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Instruction Manual - Gilson Engineering Sales Inc.

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1. 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 ALARM ACK Lockout status of the ACK key 6 TUNING Lockout status for adjustment of tuning parameters 7 CONFIGURE Lockout status for Set Up parameters SER COMM Parameter Description Values 1 STATION Theunit s station address 2 BAUDRATE Baud rate 3 CRC Whether CRC is being calculated 4 SHEDTIME Time between communications before controller sheds 5 SHEDMODE State of the controller if communications is lost sheds 6 SHEDOUT Output if the unit sheds 7 SHEDSP Setpoint status if communications is lost 8 DESIG SP Value of the setpoint if controller sheds 62 Chapter 5 535 User s Manual Tuning CHAPTER 6 TUNING OVERVIEW The self tuning function of the 535 consists of two distinct components Pretune and Adaptive Tune In addition you may choose from three types For more information about Pretune of Pretune and Adaptive Tune refer to the section on Tuning applications in Chapter 7 TYPE 1 for slow thermal processes 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
2. H 6 000 152 mo GASKET FRONT SIDE e Place bezel gasket around the controller case starting at the back of con troller Then slide the gasket against the back of the bezel With the bezel gasket in place insert the 535 into the panel cutout from the front of the panel 5 Slidethe mounting collar over the back of the case as shownin Figure 3 2 The collar clip edges will lock with matching edges on the controller case CI Mounting Clip Mounting Collar Collar Screws 1 of 4 gt Front Panel 535 User s Manual Chapter 3 or OOCL EEEEEEEEE 3 622 92 00 MIN 3 653 92 80 MAX 3 585 91 06 gt CUTOUT Figure 3 2 Attaching mounting collar m lt XVIN 0826 39 00 26 229 5 EDT 7 CAUTION The enclosure into which the 535 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 Terminal Assignments Actual 535 device only has top and bottom numbers of each column of terminals marked WARNING ELECTRIC SHOCK HAZARD Terminals 1 and 2 carry live power DO NOT touch these terminals wh
3. 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 5 5 0 15 65 Figure 3 11 4KB 687 88 Recommend use of both MOV snubber 2 Solid State Relay Triac Output e Output 1 is always Control 1 e Respective jumper J1 J2orJ3 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 Line Power Terminals used Terminals used Terminals used Terminals used with Output with Output with Output with Output Module 1 Module 2 Module 3 Module 4 5 amp D 7 159 Figure a 12 SSR Relay Output Wiring 4l 6601 ne R Recommend use of both MOV and snubber 535 User s Manual Chapter 3 Mechanical Relay Output wiring Refer to Figure 4 2 for location of the Secondinput jumper connector onthe option board must be in either mA milliamp or V voltage position Figure 3 13 DC Logic Output Wiring Figure 3 14 Milliamp Output Wiring Figure 3 15 Position Proportioning Output Wiring 18 3 DC Logic SS
4. D Certification H Five Digital Inputs and J Serial Communications Enter 0 if not desired RS 485 Serial S Note 1 Capability for position proportioning output is specifed by ordering 535 11xxAxxx00 535 33xxAxxx00 or 535 44xxAxxx00 Note 2 Capability for velocity proportioning output is specifed by ordering 535 11xxxxxx00 535 33xxxxxx00 or 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 User s Manual Chapter 1 3 introduction 4 Chapter 1 535 User s Manual Operation CHAPTER 2 BASIC INTERFACE 1st 2nd 3rd EK EM ER ER ER EK N EX E ER Figure 2 1 Operator Interface Location for identification label Keys DISPLAYS The display strategy of the 535 Process Controller is the same for all control 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 In TUNING or SET UP mode for the parameter name Upon power up indicates the current setpoint 3rd Display nine 14 segment digits Foralarm m
5. 1 Analog a 2 Solid State Relay 1 3 DC Logic SSR 4 Output 3 Control Alarm Retransmission or Loop Power NONG m 0 Mechanical Relay 5 1 Analog milliamp 2 Solid State Relay triac 1 3 DC Logic SSR 4 Loop 2 decirte cene 5 Output 4 Alarm Retransmission or Loop Power osx Elend DoD 0 Mechanical Relay 0 5 amp 24 1 Analog 1051111010 iaa eeaeee 2 Solid State Relay triac 0 5 amp 24 3 DC Logic SSR 4 Loop POoWer Leeds 5 Options Enter 0 if not desired Slidewire Feedback for Position Proportioning 24 VAC 24 VDC Operation F Slidewire and 24 VAC 24 VDC G Remote B Profile Controller Option C Remote Setpoint and Profile E Set of Five Digital Inputs
6. F lt E 1 4 DIN PROCESS CONTROLLER USER S MANUAL INDUSTRIES M535 V5 MAY 2002 Table of Contents of Contents Table of Contents PAGE CHAPTER 1 INTRODUCTION e exta deo nhe tna a cens 1 9395 9 E 1 Order Code Packaging Information 2 Where 2 2 nnn hei una le id nin 2 Text formatting in this manual eee 2 CHAPTER 2 BASIC INTERFACE 02 nerrieie crono recreo renuit Dru nnn erra 5 018 a TRENAS 5 ra PE E EE 5 EH 6 Basic Operating 7 PXEIOEGIe TEE 8 CHAPTER 3 INSTALLATION 2 iore ie idco e zac inae cendo 11 Mounting the Controller 11 WINO sas 12 Power InpUt acia retten Deus ia 13 Process Variable 13 Digital InpUt S reae tot e Ehre t e o 16 1 Digital Inputs with a Switch or Relay 16 2 Digital Inputs with an Open Collector 16 Remote Setpoint 16 Ou
7. ww men 44 Chapter 5 535 User s Manual Controller Set Up Set Up 18 ACK 2 Defines whether alarm 2 may be acknowledged ACK 2 D ENABLED Allows the alarm to be acknowledged DISABLED Prevents the alarm from being acknowledged while in alarm condition 19 POWER UP 2 Defines how alarm 2 will be treated on power up POWER UP 2 D NORMAL Alarm depends on process variable NORMAL ALARM Always power up in alarm regardless of process variable DELAYED Mustleave alarm condition and reenter before activating the alarm MESSAGE 2 20 MESSAGE 2 The ALARM 2 A 9 character message associated with alarm 2 To enter message The first character of third display will be flashing Press the 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 ALARM 2 21 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 whether a rate of change alarm is interpreted as a lost or broken NO ACTION process variable causing a trip to manual output P V BREAK D NOACTION RATETIME 23 RATE TIME Defines the time period over which a rate of change alarm condition is determined 1103600 seconds D 5seconds Access Set
8. pv 2 PV 2 RTD 3rd PV 1 pv 1 535 User s Manual Chapter 3 13 install Wire NOTE Typically in the U S negative leads are red Figure 3 6 PV1 and PV2 Wiring for Milliamp RTD and Voltage Inputs 14 For PV1 THERMOCOUPLE INPUT 2 WIRE RTD Jumper wire 3 WIRE RTD Same color Third leg 4 WIRE RTD Same color Third leg Same color DO NOTconnect 4th leg VOLTAGE INPUT pus Ex Transmitter s 22 Chapter 3 For PV2 THERMOCOUPLE INPUT 2 WIRE RTD Jumper wire 3 WIRE RTD Same Third leg of RTD 4 WIRE RTD Same color Third leg Do NOT of RTD connect 4th leg VOLTAGE INPUT an pom Transmitter 535 User s Manual C WEE 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 For PV2 MILLIAMP INPUT 2 wire transmitter with separate power supply MILLIAMP INPUT 2 wire transmitter with loop power supply Ren 0 535 User s Manual MILLIAMP INPUT 4 wire transmitter with loop power supply Input power for transmitter 4 20 mA output 4 from transmitter Figure 3 7 PV1 and PV2 Wiring for Milliamp Inputs with Internal and External
9. 12 535 User s Manual Table of Contents V Table of Contents of Contents vi Table of Contents 535 User s Manual Introduction _ CHAPTER 1 INTRODUCTION 35 serer EI Fromits surge resistant power supply to its rugged construction the 535 Thank you for selecting the 535 cess controller is designed to ensure the integrity of your process with maxi Process Controller the most mum reliability hour after hour day after day The isolated inputs and out sophisticated instrument in its class puts guard against the dangers of electrical interference the frontface meets It will provide you with years of NEMA 4X standards for watertight operation and exposure to corrosiveenvi reliable trouble free performance ronments and the solid metal housing and sturdy rubber keys enhance dura bility and ESD protection 535 has been engineered to be the industry s most user friendly process controller With three digital display areas two offering upto 9 characters of true alohanumerics the 535 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 dis play technology Additional operator friendly features include custom pro grammable alarm messages illuminated keys and an easy to use menu System The 535 is the most accura
10. OUT 3 PV 1 Figure A4 1 535 Rear Terminals for Calibration it CALIBRATE CAL VREF Figure 42 ANALOG IN PRESSACK 50000 PRESS MENU Flowchart Calibration Menus PRESS ACK PRESSIMENU ern ORs Power Down Attach 20mA Attach 20mA SET BOTH Jumpers PV1 20mA to PV1 PV2 20mA to PV2 If mA calibration values are CALIBRATE PRESS ACK ANA mA IN JUMPER mA 2 93 p PRESS 95 y PRESS MENU mA CALIB FAILED CALIBRATE PV 150C If mA calibration values are COLD JUNC PRESS ACK out of range PRESS ACK PRESSMENU CALIBRATE OUTPUT X ANLG OUT PRESS ACK PRESS MENU PRESS ACK PRESSMENU 0c700c0c00c0c0cc c ccc ccccclllcclc0c0 RESET T ene SKIPPED_ SKIPPED PRESS ACK ds MENU DATA PUSH MENU seconds TO RESET PRESS MENU before two RESET RARDWARE COMPLETED SCAN PRESS DISPLAY ONLY PRESS MENU PRESSMENU 777777 777777707777 SLIDEWIRE SLIDEWIRE TEST PRESS SN PRESS MENU PRESS ACK 535 User s Manual Appendix 4 A 7 Figure 4 3 Jumper Locations on the Microcontroller Circuit Board Figure A4 4 Input Calibration Wiring Hook up wires to multimeter PV1 WARNING ELECTRIC SHOCK HAZARD Terminals 1 and 2 carry live power DO NOT touch these terminals when power is
11. Remote Setpoint Option Use terminals 13 and 14 to connectthe remote setpoint signal see Figure 3 10 Figure 3 10 13 Remote Setpoint Terminals 16 Chapter 3 535 User s Manual C install Wire OUTPUT MODULES The 535 output modules are usedfor 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 onthe 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 e Outputs 1 2 and normally closed on the power supply circuit board e Output 4 is always configured for normally open and has reduced corresponding jumpers 3 are jumper selectable for normally open and P gjump voltage and current ratings see Specifications ine Power
12. NOTE See the glossary in Appendix 6 for explanation of ramping and target setpoint Also refertothe applications in Chapter 7 Operation NOTE Allalarms are software alarms unless tied to an output relay in the SET UP mode See Chapters 5 and 7 for details onalarms Figure 2 2 Before and After Acknowledging an Alarm NOTE Powering down the 535 acknowledges clears all latched alarms When powering up all alarms will be reinitialized 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 how to react to alarm conditions Alarm Indication liticons ALM 1 and or ALM 2 lit ACK key 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 AFTER To acknowledge an alarm s 1 To acknowledge Alarm 1 press ACK once 2 To acknowledge Alarm 2 press ACK twice 3 Ifboth alarms are activated press ACK once to acknowledge Alarm 1 then again to acknowledge Alarm 2 4 The message and alarm icon dissappear Latching Alarms If an alarmis setupto
13. On the following pages is the step by step guide to the TUNING menu parameters OPERATION Either Manual or for TUNING mode Automatic Control TUNING DISPLAY or SET PT DISPLAY MENU for OPERATION mode or ST PT for SET MENU FAST Figure 6 1 to return to UP mode for SET Access the Tuning Menu Block OPERATION mode UP mode SELF TUNE Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Ew ww se 535 User s Manual Chapter 6 63 Tuning 7 TUNING TUNING 1 ADAPTIVE Activates the self tune algorithm upon transfer to automatic control ADAPTIVE D DISABLED DISABLED obice 2 PRETUNE PRETUNE POWR BACK DISABLED PROP BND 1 RESET 1 RATE 1 MAN RST 1 CYCLETM 1 Activates the pretune algorithm if unitis under manual control To initiate the Pretune cycle press the A or V Confirm by pressing ACK within two seconds D NO POWR BACK Reduces setpoint overshoot at power up or after setpoint changes D DISABLED ENABLED PROP 1 Defines the proportional band for PID set 1 0 1 to 999 0 D 50 0 RESET 1 Defines the integral time for PID set 1 1 to 9999 seconds D 20seconds RATE 1 Defines the derivative time for PID set 1 Oto 600 seconds D 1second MAN RST 1 or LOADLINE 1 Defines the manual reset f
14. Repair Replacement Parts Operator Interface Assembly 535 632 Power Supply Circuit Board 535 730 Microcontroller Circuit Board 535 731 Option Circuit Board w no Options 535 720 Option Circuit Board w Set of 5 Digital Contacts 535 721 Option Circuit Board w Slidewire Feedback 535 722 Option Circuit Board w set of 5 Digital Contacts amp Slidewire Feedback 535 723 EPROM without Remote Setpoint Option 535 740 EPROM with Remote Setpoint Option 585 741 Lithium Battery 093 044 Jumper Kit Set of All Jumper Connectors 535 660 Gasket Kit 1 Panel Gasket amp 1 Bezel Gasket 535 662 Mounting Kit Mounting Collar amp 4 screws 535 761 Bezel Retention Screw Kit 535 663 Module Retention Kit for Outputs 1 3 Includes Retention Plate 535 664 Module Retention Kit for Output 4 Set of 5 Tie Wraps 535 665 Circuit Board Support Bezel Insert 535 075 Engineering unit labels 1 sheet 535 106 535 User s Manual Appendix 2 MOUNTING COLLAR A 3 Appendix 2 535 User s Manual Troubleshooting _ APPENDIX 3 TROUBLESHOOTING SYMPTOM PROBLEM SOLUTION Display will not light up Defective power source Check power source and wiring Improper wiring Correct wiring Blown in line fuse Check wiring replace fuse Unit not inserted in case properly or screws have no
15. 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 initiation of an input change or stimulus and the start of the resulting observable response 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 Appendix 6 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 in 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 in OPERATION Mode the setpoint deviation or output in TUNING or SET UP Mode the parameter or parameter menu disturbance An undesired
16. ing setpoint or output 535 User s Manual Chapter 7 Applications Figure 7 10 Staged Outputs Example OUT1 STOP was set to 33 and OUT2 STRT was set to 50 NOTE For an analog output module for retransmission thatwas not factory installed calibrate the output for maximum accuracy Refer to Appendix 4 for details on calibration 83 Applications NOTE To take advantage of multiple setpoints make sure that the NUMBER parameter inthe SPECIAL menu is set to a value greater than 1 Figure 7 11 Combinations of Closed Digital Inputs for Each Setpoint based on BCD logic closed contact 0 contact 84 5 Setparameters LOW RANGE X and HIGH RANGE X for the first retrans mission output to define the range of the transmitted signal in engineering units This can be useful in matching the input range of the receiving de vice 6 For any other retransmission output continue to scroll through this menu and setthe TYPE X LOW RANGE X and HIGH RANGE X for the second retransmission output H DIGITAL INPUTS Digital inputs can be activated in three ways A switch signal type the rec ommended type a relay or an 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 soft ware menus see the section on parameters in Chatper 5 There are 14 con tact types for the up to 5 digital
17. 0 375 of span T gt 0 C 0 10096 of span 0 250 of span T lt 0 C 0 250 of span 0 625 of span R S gt 500 C 0 150 of span 0 375 of span R S lt 500 C 0 375 of span 0 925 of span B gt 500 C 0 150 of span 0 375 of span B lt 500 C 0 500 of span 1 000 of span W W5 amp Platinel l 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 output Cycle Time 0 3 to 120 seconds On Off Deadband up to 15 of input range in eng units Up to eight sets of PID values may be stored in memory and selected automatically based on setpoint value process variable value or the corresponding local setpoint 8 1 5 8 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 a
18. 407 402 NOISE BAND 752 352 z 0 PROCESS X100 5 408 VARIABLE 407 4 0 48 Thermocouple 405 402 Range 401 328 F TO 752 r 400 328 80 120 160 200 240 TIME SECONDS Chapter 7 535 User s Manual Applications for process noise Attempting to do this will result in degraded controller performance The Noise Band is the distance the process deviates from the setpoint due to noise in percentage of full scale Figure 7 13 shows a typical process variable response in a steady state situation In this example the process noise is within a band of about 0 5 of full scale A noise band that is too small will result in tuning parameter values based on noise rather than the effects of load and setpoint changes If the noise bandis settoo small then Adaptive Tune will attemptto retune the controller too often This may resultinthe controller tuning cycling between desirable system tuning and overly sluggish tuning While the result may be better thanthat achieved with a non adaptive controller this frequent retuning is not desirable Ifthe noise bandis settoo large the process variable will remain within the noise band and the controller will not retune itself With too large a noise band important disturbances will be ignored and the controller will be indifferent to sluggish and oscillatory behavior Noise band settings are general
19. Access the Tuning Menu Block 63 Figure 7 1 Alarm Exambples itat eer itudin 75 Figure 7 2 Duplex with reverse and direct acting outputs 77 Figure 7 3 Duplex with direct and reverse acting outputs 77 Figure 7 4 Duplex with two reverse acting outputs 78 Figure 7 5 Duplex with a gap between 78 Figure 7 6 Duplex with overlapping outputs and output limits 79 Figure 7 7 Duplex with various relative gain settings 79 Figure 7 8 Duplex with one ON OFF 80 Figure 7 9 Duplex with two ON OFF outputs 80 Figure 7 10 Staged Outputs Example 83 Figure 7 11 Combinations of Closed Digital Inputs for Each Setpoint based ON BOD logi6 84 Figure 7 12 Pretune TYPE 1 2 and 3 with Adaptive Tune 90 Figure 7 13 Noise Band Calculation Example 92 Table of Contents 535 User s Manual Table of Contents of Contents FIGURE DESCRIPTION PAGE Figure 7 14 Noise Band Values for Temperature Inputs 93
20. CONFIG CTRL TYPE OUTPUT 4 LINE FREQ REM SETPT OUTPUT 2 OUTPUT 3 ANLG RNG 2 ANLG RNG 1 RNG 3 ANLG RNG 4 CONTACT 1 CONTACT 2 PV1 INPUT PV1 TYPE SP LO LIM CONTACT 3 CONTACT 4 CONTACT 5 LOOP NAME DEG F C K DECIMAL LINEARIZE LOW RANGE HI RANGE SP HI LIM SP RAMP FILTER OFFSET GAIN RESTORE PV2 INPUT PV2 SETUP FILTER CUST LINR 1ST INPUT CONTROL ALGORITHM ACTION 2 PV2 TYPE DECIMAL LINEARIZE LOW RANGE HI RANGE OFFSET GAIN RESTORE 1ST PV XTH INPUT XTH PV 15TH INPUT 15TH PV ACTION 1 LOW OUT HIGH OUT CCW TIME D SOURCE P P TYPE CW TIME MIN TIME S W RANGE OPEN F B ALARMS ALM TYPE 1 ALM 1 OUT CLOSE F B OUT1STOP OUT2STRT ALM SRC 1 ALARM SP 1 HIGH SP 1 LOW SP 1 DEADBAND 1 LATCHING 1 ACK 1 POWER UP 1 MESSAGE 1 ALM TYPE 2 ALM SRC 2 ALARM SP 2 HIGH SP 2 LOW SP 2 LATCHING 2 DEADBAND 2 ALM 2 OUT LATCHING 2 ACK 2 POWER UP 2 MESSAGE 2 FAULT OUTPUT REM SETPT TYPE V MA RSP LO RNG RSP HI RNG RSP HIGH TRACKING BIAS LOW BIAS HIGH RSP FIXED RETRANS 2 LOW RANGE 2 HI RANGE 2 TYPE X LOW RANGE 3 HI RANGE 3 TYPE 4 LOW RANGE 4 HI RANGE 4 SELF TUNE PRETUNE TUNE PT OUT STEP LOW LIMIT TIMEOUT NOISE BND RESP TIME DEAD TIME SPECIAL AUTO TRIP TRIP DEV DES OUTPT POWER UP PWR UP OUT PWR UP SP NO OF SP SECURITY SEC CODE SP ADJUST AUTO MAN SP SELECT ALARM ACK TUNING CONFIGURE SER COMM STATION BAUD RA
21. Defines the highest bias value that may be entered R 9999 to 99999 Minimum value is BIAS LOW D 1000 Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Ers mw ep wee ww 46 Chapter 5 535 User s Manual Controller Set Up Set Up 9 RSPFIXED Defines what happens if remote setpoint is lost while it is active and then is RSP FIXED restored REMOTE SP Returns to remote setpoint when itis restored D LOCAL Local setpoint remains active when RSP is restored RETRANS RETRANS 1 TYPE 2 TYPE 2 Defines what is to be retransmitted for output 2 D PV This refers to the linearized process variable SETPOINT This is the target setpoint RAMP SP Thisis the ramping or actual setpoint when the setpoint is ramping CTRL OUT This is the control output value 2 LOW RANGE 2 Defines the low endofthe range for output 2 in engineering units Does notappear LO RANGE 2 for type CTRL OUT D R 9999 to 99999 D Dependenton the process variable range 3 HIRANGE 2 Defines the high end of the range for output 2 in engineering units Does not HI RANGE 2 appear for type CTRL OUT 9999to 99999 D D Dependentonthe process variable range 4 TYPE 3 Defines what is to be retransmitted for output 3 D PV This refers to the linearized process variable TYPE 3 SETPOINT This is the target setpoint RAMP SP Thisis the ramping
