Home

5 4 5 1/4 DIN PROCESS CONTROLLER USER`S MANUAL

1. Screws must be tight to ensure electrical connection 2 Digital Inputs with an Open Collector Figure 3 9 Digital Input Wiring with an Open An open collector is also called a transistor Wire the transistor between Collector terminal 17 and the specified digital input terminal Figure 3 9 Screws must be tight to ensure electrical connection Remote Setpoint Option Use terminals 13 and 14 to connect the remote setpoint signal 19 13 TN Figure 3 10 14 Remote Setpoint Terminals 16 Chapter 3 545 User s Manual Installation OUTPUT MODULES The 545 output modules are used for control alarms and retransmission The four output module types are Mechanical Relay Solid State Relay Triac DC Logic SSR Drive and Analog Milliamp To install these modules plug them into any of the four output sockets on the printed circuit boards refer to Chapter 4 The wiring is the same whether the modules are used for control alarm or retransmission The diagrams on the next two pages are a guide for properly connecting the various outputs To find out which module s have been ins
2. Hook up wires to multimeter PV1 1 WARNING ELECTRIC SHOCK HAZARD Terminals 1 and 2 carry live power DO NOT touch these terminals when power is on A 8 CALIBRATION H JUMPERS SELECTV ANDTCA 4 PV INPUT JUMPER CONFIGURATION 00000000000 00000000000 PREPARATION for ALL INPUT CALIBRATIONS Equipment for analog input calibration e Precision 5 1 2 or 6 1 2 digit multimeter e g Fluke 8842 or HP3478A9 a 4 1 2 digit meter will sacrifice accuracy e Four small pieces of wire e Testleads with clips e 2 Phillips screwdriver Additional equipment for thermocouple input e Precision thermocouple calibrator e g Micromite lle by Thermo Elec tric Instruments e Special limits grade Type T thermocouple wire 1 Disconnect power to the instrument 2 Remove chassis from case 3 Onthe Microcontroller Circuit Board locate jumper locations marked PV1 and 2nd near the edge connector Reposition both jumper connectors in the 2nd location onto pins for V and TCs as shown in Figure A4 3 4 Connecthook up wires betweenterminals 31 and 32 as shownin Figure A4 4 andthe multimeter Setthe meter for DC volts 5 Reinsert chassis into the case and apply power The 2nd and 3rd display should read CALIBRATE ANALOG IN 6 Allow the controller to warm up for at least 30 minutes 7 Pressthe ACK key to getto the first step parameter The 2nd display s
3. ew Ca lov wv Ens e 545 User s Manual Chapter 5 47 Software Configuration Configuration SELF TUNE SELF TUNE Forconfiguring the selftune algorithm 1 TYPE TYPE Defines the type of self tuning algorithm thatis available DISABLED PRETUNE Allows the operator to initiate Pretune only e ADAPTIVE Allows the operator to initiate Adaptive Tune only BOTH Allowsthe operatorto initiate both Pretune and Adaptive Tune D DISABLED Both Pretune and Adaptive Tune are disabled 2 PRETUNE PRETUNE Defines the type of pretune algorithm that is available TYPE 1 D TYPE1 Normally used with slowerthermal processes e TYPE2 Normally used with faster fluid or pressure pro cesses TYPES Normally used with level control applications 3 TUNEPT TYPE Defines the PV value at which the output with switch off during a TYPE 1 retune which helps prevent overshoot AUTOMATIC Pe AUTOMATIC Controller defines this point XXX X Enter any value within PV RANGE 4 OUT STEP OUT STEP Defines the output step size in absolute percent during TYPE 2 or TYPE 3 50 0 to 50 0 D 10 0 5 LOW LIMIT LOW LIMIT Defines the lower limit the process variable can reach during pretune before D aborting R The process variable range D Dependenton the process variable range 6 HILIMIT HI LIMIT Defines the upper limit the process variable can reach during pretune before aborting D R The process variable range
4. CUST LINR Parameter Description Value Loop 1 Value Loop 2 1 1stINPUT Input signal for the 1st point of the 15 point curve 2 1stPV Engineering unit value for the 1st point 3 2nd INPUT Input signal for the 2nd point of the 15 point curve 4 2ndPV Engineering unit value for the 2nd point 5 XthINPUT Input signal for the Xth last point of the 15 point curve 6 XthPV Engineering unit value for the Xth last point 7 3rd INPUT Input signal for the 3rd point of the 15 point curve 8 3rdPV Engineering unit value for the 3rd point 9 4thINPUT Input signal for the 4th point of the 15 point curve 10 4th PV Engineering unit value for the 4th point 11 5th INPUT Input signal for the 5th point of the 15 point curve 12 5thPV Engineering unit value for the 5th point 13 6th INPUT Input signal for the 6th point of the 15 point curve 14 6th PV Engineering unit value for the 6th point 15 7th INPUT Input signal for the 7th point of the 15 point curve 16 7th PV Engineering unit value for the 7th point 17 8th INPUT Input signal for the 8th point of the 15 point curve 18 8th PV Engineering unit value for the 8th point 19 9th INPUT Input signal for the 9th point of the 15 point curve 20 9th PV Engineering unit value for the 9th point 21 10th INPUT Input signal for the 10th point of the 15 point curve 22 10th PV Engineering unit value for the 10th point 23 11th INPUT Input signal for the 11th point of the 15 point curve 24 11th PV Engineering un
5. J y manua serer 3 1 1 4 DIN PROCESS CONTROLLER USER S MANUAL il moore INDUSTRIES M545 V6 JANUARY 2005 Table of Contents of Contents Table of Contents About This Manual Throughout this User s Manual information appears along the PAGE margins in the form of NOTEs CHAPTER 1 CAUTIONs and WARNINGS usually INTRODUCTION ccccscsssssssscssssssssssssssssseeeeeseseseeseesessossasssnausseseeeeeee 1 boldface Please heed these 545 MOIES E 2 safety and good practice notices for Order Code Packaging Information 2 the protection of you and your Where a ei IRR a 2 equipment Text Formatting in This 2 CHAPTER 2 CONTROLLER OPERATION censes nennen nnne nnns 5 Bcc 5 IGOTIS ete 5 M I 6 Basic Operation Procedures sssssssseene 7 Alarm Operation oie eite roce E bosse ret ests neni 8 CHAPTER INSTALLATION AND WIRING eene 11 Mounting the Controller sos ic ertt err etie reo 11 afe T 12 AG Power M 12 Process Variable Input 13 Digital Inpult S 16 Remote Setpoint Opt
6. PV1 and PV2 Wiring for Milliamp Inputs with Internal and External Power Supply 15 Di de Digital Input Wiring with a Switch or Relay 16 Digital Input Wiring with an Open Collector 16 3 10 eres Remote Setpoint Terminals 16 Mechanical Relay Output 17 SSR Relay Output Wiring 17 319 neuen DC Logic Output Wiring eseeeeeeeenene 18 3 14 Milliamp Output WiN Oessaare 18 Position Proportioning Output Wiring 18 3 46 Serial Communications Terminals 19 AO rem Location of Printed Circuit Boards 21 4 2 asco The Microcontroller Circuit Board the Option Board and the Power Supply Board 22 dud Representation of Module 25 Install Communications Module 26 usse Parts of the Menu Block 27 Independent vs Dependent Parameters 28 DS Configuration Flowchart sssssseseeennee 28
7. n TUNING or SET UP mode for the parameter name e Upon power up indicates the current setpoint 3rd Display nine 14 segment digits e Name of current foreground loop e For alarm messages errors etc n TUNING or SET UP mode for the value or choice of parameter shown in the 2nd display ICONS LIT PV2 Loop2isinthe foreground on display Loop 1 is in the background OUT1 For this output either the relay output is energized or the analog output is greater than 0 OUT2 For this output either the relay output is energized or the analog output is greater than 0 If control output is analog indicates the output is greater than 0 ALM1 Therespective alarm one is active ALM2 The respective alarm two is active ALM Analarmis active but no output is assigned 545 User s Manual Chapter 2 Figure 2 1 Operator Interface Interface FAST 8 Bui FAST t FAST FAST FAST MANUAL SET PT DISPLAY DISPLAY KEYS FAST Has no independent function Press to modify the function of another key see below MANUAL Press to toggle between manual and automatic control When lit indicates the unit is under manual control SET PT Press to select the active setpoint In SET UP or TUNING mode press to return controller to OPERATION mode When lit indicates that a setpoint other than the local SP1 is active DISPLAY Press to toggle through value
8. Control Output an observable response in the process variable The Time Constant is the Final PV interval of time between the start of that observable response and the point where the process variable reaches 63 of its final value See Figure 7 15 63 of Final PV Example After a stimulus e g valve movement if ittakes 300 seconds for a process to reach 63 of its new expected value the response time is 300 seconds If the response time is set too short the process will be unstable and cycle around the setpoint If the Response Time is set too long response to an off setpoint condition will be sluggish Itis generally better to use a response DeadTime time that is too long rather than too short Time Constant 4 Set DEAD TIME RT Response Time Figure 7 15 Self Tuning with Multiple Sets of PID and Time Constant For both Pretune and Adaptive Tune the tuned set of PID is that which is active upon initiation of the tuning function The controller cannottrip to other PID sets based on trip point or the digital input contact until Adaptive Tuning is disabled However if the PID set is tied to the corresponding local setpoint the active PID set values will change with the lo cal setpoint Each PID sethas 5 parameters that control its function proportional band reset rate manual reset orloadline and trip point For each set 2 thru 8 these values have to be manually set 1 Press
9. Equipment needed Needle nose pliers optional gt Phillips screwdriver 2 Wrist grounding strap With power off loosen two front screws and remove them Side the chassis out of the case by pulling firmly on the bezel Use Figure 4 2 to locate the jumper connector to change Using the needle nose pliers or fingers pull straight up on the connector and remove it from its pins as shown in Photo 2 Be careful not to bend the pins 2 Remove Jumpers Find the new location of the jumper connector again refer to Figure 3 2 Carefully place it over the pins then press connector straight down Make sure it is seated firmly on the pins Make any other jumper changes as needed To alter output modules 1 please refer to the next section starting with Step 3 To reassemble the controller properly orient the chassis with board open ing ontop Align the circuit boards into the grooves on the top and bottom of the case Press firmly on the front face assembly until the chassis is all the way into the case If it is difficult to slide the chassis in all the way make sure the screws have been removed they can block proper alignment and that the chassis is properly oriented Carefully insertand align screws Tighten them until the bezel is seated firmly against the gasket Do not overtighten 545 User s Manual Chapter 4 Caution Static discharge can cause damage to equipment Always use a wrist grounding str
10. 14B LOW SP 2 LOW SP 2 Specifies the low alarm set point for alarm 2 If ALM SRC 2 OUTPUT If ALM SRC 2 any other type R 0 0 to 100 0 R LOW RANGE to RANGE D 0 0 D 0 15 DEADBAND 2 DEADBAND 2 Defines the deadband for alarm 2 EN NEN if ALM SRC 2 OUTPUT If ALM SRC 2 any other type R 0 196to 100 0 1109999 0 2 D2 16 ALM 2 OUT ALM 2 OUT Selects the output number for alarm 2 e 2 e 3 4 17 LATCHING 2 LATCHING 2 Defines the latching sequence of alarm 2 e NOLATCH 18 ACK 2 ACK 2 Defines whether alarm 2 may be acknowledged D ENABLED Allows the alarm to be acknowledged e DISABLED Prevents alarm acknowledgment while alarm condition exists 19 POWER UP 2 POWER UP 2 Defines how alarm 2 will be treated on power up D NORMAL Alarm depends on process variable e ALARM Always power up in alarm regardless of PV e DELAYED Must leave amp reenter alarm condition before activating alarm 20 MESSAGE 2 MESSAGE 2 A9 character message associated with alarm 2 The first character of the 3rd ALARM 2 display will be flashing To enter message press arrow keys to scroll through character set Press FAST key to enter the selection and move to next digit Press MENU key to advance to next parameter D ALARM2 Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops Err new ww Ca v ww EXE 44 Chapter 5 545 User s Manual Software Configuration
11. Proportioning A 24 VAC 24VDC Operation F Slidewire and 24 VAC 24VDC o G Remote Setpoint B Set of Five Digital Inputs oo eee D CE Certification aes eee H Five Digital Inputs and Certification J Serial Communications Enter 0 if not desired RS 485 Serial Communications Note 1 Capability for position proportioning output with slidewire feedback is specifed by ordering 545 1 1xxAxxx00 545 33xxAxxx00 or 545 44xxAxxx00 Slidewire not required for velocity proportioning Note 2 Up to three outputs may be used for alarms Note 3 All outputs are interchangeable modules Note 4 The mechanical relay and solid state relay modules are derated to 0 5 amp at 24 Vac when used as the fourth output 545 User s Manual Chapter 1 3 introduction 4 Chapter 1 545 User s Manual Basic Interface Interface CHAPTER 2 CONTROLLER OPERATION 151 EK N EX DR ERI 2nd ER ER ER ERI ER E RU Location for identification label Keys DISPLAYS The display strategy of the 545 Process Controller is the same for all control modes Dual Loop Cascade Ratio and Feed Forward 1st Display five 7 segment digits e For the process variable value 2nd Display nine 14 segment digits e For the setpoint deviation output value or valve position if available
12. noise The controller functions to compensate for disturbances i e load changes but it cannot compensate for process noise Attempting to do this will result in degraded controller performance The Noise Bandis the distance the process deviates from the setpoint due to noise in percentage of full scale Figure 7 13 shows a typical process variable response in a steady state situation In this example the process noise is within a band of about 0 5 of full scale 752 407 402 NOISE BAND os 752 352 PROCESS 409 X100 5 VARIABLE Type T Thermocouple Range 328 F 0 752 F 0 40 80 120 160 200 240 TIME SECONDS Chapter 7 noise band thatis too small will resultin tuning parameter values based on noise rather than the effects of load and setpoint changes Ifthe noise band is set too small then Adaptive Tune will attempt to retune the controller too often This may result in the controller tuning cycling between desirable system tuning and overly sluggish tuning While the result may be better than that achieved with a non adaptive controller this frequent retuning is not desirable If the noise band is set too large the process variable will remain within the noise band and the controller will not retune itself With too large a noise band important disturbances will be ignored and the controller will be indifferent to sluggish and oscillatory behavior
13. 5 4 481 600 8 pee Recommend use of both MOV and snubber 545 User s Manual Chapter 3 NOTE Refer to Figure 4 2 for location of the corresponding jumpers Second input jumper connector on the option board must be in either mA milliamp or V voltage position Figure 3 11 Mechanical Relay Output Wiring Figure 3 12 SSR Relay Output Wiring 17 Installation Figure 3 13 DC Logic Output Wiring Figure 3 14 Milliamp Output Wiring Figure 3 15 Position Proportioning Output Wiring 18 3 DC Logic SSR Drive Output e Output 1 is always Control 1 e Respective jumper J1 J2 or J3 must be set to normally open for DC Logic output e Output 4 is always configured for normally open Terminals used Terminals used Terminals used Terminals used with Output with Output with Output with Output Module 1 Module 2 Module 3 Module 4 5 15 0 Ee 4g se se 4 Milliamp Output e Output 1 is always Control 1 e Respective jumper J1 J2 or J3 must be set to normally open for Milliamp output Terminals used Terminals used Terminals used Terminals used with Output with Output with Output with
14. 545 User s Manual Applications INPUT TYPE Figure 7 14 B E J K N R S T WWSPLATINE RTD 0 1 RTD Noise Band Values for 01 01 01 01 04 01 01 01 01 01 01 Temperature Inputs 041 04 04 04 01 04 01 01 01 04 04 041 04 04 01 01 04 02 04 01 01 02 041 02 02 04 01 01 03 01 02 02 03 01 02 02 04 01 01 04 01 02 02 05 02 02 02 02 02 02 05 01 02 03 06 02 03 03 02 02 02 06 01 03 03 07 02 03 03 02 03 02 06 02 03 04 08 02 04 04 03 03 03 07 02 04 04 09 03 04 04 03 03 03 08 02 04 O5 10 03 04 04 03 04 03 09 02 04 05 11 Peak to Peak Noise F _ o Noise band settings are generally between 0 196 and 1 096 with most common settings of 0 2 or 0 3 Figure 7 14 shows the conversion of peak to peak noise to an appropriate noise band for each T C type amp RTD 3 Set RESP TIME The response time is the most critical value in Adaptive Tuning Response time represents the time lag from a change in valve position controller output to a specific amount of change in process variable Specifically Response Time is equal to the Dead time of the process plus one Time Constant The Dead time is the time between initiation of an input change and the start of
15. CHAPTER 6 TUNING OVERVIEW The self tune function of the 545 consists of two distinct components Pretune NOTE and Adaptive Tune In addition you may choose from three type of Pretune For information about Pretune and Adaptive Tune refer to section TYPE 1 for slow thermal processes on Tuning applications in Chapter 7 TYPE 2 for fast fluid or pressure processes TYPE 3 for level control applications e Choose the type of Pretune in the SELF TUNE menu e Pretune and Adaptive Tune may be used separately or together Refer to NOTE Chapter 7 for more information Loop 1 is in the foreground upon power up When Loop 2 is in the e Each control loop has its own set of TUNING parameters foreground both the PV2 icon and On the following pages is the step by step guide to the tuning parameters DISPLAY key will be lit ji FAS e 0 displayed N to mo OPERATION Either Manual or Automatic Control for TUNING mode DISPLAY or SET PT for OPERATION mode MEU FAST for Loop 2 SET UP mode OPERATION OPERATION non Either Manual or for TUNING mode TUNING SET UP SELF TUNE Automatic Control LOOP 2 DISPLAY or SET PT for OPERATION mode DISPLAY MEW FAST or SET PT for Loop 1 MENU FAST Figure 6 1 to return SET UP mode for Loop 1 A th Block OPERATION SET UP mo
16. Exit Set Up and set the manual output to 0 Enter configuration and change the CLOSE F B value until the actuator just reaches its full closed position 11 Set the parameter P PROP D B which is used to eliminate cycling of the motor A low deadband setting may result in motor overspin or cycling A high deadband will result in reduction of sensitivity To set a Goto the TUNING menu b Set P PROP D B to 5 c Place controller under Manual control 545 User s Manual Chapter 7 CAUTION The relay in socket 1 drives the motor counterclockwise and the relay in output socket 2 drives the motor clockwise This is important for Wiring the outputs Selecting the control ACTION 1 parameter or Determining the normally open or normally closed relays The configuration choices influence the way the position proportioning algorithm works NOTE OPEN F B and CLOSE F B values are always reference to the CCW end of the Slidewire NOTE P PROP D B can only be configured if the Slidewire Feedback is wired to the controller 81 Applications NOTE Adaptive tuning is notavailable with velocity position proportioning control 82 d Change the output percentage and observe if the valve stabilizes at the new value e Ifthe valve oscillates increase the P PROP D B value by 0 5 re peat until oscillation stops E VELOCITY POSITION PROPORTIONING CONTROL Velocity position propor
17. REVERSE 4 FIXEDLAG Defines the fixed amount of lag between control iterations 0 R Oto 14400 seconds D Oseconds 5 VARBL LAG VARBL LAG Defines the variable amound of lag between control iterations 00 R Oto 14400 seconds D Oseconds 6 MAX LAG MAX LAG Sets the maximum lag time as a result of PV2 action 0 Oto 14400 seconds D Oseconds Access SetUp Nextmenu Next parameter Next value AccessTuning Return to Operation Switch Loops Err nee wee ww a v ww EXE 38 Chapter 5 545 User s Manual Software Configuration Configuration 10 11 12 545 User s Manual PV BREAK Defines the manual output level if the process variable inputis lost Standard Velocity Prop R 5t0105 D CW DO e CCW e OUTS OFF On Off Dual On Off PID On Off e ON e 1 ON 2 ON R 5to 105 2 ON D OFF 1 ON Z OFF R 5to105 2 OFF e 1 OFF 2 ON 0 2 OFF D 1 OFF 2 Feed ForwardLoop 1 Feed ForwardLoop2 5t0105 6 100to 100 FEEDFWD D 0 D 0 LOW OUT Defines the lowest output value that can be achieved in automatic control R 0 100 Maximumis HIGH OUT D 0 HIGH OUT Defines the highest output value that can be achieved in automatic control R 0 100 Minimumis LOW OUT D 100 FFLO LIM Defines the low limit for the feed forward output contribution when Loop 2 is in AUTO mode 100 to 100 D 100 FF HI LIM Defines the high limit forthe feed forward output contri
18. SP RAMP 11099999 units hour OFF Deactives the function 10 FILTER Defines the setting for the low pass input filter FILTER R Oto 120 seconds DO 11 PV OFFSET Defines the offset to the process variable in engineering units PV OFFSET R 9999 to 99999 units DO 12 PV GAIN This defines the gain to the process variable PV GAIN 0 100 to 10 000 units D 1 000 NOTE Referto Chapter 7 for more information on Offset and Gain Access SetUp Nextmenu Next parameter Next value AccessTuning Return to Operation Switch Loops Err new eem ww a v ww EXE 36 Chapter 5 545 User s Manual Software Configuration Configuration 13 PV RESTOR Defines the control mode whena broken process variable signalis restored PV RESTOR LASTMODE MANUAL AUTOMATIC CUST LINR CUST LINR Definesacustomlinearizationcurveforthe process variable input Points 1 and 15 are fixedtothelow and high end ofthe input range and require only setting a corre sponding PV value Points 2 through 14 the Xth points require setting both the input and PV values Itis not necessary to use all 15 points Whenever the XTH INPUT becomes the high end of the range that will be the last point in the lineraization table 1 1ST INPUT Specifies the input signal for to the first point TST INPUT D Thelow end ofthe appropriate input range e g 4 00mA D 2 1ST PV Specifies the engineering unit value for to the
19. terial A will always by in the proper ratio to material B even as the flow of B is controlled to a specific rate By controlling the flow rate of B the total discharge from the mixer in Figure 7 23 can also be regulated Material B PV1 has the only user defined setpoint in the system The total flow setpoint of the system is calculated by the following formula Total Flow PV1 PV2 x Loop2 SP Ratio SP Bias Secondary Loop Primary Loop PV1 RETRANS MATERIAL A MIXER MATERIAL FLOW SENSOR Hardware Configuration Followwiring as in Figure 7 24 545 User s Manual Chapter 7 NOTE In dual stream Ratio Control enter the ratio and bias values in the TUNING menu of Loop 2under SP RATIO and SP BIAS Figure 7 23 Ratio Control in Mixing Application Controlled Stream Functional View 105 Applications Figure 7 24 Ratio Control in Mixing Application Controlled Stream Wiring View TUNING Put Loop 1 under manual control when tuning Loop 2 in order to hold Loop 2 SP at a constant 106 9 EARTH NOT GND USED COMM COLD 57 01238 1 COLD JUNC 24 Eg EVI FLOW SENSOR i qo MATERIAL A MIXER 4 3 2 2 1 MATERIAL B FLOW SENSOR Software Configuration 1 ForLoop 1 a Inthe CONFIG menu set CTRL TYPE to RATIO b Setallotherparametersfora standard control loop 2 ForLoop2 a Inthe
20. 2 REL GAIN 2 Return to Operation Switch DISPLAY Loops DISPLAY 65 15 CYCLE 2 CYCLETM 2 Defines the cycle time for control output 2 when using a time proportioning 0 3 to 120 0 seconds D 15 0 seconds DEADBAND 2 16 DEADBAND 2 Defines the dead band for control output 2 when using on off control 11099999 in engineering units D 2 17 RSP RATIO RSP RATIO Defines the multiplier applied to the remote set point R 99 99 to 99 99 D 1 00 18 RSP BIAS RSP BIAS Defines the bias additive term applied to the remote set point D R Any value in engineering units minimum is BIAS LOW maximum is BIAS HIGH D Dependent on the BIAS LOW and BIAS HIGH values 19 FFWD GAIN FFWD GAIN Multiplier applied to the feed forward input R 99 99 to 99 99 D 1 00 20 FFWD ZERO FFWD ZERO Zero point of the feed forward output contribution 9999 to 99999 0 21 FF BRK GN FF BRK GN Multiplier applied to the feed forward input if PV is broken R 99 99 to 99 99 D 1 00 22 FF BRK ZR FF BRK ZR Zero point of the feed forward input contribution if PV is broken D 0 NO OF PID 23 NO OF PID Defines the number of PID sets that will be stored and available for use E H 1108 For numbers 1 PID TRIP defines tripping between the PID sets e SPNUMBER Number of PID sets number of local setpoints specified in NO OF SP Each PID set has a respective SP NUMBER D 1 Access SetUp Nextmenu Ne
21. 2 DEG F C K Selectsthetemperatureunitif using athermocouple or RTD DEG F C K D FAHR e CELSIUS e KELVIN 3 DECIMAL Specifies the decimal point position Decimal e XXXX X e XXX XX XX XXX X XXXX 4 LINEARIZE Specifies if the inputis to be linearized automactic for T C s and RTD s LINEARIZE e SQR ROOT Square rootlinearizationis activated e CUSTOM 15 pointcustomlinearizationcurveisactivated Access SetUp Nextmenu Next parameter Next value AccessTuning Return to Operation Switch Loops Emsj ww pee Cally wv Ene pen 545 User s Manual Chapter 5 35 Software Configuration Configuration 5 LOW RANGE LOW RANGE Specifies the engineering unit value corresponding to the lowest input value D e g 4mA 9999 to 99999 Maximum is RANGE D Dependent on Input Selection 6 HIRANGE RANGE Specifies the engineering unit value corresponding to the highest input value D e g 20mA 9999to 99999 Minimum is LOW RANGE D Dependenton Input Selection 7 SPLOLIM SP LO LIM Definesthelowestsetpointvaluethat can be entered from the front panel only D 9999 to 99999 Minimum is LOW RANGE Maximum is SP HI LIM D Dependenton LOW RANGE 8 SPHILIM Defines the highest setpoint value that can be entered from the front panel SP HI LIM ou D 9999to 99999 Minimum is SP LO LIM Maximum is HI RANGE D Dependenton HI RANGE 9 SPRAMP Defines the rate of change for setpoint changes
22. DIN 5 220 unc 23 EJ uv 24 E Flow Sensor 24 Material A Controlled Stream 1 Material B Wild Stream Flow Sensor Chapter 7 545 User s Manual Applications Hardware Configuration e Follow wiring asin Figure 7 22 e Setthe PV jumper of Loop 1 and the RSP jumpers to position Make sure the software ranges of both inputs match the range of the corre sponding transmitter Software Configuration 1 Inthe PV INPUT menu set HI RANGE and LOW RANGE 2 Inthe REM SETPT menu set RSP LO RNG and RSP HI RNG 3 Inthe TUNING menu RSP RATIO adjusts the ratio between the two streams The value of this parameter is multiplied by the remote setpoint signal to yield the effective remote setpoint Example In this example the remote setpoint signal is the flow rate of Material B The desired amount of B is twice that of A Therefore the ratio is 2 0 If the flow of Material Bis measured at 50 gallons minute the effective remote setpoint value would be 2 times 50 or 100 The 535 would try to maintain the flow of Material Aat 100 As the flow of Material B changes the setpoint would change accord ingly always in a 2 1 ratio Ratio control with combined discharge monitoring This process requires not only the same ratio of blending as in example 1 but also requires the control of the combined discharge rate In this example ma
23. Disconnect power to the instrument 2 Remove chassis from case N Appendix 4 545 User s Manual Calibration __ 3 Onthe Microcontroller Circuit Board locate jumper locations marked PV1 and 2nd near the edge connector Reposition both jumper connectors in the 2nd location onto pins for V and TCs as shown Figure 4 3 4 Reinsert chassis into the case and apply power 5 Allow controller to warm up for at least 30 minutes The 2nd and 3rd displays should read CALIBRATE ANALOG IN CALIBRATE Menu ANALOG IN section Press MENU three times to reach the CALIBRATE ANLG OUT Menu 6 Connect hook up wires to the terminals for the corresponding milliamp output modules Output 1 uses terminals 3 and 4 Output 2 uses terminals 5 and 6 Output 3 uses terminals 7 and 8 shown in Figure A4 8 Output 4 uses terminals 15 and 16 Attach the test leads from the multimeter to the wires and then plug the test leads into the meter Set the meter for DC milliamp 7 Press ACK The 2nd display will read OUTPUT1 OUTPUT2 OUTPUTS or OUTPUT4 depending on the module installation 8 Press MENU to scroll to the output to be calibrated see Figure A4 9 The 3rd display should read 4mA The multimeter should read a value close to 4 00 9 Wait one minute Use and V and FAST on the controller to change the meter s display to exactly 4 00mA 10 Press MENU The 3rd display should read 20mA 11 Let this setting stabilize
24. MAN Closing input trips the controller to manual Opening input reverts controllerto automatic Override by using MANUAL key a commu nications command or trip to automatic function L2 2ND SP Closing input changes active setpointto the 2nd local setpoint Open ing input reverts controller to previous setpoint digital input Over ride by selecting a different setpoint via the SET PT key acommu nications command or other digital inputs L2 2ND PID Closing input changes active set of PID values to 2nd set Opening input bases active set of PID on rules defined in PID TRIP and TRIP 1 to TRIP 8 Override input only by directly linking PID set to the ac tive setpoint and changing the active setpoint L2 ALARM ACK Closing input acknowledges all active alarms Opening input re arms the controller If the digital input remains closed it does not continue to immediately acknowledge alarms as they become ac tive L2 RSP INH Reset Inhibition Closing input deactivates I integral term regard less of the PID values being used Opening input activates I term if applicable 545 User s Manual Applications e L2 D A R A Direct Acting Reverse Acting Closing input reverses action of the first control output from direct to reverse or reverse to direct Open ing reinstates original action L2 NO A T Closing input temporarily disables Adaptive Tuning Opening input enables it e L2 LCK MAN
25. PV2 SP2 RAMP SP2 and LOOP2OUT ALARMS The 545 controller has two software alarms per loop for a total of four alarms High and low alarms may be sourced to the PV SP RAMP SP DEVIATION and OUTPUT If an alarm is tripped the alarm message will show the ACK key will illuminate if acknowledgeable and the ALM icon will light If the alarm is tied to the first available non control output the 1 below the ALM icon will light Similarly if the alarm is tied to the second non control output the 2 below the ALM will light The availability of outputs determines how many alarms can be tied to relays Global Alarm feature allows one or more of the internal software alarms to be tied to the same single physical output The acknowledge key is active for alarms associated with either loop The order in which alarms are acknowledged is loop1 alarm1 loop1 alarm 2 loop2 alarm 1 loop2 alarm2 DIGITAL INPUTS A set of five external digital inputs activated by dry contacts or open collector transistors are available Each can be configured to perform one of the following functions Select remote setpoint Select either direct or reverse Select manual control control action Select second local setpoint Disable adaptive tuning Select a second set of Addressable through serial PID values communications only Acknowledge alarms Inhibit the reset term e Simulate front panel keys Lock controller in manual mode In ad
26. control output The end product which is at some desired value that is the result of having been processed or manipulated control mode automatic A user selected method of operation where the controller determines the control output control mode manual A user selected method of operation where the operator determines the control output control parameters User defined values that specify how the process is to be controlled controlled variable A process variable which is to be controlled at some desired value by means of manipulating another process variable CRC cyclic redundancy check An error checking technique in which a checking number is generated by taking the remainder after dividing all the bits in a block in serial form by a predeter mined binary number CSA Acronym for Canadian Standards Association cycle time The time necessary to complete a full ON through OFF period in a time proportioning control system cycling oscillation A periodic change in the factor under control usually resulting in signal excursions above and below the control point DIN Deutsche Industrial Norms a German agency that sets standard for engineering units and dimensions damping The decrease in amplitude of an oscillation due to the dissipation of energy damped 1 4 amplitude The loss of one quarter of the amount of amplitude with every oscillation A 18 dead band A temperature band between he
