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1/4 DIN PROFILE CONTROLLER USER`S MANUAL 5 3 5

1. 17 2 Solid State Relay Triac 17 535 PROF User s Manual Table of Contents About This Manual Throughout this Users Manual information appears along the margins NOTE CAUTION and WARNING Please heed these safety and good practice notices for the protection of you and your equipment Table of Contents of Contents CHAPTER3 PAGE INSTALLATION CONTINUED Output Modules 3 DC Logic SSR Drive Output 18 4 Milliamp Output 22 iain knee dens 18 5 Position Proportioning Output 18 Serial Communications sessssssesseeeeeen 19 Limit eene nnne nnne 20 CHAPTER4 HARDWARE SETUP tree 21 Hardware Input Types 21 ThE Process oett aee ned uen nie nta rua 21 The Remote Setpoint 22 Mechanical Rela yS 22 Accessing and Changing Jumpers 23 Adding and Changing Output 24 Special Communications Module 26 CHAPTER5 SOFTWARE CONFIGURATION
2. 8 To Change from Auto to Manual Control Bumpless Transfer 8 To Change from Manual to 8 To Change Manual Output Values 8 To Override Security 8 To Display Control Output Value 9 To Display the Active PID 9 Alarm 9 Alama IGICAOM eT 9 To Acknowledge an Alarm s 10 Latching 10 Limit SEQUENCE uet 10 More On Ala tims eie EO aui er ia aes 10 CHAPTER3 INSTALLATION 11 Mounting the Controller 11 crs Er P 12 AG Power nput i els 13 Process Variable 13 Digital INPUt S 4 3 0 rcr a eer ed Eee 16 1 Digital Inputs with a Switch or Relay 16 2 Digital Inputs with an Open Collector 16 Remote Setpoint Option 16 Output Mod le S 2 2 ride oit erri foetu es 17 1 Mechanical Relay
3. C Remote Setpoint and Profile E Set of Five Digital D Certification sss H Five Digital Inputs and Certification J Serial Communications Enter 0 if not desired RS 485 Serial Communications S p E Note 1 Capability for position proportioning output is specified by ordering 535 11xxAxxx00 535 33xxAxxx00 535 44xxAxxx00 Note 2 Capability for velocity proportioning output is specified by ordering 535 11 00 535 33xxxxxx00 535 44xxxxxx00 Note 3 Up to two outputs may be used for alarms Note 4 All outputs are interchangeable modules Note 5 The mechanical relay and solid state relay modules are derated to 0 5 amp at 24 Vac when used as the fourth output 535 PROF User s Manual Chapter 1 3 Operation CHAPTER 2 BASIC INTERFACE Cose TQ pin ra Icons I Figure 2 1 Operator Interface Location for identification label Keys DISPLAYS The display strategy of the 535 Profile Controller is the same for all modes 1st Display five 7 segment digits Forthe process variable value 2nd Display nine 14 segment digits Forthe setpoint deviation output level or valve position if available n RECIPE SETUP
4. 110 Goad 111 psc 111 Software Configuration 111 Basic Operating Procedures 112 S Reset Inhibition ein uci dln ei tre 112 Software Configuration essen 112 T Process Variable Reading Correction 112 U Serial Communications 113 Hardware Configuration 113 Software Configuration 113 M Cascade Control snieni acne paie 114 Hardware Configuration 116 Software Configuration 116 Tuning Cascade 1 116 W Ratio Coritrol uui aeria cocti tribua conta t s a E a ee daa 117 Hardware Configuration 118 Software Configuration 118 Table of Contents 535 PROF User s Manual Table of Contents of Contents APPENDIX 1 PAGE MENUFLOWCHARTS seien tensa nnne n anna anna A 1 APPENDIX2 PARTS 3 TROUBLESHOOTING 4 APPENDIX 4 CALIBRATION eR 6 Preparation For All Input Calibrations A 7 Thermocouple Cold Junction Calibration
5. 27 sU 27 Paralimelels iit ener PARE quein pes eO E ANTA DREAM ental deus 29 Configuration and Operation 29 Where to Go Next ssssssssssssssseseeeee enne nennen 29 Software Menus and Parameters 31 CONEIG iubere edle Eine 31 REC CONF e M P 37 PNI INPUT cC 39 Padre 41 ERR 43 CONTROL TUE 44 ALARMS nen 46 SETPT 50 BETRANS eterni EE 51 SELF TUNE ncn rt cr nino ti Pret co ee ain ete 53 SPECIAL T 54 EMT 56 SER COMME irae saoi ERR e Eu rena E Res 57 c 58 Parameter Value Charts 61 CHAPTER6 QR Ic ETE 71 71 72 TUNING Value CHAM ascos 76 Self Tune Messages and Troubleshooting 78 CHAPTER7 APPLICATIONS 2 79 A Profile O10 8 60 pce 79 Software Configuration 80
6. A 8 Analog Milliamp Input Calibration esee 8 Milliamp Output Calibration A 9 Reset IBI A 10 Hardware Scan 11 Silo ITE PEL A 11 Quick Calibration Procedure A 11 APPENDIX 5 SPECIFICATIONS enne ute A 12 APPENDIX 6 GLOSSARY A 17 APPENDIX 7 ISOLATION BLOCK DIAGRAM A 22 535 PROF User s Manual Table of Contents V Table of Contents of Contents LIST OF FIGURES PAGE Figure2 1 Operator Interface 4 Figure2 2 Before and After Acknowledging An Alarm 9 Figure3 1 Instrument Panel amp Cutout Dimensions 11 Figure 3 2 Attaching Mounting Collar esee 11 Figure3 3 All535 PROF Terminal Assignments 12 Figure 3 4 AC Power Input Terminals esee 13 Figure3 5 Process Variable 13 Figure 3 6 PV1 and PV2 Wiring for Milliamp RTD and Voltage t erre eae 14 7 PV1 and PV2 Wiring for Milliamp Inpu
7. 1 to 12 It defines the length ofthe current soak segment Time units are defined by the TIME BASE parameter inthe REC CONF menu Choices are D OFF Selecting off eliminates the SOAK and makes possible 2 or more rampsto different setpoints R 00 01 to99 59 HR MN if TIME BASE HOURS MIN R 00 01 t099 59MN SC if TIME BASE MIN SEC 11 Thenextparameter is SOAK EV 21 to 12 It defines which events will be activated during this soak segment This parameter will only appear if SOAK TM is not OFF Choices are D NONE e EVENT 1 event output 1 is selected EVENT2 event output 2 is selected e EVENT12 eventoutputs 1 and2are selected e EVENT3 event output 3 is selected e EVENT13 eventoutputs 1 and3 are selected e EVENT23 eventoutputs2 and3are selected e EVENT 123 eventoutputs 1 2 and 3 are selected 12 The last parameter is PID SET 21 to 12 It selects which PID set to use during the current ramp and soak segments This parameter only appears if NO OF PID SEG SELECT in the TUNING menu Choices are D LASTSET Chapter 7 535 PROF User s Manual ions t PROFILE CONTROLLER SET UP WORKSHEET RECIPE Start From Time Base Use this chart to set up your recipe s 20 UV Idle Setpoint Process Variable HRS MIN MIN SEC EVE 83 Chapter 7 535 PROF User s Manual Applications Figure 7 1 C
8. 95 Software Configuration sssssseeeenn 95 F Velocity Position Proportioning Control 96 Hardware Configuration 96 Software Configuration ssiri oesie 96 G Staged Outputs 97 Hardware Configuration sssini 97 Software Configuration 97 H Retransmission correre 97 Hardware Configuration 97 Software Configuration sissi 97 Digital Inputs menn 98 Hardware Configuration 98 Software Configuration sssssseeeeeeenen 98 Basic Operating Procedures 100 J Remote Setpoint 100 Hardware Configuration 100 Software Configuration seen 100 Basic Operating Procedures 101 K Multiple 101 Software Configuration Lo ecrit enn 101 Basic Operating Procedures 101 Multiple Sets of PID Values 101 Software Configuration 101 Basic Operating 102 Using with Adaptive and Pretune 102 M POWerDaCK d
9. EE 102 Software Configuration 103 N Self Tune Powertune ssssssssssseeeenee enne 103 T 103 Adaptive TUNG aieea nea ekan Eaa a 103 535 PROF User s Manual Table of Contents iii Table of Contents of Contents CHAPTER7 PAGE APPLICATIONS CONTINUED N Self Tune Powertune amp Software Configurations sse 104 Pretune by 5 2 104 Pretune Type 1 amp Adaptive Tune 104 Pretune Type 2 or 3 amp Adaptive Tune 106 Adaptive Tune by Itself 106 Self Tuning with Multiple Sets of PID 108 Self Tune with Time Proportioning Outputs 108 Self Tune with Control Valves 108 O 109 Software Configuration sissies 109 P Input Linearization ssseeenm 109 Thermocouple and Linearization 109 Square Root Linearization 109 Hardware Configuration 110 Software Configuration 110 Custom Linearization siiis n 110 Software Configuration
10. 531 EPROM Kit 532 740 532 EPROM Kit 535 74 535 EPROM kit RSP 585 775 535 Profiler EPROM Kit 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
11. Ce 535 PROF User s Manual Chapter 6 71 Tuning TUNING TUNING 1 SP SELECT Replaces function ofthe SET PT key Selects the setpoint used when a recipe isnotrunning or held SP SELECT D REMOTESP Only if RSP option is installed REMOTE SP LOCALSP e LOCALSP2 NO OF SP hastobe2 e LOCALSPS3 NO OF SP hasto be3 e LOCALSP4 NO OF SP hastobe4 e LOCALSP5 NO OF SP hastobe 5 e LOCALSP6 NO OF SP hastobe 6 LOCALSP7 NO OF SP has to be 7 e LOCALSP8 NO OF SP has to be 8 2 ADAPTIVE ADAPTIVE Activates the self tune algorithm upon transfer to automatic control Only al lowed to operate during soak segments DISABLED D DISABLED e ENABLED 3 PRETUNE PRETUNE Activates the pretune algorithm if unitis under manual control Notselectable ifa recipe is running or holding To initiate the Pretune cycle press the or W Confirm by pressing ACK within two seconds D NO 4 POWR BACK POWR BACK Reduces setpoint overshootat power up or after setpoint changes DISABLED D DISABLED e ENABLED 5 PROP BND 1 PROP BND 1 Defines the proportional band for PID set 1 0 1t0999 0 D 50 0 6 RESET 1 RESET 1 Defines the integral time for PID set 1 EE EE R 1109999 seconds D 20seconds Access SetUp Returnto Operation Nextmenu Next parameter Next value AccessTuning Return to Operation Pme e a 72 Chapter 6 535 PROF User s Manual 7
12. HIGH SP 2 Specifies the high alarm set point for alarm 2 of type HIGH LOW lf ALM SRC 2 OUTPUT I ALM SRC 2 any othertype R 0 0 to 100 0 R LOWRANGEtoHI RANGE D 0 0 14B LOW SP 2 LOW SP 2 Specifies the low alarm set point for alarm 2 of type HIGH LOW If ALM SRC 2 OUTPUT If ALM SRC 2 any other type R 0 0 to 100 0 R LOWRANGEtoHI RANGE D 0 096 15 DEADBAND 2 Defines the deadbandforalarm 2 DEADBAND 2 If ALM SRC 2 OUTPUT If ALM SRC 2 any othertype 0 1 to 100 0 R 11099999 D 2 D 2 16 ALM 2 OUT Selects the output number for alarm 2 D NONE ALM 2 OUT e 2 P NONE e 4 17 LATCHING 2 Defines the latching sequence of alarm 2 LATCHING 2 e NOLATCH 18 2 Defines whether alarm 2 may be acknowledged D ENABLED Allowsthealarmtobeacknowledged ACK 2 DISABLED Prevents the alarm from being acknowledged whileinalarm condition 19 POWER UP 2 Defines how alarm 2 willbe treated on power up D NORMAL Alarm depends on process variable POWER UP 2 e ALARM Always power upinalarm regardless of process variable NORMAL e DELAYED Must leave alarm condition and reenter before activating the alarm Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation mee espe e 535 PROF User s Manual Chapter 5 49 Controller Set Up Set Up 20 MESSAGE 2 MESSAGE 2 A 9 character message associ
13. 0 CONTROL OUTPUT 0 00 1 1 Low Out Limit 700 500 300 o i 1 1 PRETUNE ADAPTIVE CONTROL OUTPUT 0 SP NOISE BUMP ADAPTIVE TIME lt Pretune 100 70 50 D CONTROL OUTPUT o 900 700 500 300 t BUMP ADAPTIVE TIME p gt Pretune 535 PROF User s Manual Figure 7 13 Pretune TYPE 1 TYPE 2 and TYPE 3 with Adaptive Tune TYPE 1 Pretune Adaptive Control e A to B is ON OFF control to determine initial PID values e is Pretune completed so Adaptive PID control beings if ENABLED Note Noise Band and Resp Time must be entered before enabling Adaptive TUne TYPE 2 Pretune Adaptive Control Ato B is a5 second noise band measurement B to C is an open loop bump test to determine initial PID values and response time C is Pretune completed so Adaptive PID control begins if ENABLED TYPE 3 Pretune Adaptive Control Ato Bis second noise band measurement BtoC is an impulse to determine initial PID values and response time C is Pretune completed so Adaptive PID control begins if ENABLED Chapter 7 105 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
14. PUSH MENU TO RESET PRESS ACK PRESS MENU before two HARDWARE seconds SCAN PRESS ACK DISPLAY ONLY PRESS MENU RESET COMPLETED PRESS MENU 7 77777777777777777 SLIDEWIRE SLIDEWIRE TEST PRESS y PRESS MENU PRESS ACK POP erui dedican 1 O Appendix 4 Power Down Attach 20 Attach 20 Move Jumpers 1 20 to PV1 PV2 20mA to PV2 Pv2 Pv 2 RTD 1 Pv 1 Figure 4 1 535 Rear Terminals for Calibration Figure A4 2 Flowchart Calibration Menus mA CALIB COMPLETED If mA calibration values are OK mA CALIB FAILED If mA calibration values are out of range 535 PROF User s Manual Calibration __ Figure A4 3 Jumper Locations on the Microcontroller Circuit Board CALIBRATION 7 JUMPERS SELECT V ANDTCA 4 PV INPUT JUMPER CONFIGURATION 00000000000 ooo0o00000 000 PREPARATION for ALL INPUT CALIBRATIONS Equipment for analog input calibration e Precision5 1 20r6 1 2 digit multimeter e g Fluke 88429 or HP3478A a 4 1 2 digit meter will sacrifice accuracy e Foursmall pieces of wire e Testleads with clips e 2Phillips screwdriver an TT Additional equipment forthermocouple input e Precision thermocouple calibrator e g Micromite II by Thermo Electric Instruments e Speciallimits grade
15. 27 Figure 5 2 Configuration Flowchart 28 Figure 5 3 Independentvs Dependent Parameters 29 Figure6 1 Access the Tuning Menu Block 71 Figure 7 1 Contacts for Recipe Selection 84 Figure 7 2 Alamn Examples urne tea hee rete teta ecu runt tud bancs 89 Figure 7 3 Duplex with Reverse and Direct Acting Outputs 91 Figure 7 4 Duplex with Direct and Reverse Acting Outputs 91 Figure 7 5 Duplex with Two Reverse Acting Outputs 92 Figure7 6 Duplex with A Gap Between Outputs 92 Figure 7 7 Duplex with Overlapping Outputs and Output Limits 93 Figure7 8 Duplex with Various Relative Gain Settings 93 Figure7 9 Duplex with One 94 vi Table of Contents 535 PROF User s Manual Table of Contents of Contents Figure 7 10 Duplex with Two On Off Outputs 94 Figure7 11 Staged Outputs Example 97 Figure 7 12 Combinations of Closed Digital Inputs for Each Setpoint Based on BCD Logic 98 Figure 7 13 Pretune Type 1 Type 2 a
16. 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 anundesirable level For example if the alarm setpoint is 10 with a time base of 5 sec onds 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 e 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 notapply to HIGH LOW alarms HIGH SP 1 and HIGH SP 2 ForaHIGH LOW alarm defines the high setpoint at which an alarm oc curs LOW SP 1 and LOW SP 2 Fora 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 frequent 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 th
17. 1 Defines the derivative time for PID set 1 0to600 seconds D 1second 8 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 R 0to100 D 0 9 CYCLE TM 1 Defines the cycle time for control output 1 when using atime proportioning out put 0 310 120 0 seconds D 15 0seconds 10 DEADBAND 1 Defines the dead band for control output 1 when using on off control R 1to99999 in engineering units D 2 11 P PROP D B Defines the dead band setting fora slidewire position proportioning output R O 5to 10 0 D 2 0 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 R 9999to 99999 in engineering units DO 13A PID OFST 2 For duplex applications defines the offset for the second output R 50 09010 50 0 D 0 0 13B ON OFST 2 For On Off applications defines the offset for the second output R 9999to 99999 in engineering units DO Access Set Up Return to Operation DISPLAY Next menu Next parameter Next value Emsb ww ww Chapter 6 Essi ww 535 PROF User s Manual RATE 1 RST 1 CYCLETM 1 DEADBAND 1 P PROP D B PID OFST 1 ON OFST 1 PID OFST 2 ON OFST 2 AccessTuning Return to Operation DISPLAY 7
18. SOAK Defines the length of soak segment units defined by TIME BASE param eterin REC CONF menu If TIME BASE HOURS MIN D OFF R 00 01 to 99 59 HR MN SOAK EV Defines which events will be activated during soak segment D NONE e EVENT 1 e EVENT2 EVENT 12 e EVENT3 e EVENT 13 e EVENT23 e EVENT 123 PID SET If NO OF PID SEG SELECT defines which PID setto use during ramp and soak segments D LAST SET R ito8 After PID SET you will return to the RAMP RT or RAMP TM param eter decimal point defined by DECIMAL parameter If TIME BASE MIN SEC D OFF R 00 01 to 99 59 MN SC Tocontinue programming within this recipe seta value for this segment and you will scroll through the subsequent parameters of this menu To end programming set RAMP RT or RAMP TM to OFF Next parameter Next value AccessTuning Return to Operation DISPLAY 60 Chapter 5 535 PROF User s Manual Controller Set Up Set Up PARAMETER VALUE CHARTS This section of value charts is provided for logging in the actual parameter values and selections for the process Itis recommended that these pages be photo copied so there will always be a master CONFIG Parameter Description Values 1 CTRL TYPE Type of control output s 2 LINEFREQ Power source frequency 3 PVSOURCE PV input derivation 4 REM SETPT Remote setpoint function 5 OUTPUT2 Second outp
19. 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 100 The parameters LOW OUT and HIGH OUT in the CONTROL menu specify the limits on the output Set these 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 andit was noted thatthe control valve started to stroke at 18 and at 91 it completedits stroke In this case LOW OUT should be set at 18 and HIGH OUT at 91 Chapter 7 535 PROF User s Manual Applications Note that when output limits are used the full output range from 5 to 105 is available in manual control O RAMP TO SETPOINT The 535 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 sh
20. The 535 PROF 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 installed in the controller 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 position proportioning output a special application using two mechanical or two solid state relays 1 Mechanical Relay Output NOTE e Output 1 is always Control 1 dE no um Bo ofthe e Outputs 1 2andS3are jumper selectable for normally open andnor Second input jumper connector on the mally closed on the power supply circuit board option board must be in either mA e Output 4 is always configured for normally open and has reduced milliamp or V voltage position 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 Figure 3 11 3 9 1 15 Mechanical Relay Output wiri
21. This technical brochure provides hardware installation and modification instructions for our controllers Series 531 532 535 545 and 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
22. IN ALARM __ CONDITION RELAY RELAY RELAY DE ENERGIZED ENERGIZED DE ENERGIZED ICON OFF ICON ON ICON OFF NO ALARM MAY NO ALARM 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 POWER UP ALARM CONDITION RELAY RELAY ENERGIZED ENERGIZED ENERGIZED ICON ON ICON ON ICON ON MAY CANNOT MAY ACKNOWLEDGE ACKNOWLEDGE ACKNOWLEDGE 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 89 Applications NOTE The duplex output states vary depending upon 1 Control Type PID On Off etc 2 Control Action DA RA 3 Output Limits 4 Output Gap or Overlay and 5 Ouput 2 Relative Gain and PID Output Please refer to the output state examples in this section to confirm that the 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 90 B Ifthe alarm setpointis setto 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 re quire a 100 unit change over a ten second
23. 1 2 SWITCH or PV SOURCE 1 2 BACKUP Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation Pme epus Dee De 74 Chapter 6 535 PROF User s Manual 20 PID TRIP For NO OF PID gt 1 defines the variable used to select the various PID sets PID TRIP Not applicable for SP NUMBER REC NUMBER or SEG SELECT SP VALUE e PVVALUE PID set selection based on process variable D SPVALUE PID set selection based on setpoint e DEV VALUE PID set selection based on deviation from setpoint 21 TRIP 1 Defines the value that triggers a change to the primary set 1 of PID values Theprocess variable range D Dependentonthe process variable range For each set of PID2 through 8 or equals SP NUMBER REC NUMBER or SEG SELECT setup the following group of parameters X represents the PID set number as they appear for each set of PID The controller desig nates the values for the active PID parameter in the third display with this symbol on either side 22 PROP BND X Defines the proportional band for PID set X PROP BND X R 0 110990 0 D 50 096 23 RESET X Defines the integral time for PID set X RESET X 1109999 seconds increments of 1 D D 20seconds 24 RATE X Defines the derivative time for PID set X RATE X R 0to600 seconds D 1seconds 25 MAN RST X or LOADLINE X Defines the manual reset orload line for PID set X MAN RST X
24. 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 mooreind 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 8
25. D 096 26 TRIP X This defines the value thattriggers a change to the Xth set of PID values R Theprocess variable range D Dependentonthe process variable range Access SetUp Returnto Operation Nextmenu Next parameter Next value AccessTuning Return to Operation bmw epus e 535 PROF User s Manual Chapter 6 75 7 TUNING Parameter Definition Values 1 SPSELECT Selects the setpoint used when a recipe is not running or held 2 ADAPTIVE Activates the self tune algorithm 3 PRETUNE Activates the pretune algorithm 4 POWR BACK Reduces setpoint overshoot at power up or after setpoint changes 5 PROP BND 1 Proportional band for PID set 1 6 RESET 1 Integral time for PID set 1 7 RATE 1 Derivative time for PID set 1 8 MAN RST 1 Manual reset for PID set 1 9 CYCLETM 1 Cycle time for control output 1 for time proportioning output 10 DEADBAND 1 Dead band for control output 1 for on off control 11 P PROP D B Dead band setting for slidewire position proportioning output 12A PID OFST 1 Offset for the first output for duplex applications 12B ON OFST 1 Offset for first output for on off applications 13A PID OFST 2 Offset for the second output for duplex applications 13B ON OFST 2 Offset for second output for on off applications 14 REL GAIN 2 Adjustment factor for the second output s proportional ban
26. 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 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
27. Figure4 3shows arepresentation of an output module Inspectthe 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 insertthe module in the socket Press down onthe module until it is firmly seated referto Photo 7 6 Snip Tie Wrap 7 Add Change Module 9 Replacetie wrapsforallthe 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 ofthe module and even tual failure Allseparately ordered modules should come with atie wrap Extra sets of tie wraps are available by ordering Part 535 PROF 665 NOTE For greatest accuracy calibrate all milliamp modules added for retransmission as per the instructions in Appendix 2 10 Rejoin the circuit boards by aligning the pins of their 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 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
28. SER COMM 1 STATION Defines the unit s station address 11099 STATION e OFF Disablesthe communications function D 1 2 BAUD RATE Defines the baud rate BAUD RATE e 1200BPS e 4800BPS D 9600BPS e 19200BPS 3 CRC CRC Defines whether CRC cyclic redundancy check is being calculated D YES YES NO Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation e espe e 535 PROF User s Manual Chapter 5 57 Controller Set Up Set Up 4 SHED TIME SHED TIME Defines the time interval between communications activity before the controller OFF determines that communicationsis lost sheds R 1to512seconds 5 SHED MODE Defines the state of the controller if communications is lost sheds SHED MODE D LASTMODE hRemaininautomaticormanualcontrol lastmode before LAST MODE losingcommunications MANUAL Triptomanual control e AUTOMATIC _ Triptoautomatic control SHED OUT SHED OUT Defines the output if the unit sheds and trips to manual control Choose values based onthe process Standard Control On Off Control Velocity Prop Control e 510105 ON e CW D LASTOUT D OFF e CCW D OUTS OFF SHED SP 7 SHED SP This defines the setpoint status if communications is lost LAST SP D LASTSP Continues to use setpoint that was active prior tolosingcommunications DESIG SP Goes to a designated setpoint value
29. TUNING or SET UP mode forthe parameter name Uponpower up indicates the current setpoint n OPERATION Mode displays program operating values a Thetarget soak setpoint value for this segment for example SP 1425 means the final soak setpoint during this segmentis 1425 b The current setpoint value for example RAMP 300 means the current ramping setpoint value is 300 SOAK 1425 means the current soak segment setpoint value is 1425 3rd Display nine 14 segment digits Foralarm messages loop name errors etc n RECIPE SET UP TUNING or SET UP mode the value or choice of parameter shownin the 2nd display n OPERATION Mode displays recipe status values and messages It will alternate every two seconds between the selected recipe status value and the next message if any messages are active a The ramp or soak segment number being run or held for example RAMP 10 11 means using ramp segment 10 of 11 segments in this recipe SOAK 3 4 means using soak segment 3 of 4 segments in this recipe 4 Chapter 2 Controller Operation 535 User s Manual Operation FAST 535 User s Manual FAST MANUAL b The amountoftime leftin the current ramp or soak segmentorthe amount of time the soak segment has been waiting to run or continue due to guaranteed soak for example 15 03 LEFT means 15 03 is remaining in this segment s current cycle WAIT 12 37 means the soak segment has been waiting for 12 3
30. The shaded areas onthe diagrams show which rearterminals are used for that type of wiring TOP as viewed from back of controller e EARTH COLD JUNC COLD JUNC Chapter 3 not used COMM COMM PV2 PV2 RTD 3RD PV1 PV1 535 PROF User s Manual install Wire AC Power Input Terminals 1 and 2 are for power Terminal 9 is the earth ground Use 0 5 Amp 250 V fast acting fuse in line with your AC power connection TOP GROUND Figure 3 4 AC Power Input Terminals CAUTION Do not run 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 Screws must be tight to ensure good electrical connection Process Variable Input The 535 PROF accommodates the following types of process variable inputs e Thermocouple Input e RTDInput e Voltage Input e Milliamp Input with External Power Supply e Milliamp Input with Internal Power Supply Each type of input can be wired for PV1 terminals 31 and 32 or for PV2 terminals 28 and 29 Figure 3 5 Process Variable Terminals 535 PROF User s Manual Chapter 3 13 7 Typically in the U S negative leads are red Figure 3 6 PV1 and