22. GAIN 2 0 REL GAIN 1 0 REL 0 5 Figure 7 7 Duplex with Various Relative Gain Settings PID OUTPUT 535 User s Manual Chapter 7 79 Applications Figure 7 8 Duplex with One ON OFF Output Figure 7 9 Duplex with Two ON OFF Outputs 80 Notice that the relative gain setting does not affect output 1 In this example a relative gain setting of 2 0 curve 1 results in output 2 reaching its maximum value at a PID output of 25 A relative gain setting of 1 0 results in output 2 reaching its maximum value ata PID outputof 096 A relative gain setting of 0 5 results in output 2 reaching a maximum of 5096 at a PID output of 096 Duplex with one ON OFF output Areverse acting output 1 and adirect acting on off output 2 with a positive offset Relative gain does not apply when using duplex with an on off output The deadband setting for output2 works the same as the deadband in single on off control the deadband effect for output 2 is not illustrated here PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 DIRECT nee PID OFST 1 0 ON OFST 2 VALUE 100 ON LOW OUT 0 HIGH OUT 100 50 Out2 Offset 0 from Setpoint PID OUTPUT in Engineering Units Duplex with two ON OFF outputs Areverse acting on off output 1 and adirectacting 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
23. Power Supply NOTE To use loop power there must bea loop power module installed in the 3rd or 4th output socket Compare the controller product number with the order code in Chapter 1 to determine if the 535 has a loop power module installed To install a loop power module refer to Chapter 4 15 7 Digital Input s Digital inputs can be activated in three ways a switch signal type closure of arelay or an open collector transistor Digital inputs are only functional when that option is installed via hardware The controller detects the hardware and supplies the appropriate software menu 1 Digital Inputs with a switch or relay Figure 3 8 Digital input Wiring with a Switch or Wirethe switch relay between terminal 17 and the specific digital input Relay terminal Figure 3 8 e E N O Ci A Cc mno gt sopa Figure 3 9 2 Digital Inputs with an Open Collector Digital Input Wiring with an Open collector is also called a transistor Wire the transistor between Collector terminal 17 and the specified digital input terminal Figure 3 9 Screws must be tight to ensure electrical connection
24. RSPBIAS Defines the bias additive term applied to the remote set point 18 NO OF PID Defines the number of stored and available PID sets 19 PID TRIP Defines the variable used to select the various PID sets 20 TRIP 1 Defines the value that triggers a change to primary PID set 21 PROP BND 2 Defines the proportional band for PID set 2 22 RESET 2 Defines the integral time for PID set 2 23 RATE 2 Defines the derivative time for PID set 2 24 MAN RST 2 Defines the manual reset or load line for PID set 2 25 TRIP 2 Defines the value that triggers a change to the 2nd PID set 26 PROP BND 3 Defines the proportional band for PID set 3 27 RESET 3 Defines the integral time for PID set 3 28 RATE 3 Defines the derivative time for PID set 3 29 MAN RST 3 Defines the manual reset or load line for PID set 3 68 Chapter 6 535 User s Manual oo 30 TRIP 3 Defines the value that triggers a change to the 3rd PID set 31 PROP BND 4 Defines the proportional band for PID set 4 32 RESET 4 Defines the integral time for PID set 4 33 RATE 4 Defines the derivative time for PID set 4 34 MAN RST 4 Defines the manual reset or load line for PID set 4 35 TRIP 4 This defines the value that triggers a change to the 4th PID set 36 PROP BND 5 Defines the proportional band for PID set 5 37 RESET 5 Defines the integral time for PID se
25. or actual setpoint when the setpointis ramping CTRL OUT This is the control output value 5 LOW RANGE 3 LO RANGE 3 Definesthelow endofthe range for output 3in engineering units Does notappear fortype CTRL OUT D 9999 to 99999 D Dependenton the process variable range Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation ww ew ejes a v 535 User s Manual Chapter 5 47 Controller Set Up Set Up 6 HIRANGE 3 HI RANGE 3 Defines the high end of the range for output 3 in engineering units Does not D appear fortype CTRL OUT 9999to 99999 D Dependent on the process variable range 7 TYPE TYPE 4 Defines whatis to be retransmitted for output 4 D PV This refers to the linearized process variable SETPOINT This is the target setpoint e RAMP SP This is the ramping or actual setpoint when the setpoint is ramping e CTRL OUT This is the control output value LO RANGE 4 8 LOWRANGE 4 D Defines the low end of the range for output 4 in engineering units Does not appear for type CTRL OUT 9999 to 99999 D Dependenton the process variable range 9 HIRANGE 4 Defines the high end of the range for output 4 in engineering units Does not HI RANGE 4 appear fortype CTRL OUT ee D Dependent on the process variable range SELFTUNE SELFTUNE 1 TYPE Defines the type of self tuning algorithm that is availabl
26. walls is already at an even higher temperature Although the steam supply is reduced the process liquid s temperature continues to rise for a 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 illustrated in Figure 7 20 Have the PID controller position the steam valve but add a sensor by means of another 535 controller HEAT Figure 7 20 EXCHANGER Cascade Control of Product Temperature pressure sensor temperature sensor thatwill monitorthe steam pressure The pressure control system now creates a second feedback control loop which cascades from the first Hardware Configuration Configure Unit 1 for a 4 20mA output analog module for control 535 User s Manual Chapter 7 101 Applications e Configure Unit 2 for the optional Remote Setpoint see Chapter 4 Software Configuration 1 For Unit 1 a In CONFIG menu set CTRL TYPE to STANDARD b In PVINPUT menu set the PV TYPE parameter If type is V mA set LOW RANGE and HI RANGE parameters to match the transmitter range 2 For Unit 2 Setthe RSP input jumper in the mA position on the Microcontroller Circuit Board see Chapter 4 b Goto REM SETPT menu Set RSP LO RNG to 0 Set RSP HI RNG to 100 This will set the range of the remote setpoint to 0 TO 100 to corre
27. 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 definable 15 point straight line linearization function INPUT IMPEDANCE Current Input 250 ohms Voltage Input 1 Mohms Thermocouples 10 Mohms RTDs 10 Mohms UPDATE RATE Input is sampled and output updated 10 times per second Display is updated five times per second 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 mA INPUT SIGNAL FAILURE PROTECTION When input is lost output is commanded to a predetermined output 5 to 105 Thermocouple burnout is selectable for upscale or 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 ca
28. Aprocess wheretwo PID control loops needto interactto achieve optimum control Cascade control is commonly implemented in temperature control applications where the main control variable is affected by another variable i e pressure Example In Figure 7 19 we have a 535 set up to control a heat exchanger In a PID equipped heat exchanger pressure in the steam shell more quickly reflects fluctuations in the steam supply than does the process liquid s temperature raw v OCI materials ay AKAA K A KRK ARA K K A KKK manual peu ser ww ACK rast Figure 7 19 Heat Exchanger Control Loop for HEAT Steam Supply EXCHANGER steam temperature sensor 100 Chapter 7 535 User s Manual Applications Why In this example with PID control the average temperature of the liquid inthe heat exchanger is 80 butcan vary by as much as five degrees because the steam supply itself is not constant Fluctuations inthe pressure ofthe 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 for the increased heat from the steam to travel through the process liquid to reach the temperature sensor By the time the sensor registers the higher value and calls for a decrease in steam the process liquid near the
29. D SOURCE Forderivativeaction basedon error or deviation from setpoint choose DEVIATION Forderivative action based on process variable changes choose PV B ALARMS The 535 controller has two extremely flexible and powerful software alarms Thenumber of available outputs limits how alarms are linkedto relays A Global Alarm feature allows all alarms to be assigned to the same relay The 535 indicates an alarm condition by Lighting up the alarm icon s Displaying a custom message in the 3rd display Illuminating the ACK key if the alarm is acknowledgeable Software Configuration 1 Access the ALARM menu 2 Setvalues for the following parameters All possible values are shown ALM TYPE 1 and ALM TYPE 2 Specifies the type of alarm to implement Selection includes e HIGH ALARM High process variable alarm Occurs when the process variable ex ceeds the alarm setpoint e LOW ALARM Low process variable alarm Occurs whenthe process variable goes below the alarm setpoint HIGH LOW Combination of high and low alarms Occurs when the PV exceeds the individually set high or low setpoint BAND Creates a band centered around the control setpoint that is twice the alarm setpoint Alarm occurs when the process variable travels outside ofthis band The alarm is dependenton the control setpoint As the control setpoint changes the band adjusts accordingly For example if the control setpoint is 500 and the alarm se
30. Figure 7 15 Deadtime and Time 93 Figure 7 16 Square Root Linearization Formula 95 Figure 7 17 15 point Linearization 96 Figure 7 18 Load Eine Example oerte 97 Figure 7 19 Heat Exchanger Control Loop for Steam Supply 100 Figure 7 20 Cascade Control of Product Temperature 101 Figure 7 21 Ratio Control in Mixing Application 103 Figure A4 1 535 Rear Terminals for 7 Figure A4 2 Flowchart Calibration 7 Figure A4 3 Jumper Locations on the Microcontroller Circuit Board 8 Figure A4 4 Input Calibration 8 Figure A4 5 Thermocouple Cold Junction Calibration Wiring 9 Figure A4 6 Analog mA Input Calibration Wiring 10 Figure A4 7 Analog mA Input Jumper Positions 10 Figure A4 8 Milliamp Output Calibration Wiring 11 Figure A4 9 Output Module Menu Cycle 11 Figure A4 10 Slidewire Test Wiring
31. Manual Calibration 10 11 13 Onthe Microcontroller Circuit Board locate jumper locations marked PV1 and 2nd near the edge connector Reposition both jumper connectors in the 2nd location onto pins for V and TCA as shown in Figure A4 3 Reinsert chassis into the case and apply power Allow controller to warm up for at least 30 minutes The 2nd and 3rd displays should read CALIBRATE ANALOG IN CALIBRATE Menu ANALOG IN section Press MENU three times to reach the CALIBRATE ANLG OUT Menu Connect hook up wires to the terminals for the corresponding milliamp output modules Output 1 uses terminals 3 and 4 Output 2 uses terminals 5 and 6 Output 3 uses terminals 7 and 8 shown in Figure A4 8 Output 4 uses terminals 15 and 16 Attach the test leads from the multimeter to the wires and then plug the test leads into the meter Set the meter for DC milliamp Press ACK The 2nd display will read OUTPUT1 OUTPUT2 OUTPUTS or OUTPUTA depending on the module installation Press MENU to scroll to the outputtobe calibrated see Figure A4 9 The 3rd display should read 4 mA The multimeter should read a value close to 4 00 Wait one minute Use and V and FAST on the controller to change the meter s display to exactly 4 00 mA Press MENU The 3rd display should read 20 mA Letthis setting stabilize for 5 minutes Use A and V and FAST onthe con troller to change the meter s display to exactly 20mA To calibr
32. OD HIGH OUT 100 cting Outputs REL GAIN 1 0 PID OUTPUT Duplex with direct and reverse acting outputs Areverse acting output 1 andadirect acting output 2 with no offset no restrictive output limits and a neutral relative gain with PID control PARAMETER SETTINGS ACTION 1 DIRECT E ACTION 2 REVERSE Cool PID OFST 1 0 PID OFST 2 0 AM LOW OUT 0 HIGH OUT 100 REL GAIN 10 Figure 7 3 Duplex with Direct and Reverse Acting Outputs gt PID OUTPUT 535 User s Manual Chapter 7 77 Applications Duplex with 2 reverse acting outputs Two reverse acting outputs with no offset no restrictive output limits and a neutral relative gain with PID control PARAMETER SETTINGS ACTION 1 REVERSE 0 ACTION 2 REVERSE Cool PID OFST 1 0 PID OFST 2 0 LOW OUT 0 Duplex with Two Reverse Acting REL GAIN 1 0 Outputs PID OUTPUT Duplex with a gap between outputs Areverse acting output 1 and adirect acting output 2 react with apositive offset for output 1 and a negative offset for output 2 assume no restrictive output limits and a neutral relative gain with PID control On the graph a positive offset refers to an offset to the left of 5096 a negative offset is to the right of 50 PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 DIRECT Out2 PID OFST 1 VALUE Cool PID OFST 2 VALUE Figure 7 5 LOW OUT 0 Duplex with Gap Between Outputs OUT 100 REL GAIN 1
33. 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 analternative 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 outputto 0 Enter configuration and change the CLOSE F B value until the actuator just reaches its full closed position 11 Setthe parameter P PROP D B which is used to eliminate cycling of the motor A low deadband setting may result in motor overspin or cycling A high deadband will result in reduction of sensitivity To set Goto TUNING menu b Set P PROP D B to 5 c Place controller under Manual control d Changethe output percentage and observe ifthe valve stabilizes at the new value 535 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 prop
34. PID set 3 will be active e When using PID trip values a 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 the trip variable is less than the trip value The user can set the lowest trip point the low end of the process variable range but this is not required Adigital 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 cannot trip to other PID sets based on trip point or the digital input contact until Adaptive Tuning is disabled However if the PID setis tied to the corresponding local setpoint the active PID set values will change with the local setpoint Each PID set has 5 parameters that control its function proportional band reset rate manual reset or loadline and trip point For each set 2 thru 8 these values have to be manually set 1 Press MENU to access the TUNING menu 2 Set values for p
35. alarm setpointis setto 100 and the time base setto 10 the rate of change is also 10 units per second Chapter 7 535 User s Manual Applications In example A the process variable would only have to experience aten unit change over a short period of time while in Example B itwould re quire a 100 unit change over a ten second period Example A is much more sensitive than Example B In general for a given rate of change the shorter the time period the more sensitive the rate alarm BAND ALARM 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 N 2 to 4 LATCHING NO LATCH ACK 1 DISABLED DEVIATION ALARM IN ALARM CONDITION 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 N 2 to 4 LATCHING LATCH ACK 1 ENABLED ALARM SP 1 0 535 User s Manual Figure 7 1 Alarm Examples HIGH PROCESS VARIABLE ALARM 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 RL
36. algorithms for each output PID for the first and On Off for the second Go to the CONTROL menu Set ALGORITHM to PID ON OFF 3 To make the control action for each output independent of the other Go to the CONTROL menu Set ACTION 1 or ACTION 2to either DIRECT or REVERSE action based onthe diagrams in the output examples section Figures 7 2 through 7 8 4 Gotothe TUNING menu Set values for PID OFST 1 or ON OFST 1 and PID OFST 2 or ON OFST 2 These parameters allow the user to independently offset the point at which output 1 and output 2 become active PID OFSET units are in per cent 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 output 2 so that both are on in a small band around setpoint 5 Set MAN 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 Output 2 when using PID control 7 Goto 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 o
37. be latching for details see Chapter 5 then in general it must be acknowledged in order to clear the alarm and release the relay if applicable A non latching alarm will clearitself as soon asthe process leaves the alarm condition Chapter 2 Controller Operation 535 User s Manual Operation Limit Sequence An alarm can be configured to be both latching and non acknowledgeable In this case the alarm is acknowledgeable only after the process has left the alarm condition This is similar to the function of a limit controller More on Alarms For more details on how to set up alarms and for examples of various ways alarms can be set up refer to the section on Alarms in Chapter 7 535 User s Manual Chapter 2 Controller Operation 9 Operation 10 Chapter 2 Controller Operation 535 User s Manual CHAPTER 3 INSTALLATION MOUNTING THE CONTROLLER The 535frontface is NEMA 4X rated waterproof To obtain a waterproof seal between the controller and the panel follow these directions 1 The 535 fits in a standard 1 4 DIN cutout Mount the 535 in any panel with athickness from 06 in to 275 in 1 5 mm to 7 0 mm 2 Figure 3 1 shows the controller and panel dimensions The panel cutout must be precise and the edges free from burrs and waves Figure 3 1 Instrument Panel amp Cutout Dimensions 4 7 180 182 37 OVERALL LENGTH PANEL 3 770 95 76 1 180 29 97 p
38. communications is lost 8 DESIG SP DESIG SP Defines the value of the designated setpoint if communications is lost D R Any value inthe process variable range D Dependentonthe process variable range Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Er ww ew a v 535 User s Manual Chapter 5 53 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 It is recommended that these pages be photocopied so there will always be a master CONFIG Parameter Description Values 1 CTRL TYPE Defines fundamental controller Set Up 2 LINEFREQ Defines the power source frequency 3 PV SOURCE Defines how PV input is derived from PV1 and PV2 4 REM SETPT Selects function of the remote setpoint 5 OUTPUT2 Function of the second output 6 OUTPUTS Function of the third output 7 OUTPUT 4 Function of the fourth output 8 ANLG RNG 1 Output signal for the first output 9 ANLG RNG 2 Output signal for the second output 10 ANLG RNG 3 Output signal for the third output 11 ANLG RNG 4 Output signal for the fourth output 12 CONTACT 1 Operation of the first digital input 13 CONTACT 2 Operation of the second digital input 14 CONTACT 3 Operation of the third digital input 15 CONTACT 4 Operation of the fo
39. device which completes or interrupts a circuit electrically with no moving parts Appendix 6 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 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 device 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 the controller is currently acting upon 535 User s Manua
40. has traveled well outside the range When the communications is lost for longer than the communications shed time ERROR ROM CHECKSUM On power up a problem with the EPROM is detected Controller locks up until fixed OUT1 CONF or OUT2 CONF LOST F B LOST CJC ERROR BAD EEPROM NEEDS CAL ERROR BAD MODEL NUM CAL ERROR SEE MANUAL 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 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 C
41. needs repair b Complete shipping information for return of the equipment after repair The name 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 Shipthe equipment to the Moore Industries location nearest you The returned equipment will be inspected and tested at the factory A Moore Industries repre sentative 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 ANY CAUSE OF ACTION FOR BREACH OF ANY WARRANTY BY THE dd m HE COMPANY MAKES NO EXPRESS IMPLIED OR STATUTORY WARRAN ES INCLUDING ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS OR A PARTICULAR PURPOSE WITH RESPECT TO ANY GOODS OR SER ICES SOLD BY THE COMPANY THE COMPANY DISCLAIMS ALL WARRAN ES ARISING FROM ANY COURSE OF DEALING OR TRADE USAGE AND NY BUYER OF GOODS OR SERVICES FROM THE COMPANY ACKNOWL DGES THAT THERE ARE NO WARRANTIES IMPLIED BY CUSTOM OR 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
42. on A 8 Jumper locations for Analog Thermocouple and Milliamp calibration CALIBRATION JUMPERS SELECT V AND TCA PV INPUT JUMPER CONFIGURATION oo000000 000 00000000000 Preparation for all Input Calibrations Equipment for analog input calibration Precision 5 1 2 or 6 1 2 digit multimeter e g Fluke 88429 or HP3478A9 a 4 1 2 digit meter will sacrifice accuracy Four small pieces of wire Testleads with clips 2 Phillips screwdriver Additional equipment for thermocouple input e Precision thermocouple calibrator e g Micromite Il by Thermo Electric Instruments e Special limits grade Type T thermocouple wire 1 Disconnect power to the instrument 2 Remove chassis from case 3 Onthe Microcontroller Circuit Board locate jumper locations marked PV1 and 2nd near the edge connector Reposition both jumper connectors in the 2nd location onto pins for V and TC A as shown in Figure A4 3 4 Connect hook up wires between terminals 31 and 32 and the multimeter as shown in Figure A4 4 Setthe meter for DC volts 5 Reinsert chassis into the case and apply power The 2nd and 3rd display should read CALIBRATE ANALOG IN 6 Allowthe controller to warm up for at least 30 minutes 7 Pressthe ACK key to getto the first step parameter The2nddisplay should show CAL VREF the 3rddisplay should show a value close to 5 0000 8 Themultimeter should read a value in the ran