27. input bases active set of PID on rules defined in PID TRIP and TRIP 1 to TRIP 8 Override input only by directly linking PID setto the active setpoint and changing the active setpoint e L1 ALARM ACK Closing input acknowledges all active alarms Opening input rearms the controller If the digital input remains closed it does notcontinue NOTE Only alarms configured to be to immediately acknowledge alarms as they become active acknowledged are affected by this e L1 RSP INH digital input Reset Inhibition Closing input deactivates I integral term regard less of the PID values being used Opening input activates I term if applicable e L1 D AJR A Direct Acting Reverse Acting Closing input reverses action of the first control output from direct to reverse or reverse to direct Open ing reinstates original action e L1 NO A T Closing input temporarily disables Adaptive Tuning Opening input enables it e L1 LCK MAN Closing contact places the controller in manual control at the desig nated output percentage All locked manual contacts must be opened in order to return controller to automatic control UPKEY Closingthe contact mimicsthe A key Usefulif controlleris mounted behind a window contact push buttons can be used to change setpoint values DOWNKEY Closingthe contact mimics the W key Usefulif controlleris mounted behind a window contact push buttons can be used to change setpoint values e DISP
28. of control output ON OFST is in engineering units The settings can be used to make sure there is a dead band i e no controller output around setpoint They can also be used to overlap output 1 and out put 2 so that both are on in a small band around setpoint 5 SetMAN RESET manual reset term to 50 This causes the PID output to be 50 when there is zero error This term is still active as a load line setting when using automatic reset integral so setitto 50 whether using automatic reset or not 6 REL GAIN relative gain changes the gain of Output 2 relative to Output 1 Note that the relative gain can limit the maximum output available for Out put 2 when using PID control 7 Goto the CONTROL menu Set LOW OUT and HIGH OUT to limit the maximum or minimum outputs from Output 1 and Output 2 The actual limitation on the outputs is depen dent on the offset settings the relative gain setting and the control action Duplex Output State Examples The following Duplex examples representa variety of ways this function can be setup PID control examples show the PID output percentage on the horizontal axis and On Off control examples show the process variable on the horizontal axis The vertical axes are the output of each physical output Most of these examples use the first output as heating and the second output as cooling When using PID control the 545 controller actually displays the PID output To relate thi
29. prior to communications being lost e DESIG SP Goes to adesignated setpoint value if commu nications is lost 8 DESIG SP Defines the value of the designated setpoint if communications is lost DESIG SP The process variable range D D Dependenton the process variable range Access SetUp Nextmenu Next parameter Next value AccessTuning Return to Operation Switch Loops Emsj ww pee Ca lov wv ES 545 User s Manual Chapter 5 53 Software Configuration Configuration PARAMETER VALUE CHARTS This section of value charts is provided for logging the actual parameters values and selections for the process It is recommended that these pages be photocopies so there will always be a master CONFIG Global Parameter Description Value 1 CTRL TYPE Defines fundamental controller Set Up 2 LINEFREQ Defines the power source frequency 3 LOOP1 OUT Defines standard configuration for Loop 1 4 LOOP2 OUT Defines standard configuration for Loop 2 5 OUTPUT 2 Function of the second output 6 OUTPUT 3 Function of the third output 7 OUTPUT 4 Function of the fourth output 8 ANLG RNG 1 Output signal for the first output 9 ANLG RNG 2 Output signal for the second output 10 ANLG RNG 3 Output signal for the third output 11 ANLG RNG 4 Output signal for the fourth output 12 CONTACT 1 Operation of the first digital input for Loop 1 13 CONTACT2 Operation of the second di
30. software Improper wiring Wire properly Defective RTD Replace RTD Input jumper selection improperly set Move jumper connector to proper location Improper wiring Wire properly No control output Output wiring and module location do not match Check and correct wiring or module location If SSR SSR Drive of Milliamp output jumpers J1 J2 and J3 are not set properly Set jumper connector to proper location Software configuration does not match hardware Reconfigure software to match hardware PID values not set properly Set PID values properly Can t switch to auto control Input sensor signal is not connected or valid See LOST PV message Erratic display Resetting action due to electrical noise on powerline Filter power line PID values not set properly Retune controller 545 User s Manual Appendix 3 A 5 Troubleshooting Message When does it occur What to do DEFAULTS Whenever the memory is cleared and all Entering the Set Up mode and changing a parameters revert to factory default settings parameter will clear the message If due to This may be done by purposely clearing the something other than the user purposely memory or when the unit is powered up forthe clearing the memory call factory for assis first time or if the software version is changed tance LOST CAL or Indicates that the calibration data has been Problem should never happe
31. start 100 Figure 7 18 50 Load Line Example Controller Output 0 20 40 60 80 100 Process Variable Location of Controller Span Q SECURITY The 545 security system is easily customized to fit a system s needs Software Configuration 1 Go tothe SECURITY menu 2 SEC CODE defines the security password range from 9999 to 99999 The NOTE SEC CODE does not appear rest of the security parameters can be selectively locked out unessa iunctione 3 SP ADJUST prevents the operator from using the and V keys to change the setpoint value It does not prevent the operator from changing setpoints via the SET PT key 4 AUTO MAN locks out the MANUAL key preventing the operator from transferring between automatic control and manual control 5 SP SELECT locks out the SET PT key This prevents the operator from changing among the various local setpoints or changing to remote setpoint It does not prevent the operator from changing the setpoint value via the A and V keys 6 ALARM locks out the key preventing an operator from acknowledging any alarms 7 TUNING locks out modification to the parameters in the TUNING menu preventing unauthorized changesto the tuning parameters orthe activation deactivation of the self tuning algorithm 8 CONFIGURE allows access to the configuration menus but prevents any NOTE Lock out CONFIGURE for full unauthorized chan
32. 000000 Front of controller m circuits boards still attached to front face ba Jou 5 Toreassemble the controller properly orientthe chassis with board opening ontop Align the circuit boards into the grooves on the top and bottom of the case Press firmly on the front face assembly until the chassis is all the way into the case If it is difficult to slide the chassis in all the way make sure the screws have been removed they can block proper alignment and that the chassis is properly oriented 6 Carefullyinsertand align screws Tighten them until the bezel is seated firmly against the gasket Do not overtighten Chapter 4 545 User s Manual Software Configuration Configuration CHAPTER 5 SOFTWARE CONFIGURATION The software configuration menus of the 545 contain user selected variables that define the action of the controller Read through this section before making any Figure 5 1 parameter adjustments to the controller Parts of the Menu Block When initially setting up the controller cycle through all the parameters in each Menu Press the MENU FAST to advance to the next menu ress ENU FAST So Press MENU to advance to the next parameter this also sets the value for the current parameter Use arrow keys to A Press select a value MENU INDICATOR Use the arrows keys to enter numerical values gt rl and or move through the press MENU F
33. 2 Slide chassis out of the case by pulling firmly on the bezel controller is available at the factory Consult an application engineer for FRONT FACE details Figure 4 1 Location of Printed Circuit Boards for Hardware Configuration OPTION BOARD A detailed view of the circuit boards appears in Figure 4 2 After configuring the hardware or if no changes are necessary continue setting upthe process as needed HARDWARE INPUT TYPES The Process Variable The 545 accepts several differenttypes of process variable signals Set a jumper location to specify the type of input signal Setthe signal range in the software see Chapter 5 for software menus or Chapter 7 for applications The jumpers for the process variable are located on the Microcontroller Circuit Board see Figure 4 2 The factory default is Milliamp Locations are marked as follows NOTE V Voltage Thermocouple downscaleand _ 2 upscale burnout offers a choice in MA Milliamp which direction the controller would TCV Thermocouple with downscale burnout react in the event of thermocouple ICA Th le with leb t failure For example in heat SIIOOOUpie WRTFUDSUSHE applications typically it is desirable RTD RTD to fail upscale TC A so that the System does not apply more heat 545 User s Manual Chapter 4 21 Hardware Configuration NOTE Changing the jumpers means moving the jumper connector The jumper connector slips over the pins straddling
34. 46 Chapter 5 545 User s Manual Software Configuration Configuration 4 TYPE 3 Defines what is to be retransmitted for output 3 TYPE 3 D PV1 Linearized process variable 1 PV1 e 5 1 Target setpoint 1 e RAMP SP1 Ramping actual setpoint 1 e OUTL1 Control output 1 e PV2 Linearized process variable 2 e SP2 Target setpoint 2 e RAMP SP2 Ramping actual setpoint 2 e OUTL2 Control output 2 5 LO RANGE 3 Defines the low end of the range for output 3 in engineering units LO RANGE 3 R 9999 to 99999 D D Dependent upon process variable range 6 HIRANGE 3 Defines the high end of the range for output 3 in engineering units HI RANGE 3 9999 to 99999 D D Dependenton the process variable range 7T TYPE 4 Defines what is to be retransmitted for output 4 TYPE 4 D Linearized process variable 1 PV1 e 5 1 Target setpoint 1 e RAMPSP1 Ramping actual setpoint 1 e OUTL1 Control output 1 e PV2 Linearized process variable 2 e SP2 Target setpoint 2 e RAMP SP2 Ramping actual setpoint 2 e OUTL2 Control output 2 8 LO RANGE 4 Defines the low end of the range for output 4 in engineering units LO RANGE 4 9999 to 99999 D D Dependent upon process variable range 9 HIRANGE 4 Defines the high end of the range for output 4 in engineering units HI RANGE 4 9999to 99999 D D Dependenton the process variable range Access SetUp Nextmenu Next parameter Next value Access Tuning Return to Operation Switch Loops Emsj ww
35. 535 664 Module Retention Kit for Output 4 Set of 5 Tie Wraps 535 665 Circuit Board Support Bezel Insert 535 075 Engineering unit labels 1 sheet 535 106 545 User s Manual Appendix 2 A 3 2 545 User s Manual Troubleshooting APPENDIX 3 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION Display will not light up Defective power source Check power source and wiring Improper wiring Correct wiring Blown in line fuse Check wiring replace fuse Unit not inserted in case properly or screws have not been tightened Remove unit from case and remove bezel screws then reinsert unit and properly tighten screws Improper Lost PV reading Voltage current Input jumper selection improperly set Move jumper to proper location Input range improperly selected in software Select proper range Reverse polarity Check and correct sensor wiring If controller powered improperly wired Check and correct wiring Loop power module not installed Install module Defective transmitter Replace transmitter Improper Lost PV reading Thermocouple Transmitter signal out of range Defective thermocouple Select proper range in software Replace thermocouple Input jumper selection improperly set Select Proper input Wrong TC type selected in software Select proper thermocouple type in Improper Lost PV reading RTD
36. 545 will attempt to _ adapt the Tuning parameters to the values These values may also be entered or changed manually in the SELF temporary process conditions TUNE menu For Pretune TYPE 1 Noise Band Response Time and Dead Time Adaptive Tune can be disabled via parameters must be entered manually digital input if applicable see Digital Figure 7 12 illustrates the relationship between Pretune and Adaptive Tune Inputs in this chapter or via menus 1 Gotothe TUNING menu 2 Goto parameter ADAPTIVE Software Configurations Changethe valueto DISABLED Pretune by Itself 1 Goto the SELF TUNE menu press MENU FAST 2 Setthe TYPE parameter to PRETUNE 3 Setthe PRETUNE type tothe one that best matches the process see above section 4 The next parameter TUNE PT appears only for TYPE 1 pretune This parameter sets the PV point at which the output will switch off In thermal processes this will help prevent overshoot The default is AUTOMATIC 5 Setthe value for OUT STEP This parameter defines the size of bump to be used The resulting disturbance must change the process variable by an amountthat significantly exceeds the peak to peak process noise but does not travel beyond the normal process variable range 6 Thenexttwo parameters LOW LIMIT and HI LIMIT setthe process variable boundaries If these boundaries are exceeded during the Pretune the pretune cycle will abort and return to manual control atthe output level pr
37. 555 Use these instructions with the following kits Display Assembly Kits 5812682 531 Display Assembly Kit 532 692 532 Display Assembly Kit 535 632 535 Display Assembly Kit 545 634 545 Display Assembly Kit 555 632 555 Display Assembly Kit Output and Communications Module Kits 532 600 531 532 Analog Module Kit 535 600 Mechanical Relay Module Kit 535 601 Milliamp Module Kit 535 602 SSR Module Kit 535 603 SSR Drive Module Kit 535 604 Loop Power Module Kit 535 705 RS 485 Communications Module Kit Power Supply Kit 535 790 usns 90 to 250VAC Power Supply Kit 585 782 uus 24VAC NDC Power Supply Kit Mounting Kit 535 761 Mounting Kit Miscellaneous Kits 532 100 531 532 Bypass Board Kit 535 188 Rear Terminal Upgrade Kit 535 660 531 532 535 545 555 Jumper Kit 535 662 Gasket Kit 1 Panel Gasket 1 Bezel Gasket 535 763 Bezel Retention Screw Kit 535 664 Module Retention Kit Retention Plate and Tie Wrap 535 665 Module Retention Tie Wrap Kit 093 128 Lithium Battery Universal Kit can be used with all 500 Series Controllers EPROM Kits 531 740 531 EPROM Kit 532 740 532 EPROM Kit 535 74 535 EPROM kit RSP 585 775 535 Profiler EPROM Kit
38. 6 1 ise Access the Tuning Menu Block 63 TM Alartmibxambples eO erts 75 ro Duplex With Reverse and Direct Acting Outputs 77 FECE Duplex With Direct and Reverse Acting Outputs 77 A Duplex With Two Reverse Acting Outputs 78 JB assesses Duplex With a Gap Between Outputs 78 yo m Duplex With Overlapping Outputs and Output Limits 79 a deere etree Duplex With Various Relative Gain Settings 79 Duplex With One ON OFF Output 80 pep Duplex With Two ON OFF 80 TNO tut Staged Outputs Example 83 TAA mem Combinations of Closed Digital Inputs 84 Pretune TYPE 1 2 3 with Adaptive 93 pov c Noise Band Calculation 94 FN m Noise Band Values for Temperature Inputs 95 END iiie Deadtime and Time 95 TN Oni ien Square Root Linearization Formula 97 Taf 15 point Linearization Curve 98 iv Table of Contents 5
39. 9 character message associated with Loop 1 The first character of the 3rd LOOP ONE display will be flashing To enter message press A and W keys to scroll through character set Press FAST to enter the selection and move to next digit Press MENU to advance to next parameter D LOOP ONE Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops Eese eem ww a v ww EXE 34 Chapter 5 545 User s Manual Software Configuration Configuration 20 NAME L2 A 9 character message associated with Loop 2 The first character of the 3rd NAME L2 display will be flashing To enter message press A and V keys to scroll LOOPTWO through character set Press FAST to enter the selection and move to next digit Press MENU to advance to next parameter DLOOP TWO vee PV INPUT Forconfiguring the process variable PV input 1 PV TYPE Selects the particular sensororinput range PVTYPE TC RID Voltage Current mA D DJT C D DINRTD D 1 5V D 4 20mA e ET C e JISRTD e 0 5V 0 20mA e KT C SAMARTD 0 10mV values in the e BT C 0 30mV presented order dependent NT C e 0 60mV parameters are dynamically related ATIC e e 25mV For example if SP LO LIM is set to TT C 0 and thermocouple type is changed to T C the SP LO LIM e WT C value will change to 104 the low e W5T C limit of a type B thermocouple e PLAT II T C
40. ALL MONIES PAID TO THE COMPANY BY THE BUYER FOR PURCHASE OF THE GOODS OR SERVICES ANY CAUSE OF ACTION FOR BREACH OF ANY WARRANTY BY THE COMPANY SHALL BE BARRED UNLESS THE COMPANY RECEIVES FROM THE BUYER A WRITTEN NOTICE OF THE ALLEGED DEFECT OR BREACH WITHIN TEN DAYS FROM THE EARLIEST DATE ON WHICH THE BUYER COULD REASONABLY HAVE DISCOVERED THE ALLEGED DE FECT OR BREACH AND NO ACTION FOR THE BREACH OF ANY WAR RANTY SHALL BE COMMENCED BY THE BUYER ANY LATER THAN TWELVE MONTHS FROM THE EARLIEST DATE ON WHICH THE BUYER COULD REASONABLY HAVE DISCOVERED THE ALLEGED DEFECT OR BREACH RETURN POLICY For a period of thirty six 36 months from the date of shipment and under normal conditions of use and service Moore Industries The Company will atits option replace repair or refund the purchase price for any of its manu factured products found upon return to the Company transportation charges prepaid and otherwise in accordance with the return procedures established by The Company to be defective in material or workmanship This policy extends to the original Buyer only and not to Buyer s customers or the users of Buyer s products unless Buyer is an engineering contractor in which case the policy shall extend to Buyer s immediate customer only This policy shall not apply if the product has been subject to alteration misuse accident ne glect or improper application installation or operation THE COMPANY SHALL IN NO EVENT BE LIABLE
41. Between Outputs 78 Duplex with 2 reverse acting outputs Two reverse acting outputs with no offset no restrictive output limits and a neutral relative gain with PID control PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 REVERSE PID OFST 1 0 PID OFST 2 0 LOW OUT 0 HIGH OUT 100 REL GAIN 1 0 PID OUTPUT Duplex with a gap between outputs Areverse acting output 1 direct acting output 2 react with a positive offset for output 1 anda negative offset for output 2 assume no restrictive output limits and a neutral relative gain with PID control On the graph a positive offset refers to an offset to the left of 50 a negative offset is to the right of 50 PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 DIRECT PID OFST 1 VALUE PID OFST 2 VALUE LOW OUT 0 HIGH OUT 100 REL GAIN 1 0 0 100 50 N offset 2 PID OUTPUT Chapter 7 545 User s Manual Applications Duplex with a overlapping outputs and output limits A reverse acting output 1 and a direct acting output 2 with a negative offset for output 1 a positive offset for output 2 and restrictive high and low output limits with PID control This combination of offsets results in an overlap where both outputs are active simultaneously when the PID output is around 50 The outputlimits are applied directly to the PID output This in turn limits the actual output values In this example the high
42. CHAPTER 7 PAGE Step by Step Guide to Set Up Parameters continued SECURITY M dancin aed rane 51 SER COMM reete epa 52 Parameter Value Charts isinsin aasar a aE 54 TUNING essed sees ect re sae e aaaea aaa aaa E Ee 63 eu E N A E ETE AAT E E 63 TUNING Parameter Guide 64 TUNING Value Chart etie 68 Self Tune Messages and Troubleshooting 70 APPLICATIONS oci unesena rca ae ener exon ce ceno 71 E 71 Bo In Meet PEERS 72 C Duplex Gorittol 22 2 neti ctu Lcid ELDER a des 76 D Slidewire Position Proportioning Control 81 E Velocity Position Proportioning Control 82 F Staged Outputs sssssssssssssseseeeeeeeenneeeen nnns 83 G ura M 83 Pierio 84 Remote Setpoint sii ven caia 88 J Multiple Setpoint sssseseeeenennnn 88 Multiple Sets of PID Values 89 L Powerback 90 M Self Tune POWERTUNES sene 90 N Ramp to Setpoint sessssssssseeeeene
43. Closing contact places the controller in manual control at the desig nated output percentage All locked manual contacts must be opened in order to return controller to automatic control UPKEY Closingthe contact mimicsthe A key Usefulif controlleris mounted behind a window contact push buttons can be used to change setpoint values e DOWN KEY Closing the contact mimics the W key Useful if controller is mounted behind a window contact push buttons can be used to change setpoint values e DISP KEY Closing contact mimics the DISPLAY key scroll through display of the Setpoint Deviation and Output 96 e FAST KEY Closing contact mimics the FAST key Use in conjunction with A DISPLAY and MENU keys e MENU KEY Closing contact mimics the MENU key In OPERATION pro vides entry to TUNING menu In SET UP or TUNING Moode advances through the menus e COMM ONLY Makes input status readable through communications but has no effect on the controller itself Basic Operating Procedures 1 If more than one digital input closes and their actions conflict the last digital input that closed has priority For example if one digital input closes and selects 2nd setpoint and then another digital input closes and selects a remote setpoint the remote setpoint takes precedence 2 Any digital input can be overridden by another digital input a keyboard operation or an automatic function If a closed digital input is overr
44. D Follow the guide and complete any additional steps as required by your particular application E Complete your hardware adjustments with steps 15 16 17 18 19 amp 20 EQUIPMENT To make any hardware changes to the units you will need the following equipment e Wrist grounding strap Phillips screwdriver 2 e Small flat blade screwdriver Wire cutters e C Extractor if changing the EPROM 2 500 Series Installation Guide Installation INSTRUCTIONS one of the larger two boards from the Option Board Photo 4 Be careful not to bend the To Disassemble the Unit connector pins Separate the other board in the same manner Figure 2 opposite page shows the Microcontroller Board Option Board and Power Supply Board For any hardware modifications disassemble the unit 1 With power off loosen four captive front screws with a Phillips screwdriver Remove the four screws p To Add or Change Output Modules The 500 Series units have provisions for four output modules The units come factory configured with specified modules installed in appropriate locations You can make field modifications by properly remov ing and or adding the modules into the appropriate Sockets Three of the output sockets are located on the Power Supply Circuit Board A fourth output socket is located on the Option Board refer to Figure 2 5 Aretention plate and tie wrap hold Output modules 1 2 and 3 on the Power Supply
45. D Dependenton the process variable range Access SetUp Nextmenu Next parameter Next value AccessTuning Return to Operation Switch Loops Err new wee ww a v ww EXE 48 Chapter 5 545 User s Manual Software Configuration Configuration 7 TIMEOUT Defines the execution time limit for pretune before aborting TIMEOUT 8to 1500 minutes D 1500 minutes 8 MODE Defines the control mode after pretune is completed MANUAL AUTOMATIC D AUTOMATIC 9 NOISE BND NOISE BND Defines the noise band to be used by the adaptive tuning algorithm as a per centage of the process variable range 0 1to 1096 D 0 296 10 RESP TIME Defines response time to be used by the adaptive tuning algorithm 10 to 32000 seconds D 7200 seconds 11 DEAD TIME Defines the amount of time the process runs before controller responds to an output change POWER BACK feature 0 1 to 7200 0 seconds D 0 1 seconds RESP TIME DEAD TIME SPECIAL SPECIAL For configuring special features 1 AUTO TRIP Defines the condition under which the 545 will automatically trip to automatic AUTO TRIP control from manual control upon start up OFF D OFF Deactivates this function RISINGPV Willtrip when arising process variable is within the specified deviation from the setpoint e FALLNG PV Will trip when a falling process variable is within the specified deviation from the setpoint 2 TRIP DEV Defines the dev
46. Emsj ww ew Ca lov wv Ens oes 545 User s Manual Chapter 5 41 Software Configuration Configuration 4B LOW SP 1 LOW SP 1 Specifies the low alarm setpoint for alarm 1 If ALM SRC 1 OUTPUT If ALM SRC 1 any other type R 0 0 to 100 0 R LOW RANGE to HI RANGE D 0 0 DO 5 DEADBAND 1 DEADBAND 1 Defines the deadband for alarm 1 If ALM SRC 1 OUTPUT If ALM SRC 1 any othertype R 0 196to 100 0 R 1109999 0 2 D2 6 ALM 1 OUT ALM 1 OUT Selects the output number for alarm 1 e 2 e 3 4 7 LATCHING 1 LATCHING 1 Defines the latching sequence of alarm 1 e NOLATCH 8 1 ACK 1 Defines whether alarm 1 may be acknowledged D ENABLED This allows the alarm to be acknowledged e DISABLED This prevents the alarm from being acknowl edged while in alarm condition 9 POWER UP 1 POWER UP 1 Defines how alarm 1 will be treated on power up D NORMAL Alarm depends on process variable e ALARM Always power up in alarm regardless of PV e DELAYED Mustleave alarm condition and reenter before activating the alarm 10 MESSAGE 1 MESSAGE 1 A9 character message associated with alarm 1 Thefirstcharacterofthe 3rd ALARM 1 display will be flashing To enter message press arrow keys to scroll through character set Press FAST key to enter the selection and move to next digit Press MENU key to advance to next parameter D ALARM 1 Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation
47. KEY Closing contact mimics the DISPLAY key scroll through display of the Setpoint Deviation and Output 96 e FAST KEY Closing contact mimics the FAST key Use in conjunction with A DISPLAY and MENU keys 545 User s Manual Chapter 7 85 Applications 86 MENU KEY Closing contact mimics the MENU key In OPERATION Mode pro vides entry to TUNING menu In SET UP or TUNING Mode ad vances through the menus COMM ONLY Makes input status readable through communications but has no effect on the controller itself 3 Set parameters CONTACT 4 and CONTACT 5 only those available will be shown by assigning the desired function to each output Choices are Chapter 7 L2 SP 1 4 CONTACT 4 only Allows the controller to use the digital inputs 4 and 5 to select a setpoint for Loop 2 see Figure 7 11 Ifthe state of these inputs remains constant the controller will continue to use the selected setpoint unless overridden Override the set of digital in puts by selecting a different setpoint by using SET PT key or through communications or by using the fifth digital input to select the re mote or 2nd setpoint To rearm this set of digital inputs the DIN combination must change L2 REM SP Closing input changes active setpoint to remote setpoint Opening reverts controller to previous setpoint Override by selecting a dif ferent setpoint via the SET PT key a communications command or other digital inputs L2
48. Loop 2 must be under Automatic Control Otherwisethe controller will display the error message PRETUNEL2 MANUAL Figure 7 22 Ratio Control in Mixing Application Wild Stream Wiring View 104 Similarly whenever Loop 1 output is 100 then Loop 2 SP is at 800 All the intermediate values follow a linear curve as shown in Figure 7 21 Tuning Cascade Control 1 Setthe secondary or inner loop into Manual and perform a Pretune on this loop Once the Pretune is completed the inner loop must be in Automatic mode 2 Place the primary or outer loop into Manual and perform a Pretune on this loop 3 OncePretune is complete the Cascade Control Loop is completely tuned and placing the primary loop into Automatic will allow the system to control to the desired Setpoint of the Primary loop If desired adaptive tune can be enabled for both loops V RATIO CONTROL Ratio Control is employed in blending applications that require materials to be mixed to a desired ratio In some applications not only is the ratio being con trolled but also the combined flow or total discharge rate of the mixed materials Ratio control with one wild stream Figure 7 22 shows a simple example of a two stream blending application in which one ofthe streams is wild uncontrolled Ratio control forthe type of ap plication where one loop is wild can be accomplished with a 545 configured for one loop a 17 Ed DIN 1 ES DN421 g
49. Output Module 1 Module 2 Module 3 Module 4 5KD 7 ns 40 60 sal 16 5 Position Proportioning Output with or without Slidewire Feedback POSITION PROPORTIONING Electric Motor Actuator CCW CW CCW Winding Winding Slidewire 099 Wiper 0 1050 Ohm CW Actuator Supply Current _ eR COM CCWCOM Chapter 3 545 User s Manual Installation e Mechanical relay or solid state relay modules must be installed in output sockets 1 and 2 e Whenusing velocity control slidewire feedback there are no con nections at terminals 10 11 and 12 e Use of the slidewire feedback is optional Serial Communications A twisted shielded pair of wires should be used to interconnect the host and field units Belden 9414 foil shield or 8441 braid shield 22 gauge wire acceptable for most applications The foil shielded wire has superior noise rejection characteristics The braid shielded wire has more flexibility The maximum recommended length of the RS 485 line is 4000 feet Termination resistors are required at the host and the last device on the line Some RS 485 cards converters already have a terminating resistor We recommend us
50. POS PROP 2 Goto the CONTROL menu Set SLIDEWIRE to NONE Alternatively set SLIDEWIRE to LOOP1 or LOOP2 whichever does NOT have velocity position proporioning on it 3 Set CCW TIME to the amount of time in seconds it takes for the actuator to fully rotate in the counterclockwise direction Set CW TIME to the amount of time in seconds it takes for the actuator to fully rotate in the clockwise direction Loads onthe valve may affect the time required therefore itis bestto measure these values when the valve is in service As an alternative enter the values specified by the actuator manufacturer and then make adjustments later 4 Set MIN TIME to the minimum amount of time the controller must specify for the motor to be on before it takes any action 5 Setvalues for PV BREAK DES OUTPT PWR UP OUT and SHED OUT Chapter 7 545 User s Manual Applications F STAGED OUTPUTS With staged outputs one analog output can vary its signal e g 4 20 mA over a portion of the PID output range The second analog outputthen varies its signal over another portion of the PID output range This is an excellent method to stage two control valves or two pumps using standard control signal ranges 20 mA Figure 7 10 Staged Outputs Example OUT1 STOP was set to 33 and Outputi OUT2 STHT was set to 5076 4 mA 1 0 33 50 100 PID Output Hardware Configuration The controller must have analog output modules installed
51. PV INPUT menu set SP LOLIM and SP HILIM to the same value as those for Loop 1 LOW OUT and HIGH OUT b Setall other parameters for a standard control loop c Inthe TUNING menu forLoop2 enter valuesfor SP RATIO and SP BIAS Chapter 7 545 User s Manual Applications W FEED FORWARD FEEDBACK CONTROL In feedback control controller output is based on the difference between pro cess variable and setpoint By contrast feed forward control generates an out put signal based upon the process variable Feed forward control functions compensate for system lag times by providing a predictive or anticipative out put signal based on a process measurement Typically a feed forward signal is used to enhance the performance of a feedback loop Example Below is an alkaline effluent stream with a constantly changing flow rate into which an acid is being mixed Refer to Figures 7 25 and 7 26 The acid valve is positioned as a result of the flow rate of the stream and the pH of the mix This type of control is called Feed Forward Feed Back The pH sensor is a closed feedback loop that actually measures the result of the valve s action The flow rate is an open feed forward loop adding subtracting or multiplying its output to the pH loop Figure 7 25 Feed Forward Control in Mixing PU1 OUTPUT OUTPUT Application Wiring View TO VALVE ZERO PV2 Feed Forward PV 545 Feed Forward Controller Feed Forwa