31. Tripsthe controllerto manual control Makes the second setpoint active Makes the second set of PID values active Acknowledges alarms Deactivates the resetterm Switches the control action Suspends the adaptive tune function Locks controller in manual control Remote A function Remote W function Remote MENU key function Remote FAST key function Toggle between SP DEV or OUT96 Statusreadable only through communications Runs the most recently selected recipe de faultis RECIPE 1 Aborts recipe when deacti vated Holds running recipe at current position Re sumesrunning of recipe when deactivated Resets a running or held recipe to the begin ning Forlinked recipes resetstothe beginning ofthefirstlinked recipe No action when deac tivated Aborts running or held recipe No action when deactivated Advances running or held recipe to the end of the current ramp or soak segment No action when deactivated Switches between PV1 and PV2 CONTACT 1 MANUAL Next menu Next parameter Next value AccessTuning Return to Operation Gee ew O De Chapter 5 33 Controller Set Up Set Up 13 CONTACT 2 CONTACT 2 Defines the operation of the second digital input REM SETPT D REM SETPT e MANUAL e 2ND SETPT e 2ND PID e ALARMACK e RST INHBT e D A R A e STOPA T e LOCK MAN e UPKEY e DOWNKEY e MENUKEY e FASTKEY e DISPKEY e COMM ONLY e STARTREC e HOLDREC e RESETREC e ABORTREC e N
32. line andthe respective output line draw a horizontal line The physical outputis the value where this horizontal line intersects the respective axis The illustrations assumes 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 LOW OUT 0 HIGH OUT 100 REL GAIN 1 0 Figure 7 3 Duplex with reverse and direct acting outputs 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 2 0 Figure 7 4 PID OFST 2 0 GZ LOW OUT 0 HIGH OUT 100 REL GAIN 1 0 Duplex with direct and reverse acting outputs 2225 PID OUTPUT 535 PROF User s Manual Chapter 7 91 Applications Figure 7 5 Duplex with two reverse acting outputs Figure 7 6 Duplex with a gap between outputs 92 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 PARAM
33. or output OUT while a recipe is run ning 1 Toggle the DISPLAY key until the appropriate selection appears on the 2nd display line To display the recipe number the current ramp or soak segment the time left in the segment the event status or the number of recipe cycles completed 1 Press the FAST key and toggle the DISPLAY key until the appropriate se lection appears on the 3rd display line BASIC PROCESS CONTROLLER OPERATING PROCEDURES This is a guide to controller operation when not using the profile options To select change a setpoint 1 Press the MENU key twice to display SP SELECT in the TUNING mode 2 Use the Aor V key to toggle the active setpoint Before the newly selected setpoint is made active there is two second de lay to prevent any disruptive bumps If the setpoint displayed is ramping RAMPING will show the 3rd display 3 change the setpoint value press or W while the setpoint is shown in the 2nd display To change from auto to manual control bumpless transfer 1 Whenin automatic control press the MANUAL key at any time except while inthe TUNING mode 2 TheMANUAL key willlightin red andthe 2nd display willimmediately change to indicate current output level To change from manual to auto 1 Whenin manualcontrol press MANUAL atany time except while inthe SET UP mode 2 The2nd display will not change and the MANUAL key will no longer be lit once control changes To change manua
34. process variable reading in engineering units For example if the thermo couple was always reading 3 too high the parameter could be set to 3 to compensate 3 Set GAIN This multiplies the deviation from the low end ofthe process vari NOTE PV1 GAIN is only available if able range by the gain factor and then adds it to the value of the low end of using a linear voltage Or current input the range to arrive atthe adjusted process variable value For example ifthe process variable range is 50 to 650 and the process vari able reading is 472 a GAIN of 0 995 would yield an adjusted process vari able 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 U SERIAL COMMUNICATIONS The serial communications option enables the 535 to communicate with a supervisory device such as a personal computer or programmable logic controller The communications standard utilized is RS 485 which provides a multi drop system that communicates ata high rate overlong distances Typical limitations are 32 instruments per pair of wires over a distance up to 4000 feet The 535 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 535 Through communications there is access to every Set up Tuning and Opera
35. to adapt its tuning parameters to the temporary process conditions Disable adaptive tuning by 1 Inthe TUNING menu change ADAPTIVE to DISABLED through the keypad or 2 Closing the appropriate digital input see Digital Input section in this chapter 106 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 13illustrates 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 Enter a value for parameter OUT STEP DO NOT Enter values for NOISE BND and RESP TIME The Pretune algorithm will calculate these values 6 Make sure that the 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 the controller is under automatic control 9 Activate the next parameter PRETUNE 10 Press and then 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
36. 0 1 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 o 2 01 0 1 0 1 0 1 0 1 0 1 02 04 0 1 0 1 0 2 6 3 01 0 2 0 2 0 1 0 1 0 1 03 04 02 02 0 3 2 j 01 0 2 0 2 0 1 0 1 0 1 04 01 02 02 0 5 5 5 02 02 02 02 02 02 05 01 02 03 06 Figure 7 15 a 6 02 0 3 03 02 02 02 06 01 03 03 07 Noise Band Values for Temperature z 7 02 0 3 03 02 03 02 06 02 03 04 08 Inputs g s 02 0 4 0 4 0 3 0 3 0 3 07 02 04 04 0 9 a 9 02 0 4 0 4 0 3 0 3 0 3 08 02 04 05 1 0 10 02 0 4 0 4 0 3 04 03 09 02 04 05 1 1 535 PROF User s Manual Chapter 7 107 Applications Control Output Final PV i 63 of Final PV Time gt DT Dead Time Time Constant RT Response Time Figure 7 16 Deadtime and Time Constant 108 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 Deadtime of the process plus one Time Constant The Deadtime is the time between initiation of an input change and the start of an observable response in the process variable The Time Constant is the 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 16 Example After a stimulus e g valve movement if ittakes 300 seconds for a
37. 1 Analog milliamp ssssss 2 Solid State Relay 1 3 DC Logic SSR drive 4 Output 2 Control Alarm or Retransmission NONG ette pe peteret Mechanical Relay ramp 1 Analog milliamp 2 Solid State Relay triac 1 3 DC Logic SSR drive 4 Output 3 Control Alarm Retransmission or Loop Power NOngz o on ee Mechanical Relay 5 1 Analog milliamp sssssssssssssss 2 Solid State Relay 1 3 DC Logic SSR 4 Loop Power ooo eee ces ceceeccecceceeceeeeeceeeveseesessvssesseseeees 5 Output 4 Alarm Retransmission or Loop Power 6 0 Mechanical Relay 0 5 amp 24 1 Analog milliamp s 2 Solid State Relay triac 0 5 amp 24 3 DC Logic SSR 4 VOOD F OWT eet itte teretes 5 Options Enter 0 if not desired Slidewire Feedback for Position Proportioning Output A 24 VAC 24 VDC Operation F Slidewire and 24 VAC 24 VDC G Remote cce tette B Profile Controller Option
38. 10 3 Movingthe potentiometerfrom one endtothe other should display from 0 to 100 onthe controller 4 Ifthe error message OPEN appears check the connectors and try again 5 Press ACK to exit QUICK CALIBRATION PROCEDURE Figure A4 10 This procedure may benefit users that have ISO or otherstandards requiring peri Slidewire Test Wiring odic calibration verification It enables verification and modification of the PV input without entering the Factory Configuration mode 1 Powerdownthe 545 controller and place the input jumpers in the desired posi tion refer to Figure A4 2 and Figure A4 7 2 Replace the process variable PV1 or PV2 inputsignal with a suitable milliamp calibration device 3 Apply power and allow controller to warm up for 30 minutes 4 Placecontrollerin manual mode Then press MENU and FASTtogetherto reach the PV1INPUT or PV2INPUT menu 5 Press MENU until the OFFSET parameter appears inthe 2nd display 6 Adjustthe calibration device to an output signal equal to the 0 range value for the particular input sensor for example 4mA for a 4 20 mA input 7 Verify value indicated in the 1st display is equal to the 0 range value for the particular inputsensor If incorrect use the A and V keys to scroll tothe correct value 8 Forlinear voltage or mA input Press MENU until the PV GAIN parameter ap pears inthe 2nd display For thermocouple or RTD input go to step 9 9 Adjustthe calibration
39. 30mV e NTC 0 60mV e RTC e 0 100mV e STC e 25 e TTC e WTC e W5T C e PLAT I T C 2 DEG F C K DEG F C K Selects the PV1 temperature units if using a thermocouple or RTD FAHR D FAHR e CELSIUS e KELVIN 3 DECIMAL Specifies the PV1 decimal point position DECIMAL D XXXXX XXXX X XXXXX XXX XX e XX XXX XXXXX 4 LINEARIZE Specifies if the PV1 inputis to be linearized NOTE T C s and RTD s are auto matically linearized LINEARIZE SQR ROOT Square rootlinearizationis activated e CUSTOM 15 pointcustom linearization curveis activated Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation Gee ee wv 535 PROF User s Manual Chapter 5 39 Controller Set Up Set Up LOW RANGE D HI RANGE D SP LO D SP HI LIM D CAUTION Set parameter values in the presented order dependent parameters are dyna mically related and changing values of one can alter the value of another For example if SP LO LIM is setto 0 and then thermocouple type is changed to B T C the SP LO LIM value will change to 104 the low limit of a type B thermocouple SP RAMP FILTER OFFSET 10 11 LOW RANGE Specifies the engineering unit value corresponding to the lowest PV1 input value e g 4 mA R 9999t099999 Max is HIRANGE D Dependentonthe inputselection HI RA
40. Ground Referenced 2 Vd Digital Inputs 1 5 RS485 Serial Communications Interface E Ve Line N G l Isolated output ground 4 Earth referenced ground 1 Each of the three ground circuits are isolated from each other to E withstand a potential of 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 Milliamp Loop Power and SSR Drive modules in output positions 1 2 3 and 4 are not isolated from each other l Internal ground V Milliamp Module Mechanical Relay SSR Driver Loop Power SSR Output A 22 Appendix 7 535 PROF 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 ac
41. LINE FREQ Definesthe powersourcefrequency GOHZ D 60HZ 3 PV SOURCE Defines how the PV inputis derived from PV1 and PV2 D Use PV1 PV SOURCE e 1 2 SWITCH Use PV1 until contact com selects PV2 1 ZBACKUP Use PV2 if PV1 is broken PV1 e PV1 PV2 Use PV1 PV2 e PV1 PV2 Use PV1 PV2 NOTE e AVG PV Usethe average of PV1 and PV2 PV1 and PV2 can be of different types e HISELECT Use PV1 orPV2 whicheveris greater and different range e LOSELECT Use PV1 or PV2 whicheveris less 4 REM 5 Selects function ofthe remote setpoint 5 OUTPUT 2 Defines the function of the second output e ALM EV ON Foran alarm or event output e ALM EV OFF Foranalarm or event output e RETRANS Retransmission OUTPUT 2 e COMM ONLY Outputaddressable only through communication OFF D OFF Completely deactivates the output Access SetUp Returnto Operation Nextmenu Next parameter Next value AccessTuning Return to Operation eee pee wv 535 PROF User s Manual Chapter 5 31 Access Set Up rast OUTPUT 3 OUTPUT 4 ANLG RNG 1 ANLG RNG 2 ANLG RNG 3 ANLG RNG 4 DISPLAY Return to Operation T 10 11 Next menu Eest ue ww Lativ Chapter 5 Controller Set Up Set Up OUTPUT 3 Defines the function of the third output e ALM EV ON Foran alarm or event output e ALM EV OFF Foran alarm or event output e RETRANS Retransmission e COMM O
42. MANGAL LAST MODE AUTOMATIC D LASTMODE Will power up inthe same mode prior to power down e PRETUNE Will Pretune on every power up Recommendedfor TYPE 1 pretune only RECIPE 5 PWR UP REC Selects the recipe to use after power up Appears only if PWR UP REC POWERUP RECIPE D LASTREC Lastrecipe used LAST REC R RECIPE 1 to20 Selectrecipe number 6 PWR UP RUN Specified how to use the selected recipe after power up Appears only if POWER UP RECIPE PWR UP RUN e STARTREC Start from the beginning of the recipe RESUME REC RESUME REC Resume recipe from where it left off before powerdown e HOLDREC Hold recipe from where itleft off before power down 7 PWR UP OUT Defines the output of the controller if powering up in manual mode LAST OUT PWR UP OUT means the output value will be equal to the last output value while in automatic Choose values based on your process Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation Geien ee wv 535 PROF User s Manual Chapter 5 55 Controller Set Up Set Up Standard Control On Off Control Velocity Prop Control e 5to10576 e ON e CW D LASTOUT D OFF CCW D OUTS OFF 8 PWR UP SP PWR UP SP Defines the setpoint upon power up LAST SP D LASTSP Powers up with the same setpoint local or re mote thatwas active priorto power down LOCAL Powers up usingthe primary local s
43. Microcontroller and Power Supply board are attached to either side of the Option board by male female pin connectors Use a gentle rocking 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 retra
44. NEXT LINK SOAK HYST RAMP SOAK SP SOAK EV Configure these parameters for each recipe up to 20 Each recipe has up to 12 ramp and 12 soak segments IDLE SP SOAK TM PID SET TUNING SP SELECT RATE 1 ADAPTIVE PRETUNE POWR BACK PROP BND 1 RESET 1 P PROP D B PID OFST 1 RSP BIAS MAN RST 1 CYCLE TM 1 DEADBAND 1 PID OFST 2 REL GAIN 2 CYCLE TM 2 DEADBAND 2 RSP RATIO 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 6 TRIP 6 Up to 8 times depending on NO OF PID PROP BND 7 RESET 7 RATE 7 MAN RST 2 TRIP 7 PROP BND 8 RESET 8 RATE 8 MAN RST 8 TRIP 8 A 2 Appendix 1 535 PROF User s Manual WEITEN 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 4 Output Modules Mechanical Relay Module 535600 Analog milliamp Module 535601 Solid State Relay Module 535602 DC Logic SSR Drive Module 535 603 Loop Power Module 535604 RS 485 Communications Module 535 705 Repair R
45. 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 of RTD 4 WIRE RTD Same color Third leg Same color DO NOT connect 4th leg VOLTAGE INPUT 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 Do NOT of RTD connect 4th leg VOLTAGE INPUT 535 PROF User s Manual install Wire _ For PV1 MILLIAMP INPUT 2 wire transmitter with separate power supply MILLIAMP INPUT 2 wire transmitter with loop power supply MILLIAMP INPUT 4 wire transmitter with loop power supply Input power for transmitter 4 20 mA output from transmitter 535 PROF User s Manual For PV2 MILLIAMP INPUT 2 wire transmitter with separate power supply MILLIAMP INPUT 2 wire transmitter with loop power supply 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 or 4th output socket Compare the controller product number with the order code in Chapter 1 to determine if the 535 PROF has a loop power module installed To
46. RAMP SP and OUTPUT ALARMS The 535 controller has two software alarms High and low alarms may be sourced to the PV SP RAMP SP DEVIATION and OUT PUT 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 Up to two alarm outputs are available if an associated mechanical solid state relay or DC logic module is installed in any output socket not used for control 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 A 14 Appendix 5 DIGITAL INPUTS A set of five external dry contacts or open collector transistor driven inputs are available Each can be configured to perform one of the following functions Select remote setpoint Select either direct or reverse control action Select manual controle Select second local setpoint Disable adaptive tuning Select a second set of PID values Addressable through serial communications only Inhibit the reset term Lock controller in manual e Acknowledge alarms e Simulate A
47. SETUP e NOTPV1 Enables userto enter differentvalues forthe fol AME AS PV1 lowing PV2parameters xia 2 PV2 TYPE Selects the particular sensor or input range for PV2 T C RTD VOLTAGE CURRENT mA D JT C D DINRTD D 1 5V D 4 20mA e ET C e JISRTD e 05V 0 20mA PV2TYPE e KTC e SAMARTD 010mV e BT C 0 30mV e NT C 0 60mV e 0 100mV e ST C 4 25mV TTC WTC e e PLAT II T C 3 DECIMAL Specifies the PV2 decimal point position D XXXXX e e XX XXX X XXXX Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation DECIMAL mee 535 PROF User s Manual Chapter 5 41 Controller Set Up Set Up LINEARIZE Specifies if the PV2 inputis to be linearized Thermocouples and RTD s are NONE automatically linearized D NONE SQR ROOT Square rootlinearizationis activated LOW RANGE NR Specifies the engineering unitvalue corresponding to the lowest PV2 inputvalue D e g 4mA R 9999t099999 Max is HIRANGE D Dependentonthe inputselection HI RANGE 6 HI RANGE D Specifies the engineering unit value correspondingtothe highest PV2 input value e g 20 R 99991099999 Min is LOW RANGE D Dependentonthe inputselection FILTER 7 FILTER Setting for the low pass PV2 input filter R 0to120seconds D Oseconds OFFSET OFFSET Defines the offsetto PV2 in engin
48. Type T thermocouple wire 1 Disconnect powertothe instrument 2 Remove chassis from case 3 OntheMicrocontroller Circuit Board locate jumpers locations marked PV1 and 2ndnearthe edge connector Reposition both jumper connectors in the 2ndlo cation onto pins for V and TC A as shown Figure A4 3 4 Connecthookupwires betweenterminals 31 and 32 andthe multimeter as shown Hook up in Figure A4 4 to Setthe meter for DC volts multimeter t Reinsertchassis into the case and apply power PV1 The2ndand3rddisplay should read CALIBRATE ANALOG IN 6 Allowthe controllerto warm up for atleast 30 minutes PV14 7 Press the ACK key to get to the first step parameter The 2nd display should show CAL VREF the 3rd display should show a value close to 5 0000 WARNING ELECTRIC SHOCK HAZARD 8 Themultimeter should read a value in the range 4 9750 5 0250 Terminals 1 and 2 carry live power Use the A and V and FAST keys on the controller until the display on the DO NOT touch these terminals when controller matchesthe meter reading power is on 535 PROF User s Manual Appendix 4 A 7 9 Press MENU key The 2nd display should show CAL 120mV The 3rd display should show a value close to 120 000 Match controller display to multimeter value using A and V keys 10 Press MENU four more times Each time match the displays of the controller andthe multimeter Press ACK when d
49. achieved in automatic control R 0 100 Maxis HIGH OUT D 0 HIGH OUT 6 HIGH OUT 100 Defines the highest output value that can be achieved in automatic control R 0 100 Min is LOW OUT D 100 ACTION 2 7 ACTION 2 Defines the action of the second control output Access Set Up Return to Operation Next menu Next parameter Nextvalue AccessTuning Return to Operation Zash 44 Chapter 5 535 PROF User s Manual Controller Set Up Set Up D DIRECT e REVERSE 8 P P TYPE Defines the type of position proportioning algorithm Choose values basedon the process P P TYPE Feedback option installed Feedback option notinstalled D SLIDEWIRE e SLIDEWIRE e VELOCITY D VELOCITY 9 CCW TIME Defines the time it takes a motor to fully stroke counter clockwise R 1to200seconds CCWTIME D 60seconds 10 CW TIME Defines the time it takes a motor to fully stroke clockwise 1to200seconds D 60seconds CWTIME 11 MIN TIME Defines the minimum amountoftime the controller must specify for the motorto be on before it takes action R_0 1to 10 0 seconds MIN TIME D 0 1seconds 12 S W RANGE Specifies the full range resistance ofthe slide e g 100 ohms R 0 10500hms S W RANGE D 100Ohms 13 OPEN F B Definesthe feedback ohm valuecorrespondingtofullopen 100 output PEN F B R OtoS W RANGE O D Dependenton S W RANGE value D 14 CLOSE F B Defines the feedback ohm val
50. an excessive 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 Place the controller under manual control 10 Accessthe TUNING menu press MENU 11 Accessthe parameter PRETUNE press MENU 12 Press Aand then ACK to begin Pretuning The 3rd display will show the message EXECUTING 13 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 1 Gotothe SELF TUNE menu 2 Set TYPE to BOTH 3 Set PRETUNE to TYPE 1 4 Setavalue for TUNE PT NOTE TUNE PT AUTOMATIC will work correctly only if the controllers setpiontis set up properly beforehand Set NOISE BND parameter Set the RESP TIME parameter 7 Make sure that the process is reasonably stable and place the controller oo Chapter 7 535 PROF User s Manual Applications under manual control 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 and then ACK to begin Pretuning The 3rd display will show the message EXECUTING 100 High Out Limit
51. as shown Figure 7 21 Whenin operation Unit 2 must be under remote setpoint control Tuning Cascade Control 1 The secondary loop is controlled by Unit 2 which does most of the work in controlling the process Putthe secondary loop Unit 2 under Manual con trol and perform a Pretune on it Once that Pretune is completed put the Unit 2 under Automatic control 2 The primary loop is controlled by Unit 1 which controls disturbances or load changes in the process Now place the primary loop Unit 1 into Manual and perform a Pretune on this loop Once this Pretune is complete the Cascade Control Loop is completely tuned Place Unit 1 into Automatic controlto allow the system to controlto the desired Setpoint ofthe Primary loop 116 Chapter 7 535 PROF User s Manual Applications W RATIO CONTROL Ratio Controlis employed in mixing applications that require the materials to be mixed to a desired ratio For example A given process requires Material A to be blended with Material Bina2 1 ratio Material Bis uncontrolled or wild Flow sensors transmitters are usedto measure the flow rate of each stream The flow signal for Material A is wired to the process variable input and the flow signal for Material B is wired to the remote setpoint input of the 535 Forthis example as shown in Figure 7 22 we would set RSP RATIO to 2 0 If the flow of Material B is measured at 50 gallons minute the effective remote setpointvalu
52. codeisentered the operator hasfullaccess The security feature is reactivated afterone minute of keypad inactivity If the security code is forgtton the security feature can still be overridden The security override code is Store this number in a secure place and blacken out the code in this manual to limit access S RESET INHIBITION Reset Inhibition is useful in some systems either at the 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 itto zero Software Configuration 1 Gotothe CONFIG menu 2 Setcorresponding parameter s CONTACT 1to CONTACT 5 to RST INHBT T PROCESS VARIABLE READING CORRECTION Conditions extraneous to the controller and 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 OFFSET and GAIN parameters can be usedto compensateforthese extraneous conditions NOTE This feature is provided as a convenience only Correcting the cause of the erroneous reading is recommended 1 Gotothe PV1 INPUT menu Chapter 7 535 PROF User s Manual Applications 2 Set OFFSET This parameter either adds or subtracts a set value from the
53. cold junction 8 Formilliamp output calibration proceed to Milliamp Output Calibration Let the controller warm up for 10 minutes then skip to step 5 9 Ifcalibrationis complete power down then place allthe jumpers in their origi nal 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 input current see Figure A4 6 Make sure terminal screws are securely tightened but do not connect the wires yet leave inputs floating 2 Turnonpowertothe unit 3 Press 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 Powerdownthe controller and remove chassis from the case A 8 Appendix 4 Type T 126 thermocouple wires floating red Figure A4 5 Thermocouple Cold Junction Calibration Wiring 535 PROF User s Manual Calibration Wires to 20 current floating PV2 PV2 PV1 PV1 Figure A4 6 Analog mA Input Calibration Wiring 000000 000000 Figure A4 7 Analog mA Input Jumper Positions 535 PROF User s Manual 6 Remove both input jumper connectors from the pins inthe 2nd position Place one of the jumpers onthe PV 1 position mA
54. completed If calibration is complete power down Place the jumpers into their original positions see Chapter 4 15 If the controller briefly displays mA CALIB FAILED PV2 calibration was not successful Check the 20mA connections and return to step 3 to recalibrate the PV1 and PV2 inputs MILLIAMP OUTPUT CALIBRATION Ifthe controller uses milliamp outputs itis usually notnecessary to calibrate them If the milliamp output are being used for accurate retransmission of data it is rec ommended thateach output with an analog module be calibrated annually to main tain optimal performance Equipment needed e Precision 5 1 2 digit multimeter e g Fluke 88429 or HP3478A 4 1 2 digit meters sacrifice accuracy e Two small pieces of wire for every milliamp output e Testleads with banana clips e 2Phillipsscrewdriver 1 Disconnectpowertothe instrument 2 Remove chassis from case N Appendix 4 A 9 3 Onthe Microcontroller Circuit Board locate jumper locations marked PV 1 and 2nd near the edge connector Reposition both jumper connectors in the 2nd location onto pins for V and TCA as shown in Figure A4 3 4 Reinsertchassis into the case and apply power 5 Allow controller to warm up for atleast 30 minutes The2ndand3rddisplays 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
55. device to an output signal equal tothe 100 range value forthe 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 Aand WV 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 o9 RON 535 PROF User s Manual Appendix 4 A 11 Specifications _ APPENDIX5 SPECIFICATIONS ACCURACY LINEAR Voltage Current RTD 1 0 1 THERMOCOUPLE J K N E gt 00 J K N E lt 0C T gt 0 C T lt 0 C R S gt 500 C R S lt 500 C B gt 500 C B lt 500 C TYPICAL 0 025 of full scale 0 050 of full scale 0 050 of span 0 095 of span 0 060 of span 0 150 of span 0 100 of span 0 250 of span 0 150 of span 0 375 of span 0 150 of span 0 500 of span MAXIMUM 0 100 of full scale 0 150 of full scale 0 150 of span 0 225 of span 0 150 of span 0 375 of span 0 250 of span 0 625 of span 0 375 of span 0 925 of span 0 375 of span 1 000 of span SELF TUNING OF PID VALUES 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 inf