43. selection based on process variable D SP VALUE PID set selection based on setpoint DEV VALUE PID set selection based on deviation from setpoint TRIP 1 20 TRIP 1 Defines the value that triggers a change to the primary set 1 of PID values R The process variable range D Dependent on the process variable range D FOR EACH SET OF PID 2 THROUGH 8 you need to set up the following group of parameters X represents the PID set number Set up the param eters as they appear for each set of PID The controller designates the values for the active PID parameter in the third display with an on either side Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Eve ew ejes JO 66 Chapter 6 535 User s Manual 21 PROP BND X Defines the proportional band for PID set X PROP BND X 0 1 to 999 0 D 50 0 22 RESET X Defines the integral time for PID set X RESET X R 1 to 9999 seconds increments of 1 D 20 seconds 23 RATE X Defines the derivative time for PID set X RATE X Oto 600 seconds D 1 seconds 24 MAN RST X or LOADLINE X Defines the manual reset or load line for PID set X MAN RST X Oto 100 a D 0 25 TRIP X This defines the value thattriggers a change to the Xth set of PID values TRIP X R Theprocess variable range D D Dependenton the process variable range Access Set Up Return to Operation Next me
44. up parameters and 535 applications refer to Chapter 7 535 User s Manual Chapter 5 27 Controller Set Up Set Up m PARAMETERS MANUAL Within each menu are parameters for particular control functions Select val ues for each parameter depending onthe specific application Use the MENU key to access parameters for a particular menu the parameter name will re TUNE PT AUTOMATIC Figure 5 2 place the menu name in the 2nd display and the parameter value will show in Independent vs Dependent the 3rd display Parameters This chapter outlines all the available parameters for the 535 Some parameters are independent of any special configuration and others are dependent on the individual configuration This manual displays these two types of param eters differently refer to Figure 5 2 A special feature of the 535 called Smart Menus determines the correct parameters to display for the specific configu ration so not all the listed parameters will appear MANUAL PERATION 0 DISPLAY MEW FAST for TUNING mode TUNING DISPLAY or for SET UP SET PT for Figure 5 3 or SET PT mode FAST Configuration Flowchart to return to OPERATION mode for SET UP OPERATION mode mode to toggle through the 12 menu blocks in SET UP mode SER COMM 28 Chapter 5 535 User s Manual Controller Set Up Set Up CONFIGURATION AND OPERATION Figure 5 3 shows the relationsh
45. used for level control applications Pretuneis anon demand function Uponinitiation there is afive 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 Fromthis information the initial Proportional Band Reset and Rate P Land D values and dead time are calculated When using TYPE 2 or TYPE 3 Pretune the Noise Band NOISE BND and Response Time RESP TIME 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 Fortuning anon integrating process the process must be able to reach a Stabilization point after a manual step change and The process should not be subject to load changes while Pretune operates If these conditions are not fulfilled set the Adaptive Tune to run by itself Adaptive Tune CAUTION Adaptive Tune continuously monitors the process and natural disturbancesand Disable weeds Tuning pas makes adjustments in the tuning parameters to compensate forthesechanges Process conditions e g forshutdown tank draining etc Otherwise the 535 In order to make accurate calculations Adaptive Tune needs noise bandand will attempt to adapt the Tuning response time values Pretune TYPE 2 and TYPE 3 automatically calculate parameters to the temporary process these values These value
46. variable rather than PID output PARAMETER SETTINGS ACTION 1 REVERSE ACTION 2 DIRECT ON OFST 1 VALUE ON OFST 2 VALUE Offset1 sp 2 High PROCESS VARIABLE Range Chapter 7 535 User s Manual Applications D SLIDEWIRE POSITION PROPORTIONING CONTROL Slidewire position proportioning utilizes a slidewire feedback signal to determine the actual position of the actuator being controlled Hardware Configuration Thecontroller musthave the Slidewire Feedback option installed Refer to the order code in Chapter 1 for more information Thecontroller must have mechanical relays solid state relays or DC logic modules installed in the first two output sockets TheSlidewire does NOT have to be wired to the controller in order to set up position proportioning Software Configuration 1 To configure the controller before wiring the slidewire feedback signal to the controller complete these steps a Gotothe CONTROL menu Setavalue for PV BREAK Go to the SPECIAL menu Seta value for DES OUTPT Setavalue 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 Go to the CONTROL menu For S W RANGE specify the full range resistance ofthe slidewire from end to end With a 100 ohm slidewire this parameter should be set to 100 8 Scrollto
47. 0 0 L N 100 Offset 1 50 0 PID OUTPUT 78 Chapter 7 535 User s Manual Applications Duplex with overlapping outputs and output limits reverse acting output 1 anda direct acting output 2 with a negative offsetfor output 1 a positive offset for output 2 and restrictive high and low output limits with PID control This combination of offsets results inan 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 offset settings control action and relative gain setting with PID control PARAMETER SETTINGS ACTION 1 REVERSE ACTION2 DIRECT n i Out2 PID OFST 1 VALUE ea Cool PID OFST 2 VALUE 100 LOW OUT 10 HIGH OUT 85 REL GAIN 1 0 100 Figure 7 6 N Duplex with Overlapping Outputs NN and Output Limits 10 50 0 PID OUTPUT Duplex with various relative gain settings Areverse acting output 1 and adirect 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 Hee um PID OFST 1 0 PID OFST 2 0 100 LOW OUT 0 HIGH OUT 100 REL
48. 21 we would set RSP RATIO to 2 0 If the flow of Material B is measured at 50 gallons minute the effective remote setpoint value would be 2 times 50 or 100 The 535 controller would try to 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 Figure 7 21 Ratio Control in Mixing Applicatoin BOTTOM As viewed from rear flow sensor MATERIAL A 2 CONTROLLED STREAM MIXER MATERIAL B WILD STREAM flow sensor Hardware Configuration e Setthe process variable jumper and remote setpoint jumper to mA Make sure that both inputs are setupto acceptthe corresponding signal fromthe flow transmitters Wireasin Figure 7 21 Software Configuration 1 Make sure that the range of both inputs matches the range of the corresponding transmitter 535 User s Manual Chapter 7 103 Applications Go to the PV INPUT menu Set the HI RANGE and LOW RANGE parameters Go to the REM SETPT menu d Setthe RSP HI RNG and RSP LO RNG parameters 2 Adjust the ratio between the two streams a Goto TUNING menu b Setthe RSP RATIO parameter The value of this parameter will be multiplied by the remote setpoint signal to yield the effective remote setpoint 104 Chapter 7 535 User s Manual Menu Flowcharts APPENDIX 1 OWCHARTS PV SOURCE SET UP
49. 6 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 18 Figure 3 14 Milliamp Output Wiring 18 Figure 3 15 Position Proportioning Output Wiring 18 Figure 3 16 Serial Communications Terminals 19 Figure 3 17 535 Wiring with Limit Control 20 Figure 4 1 Location of Printed Circuit Boards for Hardware Cohfigui allo 21 Figure 4 2 The Microcontroller Circuit Board the Option Board and the Power Supply 22 Figure 4 3 Representation of Module 25 Figure 4 4 Install Communications Module onto Microcontroller Board 26 Figure 5 1 Menu Flowchart for Set 0 27 Figure 5 2 Independent vs Dependent Parameters 28 Figure 5 3 Configuration 28 Figure 6 1
50. 8 Duplex with a gap between outputs 78 Duplex with overlapping outputs and output limits 79 Duplex with various relative gain settings 79 Duplex with one ON OFF output 80 Duplex with two ON OFF outputs 80 D Slidewire Position Proportioning Control 81 E Velocity Position Proportioning Control 82 83 G Retrans MISSION ER On EE Ode eR PRU LL Ra eode 83 H Digital Inp ts reet nett eee e 84 Remote Setpoint certi ipee ci e eed 86 J Multiple Setpoint ennt 87 Multiple Sets of PID 87 Le POWSIDAGK 5 88 M Self Tune Powers 89 Pretune by 89 Pretune TYPE 1 and Adaptive 91 Pretune TYPE 2 or TYPE 3 and Adaptvie Tune 91 Adaptive Tune by 92 Self Tune with Multiple Sets 94 Self Tune with Time Proportioning Out
51. ER AC POWER 0 5 AMP 250 V FAST FUSE ACTING L1 L2 L1 LOAD FOR CONTROL POWER Limit Control Temperature applications where abnormally high orlowtemperature conditions pose potential hazards for damage to equipment product and operator For such applications we recommend the use of an FM approved temperature limit device in conjunction with the process controller This wiring example illustrates atypical application using the 535 Process Controller with a 353 Limit EARTH GROUND 535 PROCESS CONTROLLER FAST ACTING FUSE MERCURY RELAY FAST ACTING FUSE HIGH LIMIT MECHANICAL CONTACTOR L1 XXe i2 INDICATOR ON WHEN LIMIT TRIPS LIMIT CONTROLLER AC POWER OPTIONAL MOMENTARY SWITCH MANUAL RESET FOR LIMIT CONTROL L2 RELAY CONTACTOR COIL POWER incom 353 LIMIT CONTROLLER FUSE PROCESS SENSOR LIMIT SENSOR Chapter 3 535 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 NOTE Hardware configuration ofthe input signal The 535 controller comes factory set with the following OUR uS BEDS C e All specified modules and options installed for details refer to the Order engineer for details Code in Chapter 1 Process variable and remote setpoint set to accept a milliamp input Relay output
52. ION Compare the product number to the ordering code on page 3 to determine the outputs and options installed on the 535 The product number is printed on the label on the top of the controller case Included with this 535 are e 535 User s Manual mounting hardware e 1sheet of Engineering unit adhesive labels WHERE TO GO NEXT become more familiar with the 535 interface continue to Chapter 2 Forimportant hardware installation guidelines see Chapters 3 and 4 Foradetailed description of all the software menus and parameters of the 535 follow through Chapters 5 and 6 Appendix 1 can be used as a basic guideline to these parameters TEXT FORMATTING IN THIS MANUAL Feature Format KEYS SETPT DISPLAY Or ICONS OUT ALM MENUS CONFIG TUNING PARAMETERS CYCLE TM 1 MIN OUT2 PARAMETER VALUES OFF SETPOINT LAST OUT DISPLAY MESSAGES TOO HOT OUT 2 Chapter 1 535 User s Manual Introduction _ 535 0 0 Order Output 1 Control Code NOR 0 Mechanical Relay 5 1 Analog 2 Solid State Relay triac eee 3 DC Logic SSR drive 4 Output 2 Control Alarm or Retransmission e 0 Mechanical Relay 5
53. ION OUTPUT e PV2 Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation ww ew a v 535 User s Manual Chapter 5 43 Controller Set Up Set Up 13 ALARM SP 2 ALARM SP 2 Specifies the alarm set point for alarm 2 except HIGH LOW D For HIGH or LOW alarms If ALM SRC 2 OUTPUT If ALM SRC 2 any other type 0 0 to 100 0 LOW RANGE to HI RANGE D 0 0 D 0 For BAND alarms 11099999 D 0 For DEVIATION RATE alarms R 9999to 99999 D 0 14A HIGH SP 2 HIGH SP 2 Specifies the high alarm set point for alarm 2 of type HIGH LOW if ALM SRC 2 OUTPUT If ALM SRC 2 any other type 0 0 to 100 0 LOW RANGE to HI RANGE D 0 096 D 0 14B LOW SP 2 Specifies the low alarm set point for alarm 2 of type HIGH LOW LOW SP 2 If ALM SRC 2 OUTPUT If ALM SRC 2 any other type 0 096to 100 0 LOW RANGE to HI RANGE D 0 095 0 15 DEADBAND 2 Defines the deadband for alarm 2 If ALM SRC 2 OUTPUT If ALM SRC 2 any other type DEADBAND 2 0 1 to 100 0 11099999 16 ALM 2 OUT Selects the output number for alarm 2 ALM 2 OUT oo NOE 4 17 LATCHING 2 Defines the latching sequence of alarm 2 LATCHING 2 B LATCH LATCH e NOLATCH Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Eras wes
54. K MAN Closing contact places the controller in manual control atthe desig nated output percentage All locked manual contacts mustbe opened in order to return controller to automatic control UPKEY DOWN KEY Closingthe contact mimics the designated A or V key Usefulif con troller is mounted behind a window contact push buttons can be used to change setpoint values e DISP KEY Closing contact mimics the DISPLAY key scroll through display of the Setpoint Deviation and Output e FAST KEY Closing contact mimics the FAST key Use in conjunction with A DISPLAY and MENU keys MENUKEY Closing contact mimics the MENU key In OPERATION Mode pro vides entry to TUNING menu In SET UP or TUNING Mode ad 535 User s Manual Chapter 7 85 Applications NOTE There is a one second delay before a closed digital input takes action 86 vances through the menus 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 If morethanone 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 preced
55. Menu A 11 Hardware SCAM eode reiner ti sshd eee eer da deed a A 12 E OAE 12 Quick Calibration 12 APPENDIX 5 SPECIFICATIONS iiie i ener iere dei A 13 APPENDIX 6 GLOSSARY c A 17 APPENDIX 7 ISOLATION BLOCK DIAGRAM ener A 23 535 User s Manual Table of Contents iii Table of Contents of Contents List of Figures FIGURE DESCRIPTION PAGE Figure 2 1 Operator iirinn 5 Figure 2 2 Before and After Acknowledging an Alarm 8 Figure 3 1 Instrument Panel amp Cutout Dimensions 11 Figure 3 2 Attaching mounting collar eene 11 Figure 3 3 All 535 Terminal Assignment 12 Figure 3 4 AC Power Input Terminals 13 Figure 3 5 Process Variable Terminals 13 Figure 3 6 PV1 and PV2 Wiring for Milliamp RTD and Voltage Inputs 14 Figure 3 7 PV1 and PV2 Wiring for Milliamp Inputs with Internal and External Power Supply sse 15 Figure 3 8 Digital input Wiring with a Switch or Relay 16 Figure 3 9 Digital Input Wiring with an Open Collector 1
56. Next menu Next parameter Next value Access Tuning Return to Operation Eras wes ww 42 Chapter 5 535 User s Manual Controller Set Up Set Up 8 ACK 1 Defines whether alarm 1 may be acknowledged ACK 1 D ENABLED Allows the alarm to be acknowledged DISABLED Prevents the alarm from being acknowledged while in alarm condition 9 POWER UP 1 Defines how alarm 1 will be treated on power up POWER UP 1 D NORMAL Alarm depends on process variable ALARM Always power up in alarm regardless of PV DELAYED Must leave alarm condition and reenter before activating the alarm 10 MESSAGE 1 A 9 character message associated with alarm 1 To enter message The first MESSAGE 1 character of third display will be flashing Press the and W keys to scroll through the character set Press FAST key to advance to subsequent ALARM 1 characters Press the MENU to advance to next parameter D ALARM 1 11 ALM TYPE 2 Defines the type of alarm for alarm 2 ALM TYPE 2 HIGHALRM LOWALARM HIGH LOW Separate High amp Low alarm setpoints in one alarm BAND DEVIATION MANUAL Causes an alarm when in manual control REMOTE SP Causes an alarm when in Remote Setpoint RATE Selects a rate of change alarm D OFF Deactivates the first alarm 12 ALM SRC 2 ALM SRC 2 Selects the source ofthe value being monitored by HIGH LOW or HIGH LOW alarm 2 D PV SP e RAMPSP DEVIAT
57. PUT ALARM SP 1 and ALARM SP 2 Defines the point at which an alarm occurs For a RATE rate of change alarm it specifies the amount of change per RATE TIME period that mustoccur beforethe alarm activates A negative value specifies a nega tive rate of change Does not apply to HIGH LOW alarms HIGH SP 1 and HIGH SP 2 ForaHIGH LOW alarm defines the high setpoint at which an alarm oc curs LOW SP 1 and LOW SP 2 For a HIGH LOW alarm defines the low setpoint at which an alarm oc curs DEADBAND 1 and DEADBAND 2 Specifies the range through which the process variable must travel be fore leaving an alarm condition see alarm examples at the end of this section Prevents frequent alarm oscillation or chattering if the pro cess variable has stabilized around the alarm point ALM 1 OUT and ALM 2 OUT For any enabled alarm selects the output number to which the selected alarm will be assigned It is possible to assign both alarms to the same output relay thus creating a global alarm application LATCHING 1 and LATCHING 2 A latching YES alarm will remain active after leaving the alarm condi tion unless it is acknowledged A non latching NO alarm will return to the non alarm state when leaving the alarm condition without being ac knowledged 535 User s Manual Chapter 7 73 Applications Alarm Parameters Reference For Alarm 1 Parameter Description ALM TYPE 1 Type ALM SRC 1 Sou
58. R UP SP D LASTSP Powers up with the same setpoint local or LAST SP remote that was active prior to power down LOCAL Powers up using primary local setpoint REMOTE Powers up using remote setpoint if available 7 NO OF SP Defines the number of local setpoints up to 8 to be stored for selection by BCD binary coded decimal digital inputs or front SET PT key 1through8 D 1 ECURITY SECURITY SECH For configuring the security function SEC CODE 1 SEC CODE Defines the security code temporarily unlocking the instrument 9999 to 99999 D 0 2 SP ADJUST Defines lockout status setpoint changes SP ADJUST D UNLOCKED UNLOCKED LOCKED AUTO MAN Defines lockout status of the MANUAL key AUTO MAN D UNLOCKED UNLOCKED LOCKED Defines lockout status of the SET PT key SP SELECT D UNLOCKED UNLOCKED LOCKED 5 ALARMACK Defines lockout status of the ACK key ALARM ACK D UNLOCKED UNLOCKED LOCKED 6 TUNING TUNING Defines lockout status of the tuning parameters D UNLOCKED UNLOCKED LOCKED Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation ww eme a v 535 User s Manual Chapter 5 51 Controller Set Up Set Up 7T CONFIGURE CONFIGURE Defines lockout status of the configuration parameters UNLOCKED D UNLOCKED LOCKED SER COMM SER COMM 1 STATION Defines the unit s stat
59. R Drive Output e Output 1 is always Control 1 Respective jumper J1 J2 or J3 mustbe set to normally open for DC Logic output e Output 4 is always configured for normally open Terminals used Terminals used Terminals used Terminals used with Output with Output with Output with Output Module 1 Module 2 Module 3 Module 4 3 CD 5 CB 115 Load 4 6 8 Kb 16 KD 4 Milliamp Output e Output 1 is always Control 1 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 56 7 1507 m Load se 6 5 Position Proportioning Output with or without Slidewire Feedback POSITION PROPORTIONING UT Electric Motor Actuator OUTP CW Winding Winding Slidewire Wiper 0 1050 Ohm CW Actuator Supply Current Chapter 3 535 User s Manual ooo install Wire Mechanical relay or solid state relay modules must be installed in output sockets 1 and 2 When using velocity control no slide
60. 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 SAGE IN THE TRADE OF THE BUYER AND OF THE COMPANY AND THAT NY PRIOR DEALINGS OF THE BUYER WITH THE COMPANY DO NOT IM LY THAT THE COMPANY WARRANTS THE GOODS OR SERVICES IN ANY WAY ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY AGREES WITH THE COMPANY THAT THE SOLE AND EXCLUSIVE REMEDIES FOR BREACH OF ANY WARRANTY CONCERNING THE GOODS OR SERVICES SHALL BE FOR THE COMPANY AT ITS OPTION TO REPAIR OR REPLACE THE GOODS OR SERVICES OR REFUND THE PURCHASE PRICE THE COMPANY SHALL IN NO EVENT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES EVEN IF THE COMPANY FAILS IN ANY ATTEMPT TO REMEDY DEFECTS IN THE GOODS OR SERVICES BUT IN SUCH CASE THE BUYER SHALL BE ENTITLED TO NO MORE THAN A REFUND OF ALL MONIES PAID TO THE COMPANY BY THE BUYER FOR PURCHASE OF THE GOODS OR SERVICES 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 at its option replace repair or refund the purchase price for any of its manufactured products found upon return to the Com pany 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 an
61. T 1 Defines the operation of the first digital input SETPT 1 8 REM SETPT D MANUAL CONTACT 2 2ND SETPT 2ND PID ALARM ACK RST INHBT D AJR A STOP A T LOCK MAN UP KEY DOWN KEY DISP KEY FAST KEY MENU KEY COMM ONLY PV2 SWITCH 13 CONTACT2 Defines the operation of the second digital input D REM SETPT REM SETPT s MANUAL Return to Operation DISPLAY Access Set Up Eve ww 32 Next menu 2ND SETPT 2ND PID ALARM ACK RST INHBT D A R A STOP A T LOCK MAN UP KEY DOWN KEY DISP KEY FAST KEY MENU KEY COMM ONLY PV2 SWITCH Next parameter Eee Chapter 5 Assigns the first four digital inputs to select setpoints 1 through 8 via BCD signal Makes the remote setpoint active Trips the controller to manual control Makes the second setpoint active Makes the second set of PID values active Acknowledges alarms Deactivates the reset term Switches the control action Suspends the adaptive tune function Locks controller in manual control Remote A function Remote function Toggle between SP DEV or OUT Activates FAST key Activates MENU key Status readable only through communications Switches between PV1 and PV2 Makes the remote setpoint active Trips the controller to manual control Makes the second setpoint active Makes the second set of PID values active Acknowledges alarms Deactivates the reset term Switches the control action Suspends t
