. In this
arrangement, the controller acts as a control signal
selector and as an automatic backup. As a backup
the controller will assume control of the process in
the event of an indicated computer failure.
The CS 3 - Ratio PID Controller is used where
one variable must automatically be maintained in
definite proportion to another variable. The PID
algorithm is executed to maintain a “controlled line”
at a predetermined proportion to the uncontrolled
or “wild line”.
The CS 4 - Automatic/Manual Station configures
the controller into a conventional single station
automatic-manual selector. In “Auto”, the Auto
Input is passed directly through the station to the
output . In “Manual” , the station acts as a manual
loader.
The CS - 5 Ratio Automatic/Manual Station
configures the controller into a versatile ratio
station with manual loading.
8
S-DCI-53MC5000_3
The CS 20 - Two Loop Controller consists of two
identical standard PID controllers, in effect making
the unit equivalent to two individual controllers.
The CS 21 - Two Loop Cascade Controller
consists of two standard PID control loops
arranged in the usual cascade setup with a primary
and related secondary controller. The output of the
primary controller, based on its setpoint and
process variable, becomes the setpoint for the
secondary control.
The CS 22 - Two Loop Override Controller
consists of two standard PID control loops. Override
control is used where two interdependent variables
are being controlled via a single element and neither
variable may exceed a safe limit. Such a process
requires that the variable tending to depart in the
undesirabledirection be the loop maintaining control
of the final element. To accomplish this the two
control loops are arranged such that both loops
holding the unselected loop near the active control
output range.
The CS 40 - Four Loop Controller consists of four
identical standard PID controllers, in effect making
the unit equivalent to four individual controllers.
The CS 41 - Dual Two Loop Cascade Controller
consists of dual sets of two standard PID control
loops arranged in the usual cascade setup with a
primary and related secondary controller.
Since the loops are independent in the two and fourloop versions, any combination of loop types and
modes is easily configured. For example, a Fourloop controller can be configured with two standard
PID loops and one two loop cascade.
F-CIM
(Control Interconnection Module)
For more complex process applications, ABB has
developed F-CIM configuration. F-CIM is an easy-touse configuration technique which connects control
modules in any sequence desired. It is possible to
use pre-configured modules and add or modify
modules to develop any control scheme. Most
modules have no limit on the number of times they
can be used. For special applications, custom
modules can be created. This provides an almost
unlimited ability to develop control strategies quickly
and easily.
S-DCI-53MC5000_3
Micro-DCI Process Control Station Series 53MC5000
Standard Module Types Include:
General Modules
Read
Write
Display
Numerical Operations
Pre-written, selectable equations
Add, Subtract, Multiply, Divide
Square Root
Log (base 2)
X to the power Y
Absolute value
Logical Operations
AND
OR
XOR
Control Modules
Setpoint Generation
PV Deviation
PID algorithm
Auto/Manual Switching
F-TRAN
F-TRAN is a proprietary programming language
developed by MicroMod especially for use in
developing custom control strategies in Micro-DCI
controllers.
The F-TRAN programming capability provides the
math and logic requirements for batch and modelbased advanced control.
The F-TRAN programming language is a high level
scientific programming language, with programs
written as a series of data statements. F-TRAN
language statements operate on the Controller data
base to produce numerical or logical outputs. The
Controller I/O and display, for example, are a part of
this data base.
The following is a summary of some of the F-TRAN
programming operations:
Numerical Operations
Addition
Subtraction
Multiplication
Division
Square Root
Compare
Log (base 2)
2x
Yx
Swap (X‹—›Y)
Duplicate
Get Pulse Input Data
Absolute Value
Totalize
For program flow control, unconditional jumps and
conditional skips, forward and back , are allowed.
Indirect addressing, which allows the user to
program advanced control schemes such as dead
time compensation and mathematical model based
approaches, is also supported. These features
greatly enhance the utility of the F-TRAN
programming language in the 53MC5000.
Prewritten subroutines, such as the PID control
algorithm, are included in firmware and can be
accessed from a custom F-TRAN program. These
subroutines are well documented for the user. This
greatly simplifies the task of creating a custom
control application program.