52. TIME parameter Make sure thatthe process is reasonably stable and place the controller under manual control 8 Press MENU to access the TUNING menu Set ADAPTIVE to ENABLED The Adaptive Tuning cycle does not begin until the controller is under automatic control 9 Activate the next parameter PRETUNE 10 Press ACK to begin Pretuning The 3rd display will show the message EXECUTING 11 When Pretune is complete the 3rd display will show COMPLETED for two seconds and then return to the current menu display The controller will automatically transfer to automatic control upon completion of Pretune if set to do so or upon manual transfer Figure 7 12 illustrates the operation of Pretune TYPE 1 with Adaptive Tune Pretune TYPE 2 or 3 amp Adaptive Tune 1 Goto the SELF TUNE menu Set the TYPE parameter to BOTH Set the PRETUNE parameter to TYPE 2 or TYPE 3 Setthe value for OUTSTEP DO NOT Enter values for NOISE BND RESP TIME and DEAD TIME The Pretune algorithm should calculate these values 6 Makesurethatthe process is reasonably stable and place the controller under manual control 7 Press MENU to access the TUNING menu 8 Setparameter ADAPTIVE to ENABLED The Adaptive Tuning cycle does not begin until the controller is under automatic control 9 Activate the next parameter PRETUNE 10 Press ACK to begin Pretuning The 3rd display will show the message EXECUTING RON Chapt
53. a voltage or current in an analog system binary coded decimal BCD A notation in which the individual decimal digits are represented by a group of binary bits e g in the 8 4 2 1 coded decimal notation each decimal digit is represented by four binary bits bezel The flat portion surrounding the face of the controller which holds the keys and display bump A sudden increase in the output power initiated by the controller in order to determine the system response during a self tune procedure calibration The act of adjustment or verification of the controller unit by comparison of the unit s reading and standards of known accuracy and stability cascade control Control in which the output of one controller or loop is the setpoint for another controller or loop closed loop Control system that has a sensing device for process variable feedback cold junction Point of connection between thermocouple metals and the electronic instrument cold junction compensation Elec tronic means used to compensate for the effect of temperature at the cold junction Appendix 6 configuration Also called Set Up The selection of hardware devices and software routines that function together contact In hardware a set of conduc tors that can be brought into contact by electromechanical action and thereby produce switching In software a symbolic set of points whose open or closed condition depends on the logic s
54. background bring that loop forward using FAST DISPLAY 2 To acknowledge Alarm 1 press ACK once 3 To acknowledge Alarm 2 press ACK twice 4 Ifbothalarmsare activated press ACK once to acknowledge Alarm 1 then again to acknowledge Alarm 2 5 The message and alarm icon disappear Chapter 2 545 User s Manual Basic Interface Interface BEFORE Latching Alarms If an alarm is set up to be latching for details see Chapter 5 then in general it must be acknowledged in order to clear the alarm and release the relay if applicable A non latching alarm will clear itself as soon as the process leaves the alarm condition Limit Sequence An alarm can be configured to be both latching and non acknowledgeable In this case the alarm is acknowledgeable only after the process has leftthe alarm condition This is similar to the function of a limit controller More on Alarms For more details on howto setup alarms and for examples of various ways alarms can be set up refer to the section on Alarms in Chapter 7 545 User s Manual Chapter 2 NOTE Powering down the 545 acknowledges clears all latched alarms When powering up all alarms will be reinitialized Figure 2 2 Before and After Acknowledging an Alarm BasicInterface Interface 10 Chapter 2 545 User s Manual Installation CHAPTER 3 INSTALLATION AND WIRING MOUNTING THE CONTROLLER The 545 front face is NEMA 4X rated waterproof To ob
55. begins if ENABLED OUTPUT 0 ADAPTIVE TIME Pretune 545 User s Manual Chapter 7 93 Applications NOTE Adaptive tuning is not available for velocity position proportional control CAUTION If the process conditions are temporarily changed e g during process shutdown draining of a tank etc disable adaptive tuning Otherwise the controller will attempt to adaptits tuning parameters to the temporary process conditions Disable adaptive tuning by 1 Inthe TUNING menu change ADAPTIVE to DISABLED through the keypad or 2 Closingthe appropriate digital input see Digital Input section in this chapter Figure 7 13 Noise Band Calculation Example 94 Adaptive Tune by Itself 1 Go to the SELF TUNE menu 2 Setthe TYPE parameter to ADAPTIVE 3 4 Setthe ADAPTIVE parameter to ENABLED The Adaptive Tuning cycle does Press MENU to access the TUNING menu not begin until the controller is under automatic control Poor Pretune Results If Pretune results are poor or process conditions do not allow Pretune to run the POWERBACK and Adaptive Tune parameters can be manually configured Proper setting of the noise band and response time parameters will yield excellent adaptive control without running the Pretune function 1 2 Go to the SELF TUNE menu Set NOISE BND The noise band is chosen to distinguish between disturbances which affect the process and process variable
56. first point 1ST PV 9999 to 99999 000 DO 3 XTH INPUT Specifies the input signal for to the XTH point X is 2 to 14 XTH INPUT R Any value greater than the first input D D Thelow end ofthe appropriate input range e g 4 00mA 4 XTH PV Specifies the engineering unit value for to the XTH point X is 2 to 14 XTH PV R 9999 to 99999 00 DO 5 15TH INPT Specifies the input signal for to the 15th point 15TH INPUT 9999to 99999 D D Thehigh end of the appropriate input range e g 20 00mA 6 15TH PV Specifies the engineering unit value for to the 15th point 15TH PV 9999to 99999 Minimum is XTH 1 INPUT DO Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops Emsj ww ew Ca lov wv ETE 545 User s Manual Chapter 5 37 Software Configuration Configuration CONTROL CONTROL Forconfiguring choices forthe control algorithm 1 ALGORITHM Defines the control algorithm used e PI PD JP e ON OFF e PID ON OFF For duplex applications using PID for the first output and on off for the second output 2 D SOURCE D SOURCE Selects the variable used to determine the derivative action D PV D term will not react when you change the setpoint e DEVIATION D term will react when you change the setpoint 3 ACTION 1 ACTION 1 Defines the action of the first control output REVERSE DIRECT _ _
57. for MEW FAST to return to SET UP OPERATION mode for Loop 2 SET UP mode MENW for OPERATION mode MANUAL mode TUNIN OPERATION UNING mode TUNING MEW FAST DISPLAY or _ or SET PT for Loop 1 SET PT for MENU FAST to toggle trough to return to SET UP mode OPERATION mode for Loop 1 in SET UP mode SET UP mode eee RETRANS SELF TUNE CONFIG SECURITY PVINPUT EE CUST LINR MENU FAST to toggle through menu blocks in SET UP mode 28 Chapter 5 545 User s Manual Software Configuration Configuration CONFIGURATION AND OPERATION Figure 5 3 shows the relationships among the different modes of the 545 and the configuration menus e Parameter changes can only be made to the loop in the foreground Loop 1 upon power up To bring the background loop into the foreground to view and make changes hold down FAST and press DISPLAY e SETUP menus only be accessed from manual control To transfer the 545 from automatic to manual control press MANUAL e To access the SET UP menus hold down FAST and press MENU The MENU key will illuminate and CONFIG will appear in the 2nd display e Toaccess the parameters for a particular menu press MENU e Toselecta parameter value use and V Press MENU to advance to the next parameter or FAST MENU to advance to the next menu e To advance to the next menu press FAST MENU TUNING mode andthe TUNING menu can b
58. in the first two output sockets Software Configuration 1 Gotothe CONFIG menu Set CTRL TYPE to STAGED 2 Gotothe CONTROL menu 3 For OUT1 STOP specify where the first output reaches 10096 4 For OUT2 START specify where the second output begins G RETRANSMISSION The retransmission feature be used to transmit a milliamp signal Forananalog output module for corresponding to any of the following values PV SP1 Ramp SP1 OutL1 PV2 retransmission that was not factory SP2 Ramp SP2 OUTL2 A common application is to use it to record one of erry ovens a these variables with a recorder Appendix 4 for details on calibration Hardware Configuration e There must be an analog module installed in output socket 2 or 4 Software Configuration Up to two outputs can be configured for retransmission The menu will scroll through the configuration parameters for specified value X 2 3 or 4 1 Gotothe CONFIG menu 2 For OUTPUT 2 OUTPUT 3 and OUTPUT 4 parameters set one or two of them to RETRANS 3 Gotothe RETRANS menu 4 Setthecorresponding parameter TYPE X for the first retransmission out putto define whatis being transmitted the process variable setpoint ramping setpoint or output 545 User s Manual Chapter 7 83 Applications NOTE To take advantage of multiple setpoints make sure that the SP NUMBER parameter in the SPECIAL menu is set to a value greater than 1 Figure 7 1
59. motion and carefully apply pressure in a uniform direction to separate Photo 4 Separate Boards Installation Guide 500 Series 3 Installation NOTE Front of Unit Back of Unit If you replace the EPROM chip you toward Operator Interface toward rear terminals must align the notch facing the front of the unit BATTERY 5 Pin Connector o Female 22 Pin Connector NOTE The 5 and 22 Pin connnectors on the boards are all keyed so they will only align one correct way Male 22 Pin Remote Setpoint Jumper Male 22 Pin Connector Connector Output 4 4 Male 12 Pin Male 22 Pin Connector Connector Figure 2 12 Pin Female 56 22 Pin Female Microntroller Board Connector Connector Option Board and Power Supply Board 5 Pin Connector Module Retention Plate over Outputs 1 2 3 NOJ1NC NOJ2NC NOJ3 NC 4 500 Series Installation Guide Installation 8 Replace tie wraps for the Retention Plate and for Output Module 4 with new ones Failure to use these devices may result in a loosening of the module and eventual failure If you ordered a module separately it should have come with a tie wrap An extra set of tie wraps is available by order ing Part 535 665 Note For greatest accuracy milliamp modules added for retransmission must be calibrated per instructions in Operator s Manual To Change the Option Board 9 See Photos 3 and 4 Replace the existin
60. not both This action is in addition the selected alarm type additive alarm function OUTPUT Fora RATE alarm selects the output action Use to obtain early indica tionofapossible breakin the process variable signal Select PV BREAK to have rate of change alarm take the same action as a detection of a breakinthe process variable signal where ittrips to manual control ata predetermined output RATE TIME For RATE alarms defines the time period over which a discrete change in process variable must occur for the rate alarm to be activated The amount of change is defined by the alarm setpoint The rate of change is defined as the amount of change divided by the time period 545 User s Manual Applications Example A Ifthe alarm setpoint is set to 10 and the time base is set to 1 second the rate of change is 10 units per second B Ifthe alarm setpoint is set to 100 and the time base set to 10 the rate of change is also 10 units per second In example A the process variable would only have to experience a ten unit change over a short period of time while in Example B it would require a 100 unit change over a ten second period Example A is much more sensitive than Example B In general for a given rate of change the shorter the time period the more sensitive the rate alarm BAND ALARM Figure 7 1 Alarm Examples HIGH PROCESS VARIABLE ALARM IN ALARM IN ALAR IN ALARM _ RELAY RELAY RELAY DE EN
61. to 1816 E 454 to 1832 270 to 1000 J 346 to 1832 210 to 1000 K 418 to 2500 250 to 1371 N 328 to 2372 200 to 1300 R 32 to 3182 0 to 1750 5 32 to 3182 0 to 1750 T 328 to 752 200 to 400 W 32 to 4172 0 to 2300 W5 32 to 4172 0 to 2300 Platinel II 148 to 2550 100 to 1399 RTDS RANGE F RANGE C 100 ohms Pt DIN 328 to 1562 200 to 850 328 0 to 545 0 200 0 to 285 0 100 ohms Pt JIS 328 to 1202 200 to 650 328 0 to 545 0 200 0 to 285 0 100 ohms Pt SAMA 328 to 1202 200 to 650 328 0 to 545 0 200 0 to 285 0 TRANSMITTER SIGNALS INPUT RANGE Milliamps DC 4 to 20 0 to 20 Voltage DC 1105 0105 Millivolts DC 0to 10 0 to 30 0 to 60 0 to 100 25 to 25 LINEARIZATION Thermocouple and RTD inputs are automatically linearized Transmitter inputs may be linearized with a square root function or user defineable 15 point straight line linearization function INPUT IMPEDANCE Current Input 250 ohms Thermocouples 10 Mohms Voltage Input 1 Mohms RTDs 10 Mohms UPDATE RATE Input is sampled and output updated 8 times per second Display is updated five times per second TRANSMITTER LOOP POWER Isolated 24 Vdc nominally loaded loop power supply is available if a loop power module is installed in an output socket Capacity is 25 mA INPUT SIGNAL FAILURE PROTECTION When input is lost output is commanded to a predetermined output 5 to 105 Thermocouple burnout is selectable for upscale or downsca
62. 1 Combinations of Closed Digital Inputs for Each Setpoint based on BCD logic X closed contact open contact 84 5 Set parameters LOW RANGE X and HIGH RANGE X for the first retrans mission output to define the range of the transmitted signal in engineering units This can be useful in matchingthe input range ofthe receiving device 6 Foranyotherretransmission output continue to scroll through the this menu and setthe TYPE X LOW RANGE X and HIGH RANGE X for the second retransmission output H DIGITAL INPUTS Digital inputs can be activated in three ways A switch signal type the rec ommended type a relay or and open collector transistor Digital inputs are only functional when that option is installed via hardware The controller detects the hardware type and supplies the appropriate software menus see the section on parameters in Chapter 5 There are 14 contacttypes for the five digital inputs Hardware Configuration e This optional feature is only available if ordered originally from the factory Product 545xxxxxxDx00 The five digital inputs share a common ground Software Configuration 1 Gotothe CONFIG menu 2 Set parameters CONTACT 1 through CONTACT 3 only those available will shown by assigning the desired function to each output Choices are L1 SP 1 4 CONTACT 1 only Allows the controller to use the digital inputs 1 and 2 to select a setpoint for Loop 1 see Figure 7 11 If the state of t
63. 1 To pretune Loop 2 with a Type 1 pretune Loop 1 must be under manual control Otherwise the controller will display the errormessage PRETUNE LP1 AUTO 2 Topretune Loop 1 Loop 2 mustbe under Automatic Control Otherwise the controller will display the error message PRETUNE L2 MANUAL N RAMP TO SETPOINT The 545 contains a ramp to setpoint function that may be used at the user s discretion This function is especially useful in processes where the rate of change of the setpoint must be limited When the ramping function is activated the controller internally establishes a series of setpoints between the original setpoint and the new target setpoint These interim setpoints are referred to as the actual setpoint Either setpoint may be viewed by the user When the setpoint is ramping RAMPING will be shown in the 3rd display when the actual ramping setpoint is displayed When the target setpoint is being shown RAMPING will not appear Pressing the DISPLAY key will scroll the 2nd display as follows From the target setpoint to the actual ramping setpoint e To the deviation from setpoint e To the output level and Back to the target setpoint Note that when ramping the deviation indication is with respect to the target setpoint The ramp to setpoint function is triggered by one of three conditions 1 Upon power up if the 545 powers up in automatic control then the setpoint will ramp from the process variable valu
64. 20 OUT2 STRT Defines the starting point for control output 2 when staging outputs 01099 50 Next parameter Next value Access Tuning Return to Operation Switch Loops Sesje ww Ca v ww _ Erne fora Chapter 5 545 User s Manual Software Configuration Configuration ALARMS ALARMS For configuring alarms 1 ALM TYPE 1 Defines the type of alarm for alarm 1 ALM TYPE 1 HIGHALRM OFF e LOW ALARM e HIGH LOW Separate High and Low alarm setpoints in one alarm e BAND e DEVIATION e MANUAL Causes an alarm when in manual control e REMOTE SP Causes an alarm when in Remote Setpoint e RATE Selects a rate of change alarm D OFF Deactivates the first alarm 2 ALM SRC 1 Selects the source of the value being monitored by a HIGH LOW or HIGH LOW ALM SRC 1 D PV e SP e RAMP SP e DEVIATION OUTPUT 3 ALARM SP 1 Specifies the alarm set point for alarm 1 ALARM SP 1 For HIGH or LOW alarms If ALM SRC 1 OUTPUT If ALM SRC 1 any othertype R 0 0 to 100 0 R LOW RANGE to RANGE D 0 0 DO For BAND alarms R 11099999 For DEVIATION RATE alarms R 9999 to 99999 0 4A HIGH 1 Specifies the high alarm set point for alarm 1 HIGH SP 1 If ALM SRC 1 OUTPUT If ALM SRC 1 any other type D R 0 096to 100 0 R LOWRANGE to HI RANGE D 0 096 Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops
65. 45 User s Manual Table of Contents of Contents FIGURE DESCRIPTION Pace Yale T Load Line 99 AAG asses Cascade Control of Product Temperature Functional View 102 4 20 assises Cascade Control of Produce Temperature Wiring View E E mnn 103 1 21 aie The Functions of Cascade Control 103 13 22 ades Ratio Control in Mixing Application Wild Stream WING VIOW aaepe 104 nanii Ratio Control in Mixing Application Controlled Stream Functional VIGW i Ee Eee 105 4 245 uiae Ratio Control in Mixing Application Controlled Stream WIT VOW rer 106 T29 ces Feed Forward Control in Mixing Application WiriDg VOW 107 1 20 Feed Forward Control in Mixing Application PUNCtionall ViOW etcetera toit eter 107 VDF assises Fixed and Variable Lag Example Compound Loop Chlorine Control 108 545 Rear Terminals for Calibration 7 4 amp 4 2 Flowchart Calibration Menus 7 A4 3 Jumper Locations on the Microcontroller Circuit Board 8 A4 4 Input Calibration Wiring eese 8 A45 Thermocouple Cold Junction Calibration Wiring
66. 5 to RST INHBT S PROCESS VARIABLE READING CORRECTION Conditions extraneous to the controller an aging thermocouple out of calibration transmitter lead wire resistance etc can cause the display to indicate a value other than the actual process value The PV OFFSET and PV GAIN parameters can be used to compensate for these extraneous conditions NOTE This feature is provided as a convenience only Correcting the cause of the erroneous reading is recommended 1 Goto the PV INPUT menu 2 Set PV OFFSET This parameter either adds or subtracts a set value from the process variable reading in engineering units For example if the ther mocouple was always reading 3 too high the parameter could be set to 3 to compensate Set PV GAIN This multiplies the deviation from the low end of the process variable range by the gain factor and then adds it to the value of the low end of the range to arrive at the adjusted process variable value For example if the process variable range is 50 to 650 and the process variable reading is 472 a PV GAIN of 995 would yield an adjusted process variable equal to 472 50 x 995 50 470 With a combination of both offset and gain factors just about any inaccuracy in the sensor or transmitter can be compensated Chapter 7 545 User s Manual Applications T SERIAL COMMUNICATIONS The serial communications option enables the 545 to communicate with a supervisory devi
67. 500 volts for 1 minute or 600 volts for 1 second 2 RSP Slidewire and the PV inputs are isolated to withstand 50 volts peak between each other for 1 minute 3 PV1 PV2 have isolation to 10 volts or continuous between each other 4 Milliamp Loop Power and SSR Drive modules in output positions 1 2 3 and 4 are not isolated from each other L Earth referenced ground Internal ground ml Ju i Milliamp Module Mechanical Relay SSR Driver Loop Power SSR Output 545 User s Manual Appendix 7 A 23 Isolation Block Diagram Block Diagram A 24 Appendix 7 545 User s Manual RETURN PROCEDURES To return equipment to Moore Industries for repair follow these four steps 1 Call Moore Industries and request a Returned Material Authorization RMA number Warranty Repair If you are unsure if your unit is still under warranty we can use the unit s serial number to verify the warranty status for you over the phone Be sure to include the RMA number on all documentation Non Warranty Repair If your unit is out of warranty be prepared to give us a Purchase Order number when you call In most cases we will be able to quote you the repair costs at that time The repair price you are quoted will be a Not To Exceed price which means that the actual repair costs may be less than the quote Be sure to include the RMA number on all documentation Provide us with the following docu
68. 6 TRIP 6 PROP BND 7 RESET 7 RATE 7 MAN RST 2 TRIP 7 Up to 8 times depending on NO OF PID PROP BND 8 RESET 8 RATE 8 MAN RST 8 TRIP 8 A 2 Appendix 1 545 User s Manual APPENDIX 2 PARTS LIST OPERATOR CIRCUIT CIRCUIT BOARDS BEZEL CONTROLLER BODY MOUNTING INTERFACE BOARD SUPPORT GASKET shown with mounting COLLAR ASSEMBLY BEZEL INSERT collar in place shown with bezel insert in place ITEM PART Output Modules Mechanical Relay Module 535 600 Analog Milliamp Module 535 601 Solid State Relay Module 535 602 DC Logic SSR Drive Module 535 603 Loop Power Module 535 604 RS 485 Communications Module 535 705 Repair Replacement Parts Operator Interface Assembly 545 634 Power Supply Circuit Board 535 730 Microcontroller Circuit Board 535 731 Option Circuit Board w no Options 535 720 Option Circuit Board w Set of 5 Digital Contacts 535 721 Option Circuit Board w Slidewire Feedback 535 722 Option Circuit Board w set of 5 Digital Contacts amp Slidewire Feedback 535 723 EPROM w no Remote Setpoint Option 545 740 EPROM w Remote Setpoint Option 545 741 Lithium Battery 093 128 Jumper Kit Set of All Jumper Connectors 545 660 Gasket Kit 1 Panel Gasket amp 1 Bezel Gasket 535 662 Mounting Kit Mounting Collar amp 4 screws 535 761 Bezel Retention Screw Kit 535 663 Module Retention Kit for Outputs 1 3 Includes Retention Plate
69. 9 A4 6 Analog mA Input Calibration Wiring 10 A4 7 Analog mA Input Jumper 10 A4 B Milliamp Output Calibration Wiring 11 A4 9 Output Module Menu Cycle 11 A4 10 Slidewire Test Wiring essen 12 545 User s Manual Table of Contents V Table of Contents of Contents vi Table of Contents 545 User s Manual Introduction _ CHAPTER 1 INTRODUCTION o 7 1 From its surge resistant power supply its rugged construction the 545 Thank you for selecting the dual process controller is designed to ensure the integrity of your process with loop Process Controller The 545 is maximum reliability hour after hour day after day The isolated inputs user configurable for any of the and outputs guard against the dangers of electrical interference the front following functions face meets NEMA 4X standards for watertight operation and exposure to Two independent PID loops corrosive environments and the solid metal housing and sturdy rubber keys Single Station Cascade Control enhance durability and ESD protection Single Station Ratio Control The 545 has been engineered to be the industry s most user friendly Feed Forward Control process controller With th
70. AST Go to next Menu Block This is a Menu Its name will show in the 2nd display This is a menu Parameter The name shows in the 3rd display In this manual independent parameters appear as white text on black and dependent parameters appear as black lt This is a parameter Value These values appear in the 3rd display replacing the parameter name In this manual parameter graphics selection group indicate the default factory setting If the default value is dependent on other variables D is shown MENUS In SETUP mode there are 12 sets of options that control different aspects of 545 operation in TUNING mode there is one Each set of options is called a menu When traversing the two modes the menu names appear in the 2nd display Most of the menus are loop dependent that is each loop has its own set of parameters for that menu Three of the menus are global that is one set of parameters applies to both loops CONFIG Global Modeselection and input output hardware assignments PV INPUT Process variable input options CUST LINR Linearization curve options for PV input CONTROL Control options ALARMS Alarm options REM SETPT Global Controller remote setpoint options RETRANS Global Retransmission output options SELF TUNE Self tune algorithm options SPECIAL Special feature options SECURITY Global Security functions SER COMM Global SerialCommunications options requires
71. Configuration 21 22 23 FAULT Defines whether either of the alarm relays will trip if a fault condition lost pro cess variable is detected Only appears if at least one alarm relay is installed D OFF ALARM 1 e ALARM2 OUTPUT Defines whether a rate of change alarm will be interpreted as a lost or broken process variable causing a trip to manual output e P V BREAK NOACTION RATE TIME Defines the time period over which a rate of change alarm condition will be determined R 1 to 3600 seconds D 5seconds REM SETPT For configuring the remote setpoint GLOBAL 1 TYPE V mA Specifies the type of input signal that will be used for remote setpoint D 1 5 4 20 Volts mA e 0 5 0 20 Volts mA 2 RSP LO RNG Specifies the engineering unit value corresponding to the lowest remote setpoint input value e g 4mA 9999 to 99999 RSP HI RNG Specifies the engineering unit value corresponding to the highest remote setpoint input value e g 20mA 9999to 99999 D 1000 TRACKING Defines whether the local setpoints 1 to 8 will track the remote setpoint D NO YES Access SetUp Nextmenu Next parameter Next value AccessTuning FAST menu Fast Lv vew 545 User s Manual Chapter 5 FAULT OUTPUT NO ACTION RATE TIME REM SETPT TYPEV MA 1 5 4 20 RSP LO RNG RSP HI RNG TRACKING Return to Operation S
72. Current is limited to 25mA 24V nominally loading CONTROL OUTPUTS Up to two output modules per loop may be designated for control Any combination of output modules with the exception of the loop power supply module may be used Duplex control is available if output modules are installed in the first and second output sockets for either loop Position proportioning control with feedback is available if mechanical or solid state relay modules are installed in the first two output sockets and the slidewire feedback option is installed The feedback option may be added in the field Slidewire feedback range is 0 to 1050 ohms Slidewire SP available for either loop 1 or loop 2 one loop only Velocity position proportioning control is available by installing mechanical or solid state relay modules in the first two output sockets A special algorithm controls an electric actuator without the slidewire feedback signal Staged split range outputs are available if analog modules are installed in the first and second output sockets This algorithm will allow the output range to be split between the two outputs 545 User s Manual Specifications RETRANSMISSION OUTPUT Based on available outputs any socket not used for control up to two different variables can be simultaneously pro grammed for retransmission Each precise 16 bit resolution output may be scaled for any range Variable selection includes PV1 SP1 RAMP SP1 LOOP1OUT
73. ERGIZED ENERGIZED DE ENERGIZED RELAY RELAY RELAY RELAY ENERGIZED DE ENERGIZED ENERGIZED DE ENERGIZED ICON OFF ICON ON ICON OFF ICON OFF ICON ON ICON OFF ICON ON NO ALARM MAY NO ALARM ACKNOWLEDGE NO ALARM CANNOT NO ALARM CANNOT ACKNOWLEDGE ACKNOWLEDGE PARAMETER SETTINGS OUTPUT N ALM RLY ON N 2 to 4 ALM TYPE 1 HIGH ALRM ALM 1 OUT N N 2 to 4 LATCHING NO LATCH ACK 1 ENABLED PARAMETER SETTINGS OUTPUT N ALM RLY OFF N 2 to 4 ALM TYPE 1 BAND ALM 1 OUT N N 2 to 4 LATCHING NO LATCH ACK 1 DISABLED DEVIATION ALARM IN ALARM CONDITION u DES CONDITION RELAY RELAY MUST RELAY RELAY DE ENERGIZED ENERGIZED er rth ENERGIZED ENERGIZED ENERGIZED POWER UP ALARM ICON OFF ICON ON ICON AND ICON ON ICON ON ICON ON DE ENERGIZE NO ALARM MAY RELAY MAY CANNOT MAY ACKNOWLEDGE ACKNOWLEDGE ACKNOWLEDGE ACKNOWLEDGE PARAMETER SETTINGS OUTPUT N ALM RLY ON N 2 to 4 ALM TYPE 1 DEVIATION ALM 1 OUT N N 2 to 4 LATCHING LATCH ACK 1 ENABLED ALARM SP 1 lt 0 545 User s Manual PARAMETER SETTINGS OUTPUT N ALM RLY ON N 2 to 4 ALM TYPE 1 HIGH ALM ALM 1 OUT N N 2 to 4 LATCHING 1 LATCH ACK 1 DISABLED POWER UP 1 ALARM Chapter 7 75 Applications NOTE The duplex output states vary depending upon 1 Control Type PID On Off etc 2 Control Action DA RA 3 Output L
74. F Staged Outputs sss 83 N 96 Ratio Control sss 104 G Retransmission sss 83 O InputLinearization 97 W FeedForward Feedback Control 107 H Digital Inputs P Load Line X Lag Time net e tatis 108 A CONTROLTYPE Each of the control loops in the 545 can be independently configured Software Configuration 1 Gotothe CONTROL menu 2 Forthe parameter ALGORITHM select the type of 545 control e ON OFF Crude control similar to a household thermostat Used primarily on slow stable processes where moderate deviation cycling around setpoint is tolerable Only available with SSR SSR Drive and relay outputs e P Proportional only control Provides much better control than on off Used on processes that are less stable or require tighter control but have few load variations and do not require a wide range of setpoints e PI Proportional plus integral control In addition to proportional control itcompensates for control errors due to a wide range of setpoints or load requirements The integral term works to eliminate offsets e PD Proportional plus derivative control In addition to proportional con trol it compensates for control errors due to fast load variations PID Proportional plus integral plus derivative control In addition to pro portional co
75. FOR ANY INCIDENTAL OR CONSE QUENTIAL DAMAGES WORLDWIDE www miinet com China sales mooreind sh cn Tel 86 21 62491499 FAX 86 21 62490635 United Kingdom sales mooreind com Tel 01293 514488 FAX 01293 536852 Belgium info mooreind be Tel 03 448 10 18 FAX 03 440 17 97 The Netherlands sales mooreind nl Tel 0 344 617971 FAX 0 344 615920 United States info miinet com MO ORE Tel 818 894 7111 FAX 818 891 2816 INDUSTRIES rei 02 8535 7200 rix 02 9525 725 2006 Moore Industries International Inc Specifications and Information subject to change without notice
76. GH LOW alarm 2 15 DEADBAND 2 Deadband for alarm 2 16 ALM 2 OUT Output number for alarm 2 17 LATCHING 2 Latching sequence for alarm 2 18 ACK 2 Whether alarm 2 may be acknowledged 19 POWERUP 2 How alarm 2 will be treated upon power up 20 MESSAGE 2 Nine character message associated with alarm 2 21 FAULT Alarm relay status if fault condition is detected 22 OUTPUT Output if the rate of change alarm is tripped 23 RATE TIME Time period over which a rate of change alarm is determined 58 Chapter 5 545 User s Manual Software Configuration Configuration REM SETPT Global Parameter Description Value 1 TYPEV mA Input signal to be used for remote setpoint 2 RSP LORNG Engineering unit value corresponding to low remote setpoint input value 3 RSP HIRNG Engineering unit value corresponding to high remote setpoint input value 4 RSP LOW Lowest setpoint value to be accepted from the remote setpoint source 5 RSP HIGH Highest setpoint value to be accepted from the remote setpoint source 6 TRACKING Whether the local setpoint will track the remote setpoint 7 BIASLOW Lowest bias value that may be entered 8 BIAS HIGH Highest bias value that may be entered 9 RSPFIXED What happens if remote setpoint is lost while active and then restored RETRANS Global Parameter Description Value 1 TYPE2 Whatis to be retransmitted for output 2 2 LORANGE2 Low end of the