62. T LINEARIZATION Thermocouple and RTD Linearization For athermocoupleor 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 corresponding to the flow being measured To linearize this signal for use by the 535 the square root of PV Low Range Hi Range Low Range V input V high 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 15 the low end of the input signal range e g volt or 4 mA Figure 7 16 Square Root Linearization Formula Example PV range is 0 1000 Input signal range is 1 5 volts Input signal is 3 volts Therefore PV 0 1000 0 3 1 5 1 1000 5 707 535 User s Manual Chapter 7 95 Applications Figure 7 17 15 point Linearization Curve 96 the signal mustbe calculated The 535 has the capability to perform this square rootlinearization For the first 1 of the input span the inputis treated in a linear fashion Then itis a calculated value using the formula in Figure 7 16 Hardware Configuration Avoltage or milliamp input must be installed on the controller So
63. TE SHED TIME SHED MODE SHED OUT SHED SP DESIG SP 535 User s Manual Appendix 1 RATE TIME m Z c T gt 1 Menu Flowcharts Flowcharts TUNING ADAPTIVE MAN RST 1 RESET 1 RATE 1 PID OFST 1 PID OFST 2 NO OF PID PRETUNE POWR BACK 1PROP BND 1 CYCLE TM 1 DEADBAND 1 P PROP D B REL GAIN 2 CYCLE TM 2 DEADBAND 2 RSP RATIO RSP BIAS PID TRIP TRIP 1 RESET 2 RATE 2 MAN RST 2 TRIP 2 RESET 3 RATE 2 MAN RST 3 TRIP 3 RESET 4 RATE 4 MAN RST 4 TRIP 4 RESET 5 RATE 5 MAN RST 5 TRIP 5 RESET 6 RATE 6 MAN RST 6 TRIP 6 Up to 8 times depending on NO OF PID z rer lr np ng 2112212 12 12 S 2 2 2 00 3 ILo llalla N RESET 7 RATE 7 MAN RST 2 TRIP 7 RESET 8 RATE 8 MAN RST 8 TRIP 8 A 2 Appendix 1 535 User s Manual APPENDIX 2 PARTS LIST qs OPERATOR CIRCUIT CIRCUIT BOARDS BEZEL INTERFACE BOARD SUPPORT GASKET ASSEMBLY BEZEL INSERT shown with bezel insert in place ITEM CONTROLLER BODY shown with mounting collar in place PART Output Modules Mechanical Relay Module 535 600 Analog milliamp Module 535 601 Solid State Relay Module 535 602 DC Logic SSR Drive Module 535 603 Loop Power Module 535 604 RS 485 Communications Module 535 705
64. TION and WARNING Please heed these safety and good practice notices for the protection of you and your equipment Table of Contents of Contents CHAPTER 5 PAGE CONTROLLER SET UP cont d Text Formatting in This Manual 29 Software Menus and 30 ee icu 30 mA ANN UU ET 34 21 cti treo reparte anita 36 CUS IE EINE dieere tei esteri rr ed diae dace ads 38 CONTROL EQUUS 39 ALARMS ziii 41 gius 46 2 usb eiae re de ERR v 47 SELF TUNE EH 48 vires teres 50 Sizes 51 sismo 52 Parameter Value ae Rt kee 50 CHAPTER6 zc EAT 63 OVO IMIOW E 63 TUNING Menu Parameters sss 64 TUNING Parameter Value 68 Self Tune Messages and Troubleshooting 70 CHAPTER 7 APPLICATIONS 2c 71 A Control Type iuit r coe eee 71 AX CI ID nie 72 exuere E 76 Duplex with reverse and direct acting outputs 77 Duplex with direct and reverse acting outputs 77 Duplex with 2 reverse acting 7
65. Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation ww ew ej wes a v 535 User s Manual Chapter 5 45 Controller Set Up Set Up REM SETPT REM SETPT This menu appears only if parameter REM SETPT of the CONFIG menu ENABLED RSP TYPE 1 TYPEV mA 15420 Specifies the type of input signal that will be used for remote setpoint D 1 5 4 20 1 5 volt or 4 20 mA remote setpoint 0 5 0 20 0 5 volt or 0 20 mA remote setpoint RSP LO RNG 2 RSP LO RNG Specifies the engineering unit value corresponding to the lowest remote setpoint input value e g 4 mA R 9999to 99999 D 0 RSP HI RNG 3 RSP HI RNG 1000 Specifies the engineering unit value corresponding to the highest remote setpoint input value e g 20 mA 9999to 99999 D 1000 RSE TOW 4 RSP LOW Defines the lowest setpoint value to be accepted from the remote setpoint source RSP HIGH 9999 to 99999 D Dependenton RSP LO RNG value 5 RSP HIGH Defines the highest setpoint value from a remote setpoint source 9999 to 99999 D Dependenton RSP HI RNG value TRACKING 6 TRACKING NO Defines whether the local setpoints 1 to 8 will track the remote setpoint D NO YES BIAS LOW 7T BIASLOW 1000 Defines the lowest bias value that may be entered R 9999 to 99999 Maximum value is BIAS HIGH D 1000 BIAS HIGH 8 BIASHIGH 1000
66. Y 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 75 Applications NOTE The duplex output states vary depending upon 1 2 3 4 5 Control Type PID On Off etc Control Action DA RA Output Limits Output Gap or Overlay and 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 the TUNING menu 76 C DUPLEX CONTROL The Duplex control algorithm enables two discrete control outputs for the control loop Duplex controlis commonly used for applications that require both heating and cooling orwhen 2 control elements are needed to achieve the desired result Hardware Configuration 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 Tousedifferent
67. al 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 on Digital Inputs The SET PT key is lit when a setpoint other than the primary local setpoint is active K MULTIPLE SETS OF PID VALUES The 535 has the ability to store up to eight sets of PID values This can be a valuable feature for operating the controller under conditions which require different tuning parameters for optimal control There are various methods of selecting which set should be active These methods are explained in this section Software Configuration 1 Goto the TUNING menu 2 NO OF PID is the desired number of PID sets to be stored SP VALUE automatically sets this value equal to the number of stored local setpoints each PID set will be active when its respective local setpoint is active 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 535 User s Manual Chapter 7 87 Applications 88 Basic Operating Procedures A PID set can be selected in one of four ways For NO OF PID PV NUMBER the PID set 1 or 2 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
68. al 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 and 4 are not isolated from each other d E Milliamp Module Mechanical Relay SSR Driver Loop Power SSR Output L Earth referenced ground L Internal ground h 535 User s Manual Appendix 7 A 23 Isolation Block Diagram Block Diagram A 24 Appendix 7 535 User s Manual RETURN PROCEDURES To return equipment to Moore Industries for repair follow these four steps 1 Call Moore Industries and request a Returned Material Authorization RMA number Warranty Repair If you are unsure if your unit is still under warranty we can use the unit s serial number to verify the warranty status for you over the phone Be sure to include the RMA number on all documentation Non Warranty Repair If your unit is out of warranty be prepared to give us a Purchase Order number when you call In most cases we will be able to quote you the repair costs at that time The repair price you are quoted will be a Not To Exceed price which means that the actual repair costs may be less than the quote Be sure to include the RMA number on all documentation Provide us with the following documentation a Anote listing the symptoms that indicate the unit
69. all 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 and EPROM change Call factory for assistance Enter calibration menu and recalibrate the controller Call factory for assistance This is a fatal error and requires an EPROM or EEPROM change Call factory for assistance Install the 535 chassis into the actual case with which it was shipped then run calibration again If you experience further problems call factory for assistance 535 User s Manual Calibration APPENDIX 4 CALIBRATION To maintain optimum performance once a year calibrate the analog input the cold junction and milliamp output when used To achieve published accuracy specifications follow directions carefully and use calibrated instruments of like quality to those suggested Ifthe controller is moved into an alternate case or the hardware configuration is changed and the thermocouple input is needed recalibrate the cold junc tion for maximum accuracy Failure to do so may result in small junction tem perature 0 6 C 1 1 F Access the parts of the calibration menu as shown in Figure A4 2 our 1 i our ts Pv our2 PV2 zil i OUT 2 i oura fi i
70. arameters 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 L 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 to control parameters which in turn helps to eliminate overshoot of the Setpoint Software Configuration 1 Gotothe TUNING menu 2 Set POWR BACK parameter to ENABLED 3 Gotothe SELF TUNE menu 4 ForDEADTIME setthe value time thatthe controller should wait before invoking anoutputchange This valueistypically the deadtime ofthe process Or let Pretune calculate the dead time then complete just steps 1 and 2 above Chapter 7 535 User s Manual Applications M 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 TYPE2 Normally used for fast fluid or pressure processes TYPES Normally
71. ate another analog output Move the wires and test leads to the new output terminals Press MENU until the 3rd display shows 4mA for the corresponding output in the 2nd display Repeat step 9 11 To complete calibration press ACK key disconnect the power and place the jumper connectors back into their original position RESET MENU DATA Resets all parameter values back to their factory default values except for cali bration information Referto the flowchart in Figure A4 2 1 2 3 e 535 User s Manual Disconnect power to the instrument Remove chassis from case On the Microcontroller Circuit Board set jumpers at the 2nd PV location to V and TCA Press MENU key until the display shows RESET MENU DATA Press the ACK key 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 To try again press ACK key and then press MENU key within two seconds When complete return jumpers to their original positions Appendix 4 OUT 1 OUT 1 our 2 OUT 2 Connect to multi meter Figure A4 8 Milliamp Output Calibration Wiring TO OTHER CALIBRATION MENU Figure A4 9 OUTPUT X PRESS MENU OUTPUT X PRESS AC PRESS MENU EACH OUTPUT WILL GO THROUGH THIS CYCLE Output Module Menu Cycle Calibration Figu
72. ay to activate an alarm if there has been a power failure DELAYED Controller will never power up alarm regardless of system s alarm condition The system must leave and reenter the alarm condition before the alarm will activate This is typically used to avoid alarms during start up MESSAGE 1 and MESSAGE 2 Allows userto specify a nine character message to be displayed when the respective alarm is active If both alarms are active or any other diagnostic message is present the messages will alternate FAULT Activates an alarm ifthe process variable signalis lost Assignthis func tion to either Alarm 1 or Alarm 2 not both This action is in addition to the selected alarm type additive alarm function OUTPUT ForaRATE alarm selects the output action Use to obtain early indica tion ofa possible breakinthe process variable signal Select PV BREAK to have rate of change alarm take the same action as a detection of a break in the process variable signal where it trips to manual control at apredetermined output RATE TIME For RATEalarms 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 Ifthealarmsetpointis setto 10 andthe time base is setto 1 second the rate of change is 10 units per second B Ifthe
73. bove setpoint in the heat mode open loop Control system with no sensory feedback optimization The act of controlling a process at its maximum possible level of performance usually as expressed in economic terms output modules Plug in devices that provide power handling to enable process control These A 19 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 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 Powers 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 POWERTUNE G The Powers exclusive special self tuning function Consists of an on demand pretune that calculates PID values or provide preliminary PID values and pr
74. 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 earth ground A terminal used on the 535 to ensure by means of a special connection the grounding earthing of part of the controller engineering unit Terms of data measurement such as degrees Celsius pounds grams etc 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 535 User s Manual 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 inte
75. control action Suspends the adaptive tune function Locks controller in manual control Remote A function Remote function Toggle between SP DEV or OUT Activates FAST key Activates MENU key Status readable only through communications PV1TYPE JT C D CAUTION Set parameter values in the presented order dependent parameters are dynamically related and changing values of one can alter the value of another For example if SP LO is set to 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 Access Set Up Eve ww 34 Return to Operation Next menu DISPLAY D LOOPONE PV INPUT PV1 INPUT 1 PV1 Specifies the particular sensor range or input range for PV1 T C RTD VOLTAGE CURRENT mA J T C D DINRTD D 1 5V D 4 20mA ET C e JISRTD e 0 5V e 0 20mA KT C e SAMARTD 0 10mV BT C e 0 30 NT C 0 60mV RT C e 0 100mV ST C e 25mV TT C WT C W5T C PLAT II T C Next parameter Chapter 5 a v Next value Return to Operation DISPLAY Access Tuning 535 User s Manual Controller Set Up Set Up 2 DEG F C K Selects the PV1 temperature units if using athermocouple or RTD DEG F C K e CELSIUS e KELVIN 3 DECIMAL DECIMAL Specifies the PV1 decimal point position D XXXXX e XXXXX XXX XX XX XXX XXXXX 4 LINEARIZE Specifies if th
76. ct 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 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 control action proportional P Control action in which there is a continuous linear relation between the output and the input control action proportional plus derivative PD A control algorithm that provides proportional control with the addition of derivative action to compensate for rapid changes in process variable EN OMM control action proportional plus integral PI A control algorithm that provides proportional control with the addition of integral action to compensate for offsets between setpoint and process variable control action proportional plus integral plus de
77. d 23 RATE TIME Time period over which a rate of change alarm is determined 56 Chapter 5 535 User s Manual Controller Set Up Set Up CUST LINR Parameter Description Value 1 1stINPUT Input signal for the 1st point of the 15 point curve 2 1stPV Engineering unit value for the 1st point 3 XthINPUT Input signal for the Xth Point of the 15 point curve 4 XthPV Engineering unit value for the Xth point 5 2nd INPUT Input signal for the 2nd point of the 15 point curve 6 2ndPV Engineering unit value for the 2nd point 7 3rd INPUT Input signal for the 3rd point of the 15 point curve 8 3rdPV Engineering unit value for the 3rd point 9 4th INPUT Input signal for the 4th point of the 15 point curve 10 4thPV Engineering unit value for the 4th point 11 5th INPUT Input signal for the 5th point of the 15 point curve 12 5thPV Engineering unit value for the 5th point 13 6th INPUT Input signal for the 6th point of the 15 point curve 14 6thPV Engineering unit value for the 6th point 15 7th INPUT Input signal for the 7th point of the 15 point curve 16 7th PV Engineering unit value for the 7th point 17 8th INPUT Input signal for the 8th point of the 15 point curve 18 8th PV Engineering unit value for the 8th point 19 9th INPUT Input signal for the 9th point of the 15 point curve 20 9th PV Engineering unit value for the 9th point 21 10th INPUT Input si
78. d FAST together to reach the PV1 INPUT or PV2 INPUT menu 5 Press MENU until the OFFSET parameter appears in the 2nd display 6 Adjustthe calibration device to an output signal equal to the 096 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 input sensor If incorrect use the and keys to scroll to the cor rect value 8 Forlinearvoltage or mAinput Press MENU untilthe PV GAIN parameter ap pears in the 2nd display For thermocouple or RTD input go to step 9 9 Adjustthe calibration device to an output signal equal to the 100 range value for the particular sensor 10 Verify that the value shown in the 1st display is equal to 100 of the range value for the particular input sensor If the value is not correct use the A and 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 ak 4 535 User s Manual Specifications APPENDIX 5 SPECIFICATIONS ACCURACY TYPICAL MAXIMUM LINEAR Voltage 0 025 of full scale 0 100 of full scale Current 0 050 of full scale 0 150 of full scale RTD 1 0 0 050 of span 0 150 of span 0 1 0 095 of span 0 225 of span THERMOCOUPLE J K N E gt 0 0 060 of span 0 150 of span J K N E lt 0 0 150 of span
79. d line is a manual reset superimposed on the automatic reset action Adjusting the MAN RST tuning constant shifts the controller proportional band 100 50 Figure 7 18 Load Line Example Controller Output 0 20 40 60 80 100 Process Variable Location of Controller Span with respect to the setpoint Whenusedwith a proportional only or proportional derivative control algorithm the MAN RST parameter located in the TUNING menu is in effect manual reset However when the automatic reset term is present the reset action gradually shifts the proportional band to eliminate offset between the setpoint and the process In this case load line provides an initial shift at which the reset action begins Load line is adjusted by observing the percent output required to control the process and then adjusting the load line to that value This minimizes the effect of momentary power outages and transients Load line may also be adjusted to give the best response when bringing the load to the desired level from a cold start Q SECURITY The 535 security system is easily customized to fit a system s needs Software Configuration NOTE SEC CODE does not appear 1 Goto SECURITY menu unless all functions are unlocked 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 opera
80. d not to Buyer s customers or the users of Buyer s products un less Buyer is an engineering contractor in which case the policy shall extend to Buyer s immediate customer only This policy shall not ap ply 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 gt gt lt The Interface Solution Experts www miinet com 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 China sales mooreind com cn Tel 86 21 68406724 FAX 86 21 50623585 United Kingdom sales mooreind com Tel 01293 514488 FAX 01293 536852 United States info miinet com MOORE Tel 818 894 7111 FAX 818 891 2816 INDUSTRIES 8536 7200 rax 02 8525 7206
81. e Chapter 4 535 User s Manual 6 change module 4 Output Module 4 on the Option board is also held in place by a tie wrap Snip tie wrap to remove module as shown in Photo 6 7 Figure 4 3 shows a representation of an output module Inspect the module s to make sure that the pins are straight 8 Toinstall any module align its pins with the holes in the circuit board and carefully insertthe module in the socket Press down on the module until it is firmly seated refer to Photo 8 6 Snip Tie Wrap 8 Add Change Module 9 Replace tie wraps for all the modules the Retention Plate and Output Module 4 with new ones before reassembling the controller Failure to use the tie wraps may resultin loosening of the module and even tual failure All separately ordered modules should come with a tie wrap Extra sets of tie wraps are available by ordering Part 535 665 10 Rejoin the circuit boards by aligning the pins of their connectors then squeezing 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 Toreattachthe board assemblyto the frontface assembly align the boards with the open area on top into the slots of the font face assembly The clips should snap into place 12 Toreassemble the controller properly orientthe chassis with board open ing on top Align the circuit board
82. e TYPE e PRETUNE Allows the operator to initiate Pretune only e ADAPTIVE Allows the operator to initiate Adaptive Tune only DISABLED BOTH Allows the operator to initiate both Pretune and Adaptive Tune D DISABLED Both Pretune and Adaptive Tune are disabled 2 PRETUNE PRETUNE Defines the type of pretune algorithm that is available TYPE 1 D TYPE 1 Normally used with slower thermal processes TYPE 2 Normally used with faster fluid or pressure processes TYPES Normally used with level control applications 3 TUNEPT TUNE PT Definesthe PV value at which the output will switch off during a TYPE 1 pretune Helps prevent overshoot AUTOMATIC R Any value in PV input range D AUTOMATIC Controller defines this point low end for Automatic Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Ers mw me wee ww Jv 48 Chapter 5 535 User s Manual Controller Set Up Set Up 4 OUT STEP Defines the output step size in absolute percent during a TYPE 2 or TYPE 3 OUT STEP pretune 50 to 50 0 D 10 0 5 LOW LIMIT Defines the lower most limit the process variable can reach during pretune LOW LIMIT before aborting D R Any value inthe process variable range D Dependentonthe process variable range 6 HILIMIT Defines the upper most limit the process variable can reach during pretune HI LIMIT before aborting D R Anyvalueinth