Easy-Tune™
Easy-Tune is MicroMod’s self-tuning algorithm
included as standard in all versions of the MC5000.
This algorithm estimates the process as first order
and calculates the process gain, first order time
constant, and deadtime. The controller has the ability
to execute the subroutine manually or automatically
to precisely calculate loop tuning coefficients.
Calculated coefficients can be displayed or
automatically be entered into the loop.
Refer to Technical Bulletin 53MC2000-ST for a
complete description of Easy-Tune.
Hardware Expansion Options
Every controller is supplied with the following
standard
I/O:
• 4 Analog Inputs
• 2 Analog Outputs
• 2 Discrete Inputs
• 2 Discrete Outputs
• Standard Data Highway
• RS-232 Configuration Port
Standard analog and discrete I/O is built into the
Main Board and available for use with any of the
FCS, F-CIM, or F-TRAN configuration techniques.
Terminations for standard I/O may be made either
directly to the back of the unit or to a remote
mounted Interface Terminal Board (ITB).
Logical Operations
AND
OR
Duplicate
XOR
Invert
9
Micro-DCI Process Control Station Series 53MC5000
The modular design of the 53MC5000 permits
additional I/O through use of an Expansion Board.
Each Expansion Board has dedicated slots to add
analog, discrete, or communication options. The
following options are available via Option Boards
which plug into the Expansion Board:
•
6 DI/ 4DO Option Board
or
16 DI/DO Option Board
•
Single Channel Analog Option
or
Multi-Channel Analog I/O Option
•
MicroLink Communication Option
Single or Redundant
•
Multi-Channel Analog/HART
Communications
•
Digital Device Interface HART
Communications
•
Digital Device Interface PLC/Printer
Communications
The 6 DI/4 DO Option Board provides an additional 6
discrete inputs and 4 discrete outputs to the standard
I/O (total of 8 DI and 6 DO). The 16 DI/DO Option
board provides any combination of 16 discrete
signals, inputs or outputs. The 16 DI/DO Option
Board uses OPTO 22 modules allowing individual
selection of the module type to match the
application. The Single-Channel Analog Input Option
Board provides an additional analog input through a
Custom Linearization Module. Different modules
types are available including; thermocouple, RTD,
and voltage. The Multi-Channel Analog I/O Option
Board permits an additional 4 analog inputs and 2
analog outputs as well as the Custom Linearization
Module (total of 9 analog inputs and 4 analog
outputs). Wiring to Option points utilizes remotemounted ITB’s. All expanded I/O is available for use
with any of the FCS, F-CIM, or F-TRAN
configurations.
Communications
The Standard RS-422/485 communication port
provides instant communication between the
53MC5000 and a Supervisor-PC™ in a new or
existing Micro-DCI network. The Supervisor-PC
network provides data exchange for process control
and monitoring, as well as the ability to upload and
download database and programs.
10
S-DCI-53MC5000_3
MicroLink is an optional high-speed data highway
board plugged into the Expansion Board described
above. MicroLink permits single or redundant
communications at up to two (2) megabaud data
transfer rate. MicroLink utilizes Peer-to-Peer
communication enabling data transfer directly
between instruments for increased network
efficiency and reliability. The user may identify up to
twenty-four 24 remote values to be obtained over the
network. Transfer is accomplished by entering the
instrument address and database location of the
value to be obtained, the instrument database
location where the value is to be placed, and the
desired sample rate.
The SCADA Adapter provides a way of connecting a
network of Modular Controllers to a variety of data
communication devices. Typically, data
communication devices are required when the total
highway length exceeds the RS-485 4000 foot
limitation. The SCADA Adapter performs the
function of converting the RS485 Datalink to RS232
for direct connection to the data communication
device. The SCADA Adaptor also provides the
control elements necessary for data communication
modems, such as Request to Send (RTS) and Clear
to Send (CTS). The SCADA Apaptor is used in
conjunction with the 53SU5000 Supervisor-PC to
provide a complete data acquisition and monitoring
system.
The PLC/Printer Interface is an exceptional way to
extend the input/output capacity of the 53MC5000 by
providing a convienient way to import/export
Programmable Logic Controller (PLC) information.
