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

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 PWR - Power

2 AI - Input signal 2 AI - Input signal

3 GND - Input ground 3 GND - Input ground

1 PWR - Power

2 AI - Input signal 2 AI - Input signal

3 GND - Input ground 3 GND - Input ground

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 PWR - Loop power input

2 SNK - Current sink input

3 SRC - Current source output

4 GND - Ground

1234

Figure 4: Analog output pinouts

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