83. e PV1 inputis to be linearized NOTE T C s and RTD s are auto matically linearized NONE D NONE SQR ROOT Square root linearization is activated CUSTOM 15 point custom linearization curve is activated 5 LOWRANGE LOW RANGE Specifies the engineering unit value corresponding to the lowest PV1 input D value e g 4 mA 9999 to 99999 Max is HI RANGE D Dependent on the input selection 6 HI RANGE HI RANGE Specifies the engineering unit value corresponding to the highest PV1 input value e g 20mA D R 9999to 99999 Min is LOW RANGE D Dependent on the input selection Defines the lowest setpoint value that can be entered from the front panel only D 9999 to 99999 Max is SP HI LIM Min is LOW RANGE D Dependentonthe LOW RANGE value 8 SPHILIM Definesthehighestsetpointvaluethatcanbe enteredfromthe frontpanelonly D R 9999to 99999 Min is SP LO LIM Maximum is HI RANGE D Dependent on HI RANGE Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation ww ew ejes a v 535 User s Manual Chapter 5 35 Controller Set Up Set Up 9 SPRAMP SP RAMP Defines the rate of change for setpoint changes D OFF Deactivates this function 11099999 per hour 10 FILTER FILTER Specifies the setting for the low pass PV1 inputfilter 503354 R Oto 120 seconds D Oseconds 11 OFFSET OFFSET De
84. e process variable range D Dependentonthe process variable range 7 TIMEOUT TIMEOUT This defines the execution time limit for pretune before aborting 8101500 minutes D 1500minutes 8 MODE Defines the control mode after pretune is completed or aborted AUTOMATIC MANUAL D AUTOMATIC 9 NOISE BND NOISE BND Defines the noise band to be used by the adaptive tuning algorithm 0 1560 10 of the process variable range D 0 2 10 RESP TIME Defines response time to be used by the adaptive tuning algorithm 101032000 seconds D 7200seconds 11 DEAD TIME Defines the amountoftime requiredfor process to begin to respondto an output change used by POWERBACK algorithm 0 1 seconds to 7200 0 seconds D 0 1 seconds RESP TIME DEADTIME Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation ww ew ejes JO e 535 User s Manual Chapter 5 49 SPECIAL AUTO TRIP TRIP DEV D DES OUTPT POWER UP LAST MODE PWR UP OUT Controller Set Up Set Up SPECIAL 1 AUTO TRIP Defines the condition under which the 535 will automatically trip to automatic control from manual control upon start up D OFF Deactivates this function e RISING PV Will trip when a rising process variable is within the specified deviation from the setpoint FALLNG PV Willtripwhen a falling process variable is within the specifi
85. e the next parameter PRETUNE 10 Press ACK to begin Pretuning The 3rd display will show the message EXECUTING 11 When is complete the 3rd display will show COMPLETED for two seconds and then return to the current menu display The controller will automatically transfer to automatic control upon completion of Pretune if set to do so or upon manual transfer Figure 7 12 illustrates the operation of Pretune TYPE 1 with Adaptive Tune NOaP WON Pretune TYPE 2 or 3 amp Adaptive Tune 1 Goto SELF TUNE menu 2 Setthe TYPE parameter to BOTH 535 User s Manual Chapter 7 91 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 attemptto adapt its tuning parameters to the temporary process conditions Disable adaptive tuning by 1 In the TUNING menu change ADAPTIVE to DISABLED through the keypad or 2 Closing the appropriate digital input see Digital Input section in this chapter Figure 7 13 Noise Band Calculation Example 92 3 Setthe PRETUNE parameter to TYPE 2 or TYPE 3 4 DO NOT Enter values for NOISE BND and RESP TIME The Pretune algorithm will calculate these values 2 Make sure that the process is reasonably stable and place the controller under manual cont
86. ed from other inputs and outputs within the same block CONTROLLER ARCHITECTURE The 535 Controller hardware can be configured as follows Inputs One universal process variable input is standard Available options include remote setpoint slidewire feedback and 5 digital inputs Outputs Four outputs are available See Ordering Information RS 485 Communications Available as option with any configura tion 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 THERMOCOUPLES RANGE RANGE 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 Ww 32 to 4172 0 to 2300 w5 32 to 4172 0 to 2300 Platinel II 148 to 2550 100 to 1399 Continued on following page Appendix 5 A 13 Specifications RTDs RANGE RANGE C 100 Pt DIN 328 to 1562 200 to 850 328 0 to 545 0 200 0 to 285 0 100 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 1to5 0105 Millivolts DC Oto
87. ed deviation from the setpoint 2 TRIP DEV Defines the deviation from setpoint atwhich the controller will trip to automatic For AUTO TRIP RISING PV For AUTO TRIP FALLING PV R 99999t00 R 01099999 D 0 D 0 3 DES OUTPT If a digital inputis defined to trip the controller to manual mode this designates the output value after the trip LAST OUT means that the output value will be equal to the last output value while in automatic Choose values based on the process Standard Control On Off Control Velocity Prop Control 510 105 ON CW D LASTOUT D OFF CCW D OUTS OFF 4 POWER UP Defines the control mode upon power up D LASTMODE Will power up in the same mode prior to power down PRETUNE Will Pretune on every power up Recommended for TYPE 1 pretune only MANUAL AUTOMATIC 5 PWR UP OUT Defines the output of the controller if powering up in manualmode LAST OUT means that the output value will be equal to the last output value while in automatic Choose values based on the process Standard Control On Off Control Velocity Prop Control e b5to 105 ON OW D LASTOUT D OFF COW D OUTS OFF Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation erar wes Srasr wenu ww v menu 50 Chapter 5 535 User s Manual Controller Set Up Set Up 6 PWR UP SP Defines the setpoint upon power up PW
88. emove the 20mA input from the PV1 terminals and attach itto the PV2 ter minals see Figure A4 6 Make sure the terminal connections are fastened tightly and that a20mA 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 current is flowing then press ACK to calibrate the PV2 input 14 Ifthe controller briefle displays mA CALIB COMPLETED PV2calibration was successful andthe analog milliamp calibration procedure has been completed If calibration is complete power down Place the jumpers into their original positions see Chapter 4 15 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 not necessary to calibrate them Ifthe milliamp outputs are being used for accurate retransmission of data itis rec ommended that each output with an analog module be calibrated annually to maintain optimal performance Equipment needed 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 Testleads with banana clips 2 Phillips screwdriver 1 Disconnect power to the instrument 2 Remove chassis from case Appendix 4 535 User s
89. en power is on WARNING Terminal 9 must be grounded to avoid potential shock hazard and improved noise immunity to your system 12 6 Insertthe four mounting collar screws from the rear ofthe collar Gradually 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 Powers 535 controllers are thoroughly tested calibrated and burned in at the factory so the controller is ready to install Before beginning read this chapter thoroughly andtake great care in planning a system A properly designed system can help preventproblems such as electrical noise disturbances and dangerous extreme conditions 1 For improved electrical noise immunity install the 535 as far away as possible from motors relays and other similar noise generators 2 Donotrun low power sensor input lines in the same bundle as AC power lines Grouping these lines in the same bundle can create electrical noise interference 3 All wiring and fusing should conform to the National Electric Code and to any locally applicable codes 4 An excellent resource about good wiring practices is the IEEE Standard No 518 1982 and is available from IEEE Inc 345 East 47th Street New York NY 10017 212 705 7900 Diagrams on the next three pages serve as guides fo
90. en When a locked function is attempted the operator will have the opportunity to enter the security code Ifthe correct security code is entered the operator has full access The security feature is reactivated after one minute of keypad inactivity Ifthe security code is forgtton the security feature can still be overridden The security override codeis IPAE aa Storethis number in a secure place and blacken outthe code in this manual to limit access R RESET INHIBITION Reset Inhibition is useful in some systems either atthe start up of a process or whena sustained offset of process variable from setpoint exists In conditions like these the continuous error signal may cause the process temperature to greatly overshoot setpoint Any of the digital inputs may be set up so that the contact closure disables the reset action sets it to zero Software Configuration 1 Gotothe CONFIG menu 2 Set corresponding parameter s CONTACT 1 to CONTACT 5 to RST INHBT S PROCESS VARIABLE READING CORRECTION Conditions extraneous to the controller an aging thermocouple out of calibration transmitter lead wire resistance etc can cause the display to indicate a value other than the actual process value The PV OFFSET and PV GAIN parameters can be usedto compensate for these extraneous conditions NOTE This feature is provided as a convenience only Correcting the cause ofthe erroneous reading is recommended 1 Goto the PV INPUT m
91. en setpoint changes DEVIATION Derivative term will react when setpoint changes 3 ACTION 1 Defines the action of the first control output ACTION 1 v RC REVERSE D REVERSE 4 PVBREAK Defines the manual output level if the process variable input is lost Choose values based on the process type PV BREAK Standard Control On Off Control Velocity Prop Control D e 5to105 ON CW D 0 D OFF COW D OUTS OFF 5 LOW OUT Defines the lowest output value that can be achieved in automatic control R 0 100956 Maxis HIGH OUT D ox Oo 0 Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Ers me eme Eesge JO e 535 User s Manual Chapter 5 39 Controller Set Up Set Up 6 HIGH OUT HIGH OUT Defines the highest output value that can be achieved in automatic control 100 0 100 Min is LOW OUT D 100 7 ACTION 2 ACTION 2 Defines the action of the second control output DIRECT D DIRECT REVERSE 8 P P TYPE P P TYPE Defines the type of position proportioning algorithm Choose values based on the process D Feedback option installed Feedback option not installed D SLIDEWIRE e SLIDEWIRE e VELOCITY D VELOCITY 9 CCW TIME CCW TIME Defines the time it takes a motor to fully stroke counter clockwise R 1to200 seconds D 60seconds 10 CW TIME Defines the time it takes a motor to fully stroke clockwise CWTIME R 1to200 seconds D 60sec
92. ence 2 Any digital input can be overridden by another digital input a keyboard operation 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 inputcloses and selects the 2nd setpoint and thenadifferentsetpointis selected through the keyboard the keyboard selection takes precedence 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 Refer to the order code in Chapter 1 Before configuring the software make sure the corresponding jumper is set properly Refer to Chapter 4 to check or change jumper positions Software Configuration 1 Goto the REM SETPT menu 2 RSP TYPE defines the input signal range e g 4 20 3 RSP LO RNG RSP HI RNG define the range of the remote setpoint in engineering units The correct range will be dependent on the source of the remote setpoint signal 4 RSP LOW and RSP HIGH set limits on the remote setpoint value in engineering units 5 TRACKING determines whether or not the controller will revert to a local setpoint if the remote setpoint signal is lost This prevents a process upset due to a sudden change in setpoint 6 BIAS LOW and BIAS HIGH set limits on an operator entered bias value 7 RSP FIXED determines t
93. endix 5 535 User s Manual 6 GLOSSARY adaptive control Control in which automatic means are used to change the type or influence or both of control parameters in such a way as to improve the performance of the control system adaptive tune A component of the 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 535 User s Manual alarm manual A type of alarm set up to occur when the controller is put into manual mode of o
94. enu 2 Set PV OFFSET This parameter either adds or subtracts a set value from the process variable reading in engineering units For example if the ther mocouple was always reading 3 too high the parameter could be set to 3 to compensate 3 Set PV GAIN This multiplies the deviation from the low end ofthe process variable range by the gain factor and then adds itto the value ofthe low end Chapter 7 535 User s Manual Applications ofthe range to arrive at the adjusted process variable value For example if the process variable range is 50 to 650 and the process variable reading is 472 a PV GAIN of 995 would yield an adjusted process variable equal to 472 50 x 995 50 470 With a combination of both offset and gain factors just about any inaccuracy in the sensor or transmitter can be compensated T 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 systemthat communicates ata high rate over long distances Typicallimitations 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 communicati
95. essages loop name errors etc In TUNING or SET UP mode the value or choice of parameter shown in the 2nd display ICONS LIT OUT Indicates either 1 relay output is energized or 2 analog output is greater than 0 OUT ALM1 Indicates the respective alarm one is active ALM2 Indicates the respective alarm two is active 535 User s Manual Chapter 2 Controller Operation 5 Operation FAST FAST FAST FAST MANUAL SET PT DISPLAY DENG ACK KEYS FAST Has no independent function Press to modify the function of another key see below MANUAL Press to toggle between manual and automatic control When lit indicates the unit is under manual control SET PT Press to select the active SP When lit indicates that a setpoint other than the primary e g RSP SP2 is active DISPLAY Press to toggle through values in the 2nd display for setpoint ramp ing setpoint deviation PV1 PV2 output and valve position each if available In Tuning or Set Up mode press to return controller to Operation mode dis play will show current setpoint Press to increase the value or selection of displayed parameter FAST A Press to scroll through values at a faster rate V Press to decrease the value or selection of displayed parameter FAST V Press to scroll through values at a faster rate ACK Press to acknowledge an alarm s When lit indicates
96. et 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 atime proportioning output use as short of a cycle time as possible within the constraint of maintaining a reasonable life on relays contacts or heating elements Self Tune with Control Valves In many systems utilizing a control valve the point at which the control valve begins to stroke does not coincide with 096 output and the point at which it completes its stroke doesn t coincide with 10096 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 manualthe control output was slowly increased and itwas noted thatthe control valve started to stroke at 1896 and at 91 it completed its stroke In this case LOW OUT should be set at 1896 and HIGH OUT at 9196 Note that when output limits are used the full output range from 5 to 105 is available in manual control N 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 Whenthe ramping function is activated the c
97. fines the offsetto PV1 in engineering units D 0 GAIN 12 GAIN Defines the gain to PV1 1 000 R 0 100to 10 000 D 1 000 13 RESTORE RESTORE Defines the control mode when a broken PV1 signal is restored LAST MODE D LASTMODE MANUAL AUTOMATIC PV2INPUT PV2 INPUT 1 PV2SETUP Defines function of PV2 D SAME AS PV1 All PV2 parameters are set to the same values PV2 SETUP as PV1 no further parameters will appear SAME AS PV1 NOT PV1 Enables user to enter different values for the following PV2 parameters Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation erar wes Eras m ww 36 Chapter 5 535 User s Manual Controller Set Up Set Up 2 PV2TYPE Selects the particular sensor or input range for PV2 PV2TYPE T C RTD VOLTAGE CURRENT mA D JT C D DINRTD D 1 5V D 4 20mA e ETC e JISRTD e 0 5V e 0 20mA e KT C e SAMARTD 0 10mV e BT C 0 30mV e NTC 0 60 mV e RTC 0 100mV e ST C e 25 e TTC WTC W5T C e PLAT IT C 3 DECIMAL Specifies the PV2 decimal point position DECIMAL D XXXXX XXXXX XXXXX XXAXXX XXXXX 4 LINEARIZE LINEARIZE Specifies if the PV2 inputisto be linearized Thermocouples and RTD s are automatically linearized D NONE SQR ROOT Square root linearization is activated 5 LOW RANGE LOW RANGE Specifies the engineering unit value corresponding to the l
98. ftware Configuration 1 Goto the PV INPUT menu 2 Set LINEARIZE to SQR ROOT Custom Linearization Custom linearization allows virtually any nonlinear signalto be linearized using a 15 point straight line approximation curve see Figure 7 17 Typical 15th 10th PV VALUE in engineering units 1st 5th 10th 15th INPUT VALUE in milliamps or voltage applications are linearizing signals from nonlinear transducers or controlling volume based on level readings for irregularly shaped vessels To define the function enter data point pairs the engineering units corresponding to a particular voltage or current input Software Configuration 1 Goto the PV INPUT menu 2 Setthe parameter LINEARIZE to CUSTOM 3 Goto the CUST LINR menu 4 Enter values for the 1ST INPUT and 1ST PV data points All the input parameters define the actual milliamp or voltage input All the PV parameters define the corresponding process variable value in engineering units Itis 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 Chapter 7 535 User s Manual Applications interpolated using a straight line relationship between the points The only limitation is thatthe resulting linearization curve must be either ever increasing or ever decreasing P LOAD LINE Loa
99. ge 4 9750 5 0250 Use the A and V and FAST keys on the controller until the display on the controller matches the meter reading Appendix 4 535 User s Manual Calibration 9 Press MENU key The 2nddisplay should show CAL 120mV The 3rd display should show avalue 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 and the multimeter Press ACK when done The 2nd display should show CALIBRATE the 3rd display should show ANA mA IN 11 Turn off power to the unit 12 For thermocouple input proceed to the Thermocouple Cold Junction Cali bration 13 For milliamp input proceed to Analog Milliamp Input Calibration 14 For milliamp output calibration let the controller warm up for 10 minutes then skip to step 5 of Milliamp Output Calibration 15 If calibration is 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 multi meter also and are nottouching each other 2 Tum on powerto the unit and let controller warm up for 30 minutes in the nor mal horizontal position while the unit is warming up the rear face of the con troller should be vertical not horizontal 3 Presst
100. gnal for the 10th point of the 15 point curve 22 10th PV Engineering unit value for the 10th point 23 11th INPUT Input signal forthe 11th point of the 15 point curve 24 11th PV Engineering unit value for the 1 1th point 25 12th INPUT Input signal for the 12th point of the 15 point curve 26 12th PV Engineering unit value for the 12th point 27 13th INPUT Input signal for the 13th point of the 15 point curve 28 13th PV Engineering unit value for the 13th point 29 14th INPUT Input signal for the 14th point of the 15 point curve 30 14th PV Engineering unit value for the 14th point 31 15th INPUT Input signal for the15th point of the 15 point curve 32 15th PV Engineering unit value for the 15th point 535 User s Manual Chapter 5 57 Controller Set Up Set Up CONTROL Parameter Description Value 1 ALGORITHM Control algorithm used 2 D SOURCE Variable used to determine the derivative value ACTION 1 Action of the first control output 4 PVBREAK Output level if the process variable input is lost 5 LOW OUT Lowest output value that can be achieved in automatic control 6 HIGH OUT Highest output value that can be achieved in automatic control 7 ACTION 2 Action of the second control output 8 P P TYPE Type of position proportioning algorithm 9 CCWTIME Time it takes a motor to fully stroke in the CCW direction 10 CWTIME Time it takes a motor to fully stroke in the CW direction 11 MIN TIME Minimu