The Digital Device Interfaces (DDI-A and DDI-B)
each provide the capability to transfer logical bit
indicators and floating point variable to or from a
PLC. PLC types that the 53MC5000 can
communicate with are Allen Bradley, Modbus RTU,
Siemens S5, and Koyo. In Modbus RTU mode, the
53MC5000 can be configured as a Modbus master
or as a slave. The 53MC5000 can also
communicate with OPTO 22 digital and analog
inputs and outputs. Each DDI option is also capable
of sending serial output datalog information to a
printer. The output can be either the resident
standard format datalog program or user generated
free format datalog programs.
S-DCI-53MC5000_3
Micro-DCI Process Control Station Series 53MC5000
Ordering Information
Model Number Designation
See Notes on following page for explanation of functionality and options
Model Code
53MC5
01 - 05
53MC5
06 07 08 09 10 11 12 13 14 15 16
Process Control Station
No. of Control Loops
One Loop (Note 2)
1
Two Loops (Note 2)
2
Four Loops (Note 2)
4
Power Requirements
AC (110/220, 220/240 Vac 50/60 Hz)
1
DC (24 Vdc)
2
Functional Requirements
Standard
1
Extended Programmable provides F-TRAN programming language
2
Design Level/Display Type
Standard Resolution (48x96 pixels)
A 2
High Resolution (96x192 pixels -SEE NOTES)
B 4
Main Rear Terminal Requirement
Standard Rear Terminal Board
1
Cord Set Connector (for remote termination of standard I/O - includes backplane, ITB
and 5 ft. cable. For special cable lengths see Accessories)
5
Chassis
Standard (supports standard I/O only)
A
Expansion Ready (required for any I/O or communication options )
B
Safety Classification
General Purpose
A
Factory Mutual Class 1, Division 2 Class A,B,C,D
B
Discrete I/O Option - includes PCB, 5 ft cable and ITB
Not Implemented
X
6 DI (26V max) and 4 DO (150mA, 50V max.) - no additional modules required
C
16 DI/DO - requires plug-in modules, select from Accessories
F
DDI-A Printer / PLC Interface (includes PCB, RS-232/485 converter ITB & 5 ft cable)
M
Dual Relay Board (adds two SPDT, 24 Vdc powered relays with 10A, 240 Vac contacts)
Not Implemented
X
One board
1
Two boards
2
Three boards
3
Analog I/O Option (Note 7)
Not Implemented
X
Single Channel (requires Analog Conversion Module - see next line)
A
Multi Channel Analog I/O (analog conversion module required if using universal input)
D
Analog Conversion Modules (Required for Analog I/O option - select additional modules from P-DCI-Spares)
Not Implemented
0-5Vdc
RTD 100 Ohm, -100 to 100 C
Thermocouple Type J, 0 to 760 C
Communication A Option
Not Implemented
Datalink cable and ITB (connect between controllers with Cord Set terminations for standard I/O)
MicroLink-A - high speed host & peer-to-peer communications (includes PCB, 2.5 Ft cable and ITB)
Communication B Option (Includes PCB, cable and ITB)
Not Implemented
MicroLink-B Communications (provides redundant MicroLink when ordered with MicroLink A.)
DDI-B Printer/PLC Interface (includes PCB, RS-232/485 converter ITB & 5 ft cable)
Conformal Coating
Not Implemented
Required
17 18 19 20
X
B
C
D
X
C
F
X
C
J
X
A
11
S-DCI-53MC5000_3
Micro-DCI Process Control Station Series 53MC5000
ACCESSORIES
Configuration Software
MicroTools for Windows 2000 and XP/Professional - see price list P-DCI-53MT600
Mounting & Installation Hardware
Channel for wall mounting remote termination boards (4 ft. length)
129A003U03
DIN Rail Adaptor Kit
614B958U01
DIN to 3x6 Panel Mounting Adaptor
614B762U02
Panel Filler Kit
612B403U01
Horizontal Multiple Mounting Trim Collar - see Spare & Expansion Parts P-DCI-Spare
Rear-of-case Tag
388B708A11
Plastic Tag (front door latch)
250-ohm Input Resistors
161M417U05
Digital Input/output Modules for 16 DI/DO Option:
Digital Input Modules
12-32Vac / 10-32Vdc
2.5 - 28Vdc
90 - 140Vdc
180 - 280Vdc
Digital Output Modules
5 - 60Vdc
5 - 200 Vdc
12 - 140 Vac
Opto model:
G4IDC5
G4IDC5D
G4IAC5
G4IAC5A
MicroMod model number:
2004AP10120A
2004AP10100A
2004AP10140A
2004AP10150A
G4ODC5
G4ODC5A
G4OAC5
2005AP21100A
2005AP21110A
2005AP21120A
Note: Additional digital I/O modules may be purchased directly from OPTO 22.
