COMMANDER 501 Process Controller

Specification DataFile

■■ PID control with easily programmed

standard templates
– single loop, heat/cool, motorized valve,
auto/manual station, indicator, analog
backup

■■ Clear process display and color-

coordinated switches
– process visibility, ease of operation

■■ Comprehensive input/output capabilities

– up to three analog inputs, two analog
outputs, four relays and four digital inputs

■■ Process security and plant safety

– loop-break alarm, processor watchdog,
password-protection and intelligent power
recovery

■■ Unique Control Efficiency Monitor (CEM)

– two Autotune algorithms plus manual fine-
tuning using CEM

■■ PC configuration for ease of setup

– easy access to advanced features and
standard settings

■■ IP66/NEMA4X front face COMMANDER 501 – stand-alone

– reliability in the harshest environments
controller in a short-case, 6 x 3
■■ RS485 MODBUS™ serial communication format for basic applications
– SCADA, PLC and open system integration

ABB Automation
1
COMMANDER 501

The COMMANDER 501 is a versatile single-loop

controller with advanced control features built-
in as standard, e.g. gain scheduling, process
optimization, alarm logic, maths and linearizers.
The instrument can be commissioned using a
built-in library of application templates and
advanced autotune facilities. Configurations
can also be edited and stored off-line using our
Windows™-based PC Configurator.
A wide range of process connections is included
in the standard instrument; a choice of option
cards provides additional input/output for
complex applications. MODBUS serial
communications are available for integration
with factory automation systems.
IP66 (NEMA 4X) front panel protection makes the
COMMANDER 501 an extremely robust
controller, suitable for use in a wide variety of
industrial environments.

Process Connections

Universal Process Input PID Control

• Thermocouple Primary Outputs
• RTD 1 x Analog/Logic Alarms
• mA 2 x Relay Outputs
Retransmission
• Volts, mV

Transmitter Power
Supply (45mA)

Additional PID Control

Fixed Process Input Outputs
• mA Alarms
2 x Relays
• mV 1 x Analog/Logic Retransmission
•THC *

2 x Digital Inputs Serial Communications

RS485 MODBUS RTU
Additional Inputs
• 2 x Digital
SCADA systems (on PC)
• Universal Process Input
• Transmitter Power
KEY: Standard Option
Supply (23mA)
* Only if standard universal input is THC

2
Process Visibility and Operation Control Efficiency Monitor (CEM)
Three high-visibility, colored digital displays show Process CEM measurements are designed to help you fine-tune your
Variable, Set Point and Controller Output simultaneously. process manually. Six key-performance parameters are
Dual, 40-segment bargraphs give an instant indication of measured and displayed, allowing you to vary your PID
process status. For clarity, function keys are color-coded to settings to match the process needs and measure the results
match their corresponding displays. of your investment.

Eight individual tactile front panel keys make the controller x1

PV x2
very operator-friendly, with one-touch access to local/remote
set point adjustment, alarm acknowledgment, auto/manual +2%
and output adjustment.
95% –2%
Secret-til-lit LED indicators display controller modes and alarm
status, and provide extensive controller and plant diagnostics. y2 Set Point
y1 tperiod
All of these features ensure that the controller is operator-
friendly and no specific training is required for operational use.
5%
tapproach t

