ABB C320 User manual

Booster Pump Controller
C320
User Guide
IM/C320_6

ABB
EN ISO 9001:2000
Cert. No. Q5907
The Company
We are an established world force in the design and manufacture of
instrumentation for industrial process control, flow measurement, gas and
liquid analysis and environmental applications.
As a part of ABB, a world leader in process automation technology, we offer
customers application expertise, service and support worldwide.
We are committed to teamwork, high quality manufacturing, advanced
technology and unrivalled service and support.
The quality, accuracy and performance of the Company’s products result
from over 100 years experience, combined with a continuous program of
innovative design and development to incorporate the latest technology.
The UKAS Calibration Laboratory No. 0255 is just one of the ten flow
calibration plants operated by the Company, and is indicative of our
dedication to quality and accuracy.
EN 29001 (ISO 9001)
Lenno, Italy – Cert. No. 9/90A
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Health and Safety
To ensure that our products are safe and without risk to health, the following points must be noted:
1. The relevant sections of these instructions must be read carefully before proceeding.
2. Warning labels on containers and packages must be observed.
3. Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and
in accordance with the information given.
4. Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in
conditions of high pressure and/or temperature.
5. Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry.
Normal safe handling procedures must be used.
6. When disposing of chemicals ensure that no two chemicals are mixed.
Safety advice concerning the use of the equipment described in this manual or any relevant hazard data sheets
(where applicable) may be obtained from the Company address on the back cover, together with servicing and
spares information.
Electrical Safety
This equipment complies with the requirements of CEI/IEC 61010-1:2001-2 'Safety Requirements for Electrical
Equipment for Measurement, Control and Laboratory Use'. If the equipment is used in a manner NOT specified by
the Company, the protection provided by the equipment may be impaired.
Symbols
One or more of the following symbols may appear on the equipment labelling:
Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use
of this manual for any other purpose is specifically prohibited and its contents are not to be reproduced in full or part
without prior approval of the Technical Communications Department.
Warning – Refer to the manual for instructions
Caution – Risk of electric shock
Protective earth (ground) terminal
Earth (ground) terminal
Direct current supply only
Alternating current supply only
Both direct and alternating current supply
The equipment is protected
through double insulation

1
The COMMANDER 320 Booster Pump Controller acts as a differential pressure switch for use
in the regeneration section of a pasteurizer. If the difference between pasteurized milk
pressure and raw milk pressure falls below a preset level, the controller shuts down the raw
milk booster pump or alternatively, channels the pasteurized milk into the divert flow.
The COMMANDER 320 has the following features:
• Two 4 to 20mA analog inputs.
• A transmitter power supply capable of powering the raw and pasteurized 2-wire
pressure transmitters.
• A digital display of the raw and pasteurized product pressures.
• A bargraph display of the difference between the raw and pasteurized pressures.
• A deviation alarm to detect when the difference between the raw and pasteurized
pressures falls below a preset minimum.
• A start-up alarm which allows the booster pump to remain off until the normal system
operating back pressure is achieved.
• A manual override facility which allows the booster pump to be turned off using a digital input.
• Selectable pressure differential retransmission output.
• Three relay outputs: two for booster pump or divert valve control, one to operate a
warning light or horn.
This manual is divided into 4 sections and contains all the information necessary to install,
configure and operate the instrument.
GETTING STARTED
Symbol Identification and Contents of Sections
Displays and Function Keys
• Displays and function keys
• LED Indication
• Error Messages
Operating Level
• Operating Page
• Operating Page Messages
• Alarm Acknowledge Page
• Security Access
Configuration Level
• Set Up Alarms
• Set Up Inputs
• Set Up Display
• Scale Adjustment
• Security Code Set Up
• Commissioning
Installation
• Siting
• Mounting
• Electrical connections