Notes:
Functionality
Standard Functionality provides FCS and FCIM configuration (pre-configured, modifiable control strategies and
function-block configuration)
Extended Functionality provides F-TRAN high-level language programming.
Main Rear Terminals
Standard rear terminal board provides connection for standard I/O on the back of the controller.
Cord Set Connector allows remote connection of standard I/O only.
Design Level / Display
Design Level B provides High Resolution display, new front panel menu configuration system, real-time clock and
hot-swap display features. The Design Level B is a licensed product; end-user name and contact information MUST
be supplied at time of order.
Digital and Dual Relay I/O Options
6 DI / 4 DO option does not require any additional modules.
16 DI / DO option requires plug-in digital modules
Dual Relay option may also be used with 6 DI / 4 DO or Standard Digital I/O as interposing relays
Analog I/O Options
Single Channel Analog option provides one additional universal input. Input type is determined by selection of Analog
Conditioning Module.
Multi-Channel Analog option provides four additional analog inputs, two additional analog outputs, and one universal
input. Input type is determined by selection of Analog Conditioning Module.
Additional Analog Conditioning Modules are available for other input types. Refer to Price Sheet P-DCI-Spares for full
listing
Special Cable Lengths
All I/O and communication options are supplied with the option board (PCB), standard cable and ITB (termination
board). If non-standard cable length is required, select “Not Implemented” (X) in model number and specify PCB,
cable and ITB separately from Spare and Expansion Parts List P-DCI-53MC5000-Spare
Factory Configuration
MicroMod Automation can provide custom configuration services. Contact Customer Service for quotation.
12
S-DCI-53MC5000_3
Micro-DCI Process Control Station Series 53MC5000
More complex strategies can be implemented using
F-CIM or F-TRAN in an Extended Level 53MC5000
Engineering Specifications
OPERATING CHARACTERISTICS
Power Requirements:
21 to 28 VDC
120 VAC +/- 10%, 50/60 Hz
220/240 VAC +/- 10%, 50/60 Hz
Power Consumption:
AC Operation: 36 W max
Internal Power Supply
Available Power Output for Transmitters:
24-26V dc, 80 mA, short circuit protected
Output Ripple: 200 mV p-p maximum
ENVIRONMENTAL CHARACTERISTICS
(Enclosed temperature controlled locations (class A and
B per ISA S71.01 1985)
Ambient Temperature Limits: 4 to 52°C (+40 to 125°F)
for single mount; 4 to 40°C (+40 to 103°F) for
high density installations (For high density
installations - consult Factory)
Relative Humidity Limits: 10 to 90% maximum
Temp. Effect on Accuracy: +/-0.28% per 28° (50°F)
from reference temp. of 25°C (77°F)
Enclosure Classification: NEMA type 1/IEC
529 Type IP20
PHYSICAL CHARACTERISTICS
Materials of Construction
Case: Steel
Finish: RAL 9002, Light Gray
Circuit Boards: Glass epoxy
Bezel: ULTEM 1000 (Polyetherimide Resin)
Flamability-UL94 5V
Dimensions: DIN case only
2 27/32"W x 5 21/32"H x 12 26/32"L
(72 mm W x 144 mm H x 305 mm L)
Mounting: Flush panel (1/8" to 1" Thickness)
Panel Cutout: 2 11/16"W x 5 7/16"H
(68 mm W x 138 mm H)
Weight: 5 lbs. (approximate)
INPUT SIGNALS
Analog Inputs
(All analog inputs are referenced to signal common.)