tsettle

COMMANDER 500
Start of
58.8 Calculation
62.4

15.0 Out-of-the-Box and Installed-in-Minutes

The COMMANDER 501 has been designed to minimize your
configuration and commissioning time, as you need only enter
values that relate to your process. Application templates,
offering preconfigured customized control strategies, allow
rapid setup of the controller. Templates are selected via the PC
Process Security and Self-diagnostics configurator or the front panel keys. Alternatively the unit may
To keep your process stable and secure, the be supplied preconfigured. Once a template is selected only
COMMANDER 501 has intelligent diagnostics and three key settings are required and the controller is ready-to-
responses, which can be used for process safety to initiate an run.
action or to indicate a fault. A processor watchdog monitors the
Complete configurations can be created, edited and stored
processor continuously; a unique loop-break alarm detects
off-line, using the COMMANDER PC configuration editor. A
analog output failure; and there is an open circuit detector on
dedicated cable connects the PC to a jack socket on the top of
the input. Using these signals, safety shutdown strategies can
the controller for rapid upload, or download, of configurations.
be initiated.
Copies of the configurations can be saved and produced as
For configuration data security, there are three levels of hard copy.
password protection plus front panel function key lockouts,
A dual mode, intelligent autotune requires no prior knowledge
ensuring total process security.
of PID settings and offers a choice of fast response or
Custom Linearizer minimum overshoot strategies.
The COMMANDER 501 has two separate 15-breakpoint
linearizers which can be programmed via the PC configurator
and applied to either inputs or outputs. These can be used for
non-standard thermocouples, non-linear tank levels or any Process Alarms
non-linear input. The output linearizer accommodates any
The COMMANDER 501 has eight internal
non-linear control elements.
process alarms. These can be soft-wired
to control strategies, logic equations and
output relays.
Maths and Soft-Wiring 100
COMMANDER 500

PV
58.8 X

Four individual math blocks, each having up to 7 operators and Each alarm can have a separate 80 SP
62.4 W

operands, provide functions such as average, maximum and hysteresis value, programmable in
MST SLV R

60

minimum calculations. Square root, relative humidity and engineering units or time. Alarms can also 40

arithmetic functions are also included as standard. Inputs can be enabled or disabled via digital inputs
20 OP
15.0 Y

be selected or switched in and out of calculations by digital and can be configured as annunciators, M OP1 OP2 FF

signals. This allows both simple and advanced calculations to so the alarm may be disabled once
0

be processed and these can be soft-wired to control functions. acknowledged.

3
Customized Application Templates
Templates are provided to make the basic configuration for a
particular application as simple as possible. When a template
is selected the COMMANDER 501 assumes the preset form
for that template (see below). The inputs and software blocks
are soft-wired automatically to perform the selected function.

Configuration time is greatly reduced as 90% of the choices

you would normally need to make in similar products are
already preconfigured.

The COMMANDER 501 offers the following templates:

1 Single loop controller with local set point
2 Single loop controller with remote set point
3 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 station
8 Dual indicator/manual loader station

Single Loop Control Template – Example

A single element drum level is used in industrial boiler applications with slowly changing steam demand and/or constant BTU
content fuel-fired boilers.
L L
R
Steam
LSPt
Local Set Point

Steam Constant Head Remote Set Point Input

RSPt
Reservoir
IP2
CSPt
PID PID O/P
Process Variable Input
PV Control Loop
LT IP1
Water/Steam Drum Level
Interface Transmitter

Water with Control Output

Steam Bubbles I/P OP1
Boiler
Drum
Feedwater Manual Output
Feedwater
Control Valve

Sequencing and Logic Control Intelligent Adjustable Power Recovery

The COMMANDER 501 offers comprehensive sequencing, to Two forms of plant power failure recovery are available
complement its advanced analog control features, and six programmable between 0 and 9999s for recovery time:
logic equations, with up to fifteen elements per equation.
These logic equations, when combined with delay timers, real- ‘HOT’ restart – if the power is restored within the recovery time
time alarms and extensive I/O, make the COMMANDER 501 a the COMMANDER 501 defaults to Auto mode, allowing the
powerful interlocking controller. process to be up-and-running without delay.

‘COLD’ restart – if the power is not restored within the preset

recovery time, the controller defaults to Manual mode, or a
A A.B predetermined control output. This ensures that after power
B Q = (A . B) . (C . D) failure the controller does not start to control the process
C.D
without operator acknowledgment.
C
D
Industrial Robust Design
The front face has been designed to meet IP66/NEMA4X
rating with a unique moulded case and panel seal. A chemical
resistant polyester front panel ensures a secure investment for
any environment.