77. IVE REMEDIES FOR BREACH OF ANY WARRANTY CONCERNING THE GOODS OR SERVICES SHALL BE FOR THE COMPANY AT ITS OPTION TO REPAIR OR REPLACE THE GOODS OR SERVICES OR REFUND THE PURCHASE PRICE THE COMPANY SHALL IN NO EVENT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES EVEN IF THE COMPANY FAILS IN ANY ATTEMPT TO REMEDY DEFECTS IN THE GOODS OR SERVICES BUT IN SUCH CASE THE BUYER SHALL BE ENTITLED TO NO MORE THAN A REFUND OF ALL MONIES PAID TO THE COMPANY BY THE BUYER FOR PURCHASE OF THE GOODS OR SERVICES ANY CAUSE OF ACTION FOR BREACH OF ANY WARRANTY BY THE COMPANY SHALL BE BARRED UNLESS THE COMPANY RECEIVES FROM THE BUYER A WRITTEN NOTICE OF THE ALLEGED DEFECT OR BREACH WITHIN TEN DAYS FROM THE EARLIEST DATE ON WHICH THE BUYER COULD REASONABLY HAVE DISCOVERED THE ALLEGED DE FECT OR BREACH AND NO ACTION FOR THE BREACH OF ANY WAR RANTY SHALL BE COMMENCED BY THE BUYER ANY LATER THAN TWELVE MONTHS FROM THE EARLIEST DATE ON WHICH THE BUYER COULD REASONABLY HAVE DISCOVERED THE ALLEGED DEFECT OR BREACH RETURN POLICY For a period of thirty six 36 months from the date of shipment and under normal conditions of use and service Moore Industries The Company will atits option replace repair or refund the purchase price for any of its manu factured products found upon return to the Company transportation charges prepaid and otherwise in accordance with the return procedures established by The Company to be defective in material or workm
78. L1 2ND SP Makes the second setpoint active e L1 2ND PID Makes the second set of PID values active e L1 ALARM ACK Acknowledges alarms e L1 RST INH Deactivates the reset term L1 D A R A Switches the control action L1 NO A T Suspends the adaptive tune function e L1 LCK MAN Locks controller in manual control e UPKEY Remote A function e DOWNKEY Remote W function e DISPKEY Toggle between SP DEV or OUT e FASTKEY Actives FAST key e MENUKEY Activates MENU key e COMM ONLY Status readable only through communica tions L1 SP 1 4 Assigns the first two digital inputs to select setpoints 1 through 4 via BCD signal e L1 REM SP Makes the remote setpoint active 13 CONTACT2 CONTACT 2 Defines the operation of the second digital input for Loop 1 11 Trips the controller to manual control e L1 2ND SP Makes the second setpoint active e L1 2ND PID Makes the second set of PID values active e L1 ALARM ACK Acknowledges alarms e L1 RST INH Deactivates the reset term e L1 D A R A Switches the control action L1 NO A T Suspends the adaptive tune function e L1 LCK MAN Locks controller in manual control e UPKEY Remote A function e DOWNKEY Remote W function e DISPKEY Toggles between SP DEV or OUT e FAST KEY Actives FAST key e MENU KEY Activates MENU key e COMM ONLY Status readable only through communica tions D L1 REM SP Makes the remote setpoint active Access SetUp Nextmenu Next pa
79. MENU to access the TUNING menu 2 Set values for parameters 1 thru 20 these include the first PID set 3 Press MENU to access these parameters for each additional PID set 2 through 8 PROP BND RESET RATE MAN RST and TRIP 545 User s Manual Chapter 7 95 Applications 96 Self Tune with Time Proportioning Outputs When using either the Pretune or the Adaptive Tune with a time proportioning output use as short of a cycle time as possible within the constraint of maintaining a reasonable life on relays contacts or heating elements Self Tune with Control Valves In many systems utilizing a control valve the point at which the control valve begins to stroke does not coincide with 0 output and the point at which it completes its stroke doesn t coincide with 10096 The parameters LOW OUT andHIGH OUT inthe CONTROL menu specifythe limits onthe output Setthese limits to correspond with the starting and stopping point of the valve s stroke This prevents a form of windup and thus provides the adaptive control algorithm with the most accurate information For example in manual the control output was slowly increased and it was noted thatthe control valve started to stroke at 18 and at 91 it completed its stroke In this case LOW OUT should be set at 18 and HIGH OUT at 91 Note that when output limits are used the full output range from 5 to 105 is available in manual control Self Tune with Cascade Control
80. MENU until the display indicates CALIBRATE ANA mA IN then press ACK If the display shows PV1 20mA PRESS ACK move ahead to step 8 4 Thecontroller will display SET BOTH JUMPER mA 5 Power down the controller and remove chassis from the case 545 User s Manual Appendix 4 A 9 Calibration Figure A4 6 Wires to 20 current floating 2 PV2 Pvi PVI Analog mA Input Calibration Wiring Figure A4 7 Analog mA Input Jumper Positions A 10 6 Remove both inputjumper connectors from the pins inthe 2nd position Place one of the jumpers on the PV1 position mA pins and place the other jumper on the 2nd position mA pins as shown in Figure A4 7 Reinsert the chassis into the case and apply power The controller should display PV1 20mA PRESS ACK to indicate it is ready to calibrate the PV1 milliamp input 8 Connecta precision 20mA inputto the PV1 terminals 31 is PV1 32 is PV1 Make sure the terminal connections are fastened tightly and that a 20mA current is flowing through PV1 Do not connect the 20mA current to PV2 yet 9 Letthecontroller warm upforatleast 10 minutes keep in normal horizontal position Make sure the currentis flowing then press ACK to calibrate the PV1 input 10 Ifthe controller displays PV2 20mA PRESS PV1 calibration was suc cessful Move on to step 12 11 Ifthe controller briefly displays mA CALIB FAILED PV1 calibration was no
81. Manual 6 Tochange module 4 Output Module 4 on the Option board is also held in place by a tie wrap Snip tie wrap to remove module as shown in Photo 6 7 Figure 4 3 shows a representation of an output module Inspect the module s to make sure that the pins are straight 8 Toinstall any module align its pins with the holes in the circuit board and carefully insert the module in the socket Press down on the module until it is firmly seated refer to Photo 7 6 Snip Tie Wrap 7 Add Change Module 9 Replace tie wraps for all the modules the Retention Plate and Output Mod ule 4 with new ones before reassembling the controller Failure to use the tie wraps may result in loosening of the module and even tual failure All separately ordered modules should come with a tie wrap Extra sets of tie wraps are available by ordering Part 545 665 NOTE For greatest accuracy calibrate all milliamp modules added for retransmission as per the instructions in Appendix 2 10 Rejointhe circuit boards by aligningthe pins oftheir connectors then squeez ing the board s together Make sure that all three printed circuit boards are properly seated against one another check along side edges for gaps Make sure the cable assemblies are not pinched 11 To reattach the board assembly to the front face assembly align the boards with the open area ontop into the slots of the font face assembly The clips should snap into place 12 To re
82. NE again INPUT ERR 1 2 3 PV or Cold Junction break detected during PRETUNE Check the described conditions and make corrections or repairs 1 2 83 PV HIGH or PV LOW detected during PRETUNE 1 2 3 SLIDEWIRE break detected during PRETUNE 1 2 3 REMOTE SP break detected during PRETUNE OUT ERROR 1 2 3 The initial control output is outside the high and low limits Change the manual output percent and run PRETUNE again defined in the Control Menu DATA ERR 2 3 The PV moved too quickly to be Analyzed Increase the OUT STEP size and run PRETUNE again ZERO ERR 2 3 One or more model parameters are calculated to be zero Increase the OUT STEP size and run PRETUNE again DEV ERROR 1 The initial PV is too close to the TUNE PT Move Tune PT or the set point if TUNE PT is automatic farther from the process variable and run PRETUNE again RETRY 1 2 3 The Process Variable went beyond the HI LIMIT or LOW Check if any PID values are generated and if they are LIMIT acceptable If not eliminate noise sources if possible and run PRETUNE again If Pretune and Adaptive Tune do not generate optimal PID values for control check the following menu entries Potential Problem Corrective Action RESPONSE Adaptive Tune cannot run if RESPONSE TIME is inaccurate Run TYPE 2 or TYPE 3 Pretune to obtain the correct value TIME or enter it manually NOISE BAND Adaptive Tune cannot compensate
83. NTROL ALGORITHM PV BREAK 2ND INPUT 2ND PV 15TH INPUT 15TH PV FIXED LAG VARBL LAG MAX LAG FF LO LIM 1ST PV ACTION 1 LOW OUT HIGH OUT FF HI LIM ACTION 2 CCW TIME CW TIME MIN TIME S W RANGE OPEN F B CLOSE F B OUT1 STOP ALARMS ALM TYPE 1 ALM 1 OUT OUT2 STRT ALM SRC 1 ALARM SP 1 LOW SP 1 DEADBAND 1 LATCHING 1 POWER UP 1 ALM TYPE 2 z ALM SRC 2 ALARM SP 2 LOW SP 2 DEADBAND 2 ALM 2 OUT LATCHING 2 POWER UP 2 H MESSAGE 2 FAULT OUTPUT RATE TIME REM SETPT ECCL sss man RETRANS TYPE 2 LORANGE2 HIRANGEZ TYPE 3 LO RANGE 3 HIRANGE 3 TYPE 4 LO RANGE 4 HIRANGE 4 SELF TUNE TYPE PRETUNE TUNE PT OUT STEP LOW LIMIT HI LIMIT TIMEOUT H worse BND RESP TIME DEAD TIME SPECIAL AUTO TRIP TRIP DEV DES OUTPT POWER UP PWR UP OUT PWR UP SP secum 9 sec cone jH sP anus 545 User s Manual Appendix 1 A 1 Menu Flowcharts Flowcharts ADAPTIVE PRETUNE POWR BACK RESET 1 TUNING RATE 1 PID OFST 2 PROP BND 1 MAN RST 1 CYCLE TM 1 DEADBAND 1 P PROP D B PID OFST 1 REL GAIN 2 CYCLE TM 2 DEADBAND 2 RSP RATIO RSP BIAS FF BRK ZR NO OF PID PID TRIP TRIP 1 PROP BND 2 RESET 2 RATE 2 MAN RST 2 TRIP 2 PROP BND 3 RESET 3 RATE 2 MAN RST 3 TRIP 3 PROP BND 4 RESET 4 RATE 4 MAN RST 4 TRIP 4 PROP BND 5 RESET 5 RATE 5 MAN RST 5 TRIP 5 PROP BND 6 RESET 6 RATE 6 MAN RST
84. No RSP 585 770 535 Profiler EPROM Kit RSP 535 740 535 EPROM Kit No RSP 545 740 545 EPROM Kit No RSP 545 741 545 EPROM kit RSP 555 740 555 EPROM kit Microcontroller MCU Board Kits 585 7315 MCU Board Kit 545 738 MCU Board Kit with CE Option Option Board Kits b8b 720 inane 531 532 535 545 Option Board Kit No Options 585 721 531 532 535 545 Option Board Kit Digital Inputs 585 722 5 535 545 Option Board Kit Slidewire Feedback 585 729 535 545 Option Board Kit Digital Inputs and Slidewire Feedback 545 724 531 532 535 545 555 RSP 545 725 iis 531 532 535 545 555 Option Board Kit Digital Inputs and RSP 545 726 535 545 555 Option Board Kit Slidewire Feedback and RSP 545 727 535 545 555 Option Board Kit Digital Inputs Slidewire Feedback and RSP HOW TO USE THIS MANUAL A CAUTION Static discharge will cause damage to equipment Always ground yourself with a wrist grounding strap when handling electronics to prevent static discharge B Before removing or inserting any hardware on the controller copy down all configuration parameters Also replacing the battery EPROM or MCU Board will erase parameter settings and they will need to be reset C Forall hardware adjustments perform steps 1 2 and 3
85. ON Inputs and outputs are grouped into the following blocks Block 1A process variable input 1 Block 1B process variable input 2 Accuracy specifications are at reference conditions 25 C Still Air and only apply for NIST ranges PV1 Thermocouple Cold Junction accuracy is 0 02 degree from reference conditions PV2 Thermocouple Cold Junction Accuracy is 0 10 degree from Block 2 outputs 1 2 and 4 reference conditions Display accuracy is 1 digit Cold Junction Block 3 communications set of five digital inputs output 3 Earth Ground accuracy is 0 02 degree Detailed accuracy information is Block 4 remote setpoint available upon request CONTROL ALGORITHM PID P with manual reset Pl PD with manual reset and On Off are selectable from the front panel Duplex outputs each use the same algorithm except On Off may be used with PID The control output may be configured for cascade ratio and feed forward applications Fixed lag capability is available for PID loops with a constant delay Variable lag capability is available when using the feed forward mode where the source of feed forward contribution may fluctuate Feed forward contribution automatically modifies the length of the lag time TUNING PARAMETERS Each block is electrically isolated from the other blocks to withstand a HIPOT potential of 500 Vac for 1 minute or 600 Vac for 1 second with the exception of blocks 1 and 4 which are isolated to withstand a HIPOT pot
86. ON the default mode of the controller When the 545 is operating you can change setpoints select manual control and change output level acknowledge alarms and monitor conditions SET UP also referred to as configuration Here you set up the basic func tions of the instrument such as input and output assignments alarm types and special functions TUNING where you configure function parameters for Proportional Integral and Derivation PID control Use this mode periodically to optimize the control performance of the instrument ORDER CODE PACKAGING INFORMATION Comparing the product number to the ordering code on page 3 to determine the outputs and options installed on the 545 The product number is printed on the label on the top of the controller case Included with the 545 are e 545 User s Manual e mounting hardware e 1 sheet engineering unit adhesive labels WHERETO GO NEXT e To become more familiar with the 545 interface continue to Chapter 2 e Forimportant hardware installation guidelines see Chapters and 4 e For a detailed description of all the software menus and parameters of the 545 follow through Chapter 5 and 6 Appendix 1 can be usedasa guide to these parameters TEXT FORMATTING INTHIS MANUAL Feature Format KEYS SET PT DISPLAY or ICONS OUT ALM MENUS CONFIG TUNING PARAMETERS CYCLE TM 1 MIN OUT2 PARAMETER VALUES OFF SETPOINT LAST OUT DISPLAY MESSAGES TOO HOT OUT 2 Chapter 1 545
87. Switch Loops Err new ww v ww EXE 42 Chapter 5 545 User s Manual Software Configuration Configuration 11 12 13 14 ALM TYPE 2 Defines the type of alarm for alarm 2 e HIGHALRM e LOWALARM e HIGHLOW Separate High and Low alarm setpoints in one alarm e BAND e DEVIATION MANUAL Causesanalarm when in manual control e REMOTE SP Causes an alarm when in Remote Setpoint e RATE Selects rate of change alarm D OFF Deactivates the first alarm ALM SRC 2 Selects the source of the value being monitored by a HIGH LOW or HIGH LOW alarm 2 D PV e SP e RAMP SP DEVIATION OUTPUT ALARM SP 2 Specifies the alarm setpoint for alarm 2 For HIGH or LOW alarms If ALM SRC 2 OUTPUT If ALM SRC 2 any othertype R 0 0 to 100 0 R LOW RANGE to HI RANGE D 0 0 D 0 For BAND alarms R 11099999 D 0 For DEVIATION or RATE alarms R 9999 to 99999 D 0 A HIGH SP 2 Specifies the high alarm setpoint for alarm 1 If ALM SRC 2 OUTPUT If ALM SRC 2 any other type R 0 0 to 100 0 R LOW RANGE to HI RANGE D 0 0 DO Access Set Up Next menu Next parameter Next value Access Tuning FAST menu a Lv vew 545 User s Manual Chapter 5 ALM TYPE 2 ALM SRC 2 ALARM SP 2 D HIGH SP 2 D Return to Operation DISPLAY Switch Loops FAST DISPLAY 43 Software Configuration Configuration
88. Thermocouple Input CAUTION e RTD Input Do not run low power sensor input Volt delnput lines in the same bundle as AC power Inpu lines Grouping these lines inthe same Milliamp Input with External Power Supply bundle can create electrical noise e Milliamp Input with Internal Power Supply interference Each type of input can be wired for PV1 terminals 31 and 32 or for PV2 termi nals 28 and 29 Digital Input s TOP Figure 3 5 Process Variable Terminals Screws must be tiaht to ensure aood electrical connection 545 User s Manual Chapter 3 13 Installation NOTE Typically in the U S negative leads are red Figure 3 6 PV1 and PV2 Wiring for Milliamp RTD and Voltage Inputs 14 For PV1 THERMOCOUPLE INPUT 2 WIRE RTD Jumper wire 3 WIRE RTD Same color Third leg 4 WIRE RTD Same color Third leg Same color DO NOT connect 4th leg VOLTAGE INPUT 31 e 4 Transmitter Chapter 3 For PV2 THERMOCOUPLE INPUT 2 WIRE RTD Jumper wire 3 WIRE RTD Third leg of RTD 4 WIRE RTD Same color Third leg NOT of RTD connect 4th leg VOLTAGE INPUT gl P z Transmitter 545 User s Manual installation For PV1 MILLIAMP INPUT 2 wire transmitter with separate power supply _ External Power Supply MILLIAMP INPUT 2 wire transmitter with loop power su
89. User s Manual Introduction _ 545 IC Ilolo Order Output 1 Control Code NONG LE 0 Mechanical Relay 5 1 Analog 2 Solid State Relay triac 1 3 DC Logic SSR drive _ 4 Output 2 Control Alarm or Retransmission NOME 0 Mechanical Relay 5 t itae 1 Analog sae ach NO ENTRE TEE 2 Solid State Relay triac 1 3 DC Logic eee 4 Output 3 Control Alarm Retransmission or Loop Power Gees E er 0 Mechanical Relay 5 1 Analog milliaMp 0 2 0 0 cccecccceccecceceeseseeeeeeeseeees 2 Solid State Relay triac 1 3 DC Logic SSR 4 Loop 5 Output 4 Control Alarm Retransmission Loop Power m Se oe 0 Mechanical Relay 0 5 amp 24 1 Analog apo so tees 2 Solid State Relay triac 0 5 amp 24 3 DG Eogic SSR OVE acea 4 LOO WEN PR D 5 Options Enter 0 if not desired Slidewire Feedback for Position
90. al setpoints up to 8 to be stored for selection by the front SET PT key or up to 4 for selection by BCD Binary Coded Decimal digital inputs D 1 Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops Err wee ww Ca v ww EXE 50 Chapter 5 545 User s Manual Software Configuration Configuration SECURITY SECURITY Forconfiguring the security function GLOBAL 1 SEC CODE Defines the security code for temporarily unlocking the instrument SEC CODE 9999t0 99999 20 DO 2 SP ADJUST Defines lockout status for setpoint changes SP ADJUST D UNLOCKED UNLOCKED LOCKED 3 AUTO MAN Defines lockout status for MANUAL key AUTO MAN D UNLOCKED UNLOCKED LOCKED 4 SP SELECT Defines lockout status for SET PT key SP SELECT D UNLOCKED UNLOCKED e LOCKED 5 ALARM ACK Defines lockout status for ACK key ALARM ACK D UNLOCKED UNLOCKED e LOCKED 6 TUNING Defines lockout status for adjusments to tuning parameters TUNING D UNLOCKED UNLOCKED LOCKED 7 CONFIGURE Defines lockout status for configuration parameters CONFIGURE D UNLOCKED UNLOCKED e LOCKED Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops Emsj ww ew Ca lov wv Fs pseu 545 User s Manual Chapter 5 51 Software Configuration Configuration SER COMM SER COMM Forconfiguring the
91. anship This policy extends to the original Buyer only and not to Buyer s customers or the users of Buyer s products unless Buyer is an engineering contractor in which case the policy shall extend to Buyer s immediate customer only This policy shall not apply if the product has been subject to alteration misuse accident ne glect or improper application installation or operation THE COMPANY SHALL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSE QUENTIAL DAMAGES WORLDWIDE www miinet com China sales mooreind sh cn Tel 86 21 62491499 FAX 86 21 62490635 United Kingdom sales mooreind com Tel 01293 514488 FAX 01293 536852 Belgium info mooreind be Tel 03 448 10 18 FAX 03 440 17 97 The Netherlands sales mooreind nl Tel 0 344 617971 FAX 0 344 615920 United States info miinet com MO ORE Tel 818 894 7111 FAX 818 891 2816 INDUSTRIES rei 02 8535 7200 rix 02 9525 725 2006 Moore Industries International Inc Specifications and Information subject to change without notice 500 SERIES Form M500 V6 Process Controllers Hardware Installation and Modification Manual for Electronic Products Series 531 532 535 545 555 Model 2 il moore INDUSTRIES M500 V6 JUNE 2005 Installation INTRODUCTION This technical brochure provides hardware installation and modification instructions for our controllers Series 531 532 535 545 and
92. ap when handling electronics to prevent static discharge 23 Hardware Configuration Configuration 24 3 Pry Clips ADDING AND CHANGING OUTPUT MODULES The 545 has provisions forfour output modules A controller ordered with output module options already has the modules properly installed Follow these instruc tions to add modules change module type s or change module location s Equipment needed Wrist grounding strap Phillips screwdriver 2 Small flat blade screwdriver Wire cutters 1 With power off loosen two front screws and remove them 2 Slide the chassis out of the case by pulling firmly on the bezel 3 Use aflat screwdriver to carefully pry apart the clips that hold the front face assembly to the chassis as in Photo 3 Separate the printed circuit board assembly from the front face assembly Use care not to break the clips or scratch the circuit boards 4 Asshown in Photo 4 carefully pry apart using hands ora small flat screw driver the smaller Option board and the Power Supply board the one with 3 modules 5 To change modules 1 2 or 3 Output modules 1 2 and 3 are firmly held in place by a retention plate and tie wrap Carefully snip the tie wrap with a wire cutter To prevent damage to the surface mount components ALWAYS snip the tie wrap on TOP of the Retention Plate as shown in Photo 5 Remove the retention plate 4 Separate Boards 5 Remove Retention Plate Chapter 4 545 User s
93. apter 3 11 Installation CAUTION The enclosure into which the 545 Controller is mounted must be grounded according to CSA standard C22 2 No 0 4 WARNING Avoid electrical shock Do not connect AC power wiring at the source distribution panel until all wiring connections are complete Figure 3 3 Terminal Assignments Actual 545 device only has top and bottom numbers of each column of terminals marked WARNING Electric Shock Hazard Terminals 1 and 2 carry live power DO NOT touch these terminals when power is on WARNING Terminal 9 must be grounded to avoid potential shock hazard and reduced noise immunity to your system 12 6 Insert the four mounting collar screws from the rear of the collar Gradu ally tighten the screws using a Phillips 2 screwdriver to secure the controller against the panel 7 Ifthere is difficulty with any of the mounting requirements apply a bead of caulk or silicone sealant behind the panel around the perimeter of the case WIRING Our545 controllers are thoroughly tested calibrated and burned in atthe fac tory so the controller is ready to install Before beginning read this chapter thor oughly and take great care in planning a system A properly designed system can help prevent problems such as electrical noise disturbances and danger ous extreme conditions 1 Forimproved electrical noise immunity install the 545 as far away as pos sible f
94. arameters X LAG TIME These functions are for slow processes with long or changing lag times Figure 7 27 shows acompound loop flow pacing feed forward feed back water chlorination control system The fixed lag time is the time under steady flow it takes the chlorine to travel from the injector to the residual sampling point Under fluctuating flow rates the travel time between the injector and the sampling point will vary When variable lag time is invoked changes in the flow past the flow meter automatically increase or decrease the lag time between the injector and sampling point Residual Signal 945 Controller Valve Control Signal Chlorine Residual Analyzer Flow Sample Flow Signal Chlorine Tank Residual Water FI Sampling Point SP Chlorine Water Flow Injector Fixed Lag Fixed Lag FIXED LAG is a constant delay that prevents change in the control output before the results of the previous control value change can be measured The fixed lag function may be used with the following control types ONE LOOP DUALLOOP FFWD SUM and FFWD MULT Chapter 7 545 User s Manual Applications Software Configuration 1 In the CONFIG menu set CTRL TYPE to ONE LOOP DUAL LOOP FFWD SUM or FFWD MULT 2 Inthe CONTROL menu set the FIXED LAG from 0 to 14400 seconds 3 Setup all other parameters as needed for your control application Remember changes in the control
95. assemble the controller properly orient the chassis with board open ing ontop Align the circuit boards into the grooves on the top and bottom of the case Press firmly on the front face assembly until the chassis is all the way into the case If itis difficultto slide the chassis in all the way make sure the screws have been removed they can block proper alignment and that the chassis is properly oriented 13 Carefully insert and align screws Tighten them until the bezel is seated firmly against the gasket Do not overtighten 545 User s Manual Chapter 4 Hardware Configuration Figure 4 3 Representation of Module 25 Hardware Configuration Configuration Figure 4 4 Install Communications Module onto Microcontroller Board 26 SPECIAL COMMUNICATIONS MODULE A special communications module is available for the 545 see order code in Chapter 1 for details Equipment needed Wrist grounding strap Phillips screwdriver 2 Small flat blade screwdriver 1 Before installing the communications module set up the hardware wiring for the application See Chapter 4 for details 2 With power off loosen two front screws and remove them Slide the chassis out of the case by pulling firmly on the bezel Do not detach the board assembly from the front face of the controller 4 Orient the Communications Module as shown and attach it to Connectors P1 and P2 as shown in Figure 4 4 Insert module onto connectors
96. ating and cooling functions the range through which an input can be varied without initiating observable change in output dead time The interval of time be tween initiation of an input change or stimulus and the start of the resulting observable response default settings Parameters selec tions that have been made at the factory derivative Anticipatory action that senses the rate of change of tempera ture and compensates to minimize overshoot and undershoot Also rate derivative action See control action derivative deviation The difference between the value of the controlled variable and the value at which it is being controlled digital input Used in this manual to indicate the status of a dry contact also called gate display 1st The top largest display of controller face that is used to display the process variable value display 2nd The middle display of the controller face used to indicate Operation Mode setpoint deviation or output Tuning and Set Up Mode parameter or parameter menu display 3rd The bottom display of the controller face that is used to indicate Operation Mode alarm or error message Tuning of Set up Mode the value or choice of the parameter disturbance An undesired change that takes place in a process that tends to affect adversely the value of a con trolled variable duplex control Control method where the temperature of the end product i
97. ation standard for specifying a product s resistance to water and corrosion normally open A switched output i e relay etc whose unpowered state has no connection normally closed A switched output i e relay whose unpowered state provides connection noise An unwanted component of a signal or variable noise band A measurement of the amount of random process noise affecting the measurement of the process variable Appendix 6 offset The difference between the setpoint and the actual process variable or adjustment to actual input temperature and to the temperature values the controller uses for display and control ON OFF control Control of a process variable about a setpoint by turning the output full ON below setpoint and full OFF above setpoint open loop Control system with no sensory feedback optimization The act of controlling a process at its maximum possible level of performance usually as expressed in economic terms output Action in response to difference between setpoint and process variable output modules Plug in devices that provide power handling to enable process control These modules are either binary on off such as a relay or analog continuously variable for current loop control overshoot Condition where tempera ture exceeds setpoint due to initial power up or process changes P control Proportioning control PD control Proportioning control with rate ac
98. board firmly in place To remove the retention plate snip the tie wrap with wire cutters Photo 5 OPTION BOARD Figure 1 Location of Printed Circuit Boards for Hardware Configuration 2 Slide the chassis out of the case by pulling on front face plate assembly at the bezel see Figure 1 3 Locate the retention clips holding the front face assembly to the rest of the chassis Pry apart these retention clips gently with a screwdriver to separate the printed circuit board group from the front face assembly Photo 3 Photo 5 Remove Retention Plate CAUTION Always snip the tie wrap on top of the Retention Plate as shown in photo 5 to prevent damage to the surface mount components 6 Adisposable tie wrap Take care not to Photo 3 Pry Clips holds Output module break the clips or 4 on the Option scratch the circuit board board in place To The Microcontroller Board and Power Supply Board remove the module remain attached to the Operator Interface Assem snip the tie wrap bly by wired connectors Photo 6 7 Inspect each module before installation to make sure the pins are straight Align 22 the pins with the Photo 6 socket holes and Snip Tie Wrap on Mod 4 carefully insert the module Press down on the module to seat it firmly on the board 4 The Microcontroller and Power Supply board are attached to either side of the Option board by male female pin connectors Use a gentle rocking
99. bution when Loop 2isin AUTO mode RH 100to 100 D 10096 ACTION 2 Defines the action of the second control output D DIRECT e REVERSE Access SetUp Nextmenu Next parameter Next value AccessTuning Ese ww iv Chapter 5 PV BREAK D LOW OUT HIGH OUT 100 FF LO LIM FF HI LIM 100 ACTION 2 DIRECT Return to Operation DISPLAY Switch Loops FAST DISPLAY 39 Access Set Up Erast mewu CCWTIME CWTIME MIN TIME S W RANGE OPEN F B D CLOSE F B OUT1 STOP OUT2 STRT Next menu Software Configuration Configuration 13 CCW TIME Defines the time it takes a motor to fully stroke counterclockwise R 1to200seconds D 60seconds 14 CW TIME Defines the time it takes a motor to fully stroke clockwise R 1to200seconds D 60seconds 15 MIN TIME Defines the minimum amountof time the controller must specify forthe motorto be on before it takes action R 0 1to 10 0 seconds D 0 1seconds 16 S W RANGE Specifies the full range resistance of the slide e g 100 ohms R 0 10500hms D 100Ohms 17 OPEN F B Defines the feedback ohm value corresponding to full open 100 output OtoS W RANGE D Dependentupon S W RANGE value 18 CLOSE F B Defines the feedback ohm value corresponding to full close 0 output R OtoS WRANGE D 100 19 OUT1 STOP Defines the stopping point for control output 1 when staging outputs R 1to100 D 50
100. ce such as a personal computer or programmable logic controller The communications standard utilized is RS 485 which provides a multi drop system thatcommunicates ata high rate over long distances Typical limitations are 32 instruments per pair of wires over a distance up to 4000 feet The 545 uses a proprietary protocol which provides an extremely fast and accurate response to any command Cyclic redundancy checking CRC virtually ensures the integrity of any data read by the 545 Through communications there is access to every Set up Tuning and Operating parameter For details on 545 protocol contact a Moore Industries application engineer Hardware Configuration e This optional features is only available if ordered originally from the factory The circuitry for communications is contained on a modular circuit board that plugs into the Microcontroller Circuit Board Refer to the order code in Chapter 1 for details Software Configuration 1 Access the SER COMM menu 2 STATION specifies the unit s station address Itis the only way one 545 can be distinguished from another Each 545 onthe same RS 485 interface must have a unique station address 3 Choose a BAUD RATE from 1200 to 19 200 In general select the highest value However every instrument on the RS 485 interface must be set to the same baud rate 4 CRC indicates the cyclic redundancy checking feature If the host supports it activating this option is recommen
101. cess where two PID control loops need to interact to achieve optimum control Cascade Control is commonly implemented in temperature control applications where the main control variable is affected by another variable i e pressure see Figure 7 19 When the 545 is configured for Cascade Loop 1 is automatically the primary or outer feedback Loop and Loop 2 is the secondary or inner feedback loop Loop 1 will not have a physical output but rather the PID algorithm output is internally fed to Loop 2 as its Setpoint Loop 2 s output comes out of Output 1 Should Loop 2 require two outputs e g duplex staged the second output would come out of Output 2 raw materials EXCHANGER d001 3dISLNO pressure sensor temperature sensor Hardware Configuration e Wireasin Figure 7 20 Software Configuration 1 ForLoop 1 a In CONFIG menu set CTRL TYPE to CASCADE b In PV INPUT menu set the PV TYPE If type is V mA set LO RANGE and HI RANGE parameters to match the transmitter range Chapter 7 545 User s Manual Applications raw materials Boa DU Hios DIN 1 8A on 2 19 ow 200 E DIN 4 21 g EXCHANGER ons 2200 steam 2 48 penser OUTSIDE LOOP temperature sensor INSIDE LOOP c Gotothe CONTROL menu If you want an increase in Loop 1 process variable to result in an incr