2
Section Page
CONTENTS
1 DISPLAYS AND CONTROLS ............................................................................. 3
1.1 Introduction .................................................................................................................3
1.2 Use of Controls ...........................................................................................................3
1.3 Displays and LED Indicators ....................................................................................... 4
1.3.1 LED Indications, Relay and Alarm States ........................................................ 4
1.3.2 Deviation Bargraph .......................................................................................... 5
1.4 Instrument Power-up ................................................................................................... 5
2 OPERATING LEVEL........................................................................................... 6
2.1 Operating Page ........................................................................................................... 6
2.2 Operating Page Messages .........................................................................................6
2.3 Alarm Acknowledge Page ...........................................................................................6
2.4 Security Access ..........................................................................................................7
2.4.1 Security Code Page .........................................................................................8
3 CONFIGURATION LEVEL.................................................................................. 9
3.1 Preparation for Changes to the Parameters ...............................................................9
3.2 Set Up Alarms Page .................................................................................................10
3.3 Set Up Inputs ............................................................................................................12
3.4 Set Up Display Page .................................................................................................14
3.5 Retransmission Output Page ....................................................................................15
3.6 Scale Adjustment Page .............................................................................................16
3.7 Access Page .............................................................................................................18
3.8 Commissioning .........................................................................................................19
4 INSTALLATION ................................................................................................ 20
4.1 Checking the Code Number ......................................................................................20
4.2 Siting .........................................................................................................................21
4.3 Mounting ...................................................................................................................22
4.4 Access to Terminals .................................................................................................. 23
4.5 Setting the Input Selector Links ................................................................................24
4.6 Setting the Isolated Output Link ................................................................................24
4.7 Cable Glands and Conduit Fixings ...........................................................................25
4.7.1 Cable Glands (IEC – 20mm) ..........................................................................25
4.7.2 Conduit Adaptors (N. American – 0.5in) ........................................................25
4.7.3 Cable Glands (N. American – 0.5in) ..............................................................26
4.8 Connections Summary .............................................................................................. 27
4.9 Input Connections ..................................................................................................... 29
4.9.1 Current Input .................................................................................................. 29
4.9.2 2-wire Transmitter .......................................................................................... 29
4.10 Output Connections ................................................................................................29
4.11 Logic Input Connection ...........................................................................................29
4.12 Relay Connections .................................................................................................. 30
4.13 Power Supply Selection and AC Connections ........................................................ 31
SPECIFICATION .................................................................................................... 32

3
1.1 Introduction – Fig. 1.1
The Commander 320 front panel display, function keys and LED indicators are shown in
Fig. 1.1
Note. Continued pressure on the
and switches causes the
rate of change of the displayed
value to increase. To make small
adjustments operate the switches
momentarily.
Frame 1
Frame 2
Frame 3
Frame 4
Page 1
Frame 1
Frame 2
Frame 3
Page 2
Frame 1
Frame 2
Frame 3
Page X
Frame 4
Advance to
next Frame
Adjust
Parameter Value
Parameter X
Y
Z
Select
Used to acknowledge alarm A1 and de-energise relay 3
Fig. 1.2 Advancing to Next Page
Fig. 1.3 Moving between Frames
Fig. 1.4 Adjusting a Parameter Value
Fig. 1.5 Selecting a Parameter Choice
Fig. 1.6 Alarm Acknowledge Switch
1.2 Use of Controls – Figs. 1.2 to 1.6
1 DISPLAYS AND CONTROLS
Fig. 1.1 Front Panel Display, Function Keys and LED Indicators
'Enter' Switch LED
Deviation Bar
Graph Display
LED Indicators
Controls – Refer to
Figs. 1.2 to 1.6
Displays
RAW
PAS
A1 A2 BP2BP1
'Data Entry' Switch
(use to enter settings
and values in frames)

4
1.3 Displays and LED Indicators
The displays, LED indicators and operation/programming controls are located on the faceplate
on the front of the instrument. The displays comprise 2 rows of 6 characters.
…1 DISPLAYS AND CONTROLS
Table 1.2 LED Indications and Alarm States
Display ConditionAlarm/Relay State
A1 Active and ackd.
A1 Active and unackd.
A1 Inactive
A2 Active
A2 Inactive
Relay 1 De-energised
Relay 1 Energised
Relay 2 De-energised
Relay 2 Energised
Relay 3 Energised
Relay 3 De-energised
Pasteurized I/P pressure:
< Raw I/P pressure + divert trip level
Pasteurized I/P pressure:
≥Raw I/P pressure + divert trip level
Displayed on power up.
Active until Pasteurized I/P pressure
≥Start up trip level then remains inactive until
power is switched off and on.
Either A1 or A2 active
A1 and A2 inactive
A1 active
A1 inactive.
A1 active and unacknowledged.
A1 acknowledged.
On
Flashing
Off
On
Off
Off
On
Off
On
On
Off
LED
A1
A2
BP1
BP2
1.3.1 LED Indications, Relay and Alarm States
LED indications, relay and alarm states are shown in Table 1.2. For electrical connections –
see section 4.12.
A
b
C or c
d
E
F
G
H or h
I
J
K
L
M
N or n
O or o
P
Q
r
S
t
U
V
Y
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
Y
Table 1.1 Character Set