4
SPECIFICATION Analog Inputs
Universal Process Inputs
Summary Number
• 8 application templates: Single loop, 1 standard
Auto/Manual, Analog backup, Indicator 1 optional

• Two Autotune options Type

Universally configurable to provide
• Control Efficiency Monitor Thermocouple (THC)
Resistance thermometer (RTD)
• PC configuration
mV
• IP66/NEMA4X front face Volts
mA
Resistance
Operation
Input Impedance
Display mA 100Ω
2 x 100mm 40-segment LED bargraphs mV, V 10MΩ
2 x 10mm 4-digit LED indicators Linearizer Functions
1 x 10mm 3-digit LED indicators
Display range: –1999 to +9999 THC types B, E, J, K, L, N, R, S, T, PT100, √, 3/2, 5/2

Configuration Broken Sensor Protection

Basic configuration via front panel keys Programmable for upscale or downscale drive
Advanced feature configuration by PC only Sample Interval
Security 125ms (1 input)
Internal security switch and password-protected menus Digital filter
Programmable
Standard Functions
Cold Junction Compensation
Control Strategies Automatic CJC incorporated as standard
Single-loop, Auto/manual Station, Analog Backup, Stability 0.05°C/°C change in ambient temperature
Indicator/Manual Loader
Input Protection
Output Types Common mode rejection >120dB at 50/60Hz with
Current proportioning, Time proportioning, On/off, 300Ω imbalance resistance
Motorized valve (with and without feedback), Heat/cool. Series mode rejection > 60dB at 50/60Hz
Control Parameters Transmitter Power Supply
Four sets of PID settings, selectable via digital signals Number: 1 standard, 1 optional
Voltage: 24Vd.c. nominal
Set Points Drive: Up to 45mA as standard,
Local, remote and four local fixed set points, selectable up to 23mA on option board
via digital signals
Non-universal Process Input
Configured Outputs
Number
Three preset output values, selectable via digital signals
1 standard
Autotune Input types
On demand for 1/4 wave or minimal overshoot mA, mV only (THC only if IP1 is also THC)
Linearization B, E, J, K, L, N, R, S, T, √, 3/2, 5/2
Process Alarms
Number 8 EMC
Types High/low process,
High/low output, Emissions
High/low deviation
Meets requirements of EN50081-2
Hysteresis Level and time *
Alarm enable/disable Enable/disable of alarms via Immunity
digital signal Meets requirements of EN50082-2
Real Time Alarms *
Number 2
Programmable On time/day and duration
* Accessed via PC Configurator

5
Outputs Custom Linearizers *
Number 2
Control/Retransmission Outputs Breakpoints 15 per linearizer
Number 1 standard, 1 optional
Type Programmable as analog or * Accessed via PC Configurator
logic (digital) output
Isolation Galvanically isolated from the rest of
the circuitry
Options
Analog range 0 and 20mA (programmable), accuracy: Analog Inputs
0.25%
Number 1
Digital voltage 17V @ 20mA
Isolation Galvanically isolated from the rest of
the circuitry
Relay Outputs Type Universal (see above)
Number 2 standard, 2 optional
Analog/Digital output
Type SPST, rated 5A at 115/230V a.c.
Number 1
Isolation Galvanically isolated from the rest of
Digital Inputs the circuitry
Number 2 standard, 2 optional Type Programmable 0 to 20mA analog or
Type Volt-free 17V @ 20mA digital
Minimum pulse 200ms
Relay Outputs
Advanced Features Number 2
Type SPST, rated 5A at 115/230V ac
Maths Blocks *
Digital Inputs
Number 4 Number 2
Operators +, –, x, ÷, Average, Maximum, Type Volt-free
Minimum, High select, Low select, √, Minimum pulse 200ms
Median select, Relative Humidity
Input multiplexer (digitally selected) Serial Communications
Delay Timers * Connections RS485, 2- or 4-wire
Protocol MODBUS RTU
Number 2 Isolation Galvanically isolated from the rest of
Programmable Delay and Duration in seconds the circuitry
Logic Equations *
Number 6
Elements 15 per equation
Operators OR, AND, NOR, NAND, NOT, EXOR