102. cesses e TYPES Normally used for level control applications Pretuneis an on demand function Uponinitiation there is a five second period during which the controller monitors the activity ofthe process variable Then the control output is manipulated and the response of the process variable is monitored From this information the initial Proportional Band Reset and Rate P land D values and Dead Time are calculated When using TYPE 2 or TYPE 3 Pretune the Noise Band NOISE BND and Response Time RESP TIME and DEAD TIME will also be calculated Chapter 7 545 User s Manual Applications In order to run this algorithm the process must fulfill these requirements The process must be stable with the output in the manual mode Fortuning a non integrating process the process must be able to reach a stabilization point after a manual step change and e Theprocess should notbe subjecttoload changes while Pretune operates If these conditions are not fulfilled set the Adaptive Tune to run by itself Adaptive Tune CAUTION Adaptive Tune continuously monitors the process and naturaldisturbancesand Disable Adaptive Tuning before makes adjustments in the tuning parameters to compensateforthesechanges altering process conditions e g for In order to make accurate calculations Adaptive Tune needs noise band and shutdown tank draining etc response time values Pretune TYPE 2 and TYPE 3automaticallycalculatethese Otherwise the
103. ch loops ALM TYPE 1 and ALM TYPE 2 Specifies the type of alarm to implement Selection includes HIGH ALARM High process variable alarm Occurs when the process variable ex ceeds the alarm setpoint e LOW ALARM Low process variable alarm Occurs when the process variable goes below the alarm setpoint e HIGH LOW Combination of high and low alarms Occurs when the PV exceeds the individually set high or low setpoint BAND Creates a band centered around the control setpoint that is twice the alarm setpoint Alarm occurs when the process variable travels outside ofthis band The alarm is dependent onthe control setpoint As the control setpoint changes the band adjusts accordingly For example if the control setpoint is 500 and the alarm setpoint is 25 then the band extends from 475 to 525 e DEVIATION Similar to the band alarm but creates a band only on one side of the control setpoint Alarm occurs when the process variable deviates from the control setpoint by an amount greater than the alarm set point This alarm is dependent on the control setpoint as the control Chapter 7 545 User s Manual Applications setpoint changes the alarm point changes For example if the control setpoint is 500 and the alarm setpoint is 50 then an alarm occurs when the process variable exceeds 550 In order for an alarm to occur when the process variable drops below 450 select an alarm setpoint of 50 e MANUAL Alarm occurs w
104. comm board and TUNING Tuning parameters configuration see Chapter 6 545 User s Manual Chapter 5 CAUTION All software changes occur in realtime always perform setup functions under manual operation NOTE For information about the Tuning menu mode refer to Chapter 6 For more information about set up parameters and 545 applications refer to Chapter 7 27 Software Configuration Configuration PARAMETERS MANUAL Within each menu are parameters for particular control functions Select val ues for each parameter depending on the specific application Use the MENU key to access parameters for a particular menu the parameter name will re CONTACT1 TUNE PT AUTOMATIC Figure 5 2 place the menu name in the 2nd display and the parameter value will show in Independent vs Depedent the 3rd display Parameters This chapter outlines all the available parameters for the 545 Some parameters are independent of any special configuration and others are dependent on the individual configuration This manual displays these two types of param eters differently refer to Figure 5 2 A special feature of the 545 called Smart Menus determines the correct parameters to display for the specific configu ration so not all the listed parameters will appear Figure 5 3 Configuration Flowchart for TUNING mode MANUAL OPERATION TUNING DISPLAY FAST DISPLAY or or SET PT for Loop 2 SET PT
105. d com au The Netherlands sales mooreind nl United Kingdom sales mooreind com Tel 02 8536 7200 FAX 02 9525 7296 Tel 0 344 617971 FAX 0 344 615920 Tel 01293 514488 FAX 01293 536852 RETURN PROCEDURES To return equipment to Moore Industries for repair follow these four steps 1 Call Moore Industries and request a Returned Material Authorization RMA number Warranty Repair If you are unsure if your unit is still under warranty we can use the unit s serial number to verify the warranty status for you over the phone Be sure to include the RMA number on all documentation Non Warranty Repair If your unit is out of warranty be prepared to give us a Purchase Order number when you call In most cases we will be able to quote you the repair costs at that time The repair price you are quoted will be a Not To Exceed price which means that the actual repair costs may be less than the quote Be sure to include the RMA number on all documentation Provide us with the following documentation a Anote listing the symptoms that indicate the unit needs repair b Complete shipping information for return of the equipment after repair The and phone number of the person to contact if questions arise at the factory Use sufficient packing material and carefully pack the equipment in a sturdy shipping container 4 Ship the equipment to the Moore Industries location nearest you The return
106. de pene d LUNN MENU BIOG mode SET UP SELF TUNE LOOP 1 Access Set Up Next menu Next parameter Nextvalue Access Tuning Return to Operation Switch Loops Ess ww Eese Dee A Dev eer en 545 User s Manual Chapter 6 63 Tuning 7 7 Access Set Up Ese us 64 TUNING ADAPTIVE DISABLED PRETUNE POWR BACK DISABLED PROP BND 1 RESET 1 RATE 1 MAN RST 1 CYCLETM 1 Next menu Ere Dee wv TUNING 1 ADAPTIVE Activates the self tune algorithm upon transfer to automatic control D DISABLED ENABLED 2 PRETUNE Activates the pretune algorithm if unit is under manual control To initiate the Pretune cycle press the or Confirm by pressing within two seconds D NO 3 POWR BACK Reduces setpoint overshoot at power up or after setpoint changes D DISABLED ENABLED 4 PROP BND 1 Defines the proportional band for PID set 1 R 0 110999 0 50 0 5 1 Defines the integral time for PID set 1 1109999 seconds 20seconds 6 1 Defines the derivative time for PID set 1 R Oto 600 seconds D 1second 7 MAN RST 1 or LOADLINE 1 Defines the manual reset for PID set 1 If using automatic reset then this specifies the load line out value Oto 100 D 0 8 CYCLE TM 1 Defines the cycle time for control output 1 when using a time proportioning output O 3to 120 0 seconds D 15 0s
107. ded 5 When the 545 senses that communications is lost it can go to a predetermined state called shedding The SHED TIME parameter sets the length of time that communications can be interrupted before the controller sheds Since the 545 is a stand alone controller it does not depend on communications to operate Therefore if the shed feature is not needed set it to OFF 6 SHED MODE designates the mode to which the controller goes after it shes Setting this to MANUAL brings up the following parameters 7 Use SHED OUT to specify an output level ifthe unit sheds and trips to manual control 8 Tospecify a control setpoint in case the hostis supervising the setpoint if the 545 sheds set SHED SP to DESIG SP and then set the parameter DESIG SP to the desired setpoint 545 User s Manual Chapter 7 101 Applications Figure 7 19 Cascade Control of Product Temperature Functional View 102 U CASCADE CONTROL In Cascade control the output of one control loop outside loop becomes the remote setpoint of a second control loop inside The 545 performs this cas cade control ina single instrument The Cascade strategy enables better con trol of processes with significant lag times by breaking the process into two faster responding loops Cascade Control is typically used for the following e A slow responding process with a significant lag time Aprocess requiring more advanced or tighter control e Apro
108. dition if the set of five digital inputs is installed two can be designated to select one of four local setpoints per loop and associated PID set if desired via a binary coded decimal BCD input SETPOINT SELECTION A remote setpoint input is available for one of the two loops Signal is 0 20 4 20 mADC or 0 5 1 5 VDC jumper selectable Signal may be rationed and biased Eight local setpoints per loop may be stored in memory Setpoint selection is made via SET PT key or digital contact s FAULT OUTPUT One of the alarm outputs may be designated to also energize if the input signal is lost 545 User s Manual SERIAL COMMUNICATIONS Isolated serial communications is available using an RS 485 interface Baud rates of up to 19 200 are selectable The protocol supports CRC data checking If communications is lost a time out feature will command the controller to a particular control mode and specific setpoint or output if desired Outputs 2 4 and digital inputs can act as host controlled I O independent of the controller s function May be installed in the field DIGITAL DISPLAYS Upper display five digit seven segment Used exclusively for displaying the process variable value Height is 15 mm 0 6 in 2nd display nine character 14 segment alphanumeric Used for displaying setpoint deviation output value slidewire position actual valve position and configuration information Height is 6 mm 0 25 in 3rd display
109. e A4 9 Output Module Menu Cycle Calibration Figure A4 10 Slidewire Test Wiring HARDWARE SCAN Use this read only feature to identify the output hardware and installed options of the controller 1 Setthe jumpers to V and TCA see Figure 4 3 Power up the controller Press MENU until HARDWARE SCAN is displayed Press ACK to initiate the hardware display When complete return jumpers to their original positions SLIDEWIRE TEST If the slidewire option is installed use the following to test its function 1 Press MENU to scroll to the SLIDEWIRE TEST menu refer to Figure A4 2 2 Attach a 100 ohms to 1000 ohms potentiometer to terminals 10 11 and 12 as shown in Figure A4 10 3 Moving the potentiometer from one endto the other should display from 0 to 100 on the controller 4 Ifthe error message OPEN appears check the connectors and try again 6 Press ACK to exit QUICK CALIBRATION PROCEDURE This procedure may benefit users that have ISO or other standards requiring periodic calibration verification It enables verification and modification of the PV input without entering the Factory Configuration mode 1 Power down the 545 controller and place the input jumpers in the desired position see Figure A4 3 and Figure A4 7 2 Replace the process variable PV1 or PV2 input signal with a suitable milliamp calibration device 3 Apply power and allow controller to
110. e accessed from either auto matic or manual control To access the tuning menu press MENU e Toreturn controller to manual control press DISPLAY or SET PT A key to these functions as shown below appears atthe bottom of every page in the menu section of this chapter Access SetUp Nextmenu Next parameter Next value AccessTuning Return to Operation Switch Loops Eepe eee ww a v ww Eve peres WHERETO GO NEXT e Forinformation aboutallthe software menus and parameters continue reading this chapter Refer to Appendix 1 fora quick reference flowchart of all menus and parameters e Forinformation aboutthe installed options on the 545 compare the productlabel on top ofthe controller to the order code in Chapter 1 e Tomountthe controller and configure the wiring ofthe 545 for inputs and outputs see Chapter 3 e Toalterthe output module and jumper configuration see Chapter4 Formoreinformation aboutthe Tuning function ofthe 545 see Chapter 6 e Formoreinformation aboutapplication for the 545 see Chapter 7 TEXT FORMATTING IN THIS MANUAL Feature Format KEYS SET PT DISPLAY or ICONS OUT ALM MENUS CONFIG TUNING PARAMETERS CYCLE TM 1 MIN OUT2 PARAMETER VALUES OFF SETPOINT LAST OUT DISPLAY MESSAGES TOO HOT OUT 545 User s Manual Chapter 5 29 Software Configuration Configuration STEP BY STEP GUIDE TO SETUP PARAMETERS CONFIG CONFIG For configuring the input and output
111. e include the first PID set 3 Press MENU to access these parameters for each additional PID set 2 through 8 PROP BND RESET RATE MAN RST and TRIP L POWERBACK POWERBACK is Moore Industries proprietary algorithm which when invoked by the user reduces or eliminates setpoint overshoot at power up or after setpoint changes Powerback monitors the process variable to make predictive adjustments to control parameters which in turn helps to eliminate overshoot of the Setpoint Software Configuration 1 Goto the TUNING menu 2 Set POWR BACK parameter to ENABLED 3 Goto the SELF TUNE menu 4 The DEAD TIME is the time between initiation of an input change and the start of an observable response in the process variable Pretune will automatically calculate a value for this parameter However if Pretune is not run or results are poor value choices are R 10 to 3200 seconds D 7200 seconds M SELF TUNE POWERTUNE The Self Tune function of the 545 consists of two distinct components Pretune and Adaptive Tune These components may be used independently or in conjunction with one another For best results we recommend using them together Pretune This algorithm has three versions Choose the type that most closely matches the process to optimize the calculation of the PID parameters The three Pretune types are e TYPE1 Normally used for slow thermal processes e TYPE2 Normally used for fast fluid or pressure pro
112. e to the setpoint value atthe specified rate Chapter 7 545 User s Manual Applications 2 Onatransferfrom manualto automatic control the setpoint will ramp from the process variable value to the setpoint value at the specified rate 3 Onanysetpointchange the setpoint will ramp from the current setpointto the new target setpoint When triggered the display will automatically change to indicate the ramping setpoint Software Configuration 1 Goto the PV INPUT menu 2 Setthe SP RAMP parameter to the desired rate of change O INPUT LINEARIZATION Thermocouple and RTD Linearization Forathermocouple or RTD input the incoming signal is automatically linearized The 545 has lookup tables that it uses to provide an accurate reading of the temperature being sensed Square Root Linearization Many flow transmitters generate a nonlinear signal corresponding to the flow being measured To linearize this signal for use by the 545 the square root of the signal must be calculated The 545 has the capability to perform this square root linearization For the first 1 of the input span the input is treated in a linear fashion Then it is a calculated value using the formula in Figure 7 16 PV Low Range Hi Range Low Range V input V iow V high V low Hi Range is the high end of the process variable Low Range is the low end of the process variable V is the actual voltage or current value of the input i
113. e transmitter uses 2 wires for data and 2 wires for power triac Solid state switching device used to switch alternating current signals on and off Triac circuits are sometimes referred to as solid state relays SSR trip point Value which determines when that set of PID values becomes active velocity position proportioning This is a control technique where valve position is determined by calculating the amount of time it takes to open close a valve by moving the valve for a portion of that time windup Saturation of the integral mode of a controller developing during times when control cannot be achieved which causes the controlled variable to overshoot its setpoint when the obstacle to control is removed wild stream In mixing applications that require materials to be mixed to a desired ratio this is the one part of the material that is uncontrolled Appendix 6 A 21 22 Appendix 6 545 User s Manual Isolation Block Diagram APPENDIX 7 ISOLATION BLOCK DIAGRAM PV1 Input Output 1 Multiplexer CPU ISO Ground Referenced PV2 Input Output 2 ISO Ground Referenced RSP Input Output 3 ISO Ground Referenced Slidewire Input Output 4 V ISO Ground Referenced Vd Digital Inputs 1 5 RS485 Serial Communications Interface iL Ve Line N Isolated output ground 1 Each of the three ground circuits are isolated from each other to withstand a potential of
114. ease for the Loop 2 setpoint set ACTION 1 to DIRECT acting If you want an increase in Loop 1 process variable to result in a decrease in Loop 2 setpoint set ACTION 1 to REVERSE acting d Use LOW OUT and HIGH OUT to limitthe Loop 2 RSP values of without changing the RSP range Refer to Figure 7 21 for details Figure 7 20 Cascade Control of Produce Temperature Wiring View PV2 RANGE 0 1000 LOOP 1 LOW OUT 30 SP LOW LIM 200 LOOP 1 HIGH OUT 70 SP HI LIM 800 j 100 m Sane 100 1 8 8 3 go Figure 7 21 p 1 2 8 8 The Functions of Cascade Control 5 5 g o 8 1 Z 3096 8 8 8 3 1 0 1 0 0 200 800 1000 0 200 800 1000 Loop 2 SP Inside Loop Loop 2 SP Inside Loop 2 ForLoop2 a InPVINPUT menu set SP LO LIM and SP HI LIM to the portion of range of Loop 2 setpoint over which you want control Example Your Loop 2 range is 0 to 1000 you want its setpoint span to be 100 to 500 Remember that the setpoint span of Loop 2 is driven by the PID output of Loop 1 the outside loop Therefore you set SP LO LIM at 200 and SP HI LIM at 800 With these parameters whenever Loop 1 output is 096 the Loop 2 SP is 200 545 User s Manual Chapter 7 103 Applications TUNING TIP 1 To pretune Loop 2 with a Type 1 pretune Loop 1 mustbe under manual control Otherwise the controller will display the error message PRETUNELP1 AUTO 2 Topretune Loop 1
115. econds Next parameter Next value Access Tuning Return to Operation Switch Loops rast nsa 545 User s Manual Chapter 6 9 CTRL D B Defines the control deadband when using PID PI PD P or PID On Off Con trol R Any positive value D 15 0 seconds 10 DEADBAND 1 Defines the dead band for control output 1 when using on off control 1 to 99999 in engineering units D 2 11 P PROP D B Defines the dead band setting for a slidewire position proportioning output R 0 5to 10 0 D 2 096 12A PID OFST 1 For duplex applications defines the offset for the first output R 50 0 to 50 0 D 0 0 12B ON OFST 1 For On Off applications defines the offset for the first output 9999 to 99999 in engineering units DO 13A PID OFST 2 For duplex applications defines the offset for the second output R 50 0 to 50 0 D 0 0 13B ON OFST 2 For On Off applications defines the offset for the second output 9999 to 99999 in engineering units DO 14 REL GAIN 2 Defines the adjustment factor for the second output s proportional band It is multiplied by the effective gain of output 1 to obtain the second output s propor tional band 0 1 to 10 0 D 1 0 Access Set Up Next menu Next parameter Next value ww iv Chapter 6 545 User s Manual Access Tuning CTRL D B DEADBAND 1 P PROP D B PID OFST 1 ON OFST 1 PID OFST 2 ON OFST
116. ed equipment will be inspected and tested at the factory A Moore Industries representative will contact the person designated on your documentation if more information is needed The repaired equipment or its replacement will be returned to you in accordance with the shipping instructions furnished in your documentation WARRANTY DISCLAIMER THE COMPANY MAKES NO EXPRESS IMPLIED OR STATUTORY WARRAN TIES INCLUDING ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO ANY GOODS OR SER VICES SOLD BY THE COMPANY THE COMPANY DISCLAIMS ALL WARRAN TIES ARISING FROM ANY COURSE OF DEALING OR TRADE USAGE AND ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY ACKNOWL EDGES THAT THERE ARE NO WARRANTIES IMPLIED BY CUSTOM OR USAGE IN THE TRADE OF THE BUYER AND OF THE COMPANY AND THAT ANY PRIOR DEALINGS OF THE BUYER WITH THE COMPANY DO NOT IM PLY THAT THE COMPANY WARRANTS THE GOODS OR SERVICES IN ANY WAY ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY AGREES WITH THE COMPANY THAT THE SOLE AND EXCLUSIVE REMEDIES FOR BREACH OF ANY WARRANTY CONCERNING THE GOODS OR SERVICES SHALL BE FOR THE COMPANY AT ITS OPTION TO REPAIR OR REPLACE THE GOODS OR SERVICES OR REFUND THE PURCHASE PRICE THE COMPANY SHALL IN NO EVENT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES EVEN IF THE COMPANY FAILS IN ANY ATTEMPT TO REMEDY DEFECTS IN THE GOODS OR SERVICES BUT IN SUCH CASE THE BUYER SHALL BE ENTITLED TO NO MORE THAN A REFUND OF
117. ed or fallen below the set or limit point alarm band A type of alarm set up where a band is created around the control setpoint alarm deviation An alarm similar to a band alarm except it only creates a band on one side of the alarm setpoint alarm fault An indication that becomes active upon loss of process variable Fault alarm operates in addition to other alarm assignments alarm global The single physical output to which one or more internal software alarms are tied alarm high process variable A type of alarm that is set up to occur when the process variable goes above the alarm setpoint alarm low process variable A type of alarm that is set up to occur when the process variable goes below the alarm setpoint alarm manual A type of alarm set up to occur when the controller is put into manual mode of operation alarm power up A type of alarm that determines alarm condition on power up of the controller 545 User s Manual alarm rate of change A type of alarm set up to occur when there is an excessive change in the process variable PV value automatic controller A device or combination of devices which measures the value of a variable quantity or condition and operates to correct or limit its deviation from the setpoint baud rate Any of the standard trans mission rates for sending or receiving binary coded data bias A reference level A numeric value in a digital system or
118. enn nennen 96 O Input Linearization citi ilies dail nine 97 Thermocouple RTD Linearization 97 Square Root Linearization 97 Custom Linearization 98 Pi Load HI 98 SOC UNM scores she cata ch t edente tera teet dete duod 99 R nz Melee 100 S Process Variable Reading Correction 100 T Serial Communications 101 Cascade Control 102 Vz Ratio E 104 Ratio Control with Wild Stream 104 Ratio Control with Combined Discharge Monitoring 105 W Feed Forward Feedback Control 107 LOEO 108 FIXOG LAG 108 Variable 109 Table of Contents 545 User s Manual Table of Contents of Contents PAGE APPENDIX 1 MENU FLOWCHARTS cissie aeaaaee A 1 APPENDIX 2 PARTS LIST A 3 APPENDIX 3 TROUBLESHOOTING 5 4 CALIBRATION e A 7 Preparation for all Input Cal
119. ential of 50 volts peak for 1 minute between each other Inputs and outputs are not isolated from other inputs and outputs within the same block Blocks 1A amp 1B are ground loop isolated from each other to 10V peak to peak CONTROLLER ARCHITECTURE The 545 Controller hardware can be configured as follows Inputs Two universal process variable inputs are standard Available options include 1 remote setpoint 1 slidewire feedback and 5 digital Proportional Band 0 1 to 999 of input range Integral 1 to 39999seconds repeat Derivative 0 to 600 seconds Manual Reset Load Line 0 to 100 output Cycle Time 0 3 to 120 seconds On Off Deadband up to 15 of input range in eng units Up to eight sets of PID values may be stored in memory and selected automatically based on setpoint value process variable inputs Outputs 4 outputs are available See Ordering Information RS 485 Communications Available as an option with any configura tion PROCESS VARIABLE INPUTS 2 AVAILABLE Universal input type Any input type may be selected in the field Selection of input type thermocouple RTD voltage or current via jumper Selection of particular sensor or range is via front panel value or the corresponding local setpoint SP1 SP8 continued on next page Specifications and Information Subject to Change Without Notice 545 User s Manual Appendix 5 A 13 Specifications THERMOCOUPLES RANGE F RANGE C B 104 to 3301 40
120. equent alarm oscillation or chattering ifthe process variable has stabilized around the alarm point ALM 1 OUT and ALM 2 OUT For any enabled alarm selects the output number to which the selected alarm will be assigned It is possible to assign both alarms to the same output relay thus creating a global alarm 545 User s Manual Chapter 7 73 Applications Alarm Parameters Reference For Alarm 1 Parameter Description ALM TYPE 1 ALM SRC 1 Source ALARM SP 1 Setpoint HIGH SP 1 High setpoint LOW SP 1 Low setpoint DEADBAND 1 Deadband ALM 1 OUT Output number LATCHING 1 Latching sequence ACK 1 Acknowledging POWER UP 1 Status on power up 1 Message For Alarm 2 Parameter Description ALM TYPE 2 ALM SRC 2 Source ALARM 52 2 Setpoint HIGH SP 2 High setpoint LOW SP 2 Low setpoint DEADBAND 2 Deadband ALM 2 OUT Output number LATCHING 2 Latching sequence ACK 2 Acknowledging POWER UP 2 Status on power up MESSAGE 2 Message For either alarm depending on choices Parameter Description FAULT Fault assignment OUTPUT Output action for rate RATE TIME Time base for rate NOTE Each of the two loops has two alarms 74 Chapter 7 LATCHING 1 and LATCHING 2 Alatching YES alarm will remain active after leaving the alarm condi tion unless it is acknowledged A non latching NO alarm will return to the non alarm state when leaving the alarm cond
121. er 7 545 User s Manual Applications 11 When Pretune is complete the 3rd display will show COMPLETED fortwo Figure 7 12 seconds and then return to the current menu display Pretune TYPE 1 2 and 3 with The controller will automatically transfer to automatic control upon completion Adaptive Tune of Pretune if set to do so or upon manual transfer Figure 7 12 illustrates the operation of Pretunes TYPE 2 and TYPE 3 with Adaptive Tune High Out Limit i TYPE 1 Pretune Adaptive Control Alo B is ON OFF control to determine initial PID values 50 B is Pretune completed so Adaptive PID control beings if ENABLED CONTROL T Note Noise Band and Resp Time must be entered before OUTPUT o i Low Out Limit enabling Adaptive TUne 900 700 T PRETUNE T ADAPTIVE 10076 2 Pretune Adaptive Control Ato Bis a5 second noise band measurement Bto C is an open loop bump test to determine initial PID values and response time e is Pretune completed so Adaptive PID control begins if ENABLED 10 50 30 CONTROL OUTPUT 0 900 700 500 300 PV o ADAPTIVE mM Pretune i TYPE 3 Pretune Adaptive Control m Ato Bis 5 second noise band measurement 50 i is an impulse to determine initial PID values and response Out Step time S s CONTROL Cis Pretune completed so Adaptive PID control
122. ext value AccessTuning Eres ww meses A j v 545 User s Manual Chapter 6 PIDTRIP SPVALUE TRIP 1 D RESET X MAN RST X Return to Operation Switch Loops DISPLAY DISPLAY 67 l TUNING Parameter Definition Value Loop 1 Value Loop 2 1 ADAPTIVE Activates the self tune algorithm 2 PRETUNE Activates the pretune algorithm 3 POWR BACK Reduces setpoint overshoot 4 PROP BND 1 Defines the proportional band for PID set 1 5 RESET 1 Defines the integral time for PID set 1 6 RATE 1 Defines the derivative time for PID set 1 7 MAN RST 1 Defines the manual reset for PID set 1 8 CYCLETM 1 Defines the cycle time for control output 1 9 CTRL D B Control deadband for PID PI PD P or PID On Off 10 DEADBAND 1 Defines the dead band for control output 1 11 P PROP D B Defines the dead band setting for a slidewire output 12A PID OFST 1 For duplex applications defines the offset for the first output 12B ON OFST 1 For On Off applications defines the offset for the first output 13A PID OFST 2 For duplex applications defines the offset for the 2nd output 13B ON OFST 2 For On Off applications defines the offset for the 2nd output 14 REL GAIN 2 Defines the adjustment factor for the output 2 prop band 15 CYCLE TM 2 Defines the cycle time fo
123. for 5 minutes Use and V and FAST on the controller to change the meters display to exactly 20mA 12 To calibrate another analog output Move the wires and test leads to the new output terminals Press MENU until the 3rd display shows 4mA for the corresponding output in the 2nd display Repeat step 9 11 13 To complete calibration press ACK key disconnect the power and place the jumper connectors back into their original position RESET MENU DATA Resets all parameter values back to their factory default values except for calibration information Refer to the flowchart in Figure A4 2 1 Disconnect power to the instrument 2 Remove chassis from case 3 Onthe Microcontroller Circuit Board set jumpers at the 2nd PV location to V andTCA 4 Press MENU key until the display shows RESET MENU DATA Press the ACK key 6 Press MENU key within two seconds to reset the menu data If successful RESET COMPLETED will appear in the display If failed RESET SKIPPED will appear instead 7 Totry again press ACK key and then press MENU key within 2 seconds 8 When complete return jumpers to their original positions e 545 User s Manual Appendix 4 Connect to multi meter Figure A4 8 Milliamp Output Calibration Wiring TO OTHER CALIBRATION OUTPUT X PRESS MENU OUTPUT X PRESS MENU PRESS ACK M EACH OUTPUT WILL GO THROUGH THIS CYCLE Figur
124. for PV oscillation due to Set NOISE BAND large enough to prevent Adaptive Tune hysteresis of output device e g a sticky valve from acting on the oscillation If oscillation is not acceptable consider replacing valve PRETUNE Pretune does not develop optimum PID parameters Wrong Pretune TYPE selected Refer to Chapter 7 the Section on Self Tune 70 Chapter 6 545 User s Manual Applications CHAPTER 7 APPLICATIONS The 545 controller provides a variety of user programmable control features and capabilities The following topics are included in this chapter NOTE Controller capabilities depend upon the specified hardware option A Coritrol Type sce eerte 71 Remote 88 Security ix 99 Alanis cti cett rte ren 72 J Multiple Setpoints 88 R Resetlnhibition sss 100 C Duplex Control sss 76 Multiple Sets of PID Values 89 S Process Variable Reading Correction 100 D Slidewire Position Proportioning Control 81 L Powerback ssssseeeeene 90 Serial Communications 101 E Velocity Position Proportioning Control 82 Self Tune POWERTUNE 90 Cascade 102
125. g Option board with the NEW one Note When adding Option board for 5 digital inputs associated screw terminal in the rear terminal block must be installed See information on page 1 for ordering a Screw Kit To Change the Power Supply or Microcontroller CPU Board 10 For the Microcontroller Board disconnect the 5 pin female connector that wires it to the Display Assembly Reattach the connector to the new board You can only orient the connector one way For the Power Supply Board disconnect the 5 pin female connector that wires it to the Display Assembly Reattach the connector to the new board You can only orient the connector one way To Change the Display Assembly 11 Disconnect the 5 pin female connector that wires the Microcontroller Board to the Display Assembly Disconnect the 5 pin female connector that wires the Power Supply Board to the Display Assembly 12 Attach the new Display Assembly to the boards at the appropriate connectors CAUTION Static discharge will cause damage to equip ment Always ground yourself with a wrist grounding strap when handling electronics to prevent static discharge CAUTION Do not scratch the boards or bend the pins of the connectors Installation Guide To Change the EPROM 13 The EPROM is located on the Microcontroller Circuit board Figure 2 It has a white label that list the part number and software revision level Use an I C Extractor to carefully remove t
