A single process loop—temperature on a heating bath, pressure on a pump skid, level in a tank—often does not need a full DCS or a PLC-based strategy. A compact 1/8 DIN controller with a universal input and PID tuning handles the job with less wiring and simpler commissioning. The ABB Commander C100 is that kind of instrument: a single-loop, 1/8 DIN universal process controller launched in 1995 and widely used on heating, cooling, pressure, flow, and level loops. This guide covers the verified input/output specifications, control modes and auto-tune, communications options, and its mature lifecycle status, so engineers and maintenance teams can specify, commission, or replace C100 units with confidence. SHLY-PLC supplies ABB process instruments as an independent industrial-automation distributor; every unit is inspected and tested before dispatch.
What Is the Commander C100?
The Commander C100 is a single-loop PID controller housed in a 1/8 DIN case (48 mm wide by 96 mm high). It accepts a universal process input so it can read thermocouples, RTDs, millivolts, current, or voltage signals without changing hardware, and it provides a 4…20 mA analog output, a logic (SSR-drive) output, and an SPDT relay as standard. Additional relays, a remote set-point input, a digital input, and an RS-485 Modbus link are available as option boards.
ABB introduced the C100 in 1995. In September 2010 it was superseded by the ControlMaster CM10, which carries the same 1/8 DIN form factor and adds Ethernet/Modbus and a wider feature set. Installed C100s remain common in older packaging, food-and-beverage, HVAC, and light-process panels, so spare-parts and replacement advice is still in demand.
Key Specifications
| Parameter | Specification |
|---|---|
| Form factor | 1/8 DIN, 48 W x 96 H x 125 mm deep |
| Weight | Approx. 250 g |
| Display | 2 x 4-digit high-intensity 7-segment LED, 10 mm digit height, range -999 to +9999 |
| Control type | P, PI, PID single loop; manual, on/off, time-proportioning, current-proportioning, heat/cool |
| Auto-tune | One-shot auto-tune as standard |
| Universal input | One as standard: thermocouple (B,E,J,K,N,R,S,T), RTD Pt100, millivolts, current, DC voltage |
| Input sampling | 250 ms per channel |
| Transmitter supply | 24 V DC, 30 mA max., powers one 2-wire transmitter |
| Control output 1 (analog) | 4…20 mA into max. 750 ohm, accuracy ≤0.25 % of span |
| Control output 2 (logic) | 18 V DC at 20 mA, min. load 400 ohm, for driving solid-state relays |
| Control output 3 (relay) | SPDT relay, 5 A @ 115/230 V AC, as standard |
| Alarms | Two user-defined alarms: high/low process, high/low deviation |
| Ramp/soak | Single program, 4-segment profile, with repeat, skip, and self-seeking set point |
| Power supply | 85…265 V AC 50/60 Hz, or 24 V DC variant; <6 VA |
| Operating temperature | 0…55 °C, 5…95 % RH non-condensing |
| Front protection | IP65 (NEMA 3) on the front, IP20 on the case rear |
| Optional communications | RS-422/485 Modbus RTU slave, 2-wire or 4-wire, 2.4k or 9.6k baud |
| Lifecycle status | Legacy; superseded by ControlMaster CM10 since September 2010 |
Inputs, Outputs, and Wiring
The universal front input accepts the most common process signals without hardware links: thermocouples, Pt100 RTDs, millivolts, current, and DC voltage are configured from the front panel by entering a quick code or by using ABB's Windows PC configurator. Cold-junction compensation for thermocouples is automatic. The same loop can power a two-wire transmitter from the 24 V, 30 mA supply. The optional second input is a 4…20 mA remote set-point input (100 ohm) used for cascade or master/slave arrangements.
Three control outputs are fitted as standard, which is unusual for a 1/8 DIN instrument:
- 4…20 mA analog output for driving a control valve, an I/P converter, or a VFD reference.
- 18 V logic output, designed to trigger external solid-state relays for heater or load switching.
- SPDT relay, 5 A @ 115/230 V AC, for direct on/off or time-proportioning switching of small loads, or as the alarm/control relay.
An option board adds further relay(s), a volt-free digital input, the remote set-point input, and/or RS-485 Modbus. Heat/cool control is achieved by combining the analog, logic, and relay outputs so one heater and one cooler can be driven from the same instrument.
Control Modes and Tuning
The C100 supports manual, on/off, time-proportioning, and current-proportioning control, as well as heat/cool strategies. A one-shot auto-tune routine measures the loop and suggests PID terms; engineers can then fine-tune P, I, and D from the front keys or the PC configurator. The ramp/soak function provides a single four-segment program with guaranteed ramp/soak, program repeat, skip, and reset, which is useful for batch heat-treatment or drying cycles. Set points can be local (four fixed values), remote (from the 4…20 mA input), or ramped. Two user-defined alarms cover high/low process and high/low deviation, and can drive the onboard relay or an optional relay board.
Configuration and Communications
There are no DIP switches and no soldered links: configuration is entered from the front panel by moving a security switch and typing a quick code, or by connecting a PC running ABB's Windows configurator. With the Modbus option board fitted, the C100 acts as an RS-422/485 Modbus RTU slave at 2.4k or 9.6k baud, allowing a PLC or SCADA system to read the process variable, set point, and output and to write remote set points. Two or more C100s can be run in master/slave or cascade with the remote set-point option.
Typical Applications
- Temperature control of ovens, furnaces, environmental chambers, and heating baths
- Pressure and flow control on pump skids and compressed-air systems
- Tank level control in water treatment and dosing skids
- Packaging, food-and-beverage, and plastics machines needing a single-loop PID
- Retrofit replacement of ageing 1/8 DIN controllers on existing panels
For these duties the C100 remains a compact, well-understood loop controller. Related process instruments and control hardware can be browsed in our ABB range and the broader PLC collection.
Lifecycle and Spare Parts
The Commander C100 is a legacy product: ABB superseded it with the ControlMaster CM10 in September 2010. The CM10 keeps the 1/8 DIN footprint, offers the same universal-input concept, and adds Ethernet and modern communications, so a like-for-like panel upgrade is usually straightforward. For installed C100 loops that must stay in service, tested surplus and pre-owned units are the practical spare-parts route. SHLY-PLC stocks discontinued and legacy process instruments in our Discontinued Products range; if you have a failed C100 or need help matching an option code, send us the full order code and we will confirm availability and a compatible upgrade path.
Frequently Asked Questions
What inputs does the Commander C100 accept?
The standard universal input accepts thermocouples (B, E, J, K, N, R, S, T), Pt100 RTD, millivolts, current, and DC voltage, configured by front-panel code or PC. It also provides a 24 V, 30 mA supply for one two-wire transmitter.
What outputs are built into the C100?
Three outputs are standard: a 4…20 mA analog output (750 ohm max. load), an 18 V logic output for solid-state relays, and an SPDT 5 A relay. Option boards add extra relays, a remote set-point input, a digital input, and RS-485 Modbus.
Does the C100 have auto-tune?
Yes. A one-shot auto-tune routine measures the loop and proposes PID terms, which can then be fine-tuned from the front keys or the PC configurator. The instrument also supports manual, on/off, time-proportioning, and heat/cool control.
What replaced the ABB Commander C100?
ABB introduced the ControlMaster CM10 as the C100 successor in September 2010. It keeps the 1/8 DIN size and universal-input approach and adds Ethernet and wider communications; tested surplus C100 units remain available through independent distributors for legacy loops.