Standard Analog Input Ranges

Thermocouple Maximum Range °C Maximum Range °F Accuracy (% of reading)
B –18 to 1800 0 to 3270 0.1% or ±1°C (1.8°F) [above 200°C (392°F)]
E –100 to 900 –140 to 1650 0.1% or ±0.5°C (0.9°F)
J –100 to 900 –140 to 1650 0.1% or ±0.5°C (0.9°F)
K –100 to 1300 –140 to 2350 0.1% or ±0.5°C (0.9°F)
L –100 to 900 –140 to 1650 0.1% or ±1.5°C (2.7°F)
N –200 to 1300 –325 to 2350 0.1% or ±0.5°C (0.9°F)
R –18 to 1700 0 to 3000 0.1% or ±0.5°C (0.9°F) [above 300°C (540°F)]
S –18 to 1700 0 to 3000 0.1% or ±0.5°C (0.9°F) [above 200°C(392°F)]
T –250 to 300 –400 to 550 0.1% or ±0.5°C (0.9°F)

RTD Maximum Range °C Maximum Range °F Accuracy (% of reading)

PT100 –200 to 600 –325 to 1100 0.1% or ±0.5°C (0.9°F)

Linear Inputs Range Accuracy (% of reading)

Millivolts 0 to 500 mV 0.1% or ±10µA
Milliamps 0 to 50 mA 0.2% or ±2µA
Volts 0 to 5V 0.2% or ±2mV
Resistance 0 to 5000Ω 0.2% or ±0.08Ω
Notes. Min. span below zero Type T 70°C/126°F
Type N 105°C/189°F
Performance accuracy is not guaranteed at extreme low end of thermocouple and sq. root ranges. THC standards DIN 43710 IEC 584
RTD, 3-wire platinum, 100Ω per DIN 43760 standard (IEC751), with range of 0 to 400Ω. RTD standards DIN 43760 IEC 751

6
Physical Dielectric Strength
500V d.c. to earth:
Size Analog/digital output 1 to rest of the circuitry
76mm x 148mm x 149.5mm (500V d.c. for 1 minute)
(2.99 in. x 5.83 in. x 5.87 in.) Analog/digital output 2 to rest of the circuitry
(500V d.c. for 1 minute)
Weight
Analog input 3 (IP3) to rest of the circuitry
750g (1.6lb) (500V d.c. for 1 minute)
Serial communications to rest of the circuitry
Electrical (500V d.c. for 1 minute)

Voltage
Environmental
85 to 265V a.c. 50/60Hz
24V d.c. Operating Limits
Power consumption 0°C to 55°C (32°F to 130°F)
5 to 95%RH (non-condensing)
<10VA
Temperature stability
Power interruption protection
<0.02%/°C or 2µV/°C (<0.011%/°F or 1.11µV/°F)
Up to 60ms Long term drift <0.02% of reading or 20µV annually
Safety
Front face
General safety EN 61010-1 NEMA4X (IP66)