56. for the corresponding milliamp output modules Output 1 uses terminals 3 and 4 Output 2 uses terminals 5 and6 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 Connect to leads into the meter Set the meter for DC milliamp multimeter 7 Press ACK The 2nd display will read OUTPUT1 OUTPUT2 OUTPUT3or igure A4 8 OUTPUT4 depending onthe module installation Ctr pine 8 Press MENU to scrollto the outputtobe calibrated see Figure A4 9 The 3rd display should read 4 mA The multimeter should read a value close to 4 00 CALIBRATION 9 Wait one minute Use A and W and FAST on the controller to change the meter s display to exactly 4 00 mA 10 Press MENU The 3rd display should read 20 mA 11 Let this setting stabilize for 5 minutes Use Aand and FAST on the con trollerto change the meter s display to exactly 20mA 12 Tocalibrateanotheranalog 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 Repeatstep 9 11 13 To complete calibration press ACK key disconnectthepowerandplacethe jumper connectors back into their original position Ord S Figure A4 9 RESET MENU DATA Output Module Menu Cycle Resets a
57. if communications is lost 8 DESIG SP DESIG SP Defines the value ofthe designated setpoint if communications is lost R Anyvalueinthe process variable range D Dependentonthe process variable range RECIPE RECIPE 11020 For each recipe number as determined by the RECIPES parameter inthe REC CONF menu you will set values forthe following parameters 1 CYCLES Defines the number of times the recipe will run before ending or going to the next linked recipe NTINUAL co U e CONTINUAL R 1to99 D 1 Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation few Cav 58 Chapter 5 535 PROF User s Manual Controller Set Up 2 NEXT LINK ue ae NEXT LINK Defines which if any recipe will run after the current recipe has ended Also can place the outputin manual ata specified percentage OFF D NONE R 1to ofconfigured recipes e NOOUTPUT 3 IDLE SP IDLE SP Selects the setpointto be used when the recipe starts or after ithas completed i MALA LAST SP D LAST SP use the previous setpoint e REMOTESP use the remote setpoint if option is installed andenabled R 9999t099999 decimal point defined by DECIMAL param eter 4 SOAK HYST Defines the absolute value of the maximum allowable deviation from setpoint SOAK HYST either when a soak segment starts if GUAR SOAK START SEG or any t
58. install a loop power module refer to Chapter 4 15 Digital Input s 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 Wire the switch relay between terminal 17 and the specific digital input Digital inputs Wiring with a Switch terminal Figure 3 8 or Relay d Screws must be tight to ensure electrical connection 2 Digital Inputs with an Open Collector Figure 3 9 An open collector is also called a transistor Wire the transistor between Digital Input Wiring with an Open terminal 17 andthe specified digital inputterminal Figure 3 9 Collector A Screws must be tight to ensure electrical connection Remote Setpoint Option Use terminals 13 and 14 to connect the remote setpoint signal see Figure 3 10 H 13 Figure 3 10 Remote Setpoint Terminals 16 Chapter 3 535 PROF User s Manual OUTPUT MODULES
59. is left at zero 0 NOTE Security does not prevent the operation from the digital inputs or serial communications 112 the setpoint value It does not prevent the operator from changing setpoints via the SP SELECT in the TUNING menu 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 SP SELECT parameter in the TUNING menu This prevents the operator from changing among the various local setpoints or changing to remote setpoint Itdoes not preventthe operatorfrom changing the setpoint value via the Aand Wkeys 6 RUN KEY locks out the RUN key This prevents an operator from starting holding or aborting a recipe 7 ALARM ACK locks out the ACK key preventing an operator from acknowledging any alarms 8 TUNING locks out modification to the parameters in the TUNING menu preventing unauthorized changes to the tuning parameters or the activation deactivation of the self tuning algorithm 9 RECIPES locks out modification to the parameters in the RECIPE menu 10 CONFIGURE allows access to the configuration menus but prevents any unauthorized changes to the configuration parameters If locked out the security code is not accessible 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
60. must be configured with an analog milliamp module in the first available output e See Section Hin this chapter for instructions on configuring the retrans mission feature e Upto four model 535 controllers can be used each must be specified with the remote setpoint option e See Section J in this chapter for instructions on configuring the optional remote setpoint feature B CONTROL TYPE Software Configuration 1 Gotothe CONTROL menu 2 Forthe parameter ALGORITHM select the type of 535 control e ON OFF Crude control similar to a household thermostat Used primarily on slow stable processes where moderate deviation cycling around setpointis tolerable Only available with SSR SSR Drive and relay outputs NOTE Controller capabilities depend upon the specified hardware option 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 Proportional plus integral control In addition to proportional control it compensates for control errors due to wide range of setpoints or load requirements The integral term works to eliminate offsets PD Proportional plus derivative control In addition to proportional control it compensates for control errors due to fast load variations e PID Proportional plus integral plus derivative control In addition to proportional c
61. period Example A is much more sensitive than Example B In general fora given rate of change the shorterthe time period the more sensitive the rate alarm D DUPLEX CONTROL The Duplex control algorithm enables two discrete control outputs forthe control loop Duplex controlis commonly used for applications that require both heating andcooling or when 2 control elements are needed to achieve the desired result Hardware Configuration e The controller must have two output modules assigned to the loop any combination of output modules Software Configuration 1 Gotothe CONFIG menu Set CTRL TYPE to DUPLEX 2 Touse different algorithms for each output PID for the first and On Off for the second Gotothe CONTROL menu Set ALGORITHM to PID ON OFF the control action for each output independent of the other Gotothe CONTROL menu Set ACTION 1 or ACTION 2 to either DIRECT or REVERSE action based onthe diagrams in the output examples section Figures 7 2 through 7 8 4 Gotothe TUNING menu Setvalues 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 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 outpu
62. pins and place the other jumper on the 2nd position mA pins as shown in Figure A4 7 Reinsertthe chassis into the case and apply power The controller should dis play PV1 20mA PRESS ACK to indicate it is ready to calibrate the PV1 milli amp input 8 Connecta precision 20mA inputto the PV1 terminals 31 is PV1 32is PV1 Make sure the terminal connections are fastened tightly and that a 20mA cur rentis flowing through PV1 Do not connect the 20mA current to PV2 yet 9 Letthe controller warm up for at least 10 minutes keep in normal horizontal position Make sure the currentis flowing then press ACK to calibrate the PV 1 input 10 If the controller briefly displays PV2 20mA INPUT PV1 calibration was suc cessful Move on to step 12 11 If the controller briefly displays mA CALIB FAILED PV1 calibration was not successful Check the 20mA connections and return to step 3 to recalibrate the PV 1 in put 12 Remove the 20mA inputfromthe PV1 terminals and attach itto the PV2 termi nals see Figure A4 6 Make sure the terminal connections are fastened tightly and that a 20mA cur rentis flowing through PV2 13 Letthe controller warm up for an additional 5 minutes keep in the normal hori zontal position Make sure the currentis flowing then press ACK to calibrate the PV2 input 14 Ifthe controller briefle displays mA CALIB COMPLETED PV2 calibration was successful andthe analog milliamp calibration procedure has been
63. screws Tighten them until the bezel is seated firmly against the gasket DO NOT OVERTIGHTEN 19 If may be necessary to re configure the software 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
64. set 5 39 RATE 5 Derivative time for PID set 5 40 MAN RST 5 Manual reset or load line for PID set 5 41 TRIP 5 Value thattriggers a change to the 5th set of PID values 42 PROP BND 6 Proportional bandfor PID set 6 43 RESET 6 Integral time for PID set 6 44 RATE 6 Derivative time for PID set 6 45 MAN RST 6 Manualreset orload line for PID set 6 46 TRIP 6 Value thattriggers a change to the 6th set of PID values 47 PROP BND 7 Proportional bandfor PID set 7 48 RESET 7 Integral time for PID set 7 49 RATE 7 Derivative time for PID set 7 50 MAN RST 7 Manualreset orload line for PID set 7 51 TRIP 7 Value thattriggers a change to the 7th set of PID values 52 PROP BND 8 Proportional band for PID set 8 53 RESET 8 Integral time for PID set 8 54 RATE 8 Derivative time for PID set 8 55 MAN RST 8 Manual reset or load line for PID set 8 56 TRIP 8 Value thattriggers a change to the 8th set of PID values POWERS 535 PROF User s Manual Chapter 6 Tuning SELF TUNE MESSAGES AND TROUBLESHOOTING Refer to Chapter 7 for more information on the Self Tune function of the 535 controller When the Pretune function terminates one of the following messages will appear Message Conclusion Problem Corrective Action COMPLETED 1 PRETUNE has generated initial PID and the Dead Time values PRETUNE had generated initial PID Response 2 3 Time Band Noise and the Dead
65. setpoint value for front panel entry 8 SP HILIM Highest setpoint value for front panel entry 9 SP RAMP Rate of change for setpoint changes 10 FILTER Low pass PV 1 input filter setting 11 OFFSET PV 1 offset in engineering units 12 GAIN PV1 gain 13 RESTORE Control mode when a broken PV1 signalis restored 62 Chapter 5 535 PROF User s Manual Controller Set Up Set Up PV2 INPUT Parameter Description Values 1 PV2SETUP PV2 function 2 PV2TYPE Sensor input range for PV2 3 DECIMAL PV2 decimal point position 4 LINEARIZE PV2inputlinearization 5 LOWRANGE Engineering unit value for lowest PV2 input 6 HIRANGE Engineering unit value for highest PV2 input 7 FILTER Low pass PV2 input filter setting 8 OFFSET PV2 offset in engineering units 9 GAIN PV2 gain 10 RESTORE Control mode when a broken PV2 signalis restored 535 PROF User s Manual Chapter 5 63 Controller Set Up Set Up CUST LINR Parameter Description Values 1 1ST INPUT 1st point input signal 2 1ST PV 1st point engineering unit value 3 XTH INPUT XTH point input signal X is 2 to 14 4 XTH PV XTH point engineering unit value 5 2ND INPUT 2nd point input signal 6 2ND PV 2nd point engineering unit value 7 3RD INPUT 8rd pointinput signal 8 3RD PV 3rd point engineering unit value 9 4TH INPUT 4th point input signal 10 ATH PV 4t
66. the desired number of PID sets to be stored SP VALUE automatically sets this value equal to the number of stored local setpoints 535 PROF User s Manual Chapter 7 101 Applications 102 each PID set will be active when its respective local setpoint is active 3 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 six ways e For NO OF PID PV NUMBER the PID set 1 or2 is selected when PV1 or PV2 is used ForNO 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 e For NO OF PID REC NUMBER the PID set 1 8 is the same as the current recipe number which is running or on hold e For NO OF PID SEG SELECT the PID set 1 8 isassignedtothe current recipe segment as defined by the PID SET parameter in the RECIPE menu e When NO OF PID a number 2 8 PID set becomes active 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 highesttrip point The PID set with the lowesttrip point is also active when t
67. the front face assembly until the chassis is all the way into the case If itis 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 13 Carefully insert and align screws Tighten them until the bezel is seated firmly against the gasket Do not overtighten 535 PROF User s Manual Chapter 4 Hardware Set Up Figure 4 3 Representation of Module 25 Hardware Set Up Set Up Figure 4 4 Install Communications Module onto Microcontroller Board 26 SPECIAL COMMUNICATIONS MODULE Aspecial communications module is available for the 535 PROF see order code in Chapter 1 for details Equipment needed Wrist grounding strap Phillips screwdriver 2 Small flat blade screwdriver Before installing the communications module set up the hardware wiring for the application See Chapter 4 for details With power off loosen the four front screws and remove them Side the chassis out of the case by pulling firmly on the bezel Do not detach the board assembly form the front face of the controller Orientthe Communications Module as shown and attach it to Connectors P1 and P2 as shown in Figure 4 4 Insert module onto connectors 000000 000000 Front of controller a circuits boards still attached to front face jo 5 Toreassemble the controller properly orient
68. there is an excessive change in the process variable PV value baud rate Any of the standard transmission rates for sending or receiving binary coded data 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 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 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 is the setpoint for another controller 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 configuration Also called set up selection of hardware devices and software routines that function together cold junction compensation Electronic means used to compensate for the effect of temperature at the cold junction contact In hardware a set of conductors that can be brought into contact by electromechanical action and thereby produce switching In App
69. time of OFF effectively skips the dwell allowing two 2 consecutive ramps of different rates Recipes may be link if more than twelve 12 segments are necessary GUARANTEED SOAK WITH ADJUSTABLE HYSTERESIS When activated dwell time doesn t start until the ramp setpoint has been achieved within the specified hysteresis a positive or negative deviation from the dwell setpoint 3 EVENT OUTPUT CAPABILITY Up to three 3 event outputs programmable per segment may be selected depending on the availability of controller outputs The 535 has four 4 outputs if one is used for control three are available for events Likewise if one is used for control and one is used for alarm two are available for events These outputs are available for turning on fans starting other processes or performing other functions RAMPS PROGRAM IN TIME OR RATE A ramp can be programmed to take place over a specific amount of time or be based on the rate of change of the PV per time unit If time based the time to reach setpoint must be between 0 01 and 99 59 minutes seconds or hours minutes If rate based the setpoint must be reached at a rate between 9999 and 99999 engineering units per second or per minute DUAL TIME RATE Two modes are available Hour Minutes or Minutes Seconds MULTIPLE CYCLES 1 99 PER RECIPE A 16 Appendix 5 Recipes may be programmed to automatically repeat up to 99 times or continually RECIPE LINKING All twenty 20 rec
70. transfer to automatic control upon completion of Pretune if set to do so or upon manual transfer Figure 7 13 illustrates the operation of Pretunes TYPE 2 and TYPE 3 with Adaptive Tune o9 RON Adaptive Tune by Itself Gotothe SELF TUNE menu Setthe TYPE parameterto ADAPTIVE Press MENU to access the TUNING menu Enter values for NOISE BND and RESP TIME as described below Setthe ADAPTIVE parameterto ENABLED The Adaptive Tuning cycle does notbegin the controller is under automatic control If Pretune results are poor or process conditions do not allow Pretune to run 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 Gotothe SELF TUNE menu 2 SetNOISE BND The noise bandis chosento distinguish between disturbances which affect the process and process variable noise The controller functions to gt 7 535 PROF User s Manual Applications compensate for disturbances i e load changes butit 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 14 shows a typical process variable response in a steady state situation In this example the process noise is within a band
71. 26 Vv 3 770 foire ecce 3 585 91 06 gt 6 000 152 40 GASKET SIDE CUTOUT 3 Place bezel gasket around the controller case starting at the back of con troller Then slide the gasket against the back of the bezel 4 With the bezel gasket in place insert the 535 PROF into the panel cutout from the front of the panel 5 Slide the mounting collar over the back ofthe case as shown in Figure 3 2 The collar clip edges will lock with matching edges on the controller case 6 Insertthe four mounting collar screws from the rear of the collar Gradually Mounting Clip 2 SS Figure 3 2 Attaching mounting collar Bezel Mounting Collar Collar Screws 1 of 4 535 PROF User s Manual Chapter 3 11 0 0 1 5 CAUTION The enclosure into which the 535 PROF 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 All 535 PROF Terminal Assignments Actual 535 PROF 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 tou
72. 3 Tuning 7 14 REL GAIN 2 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 R 0 1t0 10 0 D 1 0 15 CYCLE TM 2 CYCLETM 2 Defines the cycle time for control output 2 when using time proportioning R 0 3to 120 0 seconds D 15 0seconds 16 DEADBAND 2 DEADBAND 2 Defines the dead band for control output 2 when using on off control R 1t099999 in engineering units D 2 17 RSP RATIO RSP RATIO Defines the multiplier applied to the remote setpoint R 99 99t099 99 D 1 00 18 RSP BIAS RSP BIAS Defines the bias additive term applied to the remote set point D Any value in engineering units minimum is BIAS LOW maximum is BIAS HIGH D Dependentonthe BIAS LOW and BIAS HIGH values 19 NO OF PID NO OF PID Defines the number of PID sets that will be stored and available for use 1108 Fornumbers gt 1 PID TRIP defines tripping be tween the PID sets D 1 e SP NUMBER PID Set current local setpoint specified in NO OF SP Each PID set has a respective SP NUMBER e REC NUMBER PID Set current recipe If no recipe is run ning or held previous PID setis used e SEG SELECT PID Set set assigned to the current recipe segment If no recipe is running or held previ ous PID set is used e PVNUMBER PID Set process variable PV1 or PV2 used when PV SOURCE
73. 35 PROF User s Manual Chapter 5 47 Controller Set Up Set Up 10 MESSAGE 1 MESSAGE 1 A 9 character message associated with alarm 1 To enter message The first ALARM 1 character of third display will be flashing Press the 4 and W keys to scroll through the character set Press FAST key to advance to subsequent characters Pressthe MENU to advanceto next parameter D ALARM 1 ALM TYPE 2 11 ALM TYPE 2 Defines the type of alarm for alarm 2 e HIGHALRM e LOWALARM e HIGHLOW Separate High amp Low alarm setpoints in one alarm e BAND DEVIATION MANUAL Causesanalarm when in manual control e REMOTESP Causes an alarm when in Remote Setpoint e RATE Selects arate of change alarm D OFF Deactivates the first alarm ALM SRC 2 12 ALM SRC 2 Selects the source ofthe value being monitored by HIGH LOW or HIGH LOW alarm 2 D PV e SP e RAMP SP DEVIATION e OUTPUT ALARM SP 2 13 ALARM SP 2 D Specifies the alarm set point for alarm 2 except HIGH LOW For HIGH or LOW alarms IfALM SRC 2 OUTPUT If ALM SRC 2 any othertype 0 0 to 100 0 R LOWRANGEtoHIRANGE D 0 0 ForBANDalarms R 1t099999 D 0 For DEVIATION or RATE alarms R 9999t099999 D 0 Access Set Up Return to Operation Next menu Next parameter Nextvalue AccessTuning Return to Operation mme espe e De 48 Chapter 5 535 PROF User s Manual Controller Set Up Set Up 14A HIGH SP 2
74. 35 PROF has provisions for four output modules A controller ordered with output module options already has the modules properly installed Follow these instructionto 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 the four front screws and remove them 2 Side 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 Asshownin Photo 4 carefully pry apart using hands or a small flat screw driver the smaller Option board and the Power Supply board the one with 3 modules 5 Tochange modules 1 2 or3 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 4 535 PROF User s Manual 6 Tochange module 4 Output Module 4 on the Option board is also held in place by a tie wrap Sniptie wrap to remove module as shown in Photo 6
75. 5 CB 7KB 15 49 66 881 16kD 4 Milliamp Output 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 Output Module 1 Module 2 Module 3 Module 4 51 76 1156 419 6 8 16 5 Position Proportioning Output with or without Slidewire Feedback POSITION PROPORTIONING Electric Motor Actuator OUTPUT CCW CW Winding Winding wx Slidewire Wiper 0 1050 Ohm Cw Actuator Supply Current M race COM CCW COM Chapter 3 535 PROF User s Manual e Mechanical relay or solid state relay modules must be installed in output sockets 1 and 2 e Whenusing velocity control no 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 are accep
76. 535 PROFILER 7 88 UAL pm cm 2 IE 2 Ez PH 1 4 DIN PROFILE CONTROLLER USER S MANUAL Ul moore INDUSTRIES M535 PROF V5 JULY 2004 Table of Contents of Contents TABLE OF CONTENTS PAGE CHAPTER1 INTRODUCTION 2 caua teu enean cenar rein S 1 535 Profile Controller Modes sssseseeemennnne 1 Order Code Packaging Information 2 Where to Go Next nennen nnne nnne nennen 2 Text Formatting in this Manual eee 2 CHAPTER2 BASICINTEHEFAQGE rli ioo aHa Saan 4 DISPLAYS CET 4 iB 5 Mim 5 Basic Profile Controller Operating Procedures 7 To Enter the RECIPE SET UP 7 To Enter the SET UP Mode 7 TO RUM A RECIPO deursnee 7 a RECIPS steep repeto ei e peine 7 To Abort a Recipe and Switch to Manual Control 7 To Abort a Recipe and Control to the Idle Setpoint 7 To Display the Setpoint SP while a Recipe Is Running 8 To Display the Recipe Number 8 Basic Process Controller Operating Procedures 8 ToSelect Change a Setpoint
77. 7 c The status of events will be displayed Active events will be indicated by a 1 and inactive events by a 0 for example EVENT 000 means events 1 2 and 3 are inactive EVENT 100 means event 1 is active and events 2 and are inactive EVENT 111 means events 1 2 and 3 are active d The current cycle number and the total number of cycles will be dis played for example CYCLE 1 1 means the first and only cycle is currently active CYCLE 13 99 means the thirteenth of 99 cycles is currently active CYCLE 246 means the 246th cycle in continual cycling is currently active e Thecurrent recipe number will be displayed for example RECIPE 6 means the sixth recipe is currently active ICONS LIT OUT Indicates eitherthe relay output is energized or the analog output is greaterthan 0 ALM1 Indicates the respective alarm one is active ALM 2 Indicates the respective alarm two is active ALM Indicates an alarm wihtout an assigned output is active KEYS FAST No independent function Press to modify the function of another key MANUAL Presstotoggle between manual and automatic control When lit indicates the unitis under manual control Press to abort a running or held recipe and return controller to manual control RUN ForProfile Control Pressto Run Hold or Abort a recipe When a recipe is active press to prompt a display message for selecting the recipe nuumber 1 through 20 When l
78. 9 84 ii Table of Contents 535 PROF User s Manual Table of Contents of Contents CHAPTER7 PAGE APPLICATIONS CONTINUED A Profile Control Master Slave Operation sese 84 Hardware Configuration sirince naani 85 B Control Type dec Me nun ag eR RE RR Rae 85 Software Configuration nti eterne cs 85 SS ICH M TL 86 Software Configuration isin en hie 86 D Duplex nennen nnns 90 Hardware Configuration 90 Software Configuration 90 Duplex Output State Examples 91 Duplex with Reverse and Direct Acting Outputs 91 Duplex with Direct and Reverse Acting Outputs 91 Duplex with 2 Reverse Acting 92 Duplex with a Gap Between 92 Duplex with a Overlapping Outputs and Output Limits 93 Duplex with Various Relative Gain Settings 93 Duplex with One On Off Output 94 Duplex with Two On Off Outputs 94 Slidewire Position Proportioning 95 Hardware Configuration
79. 94 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 mooreind 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
80. ALARMACK Closing input acknowledges all active alarms Opening input rearms the controller If the digital input remains closed it does notcontinue to immediately acknowledge alarms as they become active e RST INHBT Reset Inhibition Closing input deactivates I integral term regard NOTE Only alarms configured to be less of the PID values being used Opening input activates I term acknowledged are affected by this if applicable digital input e D AJR A Direct Acting Reverse Acting Closing input reverses action of the firstcontrol output from directto reverse or reverseto direct Opening reinstates original action e STOPA T Closing inputtemporarily disables Adaptive Tuning Opening input enables it LOCK MAN Closing contact places the controller in manual control atthe desig nated output percentage All locked manual contacts must be opened in order to return controller to automatic control e UPKEY DOWN KEY Closing the contact mimics the designated A or W key Useful if controlleris mounted behind a window contact push buttons can be used to change setpoint values DISP KEY Closing contact mimics the DISPLAY key scroll through display of the Setpoint Deviation and Output e FAST KEY Closing contact mimics the FAST key Use in conjunction with A V DISPLAY and MENU keys 535 PROF User s Manual Chapter 7 99 Applications NOTE There is a one second delay before a closed digital i