126. ges to the configuration parameters If locked out the RE al ey ara e security code is not accessible 545 User s Manual Chapter 7 99 Applications NOTE The security function is compromised ifthe security code is left at zero 0 NOTE Security does not prevent the operation from the digital inputs or serialcommunications NOTE PV GAIN is only available if using a linear voltage or current input 100 Basic Operating Procedures The security feature can be overridden When a locked function is attempted the operator will have the opportunity to enterthe security code Ifthe correct security codeisentered the operator hasfullaccess The security feature is reactivated after one minute of keypad inactivity If the security code is forgotten the security feature can still be overridden The security override codeis SPA FAM Store this number in a secure place and blacken outthe code in this manual to limit access R RESET INHIBITION Reset Inhibition is useful in some systems either atthe start up of a process or when a sustained offset of process variable from setpoint exists In conditions like these the continuous error signal may cause the process temperature to greatly overshoot setpoint Any of the digital inputs may be set up so that the contact closure disables the reset action sets it to zero Software Configuration 1 Gotothe CONFIG menu 2 Set corresponding parameter s CONTACT 1 to CONTACT
127. ggles between SP DEV or OUT e FAST KEY Actives FAST key e MENU KEY Activates MENU key e COMM ONLY Status readable only through communica tions e L2 SP 1 4 Assigns DIN 4 and 5 to select setpoints 1 through 4 via BCD signal e 12 REM SP Makes the remote setpoint active Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops 545 User s Manual Eebe ww a w ew p Chapter 5 33 Software Configuration Configuration 16 CONTACT 5 CONTACT 5 Defines the operation of the fifth digital input for the Loop 2 e L2 MAN Trips the controller to manual control e L2 2ND SP Makes the second setpoint active e L2 2ND PID Makes the second set of PID values active e L2 ALARM ACK Acknowledges alarms e L2 RST INH Deactivates the reset term e L2 D A R A Switches the control action e L2 NO A T Suspends the adaptive tune function e L2 LCK MAN Locks controller in manual control e UPKEY Remote A function e DOWNKEY Remote W function e DISPKEY Toggle between SP DEV or OUT e FASTKEY Activates FAST key e MENUKEY Activates MENU key e COMM ONLY Status readable only through communica tions D L2 REM SP Makes the remote setpoint active 17 RSP ASSN RSP ASSN Defines the loop that uses the Remote Set Point D NONE e LOOP2 e BOTH 18 SLIDEWIRE SLIDEWIRE Defines the loop that uses the Slidewire Feedback e LOOP 2 D NONE 19 NAME L1 NAME L1 A
128. gital input for Loop 1 14 CONTACT3 Operation of the third digital input for Loop 1 15 CONTACTA Operation of the fourth digital input for Loop 2 16 CONTACT5 Operation of the fifth digital input for Loop 2 17 RSP ASSN Defines which loop uses the Remote Set Point 18 SLIDEWIRE Defines which loop uses Slidewire Feedback 19 NAME L1 Allows 9 character message to name Loop 1 20 NAME L2 Allows 9 character message to name Loop 2 54 Chapter 5 545 User s Manual Software Configuration Configuration PV INPUT Parameter Description Value Loop 1 Value Loop 2 1 PV TYPE Sensor or range to be used 2 DEG Temperature engineering unit 3 DECIMAL Decimal point position 4 LINEARIZE Type of input linearization 5 LOW RANGE Engineering unit value for lowerst input value 6 HIRANGE Engineering unit value for highest input value 7 SPLOLIM Lowest setpoint value that can be entered from front panel 8 SPHILIM Highest setpoint value that can be entered from front panel 9 SP RAMP Rate of change for setpoint changes 10 FILTER Setting for the low pass input filter 11 PV OFFSET Offset to the PV in engineering units 12 PV GAIN Gain to the PV 13 PV RESTOR Control mode when a broken PV is restored 545 User s Manual Chapter 5 55 Software Configuration Configuration
129. hardware assignments GLOBAL 1 CTRL TYPE CTRL TYPE Defines the fundamental controller setup ONE LOOP ONELOOP Single PV Single Control Output e DUALLOOP Two PV with Control Output for each e RATIO Two loops with Set Points rationed e CASCADE Two PV with single Control Output e FFWD SUM Single loop control 2nd PV added to or sub tracted from output value FFWD MULT Single loop control 2nd PV multiplies output value 2 LOOP1 OUT LOOP1 OUT Defines standard configuration for Loop 1 D STANDARD Standard control output e DUPLEX Duplex outputs Refer to Chapter 7 STAGED Staged outputs Refer to Chapter 7 e POS PROP Position proportioning control output 3 LOOP2 OUT LOOP2 OUT Defines standard configuration for Loop 2 D STANDARD Standard control output e DUPLEX Duplex outputs Refer to Chapter 7 STAGED Staged outputs Refer to Chapter 7 e POS PROP Position proportioning control output NONE Allows second loop to function as an indicator 4 LINE FREQ LINE FREQ Specifies the power source frequency e 50Hz 5 OUTPUT 2 OUTPUT 2 Defines the function of the second output OFF D OFF Completely deactivates output ALM RLY ON ALM RLY OFF e RETRANS Retransmission e COMM ONLY Output addressable only through communi cations Access SetUp Nextmenu Next parameter Next value AccessTuning Return to Operation Switch Loops Ewej ww wee ww a v ww EXE 30 Chapter 5 545 User s Manual Soft
130. he EPROM If you do not have an I C extractor gently use a small flat blade screwdriver to pry up the EPROM DO Not bend the EPROM legs 14 Carefully insert the new EPROM To position correctly match the notched end of the EPROM to the markings on the board The notched end will face towards the display Make sure all pins are in the socket To Reassemble the Unit 15 See Figure 2 Align the connector pins on the Option Board with the connector sockets on the Microcontroller and Power Supply boards Squeeze them together making certain all three are properly seated against one another Check along the side edges for gaps Make sure the conector is properly aligned Also check that the cable assemblies are not pinched 16 See Figure 2 Align the board assembly with the front face assembly with the Option board at the bottom see Figure 1 Reinstall the retention clips Align the boards into the slots of the front face assembly and the clips will snap into place 17 When you are ready to reassemble the unit align the boards in the chassis with the case s top and bottom grooves Press firmly to slide the chassis into the case If you have difficulty check that you have properly oriented the chassis and there are no screws interfering with the case 18 Carefully insert and align screws Tighten them until the bezel is seated firmly against the gasket DO NOT OVERTIGHTEN 19 If may be necessary to re configure the soft
131. he PV parameters define the corresponding process variable value in engineering units It is not necessary to use all 15 points Whenever the XTH INPUT becomes the high end of the input range that will be the last point in the table Once the various points are defined the values between the points are interpolated using a straight line relationship between the points The only limitation is that the resulting linearization curve must be either ever increasing or ever decreasing P LOAD LINE Loadline is a manual reset superimposed on the automatic reset action Adjusting the MAN RST tuning constant shifts the controller proportional band with respect to the setpoint When used with a proportional only or proportional derivative control algorithm the MAN RST parameter located in the TUNING menu is in effect manual reset However when the automatic reset term is present the reset action gradually shifts the proportional band to eliminate offset between the setpoint and the process In this case load line provides an initial shift at which the reset action begins Load line is adjusted by observing the percent output requiredto control the process and then adjusting the load line to that value This minimizes the effect of momentary power outages and transients Load line may also be Chapter 7 545 User s Manual Applications adjusted to give the best response when bringing the load to the desired level from a cold
132. hen the controller is put into manual mode of opera tion This may be useful for security purposes or to alert the operator that 545 is no longer under automatic control RATE Alarm occurs when the process variable changes at a rate greater than whatis specified by the alarm setpoint and time base This alarm helps to anticipate problems before the process variable can reach an undesirable level For example ifthe alarm setpointis 10 with atime base of 5 seconds an alarm occurs whenever a change in process variable greater than 10 occurs in 5 seconds ALM SRC 1 and ALM SRC 2 For HIGH LOW or HIGH LOW alarms specifies the variable source upon which a selected alarm is based Selection includes e PV e PV2 e SP e RAMP SP DEVIATION OUTPUT ALARM SP 1 and ALARM SP 2 Defines the point at which an alarm occurs Fora RATE rate of change alarm it specifies the amount of change per RATE TIME period that mustoccur before the alarm activates A negative value specifies a nega tive rate of change Does not apply to HIGH LOW alarms HIGH SP 1 and HIGH SP 2 Fora HIGH LOW alarm defines the high setpoint at which an alarm oc curs LOW SP 1 and LOW SP 2 For a HIGH LOW alarm defines the low setpoint at which an alarm oc curs DEADBAND 1 and DEADBAND 2 Specifies the range through which the process variable must travel be fore leaving an alarm condition See alarm examples at the end of this section Prevents fr
133. hese inputs remains constant the controller will continue to use the selected setpointunless overridden Override the set of digital inputs by selecting a different setpoint by using SET PT key or through communications or by using the fifth digital input to select the re mote or 2nd setpoint To rearm this set of digital inputs the DIN com bination must change Setpoints DIN 1 DIN 2 DIN 4 DIN 5 Loop 1 SP1 0 0 LoopiSP2 X 0 Loop 1 SP3 0 X Loop 1 SP4 X X Loop 2 SP1 0 0 Loop 2 SP2 X 0 Loop 2 SP3 0 X Loop 2 SP4 X X L1 REM SP Closing input changes active setpoint to remote setpoint Opening reverts controller to previous setpoint Override by selecting a differ entsetpointviathe SET PT key acommunications command or other digital inputs Chapter 7 545 User s Manual Applications e L1 MAN NOTE The second display does not change when tripping to manual from Closing inputtrips the controllerto manual Opening input reverts con a closed digital input troller to automatic Override by using MANUAL key a communica tions command or trip to automatic function e L1 2ND SP Closing input changes active setpointto the 2nd local setpoint Open ing input reverts controllerto previous setpoint digital input Override by selecting a different setpoint via the SET PT key a communica tions command or other digital inputs e L1 2ND PID Closing input changes active set of PID values to 2nd set Opening
134. hould show CAL VREF the 3rd display should show a value close to 5 0000 8 The multimeter should read a value in the range 4 9750 5 0250 Use the A and V and FAST keys on the controller until the display on the controller matches the meter reading Appendix 4 545 User s Manual Calibration 9 Press MENU key The 2nd display should show CAL 120mV The 3rd display should showa value close to 120 000 Match the controller display to the multimeter value using the and V keys 10 Press MENU three more times Each time match the displays of the con troller and the multimeter Press ACK when done The 2nd display should show CALIBRATE the 3rd display should show ANA mAIN 11 Turn off power to the unit 12 For thermocouple input proceed to Thermocouple Cold Junction Calibra tion 13 For analog milliamp input proceed to Analog Milliamp Input Calibration 14 For milliamp output letthe controller warm up for 10 minutes then skip to step 5 of Milliamp Output Calibration 15 If calibration is complete place all the jumpers back in their original posi tions as specified in Chapter 3 THERMOCOUPLE COLD JUNCTION CALIBRATION 1 Connectthe two pairs of T C wire to terminals 28 29 31 and 32 as shownin Figure A4 5 Make sure the T C wires are floating disconnect from the mul timeter also and are not touching each other 2 Turn on power to the unit and let controller warm up for 30 minutes in the normal horizo
135. iation from setpoint at which the controller trips to automatic TRIP DEV If AUTO TRIP RISING PV If AUTO TRIP FALLING PV D 99999 to 0 Oto 99999 D 0 D 0 Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops Emsj ww ew Cally wv ETE 545 User s Manual Chapter 5 49 Software Configuration Configuration 3 DES OUT N N 1 to 5 DES OUT N Designates the output value the corresponding digital inputhas placed the con trollerin manual mode Choose values based on your process Standard Control On Off Control Velocity Prop Control e 5to105 6 ON CW D LASTOUT D OFF CCW D OUTS OFF 4 POWER UP Definesthe control mode upon powerup D LASTMODE Powerupinthesame mode prior to power down MANUAL AUTOMATIC e PRETUNE Will Pretune on every power up recommended for TYPE 1 pretune only 5 PWR UP OUT Definesthe outputofthe controllerif powering upin manual mode Choose val PWR UP OUT ues based on your process Standard Control On Off Control Velocity Prop Control e 5t0105 6 ON e CW D LASTOUT D OFF CCW D OUTS OFF 6 PWR UP SP This definesthe setpoint upon power up D LASTSP Will powerup withthe same setpoint localor re LAST SP mote that was active priorto power down LOCAL Will power up using primary local setpoint e REMOTE Will power up using remote setpoint if available 7 NO OF SP Defines the number of loc
136. ibrations A 8 Thermocouple Cold Junction Calibration A 9 Analog Milliamp Input Calibration eese A 9 Milliamp Output Calibration sssini A 10 Reset Menu Data esssssssseeeeee eene A 11 HardWare cUm 12 Slidewire Test sessssessessssseeseeneeeeenn nennen nennen A 12 Quick Calibration Procedure sesseeeeeeeene A 12 APPENDIX 5 SPECIFICATIONS 2 tip t ee nseocu d tue inae eaaet c eR A 13 APPENDIX 6 GLOSSARY e A 17 APPENDIX 7 ISOLATION BLOCK DIAGRAM ccce A 23 545 User s Manual Table of Contents Table of Contents of Contents List of Figures FIGURE DESCRIPTION PAGE Operator Interface 5 2 2 Before and After Acknowledging an Alarm 9 SHAD Instrument Panel amp Cutout Dimensions 11 3 2 isses Attaching Mounting 11 SC ER Terminal Assignments 12 nitore AC Power Input Terminals 13 iS ro pe ERE Process Variable Terminals 18 3 6 PV1 and PV2 Wiring for Milliamp RTD and Voltage Inputs 14
137. ically eliminates offset or droop between setpoint and actual process tempera ture Also integral reset term see reset relative gain An open loop gain determined with all other manipulated variables constant divided by the same gain determined with all other controlled variables constant retransmission a feature on the 545 which allows the transmission of milliamp signal corresponding to the process variable target setpoint or actual setpoint to another devices typically a chart recorder SSR drive A D C on off signal output for controlling a solid state relay sample interval The time interval between measurements or observa tions of a variable secondary loop The inner loop of a cascade system self tune A method of automatically calculating and inserting optimum PID parameters by testing system response and timing Appendix 6 serial communications The sending or receiving of binary coded data to a supervisory device such as a personal computer or programmable logic controller set up Also called configuration selection of hardware devices and software routines that function together setpoint An input variable which sets the desired value of a controlled variable setpoint actual The desired value of a controlled variable that the controller is currently acting upon setpoint deviation from The number of units difference between the current process variable and the setpoi
138. idden then it must be opened in order to be rearmed For example if one digital input closes and selects the 2nd setpoint and then a different setpoint is selected through the keyboard the keyboard selection takes precedence 545 User s Manual Chapter 7 87 Applications NOTE There is one second delay before a closed digital input takes action 88 I REMOTE SETPOINT The Remote Setpoint can be assigned to Loop 1 Loop 2 or both Remote setpoint limits are the same as setpoint limits Hardware Configuration This optional feature is available only if ordered originally from the factory Product 545 xxxxxBxx00 or 545 xxxxxExx00 Referto the order code in Chapter 1 e Before configuring the software make sure the corresponding jumperis set properly Refer to Chapter 4 to check or change jumper positions Software Configuration 1 Gotothe REM SETPT menu 2 Set TYPE V mA to define the input signal range e g 4 20 3 RSP LO RNG and RSP HI RNG define the range of the remote setpoint in engineering units The correct range will be dependent on the source of the remote setpoint signal 4 RSP LOW and RSP HIGH set limits on the remote setpoint value in engineering units 5 TRACKING determines whether or not the controller will revert to a local setpoint if the remote setpoint signal is lost This prevents a process upset due to a sudden change in setpoint 6 BIASLOW and BIAS HIGH set limits on an
139. imits 4 Output Gap or Overlay and 5 Output 2 Relative Gain and PID Output Please refer to the output state examples in this section to confirm thatthe configuration is appropriate for the process NOTE Set manual reset load line parameters to 50 when using Duplex control MAN RST X parameter is in the TUNING menu 76 C DUPLEX CONTROL The Duplex control algorithm enables two discrete control outputs for the control loop Duplex controlis commonly used for applications that require both heating and cooling or when 2 control elements are needed to achieve the desired result Hardware Configuration The controller must have two output modules assigned to the loop any combination of output modules Software Configuration 1 Goto the CONFIG menu Set LOOP1 OUT or LOOP2 OUT to DUPLEX 2 Touse different algorithms for each output PID for the first and On Off for the second Go to the CONTROL menu Set ALGORITHM to PID ON OFF the control action for each output independent of the other Go to the CONTROL menu Set ACTION 1 or ACTION 2 to either DIRECT or REVERSE action based on the diagrams in the output examples section Figures 7 2 through 7 8 4 Goto the TUNING menu Set values for PID OFST 1 or ON OFST 1 and PID OFST 2 or ON OFST 2 These parameters allow the user to independently offset the point at which output 1 and output 2 become active PID OFSET units are in percent
140. ing RS 232 RS 485 converter Product 500 485 The communication Figure 3 16 protocol is asynchronous bidirectional half duplex hence the leads are Serial Communications Terminals labelled Comm and Comm 545 Terminals To Comm terminal of next Moore Industries device To Comm terminal of next Moore Industries device Use a 60 to 100 Ohm terminating resistor connected to the two data terminals of the final device on the line CAUTION The shield needs to be connected continuously but only tied to one ground at the host Failure to follow these proper wiring practices could result in transmission errors and other communications problems 545 User s Manual Chapter 3 19 Installation 20 Chapter 3 545 User s Manual Hardware Configuration Configuration CHAPTER 4 HARDWARE CONFIGURATION Hardware configuration determines the available outputs as well as the type of input signal The 545 controller comes factory set with the following e Allspecified module and options installed for details refer to the Order Code in Chapter 1 e Process variable and remote setpoint set to accept a milliamp input e Relay outputs set to normally open Alter the factory configuration of the 545 requires accessing the circuit boards and locating the jumpers and output modules see Figure 4 1 1 With the power off loosen the four front screws and remove them NOTE Hardware configuration of the
141. ion 16 Output MOAUICS 17 Serial 19 CHAPTER 4 HARDWARE CONFIGURATION 21 Hardware Input Types ives 21 Accessing and Changing Jumpers 23 Adding and Changing Output 24 Special Communications Module 26 CHAPTER5 SOFTWARE CONFIGURATION 27 Ment S EE 27 Parameter Sires 28 Configuration and Operation 29 Where t0 GO NOXt een da do a een s P oan 29 Text Formatting in This Manual eene 29 Step by Step Guide to Set Up 30 GOIN Gites 30 PVINPUT a 35 CUSTC LINE senex hehe rb reta 37 CONTROL 38 ALARMS tette eta E 41 SE TIP iie trate bee Ru naues 45 RETRANS a a 46 SELF TUNE EE 48 ze E 49 545 User s Manual Table of Contents i Table of Contents of Contents CHAPTER6
142. ior to the initiation of pretune 7 Thenextparameter TIMEOUT defines the maximum time in minutes within which pretune must complete its calculations before it is aborted The first time a pretune is performed set TIMEOUT to its maximum value Make note of the length of the pretune cycle Then adjust TIMEOUT to a value about twice the pretune time The purpose of this parameter is to prevent a Pretune cycle from continuing for an excessive period of time if a problem develops The value has no impact on the PID values being calculated 8 Nextis MODE This defines what mode the controller will enter when pretune iscompleted Select MANUAL ifthere will be aneedto review PID parameters before attempting to control with them the default is AUTOMATIC 9 If POWERBACK algorithm is being utilized set a value for DEAD TIME 10 Place the controller under manual control 545 User s Manual Chapter 7 91 Applications 92 11 the TUNING menu press MENU Set the first parameter ADAPTIVE to DISABLED 12 Activate the next parameter PRETUNE 13 Press ACK to begin Pretuning The 3rd display will show the message EXECUTING 14 When Pretune is complete the 3rd display will show COMPLETED for two seconds and then return to the current menu display Pretune TYPE 1 amp Adaptive Tune Go to the SELF TUNE menu Set TYPE to BOTH Set PRETUNE to TYPE 1 Set a value for TUNE PT Set NOISE BND parameter Set the RESP
143. it value for the 1 1th point 25 12th INPUT Input signal for the 12th point of the 15 point curve 26 12th PV Engineering unit value for the 12th point 27 13th INPUT Input signal for the 13th point of the 15 point curve 28 13th PV Engineering unit value for the 13th point 29 14th INPUT Input signal for the 14th point of the 15 point curve 30 14th PV Engineering unit value for the 14th point 31 15th INPUT Input signal for the15th point of the 15 point curve 32 15th PV Engineering unit value for the 15th point 56 Chapter 5 545 User s Manual Software Configuration Configuration CONTROL Parameter Description Value Loop 1 Value Loop 2 1 ALGORITHM Control algorithm used 2 D SOURCE Variable used to determine the derivative value 3 ACTION 1 Action of the first control output 4 FIXEDLAG Fixed amount of lag between control iterations 5 VARBL LAG Variable amount of lag between control iterations 6 MAX LAG Maximum as result of PV2 action 7 PVBREAK Output level if the process variable input is lost 8 LOW OUT Lowest output value in automatic control 9 HIGH OUT Highest output value in automatic control 10 FFLOLIM Low limit for feed forward output contribution when Loop 2 is in automatic control 11 FFHILIM High limit for feed forward output contribution when Loop 2 is in automatic control 12 ACTION 2 Action of the second control output 13 CCW TIME Time for motor to fully stro
144. ith changes in prevailing conditions Common variables are level pressure and temperature proportional band The change input required to produce a full range change in the output due to proportional control action The area around the setpoint where proportional control occurs RTD Resistance Temperature Detec tor Resistive sensing device displaying resistance versus temperature charac teristics Displays positive temperature coefficient ramping see setpoint ramping rate Anticipatory action that senses the rate of change of temperature and compensates to minimize overshoot Also derivative rate action The derivative function of a controller rate time The time interval over which the system temperature is sampled for the derivative function A 20 ratio The value obtained by dividing one number by another used to determine proportions ratio control Control in which the setpoint of one loop is a ratio of the process variable of another loop or sensor output regulate The act of maintaining a controlled variable at or near its setpoint in the face of load distur bances relay mechanical An electrome chanical device that completes or interrupts a circuit by physically moving electrical contacts into contact with each other relay solid state A solid state switching device which completes or interrupts a circuit electrically with no moving parts reset Control action that automat
145. ition without being ac knowledged ACK 1 and ACK 2 For any enabled alarm enables or disables operator use of the ACK key to acknowledge an alarm at any time even if the control process is still in the alarm condition Alatching alarm can always be acknowledged when itis out of the alarm condition When either alarm is available to be acknowledged the ACK key will be illuminated If both alarms are acknowledgeable pressing ACK will firstacknowledge alarm 1 Pressing ACK a second time will acknowl edge alarm 2 POWER UP 1 and POWER UP 2 For any enabled alarm selects the alarm condition upon power up Choices are NORMAL Controller will power up in alarm only if it is in alarm condition e ALARM Controller always powers up in alarm regardless of system s alarm condition This is an excellent way to activate an alarm if there has been a power failure e DELAYED Controller will never power up in alarm regardless of system s alarm condition The system must leave and reenter the alarm condition before the alarm will activate This is typically used to avoid alarms during start up MESSAGE 1 and MESSAGE 2 Allows user to specify a nine character message to be displayed when the respective alarmis active If both alarms are active or any other diag nostic message is present the messages will alternate FAULT Activates an alarm if the process variable signalis lost Assign this func tion to either Alarm 1 or Alarm 2
146. ke in the CCW direction 14 CWTIME Time for motor to fully stroke in the CW direction 15 MIN TIME Minimum on time for the motor before taking action 16 S W RANGE Full range resistance of the slidewire 17 OPEN F B Feedback ohm value when the valve is open 18 CLOSE F B Feedback ohm value when the valve is closed 19 OUT1 STOP Stopping point for control output 1 when staging outputs 20 OUT2 STRT Starting point for control output 2 when staging outputs 545 User s Manual Chapter 5 57 Software Configuration Configuration ALARMS Parameter Description Value Loop 1 Value Loop 2 1 ALM TYPE 1 Type of alarm for alarm 1 2 ALM SRC 1 Source of value monitored by HIGH LOW or HIGH LOW alarm 1 3 ALARM SP 1 Alarm setpoint for alarm 1 except for HIGH LOW HIGH SP 1 High alarm setpoint for HIGH LOW alarm 1 4B LOWSP 1 Low alarm setpoint for HIGH LOW alarm 1 5 DEADBAND 1 Deadband for alarm 1 6 ALM 1 OUT Output number for alarm 1 7 LATCHING 1 Latching sequence for alarm 1 8 ACK 1 Whether alarm 1 may be acknowledged 9 POWERUP 1 How alarm 1 will be treated upon power up 10 MESSAGE 1 Nine character message associated with alarm 1 11 ALM TYPE 2 Type of alarm for alarm 2 12 ALM SRC 2 Source of value monitored by HIGH LOW or HIGH LOW alarm 2 13 ALARM SP 2 Alarm setpoint for alarm 1 except for HIGH LOW 14A HIGH SP 2 High alarm setpoint for HIGH LOW alarm 2 14B LOW SP 2 Low alarm setpoint for HI
147. le A 14 Appendix 5 INPUT FILTER Single pole lowpass digital filter with selectable time constant from 0 to 120 seconds CALIBRATION The controller comes fully calibrated from the factory and continu ously calibrates itself for component aging due to temperature and time except for the reference voltage Field calibration can be easily performed with a precision multimeter and thermocouple simulator Process variable offset and gain factors are provided to correct for Sensor errors OUTPUT MODULES The controller can have a total of four control outputs alarm outputs and or loop power modules installed There are five types of output modules which can be configured to suit your particular application The modules may be ordered factory installed or they may be installed in the field Analog module Either 0 20mA or 4 20 front panel selectable into a load up to 1000 ohms Accuracy 5pA 25 Mechanical relay module SPDT electromechanical relay Resistive load rated at 5 amps at 120 240 VAC Normally open or normally closed selection is made by jumper Output 4 is rated at 0 5 amps at 24 VAC and is always normally open Solid state relay triac module Resistive load rated at 1 amp at 120 240 VAC Output 4 is rated at 0 5 amps at 24 VAC These outputs are normally open DC logic SSR drive module voltage is 17 Vdc nominal OFF voltage is less than 0 5 Vdc Current limited to 40mA Loop power supply module
148. mentation a Anote listing the symptoms that indicate the unit needs repair b Complete shipping information for return of the equipment after repair The and phone number of the person to contact if questions arise at the factory Use sufficient packing material and carefully pack the equipment in a sturdy shipping container 4 Ship the equipment to the Moore Industries location nearest you The returned equipment will be inspected and tested at the factory A Moore Industries representative will contact the person designated on your documentation if more information is needed The repaired equipment or its replacement will be returned to you in accordance with the shipping instructions furnished in your documentation WARRANTY DISCLAIMER THE COMPANY MAKES NO EXPRESS IMPLIED OR STATUTORY WARRAN TIES INCLUDING ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO ANY GOODS OR SER VICES SOLD BY THE COMPANY THE COMPANY DISCLAIMS ALL WARRAN TIES ARISING FROM ANY COURSE OF DEALING OR TRADE USAGE AND ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY ACKNOWL EDGES THAT THERE ARE NO WARRANTIES IMPLIED BY CUSTOM OR USAGE IN THE TRADE OF THE BUYER AND OF THE COMPANY AND THAT ANY PRIOR DEALINGS OF THE BUYER WITH THE COMPANY DO NOT IM PLY THAT THE COMPANY WARRANTS THE GOODS OR SERVICES IN ANY WAY ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY AGREES WITH THE COMPANY THAT THE SOLE AND EXCLUS
149. n Must correct ERROR BAD CAL DATA PV1 UNDER or PV1 OVER or PV2 UNDER or PV2 OVER or LOST PV1 or LOST PV2 LOST RSP COMM SHED ERROR ROM CHECKSUM OUT1 CONF or OUT2 CONF or OUT3 CONF or OUT4 CONF LOST F B LOST CJC ERROR BAD EEPROM NEEDS CAL ERROR BAD MODEL NUM A 6 lost Occurs if all the memory has been erased When the process variable value travels slightly outside the boundaries of the instru ment span Does not apply to thermocouple or RTD inputs When the controller senses a lost process variable signal or the input signal travels well beyond the instrument span When the remote setpoint is in use and the controller senses that the signal has been lost or has traveled well outside the range When the communications is lost for longer than the communications shed time On power up a problem with the EPROM is detected Controller locks up until fixed Upon power up controller senses that the modules needed for control as determined by software configuration are not present The slidewire feedback is sensed as lost The cold junction is sensed as lost During power up an EEPROM failure is detected Controller locks up until fixed When the controller is powered up with default calibration data input and output accuracy specifications may not be met During power up a discrepancy was found between the EEPROM s and controller s model numbers Controller locks up until fi
150. nine character 14 segment alphanumeric Used for indicating which loop is displayed and for displaying alarm messages and configuration information Height is 6 mm 0 25 in All displays are vacuum fluorescent Color is blue green STATUS INDICATORS There are two types of indicators icons and illuminated keys ALM 1 and ALM 2 icons alarm 1 and alarm 2 status OUT 1 and OUT 2 icons control output 1 and control output 2 status PV2 icon illuminated 2nd loop is on display DISPLAY key illuminated 2nd loop is on display MAN key illuminated controller is in manual control mode ACK key illuminated alarm may be acknowledged SET PT key illuminated setpoint other than primary local setpoint is active MENU key illuminated controller is in configuration mode DIMENSIONS Meets 1 4 DIN designation as specified in DIN standard number 43 700 See diagram for details MOUNTING Panel mounted See diagram for details WIRING CONNECTIONS 31 screw terminals in the rear of the instrument continued on next page Appendix 5 A 15 Specifications POWER CONSUMPTION 15 VA at 120 VAC 60 Hz typical WEIGHT Approximately 1 kg 2 2 lbs AMBIENT TEMPERATURE Operative Limits 0 to 50 C 32 to 122 F Storage Limits 40 to 70 40 to 158 F RELATIVE HUMIDITY 10 to 90 non condensing VOLTAGE AND FREQUENCY Universal power supply 90 to 250 VAC 48 to 62 Hz NOISE IMMUNITY Common mode rejec
