ABB RMC-100 User guide

A scalable controller supporting control and
measurement applications from simple to
large oil and gas production and
transmission sites
Introduction
The startup guide is designed for typical installations only. Installations must be performed
by personnel knowledgeable of the Remote Modular Controller 100, local and national
codes, communication wiring, and electrical wiring. Many sites have unique system
installation requirements. In these cases it is important to reference site-specific
documentation.
In this startup guide, the Remote Modular Controller 100 will be referred to as the RMC or
the controller, unless otherwise indicated.
WARNING – Bodily injury/ equipment damage. Although there may
be alternate methods of installation and commissioning of the RMC, it
is recommended that technicians perform the procedures in the
presented order: plan, install, wire before applying power, apply power,
verify power-on sequence, and configure.
WARNING – Bodily injury. The RMC-100 startup guide does not
address any requirements for the installation of product(s) in hazardous
(classified) locations. Refer to the installation instructions and local and
national electrical codes for installation requirements in hazardous
(classified) locations.
Startup guide
Remote Modular Controller
RMC-100

2| 2105551-001 rev. AC
Read and consider the contents of this startup guide prior to beginning installation of
the equipment. For any questions that are not answered in this guide or in the
documentation listed in the Additional information section, call the ABB main office
number listed on the back page of this guide.
Cyber security
This product is designed to be connected, and communicate information and data,
via a network interface, which should be connected to a secure network. It is the
customer's sole responsibility to provide and continuously ensure a secure
connection between the product and the customer network or any other network (as
the case may be). The customer shall establish and maintain appropriate measures
(such as, but not limited to, the installation of firewalls, application of authentication
measures, encryption of data, installation of antivirus programs, etc.) to protect this
product, the network, its system and interfaces against any kind of security
breaches, unauthorized access, interference, intrusion, leakage and/or theft of data
or information. ABB Inc. and its affiliates are not liable for damages and/or losses
related to such security breaches, any unauthorized access, interference, intrusion,
leakage and/or theft of data or information.
Although ABB provides functionality testing on the products and updates that it
releases, the customer should institute its own testing program for any product
updates or other major system updates (to include, but not limited to, code changes,
configuration file changes, third party software updates or patches, hardware change
out, etc.) to ensure that the security measures that the customer has implemented
have not been compromised and that system functionality in the customer's
environment is as expected
Additional information
Additional free publications, user drawings, and software for the Remote Modular
Controller 100 are available for download at www.abb.com/totalflow. The following is
a short list of related documents and drawings for quick reference.
Document name Number
RMC-100 user manual 2105552
RMC -100 data sheet 2101126
TFIO module user manual 2101226
RMC-100 AI to ABB 2600 T pressure transmitter 2105593
RMC-100 COMM (RS485) to ABB XMV(267/269CS/266J) W/RTD 2105579
RMC-100 to ABB FCB Coriolis meter 2105592
Assumptions
— The software PCCU32 version 7.55 or newer is installed and operational on the
PC used to communicate with the RMC equipment for configurations. Previous
versions of PCCU32 are not compatible.
— Installation and maintenance will only be conducted by personnel authorized to
work on electrical installations.
— Installation and maintenance will be conducted in accordance with relevant
national and local codes.

2105551-001 rev. AC | 3
1 Health and safety
1.1 Safety warning and note conventions
DANGER – Serious damage to health / risk to life. This symbol, in
conjunction with the signal word "DANGER", indicates an imminent
electrical hazard. Failure to observe this safety information will result in
death or severe injury. The text may state the hazard, what to do or not
do to avoid the hazard, and what the result would be if not followed.
DANGER – Serious damage to health / risk to life. This symbol, in
conjunction with the signal word "DANGER", indicates an imminent
danger. Failure to observe this safety information will result in death or
severe injury. The text may state the hazard, how to avoid the hazard,
and what the result would be if not followed.
WARNING – Bodily injury / property damage / equipment damage.
This symbol, in conjunction with the signal word "WARNING", indicates
a potentially dangerous situation. Failure to observe this safety
information may result in severe injury. The text may state the hazard,
how to avoid the hazard, and what the result would be if not followed.
CAUTION – Property damage / minor injury. This symbol, in
conjunction with the signal word "CAUTION", indicates a potentially
dangerous situation. Failure to observe this safety information may
result in minor or moderate injury. The symbol may also be used for
property damage warnings. The text may state the hazard, how to
avoid the hazard, and what the result would be if not followed.
NOTICE – Property damage / data loss. This symbol indicates a
potential situation where data could be corrupted, gas samples could
be contaminated, or normal operation could be effected if
recommendations are not followed. The text may state the condition,
how to avoid undesirable results, and what the results would be if not
followed.
IMPORTANT NOTE: This symbol indicates useful information,
important information, or information to clarify a concept. The signal
words "IMPORTANT NOTE" do not indicate a dangerous or harmful
situation.
1.2 Potential safety hazards
The Remote Modular Controller operates on 9 to 30 Vdc. There are no hazardous
voltages present in the controller. There are no chemical or burn hazards.
WARNING – Bodily injury. Read and follow instructions contained in
this guide before and during equipment installation. Failure to do so
could result in bodily injury or equipment damage.