81. AMP UNIT SP START GUAR SOAK EVT 1 OUT HOLD EVT RNG 1 CONTACT 2 CONTACT 3 TIME BASE EVT 2 OUT PV1 INPUT PV1 TYPE SP LO LIM EVT 3 OUT DEG F C K DECIMAL LINEARIZE LOW RANGE HIRANGE SP HI LIM SP RAMP FILTER OFFSET RESTORE PV2 INPUT PV2 SETUP PV2 TYPE DECIMAL LINEARIZE LOW RANGE HIRANGE FILTER OFFSET GAIN RESTORE CUST LINR 1ST INPUT 1ST PV INPUT XTH PV 15TH INPUT 15TH PV CONTROL ALGORITHM j D SOURCE ACTION 1 PV BREAK LOW OUT HIGH OUT ACTION 2 P P TYPE CCW TIME CW TIME MIN TIME S W RANGE OUT1STOP OUT2STRT OPEN F B ALARMS ALM TYPE 1 ALM 1 OUT CLOSE F B ALM SRC 1 ALARM SP 1 wessaes RATE TIME LATCHING 1 ALM SRC 2 REM SETPT TYPEV MA RSP LO H RsP HIRNG 5 H RSP HIGH H TRACKING BIAS LOW BIASHIGH RSP FIXED RETRANS TYPE 2 LOW RANGE 2 HI RANGE 2 TYPE 3 LOW RANGE 3 HI RANGE 3 TYPE 4 LOW 4 HI RANGE 4 SELF TUNE PRETUNE TUNE PT OUT STEP LOW LIMIT HI LIMIT TIMEOUT NOISE BND RESP TIME DEAD TIME SPECIAL AUTO TRIP TRIP DEV DES OUTPT PowER HPwR uP REC PWR UP RUN PWR UP our 5 H NO OF SP SECURITY SEC CODE SP ADJUST j AUTO MAN SP SELECT RUN KEY ALARM ACK 535 PROF User s Manual Appendix 1 A 1 Menu Flowcharts Flowcharts RECIPE RAMP RT CYCLES RAMP EV
82. ARM ACK e MANUAL e 2ND SETPT e 2ND PID D ALARMACK e RST INHBT e D A R A e STOPA T e LOCK MAN e UPKEY e DOWNKEY e MENUKEY e FASTKEY e DISP KEY e COMM ONLY e STARTREC e HOLDREC e RESETREC e ABORTREC e NEXTSEG e PV2 SWITCH 17 LOOP NAME A 9 character message associated with the loop The first character of the 3rd LOOP NAME display will be flashing To enter message press and V keys to scroll LOOP ONE through character set Press FAST key to enter the selection and move to next digit Press MENU key to advance to next parameter D LOOPONE REC CONF REC CONF 1 RECIPES Definesthe number of recipes available inthe 535 RECIPES dee E R 11020 D 1 2 TIME BASE Defines time base units for recipes TIME BASE e MIN SEC Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation eee pee wv 535 PROF User s Manual Chapter 5 37 Controller Set Up Set Up 3 RAMP UNIT RAMP UNIT Defines rampsegmentterms e RATE 4 SP START SP START Defines initial value forthe first ramp segment s setpoint PV e DLESP the IDLE SP is the first value o PY D PV The starting value will be adjusted to account for the initialPV value 5 GUAR SOAK GUAR SOAK Selects whether guaranteed soak 5 used during each soak segment D OFF guaranteed soak will not occur START SEG guaranteed soak can occu
83. ARRANTS 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 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 transportat
84. Aprocesswheretwo PID control loops need to interactto achieve optimum control Cascade controlis commonly implemented in temperature control applications wherethe main control variable is affected by another variable i e pressure Example raw materials HERE EEEEEERENEE MANUAL pisPLAY Vv ACK MENU HEAT EXCHANGER temperature sensor Chapter 7 535 PROF User s Manual Applications In Figure 7 20we have a535 set up to control a heat exchanger In a PID equipped heat exchanger pressure in the steam shell more quickly reflects fluctuations inthe steam supply than does the process liquid s temperature Why In this example with PID control the average temperature ofthe liquid in the heat exchanger of 80 but can vary by as much as five degrees because the steam supply itself is not constant Fluctuations inthe pressure of the steam supply cause fluctuations in the temperature of the steam within the heat exchanger So the process liquid s temperature begins to rise but it takes several minutes forthe increased heat from the steamtotravelthroughthe process liquid to reach the temperature sensor By the time the sensor registers the higher value and calls fora decrease in steam the process liquid near the walls is already atanevenhighertemperature Although the steam supply is reduced the process liquid s temperature continues to rise for a
85. 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 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 bee
86. D 535 PROF User s Manual Chapter 7 103 Applications 104 Software Configurations Pretune by Itself 1 Gotothe 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 If using TYPE 2 or TYPE 3 pretune Set the 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 Ifthese boundaries are exceeded duringthe Pretune the pretune cycle will abort and return to manual control at the output level prior 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 abouttwice the pretune time The purpose of this parameter is to prevent a Pretune cycle from continuing for
87. ETER 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 reverse acting output 1 and a direct acting output 2 react with a positive offset for output 1 negative offset for output 2 assume no restrictive output limits and aneutral 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 o 100 50 Offset PID OUTPUT Chapter 7 535 PROF User s Manual Applications Duplex with 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 output limits are applied directly to the PID output This in turn limits the actual output values In this example the high 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 off
88. EXTSEG e PV2 SWITCH Access Set Up Return to Operation Next menu Next parameter Nextvalue AccessTuning Return to Operation wer espe e Cav 34 Chapter 5 535 PROF User s Manual Controller Set Up Set Up 14 CONTACT 3 Defines the operation of the third digital input e REM SETPT MANUAL D 2ND SETPT 2ND PID e ALARMACK e HST INHBT e D A R A STOP A T e OCK MAN e UPKEY e DOWNKEY e MENUKEY e FASTKEY e DISPKEY e COMM ONLY e STARTREC e HOLDREC e RESETREC e ABORTREC e NEXTSEG e PV2 SWITCH CONTACT 3 Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation eee 535 PROF User s Manual Chapter 5 35 Controller Set Up Set Up 15 CONTACT 4 CONTACT 4 Defines the operation of the fourth digital input e MANUAL e 2ND SETPT D 2ND PID ALARMACK e RST INHBT e D A R A e STOPA T e LOCK MAN e UPKEY e DOWNKEY e MENUKEY e FASTKEY e DISP KEY e COMM ONLY e STARTREC e HOLDREC e RESETREC e ABORTREC e NEXTSEG e PV2 SWITCH Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation wer espe De 36 5 535 PROF User s Manual Controller Set Up Set Up 16 CONTACT 5 This defines the operation of the fifth digital input CONTACT 5 e REM SETPT AL
89. In Automatic control press to enter RECIPE SET UP mode In Manual control press to enter the SET UP mode In SET UP mode press to advance through menus Use MENU by itself to access the parameters of a particular menu 6 Chapter 2 Controller Operation 535 User s Manual Operation 535 User s Manual BASIC PROFILE CONTROLLER OPERATING PROCEDURES Use the following as a quick guide to key operating functions of the 535 PROF To Enter the RECIPE SET UP Mode 1 Toenterthe RECIPE SET UP mode from any other mode hold down FAST and press MENU The MENU key will illuminate The 2nd display line will indicate RECIPE where represents the recipe number 2 Usethe A or V key to select the recipe number 3 Press MENU by itself The first parameter of this menu for this recipe will appear in the 2nd display replacing RECIPE while the choices or selec tions appear in the 3rd display 4 Pressing DISPLAY at any time exits the RECIPE SET UP mode and re turns you to OPERATION mode To Enter the SET UP Mode 1 Ifyou are notin MANUAL control press MANUAL The MANUAL key will illuminate 2 Hold down FAST and press MENU The MENU key will illuminate RECIPE will appear alone in the 2nd display Entering the SET UP mode first gives you access to the RECIPE SET UP mode 3 Hold down FAST andpress MENU CONFIG appears alone in the 2nd dis play You are now in the SET UP mode See Chapter 5 fora list of all Set Up parameter
90. LOW RANGE 4 LO RANGE 4 Definesthelowendofthe range for output 4 in engineering units Doesnotappearfor type CTRL OUT D R 9999to99999 D Dependentonthe process variable range Access SetUp Returnto Operation Nextmenu Next parameter Next value AccessTuning Return to Operation wer e 52 Chapter 5 535 PROF User s Manual Controller Set Up Set Up 9 HI RANGE 4 Definesthe high endofthe rangeforoutput4 in engineeringunits Does notappear HI RANGE 4 fortype CTRL OUT R 99991099999 D Dependentonthe process variable range SELFTUNE SELF TUNE 1 TYPE TYPE This defines the type of self tuning algorithm that is available e PRETUNE Allowsthe operatortoinitiate Pretune only DISABLED 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 Defines the type of pretune algorithm thatis available PRETUNE D TYPE1 Normally used with slowerthermal processes TYPE2 Normally used with faster fluid or pressure processes TYPES Normally used with level control applications 3 TUNE PT Defines the PV value at which the output will switch off during a TYPE 1 pretune TUNE PT Helps prevent overshoot R Any value in PV input range AUTOMATIC D AUTOMATIC Controllerdefines this point 4 OUT STEP Defines the output step size in absolute
91. NGE Specifies the engineering unit value corresponding to the highest PV1 input value e g 20mA R 99991099999 Min is LOW RANGE D Dependentonthe inputselection SP LO Defines the lowest setpoint value that can be entered from the front panel only R 9999t099999 Max is SP HI LIM Min is LOW RANGE D Dependentonthe LOW RANGE value SP HI LIM Defines the highest setpoint value thatcan be entered from the front panel only R 9999t099999 Min is SP LO LIM Maximum is HI RANGE D DependentonHI RANGE SP RAMP Definesthe rate of changefor setpoint changes D OFF Deactivates this function 1t099999 units perhour FILTER Setting for the low pass PV1 input filter R Oto120 seconds D Oseconds OFFSET Defines the offsetto PV1 in engineering units R 99991099999 D 0 Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation Zash ev 40 Chapter 5 535 PROF User s Manual Controller Set Up Set Up 12 GAIN Defines the gainto PV1 GAIN 0 100to 10 000 1000 D 1 000 13 RESTORE Definesthe control mode when a broken PV1 signalis restored RESTORE D LASTMODE LAST MODE e MANUAL AUTOMATIC e STARTREC e RESUME REC e HOLDREC PV2 INPUT PV2 INPUT 1 PV2 SETUP Defines function of PV2 D SAME AS PV1 All PV2 parameters are set to the same values as PV1 no further parameters will appear PV2
92. NLY Outputaddressable only through communications D OFF Completely deactivates the output OUTPUT 4 Defines the function of the fourth output e ALM EV ON Foran alarm or event output e ALM EV OFF Foran alarm or event output e RETRANS Retransmission e COMM ONLY Outputaddressable only through communications D OFF Completely deactivates the output ANLG RNG 1 Defines the output signal for the first output D 4 20mA 020mA e 204mA e 20 0mA ANLG RNG 2 Definesthe outputsignalforthe second output D 4 20mA 0 20 e 204mA e 20 0mA RNG 3 Defines the output signal forthe third output D 4 20mA e 020mA e 20 4mA e 20 0mA ANLG RNG 4 Definesthe outputsignalforthe fourth output D 4 20mA 020mA e 20 4mA e 20 0mA Next parameter Next value AccessTuning Return to Operation DISPLAY 535 PROF User s Manual Controller Set Up Set Up 12 CONTACT 1 Defines the operation ofthe first digital input Access Set Up RECIPE 1 7 SETPT 1 8 REM SETPT MANUAL 2ND SETPT 2ND PID ALARMACK RST INHBT D AJR A STOP A T LOCK MAN UP KEY DOWNKEY MENU KEY FAST KEY DISP KEY COMM ONLY STARTREC HOLDREC RESETREC ABORTREC NEXT SEG PV2 SWITCH Eve ew 535 PROF User s Manual Returnto Operation DISPLAY Choosestherecipe number uses Binary contact 1 3 Chooses Localsetpoint 1 8 uses BCD contacts 1 4 Makesthe remote setpoint active
93. SIGNAL FAILURE PROTECTION When input is lost output is commanded to a predetermined output 5 to 105 Thermocouple burnout is selectable for upscale or downscale INPUT FILTER Single pole lowpass digital filter with selectable time constant from 0 to 120 seconds CALIBRATION Comes fully calibrated from the factory and continuously calibrates itself for component aging due to temperature and time except for the reference voltage Field calibration can be easily performed in the field 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 20 mA or 4 20 mA front panel select able into a load up to 10000hms Accuracy 5 25 C 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 logi
94. TUNING menu is in effect manual reset 100 Figure 7 19 50 Load Line Example Controller Output 0 20 40 60 80 100 Process Variable Indication of Controller Span 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 required to control the process and then adjusting the load line to that value This minimizes the effect of momentary power outages andtransients Load line may also be adjusted to give the best response when bringing the load to the desired level from a cold start R SECURITY NOTE SEC CODE does not appear The 535 security system is easily customized to fit a system s needs unless all functions are unlocked Software Configuration 1 Gotothe SECURITY menu 2 SEC CODE defines the security password range from 9999 to 99999 The rest of the security parameters can be selectively locked out 3 SP ADJUST prevents the operator from using the A and Wkeys to change 535 PROF User s Manual Chapter 7 111 Applications NOTE Lock out CONFIGURE for full security If left unlocked the operator will have access to the security code NOTE The security function is compromised if the security code
95. Time values ABORTED 1 2 3 User has aborted PRETUNE before completion LIMIT ERR 1 The Process variable went beyond the HI Change the HI LIMIT and LOW LIMIT or the HIGH LIMIT or LOW LIMIT OUT and LOW OUT and run Pretune again 23 The Process variable went beyond the HI Change the HI LIMIT and LOW LIMIT or the or size and run Pretune again LIMIT or LOW LIMIT OUT STEP si d P gai 1 2 3 The inital process variable was near or beyond Change the manual output percentage or the HI nd the HI LIMIT or LOW LIMIT LIMIT and LOW LIMIT and run Pretune again TIMEOUT 1 2 3 TIMEOUT limit was reached before Pretune Set a longer TIMEOUT period and or increase the ns completed OUT STEP size and run Pretune again Eliminate the noise source if possible or increase 1 2 Too much PV noise was detected NOISE ERR 2 3 the OUT STEP and Pretune again INPUT ERR 1 2 3 PV or Cold Junction break detected during Check the described conditions and make Pretune corrections or repairs 1 2 3 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 The initial control output is outside the high and Change the manual output percent and run Pretune OUT ERROR 1 2 3 low limits defined in the Control menu again Decrease the OUT STEP size and run Pretune DATA ERR 2 3 The PV moved too quickly to be analyzed or more model parameters are calculate
96. When using TYPE 2 or TYPE 3 Pretune the Noise Band NOISE BND and Response Time RESP TIME will also be calculated In order to run this algorithm the process must fulfill these requirements The process must be stable with the output in the manual mode e Fortuninganon integrating process the process mustbe able to reach a stabilization point after a manual step change and e Theprocess should notbe subjectto load changes while Pretune operates If these conditions are not fulfilled set the Adaptive Tune run by itself Adaptive Tune CAUTION Adaptive Tune continuously monitors the process andnaturaldisturbancesand Disable Adative 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 DT a response time values Pretune TYPE 2 and TYPE 3 automatically calculate adapt the Tuning these values These values may also be entered or changed manually inthe temporary process conditions Self Tune menu For Pretune TYPE 1 Noise Band and Response Time Adaptive Tune can be disabled via parameters mustbe entered manually digital input if applicable see Digital Inputs in this chapter or via menus Figure 7 13 illustrates the relationship between Pretune and Adaptive Tune 9 P P 1 Go to the TUNING menu 2 Goto parameter ADAPTIVE Change the value to DISABLE
97. ach other relay solid state A solid state switching device which completes or interrupts a circuit electrically with no moving parts reset Control action that automatically eliminates offset or droop between setpoint and actual process temperature Also integral reset term see reset RTD Resistance Temperature Detector Resistive sensing device displaying resistance versus temperature characteristics Displays positive temperature coefficient 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 A 20 retransmission a feature on the 535 which allows the transmission of a milliamp signal corresponding to the process variable target setpoint or actual setpoint to another devices typically a chart recorder sample interval The time interval between measurements or observations 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 serial communications The sending or receiving of binary coded data to a supervisory device such as a personal computer of programmable logic controller setpoint An input variable which sets the desired value of a controlled variable setpoint actual The desired value of a controlled variable that t
98. alarm setpoint e LOWALARM 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 process vari able 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 of this 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 setpoint This alarm is dependent on the control setpoint as the control 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 MANUAL Alarm occurs when the controller is put into manual mode of opera tion This may be usefulfor security purposes orto alertthe operator that 535 is no longer under automatic control Chapter 7 535 PROF User s Manual Applications
99. and W keys mode e Simulate DISPLAY FAST Select PV1 or PV2 and MENU keys Operate recipes In addition if the set of five digital inputs is installed four may be designated to select one of eight local setpoints and associated PID set if desired via a binary coded decimal BCD input SETPOINT SELECTION A remote setpoint input is available Signal is 0 20 4 20 mADC or 0 5 1 5 VDC jumper selectable Signal may be ratioed and biased Eight local setpoints may be stored in memory Setpoint selection is made via menu selection or digital contact s FAULT OUTPUT One of the alarm outputs may be designated to also energize if the input signal is lost SERIAL COMMUNICATIONS Isolated serial communications is available using an RS 485 interface Baud rates of up to 19 600 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 1 0 independent of the controller s function The PV may be sourced via this interface May be installed in the field 535 PROF User s Manual Specifications _ 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 de
100. application of this feature is configuring the controller to restrict operators to discrete setpoint choices The 535 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 Gotothe TUNING menu Access the SP SELECT parameter Use and to select the desired local setpoint 4 Tolinkthe PID sets to the corresponding local setpoint Set NO OF PID to SP NUMBER For details on multiple sets of PID referto the next section in this chapter Basic Operating Procedures To select a set point go to the TUNING menu access the SP SELECT parameters and scroll through the setpoints The displayed setpoint becomes active after two second of key inactivity The digital inputs can also be usedto selectthe active setpoints A single digital input may be used for selecting the second setpoint SP2 A set of four digital inputs may be used to select up to 8 setpoints see the section in this Chapter in Digital Inputs L MULTIPLE SETS OF PID VALUES The 535 has the ability to store up to eight sets of PID values This can bea 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 Gotothe TUNING menu 2 NO OF PID is
101. application using the 535 PROF Process Controller with a 353 Limit 535 PROF Wiring with Limit Control Controller EARTH GROUND 535 PROFILE CONTROLLER alg CONTROLLER T C AC POWER INPUT bg bg E L1 i 0 5 AMP 250 V FAST ACTING FUSE FAST ACTING FUSE T MERCURY RELAY LOAD FOR CONTROL POWER L2 I HIGH LIMIT MECHANICAL CONTACTOR L1 55 12 INDICATOR ON WHEN LIMIT TRIPS LIMIT CONTROLLER AC POWER L2 L1 OPTIONAL MOMENTARY SWITCH MANUAL RESET FOR LIMIT CONTROL L2 RELAY CONTACTOR COIL POWER FUSE PROCESS SENSOR 353 LIMIT CONTROLLER LIMIT SENSOR 20 Chapter 3 535 PROF User s Manual Hardware Set Up Set Up CHAPTER 4 HARDWARE SET UP Hardware configuration determines the available outputs as well as the type of input signal The 535 PROF 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 535 PROF requires accessing the circuit boards and locating the jumpers and output modules see Figure 4 1 NOTE Hardware configuration of the controller is available at the factory 1 With the power off loosen the four front screws and remove th
102. ar 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 Software Configuration 1 Gotothe PV1INPUT 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 15th 10th PV VALUE in engineering units Ce ee 1st 5th 10th 1 INPUT VALUE in milliamps or voltage parameters define the actual milliamp or voltage input All the PV parameters define the corresponding process variable value in engineering units Chapter 7 535 PROF User s Manual Applications 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 Q LOAD LINE Load line 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
103. are independent of any special configuration and others are depen dent on the individual configuration This manual displays these two types of parameters differently referto Figure 5 3 A special feature ofthe 535 PROF called Smart Menus determines the correct parameters to display forthe spe cific configuration so not all the listed parameters will appear CONFIGURATION AND OPERATION Figure 5 3showsthe relationships amongthe different modes ofthe 535 PROF andthe configuration menus e SETUP menus can only be accessed from manual control To transfer the 535 PROF from automaticto manual control press MANUAL e To access the SET UP menus hold down FAST and press MENU until CONFIG appears in the 2nd display The MENU key will also illuminate e Toaccess the parameters fora particular menu press MENU e Toselecta parameter value use and W Press MENU to advance to the next parameter or FAST MENU to advance to the next menu e Toadvance tothe next menu press FAST MENU TUNING mode andthe TUNING menu can be accessed from either auto matic or manual control To access the tuning menu press MENU RECIPE SET UP mode and the RECIPE menu can be accessed from either automatic or manual control Toaccess the RECIPE menu press FAST MENU e Toreturncontrollerto manual control press DISPLAY or SET PT TUNE PT CONTACT 1 MANUAL Access SetUp Returnto Operation Nextmenu Next parameter Next value AccessTu
104. ated with alarm 2 To enter message The first ALARM 2 character of third display will be flashing Press the A and W keys to scroll through the character set Press FAST key to advance to subsequent characters Press MENU to advance to next parameter D ALARM2 21 FAULT FAULT Defines whether either of the alarm relays will trip if a fault condition lost process variable is detected Only appears if at least one alarm relay is installed D OFF e ALARM1 e ALARM2 22 OUTPUT OUTPUT Defines whethera rate of change alarmis interpreted as alostorbroken process NO ACTION variable causing atrip to manual output e P V BREAK D NOACTION 23 RATE TIME RATETIME Defines the time period over which a rate of change alarm condition is LE 9 pides R 1to3600seconds D 5seconds REM SETPT REM SETPT This menu appears only if parameter REM SETPT of the CONFIG menu ENABLED 1 TYPE V mA RSP TYPE Specifies the type of input signal that will be usedfor remote setpoint 1 5 4 20 D 1 54 20 1 5voltor4 20 mA remote setpoint 0 50 20 0 5 voltor0 20 mA remote setpoint 2 RSP LO RNG RSP LO RNG Specifies the engineering unitvalue correspondingtothe lowest remote setpoint input value e g 4 mA R 9999t099999 3 RSP HI RNG RSP HI RNG Specifies the engineering unit value corresponding to the highest remote 100 setpoint input value e g 20 mA R 9999to99999 Access SetUp Returnto Operation Ne
105. beled next to the jumpers Figure 4 2 from the top The Microcontroller Circuit Board the Option Board and the Power Supply Board 22 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 arethree output module sockets onthe 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 configuredfor either normally open NO or normally closed NC A jumper located next to each socket determines this configuration All relay output are factory set to NO normally open 000000 5 Pin Connector 00000 Remote Setpoint Jumper mmm Male 22 Pin Male 22 Pin Connector Connector Output 4 4 Male 34 Pin Connector 5 Pin Connector Plate over Outputs 1 2 3 Jumpers NOandNC Chapter 4 535 PROF User s Manual Hardware Set Up Set Up ACCESSING AND CHANGING JUMPERS CAUTION Static discharge can cause damage to Follow these instruction to change jumpers for the Process Variable Remote equipment Always use a wrist Setpoint and Digital Inputs grounding strap when handling electronics to prevent static discharge Equipment nee
106. c SSR drive module ON voltage is 17 Vdc nominal OFF voltage is less than 0 5 Vdc Current limited to 40mA Loop power supply module Current is limited to 25 mA 24V nominally loading CONTROL OUTPUTS Up to two output modules may be designated for control Any combination of output modules with the exception of the loop power supply module may be used Appendix 5 A 13 Specifications _ Duplex control is available if output modules are installed in the first and second output sockets Position proportioning control with feedback is available if mechani cal or solid state relay modules are installed in the first two output sockets and the slidewire feedback option is installed Slidewire feedback range is 0 to 1050ohms 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 RETRANSMISSION OUTPUT Based on available outputs any socket not used for control up to two different variables can be simultaneously programmed for retransmission Each precise 16 bit resolution output may be scaled for any range Variable selection includes PV SP
107. 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 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