151. no longer be lit once control changes To change manual output values 1 Make sure the controller is under manual control 2 Usethe DISPLAY key to toggle 2nd display to output level 3 Usethe A or V key to change the value To override security If a locked operation is attempted SECURITY appears in the 2nd display for two seconds 1 Usethe A and keys to quickly enter the security code which will show in the 3rd display The starting value is O Note Two seconds of key inactivity will clear the display 2 Ifthecodeis correct CORRECT appears inthe 3rd display The display will clear after two seconds allowing full access 545 User s Manual Chapter 2 NOTE See the glossary in Appendix 6 for explanation of ramping and target setpoint Also refer to the section in Chapter 7 BasicInterface Interface NOTE All alarms are software alarms unless tied to an output relay in the SET UP mode See Chapter 5 and Chapter 7 for more details on alarms 4 Ifcodeisincorrect INCORRECT appears in the 3rd display INCORRECT will disappear after two seconds and a new security code can then be en tered 5 The controller will revert back to full security lock after one minute of key in activity To display control output value 1 Toggle DISPLAY key until the 2nd display shows OUT followed by the out put percentage This value is the PID output e n duplex applications this value does not directly refer to the o
152. nput j V high is the high end of the input signal range e g 5 volts or 20 mA Figure 7 16 mne V is the low end of the input signal range e g 1 volt or 4 mA Square Root Linearization Formula Example PV range is 0 1000 Input signal range is 1 5 volts Input signal is 3 volts Therefore PV 0 1000 0 3 1 5 1 1000 5 707 Hardware Configuration e Avoltage or milliamp input must be installed on the controller Software Configuration 1 Goto the PV INPUT menu 2 Set LINEARIZE to SQR ROOT 545 User s Manual Chapter 7 97 Applications Figure 7 17 15 point Linearization Curve 98 Custom Linearization Custom linearization allows virtually any nonlinear signal to be linearized using a 15 point straight line approximation curve see Figure 7 17 Typical applications are linearizing signals from nonlinear transducers or controlling volume based on level readings for irregularly shaped vessels To define the function enter data point pairs the engineering units corresponding to a particular voltage or current input 15th 10th PV VALUE in engineering units 1st 5th 10th 15th INPUT VALUE in milliamps or voltage Software Configuration 1 Goto the PV INPUT menu 2 Setthe parameter LINEARIZE to CUSTOM 3 Gotothe CUST LINR menu 4 Enter values for the 1ST INPUT and 1ST PV data points All the input parameters define the actual milliamp or voltage input Allt
153. nt setpoint ramping A setpoint which is determined by the ramp function of the controller where over time the control ler variable reaches a desired value setpoint target The end point of the ramp function sheds In serial communications when the signal is lost slidewire position proportioning An output algorithm that utilizes a slidewire feedback signal to determine the actual position of the actuator being con trolled solid state relay see relay solid state stability The desirable condition in which input and output are in balance and will remain so unless subject to an external stimulus staged outputs The set up of two analog outputs where one analog output varies its signal over a portion of the PID output range and the second analog output then varies its signal over the remainder of the PID output range static discharge Undesirable current resulting from the discharge of electro static energy 545 User s Manual 00 M station address The unique identifier assigned to a device for communica tions thermocouple Temperature sensing device that is constructed of two dissimilar metals wherein a measur able predictable voltage is generated corresponding to temperature thermocouple break protection Fail safe operation that assures desired output upon an open thermocouple condition thermocouple upscale burnout A Jumper position that determines whether when a thermocou
154. ntal position while the unit is warming up the rear face of the controller should be vertical not horizontal Type T 26 thermocouple wires floating red 3 Pressthe MENU key until the display indicates CALIBRATE COLD JUNC blue 4 Press the key The display should show PV 150 C PRESS ACK 5 Connect both pairs of T C wires in parallel do not daisy chain to a Type T thermocouple calibrator Both pairs must be connected or the cali bration will be accurate blue 6 Set the thermocouple calibrator to an output value of 150 C fora Type T thermocouple and allow the calibrator to stabilize for a few minutes 7 Press ACK to initiate calibration of the cold junction 8 For milliamp output calibration proceed to Milliamp Output Calibration Figure A4 5 Let the controller warm up for 10 minutes then skip to step 5 Thermocouple Cold Junction 9 If calibration is complete power down then place all the jumpers intheir Calibration Wiring original positions as specified in Chapter 3 ANALOG MILLIAMP INPUT CALIBRATION 1 Remove the thermocouple wires if present from terminals 28 29 31 and 32 Replace them with pieces of wire that will be connected to a 20 milliamp inputcurrent see Figure A4 6 Make sureterminal screws are securely tight ened but do not connect the wires yet leave inputs floating 2 Turn on power to the unit 3 Press
155. ntrol it compensates for changes in setpoint load re quirements and process variations e PID ON OFF Only available with Duplex control First output uses the PID algo rithm while second output uses on off control 545 User s Manual Chapter 7 71 Applications The ability to base alarms on parameters other than PV greatly expands the alarm capacity 72 3 For algorithms using the derivative function D choose the conditions for the derivative term Scroll to parameter D SOURCE e Forderivative action based on error or deviation from setpoint choose DEVIATION e For derivative action based on PV changes choose PV B ALARMS Eachloop ofthe 545 controller has two extremely flexible and powerful software alarms 4 alarms total The number of available outputs limits how alarms are linked to relays A Global Alarm feature allows all alarms to be assigned to the same relay The 545 indicates an alarm condition s for the foreground loop by e Liticons ALM 1 and or ALM 2 e Lit ACK key Displayed alarm message The 545 indicates an alarm condition s for the background loop by e Showing the user defined message for one or both alarms in the third dis play alternate displays for simultaneous alarms Software Configuration 1 Access the ALARM menu 2 Set values for the following parameters All possible values are shown Remember there are 2 alarms for each loop use FAST DISPLAY to swit
156. ntrol trip method 2 TRIP DEV Deviation from setpoint at which controller will trip to auto DES OUT N Output value for a designated digital input on trip to manual 4 POWER UP Control mode upon power up 5 PWR UP OUT Output of the controller is powering up in manual control 6 PWR UP SP Setpoint upon power up 7 NO OF SP Number of stored setpoints stored for selection 60 Chapter 5 545 User s Manual Software Configuration Configuration SECURITY Global Parameter Description Value 1 SEC CODE Security code for temporarily unlocking the instrument 2 SPADJUST Lockout status for setpoint changes 3 AUTO MAN Lockout status for MANUAL key 4 SPSELECT Lockout status for SETPT key 5 ALARMACK Lockout status for ACK key 6 TUNING Lockout status for adjustment of tuning parameters 7 CONFIGURE Lockout status for Set Up Parameters SER COMM Global Parameter Description Value 1 STATION The unit s station address 2 BAUD Baud rate 3 CRC Whether CRC is being calculated 4 SHEDTIME Time interval between communications activity before controller sheds 5 SHEDMODE State of the controller if communications is lost sheds 6 SHED OUT Output if the unit sheds 7 SHED SP Setpoint status if communications is lost 8 DESIG SP Value of the setpoint if controller sheds 545 User s Manual Chapter 5 Software Configuration Configuration 62 Chapter 5 545 User s Manual
157. of 50 at a PID output of 0 Duplex with one ON OFF output Areverse acting output 1 and adirect acting on off output 2 with a positive offset Relative gain does not apply when using duplex with an on off output The deadband setting for output 2 works the same as the deadband in single on off control the deadband effect for output 2 is not illustrated here PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 DIRECT PID OFST 1 0 ON OFST 2 VALUE LOW OUT 0 HIGH OUT 100 50 Out 2 Offset 0 from Setpoint PID OUTPUT in Engineering Units Duplex with two ON OFF outputs Areverse acting on off output 1 anda direct acting on off output 2 with a negative offset for output 1 and a positive offset for output 2 Note that here the horizontal axis is expressed in terms of process variable rather than PID output PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 DIRECT ON OFST 1 VALUE ON OFST 2 VALUE OFF Offset 1 SP Offset 2 High PROCESS VARIABLE Range Chapter 7 545 User s Manual Applications D SLIDEWIRE POSITION PROPORTIONING CONTROL Slidewire position proportioning utilizes a slidewire feedback signal to determine the actual position of the actuator being controlled This option is only available for one of the two control loops Hardware Configuration The controller must have Slidewire Feedback option installed Refer to the order code in Chapter 1 for more informati
158. on controller must have mechanical relays solid state relays or DC logic modules installed in the two output sockets corresponding to one control loop 1 or2 The Slidewire does NOT have to be wired to the controller in order to set up position proportioning Software Configuration 1 Toconfigure the controller before wiring the slidewire feedback signal to the controller complete these steps a Goto the CONTROL menu Set a value for PV BREAK Go to the SPECIAL menu Set a value for DES OUTPT Set a value for PWR UP OUT Go to SER COMM menu g Seta value for SHED OUT 2 Place the controller under manual control 3 Goto the CONFIG menu 4 Set either LOOP1 OUT or LOOP2 OUT to POS PROP position proportion ing 5 Set SLIDEWIRE to LOOP1 or LOOP2 6 Goto the CONTROL menu 7 For S W RANGE specify the full range resistance of the slidewire from end to end With a 100 ohm slidewire this parameter should be set to 100 8 Scroll to OPEN F B Open feedback Enter the ohm value when the actuator is fully open 0 to 1050 ohms 9 Scroll to CLOSE F B Closed feedback Enter the ohm value when the actuator is fully closed 0 to 1050 ohms 10 Measure the actual slidewire value at the terminals 10 and 11 As an alternative set up these two parameters dynamically Before entering Set Up set the manual output at 100 Enter Set Up and change the OPEN F B value until the actuator just reaches its full open position
159. ook up tables The relationship that exists between two variables when the ratio of the value of one variable to the corresponding value of the other is constant over an entire range of possibilities linearization custom User definable linearization linearization square root A function the 545 uses to linearize a non linear signal corresponding to the flow being measured by flow transmitters load line out A start up output value which is to bring initial output closer to actual steady state output 545 User s Manual load The demand for input to a process loop A signal path loop power An internal 24 volt current limited power supply used to power 2 or 4 wire transmitter on the input of the controller low pass input filter A method to block fast acting signals typically noise while allowing slow acting signals actual process variable to pass manipulated variable A quantity or condition which is varied so as to change the value of the controlled variable see also control output measuring element An element which converts any system activity or condi tion into a form or language that the controller can understand mechanical relay see relay menu Groups of parameters arranged in the software microcontroller A large scale inte grated circuit that has all the functions of a computer including memory and input output systems NEMA 4X A National Electrical Manufacturers Associ
160. operator entered bias value 7 RSP FIXED determines the signalto which the controller will revert when a lost RSP is restored fixed Options are to stay in local or automatically return to remote setpoint 8 Tobias or ratio the remote setpoint value a Goto the TUNING menu b Set RSP BIAS and RSP RATIO values Basic Operating Procedures After configuring the hardware and software select the remote input by pressing the SET PT key until RSP shows in the display e using a digital input J MULTIPLE SETPOINTS The 545 can store up to eight local setpoints and use a remote setpoint One application of this feature is configuring the controller to restrict operators to discrete setpoint choices The 545 can also store multiple sets of PID parameters see next section Software Configuration 1 Goto the SPECIAL menu 2 Set NO OF SP to the number of local setpoints desired 3 Usethe SET PT key to scroll to each local setpoint and set itto the desired value with the A or V keys 4 Tolinkthe PID sets to the corresponding local setpoint Go to the TUNING menu Chapter 7 545 User s Manual Applications Set NO OF PID to SP NUMBER For details on multiple sets of PID refer to the next section in this chapter Basic Operating Procedures To select a set point toggle the SET PT key to scroll through the setpoints The displayed setpoint becomes active after two second of key inactivity The digital inputs can also be u
161. or load line for PID set 8 60 TRIP 8 This defines the value that triggers a change to the 8th PID set 545 User s Manual Chapter 6 69 Tuning 7 SELF TUNE MESSAGES AND TROUBLESHOOTING Refer to Chapter 7 for more information on the Self Tune function of the 545 controller When the Pretune function terminates one of the following messages will appear Message Pretune Conclusion Problem Type Corrective Action COMPLETED 1 PRETUNE has generated initial PID and the Dead Time values 2 3 PRETUNE has generated initial PID Response Time Noise Band and the Dead Time values ABORTED 1 2 8 User has aborted PRETUNE before completion LIMIT ERR 1 The Process Variable went beyond the HI LIMIT or LOW Change the HI LIMIT and LOW LIMIT or the HIGH OUT LIMIT and LOW OUT and run PRETUNE again 2 3 The Process Variable went beyond the HI LIMIT or LOW Change the HI LIMIT and LOW LIMIT or the OUT STEP LIMIT size and run PRETUNE again 1 2 3 The initial Process Variable was near or beyond the HI Change the manual output percentage or the HI LIMIT and LIMIT or LOW LIMIT LOW LIMIT and run PRETUNE again TIME OUT 1 2 3 TIMEOUT limit was reached before PRETUNE completed Set a longer TIMEOUT period and or increase the OUT STEP size and run PRETUNE again NOISE ERR 1 2 3 Too much PV noise was detected Eliminate the noise source if possible or increase the OUT STEP and run PRETU
162. oreind com au The Netherlands sales mooreind nl United Kingdom sales mooreind com Tel 02 8536 7200 FAX 02 9525 7296 Tel 0 344 617971 FAX 0 344 615920 Tel 01293 514488 FAX 01293 536852 Declaration of Conformity C 4 EMC Directive 89 336 EEC Manufacturer s Name Moore Industries International Inc Manufacturer s Address 16650 Schoenborn Street North Hills CA 91343 6196 USA Declares that the product s Product Name 500 Series MODEL 1 INPUT OUTPUT POWER OPTIONS HOUSING Model Number s 500 Series T Universal Power H or J x Supply Indicates any input output option and housing as stated on the product data sheet Indicates CE Compliant Conforms to the following EMC specifications EN61326 1 1998 Electromagnetic Compatibility requirements for electrical equipment for control use Conforms to the following safety standard EN 61010 1 2001 Supplemental Information CE option requires CE KIT PN 535 765 Date Fred Adt Robert Stockham Quality Assurance Director Moore Industries International Inc European Contact Your Local Moore Industries Sales and Service Office The Interface Solution Experts www miinet com United States info miinet com Belgium info mooreind be China sales mooreind sh cn MOOR Tel 818 894 7111 FAX 818 891 2816 Tel 03 448 10 18 FAX 03 440 17 97 Tel 86 21 62481120 FAX 86 21 62490635 IND USTRIES Australia sales moorein
163. ors on the face of the controller input Process variable information being supplied to the instrument integral Control action that automati cally eliminates offset or droop between setpoint and actual process temperature Also reset 545 User s Manual Glossary internal voltage reference A precision voltage source within the 545 controller used to establish internal calibration isolation Electrical separation of sensor from high voltage circuitry Allows for application of grounded or ungrounded sensing element JIS Japanese Industrial Standards Also Japanese Industrial Standards Committee JISC Establishes stan dards on equipment and components jumper A wire that connects or bypasses a portion of a circuit on the printed circuit board jumper connectors The connecting device that straddles a jumper to connect or bypass a portion of a circuit on a printed circuit board lag fixed a consistant constant delay in detection of a control variable change lag variable A fluctuating delay in the detection of a control value change usually the feed forward contribution Source linearity The nearness with which the plot of a signal or other variable plotted against a prescribed linear scale approximates a straight line linearization A function the 545 uses to automatically linearize a non linear signal either from thermocouple or RTD temperature sensors through the use of l
164. output maximum limits the maximum value for output 1 while the low output minimum limits the maximum value for output 2 The value the actual outputs are limited to depends on offset settings control action and relative gain setting with PID control PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 DIRECT PID OFST 1 VALUE PID OFST 2 VALUE LOW OUT 10 HIGH OUT 85 REL GAIN 1 0 Figure 7 6 NJ Duplex with Overlapping Outputs NN and Output Limits 50 0 PID OUTPUT Duplex with various relative gain settings A reverse acting output 1 and a direct acting output 2 with various relative gain settings assume no offset or restrictive outputs with PID control PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 DIRECT PID OFST 1 20 PID OFST 2 0 LOW OUT 0 HIGH OUT 100 REL GAIN 2 0 REL GAIN 1 0 REL GAIN 0 5 Figure 7 7 Duplex with Various Relative Gain Settings PID OUTPUT 545 User s Manual Chapter 7 79 Applications Figure 7 8 Duplex with One ON OFF Output Figure 7 9 Duplex with Two ON OFF Outputs 80 Notice that the relative gain setting does not affect output 1 In this example a relative gain setting of 2 0 curve 1 results in output 2 reaching its maximum value at a PID output of 25 A relative gain setting of 1 0 results in output 2 reaching its maximum value ata PID output of 0 A relative gain setting of 0 5 results in output 2 reaching a maximum
165. output will occur only atthe end of the FIXED LAG period Variable Lag Variable lag VARBL LAG can be used in feed forward feed back control strat egies where the feedforward contribution PV2 input can vary and thus increase or decrease the amount of actual process lag time Variable Lag may be used with FFWD SUM and FFWD MULT control types Software Configuration 1 Inthe CONFIG menu set CTRL TYPE to FFWD SUM or FFWD MULT 2 Goto the CONTROL menu 3 Set FIXED LAG time if necessary from 0 to 14400 seconds 4 Setthe VARBL LAG time from 0 to 14400 seconds The time set should be in the middle to high end of the variable range of the PV2 input 5 Setthe MAX LAG parameter from 0 to 14400 seconds This represents the maximum lag time the variable lag feature can achieve When inthe normal operating mode the lag time will decrease as the PV2 value increases and will increases as the PV2 value decreases 545 User s Manual Chapter 7 109 Applications 110 7 545 User s Manual Menu Flowcharts Flowcharts FLOWCHARTS APPE config 9 CTRL TYPE ANLG RNG 1 LOOP1 OUT ANLG RNG 3 ANLG RNG 4 CONTACT 1 CONTACT 2 SLIDEWIRE NAME L1 ANLG RNG 2 CONTACT 3 CONTACT 4 CONTACT 5 NAME L2 PV INPUT PV TYPE SP LO LIM DECIMAL LINEARIZE LOW RANGE HIRANGE SP RAMP FILTER PVOFFSET H PVGAN DEG F C K SP HI LIM PV RESTOR CUST LINR 1ST INPUT CO
166. ple fails its output is replaced by a millivoltage which will match the thermocouple s maximum value The jumper connector should be placed in the TC A position thermocouple downscale burnout W Jumper position that determines whether when a thermocouple fails its output is replaced be a millivoltage which will match the thermocouple s minimum value The jumper connector should be placed in the TC W position three mode control See control action PID time proportioning control A control algorithm that expresses output power 0 100 as a function of percent ON versus percent OFF within a preset cycle time time proportioning output A control ler output assigned by software to facilitate time proportional control typically a relay SSR or SSR Drive output tracking A function that defines whether the local setpoint will track the remote setpoint When the controller is transferred to a local setpoint that local setpoint value will match the remote process value when the transfer occurs transducer A device which converts information of one physical form to another physical type in its output e g a thermocouple converts a temperature difference into millivolts 545 User s Manual transmitter 2 wire A device used to transmit data via a two wire current loop A two wire transmitter is loop powered transmitter 4 wire A device used to transmit data via a current loop or a DC voltage A 4 wir
167. pply 2 wire transmitter MILLIAMP INPUT 4 wire transmitter with loop power supply Input power le for transmitter 4 20 mA output from transmitter 545 User s Manual For PV1 MILLIAMP INPUT 2 wire transmitter with separate power supply External t Power Supply z Transmitter MILLIAMP INPUT 2 wire transmitter with loop power supply 2 wire transmitter MILLIAMP INPUT 4 wire transmitter with loop power supply Input power for transmitter 4 20 mA output from transmitter Chapter 3 Figure 3 7 PV1 and PV2 Wiring for Milliamp Inputs with Internal and External Power Supply NOTE To use loop power there must be a loop power module is installed in the 3rd or 4th output socket Compare the controller product number with the order code in Chapter 1 to determine if the 545 has a loop power module installed To install a loop power module refer to Chapter 4 15 Installation Digital inputs can be activated in three ways a switch signal type closure of arelay oran open collector transistor Digital inputs are only functional when that option is installed via hardware The controller detects the hardware and supplies the appropriate software menu 1 Digital Inputs with a switch or relay Figure 3 8 Digital Input Wiring with a Switch or Wire the switch relay between terminal 17 and the specific digital input Relay terminal Figure 3 8 i Pen ee
168. r control output 2 16 DEADBAND 2 Defines the dead band for control output 2 17 RSP RATIO Defines the multiplier applied to the remote set point 18 RSP BIAS Defines the bias additive term applied to the remote set point 19 FFWD GAIN Adjustment factor for feed forward input 20 FFWD ZERO Zero point of feed forward output contribution 21 FF BRK GN Adjustment factor for feed forward input if PV is broken 22 FF BRK ZR Zero point for feed forward output contribution if PV is broken 23 NO OF PID Defines the number of stored and available PID sets 24 PID TRIP Defines the variable used to select the various PID sets 25 TRIP 1 Defines the value that triggers a change to primary PID set 26 PROP BND 2 Defines the proportional band for PID set 2 27 RESET 2 Defines the integral time for PID set 2 28 RATE 2 Defines the derivative time for PID set 2 68 Chapter 6 545 User s Manual tuning 29 MAN RST 2 Defines the manual reset or load line for PID set 2 30 TRIP 2 Defines the value that triggers a change to the 2nd PID set 31 PROP BND 3 Defines the proportional band for PID set 3 32 RESET 3 Defines the integral time for PID set 3 33 RATE 3 Defines the derivative time for PID set 3 34 MAN RST 3 Defines the manual reset or load line for PID set 3 35 TRIP 3 Defines the value that triggers a change to the 3rd PID
169. rameter Next value AccessTuning Return to Operation Switch Loops Ewej ww wee ww a v ww EXE 32 Chapter 5 545 User s Manual Software Configuration Configuration 14 CONTACT 3 Defines the operation of the third digital input for Loop 1 CONTACT 3 e 11 Trips the controller to manual control D L1 2ND SP Makes the second setpoint active e L1 2ND PID Makes the second set of PID values active e L1 ALARM ACK Acknowledges alarms e L1 RST INH Deactivates the reset term e L1 D AJR A Switches the control action L1 NO A T Suspends the adaptive tune function e L1 LCK MAN Locks controller in manual control e UPKEY Remote A function e DOWNKEY Remote W function e DISPKEY Toggle between SP DEV or OUT e FASTKEY Actives FAST key e MENUKEY Activates MENU key COMM ONLY Status readable only through communica tions e L1 REM SP Makes the remote setpoint active 15 CONTACTA Defines the operation of the fourth digital input for Loop 2 CONTACT 4 D L2 MAN Trips the controller to manual control e L2 2ND SP Makes the second setpoint active e L2 2ND PID Makes the second set of PID values active e L2 ALARM ACK Acknowledges alarms e L2 RST INH Deactivates the reset term e L2 D AJR A Switches the control action e L2 NO A T Suspends the adaptive tune function e L2 LCK MAN Locks controller in manual control e UPKEY Remote A function DOWNKEY Remote W function e DISPKEY To
170. range of output 2 in engineering units 3 HIRANGE 2 High end of the range of output 2 in engineering units 4 TYPE 3 Whatis to be retransmitted for output 3 5 LORANGE 3 Low end of the range of output 3 in engineering units 6 HIRANGE 3 High end of the range of output 3 in engineering units 7 TYPE 4 What is to be retransmitted for output 4 8 LORANGE 4 Low end of the range of output 4 in engineering units 9 HIRANGE 4 High end of the range of output 4 in engineering units 545 User s Manual Chapter 5 59 Software Configuration Configuration SELF TUNE Parameter Description Value Loop 1 Value Loop 2 1 TYPE Type of self tuning algorithm that is available 2 PRETUNE Output step size in absolute percent 3 TUNEPT TYPE 1 Defines the PV value at which the output switches off 4 OUT STEP TYPE 2 amp 3 Defines output step size in absolute percent 5 LOWLIMIT Lower limit PV can reach during Pretune before aborting 6 HILIMIT Upper limit PV can reach during Pretune before aborting 7 TIMEOUT Execution time limit for Pretune before aborting 8 MODE Control mode after Pretune is completed or aborted 9 NOISE BND Noise band to be used by adaptive tuning algorithm 10 RESP TIME Response time to be used by adaptive tune 11 DEAD TIME Process run time before controller responds to output change SPECIAL Parameter Description Value Loop 1 ValueLoop2 1 AUTO Manual to Auto Co
171. rd Figure 7 26 Input PV2 Feed Forward Control in Flow Sensor 9 Mixing Application Functional View Mixing Tank Raw Material Software Configuration 1 Inthe CONFIG menu set CTRL TYPE to FFWD SUM or FFWD MULT 2 Setup andtune the PID feedback loop PV1 3 Inthe TUNING menu set the effect of the feed forward input PV2 on the control output through the following parameters 545 User s Manual Chapter 7 107 Applications Figure 7 27 Fixed and Variable Lag Example Compound Loop Chlorine Control 108 a FFWDZERO Feedforward zero This parameter is the PV2 feed forward value at which there is 0 con tribution to controller output For example if you want the feed forward contribution to be 0 when PV2 is 500 set this parameter to 500 b FFWD GAIN Feed forward gain This parameter is the feed forward output contribution multiplier For ex ample a gain of 1 causes a 1 output addition if PV2 is 1 unitabove FFWD ZERO A gain of 2 causes a 2 output addition if PV2 is 1 unit about FFWD ZERO c FFWDHILIM and FFWD LO LIM Feed forward high limit amp low limit These parameters are output clamps used to limit the amount of feed forward contribution to control output For example if you wanted the feed forward contribution to never exceed 50 set FF HI LIM to 50 FF LO LIM limits the negative contribution to the output See Figure 7 27 foran illustration of the use of these p
172. re available TYPE 1 for slow thermal processes TYPE 2 for fast fluid or pressure applicaitons and TYPE 3 for level control applications Adaptive tune Our exclusive POWERTUNE adaptive tuning APPENDIX 5 SPECIFICATIONS ACCURACY TYPICAL MAXIMUM Voltage 0 025 of full scale 0 100 of full scale Current 0 050 of full scale 0 150 of full scale LINEAR RTD 1 0 050 of span 0 150 of span 01 0 095 of span 0 225 of span algorithm automatically adjusts the PID values whenever a process THERMOCOUPLE upset occurs Preliminary information may be entered manually or J K N E gt 0 0 060 of span 0 150 of span automatically calculated by our pretune algorithm J K N E 0 0 15096 of span 0 375 of span OVERSHOOT PROTECTION Te 06 ele of span rue of span POWERBACK is proprietary user invoked setpoint overshoot T lt 0 C 0250 i of span 0 625 i of span protection algorithm When invoked POWERBACK reduces or R S gt an 0150 i of span 0 375 o of span eliminates setpoint overshoot at power up or after setpoint R S lt 0 0375 b ofspan 20925 i o of span changes POWERBACK monitors the process variable to make B 0000 0 150 b ofspan 20375 i of span predictive adjustments to the control parameters a feature that B lt 500 C 0 500 of span 1 000 of span helps eliminate overshoot of setpoint W W5 amp Platinel II 0 125 of span 0 325 of span ISOLATI
173. ree digital display areas two offering up to 9 characters of true alohanumerics the 545 effectively eliminates the cryptic messages that could confuse even the most experienced operator The bright crisp display is vacuum fluorescent and offers much better readability than any other display technology Additional operator friendly features include custom programmable alarm messages illuminated keys and an easy to use menu system The 545 is the most accurate instrument in its class With a sampling rate of eight times per second it is ideal for demanding pressure and flow applica tions The 545 also offers two universal process inputs and modular field interchangeable outputs that allow more flexibility than ever before With two independent full feature control loops the 545 can take the place of two PID controllers additionally preprogrammed functions can be called for cascade ratio and feed forward applications The 545 uses foreground and background loops that facilitate straight forward operator interface in any of the dual loop modes It also offers sophisticated control algorithms including heuristic adaptive tuning split range and duplex outputs control and open or closed loop electric actua tor control velocity control Specifications and information subject to change without notice 545 User s Manual Chapter 1 1 introduction 545 MODES There are three operating modes for the 545 controller OPERATI
174. rom motors relays and other similar noise generators 2 Donotrun low power sensor input lines in the same bundle as AC power lines Grouping these lines in the same bundle can create electrical noise interference 3 All wiring and fusing should conform to the National Electric Code and to any locally applicable codes 4 Anexcellent resource about good wiring practices is the IEEE Standard No 518 1982 andis available from IEEE Inc 345 East 47th Street New York NY 10017 212 705 7900 Diagrams on the next three pages serve as guides for wiring different types of process inputs The shaded areas on the diagrams show which rear terminals are used for that type of wiring AC Power Input TOP as viewed from back of controller LINE EARTH DIN NOT 1 e GND GND 17 USED NEUTRAL 2 Q Cw DIN 1 18 COMM OUT 1 DIN 2 1989 COMM OUT 1 4 DIN 3 20 PV2 OUT 2 DIN 4 21 I PV24 OUT 2 16 e DIN 5 22 Q RTD 3RD PV1 COLD OUT 3 8 Ii JUNC4 PV1 Chapter 3 545 User s Manual installation Terminals 1 and 2 are for power Terminal 9 is the earth ground Use a 0 5 Amp 250 V fast acting fuse in line with your AC power connection Process Variable Input TOP Figure 3 4 AC Power Input Terminals GROUND Screws must be tight to ensure good electrical connection The 545 accommodates the following types of process variable inputs e