Quantity: 4 Standard (Additional optional - See
Single Channel or Multi-Channel Analog
Option Board)
Resolution: 12 bit
Signal Range: 0-5 or 1-5 V linear or square root
Low level input (optional): RTD or
thermocouple signal.
Input Impedance: 1 megohm minimum for voltage
inputs; value of ranging resistor for current
signals.
Measurement Accuracy: +/-0.1% of span
Note: The standard rear terminal board has the
appropriate resistors on ANI0 and ANI1. If the input
signal is voltage, the resistors should be removed.
Contact Inputs
Quantity: 2 (Additional optional - See 6DI/4DO Option
Board or 16 DI/DO)
Type: Discrete inputs internally powered with
4 volts @ 2 mA dc maximum (contact inputs
are referenced to power common.)
Permissible Contact Resistance: 100 ohm maximum
Open/Close Contact Duration:
for open recognition: 0.05 s minimum
for close recognition: 0.05 s minimum
(Voltage inputs and CCI are sampled
every 0.05 seconds)
Contact Recognition Level
Closed:
1 V dc max or less than 100 ohms
Open:
4 V dc to 15 v dc or 10 mA max
Electrical Connections
Rear of case compression-type terminal strips.
Front Panel
Display: 96 x 48pixel (dot addressable)
Push-buttons: 10 (membrane type switches)
13
S-DCI-53MC5000_3
Micro-DCI Process Control Station Series 53MC5000
OUTPUT SIGNALS
Analog Outputs
(All analog output signals are referenced to
power common.)
Quantity: 2 Standard (Additional optional - See MultiChannel Analog Option Board)
Signal Range: 0 - 21.84 mA dc (4 - 20 mA dc typically)
Load Resistance: 0-750 ohms
Accuracy: +/- 0.2% of span
(Current output is refreshed every 0.05
seconds. Output is updated every 0.15
seconds in a standard control strategy or at
selected 0.05 second intervals in user
specified control strategies.)
Discrete Outputs
Quantity: 2 (Additional optional - See 6DI/4DO Option
Board or 16 DI/DO)
Type: Unpowered discrete solid state output.
Configuration: Single pole single throw, N.O., or
N.C. referenced to power common.
Voltage: 30 V dc max.
Current: 50 mA dc max.
MICROPROCESSOR SAMPLING & UPDATE
Program scan rate: selectable from 0.05 to 1.5
second
Input Signal Sampling Rate
Analog:
0.05 s for all inputs
Contact:
0.05 s for all inputs
Display Update: Configurable, every 1 to 15
Program Scans
Output Signal Update: same as Program Scan Rate
CONTROL RANGES
Proportional Band: 2 to 1000%, and “off”
Integral: 0.02 to 200 minimum, or Manual
Reset from 0 to 100%
Derivative: 0.01 to 8 minimum and “off”
COMMUNICATIONS
Standard Micro-DCI Data link
Type: RS-485/422, four wire, asynchronous
Speed: Selectable - all standard baud rates between
300 and 9600; plus 14,400 and 28,800
Mode: Binary
Optional MicroLink Communication
Type: RS-485/422, four wire, CSMA/CD, peer-to- peer
Speed: Selectable - up to 2 Megabit/sec.