108. ch these terminals when power is on WARNING Terminal 9 must be grounded to avoid potential shock hazard and improved noise immunity to your system 12 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 535 PROF controllers are thoroughly tested calibrated and burned in at the factory so the controller is ready to install Before beginning read this chapter thoroughly and take great care in planning a system A properly designed system canhelp prevent problems such as electrical noise disturbances and dangerous extreme conditions 1 Forimproved electrical noise immunity install the 535 PROF as far away as possible from motors relays and other similar noise generators 2 Donotrunlow 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
109. control parameters in such a way as to improve the performance of the control system adaptive tune A component of the 535 self tune function which continuously monitors the process and natural disturbances and makes adjustments in the tuning parameters to compensate for or improve the performance of the control system alarm A condition generated by a controller indicating that the process has exceeded 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 535 PROF User s Manual alarm rate of change A type of alarm Set up to occur when
110. controller before wiring the slidewire feedback signal to the controller complete these steps a Gotothe CONTROL menu Set a value for PV BREAK Go to the SPECIAL menu Set a value for DES OUTPT Seta value for PWR UP OUT Go to SER COMM menu g Setavalue for SHED OUT Place the controller under manual control Go to the CONFIG menu Set CTRL TYPE to POS PROP position proportioning Set P P TYPE to SLIDEWIRE Goto the CONTROL menu 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 Scrollto OPEN F B Open feedback Enter the ohm value when the actua tor is fully open 0 to 1050 ohms 9 Scrollto CLOSE F B Closed feedback Enter the ohm value when the ac tuator 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 enter ing 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 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 sen
111. d ZERO ERR 2 3 io bs zero Increase the OUT STEP size and run Pretune again Move TUNE PT or the Setpoint if TUNE PT is DEV ERROR 1 The initial PV is too close to the TUNE PT Automatic farther from the process variable and run Pretune again Check if any PID values were generated and if they are acceptable If not eliminate noise sources if possible and run Pretune again The Process variable went beyond the HI 1 2 3 RETRY LIMIT or LOW LIMIT If Pretune and Adaptive Tune do not generate optimal PID values for control check the following menu entries Message Potential Problem Corrective Action Adaptive Tune cannot run if RESPONSE TIME is Run TYPE 2 or TYPE 3 Pretune to obtain the correct value RESPONSE TIME inaccurate or enter it manually i illati Set NOISE BAND large enought to prevent Adaptive Tune NOISE BAND Adaptive Tune cannot compensate for PV oscillation g g p p due to hysteresis of output device e g a sticky valve from acting on the oscillation If oscillation is not acceptable consider replacing valve Wrong pretune TYPE selected Refer to Chapter 7 the PRETUNE Pretune does not develop optimum PID Parameters section on Self Tune 78 Chapter 6 POWERS 535 PROF User s Manual Applications NOTE Controller capabilities depend APPLICATIONS upon the specified hardware option The 535 controller provides a variety of user programmable control features an
112. d 15 CYCLE TM 2 Cycle time for control output 2 for time proportioning output 16 DEADBAND 2 Dead band for control output 2 for on off control 17 RSP RATIO Multiplier for remote set point 18 RSP BIAS Bias for remote set point 19 NO OF PID Number of PID sets 20 PID TRIP For NO OF PID gt 1 variable used to select the various PID sets 21 TRIP 1 Value that triggers a change to the primary set 1 of PID values 22 PROP BND 2 Proportional band for PID set 2 23 RESET 2 Integral time for PID set 2 24 RATE 2 Derivative time for PID set 2 25 MAN RST 2 Manual reset or load line for PID set 2 26 TRIP 2 Value that triggers a change to the 2nd set of PID values 27 PROP BND 3 Proportional band for PID set 3 76 Chapter 6 POWERS 535 PROF User s Manual 28 RESET 3 Integral time for PID set 3 29 RATE 3 Derivative time for PID set 3 30 MAN RST 3 Manual reset or load line for PID set 3 31 TRIP 3 Value that triggers a change to the 3rdset of PID values 32 PROP BND 4 Proportional band for PID set 4 33 RESET 4 Integral time for PID set 4 34 RATE 4 Derivative time for PID set 4 35 MAN RST 4 Manual reset or load line for PID set 4 36 TRIP 4 Value that triggers a change to the 4th set of PID values 37 PROP BND 5 Proportional band for PID set 5 38 RESET 5 Integral time for PID
113. d capabilities The following topics are included in this chapter A Profile Control 79 l Digital Inputs 98 Qi OadILine 111 Control Type iue eee ipie 85 J Remote Setpoint 100 R SECUN siete 111 C causato incen 86 Multiple Setpoints 101 S Reset Inhibition 112 D Duplex Control cci 90 L Multiple Sets of PID Values 101 T Process Variable Reading Correction 112 Slidewire Position Proportioning Control 95 M POWOrDack caecetreit tns 102 U Serial 113 F Velocity Position Proportioning Control 96 Self Tune POWERTUNE 103 V Cascade Control sss 114 G Staged Outputs sisina 97 1 109 W Ratio Control 117 Retransmission ssssee 97 P Input 109 A PROFILE CONTROL The 535 PROF controller is capable of storing 20 separate recipes Each recipe can consist of upto 12 ramps and 12 dwells Individual recipes may be continu ously run or be repeated up to 99 times Recipes may be linked together to form NOTE longer more complex recipes Some profile controlterms are Self Tune and Adaptive Tune may be Ramp us
114. ded Needle nose pliers optional Phillips screwdriver 2 Wrist grounding strap With power off loosen the four 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 Fon gt 2 Remove Jumpers 5 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 6 Make any other jumper changes as needed To alter output modules please refer to the next section starting with Step 3 7 Toreassemble 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 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 8 Carefullyinsertand align screws Tighten them until the bezel is seated firmly against the gasket Do not overtighten 535 PROF User s Manual Chapter 4 23 Hardware Set Up Set Up 24 3 Pry Clips ADDING AND CHANGING OUTPUT MODULES The 5
115. e 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 LATCHING 1 and LATCHING 2 A latching YES alarm will remain active after leaving the alarm condi tion unless itis acknowledged A non latching NO alarm will return to the non alarm state when leaving the alarm condition without being ac knowledged 535 PROF User s Manual Chapter 7 87 Applications Alarm Parameters Reference For Alarm 1 Parameter Description ALM TYPE 1 Type ALM SRC 1 Source ALARMSP 1 Setpoint HIGHSP 1 High setpoint LOWSP 1 Low setpoint DEADBAND 1 Deadband ALM 1 OUT Outputnumber LATCHING 1 Latching sequence ACK 1 Acknowledging POWERUP 1 Statusonpowerup MESSAGE Message For Alarm 2 Parameter Description ALM TYPE 2 Type ALM SRC 2 Source ALARMSP 2 Setpoint HIGHSP 2 High setpoint LOWSP 2 Low setpoint DEADBAND 2 Deadband ALM 20UT Outputnumber LATCHING 2 Latching sequence 2 Acknowledging POWERUP2 Statusonpowerup MESSAGE2 Message For either alarm depending on choices Parameter Description FAULT Faultassignment OUTPUT Outputactionforrate RATETIME Time base for rate 88 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 inthe alarm condition Alatching alarm can always be ac
116. e would be 2times 50 or 100 The 535 controller wouldtryto maintain the flow of Material A at 100 As the flow of Material B changes the setpoint would change accordingly always in a 2 1 ratio BOTTOM As viewed from rear flow sensor MATERIAL A 422 CONTROLLED STREAM MATERIAL B WILD STREAM flow sensor 535 PROF User s Manual Chapter 7 Figure 7 22 Ratio Control in Mixing Applicatoin 117 Applications 118 Hardware Configuration 1 Setthe process variable jumper and remote setpoint jumper to mA Make sure that both inputs are set up to accept the corresponding signal from the flow transmitters 2 Wireasin Figure 7 27 Software Configuration 1 Make sure that the range of both inputs matches the range of the corresponding transmitter a Goto the PV1 INPUT menu b Setthe HI RANGE and LOW RANGE parameters c Gotothe REM SETPT menu d Setthe RSP HI RNG and RSP LO RNG parameters 2 Adjustthe ratio between the two streams a Gotothe TUNING menu b Setthe RSP RATIO parameter The value of this parameter will be multiplied by the remote setpoint signalto yield the effective remote setpoint Chapter 7 535 PROF User s Manual Menu Flowcharts APPENDIX 1 Em MENU FLOWCHARTS conre CTRL TYPE OUTPUT 4 LINE FREQ PV SOURCE REM SETPT OUTPUT 2 OUTPUT 3 RNG 2 ANLG RNG 3 7 ANLG RNG 4 CONTACT 1 CONTACT 4 CONTACT 5 LOOP NAME R
117. ed for selection 68 Chapter 5 535 PROF User s Manual Controller Set Up Set Up SECURITY Parameter Description Values 1 SEC CODE Security code for temporarily unlocking the instrument 2 SPADJUST Lockout status for setpoint changes 3 AUTO MAN Lockout status of the MANUAL key 4 SPSELECT Lockout status of the SET PT key 5 RUNKEY Lockout status of the RUN key 6 ALARMACK Lockout status of the ACK key 7 TUNING Lockout status of the tuning parameters 8 RECIPES Lockout status of the RECIPE menu 9 CONFIGURE Lockout status of the configuration parameters SER COMM Parameter Description Values 1 STATION Unit s station address 2 BAUDRATE Baud rate 3 CRC Cyclic redundancy check 4 SHEDTIME Time interpreted as communications loss shed 5 SHEDMODE State of the controller if communications is lost sheds 6 SHEDOUT Output if the unit sheds and trips to manual control 535 PROF User s Manual Chapter 5 69 Controller Set Up Set Up RECIPE Parameter Description Values 1 CYCLES Number of recipe cycles 2 NEXTLINK Next recipe to run 3 IDLE SP Initial or ending setpoint for recipe 4 SOAKHYST Absolute value of the max deviation from setpoint for soak 5 RAMP RT Rate of rise or fall of setpoint during ramp segment 6 RAMP TM Time for ramp segment to reach soak setpoint 7 RAMP EV Events activated during ramp seg
118. ed 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 fixed During cold junction calibration a discrepancy was found between the controller type and the case type 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 must reconfigure the controller to match the current module combination Check the slidewire wiring Call factory for assistance This is a fatal error and requires a
119. ed to optimize PID settings at M varous PV LOAD points but should A rise or fall of the setpoint in a given segment Ramps may be defined bythe be used while running a recipe time it will take for the setpoint to be achieved or the rate of rise or fall necessary Consult factory for further details forthe target soak setpoint to be achieved Dwell or Soak The designated period of time in which the setpoint does not change after the ramp has been completed Guaranteed Soak Guaranteed soak insures that the soak setpoint has been achieved before the soak segment starts Example Ramp 1 is programmed for 2 hours The Soak setpoint is 400 and the soak time is set for 4 hours If 400 can not be achieved in the 2 hour ramp time the timing of the soak will not start until the setpoint has been reached Touse this feature two parameters must be defined The first one GUAR SOAK defines whether guaranteed soak is used and howitis used Itis located inthe REC CONF menu The second parameter SOAK HYST is located in the RECIPE menu It defines the absolute value of the maximum allowable deviation from setpoint when a soak segment starts If the deviation exceeds this value guaranteed soak will stop the clock until the deviation is less than the soak hysteresis Then the soak segment will begin In addition if the deviation exceeds the soak hysteresis value during the soak segment the soak timing will stop until the deviatio
120. eering units R 9999t099999 9 GAIN GAIN Defines the gain for PV2 0 100to 10 000 D 1 000 10 RESTORE Defines the control mode when a broken PV2 signalis restored D LASTMODE e AUTOMATIC e STARTREC e RESUME REC e HOLDREC EG RESTORE Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation ww epus e 42 Chapter 5 535 PROF User s Manual Controller Set Up Set Up CUST LINR CUST LINR Defines a custom linearization curve for PV1 if selected Points 1 and 15 are fixed to the low and high end of the input range and require only setting a corresponding 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 linearization table 1 1ST INPUT 1ST INPUT Specifies the input signal corresponding to the first point D D Thelowendofthe appropriate input range e g 4 00 mA 2 1ST PV Specifies the engineering unit value corresponding to the first point R 9999to99999 1ST PV 3 INPUT Specifies the input signal corresponding to the XTH point X is 2 to 14 Anyvalue greater than the first input XTH INPUT D Thelowendofthe appropriate input range e g 4 00 mA D 4 XTH PV Specifies the unit value co
121. em Consult an application engineer for 2 Slide chassis out of the case by pulling firmly on the bezel details FRONT FACE 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 continued set ting up the process as needed HARDWARE INPUT TYPES The Process Variable The 535 PROF 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 Thermocouple downscale and V Voltage upscale burnout offers a choice in which direction the controller would MA Milliamp react in the event of thermocouple TCV Thermocouple with downscale burnout failure For example in heat TCA Thermocouple with upscale burnout applications typically it is desirable to fail upscale TCA so that the RTD RTD system does not apply more heat 535 PROF User s Manual Chapter 4 21 Hardware Set Up NOTE Changing the jumpers means moving the jumper connector The jumper connector slips over the pins straddling two rows of pins The printed circuit boards are la
122. endix 6 software a symbolic set of points whose open or closed condition depends on the logic status 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 controlaction proportional P Control action in which there is a continuous linear relation between the output and the input controlaction proportional plus derivative PD A control algorithm that provides proportional control with the addition of derivative action to compensate for rapid changes in process variable controlaction proportional plus integral A control algorithm that provides proportional control with the addition of integral action to compensate for offsets between setpoint and process variable controlaction proportional plus integral plus derivative PID A control algorithm that provides proportional control with both integral and derivative action control adaptive see adaptive control control algorithm A mathematical representation of
123. eplacementParts Operator Interface Assembly 535632 Power Supply Circuit Board 535730 Microcontroller Circuit Board 535731 Option Circuit Board w no Options 535 720 Option Circuit Board w Set of 5 Digital Contacts 535721 Option Circuit Board w Slidewire Feedback 535 722 Option Circuit Board w set of 5 Digital Contacts amp Slidewire Feedback 535 723 EPROM without Remote Setpoint Option 535740 EPROM with Remote Setpoint Option 535741 Lithium Battery 093 128 Jumper Kit Set of All Jumper Connectors 535660 Gasket Kit 1 Panel Gasket amp 1 Bezel Gasket 535662 Mounting Kit Mounting Collar amp 4 screws 535761 Bezel Retention Screw Kit 535663 Module Retention Kit for Outputs 1 3 Includes Retention Plate 535 664 Module Retention Kit for Output 4 Set of 5 Tie Wraps 535665 Circuit Board Support Bezel Insert 535075 Engineering unitlabels 1 sheet 535 106 535 PROF User s Manual Appendix 2 A 3 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 Move jumper to proper location Improper Lost PV reading Input jumper selection improperly set Volta
124. etpoint e REMOTE Powers up using the remote setpoint if avail able NO OF SP Defines the number oflocal setpoints up to 8 to be stored for selection by BCD binary coded decimal digital inputs or front SET PT key Only applicable when arecipeis not running orheld 1through8 o D 1 SECURITY SECURITY For configuring the security function SEC CODE 1 SEC CODE Defines the security code temporarily unlocking the instrument R 9991099999 D 0 2 SP ADJUST SP ADJUST Defines lockout status setpoint changes UNLOCKED D UNLOCKED e LOCKED 3 AUTO MAN AUTO MAN Defines lockout status of the MANUAL key UNLOCKED D UNLOCKED LOCKED 4 SP SELECT SP SELECT Defines lockout status of the SP SELECT parameter in the TUNING menu UNLOCKED D UNLOCKED LOCKED Access SetUp Returnto Operation Nextmenu Next parameter Next value AccessTuning Return to Operation we e De 56 Chapter 5 535 PROF User s Manual Controller Set Up Set Up 5 RUN KEY Defines lockout status of the RUN key D UNLOCKED e LOCKED 6 ALARM ACK Defines lockout status of the ACK key D UNLOCKED e LOCKED 7 TUNING Defines lockout status ofthe tuning parameters D UNLOCKED e LOCKED 8 RECIPES Defines lockout status of the RECIPE menu D UNLOCKED e LOCKED 9 CONFIGURE Defines lockout status ofthe configuration parameters D UNLOCKED e LOCKED SER COMM
125. f TIME BASE HOURS MIN the ramp unit will be in PV units per minute If TIME BASE MIN SEC the ramp unit will be in PV units per second Choices are D TIME RATE 5 The next parameter is SP START It selects whether the first ramp segment s setpoint must start at the IDLE setpoint or if it can be adjusted to accountfor the initial PV value thus allowing the ramp segment to be short ened Choices are e DLESP the IDLE SP will be the starting setpoint of the first ramp segment e PV the first ramp s starting setpoint can be adjusted 6 Thenextparameteris GUAR SOAK Itselects whether the guaranteed soak feature will be used Its choices are D OFF guaranteed soak will not occur e STARTSEG guaranteed soak can occur only atthe start of a soak segment e WHOLESEG guaranteed soak can occur atthe start of or at anytime during soak segment 7 Thenext3 parameters are EVT 1 OUT EVT 2 OUT and EVT 3 OUT These select which outputs are assigned to each events Choices are D NONE 2 3 7 535 PROF User s Manual Applications 4 The numerical choices only appear if the corresponding output is config ured as ALM EVT ON or ALM EVT OFF in the CONFIG menu 8 Thenext parameter is HOLD EVT It determines whether the last segment s event s will be held active after the recipe has successfully completed Choices are D DISABLE ENABLE Now the recipes can be programmed 1 Enter the RECIPE SET UP mode T
126. 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 mechanical relay see relay menu see menu block menu block Groups of parameters arranged in the software 535 PROF User s Manual microcontroller A large scale integrated circuit that has all the functions of a computer including memory and input output systems NEMA A National Electrical Manufacturers Association 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 offset The difference in temperature between the setpoint and the actual process temperature Also the adjustment to actual input temperature and to the temperature values the controller uses tor display and control ON OFF control Control of temperature about a setpoint by turning the output full ON below setpoint and full OFF above setpoint in the heat mode open loop Control system with no sensory feedback o
127. 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 7 535 PROF User s Manual Applications G STAGED OUTPUTS With staged outputs one analog output can vary its signal e g 4 20 mA over aportion ofthe 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 11 Outputi Staged Outputs Example OUT1 STOP was set to 33 and OUT2 STRT was set to 50 4 mA 0 33 50 100 PID Output Hardware Configuration e Thecontrollermusthave analog output modules installed in the firsttwo 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 100 4 For OUT2 START specify where the second output begins H RETRANSMISSION The retransmission feature may be used to transmit a milliamp signal corresp
128. ge current 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 Transmitter signal out of range Improper Lost PV reading Defective thermocouple Select proper range in software Replace thermocouple Thermocouple Input jumper selection improperly set Select Proper input Wrong TC type selected in software Select proper thermocouple type in software Improper wiring Improper Lost PV reading Defective RTD Wire properly Replace RTD RTD Input jumper selection improperly set Move jumper connector to proper location Improper wiring No control output Output wiring and module location do not match Wire properly 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 Can t switch to auto control Input sensor signal is not connected or valid Erratic display Resetting action due to electrical noise on powerline Set PID values properly See PV LOST message Filter power line PID values not set properly A 4 Ap
129. h point engineering unit value 11 5TH INPUT 5th point input signal 12 5TH PV 5th point engineering unit value 13 6TH INPUT 6th point input signal 14 6TH PV 6th point engineering unit value 15 7TH INPUT 7th point input signal 16 7TH PV 7th point engineering unit value 17 8TH INPUT 8th point input signal 18 8TH PV 8th point engineering unit value 19 9TH INPUT 9th point input signal 20 9TH PV 9th point engineering unit value 21 10TH INPUT 10th point input signal 22 10TH PV 10th point engineering unit value 23 11TH INPUT 11th point input signal 24 14TH PV 11th point engineering unit value 25 12TH INPUT 12th point input signal 26 12TH PV 12th point engineering unit value 27 13TH INPUT 13th point input signal 28 13TH PV 13th point engineering unit value 29 14TH INPUT 14th point input signal 30 14THPV 14th point engineering unit value 31 15TH INPT 15th point input signal 32 15TH PV 15th point engineering unit value 64 Chapter 5 535 PROF User s Manual Controller Set Up Set Up CONTROL Parameter Description Values 1 ALGORITHM Control algorithm Type 2 D SOURCE Derivative action variable 3 ACTION 1 First control output action 4 PV BREAK Manual output level upon PV input loss 5 LOWOUT Lowest output value in automatic control 6 HIGHOUT Highest output value in automatic control 7 ACTION 2 Second control output action 8 P P TYPE Position propo
130. he controller is currently acting upon setpoint deviation from The number of units difference between the current process variable and the setpoint setpoint ramping A setpoint which is determined by the ramp function of the controller where over time the controller variable reaches a desired value setpoint target The end point of the ramp function set up Also called configuration selection of hardware devices and software routines that function together 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 controller Appendix 6 soak Also called dwell The designated period of time in which the setpoint does not change after the ramp has been completed soak guaranteed Guaranteed soak insures that the soak setpoint has been achieved before the soak segment starts solid state relay see relay solid state SSR drive A D C on off signal output for controlling a solid state relay 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 electrostatic energy station address The unique identifier ass
131. he display will indicate RECIPE number in the 2nd line Use and V to select the recipe to be programmed Use MENU to advance through the parameters 2 Thefirst parameter is CYCLES It selects the number of times the recipe will run before ending or going to the next linked recipe Choices e CONTINUAL D 1 R 1 99 3 Thenext parameter is NEXT LINK It defines which recipe will run next after the current recipe has completed Choices are D NONE R 1to ofconfigured recipes e NOOUTPUT 4 The next parameter is IDLE SP It defines the setpoint to be used when the recipe starts or after it has completed Choices are D LAST SP use the previous setpoint default R 99991099999 e REMOTE SP use the remote setpoint only if option installed an enabled The decimal pointis defined by the DECIMAL parameter 5 The next parameter is SOAK HYST It defines the absolute value of the maximum allowable deviation from the setpoint when a soak segment starts If the deviation exceeds this value Guaranteed Soak will occur This parameter appears only if GUAR SOAK is not OFF Choices are D OFF R 11099999 The decimal pointis defined by the DECIMAL parameter in the PV1 INPUT menu 6 The next parameter is RAMP RT 1 to 12 It defines the rate of rise or fall of the setpoint during ramp segment while approaching soak setpoint This parameter will only appear if RAMP UNIT RATE Choices are endsrecipepr
132. he trip variable is less than the trip value The user can set the lowesttrip point the low end of the process variable range but this is not required A digital input can be set to trip to the second set of PID upon closure which overrides a selection based on trip points Using with Adaptive and Pretune The 535 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 orthe digital in put 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 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 MENU to access the TUNING menu 2 Setvalues 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 POWERBACK POWERBACK is a 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
133. igned to a device for communications thermocouple Temperature sensing device that is constructed of two dissimilar metals wherein a measurable 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 thermocouple 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 s position thermocouple downscale burnout 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 t position 535 PROF User s Manual EEE ee three mode conirol 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 controller 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 p