Electrical Connections
Milliamps
(Using on-board
transmitter power supply) Analog Input 3 (–) 19 1 Analog Input 1 (–)
See Analog Input 3 (+) 20 2
19 4 1 100 Ω adjacent
Analog Input 1 (+)
20 5 2 –
Analog Input 3 (RTD2) 21 3 Analog Input 1 (RTD1)
Tx See
Transmitter PSU (+) 22 4 Analog Input 2 (–) adjacent
22 6 3 +
Digital / Analog Output 2 (+) 23 5 Analog Input 2 (+)
IP3 IP2 IP1 Digital / Analog Output 2 (–) 24 6 Transmitter PSU (+)
Milliamps Digital Input Common 2 (–) 25 7 Digital / Analog Output 1 (+)
(Using external Digital Input 3 (+) 26 8 Digital / Analog Output 1 (–)
transmitter power supply)
Digital Input 4 (+) 27 9 Digital Input Common (–)
19 4 1 (–) Relay 3 (NO/NC) 28 10 Digital Input 1 (+)
20 5 2 (+) Relay 3 Common (C) 29 11 Digital Input 2 (+)
100Ω
IP3 IP2 IP1 Relay 4 (NO/NC) 30 12 Relay 2 (NO/NC)
Relay 4 Common (C) 31 13 Relay 2 Common (C)
3-Lead RTD Thermocouple. 32
Millivolts and Volts RS485 TX (+) 14 Relay 1 (NO/NC)
Red 33
19 1
Red
RS485 TX (–) 15 Relay Common (C)
20 2 19 4 1
RS485 TX/RX (+) 34 16 1A Live (+)
21 3 20 5 2 85 to +Vs (+) 24V
21 RS485 TX/RX (–) 35 17 Neutral (–) 265V OV (–)
IP3 IP1
3
d.c.
White IP3 IP2* IP1 RS485 Common (C) 36 18 Ground a.c. Ground
*THC only if IP1 is THC
2-Lead RTD
and Resistance
MODBUS Connections
19 1
Red Tx +
32
20 2
– 33
21 3
RS485 Tx/ Rx + 34
– 35
IP3 IP1 White
Common 36

Overall Dimensions
Dimension in mm (in.) 137.5 (5.41) 18 76 (2.99) 68+0.7
–0
(0.71) (2.68+0.03
–0 )

Panel 138+1
–0
137.8 148 cut-out +0.04)
(5.43) (5.43–0
(5.83)
14 (0.55)

149.5 (5.87) 5.0 30 (1.18)

(0.2)

7
Ordering Guide
COMMANDER 501 Process Controller C501 / X X X X / X X X X
Option Board None 0 0
2 x Digital Input 0 1
2 x Relay
1 x Analog Input 0 2*
1 x Analog Output
2 x Digital Inputs
2 x Relay
RS485 MODBUS 0 3
1 x Analog Input 0 4*
1 x Analog Output
2 x Digital Inputs
2 x Relays
RS485 MODBUS
Power Supply 85V to 265V a.c. 0
24V d.c. 1
Build Standard 0
CSA approval (pending) 1
UL approval (pending) 2
Programming/Special Features Configured to factory standard S T D
Configured to customer detail C U S
Agreed special features S P X X

* If configuring a COMMANDER 501 for motorized valve control with feedback, or dual analog output on heat/cool, either option
02 or 04 must be fitted.

Instrument Coding Example C501 / 0 3 1 0 / STD

COMMANDER 501 Process Controller

MODBUS / RS485 Communications option
24V d.c. power supply
Standard build
Configured to factory standard

Licensing, Trademarks and Copyrights

MS Windows is a registered trademark of Microsoft Corporation

MODBUS is a registered trademark of Modicon Inc. Issue 3

The Company’s policy is one of continuous product

SS/C501

improvement and the right is reserved to modify the

information contained herein without notice.
© ABB 2000 Printed in UK (02.00 )

ABB Instrumentation Ltd ABB Automation Inc ABB Instrumentation

Howard Road Instrumentation Division 22016 Lenno
St. Neots, Cambs. 125 E. County Line Road Como
England, PE19 3EU Warminster, PA 18974 USA Italy
Tel: +44 (0)1480-475-321 Tel: +1 215-674-6000 Tel: +39 (0)344-58111
Fax: +44 (0)1480-217-948 Fax: +1 215-674-7183 Fax: +39 (0)344-58278