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1 DISPLAYS AND CONTROLS…
1.3.2 Deviation Bargraph – Fig. 1.7
The deviation bargraph displays:
a) The difference between the raw pressure and pasteurized pressure inputs.
b) The deviation alarm trip value
1.4 Instrument Power-up – Fig. 1.8
Caution. Ensure all connections, including the earth stud, are made correctly.
a) Check that the input sensors are installed correctly.
b) Switch on the supply to the instrument, any power-operated control circuits and the input
signals.
c) The start-up sequence shown in Fig. 1.8 is displayed when the supply is first switched on.
Fig. 1.7 Deviation Bargraph
Deviation alarm trip value
Difference between raw and pasteurized input
pressures is less than the alarm trip value
Difference between raw and pasteurized input
pressures is greater than the alarm trip value
Note. Acknowledging error clears the error but does not rectify the fault, check the
configuration.
Instrument Test identifies the instrument type, C320 – see Table 4.1
Flashing
between
Normal Display
C320
tESt
A1 BP2A2 BP1
RAW
PAS
A1 A2
100.3
200.5
BP2BP1
RAW
PAS
A1 A2
CONFIG
CHECK
BP2BP1
RAW
PAS
Configuration Check
indicates configuration error,
acknowledged by pressing
the switch.
Fig. 1.8 Instrument Displays at Power-up

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Operating Page
Pressure of raw product.
Pressure of pasteurized product.
If the difference between the two values falls below the
required level, i.e. Alarm 1 becomes Active, both values flash
ON and OFF.
2 OPERATING LEVEL
2.1 Operating Page
Information. The instrument has a dedicated Operating page. This page is used for general
monitoring of the process measurements and is not affected by the security system which
inhibits access to the alarm set up and programming pages – see section 3
5.00
10.00
2.2 Operating Page Messages
Table 2.1 Input Error Messages Displayed in the Operating Page
Reason
Failed Input – raw pressure input failure.
Failed Input – pasturized pressure input failure.
Message
F-INPt
F-INPt
Page Header – Acknowledge Alarms
Upper Display
Shows the alarm identity and type when an alarm condition is
present.
dEV-AL – deviation alarm A1
SU-AL – start up alarm A2
Lower Display
Shows the trip level of the alarm identified in the upper display.
When the alarm is acknowledged ( pressed ), ACKNGd is
displayed.
Note. If alarm A2 is active, SU-ALis displayed, but the alarm
cannot be acknowledged.
Return to top of page.
2.3 Alarm Acknowledge Page
ACKNLG
ALArMS
dEV-AL
100.5
ACKNGd
dEV-AL

7
2 OPERATING LEVEL…
2.4 Security Access – Figs 2.1 and 2.2
A security system is used to prevent tampering with the program parameters by utilizing a
security input together with an Alarm password and a Configuration password – see Figs. 2.1
and 2.2. Two levels of security are provided:
a) Security input secure – Alarm and configuration settings cannot be accessed.
The security input may be protected by a tamper-proof seal – see Fig.2.3
b) Security input insecure – Alarm and configuration settings can be accessed by use of
the correct password.
Operating
Page
(Section 2.1)
Alarm Acknowledge
Page
(Section 2.3)
Security Code
Page
(Section 2.4)
Security Link
INSECURE +
configuration
security code
Security Link SECURE
Set Up Alarms
Page
(Section 3.2)
Configuration Level –
see Section 3
SEtUP
ALArMS
SECOdE
PAGE
100.3
110.5
ACKNLG
ALArMS
Security Link
INSECURE +
alarm or
configuration
security code
Fig. 2.1 Security Access
Fig. 2.2 Security Settings
No security override on
terminals 31 and 32
323130
Secure
Security override on
terminals 31 and 32
323130
Insecure
Fig. 2.3 Tamper-proof Seal

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2.4.1 Security Code Page
Page Header – Security Code Page
Set the correct Alarm or Configuration password using the
and switches and press the switch to enter the
code.
The passwords are programmed in the Access Page – see
Section 3.7.
Software version
The Upper display indicates the EPROM series.
The lower display indicates the version number.
Return to top of page
.
…2 OPERATING LEVEL
SECOdE
VEr 2
2001
0