134. ime during a soak segment if GUAR SOAK WHOLE SEG Ifthe deviation OFF exceedsthis value guaranteed soak will occur D OFF R 1t099999 decimal point defined by DECIMAL param eter 5 RAMP RT For RAMP UNIT RATE defines the rate of rise or fall of the setpoint during RAMP RT ramp segment while approaching soak setpoint OFF If TIME BASE HOURS MIN If TIME BASE MIN SEC D OFF D OFF NOTE R 1t099999 MIN R 1to99999 SEC To end programming set The decimal pointis defined by the DECIMAL parameter RAMP RT or RAMP TIM to OFF 6 RAMP TM For RAMP UNIT TIME defines the time for ramp segment to reach soak setpoint If TIME BASE HOURS MIN If TIME BASE MIN SEC D OFF D OFF R 00 011099 59 HR MN R 00 011099 59 5 7 RAMP EV Defines which events will be activated during ramp segment RAMP EV ete NONE e EVENT 1 e EVENT2 EVENT 12 Access SetUp Returnto Operation Nextmenu Next parameter Next value AccessTuning Return to Operation e pee wv 535 PROF User s Manual Chapter 5 59 Controller Set Up Set Up SOAK EV PID SET LAST SET Access Set Up DISPLAY rast Return to Operation 10 11 Eest ueu ww e EVENT3 EVENT13 e EVENT23 e EVENT 123 SOAK SP Defines the setpoint after ramp segment has completed R 9999t099999
135. ion 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 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
136. ions under manual operation NOTE For information about the Tuning menu mode refer to Chapter 6 For more information about set up parameters and 535 PROF applications refer to Chapter 7 27 Controller Set Up Set Up Figure 5 2 Configuration Flowchart 28 operation mode MANUAL to place controller under Manual Control MANUAL OPERATION MENU TUNING DISPLAY FAST MENU AorV to scroll thru recipes DISPLAY Set Up Mode is only accessible if controller is under Manual Control DISPLAY to return to SET UP Configuration Menus i Define of recipes in REC CONF menu PV1 INPUT PV2 INPUT FAST MENU to scroll through the menu blocks ii T CUST LINR i CONTROL ALARMS REM SETPT T RETRANS SELF TUNE pi SPECIAL SECURITY 5 535 PROF User s Manual Controller Set Up Set Up PARAMETERS Within each menu are parameters for particular control functions Select val AUTOMATIC 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 place the menu name in the 2nd display and the parameter value willshowin Figure 5 3 the 3rd display Independent vs Dependent This chapter outlines all the available parameters forthe 535 PROF Some pa Parameters rameters
137. ipes may be linked to form a new longer version For example select recipe 4 to automatically follow recipe 2 REMOTE FUNCTIONS VIA DIGITAL INPUT Using the optional digital inputs the following functions may be remotely activated Start Hold Reset Abort and Segment advance MODIFY RECIPES WHILE RUNNING Individual recipes may be modified by the operator while running REMOTE RECIPE CHOICE VIA DIGITAL INPUT Using the optional digital inputs recipes 1 through 7 may be selected remotely POWER RESTORATION MODES Four different power restoration modes are available Upon Power failure and subsequent return the controller can either 1 resume a recipe where it left off 2 return to the last output of the recipe and hold it 2 Abort the recipe 4 Start a new recipe automatically TIE PID SETS TO RECIPES OR SEGMENTS Any one of eight PID sets may be tied to each recipe or segment to optimize control MASTER SLAVE CAPABILITY The 535 with profile controller option can retransmit the ramping setpoint to up to four 535s with remote setpoint creating a master slave relationship With this capability five 5 loops each running the same recipe can be controlled SEGMENT ADVANCE The operator may advance thought the program segments while a recipe is running 535 PROF User s Manual EEE eee APPENDIX 6 GLOSSARY adaptive control Control in which automatic means are used to change the type or influence or both of
138. ircuit board Figure 2 It has a white label that list the part number and software revision level Use I C Extractor to carefully remove the 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
139. 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 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
140. 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 standards on equipment and components 535 PROF User s Manual EEE eee 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 linearization A function the 535 uses to automatically linearize a non linear signal either from thermocouple or RTD temperature sensors through the use of look 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 535 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 loop power An internal 24 volt current limited power supply used to power 2 or 4 wire transmitter on the input of the controller load The demand for input to a process low pass input filter A method to block
141. it indicates a recipe is running When blinking indicates a recipe is on hold FAST RUN When recipe is running or held press to advance to next segment Chapter 2 Controller Operation 5 Operation DISPLAY Press to toggle through values in the 2nd display for setpoint ramping setpoint if available deviation PV1 If PV source is not PV1 PV2 if PV Source is not PV 1 output and valve position if available In RECIPE SET UP TUNING SET UP mode press to return controller to OPERATION mode display will show current setpoint FAST DISPLAY When a recipe is running or held press to select recipe status When norecipe is running or held pressto display EVENT 000 message La Press to increase the value or selection of displayed parameter Press to scroll through values at a faster rate Press to decrease the value or selection of displayed parameter Press to scroll through values at a faster rate ACK ACK Press to acknowledge an alarm s Press to acknowledge Run Abort and next segment commands Whenlit indicates there is an acknowledgeable alarm or an eventis being held atthe end of a recipe For events held at the end of a recipe press to acknowledge and disable the events MENU In OPERATION mode pressto access the TUNING mode menu In RECIPE SET UP SET UP or TUNING mode press to advance through a menu s parameters Use FAST MENU to advance to to the next menu
142. knowledged 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 e NORMAL Controller will power up in alarm only if itis in alarm condition 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 beenapowerfailure 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 startup MESSAGE 1 and MESSAGE 2 Allows userto specify a nine character message to be displayed when the respective alarm is active If both alarms are active or any other di agnostic message is present the messages will alternate FAULT Activates an alarm if the process variable signalis lost Assign this func tionto either Alarm 1 or Alarm 2 not both This action is in addition the selected alarmtype additive alarm function OUTPUT Fora RATE alarm selects the output action Use to obtain early indica tion of a possible break in the process variable signal Select PV BREAK to have rate of change ala
143. l in matchingthe input range ofthe receiving device 6 Foranyotherretransmission output continue to scroll through the this menu andsetthe TYPE X LOW RANGE X and HIGH RANGE X for the second retransmission output I 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 Chatper 5 There are 14 contacttypes forthe up to 5 digital inputs See Section A for digital input options when using Profile Control Hardware Configuration e This optional features is only available if ordered originally from the factory Product 535xxxxxxDx00 The up to five digital inputs share a common ground Software Configuration 1 Gotothe CONFIG menu 2 Setparameters CONTACT 1 through CONTACT 5 only those available will shown by assigning the desired function to each output Choices are e SETPT1 8 For CONTACT 1 only Allows the controller to use the first four digi tal inputs to select a setpoint see Figure 7 12 If the inputs states remain constant the controller will continue to use the selected set point unless overridden Override the set of digital inputs by select ing a different setpoint via the SP SELECT parameter in the TUN ING men
144. l 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 attmpted SECURITY appears in the 2nd display fortwo seconds 1 Usethe and V 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 8 Chapter 2 Controller Operation 535 User s Manual Operation 2 Ifthe code is correct CORRECT appears in the 3rd display The display will clear after two seconds allowing full access 4 Ifcodeis incorrect INCORRECT appears inthe 3rd display This will dis appear after two seconds and a new security code can then be entered 5 The controller will revert back to full security lock after one minute of key inactivity To display control output value 1 Toggle DISPLAY key until the 2nd display shows OUT followed by the output percentage This value is the PID output In duplex applications this value does not directly refer to the output signal referto 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 tagis notshown In this case the status of both outputs is shown in the following man ner 1 0N 2 OFF 1 and2arethe respective out
145. line is double filtered and transient protected Snubbers are provided for each relay output CONSTRUCTION Case black plastic ABS 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 8 LR 84603 Process Goma Exe Heavy Industrial Available as an option MEMORY RETENTION Lithium battery maintains all programming for approximately ten years EEPROM maintains calibration data indefinitely 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 PROFILE CONTROLLER OPTION When a 535 is specified as a profile controller the SET PT setpoint key is replaced at the factory with a RUN key to facilitate operation Setpoint access is available through use of the DISPLAY key All functions are described in the manual The 535 with profile option provides full ramp and soak capability with the following features Appendix 5 A 15 Specifications _ 20 RECIPES PROGRAMS Up to twenty 20 recipes programs may be stored in memory and recalled by number through the front panel keys digital inputs or RS 485 communications 24 SEGMENT PER RECIPE Twelve 12 ramps and twelve 12 dwells may be programmed for each recipe Programming a dwell
146. ll parameter values back to their factory default values except for calibra tion information Refer to the flowchartin Figure A4 2 1 Disconnect powerto the instrument 2 Remove chassis from case 3 Onthe Microcontroller Circuit Board set jumpers at the 2nd PV location to V and TC A 4 Press MENU key until the display shows RESET MENU DATA Pressthe 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 andthen press MENU key within two seconds 8 Whencomplete return jumpersto their original positions PRESS ACK OUTPUT X 4 mA PRESS MENU OUTPUT X 20 mA 1 PRESS MENU i 1 a A 10 Appendix 4 535 PROF User s Manual Calibration __ HARDWARE SCAN Use this read only feature to identify the output hardware and installed options of the controller 1 Setthe jumpers to V and TC see Figure 4 3 Power upthe controller Press MENU until HARDWARE SCAN is displayed Press ACK toinitiate the hardware display Whencomplete returnjumpers 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 100y to 1000y potentiometer to terminals 10 11 and 12 as shown in Figure A4
147. ment 8 SOAK SP Setpoint after ramp segment has completed 9 SOAK TM Length of soak segment 10 SOAK EV Events activated during soak segment 11 PID SET PID set for ramp and soak segments ff 70 Chapter 5 535 PROF User s Manual 6 TUNING OVERVIEW The self tune function of the 535 consists of two distinctcomponents Pretune NOTE and Adaptive Tune In addition you may choose from three type of Pretune For more information about Pretune TYPE 1 for slow thermal processes and Adaptive Tune refer to section on Tuning applications in Chapter 7 TYPE 2 for fast fluid or pressure processes TYPE for level control applications You choose the type of Pretune in the SELF TUNE menu The Pretune and Adaptive Tune components may be used separately or together On the following pages is the step by step guide to the TUNING menu paramters MANUAL to place controller under Manual Control MENU MANUAL PRENNE OPERATION DISBLAY TONING Figure 6 1 FAST MENU Access the Tuning Menu Block to scroll thru recipes DISPLAY FAST MENU Set Up Mode SET UP is only accessible if controller is under Configuration Menus Manual Control DISPLAY to return to operation mode Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation Seow Bem
148. n EEPROM 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 Install the 535 chassis into the actual case with which it was shipped then run calibration again If further problems call factory for assistance APPENDIX 4 CALIBRATION Tomaintain optimum performance once a year calibrate the analog input the coldjunction and milliamp output when used To achieve published accuracy specifications follow directions carefully and use calibrated instruments of like quality to those suggested e fthecontrolleris movedinto an alternate case orthe hardware configuration is changed and the thermocouple input is needed recalibrate the cold junction for maximum accuracy Failure to do so may result in small junction tempera ture 0 6 C 1 1 F Access the parts ofthe calibration menu as shown in Figure A4 2 CALIBRATE CAL VREF 1 PRESS CALIBRATE SET BOTH ANA mA IN LPRESSACK A UP PRESS P C 55 Press PRESS CALIBRATE PV 150 COLD JUNC PRESS J PRESS ACK PRESS PRESS MENU CALIBRATE OUTPUT X ANLG QUT ama Jensen PRESS ACK PRESSIMENU ente er RESET After two 17 seconds SKIPPED RESET MENU DATA
149. n is less than the soak hysteresis value Cycles Recipes may be repeated upto 99 times before completion or being linked to adifferent recipe Recipes may also be set upto run continuously 535 PROF User s Manual Chapter 7 79 Applications 80 Linking Recipes may be linked together to form longer more complicated programs Through the selective use of CYCLES and LINKING complex recipes with subroutines can be created Events For each ramp and dwell 1 2 or 3 available relays may be opened or closed These may be used fora variety of purposes to include starting and stopping other process equipment Upon recipe completion events may be held until released by the operator using FAST ACK Programming recipes requires the user to make selections in the REC CONF menu ofthe SET UP mode before programming the actual recipes Software Configuration The controller must be configured for the profile option before accepting recipes 1 Enterthe SETUP mode Select the REC CONF menu 2 The first parameter is RECIPES This parameter defines the number of recipes available inthe 535 Choices are D 1 1through20 The next parameter is TIME BASE It defines whether recipes are timed in hours and minutes or in minutes and seconds Choices are D HOURS MIN e MIN SEC 4 Thenext parameter is RAMP UNIT It defines the times unit for ramp seg ments hours min or min sec or rate of change required to reach setpoint I
150. n 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
151. nd 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 Usethe 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 CWTIME 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 CWTIME 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 CTRL TYPE to POS PROP 2 Gotothe CONTROL menu Set P P TYPE to VELOCITY 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
152. nd Type 3 with Adaptive pu 105 Figure 7 14 Noise Band Calculation Example 107 Figure7 15 Noise Band Values for Temperature Inputs 107 Figure 7 16 Deadtime and Time Constant 108 Figure 7 17 Square Root Linearization 110 Figure 7 18 15 pointLinearization 110 Figure 7 19 LoadLineExample oor ettet 111 Figure7 20 Heat Exchanger Control Loop for Steam Supply 114 Figure7 21 Cascade Control of Product Temperature 115 Figure7 22 Ratio Control In Mixing Applicatoin 117 Figure A4 1 535RearTerminalsfor Calibration A 6 Figure A4 2 Flowchart Calibration Menus A 6 Figure A4 3 Jumper Locations onthe Microcontroller Circuit Board A 7 Figure A4 4 Input Calibration Wiring A 7 Figure A4 5 Thermocouple Cold Junction Calibration Wiring A 8 Figure A4 6 Analog mA Input Calibration Wiring A 9 Figure A4 7 Analog Input Jumper Positions A 9 Figure A4 8 Milliamp Ou
153. nd 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 20 ON OFST 2 VALUE LOW OUT 0 HIGH OUT 100 Figure 7 9 Duplex with one ON OFF output 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 Figure 7 10 Duplex with two ON OFF outputs Offset 1 PROCESS VARIABLE 94 Chapter 7 535 PROF User s Manual Applications E SLIDEWIRE POSITION PROPORTIONING CONTROL Slidewire position proportioning utilizes a slidewire feedback signal to determine the actual position of the actuator being controlled Hardware Configuration e The controller must have the Slidewire Feedback option installed Refer to the order code in Chapter 1 for more information e The controller must have mechanical relays solid state relays or DC logic modules installed in the first two output sockets e The Slidewire does NOT have to be wired to the controller in order to set up position proportioning Software Configuration 1 Toconfigure the
154. ndly features include custom programmable alarm messages illuminated keys and easy to use menu system The 535 Profile Controlleristhe mostaccurate instrumentin its class With a sam pling rate of ten times per second itis ideal for demanding pressure and flow ap plications The controller also offers a universal process input and modular field interchangeable outputs that allow more flexibility than ever before The RS 485 serial communications interface allows the controller to utilize sophisticated soft ware routines and high speed hardware to provide exceptionally fast and accu rate transmission of data The 535 Profile Controller also offers sophisticated controlalgorithms including exclusive Adaptive Tune which constantly analyzes your process and makes modifications to the tuning parameters to ensure you re always under control 535 PROFILE CONTROLLER MODES There are four operating modes for the 535 profile controller OPERATION the default mode of the controller When the 535 PROF is oper ating you run recipes change setpoints select manual control and change output level acknowledge alarms and monitor conditions 535 PROF User s Manual Chapter 1 1 Introduction SET UP also referred to as configuration Here the basic functions of the instru ment are configured such as input and output assignments alarm types and special functions TUNING where control function parameters for Prop
155. nfigured as follows Cycle Time 0 3 to 120 seconds Inputs One univeral process variable input is standard Available On Off Deadband up to 15 of input range in eng units options include remote setpoint slidewire feedback and 5 digital Up to eight sets of PID values may be stored in memory and inputs selected automatically based on setpoint value process variable Outputs Four outputs are available See Ordering Information value or the corresponding local setpoint SP1 SP8 RS 485 Communications Available as option with any configuration PROCESS VARIABLE INPUTS 2 PROCESS VARIABLES 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 W W5 amp Platinel 0 125 of span 0 325 of span Display accuracy is 1 digit These accuracy specifications are at reference conditions 25 C and only apply for NIST ranges Detailed accuracy information is 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 PID algorithm used is non interacting TUNING PARAMETERS Proportional Band 0 1 to 999 of input range Integral 1 to 9999 seconds repeat Derivative 0 to 600 seconds Manual Reset Load Line 0 to 100 o
156. ng 4 6 8 16 Recommend use of both MOV and snubber 2 Solid State Relay Triac Output Output 1 is always Control 1 e Respective jumper J1 J2 or J3 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 f 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 Fi 3 12 3 9 CD 18 E SSR Relay Output Wiring 410 6R 8P 16 0 Recommend use of both MOV and snubber 535 PROF User s Manual Chapter 3 17 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 orJ3 mustbe set to normally open for DC Logic output e Output4is 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 3 CD
157. ng sequence of alarm 2 18 ACK 2 Acknoledge status of alarm 2 19 POWER 2 Alarm 2 power up status 20 MESSAGE 2 9 character message for with alarm 2 21 FAULT Alarm status for fault condition lost PV 22 OUTPUT Rate of change alarm effect on trip to manual output 23 RATE TIME Time period over fora rate of change alarm condition 66 Chapter 5 535 PROF User s Manual Controller Set Up Set Up REM SETPT Parameter Description Values 1 TYPE V mA Remote setpoint input signal type 2 RSP LORNG Lowest remote setpoint input value egineering unit value 3 RSP HIRNG Highest remote setpoint input value engineering unit value 4 RSP LOW Lowest setpoint value from remote setpoint source 5 RSP HIGH Highest setpoint value from a remote setpoint source 6 TRACKING Local setpoint track status of remote setpoint 7 BIASLOW Lowest bias value that may be entered 8 BIAS HIGH Highest bias value that may be entered 9 RSP FIXED Remote setpoint restoration status RETRANS Parameter Description Values 1 TYPE 2 Output 2 transmission type 2 LOW RANGE 2 Low end of the range for output 2 in engineering units 3 HIRANGE 2 High end of the range for output 2 in engineering units 4 TYPE 3 Output 3 transmission type 5 LOWRANGE 3 Low end of the range for output 3 in engineering units 6 HIRANGE 3 High end of the range for output 3 in engineering units 7 TYPE 4 Ou
158. ning Return to Operation Gebe e Des a v Akey to these functions as shown below appears at the bottom of every page in the menu section of this chapter WHERE TO GO NEXT e Forinformation aboutall the software menus and parameters continue read ing this chapter Refer to Appendix D for a quick reference flowchart of all menus and parameters e Forinformation about the installed options on the 535 PROF compare the product label on top of the controller to the order code in Chapter 1 e Tomountthe controller and configure the wiring of the 535 PROF for inputs and outputs see Chapter 3 e To alter the output module and jumper configuration of the controller see Chapter 4 535 PROF User s Manual Chapter 5 29 Controller Set Up Set Up e Forinformation about applications for the 535 PROF see Chapter 7 e Formore information aboutthe Tuning function of the 535 PROF see Chap ter6 Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation e 30 Chapter 5 535 PROF User s Manual Controller Set Up Set Up SOFTWARE MENUS AND PARAMETERS CONFIG CONFIG 1 CTRL TYPE Defines the type of control output s D STANDARD Standard control output no special algorithms CTRL TYPE e POS PROP Position proportioning control output STANDARD e STAGED Staged outputs e DUPLEX Duplex outputs 2
159. 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 howto setup alarms and for examples of various ways alarms can be set up refer to the section on Alarms in Chapter 7 10 Chapter 2 Controller Operation NOTE All alarms are software alarms unless tied to an output relay in the SET UP mode See Chapters 5 and 7 for details on alarms NOTE Powering down the 535 acknowledges clears all latched alarms When powering up all alarms will be reinitialized 535 User s Manual INSTALLATION MOUNTING THE CONTROLLER The 535 PROF frontface is NEMA 4X rated waterproof To obtain a waterproof seal between the controller and the panel follow these directions 1 The 535 PROF fits a standard 1 4 DIN cutout Mount the 535 PROF in any panel with a thickness from 06 in to 275 in 1 5 mm to 7 0 mm 2 Figure 3 1showsthe controller and panel dimensions The panelcutoutmust Figure 3 1 be precise and the edges free from burrs and waves Instrument Panel amp Cutout Dimensions 1 180 29 97 PANEL _ 3 622 92 00 MIN 3 653 92 80 MAX Y 3 770 95 76 4 7 180 182 37 OVERALL LENGTH 229 XVIN 08 26 s9 NIN 00
160. nput takes action 100 e MENUKEY Closing contact mimics the MENU key In OPERATION Mode pro vides entry to TUNING menu In SET UP or TUNING Mode advances through the menus e COMM ONLY Makes input status readable through communications but has no effect on the controller itself e PV2 SWITCH only applicable for PV SOURCE 1 2 SWITCH Closing contact causes the 535 to use PV2 as the PV input instead of PV1 Basic Operating Procedures 1 Ifmorethan 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 re mote setpoint takes precedence 2 Any digital input can be overridden by another digital input keyboard op eration or an automatic function If a closed digital input is overridden 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 J REMOTE SETPOINT Remote setpoint limits are the same as setpoint limits Hardware Configuration e The optional feature is available only if ordered originally from the factory Product 535 xxxxxBxx00 or 535 xxxxxExx00 Referto the order code in Chapter 1 e Before configuring the software make sure the corres
161. nsmission must be calibrated per instructions in Operator s Manual To Change the Option Board 9 See Photos 3 and 4 Replace the existing 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 C
162. od of time in which the setpoint does not change after the ramp has been completed earth ground A terminal used on the 535 to ensure by means of a special connection the grounding earthing of part of the controller Appendix 6 engineering unit Terms of data measurement such as degrees Celsius pounds grams etc 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 FM Factory Mutual Research Corporation an organization which sets safety standards gain The ratio of the change in output to the change in input which caused it heat cool control Control method where the temperature of the end product is maintained by controlling two final elements using two of the 535 outputs hysteresis In ON OFF control the temperature change necessary to change the output from full ON to full OFF hunting Oscillation or fluctuation of process temperature between setpoint and process variable icons Indicators on the face of the controller input Process variable information being supplied to the instrument integral Control action that automatically eliminates offset or droop between setpoint and actual process temperature Also reset internal voltage reference A precision voltage source within the 535 controller used to establish internal calibration