101. he MENU key until the display indicates CALIBRATE COLD JUNC i an 4 Pressthe 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 not be accurate red 6 Setthethermocouple calibrator to an output value of 150 C for a Type T ther mocouple and allow the calibrator to stabilize for a few minutes 7 Press ACK to initiate calibration of the cold junction 8 Formilliamp output calibration proceed to Milliamp OutputCalibration Let Figure 4 5 the controller warm up for 10 minutes then skip to step 5 Thermocouple Cold Junction 9 If calibration is complete power down then place all the jumpers in their Calibration Wiring original positions as specified in Chapter 3 ANALOG MILLIAMP INPUT CALIBRATION 1 Removethethermocouple wires if present fromterminals 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 sureterminal screws are securely tightened but do not connect the wires yet leave inputs floating 2 Turn on power to the 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 Power down the controller and remove chassis f
102. he adaptive tune function Locks controller in manual control Remote A function Remote function Toggle between SP DEV or OUT Activates FAST key Activates MENU key Status readable only through communications Switches between PV1 and PV2 Next value Access Tuning Return to Operation DISPLAY 535 User s Manual Controller Set Up Set Up 14 15 CONTACT 3 Defines the operation of the third digital input D REM SETPT MANUAL 2ND SETPT 2ND PID ALARM ACK RST INHBT D AJR A STOP A T LOCK MAN UP KEY DOWN KEY DISP KEY FAST KEY MENU KEY COMM ONLY PV2 SWITCH CONTACTA Defines the operation of the fourth digital input D Access Set Up REM SETPT MANUAL 2ND SETPT 2ND PID ALARM ACK RST INHBT D AJR A STOP A T LOCK MAN UP KEY DOWN KEY DISP KEY FAST KEY MENU KEY COMM ONLY PV2 SWITCH Err me 535 User s Manual Return to Operation Makes the remote setpoint active Trips the controller to manual control Makes the second setpoint active Makes the second set of PID values active Acknowledges alarms Deactivates the reset term Switches the control action Suspends the adaptive tune function Locks controller in manual control Remote A function Remote function Toggle between SP DEV or OUT Activates FAST key Activates MENU key Status readable only through communications Switches between PV1 and PV2 Makes the remote setpoint active Trips the cont
103. he point where the process variable reaches 63 ofits final value See DT DeadTime Figure 7 15 t TimeConstant Example RT Response Time After a stimulus e g valve movement ifittakes 300 seconds for a 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 Figure 7 15 Deadtime and Time Constant 535 User s Manual Chapter 7 93 Applications 94 around the setpoint If the Response Time is set too long response to an off setpoint condition will be sluggish It is generally better to use too long a 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 ac tive upon initiation of the tuning function The controller cannot trip to other PID sets based on trip point or the digital input contact until Adaptive Tuning is disabled However ifthe PID is tied to the corresponding local setpoint the active PID set values will change with the local setpoint Each PID set has 5 parameters that control its function proportional band reset rate manual reset or loadline and trip point For each set 2 thru 8 these values have to be manually set 1 Press MENU to access the TUNING menu 2 Set values for parameters 1 thru 20 these include the first PID set 3 Press MENU to access these parameters for each additional PID s
104. he signal to which the controller will revert when alost RSP is restored fixed Options are to stay in local or automatically return to remote setpoint 8 Tobias or ratio the remote setpoint value Goto the TUNING menu b Set RSP BIAS and RSP RATIO values Chapter 7 535 User s Manual Applications Basic Operating Procedures After configuring the hardware and software select the remote input by pressing the SET PT key until RSP shows in the display e using a digital input J MULTIPLE SETPOINTS The 535 can store up to eight local setpoints and use a remote setpoint One application of this feature is configuring the controller to restrict operators to discrete setpoint choices The 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 Usethe SET PT key to scroll to each local setpoint and set it to the desired value with the A or W keys 4 Tolink the PID sets to the corresponding local setpoint Go to the TUNING menu Set NO OF PID to SP NUMBER For details on multiple sets of PID refer to the next section in this chapter Basic Operating Procedures To select a set point toggle the SET PT key to scroll through the setpoints The displayed setpoint becomes active after two second of key inactivity The digital inputs can also be used to select the active setpoints A single digit
105. ing input trips the controller to manual Opening input reverts controllerto automatic Override by using MANUAL key a commu nications command or trip to automatic function 2ND SETPT Closing inputchanges active setpointto the 2nd local setpoint Open ing input reverts controller to previous setpoint digital input Over ride by selecting a different setpoint via the SET PT key acommu nications command or other digital inputs e 2ND PID Closing input changes active set of PID values to 2nd set Opening input bases active set of PID on rules defined in PID TRIP and TRIP 1 to TRIP 8 Override input only by directly linking PID set to the ac tive setpoint and changing the active setpoint ALARMACK Closing input acknowledges all active alarms Opening input re NOTE Only alarms configured to be arms the controller If the digital input remains closed it does not acknowledged are affected by this continue to immediately acknowledge alarms as they become ac digital input tive e INHBT Reset Inhibition Closing input deactivates l integral term regard less of the PID values being used Opening input activates I term if applicable e D AJR A Direct Acting Reverse Acting Closing input reverses action of the first control output from directto reverse orreverseto direct Open ing reinstates original action STOP A T Closing input temporarily disables Adaptive Tuning Opening input enables it e LOC
106. inputs Hardware Configuration This optional feature is only available if ordered originally from the factory Product 535xxxxxxDx00 The up to five digital inputs share acommon ground Software Configuration 1 Goto the CONFIG menu 2 Set parameters CONTACT 1 through CONTACT 5 only those available will shown by assigning the desired function to each output Choices are SETPT 1 8 For CONTACT 1 only Allows the controller to use the first four digital inputs to select a setpoint see Figure 7 11 If the state of these in puts remains constant the controller will continue to use the selected setpoint unless overridden Override the set of digital inputs by se lecting a different setpoint by using SET PT key or through commu nications or by using the fifth digital input to select the remote or 2nd setpoint To rearm this set of digital inputs the DIN combina tion must change Setpoints DIN1 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 0 SP6 0 0 5 7 X X X 0 SP8 0 0 0 X REM SETPT Closing input changes active setpoint to remote setpoint Opening reverts controller to previous setpoint Override by selecting a dif ferent setpoint viathe SET PT key acommunications command or Chapter 7 535 User s Manual Applications other digital inputs NOTE The second display does not MANUAL change when tripping to manual from a closed digital input Clos
107. ion address STATION R 11099 OFF Disables the communications function D 1 2 BAUDRATE BAUD RATE Defines the baud rate e 1200BPS 2400BPS 4800 D 9600 5 e 19200 5 3 CRC Defines whether CRC cyclic redundancy check is being calculated D YES NO 4 SHED TIME SHEDTIME Definesthetime interval between communications activity beforethe controller determines that communications is lost sheds 110512 seconds D OFF 5 SHED MODE Defines the state of the controller if communications is lost sheds SHED MODE D LASTMODE Remain in automatic or manual control last mode LAST MODE before losing communications MANUAL Tripto manual control e AUTOMATIC automatic control 6 SHED OUT SHED OUT Defines the output if the unit sheds and trips to manual control Choose values D based onthe process Standard Control On Off Control Velocity Prop Control 5to 105 ON CW D LAST OUT D OFF CCW D OUTS OFF Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation erar wes ww JE v men 52 Chapter 5 535 User s Manual Controller Set Up Set Up 7 SHEDSP Defines the setpoint status if communications is lost SHED SP D LASTSP Continues to use setpoint that was active prior LAST SP to losing communications DESIG SP Goes to a designated setpoint value if
108. ion is detected 20 OUTPUT Output if the rate of change alarm is tripped 21 RATE TIME Time period over which a rate of change will be determined 535 User s Manual Chapter 5 59 Controller Set Up Set Up REM SETPT Parameter Description Values 1 TYPEV mA Input signal to be used for remote setpoint 2 RSP LORNG Eng unit value for low remote setpoint input value RSP HIRNG Eng unit value for high remote setpoint input value 4 RSP LOW Lowest accepted setpoint value from remote setpoint source 5 RSP HIGH Highest accepted setpoint value from remote setpoint source 6 TRACKING Whether the local setpoint will track the remote setpoint 7 BIASLOW Lowest bias value that may be entered 8 BIAS HIGH Highest bias value that may be entered 9 RSPFIXED Status upon restoration of lost remote setpoint RETRANS Parameter Description Values 1 TYPE2 Whatisto be retransmitted for retransmission output 2 2 LOWRANGE 2 Low end of range in eng units for retransmission output 2 3 HIRANGE 2 High end of range in eng units for retransmission output 2 4 TYPE 3 What is to be retransmitted for retransmission output 3 5 LOW RANGE 3 Low end of range in eng units for retransmission output 3 6 HIRANGE 3 High end of range in engl units for retransmission output 3 7 4 Whatisto be retransmitted for retransmission output 4 8 LOWRANGE 4 Low end of range in eng units for retransmission ou
109. ions CHAPTER 7 APPLICATIONS The 535 controller provides a variety of user programmable control features and capabilities The following topics are included in this chapter NOTE Controller capabilities depend upon the specified hardware option Control Type oett 71 1 Remote 86 cite cote ressent 97 Alas ncn iei ini cte 72 J 87 Resetlnhibition 98 C Duplex 76 Multiple Sets of PID Values 87 S Process Variable Reading Correction 98 D Slidewire Position Proportioning Control 81 L 88 T Serial Communications 99 E Velocity Position Proportioning Control 82 Self 89 U Cascade 100 Staged Outputs 83 N 94 V 108 G Retransmission 83 Input Linearization 95 Hi Digital Inputs ote P Load Dirigentes 97 A CONTROL TYPE Software Configuration 1 Gotothe CONTROL menu 2 Forthe parameter ALGORITHM selec
110. ips among the different modes of the 535 and the configuration menus SETUP menus can only be accessed from manual control To transfer the 535 from automatic to manual control press MANUAL e To access the SET UP menus hold down FAST and press MENU The MENU key will illuminate and CONFIG will appear in the 2nd display Toaccess the parameters for a particular menu press MENU e Toselecta parameter value use and V Press MENU to advance to the next parameter or FAST MENU to advance to the next menu e Toadvance to the next menu press FAST MENU TUNING mode and the TUNING menu can be accessed from either au tomatic or manual control To access the tuning menu press MENU Toreturn controller to manual control press DISPLAY or SET PT A key to these functions as shown below appears atthe bottom of every page in the menu section of this chapter Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Eras menu Aj v WHERE TO GO NEXT Forinformation aboutallthe 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 aboutthe installed options on the 535 compare the product label on top of the controller to the order code in Chapter 1 mount the controller and configure the wiring of the 535 for input
111. ircuit boards into the grooves on the top and bottom Insert module onto connectors 909090000 Front of controller circuits boards still attached to front face pot fa Figure 4 4 Install Communications Module onto Microcontroller Board of the case Press firmly on the front face assembly until the chassis is all the way into the case If it is difficult to slide the chassis in all the way make sure the screws have been removed they can block proper alignment and that the chassis is properly oriented 6 Carefullyinsertand align screws Tighten them until the bezel is seated firmly against the gasket Do not overtighten 26 Chapter 4 535 User s Manual Controller Set Up Set Up CHAPTER 5 SOFTWARE CONFIGURATION The software configuration menus of the 535 contain user selected variables Figure 5 1 that define the action of the controller Read through this section before making Menu Flowchart for Set Up any parameter adjustments to the controller When initially setting up the This is a Menu controller cycle through all the parameters in each Menu Press the MENU FAST to advance to the next Menu Its name will show in the 2nd display MENU FAST This is a menu Parameter Duas i The name shows in the 3rd display value for the current parameter H In this manual independent parameters appear Use arrow keys to select a value press as white text o
112. l es ee setpoint deviation from The difference of the number of units 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 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 assigned to a device for communications 535 User s Manual 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 o
113. ly between 0 196 and 1 096 with most common settings of 0 296 or 0 396 Figure 7 14 shows the conversion of peak to peak noise to an appropriate noise band for each T C type amp RTD INPUT TYPE Figure 7 14 Noise Band Values for B E J K N R S T W WS PLATINEL RTD 0 1 RTD Temperature Inputs 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 2 0 1 0 1 0 1 0 2 0 1 0 2 0 2 0 1 0 1 0 1 0 3 0 1 0 2 0 2 0 3 0 1 0 2 0 2 0 1 0 1 0 1 0 4 0 1 0 2 0 2 0 5 0 2 0 2 0 2 0 2 0 2 0 2 0 5 0 1 0 2 0 3 0 6 0 2 0 3 0 3 0 2 0 2 0 2 0 6 0 1 0 3 0 3 0 7 0 2 0 3 0 3 0 2 0 3 0 2 0 6 0 2 0 3 0 4 0 8 0 2 0 4 04 0 3 0 3 0 3 0 7 0 2 0 4 0 4 0 9 0 3 0 4 0 4 0 3 0 3 0 3 0 8 0 2 0 4 0 5 1 0 0 3 0 4 0 4 0 3 0 4 0 3 0 9 0 2 0 4 0 5 14 Peak to Peak Noise F o o 1 j o O1 05 NM Oo Control Output o 3 Set RESP TIME Final PV Theresponse timeisthe mostcritical value in Adaptive Tuning Response time represents the time lag from change in valve position controller 63 of Final PV 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 inthe process variable The Time Constantisthe interval oftime betweenthe start ofthat observable response and t
114. m 2 ALM SRC 1 Selects the source of the value being monitored by HIGH LOW or HIGH LOW ALM SRC 1 D PV SP RAMPSP DEVIATION OUTPUT PV2 Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Ew ww ew a v 535 User s Manual Chapter 5 41 Controller Set Up Set Up 3 ALARMSP 1 ALARM SP 1 Specifies the alarm set point for alarm 1 except HIGH LOW For HIGH or LOW alarms If ALM SRC 1 OUTPUT If ALM SRC 1 any other type 0 0 to 100 0 R LOW RANGE to HI RANGE D 0 0 D 0 For BAND alarms R 11099999 D 0 For DEVIATION or RATE alarms R 9999 to 99999 D 0 4A HIGH SP 1 HIGH SP 1 Specifies the high alarm set point for alarm 1 of type HIGH LOW If ALM SRC 1 OUTPUT If ALM SRC 1 any other type PI 0 0 to 100 0 LOW RANGE to HI RANGE D 0 0 D 0 4B LOW SP 1 Specifies the low alarm set point for alarm 1 of type HIGH LOW LOW SP 1 If ALM SRC 1 OUTPUT If ALM SRC 1 any other type 0O 096to 100 0 R LOWRANGE to HI RANGE 5 DEADBAND 1 Defines the deadband for alarm 1 DEADBAND 1 If ALM SRC 1 OUTPUT If ALM SRC 1 any other type 2 0 1 to 100 0 R 11099999 D 2 D 2 6 ALM 1 OUT Selects the output number for alarm 1 ALM 1 OUT PH NON E e 3 e 4 LATCHING 1 7 LATCHING 1 Defines the latching sequence of alarm 1 NOE D LATCH e NOLATCH Access Set Up Return to Operation
115. m time for the motor to be on before taking action 12 S W RANGE Full range resistance of the slidewire 13 OPEN F B Feedback ohm value when the valve is open 14 CLOSE F B Feedback ohm value when the valve is closed 15 OUT1 STOP Stopping point for control output 1 when staging outputs 16 OUT2 STRT Starting point for control output 2 when staging outputs 58 Chapter 5 535 User s Manual Controller Set Up Set Up ALARMS Parameter Description Value 1 ALM TYPE 1 Type of alarm for alarm 1 2 ALM SRC 1 Source of value being monitored by HIGH or LOW alarm 1 3 ALARMSP 1 Alarm setpoint alarm 1 4 DEADBAND 1 Dead band for alarm 1 5 ALM 1 OUT Output number for alarm 1 6 LATCHING 1 Latching sequence for alarm 1 7 1 Whether alarm 1 may be acknowledged 8 POWERUP 1 How alarm 1 will be treated upon power up 9 MESSAGE Nine character mesage associated with alarm 1 10 ALM TYPE 2 Type of alarm for alarm 2 11 ALM SRC 2 Source of value being monitored by HIGH or LOW alarm 2 12 ALARM SP 2 Alarm setpoint for alarm 2 13 DEADBAND 2 Dead band for alarm 2 14 ALM 2 OUT Output number for alarm 2 15 LATCHING 2 Latching sequence for alarm 2 16 ACK 2 Whether alarm 2 may be acknowledged 17 POWER UP2 How alarm 2 will be treated upon power up 18 MESSAGE 2 Nine character message associated with alarm 2 19 FAULT Alarm status if a fault condit
116. n 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 1000 Accuracy 9 25 Appendix 5 Mechanical relay module SPDT electromechanical relay Resistive load rated at 5 amps at 120 240 VAC Normally open or normally closed selection is made by jumper Output 4 is rated at 0 5 amps at 24 VAC and is always normally open Solid state relay triac module Resistive load rated at 1 amp at 120 240 VAC Output 4 is rated at 0 5 amps at 24 VAC These outputs are normally open DC logic SSR drive module 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 Duplex control is available if output modules are installed in the first and second output sockets Position proportioning control with feedback is available if mechanical or solid state relay modules are installed in the first two output sockets and the slidewire feedback option is installed Slidewire feedback range is 0 to 1050 ohms Velocity position proportioning control is available by installing mecha
117. n black and dependent MENU parameters appear as black text on white INDICATOR Use the arrows keys to enter D 7 4 amp This is a parameter Value numerical values and or move 7 These values appear in the 3rd display press MENU FAST replacing the parameter name Go to next Menu Block In this manual parameter graphics indicate the default factory setting If the default value is dependent on other variables D is shown through the selection group MENUS CAUTION In Set Up mode there are 13 sets of options that control different aspects of 535 d pde s n real operation in Tuning mode there is one Each set of options is called a menu manual ore aian When traversing the two modes the menu names appear in the 2nd display CONFIG Mode selection and input output hardware assignments PV1INPUT 1stprocess variable input options PV2 INPUT 2nd process variable input options CUST Linearization curve options for PV1 input CONTROL Control options ALARMS Alarm options REM SETPT Controller remote setpoint options RETRANS Retransmission output options SELF TUNE Self tune algorithm options SPECIAL Special feature options SECURITY Security functions SER COMM Serial Communications options requires comm board and NOTE For information about the TUNING Tuning parameters configuration see Chapter 6 Tuning menu mode refer to Chapter 6 For more information about set
118. ng parameters 7 Use SHED OUT to specify an output level if the unit sheds and trips to manual control 8 Tospecify acontrol setpoint in case the host is supervising the setpoint if the 535 sheds Set SHED SP to DESIG SP and then set the parameter 535 User s Manual Chapter 7 99 Applications DESIG SP to the desired setpoint U 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 based on 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 controlleris now used to adjust the setpoint of the secondary 535 controller which then positions the valve Cascade Control is typically used for the following Aslow responding process with a significant lag time Aprocess requiring more advanced or tighter control
119. nical 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 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 OUTPUT If an alarm is tripped the alarm message will show the ACK key will illuminate if acknowledgeable and the ALM icon will light If the alarm is tied to the first available non control output the 1 below the ALM icon will light Similarly if the alarm is tied to the second non control output the 2 below the ALM will light The availability of outputs determines how many alarms can be tied to relays 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 ou