Mode: Binary
14
Optional HART® Communication
General
Baud Rate: 1200 (fixed)
Point-to-point
Type: Frequency Shift Keyed signal superimposed on
the 4-20 mA analog signal
Channel connections: 8 point-to-point
Multidrop Network
Type: RS485 to Frequency Shift Keyed digital signal
Channel connections: 30 HART™ Instruments (15 per
Digital Device Interface)
Optional PLC/Printer Communication
Type: Converts RS-485/422, four wire,to RS232
Communication Baud Rate: 600, 1200, 2400, 4800,
9600, 19.2k, 28.8k, 38.4k
Communication Parity: Even, Odd or None
Set-Up: 8 bits, 1 stop
PLC Protocols: Allen-Bradley™ DF-1, OPTO 22 Serial
I/O communications, Modbus Remote Terminal Unit,
and Siemens 3964
Printer Protocol: RS-485/422 serial data, to RS-232
Optional SCADA Adapter Communication
Type: Converts RS-485/422, four wire,to RS-232
Modem Baud Rate: 600, 1200, 2400, 4800,
9600, 19.2k, 28.8k, 38.4k
Modem Parity: Even or None
Modem Delay:10,20,30,40,50,100,200,
and 250 milliseconds
Data Link Baud Rate: 9600 or 28.8k
6 DI/4 DO OPTION BOARD
Contact Input Specifications
Quantity: 6
Operational Type: Optically coupled Phototransistors
Input Connections
Voltage Input mode: 2 term. (+ and -) each input
Contact Input mode: 2 terminals for each input
(one is common)
Recognition level
Voltage Input mode: Energized - 12 to 26 Vdc range,
50 ohm max. resistance, non energized- 1Vdc
maximum
Contact Input mode: Energized - 500 ohms max., 22
to 26 Vdc range. Non-energized - 60k ohms minimum
26 Vdc max.
Recognition time:
50 milliseconds
Maximum Input Voltage: 26 Vdc
Common Mode Limit: 50 V with respect to chassis
ground
Transient Rejection: Meets IEEE Std. 472-1974
for Surge Withstand Capability
S-DCI-53MC5000_3
Micro-DCI Process Control Station Series 53MC5000
Recognition level
Voltage Input mode: Energized - 12 to 26 Vdc range,
50 ohm max. resistance, non energized- 1Vdc
maximum
Contact Input mode: Energized - 500 ohms max., 22
to 26 Vdc range. Non-energized - 60k ohms minimum
26 Vdc max.
Recognition time:
50 milliseconds
Maximum Input Voltage: 26 Vdc
Common Mode Limit: 50 V with respect to chassis
ground
Transient Rejection: Meets IEEE Std. 472-1974
for Surge Withstand Capability
SINGLE CHANNEL ANALOG OPTION BOARD
Analog Inputs
Quantity:
1; Isolated
Resolution:
12 bits
Signal Range: Universal input; high-level, RTD
or thermocouple signal (See Table 1).
Measurement Accuracy: +/-0.1% Full Scale
Note: The optional rear terminal board provides
terminal connections (TB3) for the Single Channel
Analog Option universal input (ANI 8).
MULTI-CHANNEL ANALOG OPTION BOARD
Contact Output Specifications
Quantity: 4
Operational Type: Form A, SPST, normally open,
optically isolated MOSFET switch
ON Resistance:
15 ohms maximum
Load Voltage Limit:
50 Vdc or peak AC
Load Current:
150 mA
Off State Leakage Current: 1 mA maximum
Common Mode Limit: 50 V with respect to
chassis ground
Contact Protection: 250 mA Fuse
Transient Rejection (ITB): Meets IEEE Std. 472-1974
for Surge Withstand Capability
CCO Relay ITB Specifications
Number of Outputs: 2
Operational Type: SPDT
External Power Requirement: +24 Vdc, 200mA
Contact Rating: 10 Amp Resistive, 1 Amp Inductive,
250 Vac Maximum
16 DI/ DO OPTION BOARD
Analog Inputs
Non-Isolated
Quantity: 4
Resolution: 12 bits
Signal Type:
Current
Signal Range: 0 - 21.84 mA
Measurement Accuracy ± 0.2 % of
span
Frequency
Signal Range: 9 - 25,000 Hz
Input Impedance: 47 ký in series with
a 0.22 MFD capacitor
Measurement Accuracy: ± 0.2 % of span
Signal Amplitude: 4 - 25 V p-p
Pulse Width: 20 microseconds min
Isolated (Optional)
Quantity: 1
Resolution: 12 bits
Signal Range: Universal input (optional); high- level,
RTD or thermocouple signal (See Table 1)
Contact Input/Output Specifications
Quantity: 16
Operational Type: Opto 22 modules
External Power Requirements: +5 Vdc, 224 mA
+24 Vdc, 420 mA
16 DI/DO ITB Specifications
See Table 2 for a listing of applicable module types.