163. of about 0 5 of full scale 7521 NOISE BAND x Z X 100 PROCESS sf 752 352 100 5 VARIABLE 47 406 7 Type T 405 Thermocouple 10 7 14 Range 401 328 752 F 4007 Noise Band Calculation Example 328 0 40 80 120 160 200 240 TIME gt SECONDS 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 settoo 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 indifferentto sluggish and oscillatory behavior Noise band settings are generally between 0 1 and 1 0 with mostcommon settings of 0 2 or 0 3 Figure 7 15shows the conversion of peak to peak noise to an appropriate noise band for each T C type amp RTD INPUT TYPE B E J k N R S T W WS PLATINEL RTD 0 1 RTD o 01 0 1 01 0 1 01 0 1 0 1 0 1 0 1 0 1
164. ogrmming R 1t099999 MIN if TIME BASE HOURS MIN R 1t099999 SEC if TIME BASE MIN SEC 535 PROF User s Manual Chapter 7 81 Applications 82 The decimal pointis defined by the DECIMAL parameter 7 The next parameter is RAMP TM 1 to 12 It defines the time for the current ramp segment to reach the current soak setpoint This parameter will only appear if RAMP UNIT TIME Choices endsrecipeprogramming R 00 01 to99 59 HR MN if TIME BASE HOURS MIN R 00 01 to99 59MN SC if TIME BASE MIN SEC IMPORTANT For each RAMP segment you will scroll through and set values for the next six parameters However choosing OFF for either RAMP RT or RAMP TM will conclude the programming 8 The next parameter is RAMP EV 1 to 12 It selects which events will be activated during the current ramp segment Choices are D NONE EVENT 1 event output 1 is selected EVENT2 event output 2 is selected e EVENT12 eventoutputs 1 and2are selected e EVENT3 event output 3 is selected e EVENT13 eventoutputs 1 and3are selected e EVENT23 eventoutputs2 and3are selected e EVENT 123 eventoutputs 1 2 and 3 are selected 9 The next parameter is SOAK SP 1 to 12 It defines the setpoint after the current ramp segment has completed Choices are e 9999t099999 R Dependentupon process variable range The decimal point defined by the DECIMAL parameter 10 Thenext parameter is SOAK
165. on of an input change or stimulus and the start of the resulting observable response A 18 default settings Parameters selections that have been made at the factory derivative Anticipatory action that senses the rate of change of temperature 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 DIN Deutsche Industrial Norms a German agency that sets standard for engineering units and dimensions 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 the setpoint deviation or output in TUNING or SET UP Mode the 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 controlled variable duty cycle Percentage of load ON time relative to total cycle time dwell Also called soak The designated peri
166. onding to the process variable target setpoint control output or actual setpoint to another device Acommon application is to use it to record one of these variables with a recorder Hardware Configuration NOTE For an analog output module e There must be an analog module installed in output socket 2 3 or 4 for retransmission that was not factory installed calibrate the output Software Configuration for maximum accuracy Refer to Appendix 4 for details calibration Up to two outputs can be configured for retransmission The menu will scroll through the configuration parameters for specified value X 2 3or4 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 Set the corresponding parameter TYPE X for the first retransmission 535 PROF User s Manual Chapter 7 97 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 12 Combinations of Closed Digital Inputs for Each Setpoint based on BCD logic closed contact O open contact 98 output to define what is being transmitted the process variable setpoint ramping setpoint or output 5 Setparameters LOW RANGE X and HIGH RANGE X for the first retrans mission output to define the range ofthe transmitted signal in engineering units This can be usefu
167. one The2nddisplay should show CALIBRATE the 3rd display should show ANA mA IN 11 Turn off powertothe unit 12 Forthermocouple input proceedtothe Thermocouple Cold Junction Calibra tion 13 Formilliamp input proceed to Analog Milliamp Input Calibration 14 For milliamp output calibration let the controller warm up for 10 minutes then skipto step 5 of Milliamp Output Calibration 15 Ifcalibrationis complete place all the jumpers backintheiroriginal positions as specified in Chapter 3 THERMOCOUPLE COLD JUNCTION CALIBRATION 1 Connect the two pairs of T C wire to terminals 28 29 31 and 32 as shown in Figure A4 5 Make sure the T C wires are floating disconnect from the multim eter also andare nottouching each other 2 Tumonpowertothe unitandletcontroller warm up for 30 minutes in the normal horizontal position while the unit is warming up the rear face of the controller should be vertical not horizontal 3 Press the MENU key until the display indicates CALIBRATE COLD JUNC 4 Press the ACK key The display should show PV 150 C PRESS 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 calibration will notbe accurate 6 Setthe thermocouple calibrator to an output value of 150 C fora Type T ther mocouple and allow the calibrator to stabilize for a few minutes 7 Press ACK to initiate calibration of the
168. ontacts for Recipe Selection E x None O Open Closed NOTE The 535 Profile Controller can store 20 recipes but only recipes 1 through 7 may be selected remotely This will use three of the five input contacts The two remaining can be used to start or abort a recipe START REC or hold the recipe HOLD REC See Section for other input options 84 R 1t08 13 After parameter PID SET the controller will cycle to the RAMP RT or RAMP TM parameter Toend programming Set either RAMP RT OFF or RAMP OFF Tocontinue programming Set a value for for RAMP RT or RAMP TM and scroll through subsequent parameters Digital Inputs Special digital input capabilities are available for 535 as a Profile Controller see Section in this chapter for information on standard Digital Input options Profile Control digital input options are RECIPE 1 7 Selects recipe number 1through 7 using binary contacts 1 2 and 3 for the next time a recipe is run The recipe number selected must be be tween 1 and the number of recipes selected in the REC CONF menu Note that a binary value of 0 zero is inactive and values of 1 to 7 select recipes 1 to 7 respectively e START REC Active Start Recipe Inactive Abort Recipe When activated the most recently selected recipe will start running When deactivated a running or held recipe will be abo
169. ontrol itcompensates for changes in setpoint load requirements and process variations e PID ON OFF Only available with Duplex control First output uses the PID algorithm while second output uses on off control 3 Foralgorithms using the derivative function D choose the conditions for the derivative term Scrollto parameter D SOURCE Forderivative action based on error or deviation from setpoint choose DEVIATION e Forderivative action based on changes in the process variable choose PV 535 PROF User s Manual Chapter 7 85 Applications NOTE Specifying a variable other than the setpoint SP to HIGH ALARM and LOW ALARM allows for greater flexibility in creating alarm and control strategies 86 C ALARMS The 535 controller has two extremely flexible and powerful software alarms 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 535 indicates an alarm condition by e Lighting up the alarm icon s Displaying a custom message in the 3rd display the ACK key ifthe alarm is acknowledgeable Software Configuration 1 Accessthe ALARM menu 2 Setvaluesforthe following parameters All possible values are shown ALM TYPE 1 and ALM TYPE 2 Specifies the type of alarm to implement Selection includes HIGHALARM High process variable alarm Occurs when the process variable ex ceeds the
170. ormation to be used by the adaptive tune Three pretune types are available TYPE 1 for slow thermal processes TYPE 2 for fast fluid or pressure applications and TYPE 3 for level control applications Adaptive tune Our exclusive POWERTUNE adaptive tuning algorithm automatically adjusts the PID values whenever a process upset occurs Preliminary information may be input manually or automatically calculated by our pretune algorithm OVERSHOOT PROTECTION POWERBACK is a proprietary user invoked setpoint overshoot protection algorithm When invoked POWERBACK reduces or eliminates setpoint overshoot at power up or after setpoint changes POWERBACK monitors the process variable to make predictive adjustments to the control parameters a feature that helps eliminate overshoot of setpoint ISOLATION Inputs and outputs are grouped into the following blocks Block 1 process variable Block 2 outputs 1 2 and 4 Block 3 communications set of five digital inputs output 3 Earth Ground Block 4 remote setpoint 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 potential 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 CONTROLLER ARCHITECTURE The 535 Controller hardware can be co
171. ortional Integral and Deri vation PID are configured Use this mode periodically to optimize the control performance of the instrument RECIPE SET UP where the ramps dwells and events for each recipe are con figured ORDER CODE PACKAGING INFORMATION Compare the product number to the ordering code on page 3 to determine the outputs and options installed on the controller The product number is printed on the label on the top of the controller case Included with this 535 Profile Controller are e a535 Profile Controller Users Manual e mounting hardware e 1sheet of Engineering unit adhesive labels WHERE TO GO NEXT e Tobecome familiar with the controller interface continue to Chapter 2 e Forimportanthardware installation guidelines see Chapters 3 and 4 Fora detailed description of all the software menus and parameters follow through Chapters 5 and 6 Appendix 1 can be used as a basic guide lineto these parameters TEXT FORMATTING IN THIS MANUAL Feature Format KEYS RUN DISPLAY or ICONS OUT ALM MENUS CONFIG TUNING PARAMETERS CYCLE TM 1 MIN OUT2 PARAMETER VALUES OFF SETPOINT LAST OUT DISPLAY MESSAGES TOOHOT OUT 2 Chapter 1 535 PROF User s Manual Introduction _ 535 0 0 Order Output 1 Control Code NONG 0 Mechanical Relay 5
172. own 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 e From the target setpoint to the actual ramping setpoint Tothe deviation from setpoint e Tothe 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 535 powers up in automatic control then the setpoint will ramp from the process variable value to the setpoint value atthe specified rate 2 Onatransferfrom manual to automatic control the setpoint will ramp from the process variable value to the setpoint value at the specified rate 3 Onanysetpoint change 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 PV1 INPUT menu 2 Setthe SP RAMP parameter to the desired rate of change P INPUT LINEARIZATION Thermocouple and RTD Linearization Forathermocouple or RTD input the incoming signal is automatically linearized The 535 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 co
173. pendix 3 Retune controller 535 PROF User s Manual Troubleshooting Message When does itoccur Whatto 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 for the 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 happen Must correct ERROR BAD CAL DATA PV1UNDER or PV1 OVERor PV2UNDER or PV2OVERor LOST PV1 or LOST PV2 LOSTRSP COMM SHED ERROR ROM CHECKSUM OUT1 CONF or OUT2 CONF LOST F B LOST CJC ERROR BAD EEPROM NEEDS CAL ERROR BAD MODEL NUM CAL ERROR SEE MANUAL 535 PROF User s Manual 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 travelled well outside the range When the communications is lost for longer than the communications sh
174. percent during a TYPE 2 or TYPE 3 OUT STEP pretune R 50 t060 0 D 10 0 5 LOW LIMIT Definesthelowermostlimitthe process variable can reach during pretune before LOW LIMIT aborting D R Anyvalueinthe process variable range D Dependentonthe process variable range 6 HILIMIT HI LIMIT Defines the upper most limit the process variable can reach during pretune before aborting D Access SetUp Returnto Operation Nextmenu Next parameter Next value AccessTuning Return to Operation Geien eee pee wv 535 PROF User s Manual Chapter 5 53 Controller Set Up Set Up R Anyvalueinthe process variable range D Dependentonthe process variable range 7 TIMEOUT TIMEOUT This defines the execution time limit for pretune before aborting 1500 R 8101500 D 1500minutes 8 MODE Defines the control mode after pretune is completed or aborted AUTOMATIC MANUAL Go to Manual mode after pretune has completed D AUTOMATIC Go to Automatic mode after pretune has completed R RECIPE 1 to20 Run the designated recipe after pretune has completed 9 NOISE BND NOISE BND Defines the noise band to be used by the adaptive tuning algorithm R 0 1 to 10 ofthe process variable range D 0 2 10 RESP TIME RESP TIME Defines response time to be used by the adaptive tuning algorithm R 10to32000seconds D 7200seconds 11 DEAD TIME Defines the amountoftime required for proces
175. period of time This delay in the transfer of heat prevents the 535 controller from controlling the temperature more precisely The solution to the problem is Figure 7 21 Have the PID controller position the steam valve butadd a sensor by means of another 535 controller that will monitor the steam pressure The pressure control system now creates a second feedback control loop which cascades from the first materials HEAT Figure 7 21 EXCHANGER Cascade Control of Product Temperature pressure sensor temperature sensor 535 PROF User s Manual Chapter 7 115 Applications Hardware Configuration e Configure Unit 1 fora 4 20mA output analog module for control e Configure Unit 2 forthe optional Remote Setpoint see Chapter 4 Software Configuration 1 ForUnit 1 a In CONFIG menu set CTRL TYPE to STANDARD b In PV1 INPUT menu set the PV1 TYPE parameter is V mA set LOW RANGE and HI RANGE parameters to match the transmitter range 2 ForUnit 2 a Setthe RSP input jumper in the mA position on the Microcontroller Circuit Board see Chapter 4 b Goto the REM SETPT menu Set RSP LO RNG to 0 Set RSP HI RNG to 100 This will set the range ofthe remote setpoint to 0 TO 100 to correspond to the 0 to 100 output range of Unit 1 d Wire the control output of Unit 1 to the remote setpoint input of Unit 2
176. ponding jumperis set properly Refer to Chapter 4 to check or change jumper positions Software Configuration Goto the CONFIG menu Set REM SET PT to ENABLED Go to the REM SETPT menu TYPE V MA defines the input signal range e g 1 5 4 20 mA RSP LO RNG and RSP HI RNG define the range ofthe remote setpoint in engineering units The correct range will be dependent on the remote setpoint signal source 6 RSP LOW and RSP HIGH set limits on the remote setpoint value in engineering units 7 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 8 BIAS LOW and BIAS HIGH setlimits on an operator entered bias value ak WON gt Chapter 7 535 PROF User s Manual Applications 9 RSP FIXED determines the signal to which the controller will revert when a lost RSP is restored fixed Options are to stay in local or automatically return to remote setpoint 10 To bias or ratio the remote setpoint value a Gotothe TUNING menu b Set RSP BIAS and RSP RATIO values Basic Operating Procedures After configuring the hardware and software the remote setpoint can be selected by either of two methods e Goto TUNING menu REMOTE SP parameter and set it to REMOTE SP e Useadigital input K MULTIPLE SETPOINTS The 535 canto store up to eight local setpoints and use a remote setpoint One
177. process to reach 63 of its new expected value the response time is 300 seconds Ifthe response time is settoo short the process will be unstable and cycle around the setpoint If the Response Time is settoo long response to an off setpoint condition will be sluggish It is generally betterto usetoolonga response time than too short Self Tuning with Multiple Sets of PID For both Pretune and Adaptive Tune the tuned set of PID is that which is active uponinitiation of the tuning function The controller cannottrip to other PID sets based on trip point orthe digital in put 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 local 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 MENU to access the TUNING menu 2 Setvalues 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 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
178. ptimization The act of controlling a process at its maximum possible level of performance usually as expressed in economic terms 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 output Action in response to difference between setpoint and process variable Appendix 6 overshoot Condition where temperature exceeds setpoint due to initial power up or process changes P control Proportioning control parameter s A user defined variable that specifies how a particular function in the 535 will operate PD control Proportioning control with rate action PI control Proportioning control with auto reset PID control Proportioning control with auto reset and rate position proportioning A type of control output that utilizes two relays to control an electric motorized actuator POWERBACK Our proprietary algorithm which monitors the PV to make predictive judgements to control parameters in order to reduce or eliminate overshoot at powerup or after setpoint changes POWERTUNES Our exclusive special self tuning function Consists of an on demand pretune that calculates PID values or provide preliminary PID values and process information for the second tuning function Second tuning function is an adaptive tuning algorithm that automatically adjusts PID
179. puts To display the active PID set 1 Press MENU to reach Tuning Mode 2 In TUNING Mode press MENU to reach the correct Menu parameter 3 The active 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 535 operators must know how the alarms are configured the consequences of acknowledging an alarm and howto reactto alarm conditions Alarm Indication e liticons ALM 1 and or ALM 2 e lit ACK key e displayed alarm message Acknowledgable alarms meet the first two of these conditions Non acknowledgable alarms only meet the first condition only icon is lit BEFORE Figure 2 2 Before and After Acknowledging an Alarm i i i 535 User s Manual Chapter 2 Controller Operation 9 Operation To acknowledge an alarm s 1 Toacknowledge Alarm 1 press ACK once 2 Toacknowledge Alarm 2 press ACK twice 3 Ifbothalarms are activated press ACK once to acknowledge Alarm 1 then again to acknowledge Alarm 2 4 The message and alarm icon dissappear Refer to Figure 2 2 Latching Alarms 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 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
180. r only at the start of a soak segment WHOLE SEG guaranteed soak can occur at the start of or at anytime during a soak segment 6 EVT 1 OUT EVT 1 OUT Selects which output is assigned to event 1 To assign a numerical value non NONE default the corresponding outputneeds tobesetto ALM EV ONor ALM EV OFF D NONE e 2 e 3 e 4 EVT 2 OUT daos cod NS Selects which outputis assigned to event2 To assign a numerical value non de NONE fault the corresponding output needs to be setto ALM EV ON or ALIWEV OFF D NONE e 2 e 3 e 4 8 EVT 3 OUT EVT 3 OUT Selects which output is assigned to event 3 In order to assign a numerical value non default the corresponding output needs to be configured as ALM EV ON or ALM EV OFF D NONE 2 Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation ewe espe Cav 38 Chapter 5 535 PROF User s Manual Controller Set Up Set Up 9 HOLD EVT Selects whether or not the last segment s event s will be held active after the HOLD EVT recipe has been successfully completed DISABLED D DISABLED ENABLED PV1 INPUT PV1 INPUT 1 PV1 TYPE Specifies the particular sensor range or input range for PV 1 PV1TYPE T C RID VOLTAGE CURRENT mA JT C D JT C D DINRTD D 1 5V D 4 20mA e ET C e JISRTD e 0 5V e 020mA e KT C e SAMARTD 0 10mV e BT C 0
181. rm 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 amountof change is defined by the alarm setpoint The rate of change is defined as the amount of change divided by the time period Example A Ifthealarmsetpointissetto 10 and the time base is setto 1 second the rate of change is 10 units per second Chapter 7 535 PROF User s Manual BAND ALARM IN ALARM IN CONDITION CONDITION a RELAY RELAY RELAY RELAY ENERGIZED DE ENERGIZED ENERGIZED DE ENERGIZED ICON OFF ICON ON ICON OFF ICON ON NO ALARM CANNOT NO ALARM CANNOT ACKNOWLEDGE ACKNOWLEDGE PARAMETER SETTINGS OUTPUT N ALM RLY OFF N 2 to 4 ALM TYPE 1 BAND ALM 1 OUT N 2 to 4 LATCHING NO LATCH ACK 1 DISABLED DEVIATION ALARM IN ALARM NS TIME RELAY RELAY MUST DE ENERGIZED ENERGIZED ACKNOWLEDGE TO SHUT OFF ICON OFF ICON ON ICON AND DE ENERGIZE NO ALARM MAY RELAY ACKNOWLEDGE PARAMETER SETTINGS OUTPUT N ALM RLY ON N 2 to 4 ALM TYPE 1 DEVIATION ALM 1 OUT N 2 to 4 LATCHING LATCH ACK 1 ENABLED ALARM SP 1 lt 0 Figure 7 2 Alarm Examples 535 PROF User s Manual Applications HIGH PROCESS VARIABLE ALARM
182. rn to Operation ww espe e 46 Chapter 5 535 PROF User s Manual Controller Set Up Set Up 4A HIGH SP 1 Specifies the high alarm set point for alarm 1 of type HIGH LOW HIGH SP 1 lf ALM SRC 1 OUTPUT lf ALM SRC 1 any othertype 0 0 to 100 0 R LOWRANGEtoHI RANGE D 0 0 DO 4B LOW SP 1 Specifies the low alarm set pointfor alarm 1 of type HIGH LOW If ALM SRC 1 OUTPUT If ALM SRC 1 any othertype LOW SP 1 0 0 to 100 0 R LOWRANGEtoHI RANGE D 0 0 DO 5 DEADBAND 1 Defines the deadbandforalarm 1 DEADBAND 1 If ALM SRC 1 OUTPUT If ALM SRC 1 any other type R 0 1 to 100 0 R 1099909 2 D 2 D 2 6 ALM 1 OUT Selects the outputnumberforalarm 1 ALM 1 OUT D NONE 2 NONE e 3 4 7 LATCHING 1 LATCHING 1 Defines the latching sequence ofalarm 1 NONE D LATCH e NOLATCH 8 1 Defines whether alarm 1 may be acknowledged ACK 1 D ENABLED Allowsthe alarmto be acknowledged e DISABLED Prevents the alarm from being acknowledged ENABLED while in alarm condition 9 POWER UP 1 Defines howalarm 1 willbetreated on powerup D NORMAL Alarm depends on process variable POWER 1 ALARM Always power upin alarm regardless of PV NORMAL e DELAYED Must leave alarm condition and reenter before activating the alarm Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation Loew Dee 5
183. rocess value when the transfer occurs 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 wire 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 535 PROF User s Manual Appendix 6 A 21 Isolation Block Diagram Block Diagram APPENDIX 7 ISOLATION BLOCK DIAGRAM PV1 Input Output 1 Iso Ground Referenced Multiplexer PV2 Input Output 2 Iso Ground Referenced RSP Input Output 3 ISO Ground Referenced Slidewire Input Output 4 V Iso
184. rresponding to the XTH point X is 2 to 14 99991099999 XTH PV 5 15TH INPT Specifies the input signal corresponding tothe 15th point R 9999to99999 Minimumis XTH 1 INPUT 15TH D Thehighendofthe appropriate input range e g 20 00 mA D 6 15TH PV Specifies the engineering unit value corresponding tothe 15th point R 99991099999 15TH PV a o Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation mee Cav 535 PROF User s Manual Chapter 5 43 Controller Set Up Set Up CONTROL CONTROL Forconfiguring the choices forthe control algorithm ALGORITHM Definesthetype of control algorithm e PI e PD e P e ON OFF e PID ON OFF For Duplex applications using PID for the first output and on off forthe second output 2 D SOURCE D SOURCE Selects the variable for the derivative action D PV Derivative term will not react when setpoint changes e DEVIATION Derivative term will react when setpoint changes 3 ACTION 1 ACTION 1 Defines the action ofthe first control output REVERSE e DIRECT D REVERSE 4 PV BREAK Defines the manual outputlevel ifthe process variable inputis lost Choose val D ues basedonthe process type Standard Control On Off Control Velocity Prop Control e 105 CW DO D OFF e CCW OUTS OFF LOW OUT 5 LOW OUT Defines the lowest output value that can be
185. rresponding to the flow being measured To linearize this signal for use by the 535 the square root of the signal must be calculated The 535 has the capability to perform this square rootlinearization For the first 1 of the input span the input is treated a linear fashion Then it is a calculated value using the formula in Figure 7 17 535 PROF User s Manual Chapter 7 109 Applications Figure 7 17 Square Root Linearization Formula Figure 7 18 15 point Linearization Curve 110 PV Low Range Hi Range Low Range V input V low V high V tow Hi Range is the high end of the process variable Low Range is the low end of the process variable V input is the actual voltage or current value of the input V high is the high end of the input signal range e g 5 volts or 20 mA V iow is the low end of the input signal range e g 1 volt or 4 mA 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 Avoltage or milliamp input must be installed on the controller Software Configuration 1 Gotothe PV1 INPUT menu 2 Set LINEARIZE to SQR ROOT Custom Linearization Custom linearization allows virtually any nonlinear signal to be linearized using a15 pointstraightline approximation curve see Figure 7 18 Typical applications are linearizing signals from nonline