175. s maintained by controlling two final elements using two of the 545 outputs duty cycle Percentage of load ON time relative to total cycle time Appendix 6 earth ground A terminal used on the 545 to ensure by means of a special connection the grounding earthing of part of the controller engineering unit Terms of data measurement such as degrees Celsius pounds grams etc error The difference between the actual and the true value often ex pressed as a percentage of either span or full scale feedback Process signal used in control as a measure of response to control action the part of a closed loop system which automatically brings back information about the condition under control feed forward control Control in which the output of the control loop is ad justed based on the process variable and a second variable that is rationed and biased final control element Component of a control system such as a valve or contractor which directly regulates that flow of energy or material to the process FM Factory Mutual Research Corpora tion an organization which sets safety standards gain The ratio of the change in output to the change in input which caused it hunting Oscillation or fluctuation of process temperature between setpoint and process variable hysteresis In ON OFF control the process variable change necessary to change the output from full ON to full OFF icons Indicat
176. s in the 2nd display for setpoint ramp ing setpoint if available deviation output background PV lag if available and valve position if available In SET UP or TUNING mode press to return controller to OPERATION mode with display showing current setpoint When lit Loop 2 is in the foreground FAST DISPLAY Toggles between the background loop andforeground loop A Press to increase the value or selection of displayed parameter FAST 4A Press to scroll through values at a faster rate V Press to decrease the value or selection of displayed parameter FAST Press to scroll through values at a faster rate ACK Press to acknowledge an alarm s When lit indicates there is an acknowledgeable alarm MENU In OPERATION Mode press to access the TUNING mode and menu In Set Up or Tuning mode press to advance through a menu s parameters Use FAST MENU to advance to the next menu When lit indicates the controller is in SET UP mode FAST MENU Press to access the Set Up menus In SET UP mode press to advance through menus Use MENU by itself to ac cess the parameters of a particular menu Chapter 2 545 User s Manual Basic Interface Interface BASIC OPERATION PROCEDURES A Quick Explanation of Dual Loop Operation Upon power up Loop 1 is in the foreground displayed and Loop 2 is in the background hidden Setup changes only affect the foreground loop to make changes to the opera
177. s output to the actual physical output locate the PID output on the horizontal axis Draw a vertical line at that point Atthe intersection of this vertical Chapter 7 545 User s Manual Applications line andthe respective output line draw a horizontal line The physical outputis the value where this horizontal line intersects the respective axis The illustrations assume a manual reset load line term of 50 Therefore at zero error process variable equals setpoint the PID output is 50 Duplex with reverse and direct acting outputs Areverse acting output 1 anda direct acting output 2 with no offset no restrictive outputs limits and a neutral relative gain with PID control PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 DIRECT PID OFST 1 0 PID OFST 2 0 Figure 7 2 LOW OUT 0 Duplex with Reverse and Direct HIGH OUT 100 Acting Outputs REL GAIN 1 0 PID OUTPUT Duplex with direct and reverse acting outputs Areverse acting output 1 anda direct acting output 2 with no offset no restrictive output limits and a neutral relative gain with PID control PARAMETER SETTINGS ACTION 1 DIRECT ACTION 2 REVERSE PID OFST 1 0 PID OFST 2 0 LOW OUT 0 HIGH OUT 100 Figure 7 3 REL GAIN 1 0 Duplex with Direct and Reverse Acting Outputs Zs PID OUTPUT 545 User s Manual Chapter 7 77 Applications Figure 7 4 Duplex with Two Reverse Acting Outputs Figure 7 5 Duplex with a Gap
178. sed to select the active setpoints A single digital input may be used for selecting the seconds setpoint SP2 A set of two digital inputs perloop may be used to select up to 4 setpoints per loop see the section in this Chapter in Digital Inputs The SET PT key is lit when a setpoint other than the primary local setpoint is active K MULTIPLE SETS OF PIDVALUES The 545 has the ability to store up to eight sets of PID values This can be a valuable feature for operating the controller under conditions which require different tuning parameters for optimal control There are various methods of selecting which set should be active These methods are explained in this section Software Configuration 1 Goto the TUNING menu 2 NO OF PID is the desired number of PID sets to be stored SP NUMBER automatically sets this value equal to the number of stored local setpoints each PID set will be active when its respective local setpoint is active PID TRIP determines which variable selects the various PID sets process variable setpoint or deviation from setpoint 4 TRIP X defines the point in the PV range at which that set of PID values become active Basic Operating Procedures A PID set can be selected in one of four ways e For NO OF PID SP NUMBER the active set of PID values is the same as the active setpoint For example if SP3 is active then PID set 3 will be active When using PID trip values a PID set becomes acti
179. serialcommunications features GLOBAL 1 STATION STATION Defines the unit s station address one address for both loops in dual loop mode R 11099 e OFF Disables the communications function D 1 2 BAUD RATE BAUD RATE Defines the baud rate e 1200BPS e 2400BPS e 4800BPS D 9600BPS e 19200 BPS 3 CRC CRC Defines whether CRC cyclic redundancy check is being calculated YES D YES e NO 4 SHED TIME SHEDTIME Defines the time interval between communications activity before the control ler determines that communications is lost sheds 1t0512 seconds D OFF 5 SHEDMODE SHED MODE Defines the state of the controller if communications is lost sheds LAST MODE D LASTMODE The 545 remains in either automatic or manual control e MANUAL Trips to manual control AUTOMATIC Trips to automatic control 6 SHED OUT SHED OUT Definesthe outputifthe unitsheds andtripsto manual control Choose values D based on your process Standard Control On Off Control Velocity Prop Control e 105 e ON e CW D LAST OUT D OFF e CCW D OUTS OFF Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops Err nee eem ww v ww EXE 52 Chapter 5 545 User s Manual Software Configuration Configuration 7 SHED SP Defines the setpoint status if communications is lost SHED SP D LASTSP Continues to use the setpoint that was active LAST SP
180. set 36 PROP BND 4 Defines the proportional band for PID set 4 37 RESET 4 Defines the integral time for PID set 4 38 RATE 4 Defines the derivative time for PID set 4 39 MAN RST 4 Defines the manual reset or load line for PID set 4 40 TRIP 4 This defines the value that triggers a change to the 4th PID set 41 PROP BND 5 Defines the proportional bandfor PID set 5 42 RESET 5 Defines the integral time for PID set 5 43 RATE 5 Defines the derivative time for PID set 5 44 MAN RST 5 Defines the manual reset or load line for PID set 5 45 TRIP 5 This defines the value that triggers a change to the 5th PID set 46 PROP BND 6 Defines the proportional bandfor PID set 6 47 RESET 6 Defines the integral time for PID set 6 48 RATE 6 Defines the derivative time for PID set 6 49 MAN RST 6 Defines the manual reset or load line for PID set 6 50 TRIP 6 This defines the value that triggers a change to the 6th PID set 51 PROP BND 7 Defines the proportional band for PID set 7 52 RESET 7 Defines the integral time for PID set 7 53 RATE 7 Defines the derivative time for PID set 7 54 MAN RST 7 Defines the manual reset or load line for PID set 7 55 TRIP 7 This defines the value that triggers a change to the 7th PID set 56 PROP BND 8 Defines the proportional bandfor PID set 8 57 RESET 8 Defines the integral time for PID set 8 58 RATE 8 Defines the derivative time for PID set 8 59 MAN RST 8 Defines the manual reset
181. t successful Check the 20mA connections and return to step 3 to recalibrate the PV1 input 12 Remove the 20mA input from the PV1 terminals and attach it to the PV2 terminals see Figure A4 6 Make sure the terminal connections are fastened tightly and that a 20mA current is flowing through PV2 13 Let the controller warm up for an additional 5 minutes keep in the normal horizontal position Make sure the current is flowing then press ACK to calibrate the PV2 input 14 Ifthe controller displays mA CALIB COMPLETED PV2 calibration was suc cessful andthe analog milliamp calibration procedure has been completed If calibration is complete power down Place the jumpers into their original positions see Chapter 4 15 Ifthe controller briefly displays mA CALIB FAILED PV2 calibration was not successful Checkthe 20mA connections and return to step 1 recalibrate the PV1 and PV2 inputs MILLIAMP OUTPUT CALIBRATION If the controller uses milliamp outputs it is usually not necessary to calibrate them If the milliamp output are being used for accurate retransmission of data itis recommended that each output with an analog module be calibrated annu ally to maintain optimal performance Equipment needed e Precision 5 1 2 digit multimeter e g Fluke 88429 or HP3478 Ae 4 1 2 digit meters sacrifice accuracy e Two small pieces of wire for every milliamp output e Testleads with banana clips e 2 Phillips screwdriver 1
182. tain a waterproof seal between the controller and the panel follow these directions 1 The 545 fits in a standard 1 4 DIN cutout Mount the 545 in any panel with a thickness from 06 in to 275 in 1 5 mm to 7 0 mm Figure 3 1 2 Figure 3 1 shows the controller and panel dimensions The panel cutout Instrument Panel amp Cutout must be precise and the edges free from burrs and waves Dimensions 3 622 92 00 MIN _ 3 653 92 80 MAX 1 180 29 97 lt q 7 180 182 37 OVERALL LENGTH PANEL I 3 770 95 76 4 9 x O00000 8 ooooo RRR ARR AR EN ER DN R A A R 3 770 95 76 p C 004 0826 e s9 NIN 00 26 2z9 3 585 91 06 BEZEL _ 6 000 152 40 L GASKET FRONT SIDE CUTOUT 3 Place bezel gasket around the controller case starting at the back of controller Then slide the gasket against the back of the bezel 4 With the bezel gasket in place insert the 545 into the panel cutout from the front of the panel 5 Slide the mounting collar over the back of the case as shown in Figure 3 2 The collar clip edges will lock with matching edges on the controller case Mounting Clip Figure 3 2 Attaching Mounting Collar J Front Panel Mounting Collar E Collar Screws 1 of 4 545 User s Manual Ch
183. talled in the control ler compare the product number on the controller label with the section Order Code in Chapter 1 This section also includes a diagram of how to wire a posi tion proportioning output a special application using two mechanical ortwo solid state relays 1 Mechanical Relay Output e Output 1 is always Control 1 e Outputs 1 2 and 3 are jumper selectable for normally open and nor mally closed on the power supply circuit board e Output 4 is always configured for normally open and has reduced voltage and current ratings see Specifications Terminals used Terminals used Terminals used Terminals used Line Power with Output with Output with Output with Output Module 1 Module 2 Module 3 Module 4 569 79 5 8 Cb 41 61 891 16 Recommend use of both MOV and snubber 2 Solid State Relay Triac Output e Output 1 is always Control 1 e Respective jumper J1 J2 orJ3 mustbe setto normally open for SSR Triac output e Output 4 is always configured for normally open and has reduced voltage and current ratings See Specifications Terminals used Terminals used Terminals used Terminals used Line Power with Output with Output with Outpu with Output Module 1 Module 2 Module 3 Module 4 31D 15 7KB
184. tatus assigned to them by internal or external conditions control action The slope of the output of the instrument in reference to the input e g direct output increases on rise of input Typical cooling response or reverse output decreases on rise of input typical heating response control action derivative rate D The part of the control algorithm that reacts to rate of change of the process variable control action integral reset I The part of the control algorithm that reacts to offset between setpoint and process variable control action proportional P Control action in which there is a continuous linear relation between the output and the input control action proportional plus derivative PD A control algorithm that provides proportional control with the addition of derivative action to compen sate for rapid changes in process variable control action proportional plus integral PI A control algorithm that provides proportional control with the addition of integral action to compensate for offsets between setpoint and process variable control action proportional plus integral plus derivative PID A control algorithm that provides proportional control with both integral and derivative action control adaptive see adaptive control Glossary 7 control algorithm A mathematical representation of the control action to be performed control cascade see cascade control
185. tion PI control Proportioning control with auto reset PID control Proportioning control with auto reset and rate parameter s A user defined variable that specifies how a particular function in the 545 will operate position proportioning A type of control output that utilizes two relays to control an electric motorized actuator POWERBACKS Propriertary algorithm which monitors the PV to make predicitve adjustments to control parameters in order to reduce or eliminate setpoint overshoot at power up or after setpoint changes Glossary 7 POWERTUNE Moore Industries exclusive self tuning function Consists of an on demand pretune which calculates PID values or provides preliminary PID values and process information for the second tuning function Second tuning function is an adaptive tuning algorithm that automati cally adjusts PID values whenever a process upset or setpoint change occurs pretune algorithm A method by which the 545 controller initiates an output value change monitors the manner of the corresponding process variable change and then determines the appropriate PID control parameters primary loop The outer loop in a cascade system process The equipment for which supply and demand must be balanced the system under control excluding the equipment that does the control process variable In the treatment of material any characteristic or measur able attribute whose value changes w
186. tion process input gt 120 dB Normal mode rejection process input gt 80 dB AC line is double filtered and transient protected Snubbers are pro vided for each relay output CONSTRUCTION Case extruded non perforated black anodized aluminum with ABS plastic sleeve Bezel black plastic ABS Chassis assembly plug in type Keys silicone rubber with diffusion printed graphics NEMA rating front panel conforms to NEMA 4X when instrument is properly installed AGENCY APPROVALS LR 84603 Process cont Eee C Heavy Industrial Available as an option MEMORY RETENTION Lithium battery maintains all programming for approximately ten years SECURITY There are two levels of access restricted and full A configurable code is used to enter the full access level Functions not available in the restricted level are configurable A 16 Appendix 5 545 User s Manual APPENDIX 6 GLOSSARY adaptive control Control in which automatic means are used to change the type or influence or both of control parameters in such a way as to improve the performance of the control system adaptive tune A component of the 545 self tune function which continuously monitors the process and natural disturbances and makes adjustments in the tuning parameters to compensate or improve the performance of the control system alarm A condition generated by a controller indicating that the process has exceed
187. tion of the background loop it must be brought to the fore ground The controller helps the user identify the foreground and background loops with the following e When Loop 2 is in foreground DISPLAY key and the PV2 icon are lit The third display will show a message identifying the foreground loop Use the following as a quick guide to key operating functions of your 545 Most of these procedures will affect whichever loop is in the foreground at the time you execute the procedures Those that are specified by the word GLOBAL will affect both loops the whole controller To switch the foreground and background loops 1 Press FAST DISPLAY To select change a setpoint 1 Use DISPLAY key to toggle display to Set Point 2 Use SET PT key to toggle to active setpoint Before the newly selected setpoint is made active there is atwo second de lay to prevent any disruptive bumps If the setpoint displayed is ramping RAMPING will show the 3rd display 3 Tochange value press A or V To change from auto to manual control bumpless transfer 1 When in automatic control press the MANUAL key at any time except while inthe TUNING mode 2 The MANUAL key will lightin red andthe 2nd display will immediately change to indicate current output level To change from manual to auto 1 When in manual control press MANUAL at any time except while in the TUNING or SET UP mode 2 The 2nd display will not change and the MANUAL key will
188. tioning does not utilize direct feedback It estimates the position of the actuator based on time and the speed of the actuator In automatic control mode the controller will display CW to refer to energizing of the clockwise relay and CCW to refer to energizing of the counterclockwise relay A blank display means that both relays are de energized In manual control mode the display is blank unless an output change is being made Use the A and W keys to change the output the relay is only energized while the keys are being pressed The display indicates the percentage change in valve position in real time The rate of change is dependent on the values entered for CCW TIME and CW TIME The controller will transfer to manual control due to a lost process variable PV BREAK a digital input closure DES OUTPT a power up sequence PWR UP OUT or lost communications SHED OUT In these cases the output can be setto remain atits last value with both relays de energized OUTS OFF rotate fully counterclockwise CCW or rotate fully clockwise CW CCW CW will energize the respective relay for a period two times that of the CCW TIME or CW TIME Hardware Configuration The controller must have mechanical relay solid state relay or DC logic modules installed in the first two output sockets Refer to the section on Chapter 1 for more information Software Configuration 1 Goto CONFIG menu Set LOOP1 OUT or LOOP2 OUT to
189. to do so may result in small junction temperature 0 6 C 1 1 F Access the parts of the calibration menu as shown in Figure A4 2 d CALIBRATE ANALOG IN CAL VREF PRESS MENU PRESS ACK CAL 120mvV etc PRESS ACK Figure A4 1 545 Rear Terminals for Calibration Figure A4 2 Flowchart Calibration Menus PRESSMENU mA CALIB Power Down Attach 20mA Attach 20mA COMPLETED CALIBRATE SET BOTH Move Jumpers PV1 20mA to PN PV2 20mA ii to If mA calibration values are ANA mA PRESSACK JUMPER mA ys PRESS e foRess Press ACK OK PRESS MENU mA CALIB gt FAILED CALIBRATE PV 150 If mA calibration values are COLD JUNC FRESSACKS PRESS ACK out of range PRESS MENU PRESS AGK CALIBRATE OUTPUT X ANLG OUT LPRESS PRESS MENU PRESS MENU ee RESET After two i 7 SKIPPED MENU DATA PES PUSH MENU seconds SKIERE TO RESET i PRESS MENU PRESS MENU before two RESET d ee COMPLETED PRESS MENU i SLIDEWIRE SLIDEWIRE TEST PRESS ACK y PRESS MENU 2 22 22 PRESS ACK 545 User s Manual Appendix 4 A 7 Calibration Figure A4 3 Jumper Locations on the Microcontroller Circuit Board Figure A4 4 Input Calibration Wiring
190. two rows of pins The printed circuit boards are labeled next to the jumpers Figure 4 2 from the top The Microcontroller Circuit Board the Option Board and the Power Supply Board 22 Chapter 4 The Remote Setpoint Figure 4 2 shows the location of the remote setpoint jumper The factory de fault is milliamp Choose from the following settings V Remote setpoint with voltage signal jumper removed mA Remote setpoint with milliamp signal jumper installed Mechanical Relays There are three output module sockets on the Power Supply Circuit Board and one output module on the Option Board see Figure 4 2 The mechanical relay onthe Power Supply Board may be configured for either normally open NO or normally closed NC A jumper located nextto each socket determines this con figuration All relay output are factory set to NO normally open 5 Pin Connector aaa Remote Setpoint Jumper Male 22 Pin Male 22 Pin Connector Connector Output 4 4 Male 34 Pin Connector Female 34 Pin Connector 5 Pin Connector qe lo 0000 Module Retention Plate over Outputs 1 2 3 ln i t Jumpers NO and NC NO J1 NC NO J2 NC NO J3 NC 545 User s Manual Hardware Configuration Configuration ACCESSING AND CHANGING JUMPERS Follow these instructions to change jumpers for the Process Variable Remote Setpoint and Digital Inputs
191. utput signal refer to the Chapter 7 section on Duplex Control for details e For on off outputs the output value shown is either ON or OFF e Forduplex applications with two on off outputs the OUT tag is notshown In this case the status of both outputs is shownin the following manner 1 ON 2 OFF 1 and 2 are the respective outputs To display the active PID set 1 Select the desired foreground loop hold FAST press DISPLAY 2 Press MENU to reach Tuning Mode 3 In TUNING Mode press MENU to reach the correct Menu parameter 4 Theactive PID set will have an asterisk on both sides of the value ALARM OPERATION Alarms may be used in systems to provide warnings of unsafe conditions All 545 operators must know how the alarms are configured the consequences of acknowledging an alarm and how to react to alarm conditions Alarm Indication Depending on how the system is configured the 545 indicates an alarm condition s for the foreground loop by e Liticons ALM 1 and or ALM 2 e Lit ACK key e Displayed alarm message The 545 indicates an alarm condition s for the background loop by e Showing the user defined message for one or both alarms in the third display alternate displays for simultaneous alarms To acknowledge an alarm s An acknowledgeable alarm has both a lit icon and a lit ACK key A non acknowledgeable alarm has only a lit icon Figure 2 2 demonstrates acknowledging an alarm 1 If the alarm is in the
192. ve when the variable exceeds its trip point For example if PID TRIP SETPOINT and TRIP 2 500 the second set of PID values becomes active when the setpoint exceeds 500 and remains active until the setpoint drops below 500 or exceeds the next highest trip point The PID set with the lowest trip point is also active when the trip variable is less than the trip value The user can set the lowest trip point the low end of the process variable range but this is not required e Adigitalinputcan be setto trip to the second set of PID upon closure which overrides a selection based on trip points Using with Adaptive and Pretune The 545 can be programmed to automatically set the PID values using the Pretune and Adaptive Tuning functions For both functions the tuned set of PID is that which is active upon initiation of the tuning function The controller cannottrip to other PID sets based on trip point or the digital input 545 User s Manual Chapter 7 89 Applications 90 contact until Adaptive Tuning is disabled However if the PID setis tied to the corresponding local setpoint the active PID set values will change with the local setpoint Each PID set has 5 parameters that control its function proportional band reset rate manual reset or loadline and trip point For each set 2 thru 8 these values have to be manually set 1 Press MENU to access the TUNING menu 2 Set values for parameters 1 thru 20 thes
193. ware features of your controller or station Please refer to your User s Manual 20 To maintain NEMA 4X Rating you may need new mounting gaskets order part 535 662 Refer to your user s manual 500 Series 5 Declaration of Conformity C 4 EMC Directive 89 336 EEC Manufacturer s Name Moore Industries International Inc Manufacturer s Address 16650 Schoenborn Street North Hills CA 91343 6196 USA Declares that the product s Product Name 500 Series MODEL INPUT OUTPUT POWER OPTIONS HOUSING Model Number s 500 Series T 24 Vdc Hor J E Indicates any input output option and housing as stated on the product data sheet Indicates CE Compliant Conforms to the following EMC specifications EN61326 1 1998 Electromagnetic Compatibility requirements for electrical equipment for control use Conforms to the following safety standard EN 61010 1 2001 Supplemental Information CE option requires CE KIT PN 535 766 Date Fred Adt Robert Stockham Quality Assurance Director Moore Industries International Inc European Contact Your Local Moore Industries Sales and Service Office The Interface Solution Experts www miinet com United States info miinet com Belgium info mooreind be China sales mooreind sh cn MOOR Tel 818 894 7111 FAX 818 891 2816 Tel 03 448 10 18 FAX 03 440 17 97 Tel 86 21 62481120 FAX 86 21 62490635 IND USTRIES Australia sales mo
194. ware Configuration Configuration 10 11 OUTPUT 3 Defines the function of the third output D OFF Completely deactivates output e ALM RLY ON e ALM RLY OFF e RETRANS Retransmission e COMM ONLY Output addressable only through communi cations OUTPUT 4 Defines the function of the fourth output D OFF Completely deactivates output e ALM RLY ON e ALM RLY OFF e RETRANS Retransmission e COMM ONLY Output addressable only through communi cations ANLG RNG 1 Defines the output signal for the first output D 4 20mA e 0 20 e 20 4 e 20 0mA ANLG RNG 2 Defines the output signal for the second output D 4 20 e 0 20mA e 20 4mA e 20 0 ANLG RNG 3 Defines the output signal for the third output D 4 20mA e 0 20 e 20 4 e 20 0 ANLG RNG 4 Defines the output signal for the fourth output D 4 20mA e 0 20mA e 20 4 e 20 0mA Access Set Up Next menu Next parameter Next value Access Tuning FAST menu Fast Lv vew 545 User s Manual Chapter 5 OUTPUT 3 OUTPUT 4 ANLG RNG 1 ANLG RNG 2 4 20mA ANLG RNG 3 ANLG RNG 4 4 20mA Return to Operation Switch Loops DISPLAY DISPLAY 31 Software Configuration Configuration 12 CONTACT 1 CONTACT 1 Defines the operation of the first digital input for Loop 1 D L1 MAN Trips the controller to manual control e
195. warm up for 30 minutes 4 Placecontrollerin MANUAL mode then press FAST MENU to reach the PV INPUT menu 5 Press MENU until the OFFSET parameter appears in the 2nd display 6 Adjustthe calibration device to an output signal equalto the 0 range value for the particular input sensor for example 4mA for a 4 20mA input 7 Verify value indicated in the 1st display is equal to the 0 range value for the particular input sensor If incorrect use the and W keys to scrolltothe correct value 8 Forlinear voltage or mA input Press MENU until the PV GAIN parameter appears in the 2nd display For thermocouple or RTD input Continue to step 9 9 Adjust the calibration device to an output signal equal to the 10096 range value for the particular sensor 10 Verify that the value shown in the 1st display is equal to 100 of the range value for the particular input sensor If the value is not correct use the A and W keys to scroll to the correct value 11 Repeat steps 4 through 10 to verify all values 12 Press DISPLAY to return to the OPERATION mode RON Appendix 4 545 User s Manual Specifications SELF TUNING OF PID VALUES AVAILABLE FOR EACH LOOP POWERTUNE On demand pretune This is an open loop algorithm that may be used on its own to calculate PID variables or it can be used to provide preliminary PID values as well as process identification information to be used by the adaptive tune Three pretune types a
196. witch Loops DISPLAY DISPLAY 45 Software Configuration Configuration 5 BIAS LOW BIAS LOW Defines the lowest bias value that may be entered R 9999 to 99999 Maximum is BIAS HIGH D 1000 6 BIAS HIGH BIAS HIGH Defines the highest bias value that may be entered 1000 99991099999 Minimum value BIAS LOW D 1000 7 RSP FIXED RSP FIXED Defines what happens if remote setpointis lost while itis active and then is re stored e REMOTE SP Returns to remote setpoint when itis restored D LOCAL Local SP remains active when remote SP is re stored RETRANS RETRANS For configuring the retransmission output GLOBAL 1 TYPE 2 2 Defines what is to be retransmitted for output 2 PV1 D PV1 Linearized process variable 1 5 1 Target setpoint 1 e RAMP SP1 Ramping actual setpoint 1 e OUTL1 Control output 1 e PV2 Linearized process variable 2 e SP2 Target setpoint 2 e RAMP SP2 Ramping actual setpoint 2 e OUTL2 Control output 2 2 LO RANGE 2 LO RANGE 2 Defines the low end of the range of output 2 in engineering units D R 9999 to 99999 D Dependent upon process variable range 3 HIRANGE 2 HI RANGE 2 Defines the high end of the range of output 2 in engineering units D R 9999 to 99999 D Dependenton the process variable range Access SetUp Nextmenu Next parameter Next value AccessTuning Return to Operation Switch Loops Err new wee ww a v ww EXE
197. xed Appendix 3 the situation and recalibrate Call factory for assistance May not need to do anything May want to check the transmitter accuracy and check to see if range of transmitter matches the range of the controller Check wiring and sensor transmitter Check wiring and remote setpoint source Check communications wiring etc To clear message must make an auto manual change This is a fatal error and requires an EPROM change Call factory for assistance Must power down and install correct module combination or reconfigure the controller to match the current module combination Check the slidewire wiring Call factory for assistance This is a fatal error and requires an EPROM change Call factory for assistance Enter calibration menu and recalibrate the controller Call factory for assistance This is a fatal error and requires an EPROM or EEPROM change Call factory for assistance 545 User s Manual Calibration _ APPENDIX 4 CALIBRATION To maintain optimum performance once a year calibrate the analog input the cold junction and milliamp output when used To achieve published accuracy specifications follow directions carefully and use calibrated instru ments of like quality to those suggested If the controller is moved into an alternate case or the hardware configura tion is changed and the thermocouple input is needed recalibrate the cold junction for maximum accuracy Failure
198. xt parameter Next value Access Tuning Return to Operation Switch Loops Esje Dee a v few Es ene 66 Chapter 6 545 User s Manual 24 PID TRIP For NO OF PID gt 1 defines the variable used to select the various PID sets e PVVALUE PID set selection based on process variable D SPVALUE PID set selection based on setpoint e DEV VALUE PlDsetselection based on deviation from setpoint 25 TRIP 1 Defines the value thattriggers a change to the primary set 1 of PID values R The process variable range D Dependent on the process variable range FOR EACH SET OF PID 2 THROUGH you need to set up the following group of parameters X represents the PID set number Set up the param eters as they appear for each set of PID The controller designates the val ues forthe active PID parameter in the third display with an on either side 26 PROP BND X Defines the proportional band for PID set X R 0 110999 0 50 0 27 RESET X Defines the integral time for PID set X 1109999 seconds increments of 1 D 20seconds 28 RATE X Defines the derivative time for PID set X Oto 600 seconds D 1second 29 MAN RST X or LOADLINE X Defines the manual reset or load line for PID set X Oto 100 D 0 30 TRIP X This defines the value that triggers a change to the Xth set of PID values RH The process variable range D Dependenton the process variable range Access SetUp Nextmenu Next parameter N

5 4 5 1/4 DIN PROCESS CONTROLLER USER`S MANUAL

Contents

Download Pdf Manuals

Related Search

Related Contents