4| 2105551-001 rev. AC
WARNING – Equipment damage. Potential electrostatic charging
hazard: clean only with damp cloth
2 Site planning and requirements
Installing the RMC requires that customer-supplied enclosures, power sources,
wiring, and location comply with the specifications described in this section.
WARNING – Bodily injury. Carefully review the specifications listed in
this section to select compliant equipment.
Failure to comply with these specifications may create unsafe
conditions, resulting in bodily injury and equipment damage.
2.1 Enclosure requirements
The RMC must be installed in an enclosure complying with the following
specifications:
— Enclosure must protect the RMC-100 against shock and impact.
— For Class I, Division 2, or other outdoor installations, the RMC-100 shall be
installed in an enclosure rated at least Type 3R, according to the environment.
— For Class I, Zone 2 installations, the RMC-100 shall be installed inside an
enclosure tested for IP54 in accordance with IEC 60529 and IEC 60079-15.
2.2 Battery and charger requirements
When powering the controller with a battery (battery mode), comply with the
following specifications:
— Battery specifications:
–Nominal 12 Vdc Sealed Lead Acid
–RMC rating for ambient temperature with battery is Ta = -40 °C to +60 °C
(-40 °F to 140 °F)
— Battery charger specifications:
–Solar panel must be nominal 12 Vdc, 30W or less, or
–NEC Class 2 power source: 14.5 Vdc to 15.5 Vdc, 1.65 A
WARNING – Bodily injury. Do not separate when energized, this
applies to all connectors and connections.
Make sure there is no hazardous atmosphere present when performing
maintenance on the unit.
Field wiring cables and wires can be energized from optional power
sources other than the RMC. Disconnecting energized cabling or wiring
would cause a spark that would ignite a hazardous atmosphere if
present.

2105551-001 rev. AC | 5
2.3 External power supply requirements
When powering the controller with external power (EXT PWR mode), comply with
the following specifications:
— Power supply must be rated as a NEC Class 2 power source. EXT PWR mode
operation is +9 Vdc to 30 Vdc, 5A maximum.
–RMC rating for ambient temperature without battery is Ta = -40 °C to +70
°C (-40 °F to 158 °F).
WARNING – Equipment damage. A battery can not be used when the
controller is in the EXT PWR mode.
2.4 Location specifications and design
Decide on the location to install the controller. The RMC mounts on a DIN rail. Mount
the DIN rail in an enclosure or on an interior wall that meets the environmental
ratings for the location (see details in section 2.1, Enclosure requirements).
The RMC mounting surface must have sufficient strength to support the hanging
weight of the controller (maximum of 1.816 pounds) and associated equipment to
meet the requirements of IEC715. The installation location should allow sufficient
access to the RMC, power sources, cables, and connections.
If a solar panel is used, decide where and how to install the solar panel outdoors. For
optimum charging, avoid placing the solar panel where it will be in shadows any part
of the day.
2.5 Wiring requirements
All wiring connections and screw terminals for power, input ports, output ports, and
communications support 12 AWG to 22 AWG. Wire gauge selection should be based
on the voltage and current requirements of the circuitry as well as the expected
length of the wires. The gauge differs for each application.
Follow local electrical codes when selecting the appropriate wire gauge and type
based on the load current, voltage, signal type, wire length, and indoor or outdoor
application.
WARNING – Equipment damage. Field installation cable and
conductors must be rated greater than 70 °C when installed in an
ambient temperature greater than 60 °C.
3 Unpacking and inspecting
IMPORTANT NOTE: If there is any damage to the shipping carton,
keep it and the packing materials until the contents are inspected and
found to be free of damage.
To unpack the RMC and inspect for damaged, missing or incorrect parts:
1. Inspect the shipping carton for damage.
2. Carefully remove items from the carton.
3. Keep all shipping materials to return any parts.