15
S-DCI-53MC5000_3
Micro-DCI Process Control Station Series 53MC5000
Table 1: Isolation Modules Specifications
Isolation Module
5B30 Group
5B31 Group
5B32 Group
5B34 Group
5B47 Group
Signal Type
mV
Voltage
Current
RTD
Thermocouple
Accuracy
± 0.05% span
± 0.05% span
± 0.05% span
± 0.05% span
------------------
Nonlinearity
± 0.02% span
± 0.02% span
± 0.02% span
± 0.05% span
- 25 nA
Stability vs Ambient
Temperature
Input Offset
Gain
Input Bias Current
± 1 µV/°C
± 25 ppm /°C
± 3 nA
± 20 µV/°C
± 50 ppm /°C
± 0.2 n
----------------------------------------------------
± 0.02°C/°C
± 50 ppm /°C
± 3 nA
± 1 µV/°C
± 25 ppm /°C
- 25 nA
Input Resistance
Normal
Power Off
5 M ohms
40 k ohms
650 k ohms
650 k ohms
-----------------------------------
5 M ohms
40 k ohms
5 M ohms
40 k ohms
Input Protection
Continuous
Transient
240 V rms max
IEEE-STD 472
240 V rms max
IEEE-STD 472
240 V rms max
IEEE-STD 472
240 V rms max
------------------
240 V rms max
------------------
Signal Range: Universal input (optional); high- level,
RTD or thermocouple signal (See Table 1)
Measurement Accuracy: +/-0.1% Full Scale
Input Impedance: 1 megohm minimum for voltage
inputs; value of ranging resistor for current
signals.
Measurement Accuracy: +/-0.1% Full Scale
Note : The standard rear terminal board has the
appropriate resistors on ANI0 and ANI1. If the input
signal is voltage, the resistors should be removed.
16
Analog Outputs
(All analog output signals are referenced to power
common.)
Quantity:
2
Signal Range:
0 - 21.84 mA dc
Load Resistance:
0-640 ohms
Accuracy:
+/- 0.2% of span
S-DCI-53MC5000_3
Micro-DCI Process Control Station Series 53MC5000
Table 2: OPTO 22 Module Specifications
AC Input Modules:
OPTO 22
Part Number
ITB Board
Voltage
G4DC5
G4IDC5G
G4IAC5
G4IAC5A
G4IDC24
G4IAC24
5 Vdc
5 Vdc
5 Vdc
5 Vdc
24 Vdc
24 Vdc
Input Voltage
Range
12 - 32 Vac
35 - 60 Vac
90 - 140 Vac
180 - 280 Vac
12 - 32 Vac
90 - 140 Vac
Input Current
@ Max VIN
Input Maximum
for No Output
25 mA
25 mA
11 mA
6.5 mA
25 mA
11 mA
3 Vac
9 Vac
45 Vac
80 Vac
3 Vac
45 Vac
Load Current
@ 45° C
Load Current
@ 70° C
AC Output Modules:
OPTO 22
Part Number
ITB Board
Voltage
G4OAC5
G4OAC5A
G4OAC5A5(NC)
G4OAC24
G4OAC24A
5 Vdc
5 Vdc
5 Vdc
24 Vdc
24 Vdc
Output Line
Voltage Range
12 - 14- Vac
24 - 280 Vac
24 - 280 Vac
12 - 140 Vac
24 - 280 Vac
3
3
3
3
3
Amps
Amps
Amps
Amps
Amps
2
2
2
2
2
Amps
Amps
Amps
Amps
Amps
Maximum
Off-State Leakage
@ 120 Vac
5 mA ac
2.5 mA ac
2.5 mA ac
5 mA ac
2.5 mA ac
DC Input Modules:
OPTO 22
Part Number
ITB Board
Voltage
G4IC5
G4IDC5B
G4IDC5D
G4IDC5G
G4IAC5
G4IAC5A
G4IDC24
G4IAC24
5 Vdc
5 Vdc
5 Vdc
5 Vdc
5 Vdc
5 Vdc
24 Vdc
24 Vdc
Input Voltage
Range
10 - 32 Vdc
4 - 16 Vdc
2.5 - 28 Vdc
35 - 60 Vdc
90 - 140 Vdc
180 - 280 Vdc
10 - 32 Vdc
90 - 140 Vdc
Input Current
@ Max VIN
Input Maximum
for No Output
25 mA
45 mA
30 mA
6 mA
11 mA
6.5 mA
25 mA
11 mA
3 Vdc
1 Vdc
1 Vdc