120. nu Next parameter Next value Access Tuning Return to Operation Ew ww JO 535 User s Manual Chapter 6 67 Tuning 7 TUNING Parameter Definition Values 1 ADAPTIVE Activates the self tune algorithm 2 PRETUNE Activates the pretune algorithm 3 POWR BACK Reduces setpoint overshoot 4 PROP BND 1 Defines the proportional band for PID set 1 5 RESET 1 Defines the integral time for PID set 1 6 RATE 1 Defines the derivative time for PID set 1 7 MAN RST 1 Defines the manual reset for PID set 1 8 CYCLE TM 1 Defines the cycle time for control output 1 9 DEADBAND 1 Defines the dead band for control output 1 10 P PROP D B Defines the dead band setting for a slidewire output 11A PID OFST 1 For duplex applications defines the offset for the first output 11B ON OFST 1 For On Off applications defines the offset for the first output 12A PID OFST 2 For duplex applications defines the offset for the 2nd output 12B ON OFST 2 For On Off applications defines the offset for the 2nd output 13 REL GAIN 2 Defines the adjustment factor for the output 2 prop band 14 CYCLE TM 2 Defines the cycle time for control output 2 15 DEADBAND 2 Defines the dead band for control output 2 16 RSP RATIO Defines the multiplier applied to the remote set point 17
121. 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 Ibs AMBIENT TEMPERATURE Operative Limits 0 to 50 C 32 to 122 F Storage Limits 40 to 70 C 40 to 158 F RELATIVE HUMIDITY 10 to 90 non condensing VOLTAGE AND FREQUENCY Universal power supply 90 to 250 VAC 48 to 62 Hz NOISE IMMUNITY Common mode rejection process input gt 120 dB Normal mode rejection process input gt 80 dB AC line is double filtered and transient protected Snubbers are provided for each relay output CONSTRUCTION Case extruded non perforated black anodized aluminum with ABS plastic sleeve Bezel black plastic ABS Chassis assembly plug in type Keys silicone rubber with diffusion printed graphics NEMA rating front panel conforms to NEMA 4X when instrument is properly installed AGENCY APPROVALS LR 84603 Process conta Equipment C Heavy Industrial Available as an option Memory Retention Lithium battery maintains all programming for approximately ten years Security There are two levels of access restricted and full A configurable code is used to enter the full access level Functions not available in the restricted level are configurable Continued on following page Appendix 5 Specifications 16 App
122. o change jumpers for the Process Variable Remote to equipment Always use a wrist j iai grounding strap when handling electronics to prevent static Equipmentneeded Needle nose pliers optional discharge Phillips screwdriver 2 Wrist grounding strap With power off loosen two front screws and remove them Side the chassis out of the case by pulling firmly on the bezel Use Figure 4 2 to locate the jumper connector to change Using the needle nose pliers or fingers pull straight up on the connector and remove itfrom its pins as shown in Photo 4 Be careful not to bend the pins gt 4 Remove Jumpers 5 Findthe 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 itis 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 Toreassemblethe controller properly orientthe chassis with board open ing on top Align the circuit boards into the grooves on the top and bottom of the case Press firmly on the front face assembly until the chassis is all the way into the case If it is difficult to slide the chassis in all the way make sure the screws have been removed they can block proper alignment and that the chassis is properly oriented 8 Carefullyinsertandalign screws Tighten them
123. o control PID values not set properly Input sensor signal is not connected or valid Set PID values properly See PV LOST message Erratic display Resetting action due to electrical noise on powerline Filter power line 535 User s Manual PID values not set properly Appendix 3 Retune controller A 5 Troubleshooting Message When does it occur What to do DEFAULTS Whenever the memory is cleared and all Entering the Set Up mode and changing a parameter parameters revert to factory default settings will clear the message If due to something other than This may be done by purposely clearing the the user purposely clearing the memory call factory memory or when the unit is powered up for the for assistance first time or if the software version is changed LOST CAL or Indicates that the calibration data has been lost Problem should never happen Must correct the ERROR BAD CAL DATA PV1 UNDER or PV1 OVER or PV2 UNDER or PV2 OVER or LOST PV1 or LOST PV2 LOST RSP COMM SHED Occurs if all the memory has been erased When the process variable value travels slightly outside the boundaries of the instrument 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
124. ocess information for the second tuning function Second tuning function is an adaptive tuning algorithm that automatically adjusts PID values whenever a process upset or setpoint change occurs A 20 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 proportional band The change in input required to produce a full range change in output due to proportional control action ramping see setpoint ramping rate Anticipatory action that senses the rate of change of temperature and compensates to minimize overshoot Also derivative rate action The derivative function of a controller rate time The time interval over which the system temperature is sampled for the derivative function 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 each other relay solid state A solid state switching
125. oint D The low end of the appropriate input range e g 4 00 mA 2 1ST PV Specifies the engineering unit value corresponding to the first point 1ST PV 9999 to 99999 3 XTH INPUT Specifies the input signal corresponding to the XTH point X is 2 to 14 XTH INPUT Any value greater than the first input D D Thelow end ofthe appropriate input range e g 4 00 mA 4 XTH PV Specifies the unit value corresponding to the XTH point X is 2 to 14 XTH PV 9999 t0 99999 D 0 Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation erar wes ww 38 Chapter 5 535 User s Manual Controller Set Up Set Up 5 15TH INPT Specifies the input signal corresponding to the 15th point 15TH INPT 9999 to 99999 Minimum is XTH 1 INPUT D D The high end of the appropriate input range e g 20 00 mA 6 15TH PV Specifies the engineering unit value corresponding to the 15th point 15TH PV R 9999 to 99999 D 0 CONTROL CONTROL For configuring the choices for the control algorithm 1 ALGORITHM Defines the type of control algorithm ALGORITHM D PID e PI P e ON OFF e PID ON OFF ForDuplexapplications using PID for the first output and on off forthe second output 2 D SOURCE Selects the variable for the derivative action D SOURCE D PV Derivative term will not react wh
126. ommunications is lost a time out feature will command the controller to a particular control mode and specific setpoint or output if desired Outputs 2 4 and digital inputs can act as host controlled I O independent of the controller s function The PV may be sourced via this interface May be installed in the field DIGITAL DISPLAYS Upper display five digit seven segment Used exclusively for displaying the process variable value Height is 15 mm 0 6 in 2nd display nine character 14 segment alphanumeric Used for displaying setpoint deviation output value slidewire position actual valve position and configuration information Height is 6mm 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 6mm 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 SET PT key illuminated setpoint other than primary local setpoint is active MENU key illuminated controller is in configuration mode 535 User s Manual DIMENSIONS Meets 1 4 DIN designation as specified in DIN standard
127. onds 11 MIN TIME Defines the minimum amountoftime the controller must specify for the motor to be on before it takes action 0 1 to 10 0 seconds D 0 1 seconds 12 S W RANGE MIN TIME S W RANGE Specifies the full range resistance of the slide e g 100 ohms 10 0 1050 D 100 OPEN F B seine Defines the feedback ohm value corresponding to full open 100 output D Oto S W RANGE D Dependent on S W RANGE value Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation erar wes ww v men 40 Chapter 5 535 User s Manual Controller Set Up Set Up 14 CLOSE F B Defines the feedback ohm value corresponding to full close 096 output CLOSE F B Oto S W RANGE D 100O0hms 15 OUT1 STOP OUT1 STOP This defines the stopping point for control output 1 when staging outputs 11010096 5090 16 OUT2 STRT OUT2 STRT Defines the starting point for control output 2 when staging outputs 01099 D 50 ALARMS ALARMS 1 TYPE 1 Defines the type of alarm for alarm 1 ALM TYPE 1 e HIGHALRM LOWALARM HIGH LOW Separate High amp Low alarm setpoints in one alarm BAND DEVIATION MANUAL Causes an alarm when in manual control REMOTE SP Causes an alarm when in Remote Setpoint RATE Selects a rate of change alarm D OFF Deactivates the first alar
128. ons there is access to every Set up Tuning and Operating parameter For details on the 535 protocol contact a Moore Industries application engineer Hardware Configuration Thisoptionalfeature 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 Referto 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 1 200 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 Ifthe host supports it activating this option is recommended 5 When the 535 senses that communications is lost it can go to a predetermined state called shedding The SHED TIME parameter sets the length of time that communications can be interrupted before the controller sheds Since the 535 is astand alone controller itdoes not depend on communications to operate Therefore ifthe shed feature is not needed set it to OFF 6 SHED MODE designates the mode to which the controller goes after it sheds Setting this to MANUAL brings up the followi
129. ontroller internally establishes a series of setpoints between the original setpoint and the new target setpoint These interim setpoints are referred to as the actual setpoint Either setpoint may be viewed by the user When the setpoint is ramping RAMPING will be shown in the 3rd display when the actual ramping setpoint is displayed Chapter 7 535 User s Manual Applications When the target setpoint is being shown RAMPING will not appear Pressing the DISPLAY key will scroll the 2nd display as follows From the target setpoint to the actual ramping setpoint Tothe deviation from setpoint Tothe output level and Backtothe 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 at the specified rate 2 Onatransfer from manual to automatic control the setpoint will ramp from the process variable value to the setpoint value at the specified rate 3 Onany setpoint change the setpoint will ramp from the current setpoint to the new target setpoint When triggered the display will automatically change to indicate the ramping setpoint Software Configuration 1 Goto the PV INPUT menu 2 Setthe SP RAMP parameter to the desired rate of change O INPU
130. or PID set 1 If using automatic reset then this specifies the load line out value R 0to100 D 096 CYCLE TM 1 Defines the cycle time for control output 1 when using a time proportioning output 0 3to 120 0 seconds D 15 0seconds Access Set Up Return to Operation DISPLAY Next menu Next parameter Next value Access Tuning Eve Return to Operation DISPLAY 535 User s Manual ws 64 Chapter 6 9 DEADBAND 1 Defines the dead band for control output 1 when using on off control 1 to 99999 in engineering units D 2 10 P PROP D B Defines the dead band setting for a slidewire position proportioning output 0 5to 10 0 D 2 0 11 A PID OFST 1 For duplex applications defines the offset for the first output R 50 0 to 50 0 D 0 0 11B ON OFST 1 For On Off applications defines the offset for the first output R 9999to 99999 in engineering units D 0 12A PID OFST 2 For duplex applications defines the offset for the second output 50 0 to 50 0 D 0 0 12B ON OFST 2 For On Off applications defines the offset for the second output R 9999to 99999 in engineering units 13 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 pro portional band R 0 1 to 10 0 D 1 0 14 CYCLE 2 Defines the cycle time for control
131. ortioning algorithm works NOTE OPEN F B and CLOSE F B values are always reference to the CCW end of the Slidewire NOTE P PROP D B can only be configuredifthe Slidewire Feedbackis wired to the controller 81 Applications NOTE Adaptive tuning is not available with velocity position proportioning control 82 e Ifthe valve oscillates increase the P PROP D B value by 0 5 re peat until oscillation stops 12 Setthe parameter S W BREAK to define the output value for when the slide wire breaks E 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 referto energizing of the clockwise relay and CCW to refer to energizing of the counterclockwise relay A blank display means that both relays are de energized In manual control mode the display is blank unless an output change is being made Use the A and W keys to change the output the relay is only energized while the keys are being pressed The display indicates the percentage change in valve position in real time The rate of change is dependent on the values entered for CCW TIME and CW TIME The controller will transfer to manual control due to a lost process variable PV BREAK a digital input closure DES OUTPT a power up sequence PWR UP OUT or los
132. output 2 when using a time proportioning output 0 3 to 120 0 seconds D 15 0 seconds Access Set Up Return to Operation Next menu rast Erast menu 535 User s Manual Chapter 6 Next parameter Next value DEADBAND 1 P PROP D B PID OFST 1 ON OFST 1 PID OFST 2 ON OFST 2 REL GAIN 2 CYCLETM 2 Access Tuning Return to Operation mw _ 65 15 DEADBAND 2 DEADBAND 2 Defines the dead band for control output 2 when using on off control a 1 to 99999 in engineering units D2 16 RSP RATIO RSP RATIO Defines the multiplier applied to the remote set point R 99 99 to 99 99 010 D 1 00 17 RSP BIAS RSP BIAS Defines the bias additive term applied to the remote set point R Any value in engineering units minimum is BIAS LOW maximum is D Dependent on the BIAS LOW and BIAS HIGH values 18 NO OF PID NO OF PID Defines the number of PID sets that will be stored and available for use R 1108 For numbers gt 1 PID TRIP defines tripping between p the PID sets SP NUMBER Number of PID sets number of local setpoints specified in NO OF SP Each PID set has a respective SP NUMBER PVNUMBER PID Set the process variable PV1 or PV2 used when PV SOURCE 1 2 SWITCH or PV SOURCE 1 2 BACKUP D 1 PID TRIP 19 PID TRIP SP VALUE For NO OF PID 1 defines the variable used to select the various PID sets PVVALUE PID set
133. owest PV2 input value e g 4 mA D 9999 to 99999 is HI RANGE D Dependent on the input selection 6 HI RANGE HI RANGE Specifies the engineering unit value corresponding to the highest PV2 input value e g 20 mA D 9999 to 99999 Min is LOW RANGE D Dependent on the input selection 7 FILTER Setting for the low pass PV2 input filter FILTER Oto 120 seconds ho WE 4 D Oseconds Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Ew ww ew ejes a v 535 User s Manual Chapter 5 37 Controller Set Up Set Up 8 OFFSET OFFSET Defines the offset to PV2 in engineering units 00 9999to 99999 D 0 9 GAIN GAIN Defines the gain for PV2 R 0 100to 10 000 100 D 1000 10 RESTORE Defines the control mode when a broken PV2 signal is restored RESTORE D LASTMODE LAST MODE AUTOMATIC 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 1ST INPUT 1 1ST INPUT D Specifies the input signal corresponding to the first p
134. pe Corrective Action COMPLETED 1 PRETUNE has generated initial PID and the Dead Time values 2 3 PRETUNE has generated initial PID Response Time Noise Band and the Dead Time values ABORTED 1 2 3 User has aborted PRETUNE before completion LIMIT ERR 1 The Process Variable went beyond the HI LIMIT or LOW Change the HI LIMIT and LOW LIMIT or the HIGH OUT LIMIT and LOW OUT and run PRETUNE again 2 3 The Process Variable went beyond the HI LIMIT or LOW Change the HI LIMIT and LOW LIMIT or the OUT STEP LIMIT size and run PRETUNE again 1 2 3 The initial Process Variable was near or beyond the HI Change the manual output percentage or the HI LIMIT and LIMIT or LOW LIMIT LOW LIMIT and run PRETUNE again TIME OUT 1 2 3 TIMEOUT limit was reached before PRETUNE completed Set a longer TIMEOUT period and or increase the OUT STEP size and run PRETUNE again NOISE ERR 1 2 3 Too much PV noise was detected Eliminate the noise source if possible or increase the OUT STEP and run PRETUNE again INPUT ERR 1 2 3 PV or Cold Junction break detected during PRETUNE Check the described conditions and make corrections or repairs 1 2 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 OUT ERROR 1 2 3 The initial control output is outside the high and low limits Change the manual out
135. peration alarm power up A type of alarm that determines alarm condition on power up of the controller alarm rate of change A type of alarm set up to occur when 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 Appendix 6 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 effe
136. peration 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 A 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 position three mode control See control action PID time proportioning control A control algorithm that expresses output power 0 10090 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 Appendix 6 setpoint that local setpoint value will match the remote process 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 use
137. put percent and run PRETUNE again defined in the Control Menu DATA ERR 2 3 The PV moved too quickly to be Analyzed Increase the OUT STEP size and run PRETUNE again ZERO ERR 2 3 One or more model parameters are calculated to be zero Increase the OUT STEP size and run PRETUNE again DEV ERROR 1 The initial PV is too close to the TUNE PT Move Tune PT or the set point if TUNE PT is automatic farther from the process variable and run PRETUNE again RETRY 1 2 3 The Process Variable went beyond the HI LIMIT or LOW Check if any PID values are generated and if they are LIMIT acceptable If not eliminate noise sources if possible and run PRETUNE again If Pretune and Adaptive Tune do not generate optimal PID values for control checkthe following menu entries Message Potential Problem Corrective Action RESPONSE Adaptive Tune cannot run if RESPONSE TIME is inaccurate Run TYPE 2 or TYPE 3 Pretune to obtain the correct value TIME or enter it manually NOISE BAND Adaptive Tune cannot compensate for PV oscillation due to Set NOISE BAND large enough to prevent Adaptive Tune hysteresis of output device e g a sticky valve from acting on the oscillation If oscillation is not acceptable consider replacing valve PRETUNE Pretune does not develop optimum PID parameters Wrong Pretune TYPE selected Refer to Chapter 7 the Section on Self Tune 70 Chapter 6 535 User s Manual Applicat
138. puts 94 Table of Contents 535 User s Manual Table of Contents of Contents CHAPTER 7 PAGE APPLICATIONS cont d Self Tune with Control Valves 94 N 94 LineariZation aii ibn eects 95 Thermocouple and RTD Linearization 95 Square Root Linearization 95 Custom Linearization 96 Wey 0 97 Q SO CUNY 97 H Reset 98 S Process Variable Reading Correction 98 T Serial Communications 99 Cascade 100 Ne RINO CONVO PR 103 APPENDIX 1 MENUFLOWCHARTS iei A 1 APPENDIX 2 PARTS eee teeters cece A 3 APPENDIX 3 TROUBEESHOOTING reuerentia A 5 APPENDIX 4 CALIBRATION cocci aeree opener secca ueteri enne earn A 7 Preparation for all Input Calibrations A 8 Thermocouple Cold Junction Calibration A 9 Analog Milliamp Input Calibration A 9 Milliamp Output Calibration A 10 Reset
139. r wiring different types of process inputs The shaded areas on the diagrams show which rear terminals are used for that type of wiring TOP as viewed from back of controller 217 net DIN 1 is Eg COMM DIN 2 198 DIN 3 203 PV2 DIN 4 21 8 PV2 ons 22 3 RTD 3RD Sos pvi sinc 243 Chapter 3 535 User s Manual install Wire AC Power Input Terminals 1 and 2 are for power Terminal 9 is the earth ground NOTE Use a 0 5 Amp 250 V fast acting fuse in line with your AC power connection When wiring a 240 Volt system additional 0 5 Amp 250V fast acting TOP fuse is required on L2 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 accommodates the following types of process variable inputs Thermocouple Input RTD Input Voltage Input Milliamp Input with External Power Supply Milliamp Input with Internal Power Supply Each type of input can be wired for PV1 terminals 31 and 32 or for PV2 ter minals 28 and 29 Figure 3 5 Process Variable Terminals