6| 2105551-001 rev. AC
4. Compare the packing list with the materials received. Check for missing or
incorrect parts.
5. Inspect the items for damage:
- RMC exterior
- LCD display
- Optional equipment if purchased
6. For any missing, incorrect, and damaged parts or noticeable defects, call the
ABB main office number listed on the back page of this guide.
4 Basic hardware installation
This is an overview of basic hardware installation. For different installations, refer to
the user manual or call the ABB main office number listed on the back page of this
guide.
WARNING – Equipment damage. It is recommended that technicians
perform all of the procedures in the order presented in this section
before powering the RMC.
DANGER – Damage to health / risk to life / property damage.
Allowing the RMC components to make contact with a non-insulated
tool or without a proper grounding device could create a static electric
discharge resulting in bodily injury and damage to the electronic
components. Use properly insulated tools and wear a grounding strap
to eliminate static electricity when connecting or disconnecting wires.
4.1 Grounding the controller
The RMC must be grounded by mounting on a grounded DIN rail.
To ground the DIN rail:
1. Screw the DIN rail onto the mounting surface.
2. Attach a grounding wire to the DIN rail.
3. Attach the other end of the grounding wire to an electrical ground.
WARNING – Equipment damage. The DIN rail on which the controller
is mounted must be bonded to an earthing terminal. The bonding
conductor must have a cross sectional area of at least 12 AWG or 4
mm2.

2105551-001 rev. AC | 7
4.2 Mounting the RMC
To mount the controller on the DIN rail:
1. Position the RMC on the DIN rail.
2. Push the RMC onto the DIN rail until it snaps into place (Figure 1).
Figure 1: Mounting the RMC
IMPORTANT NOTE. To remove the controller, use a slotted
screwdriver inserted in the access slot of the DIN rail release clip to
loosen the clip. For more information, refer to the Maintenance and
Service section in the RMC User Manual.
4.3 Wiring COMM ports
Wire the RMC COMM ports to communicate with and power external devices. Wiring
for communication depends on the type of serial interface required by the device.
Wiring for power is required if there is no external supply powering the device.
Table 1 provides the specifications for the serial communication ports.
Table 1: Serial communication specifications
Type Maximum Length Termination
RS-232 50 feet (15 meters) Terminal connector (9 POS), screw termination
and pluggable COMM module
Active when communication module is inserted
RS-485 or
RS-422 4000 feet (1220 meters)
COMMEXPANSION
USBTYPE B
1

8| 2105551-001 rev. AC
Table 2 identifies RS-232, RS-422, and RS-485 communication pinouts for COMM 1
and COMM 2.
Table 2: COMM 1 and COMM 2 serial communication pinouts
PIN RS-232 RS-422 RS-485
1 Voltage Out (VOUT) Voltage Out (VOUT) Voltage Out (VOUT)
2 Ground (GND) Ground (GND) Ground (GND)
3 Switched voltage
(Sw VOUT)
Switched voltage
(Sw VOUT)
Switched voltage
(Sw VOUT)
4 Operate (OPER) Operate (OPER) Operate (OPER)
5 Remote request to send
(RRTS)
Remote request to send
(RRTS)
Remote request to send
(RRTS)
6 Request to send (RTS) Transmit bus+ (TBUS+) Transmit/Receive (BUS+)
7 Transmit data (TX) Transmit bus- (TBUS-) Transmit/Receive (BUS-)
8 Receive data (RX) Receive bus+ (RBUS+) Not Used
9 Clear to send (CTS) Receive bus- (RBUS-) Not Used
To wire the serial communication port:
IMPORTANT NOTE: Refer to the RMC user drawings for COMM wiring
details for specific external devices. See the Additional information
section.
CAUTION – Equipment damage. An external device can be powered
from pin 1 (VOUT) or pin 3 (Sw VOUT) on both COMM1 and COMM2.
The output voltage at these pins is dependent upon the external power
supply connected to the CHARGER/EXT PWR port.
Before connecting to these pins, ensure that the device is compatible
with the input voltage at the CHARGER/EXT PWR port. Connecting an
incompatible device may result in damage to the device.
1. Use a slotted screwdriver to pry the terminal connector off the electronic board.
2. Trim the wire covering back ¼ inch on each wire.
3. Loosen the terminal connector screws for the correct pin according to Table 2.
4. Insert the wires in the required pins. If powering the device from the COMM port:
a. Use pin 1 (VOUT) and pin 2 (GND) to provide constant voltage.
b. Use pin 3 (Sw VOUT) and pin 2 (GND) to provide switched voltage.
5. Tighten the terminal connector screws.
CAUTION – Equipment damage. Do not overtighten the terminal
connector screws as this may damage the wire.
6. Insert the terminal connector back onto the COMM port if it was removed.