186. rted This action will take place if a recipe is not running or held at the time of the contact closure e HOLD REC Active Hold Recipe Inactive Resume Recipe When activated a running recipe will be held atits current position When deactivated a held recipe will resume running from its current position e RESETREC When activated a running or held recipe is resetto the beginning If the recipe is linked to other recipes the beginning of the first linked recipe will be used When deactivated no action will be taken e ABORTREC When activated a running orheld recipe will be aborted When deacti vated no action will be taken e NEXTSEG When activated a running or held recipe will advance to the end of the current segment When deactivated no action will be taken e PV2 SWITCH only applicable if PV SOURCE 1 2 SWITCH When activated causes the controller to use PV2 as the PV input instead of PV1 Master Slave Operation The 535 Controller with profile option Is capable of operating as a master setpoint generator controlling up to 4 standard slave 535 controllers The 535 with profile option can retransmit the recipe setpoints to the remote setpoint inputs of up to 4 standard 535 controllers Configured as such a common recipe may be appliedto 5 different control loops or heating cooling zones Chapter 7 535 PROF User s Manual Applications Hardware Configuration The535 controller with profile option
187. rtioning algorithm 9 CCWTIME Counter clockwise motor stroke time 10 CW TIME Clockwise motor stroke time 11 MIN TIME Motor on time minimum value 12 S W RANGE Full range resistance of the slidewire 13 OPEN F B Feedback ohm value for full open 14 CLOSE F B Feedback ohm value for full close 15 OUT1 STOP Control output 1 stop pointfor staging outputs 16 OUT2 STRT Control output 2 start point for staging outputs 535 PROF User s Manual Chapter 5 65 Controller Set Up Set Up ALARMS Parameter Description Values 1 ALM TYPE 1 Alarm 1 type 2 ALM SRC 1 Value monitored by alarm 1 ALARM SP 1 Set pointfor alarm 1 except HIGH LOW 4A HIGH SP 1 High alarm set pointfor alarm 1 oftype HIGH LOW 4B LOW SP 1 Low alarm set pointfor alarm 1 oftype HIGH LOW 5 DEADBAND 1 Deadbandfor alarm 1 6 ALM 1 OUT Output number for alarm 1 7 LATCHING 1 the latching sequence of alarm 1 8 1 Acknowledge status of alarm 1 9 POWERUP 1 Alarm 1 power up status 10 MESSAGE 1 9 character message for with alarm 1 11 ALM TYPE 2 Alarm 2type 12 ALM SRC 2 Value monitored by alarm 2 13 ALARM SP 2 Alarm set point for alarm 2 except HIGH LOW 14A HIGH SP 2 High alarm set point for alarm 2 of type HIGH LOW 14B LOW SP 2 Low alarm set point for alarm 2 of type HIGH LOW 15 DEADBAND 2 Deadbandfor alarm 2 16 ALM 2 OUT Output number for alarm 2 17 LATCHING 2 Latchi
188. s Figure 7 20 Heat Exchanger Control Loop for Steam Supply 114 7 Use SHED OUT to specify an output level ifthe unit sheds and trips to manual control 8 To specify a control setpoint in case the host is supervising the setpoint if the 535 sheds Set SHED SP to DESIG SP and then set the parameter DESIG SP to the desired setpoint V CASCADE CONTROL While a single 535 Controller is effective in maintaining many control systems others require more sophisticated control schemes Figure 7 19 shows a sample control set up with a 535 controller Cascade control is often used to control a process more precisely In cascade control a second variable is monitored in addition to the primary controlled variable This second variable is one that more quickly reflects any changes in the process environment Cascade control involves installing one feedback loop within another as in Figure 7 20 This second loop basedon steam pressure is called the inner or secondary feedback loop The outer or primary feedback loop is based on the temperature of the liquid in the heat exchanger However instead of directly positioning the steam valve the output of the primary 535 controller is now used to adjust the setpoint of the secondary 535 controller which then positions the valve Cascade Control is typically used for the following e Aslowresponding process with a significant lag time Aprocessrequiring more advanced ortighter control e
189. s and Chapter 7 for applications Torun arecipe 1 Pressing the RUN key prompts the choice of recipe number 2 Usethe or V key to select the proper recipe 3 Press the ACK key to start the recipe To hold recipe 1 While a recipe is running indicated when the RUN keyis lit red briefly press the RUN key The key will blink on and off and the 3rd display will indicate HOLDING 2 Press the RUN key again to resume the recipe To abort a recipe and place the controller in MANUAL mode 1 While a recipe is running indicated when the RUN key is lit red press the MANUAL key The 2nd display line will show REC ABORT and the 3rd dis play willshow PRESS ACK 2 Pressthe ACK key within 5 seconds to abortthe recipe and place the con trollerin MANUAL mode The manual output value will be the last output at the pointthe recipe was aborted The raise and lower keys may be used to modify the output To abort a recipe and control to the IDLE setpoint 1 While a recipe is running indicated when the RUN key is lit red press the RUN key and hold until the 2nd display line shows REC ABORT andthe 3rd display will show PRESS 2 Press the ACK key within 5 seconds to abort the recipe and the controller Chapter 2 Controller Operation 7 Operation will control to the IDLE setpoint The raise and lower keys may be used to adjust the setpoint To display the setpoint SP ramping setpoint RAMP deviation DEV
190. s to begin to respondto an output change used by POWERBACK algorithm R 0 1 seconds to 7200 0 seconds D 0 1seconds DEAD TIME SPECIAL SPECIAL 1 AUTO TRIP AUTO TRIP This defines the condition under which the 535 PROF will automatically trip to OFF automatic control from manual control upon start up D OFF Deactivates this function e RISINGPV Will trip when a rising process variable is within the specified deviation fromthe setpoint e FALLNG PV Will trip when a falling process variable is within the specified deviation from the setpoint Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation wer Dee De 54 Chapter 5 535 PROF User s Manual Controller Set Up Set Up 2 TRIP DEV This defines the deviation from setpoint at which the controller will trip to TRIP DEV For AUTO TRIP RISING PV For AUTO TRIP FALLING PV R 99999100 01099999 DES OUTPT the last output value while in automatic Choose values based on the process digital inputis defined totrip the controllerto manual mode this designates the DES OUTPT outputvalue after the trip LAST OUT means thatthe output value will be equal to Standard Control On Off Control Velocity Prop Control e 5 0105 ON CW D LASTOUT D OFF CCW D OUTS OFF 4 POWER UP This defines the control mode upon power up POWER UP
191. set 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 7 Duplex with overlapping outputs and output limits 0 PID OUTPUT Duplex with various relative gain settings Areverse 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 0 PID OFST 2 0 LOW OUT 0 HIGH OUT 100 REL GAIN 2 0 REL GAIN 1 0 REL GAIN 0 5 Figure 7 8 Duplex with various relative gain settings PID OUTPUT 535 PROF User s Manual Chapter 7 93 Applications Notice that the relative gain setting does not affect output 1 In this example 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 of 50 at a PID output of 0 Duplex with one ON OFF output Areverse acting output 1 and a direct 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 asthe deadba
192. sisamenu When traversing the two modes the menu names appear in the 2nd display CONFIG REC CONF PV1 INPUT PV2 INPUT CUST LINR CONTROL ALARMS REM SETPT RETRANS SELF TUNE SPECIAL SECURITY SER COMM RECIPE TUNING 535 PROF User s Manual Mode selection and input output hardware assignments General recipe options 1st process variable input options 2nd process variable input options Linearization curve options for PV1 input Control algorithm options Alarm options Controller remote setpoint options Retransmission output options Selftune algorithm options Specialfeature options Security functions Serial Communications options requires comm board Individual recipe configuration Tuningparameters configuration see Chapter 6 Chapter 5 Controller Set Up Figure 5 1 Menu Flowchart for Set Up 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 text on white This is a parameter Value These values appear in the 3rd display replacing the parameter name In this manual parameter graphics indicate the default factory setting If the default value is dependent on other variables D is shown A range of values is indicated by R CAUTION All software changes occur in real time always perform set up funct
193. sitivity To set a Gotothe TUNING menu b Set P PROP D B to 5 c Placecontroller under Manual control oo oe NO a amp 535 PROF 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 95 Applications NOTE P PROP D B can only be configured if the Slidewire Feedback is wired to the controller NOTE Adaptive tuning is not available with velocity position proportioning control 96 d Change the output percentage and observe if the valve stabilizes at the new value e If the valve oscillates increase the P PROP D B value by 0 5 repeat until oscillation stops 12 Set the parameter S W BREAK to define the output value for when the slidewire breaks F VELOCITY POSITION PROPORTIONING CONTROL Velocity position proportioning 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 a
194. t 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 Gotothe 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 Chapter 7 535 PROF User s Manual Applications 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 535 controller actually displays the PID output To relate this output to the actual physical output locate the PID output on the horizontal axis Draw a vertical line at that point At the intersection of this vertical
195. table 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 using RS 232 RS 485 converter Product 500 485 The communication protocolis asynchronous bidirectional half duplex hence the leads are labelled Comm and Comm Figure 3 16 535 Serial Communications Terminals Terminals To Comm terminal of next Powers device PC Twisted shielded COMM or other host To Comm terminal of next device Use a 60 to 100 Ohm terminating resistor connected to the two data terminals of the final Powers 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 535 PROF User s Manual Chapter 3 19 Limit Control Temperature applications where abnormally high or low temperature conditions pose potential hazards for damage to equipment product and operator Forsuch applications we recommend the use of an FM approved temperature limit device in conjunction with the process controller This wiring example illustrates Figure 3 17 a typical
196. 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 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 insert and align screws Tighten them until the bezel is seated firmly against the gasket Do not overtighten Chapter 4 535 PROF User s Manual 5 SOFTWARE CONFIGURATION The software configuration menus of the 535 PROF contain user selected vari ables that define the action of the controller Read through this section before making any parameter adjustments to the controller When initially setting up the controller cycle through all the parameters in each Menu Press the MENU FAST to advance to the next Menu Press MENU to advance to the MENU FAST CONFIG next parameter this also sets the value for the current parameter Use arrow keys a press to select a value Use the arrow keys to enter numerical values and or move INDICATOR D press MENU FAST Go to next Menu Block through the selection group press MENUS VA In Set Up mode there are 13 sets of options that control different aspects of 535 PROF operation in Tuning mode there is one Eachsetofoption
197. the control action to be performed control cascade see cascade control 7 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 predetermined 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 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 dead band A temperature band between heating and cooling functions the range through which an input can be varied without initiating observable change in output dead time The interval of time between initiati
198. ting parameter For details on the 535 protocol contact a 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 It is the only way one 535 can be distinguished from another Each 535 on the same RS 485 interface must have a unique station address 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 recommended 5 Whenthe535 senses thatcommunications is lost itcan goto 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 535 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 535 PROF User s Manual Chapter 7 113 Application
199. to Chapter 7 535 PROF User s Manual Applications control parameters which in turn helps to eliminate overshoot of the Setpoint Software Configuration 1 Gotothe TUNING menu 2 SetPOWR BACK parameter to ENABLED 3 Goto the SELF TUNE menu 4 For DEAD TIME set the value time that the controller should wait before invoking an output change This value is typically the dead time of the process Or let Pretune calculate the dead time then complete just steps 1 and2 above N SELF TUNE POWERTUNE The Self Tune function of the 535 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 processes e TYPES Normally used for level control applications Pretune is an on demand function Upon initiation there is a five second period during which the controller monitors the activity of the 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
200. tput 4 transmission type 8 LOW RANGE 4 Low end of the range for output 4 in engineering units 9 HIRANGE 4 High end of the range for output 4 in engineering units 535 PROF User s Manual Chapter 5 67 Controller Set Up Set Up SELF TUNE Parameter Description Values 1 TYPE Self tuning algorithm type 2 PRETUNE Pretune algorithm type 3 TUNEPT PV value at which output switches off TYPE 1 4 OUT STEP Output step size in absolute percent TYPE 2 or 3 5 LOWLIMIT Lower limitfor PV during pretune before aborting 6 HILIMIT Upper limitfor PV during pretune before aborting 7 TIMEOUT Execution time limitfor pretune before aborting 8 MODE Control mode after pretune is completed or aborted 9 NOISEBND Noise bandfor adaptive tuning algorithm 10 RESP TIME Response time for the adaptive tuning algorithm 11 DEAD TIME Wait time for process initiation POWERBACk SPECIAL Parameter Description Values 1 AUTO TRIP Trip to automatic control from manual control upon start up 2 TRIPDEV Deviation from setpoint for a trip to automatic 3 DES OUTPT Output value after the trip 4 POWERUP Control mode upon power up 5 PWR UP REC Recipe to use after power up 6 PWR UP RUN Selected recipe status after power up 7 PWR UP OUT Outputofthe controller if powering up in manual mode 8 PWR UP SP Setpoint upon power up 9 NO OF SP Number of local setpoints up to 8 to be stor
201. tput Calibration Wiring A 10 Figure A4 9 OutputModule Menu Cycle A 10 Figure A4 10 Slidewire Test Wiring A 11 535 PROF User s Manual Table of Contents vii Introduction _ CHAPTER 1 INTRODUCTION nem i ES rz 21 From its surge resistant power supply to its rugged construction the 535 Profile Thank you for selecting the 535 Profile Controller is designedto ensure the integrity of your process with maximumreli Controller the most sophisticated ability hour after hour day after day The isolated inputs and outputs guard Sfrument in its class It will provide againstthe dangers of electrical interference the frontface meets NEMA 4X stan y ae with years ot reliable trouble tree dards for watertight operation and exposure to corrosive environments andthe peat solid metal housing and sturdy rubber keys enhance durability and ESD protec tion The 535 Profile Controller has been engineered to be the industry s most user friendly process controller With three digital display areas two offering up to 9 characters of true alphanumerics the controller 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 frie
202. ts with Internal and External Power Supply 15 Figure3 8 Digital Inputs Wiring with A Switch or Relay 16 Figure3 9 Digital Input Wiring with An Open Collector 16 Figure 3 10 Remote Setpoint Terminals 16 Figure 3 11 Mechanical Relay Output Wiring 17 Figure 3 12 SSR Relay Output Wiring 17 Figure 3 13 DC Logic Output Wiring eee 18 Figure 3 14 Milliamp Output Wiring 18 Figure3 15 Position Proportioning Output Wiring 18 Figure 3 16 Serial Communications Terminals 19 Figure 3 17 535 PROF Wiring with Limit Control esesesss 20 Figure4 1 Location of Printed Circuit Boards for Hardware Configuration sese 21 Figure4 2 Fromthe Top the Microcontroller Circuit Board the Option Board andthe Power Supply Board 22 Figure4 3 Representation of Module 25 Figure 4 4 Install Communications Module onto Microcontroller Board etie tette tu ie ed 26 Figure5 1 Menu Flowchartfor Set Up
203. tual 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 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 W
204. u or through communications or by using the fifth digital Setpoints DIN 1 DIN 2 DIN 3 DIN 4 SP X 0 0 0 SP2 0 X 0 0 SP3 X X 0 0 SP4 0 0 X 0 SP5 X 0 X 0 SP6 0 X X 0 SP7 X X X 0 SP8 0 0 0 X input to select the remote or 2nd setpoint To rearm this set of digi tal inputs the DIN combination must change e REM SETPT Chapter 7 535 PROF User s Manual Applications Closing input changes active setpoint to remote setpoint Opening reverts controller to previous setpoint Override by selecting differ entsetpointvia the SP SELECT parameter inthe TUNING menu a communications command or other digital inputs MANUAL Closing inputtrips the controllerto manual Opening input reverts con trollerto automatic Override by using MANUAL key a communica tions command or trip to automatic function NOTE Th d display d t Closing input changes active setpoint to the 2nd local setpoint Open change ing input reverts controller to previous setpoint digital input Override closed digital input by selecting a different setpoint via the SP SELECT parameter in the TUNING menu acommunications command or other digital in puts e 2ND PID Closing input changes active set of PID values to 2nd set Opening input bases active set of PID onrules definedin PID TRIP and TRIP 1 to TRIP 8 Override input only by directly linking PID set to the active setpoint and changing the active setpoint e
205. ue corresponding to full close 0 output 1000hms 15 OUT1 STOP This defines the stopping pointfor control output 1 when staging outputs R 1to100 OUT1 STOP ni Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Return to Operation mew 535 PROF User s Manual Chapter 5 45 Controller Set Up Set Up 16 OUT2 STRT OUT2 STRT Defines the starting point for control output 2 when staging outputs D 50 ALARMS ALARMS 1 ALM TYPE 1 Defines the type of alarm for alarm 1 e HIGHALRM e LOWALARM e HIGH LOW Separate High amp Low alarm setpoints in one alarm ALM TYPE 1 e BAND DEVIATION MANUAL Causesanalarm when in manual control e REMOTESP Causes an alarm when in Remote Setpoint e RATE Selects arate of change alarm D OFF Deactivates the first alarm 2 ALM SRC 1 ALM SRC 1 Selects the source of the value being monitored by HIGH LOW or HIGH LOW alarm 1 D PV e SP e RAMP SP e DEVIATION e OUTPUT e PV2 ALARM SP 1 3 ALARM SP 1 Specifies the alarm set pointfor alarm 1 except HIGH LOW For HIGHorLOW alarms IfALM SRC 1 OUTPUT If ALM SRC 1 any other type 0O 096to 100 0 R LOWRANGEtoHIRANGE D 0 0 ForBANDalarms R 11099999 D 0 For DEVIATION or RATE alarms R 9999to99999 D 0 Access Set Up Return to Operation Next menu Next parameter Nextvalue AccessTuning Retu
206. ut function 6 OUTPUT3 Third output function 7 OUTPUT4 Fourth output function 8 ANLG RNG 1 First output signal 9 ANLG RNG 2 Second output signal 10 ANLG RNG 3 Third output signal 11 ANLG RNG 4 Fourth output signal 12 CONTACT 1 First digital input operation 13 CONTACT 2 Second digital input operation 14 CONTACT 3 Third digital input operation 15 CONTACT 4 Fourth digital input operation 16 CONTACT 5 Fifth digital input operation 17 LOOP NAME Message associated with the loop 535 PROF User s Manual Chapter 5 61 Controller Set Up REC CONF Parameter Description Values 1 RECIPES the number of recipes available in the 535 2 TIME BASE Time base units for recipes RAMP UNIT Ramp segment definition time or rate 4 SPSTART Initial value for the first ramp segment s setpoint 5 GUAR SOAK Selects whether guaranteed soak is used 6 EVT 1 OUT Output assigned to event 1 7 EVT 2 OUT Output assigned to event 2 8 EVT SOUT Output assigned to event 3 9 HOLDEVT Hold status last segment s event s PV1 INPUT Parameter Description Values 1 PV1 TYPE Sensor input range for PV1 2 DEG F C K PV 1 temperature units 3 DECIMAL PV1 decimal point position 4 LINEARIZE PV1 inputlinearization 5 LOWRANGE Engineering unit value for lowest PV1 input 6 RANGE Engineering unit value for highest PV1 input 7 SPLOLIM Lowest
207. utput A 12 Appendix 5 535 PROF User s Manual Specifications _ THERMOCOUPLES RANGE F RANGE C B 104 to 3301 40 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 S 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 Il 148 to 2550 100 to 1399 RTDs RANGE F RANGE C 100ohm Pt DIN 328 to 1562 200 to 850 328 0 to 545 0 200 0 to 285 0 100ohm Pt JIS 328 to 1202 200 to 650 328 0 to 545 0 200 0 to 285 0 100 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 105 0105 Millivolts DC 0 to 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 Voltage Input 1 Mohms UPDATE RATE Input is sampled and output updated 10 times per second Display is updated five times per second Thermocouples 10 Mohms RTDs 10 Mohms 535 PROF User s Manual TRANSMITTER LOOP POWER Isolated 24 Vdc nominal loop power supply is available if a loop power module is installed in an output socket not used for control Capacity is 25 INPUT
208. values whenever a process upset or setpoint change occurs pretune algorithm A method by which the 535 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 variable In the treatment of material any characteristic or measurable attribute whose value changes with changes in prevailing conditions Common variables are level pressure and temperature 7 proportional band The change in input required to produce a full range change in output due to proportional control action ramp A rise or fall of the setpoint in a given segment Ramps may be defined by the time it will take for the setpoint to be achieved or the rate of rise or fall necessary for the target soak setpoint to be achieved 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 regulate The act of maintaining a controlled variable at or near its setpoint in the face of load disturbances relay mechanical An electromechanical device that completes or interrupts a circuit by physically moving electrical contacts into contact with e
209. viation output value slidewire position actual valve position and configuration information Height is 6 mm 0 25 in 3rd display 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 MAN key illuminated controller is in manual control mode ACK key illuminated alarm may be acknowledged RUN key illuminated a recipe 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 WIRING CONNECTIONS 29 screw terminals in the rear of the instrument 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 Storage Limits 40 to 70 C 40 to 158 F RELATIVE HUMIDITY 10 to 90 non condensing 535 PROF User s Manual VOLTAGE AND FREQUENCY Universal power supply 90 to 250 VAC 48 to 62 Hz NOISE IMMUNITY Common mode rejection process input gt 120 dB Normal mode rejection process input gt 80 dB AC
210. wendoftherangeforoutput2 inengineeringunits Doesnotappearfor D Access SetUp Returnto Operation Nextmenu Next parameter Next value AccessTuning Return to Operation Bee Dee 535 PROF User s Manual Chapter 5 51 Controller Set Up Set Up type CTRL OUT R 99991099999 D Dependentonthe process variable range HI RANGE 2 3 HI RANGE 2 Definesthehighendofthe rangeforoutput2 in engineering units Doesnotappear D fortype CTRL OUT R 99991099999 D Dependentonthe process variable range 4 TYPE 3 Defines whatis to be retransmitted for output 3 D PV This refers to the linearized process variable e SETPOINT This is the target setpoint e RAMP SP This is the ramping oractual setpoint when the setpointis ramping e CTRL OUT This is the control output value 5 LOW RANGE 3 LO RANGE 3 Definesthelow endofthe range for output3inengineeringunits Doesnotappearfor RA R 9999t099999 D Dependentonthe process variable range 6 HI RANGE 3 HI RANGE 3 Definesthehigh end ofthe rangeforoutput3 in engineering units Does notappear D fortype CTRL OUT R 9999to99999 D Dependentonthe process variable range 7 TYPE 4 Defines whatis to be retransmitted for output 4 D PV This refers to the linearized process variable e SETPOINT This is the target setpoint e RAMP SP This is the ramping oractual setpoint when the setpointis ramping e CTRL OUT This is the control output value 8
211. xtmenu Next parameter Next value AccessTuning Return to Operation a Gep we 50 Chapter 5 535 PROF User s Manual Controller Set Up Set Up D 1000 4 RSP LOW Defines the lowest setpoint value to be accepted from the remote setpointsource R 9999to99999 D Dependenton RSP LO RNG value 5 RSP HIGH RSP HIGH Definesthe highestsetpoint value from a remote setpoint source D R 9999to99999 D Dependenton RSP HI RNG value 6 TRACKING TRACKING Defines whether the local setpoints 1 to 8 will track the remote setpoint D NO e YES 7 BIAS LOW BIAS LOW Defines the lowest bias value that may be entered R 9999to 99999 Maximum value is BIAS HIGH 1000 D 1000 8 BIAS HIGH Defines the highest bias value that may be entered BIAS HIGH R 9999to 99999 Minimum value is BIAS LOW 1000 RSP LOW D 1000 9 RSP FIXED Defines what happens if remote setpoint is lost while it is active and then is RSP FIXED restored e REMOTESP Returnsto remote setpoint when itis restored D LOCAL Local setpoint remains active when RSP is ida RETRANS RETRANS 1 TYPE 2 TYPE 2 Defines whatisto be retransmitted for output 2 D PV This refers to the linearized process variable e SETPOINT This is the target setpoint e RAMP SP This isthe ramping or actual setpoint when the setpointis ramping e CTRL OUT This is the control output value LO RANGE 2 2 LOW RANGE 2 Definesthelo

1/4 DIN PROFILE CONTROLLER USER`S MANUAL 5 3 5

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