9 Vdc
45 Vdc
80 Vdc
3 Vdc
45 Vdc
Load Current
@ 45° C
Load Current
@ 70° C
DC Output Modules:
OPTO 22
Part Number
ITB Board
Voltage
Output Line
Voltage Range
G4ODC5
G4ODC5A
G4ODC24
5 Vdc
5 Vdc
24 Vdc
5 - 60 Vdc
5 - 200 Vdc
5 - 60 Vdc
3 Amps
1 Amps
3 Amps
2 Amps
0.55 Amps
2 Amps
Maximum
Off-State Leakage
@ 120 Vac
1 mA
2 mA
1 mA
Notes: All OPTO 22 modules offer the following features:
1) 4000 Vac optical isolation
5) UL recognized
2) Built-in LED Status Indicator
6) CSA certified
3) Removable Fuse - Output Modules Only
7) Meets IEEE Surge Withstand specifications
4) Will withstand one cycle surge of 80 amperes
17
S-DCI-53MC5000_3
Micro-DCI Process Control Station Series 53MC5000
Additional Information
In addition to this Specification, the
53MC5000 Process Control Station is
supported by:
• Quick Start Installation Guide
- Installation
- Functionality
- Flexible Control Strategy
• Instruction Bulletin
- Installation
- Operation
- Functionality and Displays
- Communications
- Maintenance
• Customization Guide
- F-TRAN (B-F&P Translator Language)
- F-CIM (B-F&P Control Interconnection Modules)
• MicroLink™ Instruction Bulletin
- Installation
- Network Management
- Gateway Functions
• 53MC5000 HART® Interface Instruction Bulletin
- Installation
- Operator Displays
• PLC and Printer Interfaces Instruction Bulletin
- Installation
- Allen-Bradley Mode
- OPTO 22 Mode
- Modbus RTU Mode
- Siemens S5 Mode
- Koyo Mode
- Printer Interface
www.micromodautomation.com
www.termoprocesos.com
• Custom Program Interface Instruction Bulletin
53HC3300 Rev. D
- MC5FIG
- MC5DRAW
- Documentor
Micro-PWC™ Operators Console
• Micro-PWC™ Installation and Setup Guide
- Hardware requirements
- Installation
- Start-up and Operation
• Micro-PWC™ Operator's Manual
- System Features
- Logs
- Trend Displays
- Graphics
- Process Alarms
• Micro-PWC™ Configuration Guide
- System Configuration
- Hierarchical Displays
- Configuration of Graphics
- Historical Database
- Logs
- Trending
- System Status Display
- Utilities
- Historical Block Data Coillection
- @aGlance/IT Server Interface
• MicroTools™ Configuration Tool Kit
- 53MC5000 Configuration/Programming
- On-line / off-line database editor
- Project Manager
The Company’s policy is one of continuous product improvement
and the right is reserved to modify the information contained
herein without notice.
Printed in USA
Termoprocesos e Instrumentacion S.A de C.V
Filosofos #301
Dep. 101-A
Col. Tecnologico
MicroMod
Automation,
Inc.
Monterrey, 75
N.L.,
Mexico
Town
Centre Dr.
Tel. (81) 8359-6229 y (81) 8359-6130
Rochester, NY 14623 USA
Fax. (81) 8358-3777
Tel: (585) 321-9200
Correo: [email protected]
Fax: (585) 321-9291
www.termoprocesos.com
- www.termo-tienda.
Email: [email protected]
com
18
S-DCI-53MC5000_3 September 2005
© MicroMod Automation, Inc. 2004

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