2105551-001 rev. AC | 9
7. Insert the communication module in the appropriate slot (Figure 2). The
communication module pushes the port cover downward when inserted.
COMM 1 COMM 2
RMCIO
EXPA NSI ON
COMM 2COMM 1
BAT CHARGER/EXT PWR PI
123456789 123456789
Figure 2: COMM terminals and modules
4.4 Wiring I/O ports
Wire the RMC I/O ports to monitor, control and power external devices. Wiring for
power is required if there is no external supply powering the device.
To wire the I/O port:
IMPORTANT NOTE: Refer to the RMC user drawings for I/O wiring
details for specific external devices. See the Additional information
section.
CAUTION – Equipment damage. An external device can be powered
from pin 1 (PWR) on any of the AIs (Table 3) or the AO (Table 4). The
output voltage at the PWR pin is dependent upon the external power
supply connected to the CHARGER/EXT PWR port.
Before connecting to these pins, ensure that the external device is
compatible with the input voltage at the CHARGER/EXT PWR port.
Connecting an incompatible device may result in damage to the device.
1. Use a slotted screwdriver to pry the terminal connector off the electronic board.
2. Trim the wire covering back ¼ inch on each wire.
3. Loosen the terminal connector screws for the correct pin according to the I/O
tables. See sub-sections 4.4.1, 4.4.2, 4.4.3, and 4.4.4 in this guide.
4. Insert the wires in the required pins. If powering the device from the AI or the
AO:
a. Use pin 1 (PWR) and pin 3 (GND) for devices attached to the AI.
b. Use pin 1 (PWR) and pin 4 (GND) for devices attached to the AO.
5. Tighten the terminal connector screws.
NOTICE – Property damage. Do not overtighten the terminal
connector screws as this may damage the wire.
6. Insert the terminal connector back on the I/O port if it was removed.

10 | 2105551-001 rev. AC
4.4.1 Analog input pinouts
Table 3 and Figure 3 identify the AI pinouts.
CAUTION – Equipment damage. Before connecting to pin 1 (PWR),
ensure that the external device is compatible with the input voltage at
the CHARGER/EXT PWR port. Connecting an incompatible device
may result in damage to the device.
Table 3: Analog input pinouts
Input Pin Description Input Pin Description
1
1 PWR - Power
3
1 PWR - Power
2 AI - Input signal 2 AI - Input signal
3 GND - Input ground 3 GND - Input ground
2
1 PWR - Power
4
1 PWR - Power
2 AI - Input signal 2 AI - Input signal
3 GND - Input ground 3 GND - Input ground
AI
1234
123123123123
Figure 3: Analog input pinouts
4.4.2 Analog output pinouts
Table 4 and Figure 4 identify the AO pinouts.
CAUTION – Equipment damage. Before connecting to pin 1 (PWR),
make sure that the external device is compatible with the input voltage
at the CHARGER/EXT PWR port. Connecting an incompatible device
may result in damage to the device.
Table 4: Analog output pinouts
Output PIN Description
1
1 PWR - Loop power input
2 SNK - Current sink input
3 SRC - Current source output
4 GND - Ground
AO
1
1234
Figure 4: Analog output pinouts