140. rce ALARM SP 1 Setpoint HIGH SP 1 High setpoint LOW SP 1 Low setpoint DEADBAND 1 Deadband ALM 1 OUT Output number LATCHING 1 Latching sequence ACK 1 Acknowledging POWER UP 1 Status on power up MESSAGE 1 Message For Alarm 2 Parameter Description ALM TYPE 2 Type ALM SRO 2 Source ALARM SP 2 Setpoint HIGH SP 2 High setpoint LOW SP 2 Low setpoint DEADBAND 2 Deadband ALM 2 OUT Output number LATCHING 2 Latching sequence ACK 2 Acknowledging POWER UP 2 Status on power up MESSAGE 2 Message For either alarm depending on choices Parameter Description FAULT Fault assignment OUTPUT Output action for rate RATETIME Time base for rate 74 ACK 1 and ACK 2 For any enabled alarm enables or disables operator use of the ACK key to acknowledge an alarm at any time even if the control process is still in the alarm condition Alatching alarm can always be acknowledged when itis out of the alarm condition When either alarm is available to be acknowledged the ACK key will be illuminated If both alarms are acknowledgeable pressing ACK will first acknowledge alarm 1 Pressing ACK asecond time will acknowledge alarm 2 POWER UP 1 and POWER UP 2 For any enabled alarm selects the alarm condition upon power up Choices are NORMAL Controller will power up in alarm only if itis in alarm condition ALARM Controller always powers up in alarm regardless of system s alarm condition This is an excellent w
141. re A4 10 Slidewire Test Wiring A 12 HARDWARE SCAN Use this read only feature to identify the output hardware and installed options of the controller 1 Setthe jumpers to V and TCA see Figure A4 3 Power up the controller Press MENU until HARDWARE SCAN is displayed Press ACK to initiate the hardware display When complete return jumpers to their original positions SLIDEWIRETEST 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 Attacha100to 1000 ohms potentiometerto terminals 10 11 and 12 as shown in Figure A4 10 3 Movingthe potentiometer from one endto the other should display from 0 to 100 on the controller 4 Ifthe error message OPEN appears check the connectors and try again 5 Press ACK to exit QUICK CALIBRATION PROCEDURE This procedure may benefit users that have ISO or other standards requiring periodic calibration verification It enables verification and modification of the PV input without entering the Factory Configuration mode 1 Power down the 545 controller and place the input jumpers in the desired position refer to Figure A4 2 and Figure 4 7 2 Replace the process variable PV1 or PV2 input signal with a suitable milli amp calibration device 3 Apply power and allow controller to warm up for 30 minutes 4 Place controller in manual mode Then press MENU an
142. red 535 User s Manual Chapter 5 55 Controller Set Up Set Up ALARMS Parameter Description Value 1 ALM TYPE 1 Type of alarm for alarm 1 2 ALM SRO 1 Source of value monitored by HIGH LOW or HIGH LOW alarm 1 3 ALARM SP 1 Alarm setpoint for alarm 1 except for HIGH LOW 4A HIGH SP 1 High alarm setpoint for HIGH LOW alarm 1 4A LOW SP 1 Low alarm setpoint for HIGH LOW alarm 1 5 DEADBAND 1 Deadband for alarm 1 6 ALM 1 OUT Output number for alarm 1 7 LATCHING 1 Latching sequence for alarm 1 8 ACK 1 Whether alarm 1 may be acknowledged 9 POWER UP 1 How alarm 1 will be treated upon power up 10 MESSAGE 1 Nine character message associated with alarm 1 11 ALM TYPE 2 Type of alarm for alarm 2 12 ALM SRC 2 Source of value monitored by HIGH LOW or HIGH LOW alarm 2 13 ALARM SP 2 Alarm setpoint for alarm 2 except for HIGH LOW 14A HIGH SP 2 High alarm setpoint for HIGH LOW alarm 2 14B LOW SP 2 Low alarm setpoint for HIGH LOW alarm 2 15 DEADBAND 2 Deadband for alarm 2 16 ALM 2 OUT Output number for alarm 2 17 LATCHING 2 Latching sequence for alarm 2 18 ACK 2 Whether alarm 2 may be acknowledged 19 POWER UP 2 How alarm 2 will be treated upon power up 20 MESSAGE 2 Nine character message associated with alarm 2 21 FAULT Alarm relay status if fault condition is detected 22 OUTPUT Output if the rate of change alarm is trippe
143. rivative 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 the control action to be performed control cascade see cascade control 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 A 18 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
144. rnal voltage reference A precision voltage source within the 535 controller used to establish internal calibration isolation Electrical separation of sensor from high voltage circuitry Allows for application of grounded or ungrounded sensing element offset Adjustment to actual input temperature and to the temperature values the controller uses tor display and control JIS Japanese Industrial Standards Also Japanese Industrial Standards Committee JISC Establishes standards on equipment and componenis 535 User s Manual 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 o
145. rol 3 Press MENU to access the TUNING menu 4 Setparameter ADAPTIVE to ENABLED The Adaptive Tuning cycle does not begin The controller is under automatic control 4 Activate the next parameter PRETUNE 5 Press ACK to begin Pretuning The 3rd display will show the message EXECUTING 6 When Pretune is complete the 3rd display will show COMPLETED for two seconds and then return to the current menu display The controller will automatically transfer to automatic control upon completion of Pretune if set to do so or upon manual transfer Figure 7 12 illustrates the operation of Pretunes TYPE 2 and TYPE 3 with Adaptive Tune Adaptive Tune by Itself 1 Goto the SELF TUNE menu 2 Setthe TYPE parameter to ADAPTIVE 3 Press MENU to access the TUNING menu 4 the ADAPTIVE parameter to ENABLED The Adaptive Tuning cycle does not begin The controller is under automatic control If Pretune results are poor or process conditions do not allow Pretune to run the 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 Goto the SELF TUNE menu 2 Set NOISE BND The noise bandis chosen to distinguish between disturbances which affect the process and process variable noise The controller functions to compensate for disturbances i e load changes butit cannotcompensate 752
146. roller to manual control Makes the second setpoint active Makes the second set of PID values active Acknowledges alarms Deactivates the reset term Switches the control action Suspends the adaptive tune function Locks controller in manual control Remote A function Remote function Toggle between SP DEV or OUT Activates FAST key Activates MENU key Status readable only through communications Switches between PV1 and PV2 Next menu Next parameter Next value Access Tuning Ere wm ww a y Chapter 5 CONTACT 3 2ND SETPT CONTACT 4 Return to Operation DISPLAY 33 Controller Set Up Set Up CONTACT 5 ALARM ACK LOOP NAME LOOP ONE 17 16 CONTACT 5 This defines the operation ofthe fifth digital input REM SETPT MANUAL 2ND SETPT 2ND PID ALARM ACK RST INHBT D AJR A STOP A T LOCK MAN UP KEY DOWN KEY DISP KEY FAST KEY MENU KEY COMM ONLY LOOP NAME A 9 character message associated with the loop The first character ofthe 3rd display will be flashing To enter message press A and keys to scroll through character set Press FAST key to enter the selection and moveto next digit Press MENU key to advance to next parameter Makes the remote setpoint active Trips the controllerto manual control Makes the second setpoint active Makes the second set of PID values active Acknowledges alarms Deactivates the reset term Switches the
147. rom the case Type T 26 thermocouple wires floating red blue blue 535 User s Manual Appendix 4 A 9 Wires to 20mA current floating PV24 1 PV1 Figure A4 6 Analog mA Input Calibration Wiring Figure A4 7 Analog mA Input Jumper Positions A 10 6 Remove both input jumper connectors from the pins in the 2nd position Place one ofthe jumpers on the PV1 position mA pins and place the other jumper on the 2nd position mA pins as shown in Figure A4 7 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 32 is PV1 Make sure the terminal connections are fastened tightly and that a20mA cur rent is flowing through PV1 Do not connect the 20mA current to PV2 yet 9 Let the controller warm up for at least 10 minutes keep in normal horizontal position Make sure the currentis flowing then press ACK to calibrate the PV1 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 successful Check the 20mA connections and return to step 3 to recalibrate the PV1 in put 12 R
148. s moving the jumper connector The jumper connector slips over the pins straddling two rows of pins The printed circuit boards are labeled next to the jumpers Figure 4 2 from the top The Microcontroller Circuit Board the Option Board and the Power Supply Board 22 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 Therearethree output module sockets on the Power Supply Circuit Board and one output module on the Option Board see Figure 4 2 The mechanical re lay onthe Power Supply Board may be configuredfor either normally open NO or normally closed NC A jumper located nextto each socket determines this configuration All relay outputs are factory set to NO normally open Remote Setpoint Jumper maniere Male 22 Pin Male 22 Pin Connector Connector Output 4 4 Male 34 Pin 5 Pin Connector looooo 99 NO J1 NC NO J2 NC NO J3 NC Module Retention Plate over Outputs 1 2 3 1 990 Jumpers NO and NC Chapter 4 535 User s Manual Hardware Set Up Set Up ACCESSING AND CHANGING JUMPERS CAUTION Static discharge can cause damage Follow these instructions t
149. s 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 A 21 A 22 Appendix 6 535 User s Manual Isolation Block Diagram APPENDIX 7 ISOLATION BLOCK DIAGRAM Input Output Multiplexer ISO Ground Referenced PV2 Input Output2 ISO Ground lw Referenced RSP niput Output3 O ISO Ground Referenced Slidewire Input Output 4 o V ISO Ground Referenced E Vd Digital Inputs 1 5 RS485 Serial Communications Interface L Ve Line N Isolated output ground 1 Each of the three ground circuits are isolated from each other to withstand a potenti
150. s and outputs see Chapter 3 Toalterthe output module and jumper configuration of the controller see Chapter 4 For more information about applications for the 535 see Chapter 6 e Formore information about the Tuning function of the 535 see Chapter 7 535 User s Manual Chapter 5 29 Controller Set Up Set Up CONFIG SOFTWARE MENUS AND PARAMETERS CONFIG CTRL TYPE 1 CTRL TYPE Defines the type of control output s TANDARD 5 D STANDARD Standard control output no special algorithms e POS PROP Position proportioning control output STAGED Staged outputs LINE FREQ DUPLEX Duplex outputs Defines the power source frequency 50HZ D 60HZ 3 PVSOURCE PV SOURCE Defines how the PV input is derived from PV1 and PV2 PV1 D PV1 Use PV1 e 1 2 SWITCH Use PV1 until contact com selects PV2 1 2 BACKUP Use PV2 if PV1 is broken Send PV2 can be of different types and apto bdo Al ange da e PV14PV2 Use PV14PV2 AVG PV Use the average of PV1 and PV2 HISELECT Use PV1 or PV2 whichever is greater LOSELECT Use PV1 or PV2 whichever is less REM SETPT 4 REM SETPT Selects function of the remote setpoint DISABLED D DISABLED ENABLED 5 OUTPUT2 Defines the function of the second output ALM RLY ON OUTPUT 2 ALM RLY OFF OFF e RETRANS Retransmission e ONLY Output addressable through communication D OFF Completely deactivates the output Access Set Up Return
151. s into the grooves on the top and bottom of the case Press firmly on the front face assembly until the chassis is all the way into the case If it is difficult to slide the chassis in all the way make sure the screws have been removed they can block proper alignment and that the chassis is properly oriented 13 Carefully insert and align screws Tighten them until the bezel is seated firmly against the gasket Do not overtighten SPECIAL COMMUNICATIONS MODULE Aspecial communications module is available for the 535 see order code in Chapter 1 for details 535 User s Manual Chapter 4 Hardware Set Up Figure 4 3 Representation of Module NOTE For greatest accuracy cali brate all milliamp modules added for re transmission as per the instructions in Appendix 2 25 Hardware Set Up Set Up Equipment needed Wrist grounding strap Phillips screwdriver 2 Small flat blade screwdriver 1 Before installing the communications module set up the hardware wiring for the application See Chapter 4 for details 2 With power off loosen two front screws and remove them 3 Slide the chassis out of the case by pulling firmly on the bezel Do not de tach the board assembly form the front face of the controller 4 Orientthe Communications Module as shown and attach it to Connectors P1 and P2 as shown in Figure 4 4 5 Toreassemble the controller properly orient the chassis with board open ing ontop Align the c
152. s may also be entered or changed manually inthe conditions SELF TUNE menu For Pretune TYPE 1 Noise Band and Response Time Adaptive Tune can be disabled via parameters must be entered manually Hare if CH a Digital nputs in this chapter or via menus Figure 7 12 illustrates the relationship between Pretune and Adaptive Tune 1 Go to the TUNING menu 2 Go to parameter ADAPTIVE i i Change the value to DISABLED Software Configurations ange the value to Pretune by Itself 1 Goto the SELF TUNE menu press MENU FAST 2 Setthe TYPE parameter to PRETUNE 3 Setthe PRETUNE type tothe one that best matches the process see above section 4 The next parameter TUNE PT appears only for TYPE 1 pretune This parameter sets the PV point at which the output will switch off In thermal processes this will help prevent overshoot The default is AUTOMATIC 535 User s Manual Chapter 7 89 Applications Figure 7 12 Pretune TYPE 1 2 and 3 with Adaptive Tune 90 OUTPUT o 5 Setthe value for OUT STEP This parameter defines the size of bump to be used The resulting disturbance must change the process variable by an amountthat significantly exceeds the peak to peak process noise but does not travel beyond the normal process variable range 6 Thenexttwoparameters LOW LIMIT and HILIMIT setthe process variable boundaries If these boundaries are exceeded during the Pretune the pretune cycle will abort and re
153. s process identification information 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 Specifications and information subject to change without notice 535 User s Manual OVERSHOOT PROTECTION POWERBACK is Powers 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 isolat
154. s setto normally open Altering the factory configuration of the 535 requires accessing the circuit boards and locating the jumpers and output modules see Figure 4 1 1 With the power off loosen the four front screws and remove them 2 Slide chassis out of the case by pulling firmly on the bezel 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 continue set ting up the process as needed HARDWARE INPUT TYPES The Process Variable NOTE Thermocouple downscale and upscale burnout offers a choice The 535 accepts severaldifferenttypes of process variable signals Setajumper in which direction the controller location to specify the type of input signal Set the signal range in the software would react in the event of see Chapter 5 for software menus or Chapter 7 for applications thermocouple failure For example The jumpers for the process variable are located on the Microcontroller Circuit elie lee yen Board see Figure 4 2 The factory default is Milliamp Locations are marked that the system does not apply more as follows heat V Voltage MA Milliamp TCV Thermocouple with downscale burnout A Thermocouple with upscale burnout RTD RTD 535 User s Manual Chapter 4 21 Hardware Set Up NOTE Changing the jumpers mean
155. spond to the 0 to 100 output range of Unit 1 d Wirethe control output of Unit 1 to the remote setpoint input of Unit 2 as shown in Figure 7 20 e 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 Put the secondary loop Unit 42 under Manual control 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 inthe process Now place the primary loop Unit 1 into Manual and perform a Pretuneon this loop Once this Pretune is complete the Cas cade Control Loop is completely tuned Place Unit 1 into Automatic con trol to allow the system to control to the desired Setpoint of the Primary loop 102 Chapter 7 535 User s Manual Applications V RATIO CONTROL Ratio Control is 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 B in a 2 1 ratio Material B is uncontrolled or wild Flow sensors transmitters are used to 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 For this example as shown in Figure 7
156. t 5 38 RATE 5 Defines the derivative time for PID set 5 39 MAN RST 5 Defines the manual reset or load line for PID set 5 40 TRIP 5 This defines the value that triggers a change to the 5th PID set 41 PROP BND 6 Defines the proportional band for PID set 6 42 RESET 6 Defines the integral time for PID set 6 43 RATE 6 Defines the derivative time for PID set 6 44 MAN RST 6 Defines the manual reset or load line for PID set 6 45 TRIP 6 This defines the value that triggers a change to the 6th PID set 46 PROP BND 7 Defines the proportional band for PID set 7 47 RESET 7 Defines the integral time for PID set 7 48 RATE 7 Defines the derivative time for PID set 7 49 MAN RST 7 Defines the manual reset or load line for PID set 7 50 TRIP 7 This defines the value that triggers a change to the 7th PID set 51 PROP BND 8 Defines the proportional band for PID set 8 52 RESET 8 Defines the integral time for PID set 8 53 RATE 8 Defines the derivative time for PID set 8 54 MAN RST 8 Defines the manual reset or load line for PID set 8 55 TRIP 8 This defines the value that triggers a change to the 8th PID set 535 User s Manual Chapter 6 Tuning 7 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 Pretune Conclusion Problem Ty
157. t been tightened Remove unit from case and remove bezel screws then reinsert unit and properly tighten screws Improper Lost PV reading Voltage current Input jumper selection improperly set Move jumper to proper location Input range improperly selected in software Select proper range Reverse polarity Check and correct sensor wiring If controller powered improperly wired Check and correct wiring Loop power module not installed Install module Defective transmitter Replace transmitter Improper Lost PV reading Thermocouple Transmitter signal out of range Defective thermocouple Select proper range in software Replace thermocouple Input jumper selection improperly set Select Proper input Wrong TC type selected in software Select proper thermocouple type in software Improper Lost PV reading RTD Improper wiring Defective RTD Wire properly Replace RTD Input jumper selection improperly set Move jumper connector to proper location Improper wiring Wire properly No control output Output wiring and module location do not match Check and correct wiring or module location If SSR SSR Drive of Milliamp output jumpers J1 J2 and J3 are not set properly Software configuration does not match hardware Set jumper connector to proper location Reconfigure software to match hardware Can t switch to aut
158. t communications SHED OUT In these cases the output can be set to remain atits last value with both relays de energized OUTS OFF rotate fully counterclockwise CCW or rotate fully clockwise CW CCW and CW will energize the respective relay for a period two times that of the CCW TIME or CW TIME Hardware Configuration The controller must have mechanical relay solid state relay or DC logic modules installed in the first two output sockets Refer to the section on Chapter 1 for more information Software Configuration 1 Goto CONFIG menu Set CTRL TYPE to POS PROP 2 Goto 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 ittakes for the actuator to fully rotate in the clockwise direction Loads on the valve may affectthe 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 5 Set MIN TIME to the minimum amount of time the controller must specify for the motor to be on before it takes any action 6 Setvaluesfor PV BREAK DES OUTPT PWR UP OUT and SHED OUT Chapter 7 535 User s Manual F STAGED OUTPUTS With staged outputs one analog output can vary its signal e g 4 20 mA over aportion ofthe PID o
159. t the type of 535 control ON OFF Crude control similar to a household thermostat Used primarily on slow stable processes where moderate deviation cycling around setpoint is tolerable Only available with SSR SSR Drive and relay outputs 6 Proportional only control Provides much better control than on off Used on processes that are less stable or require tighter control but havefew load variations and do not require a wide range of setpoints e Pl 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 e PD Proportional plus derivative control In addition to proportional con trol it compensates for control errors due to fast load variations e PID Proportional plus integral plus derivative control In addition to pro portional control it compensates for changes in setpoint load re quirements and process variations e PID ON OFF Only available with Duplex control First output uses the PID algo rithm while second output uses on off control 3 Foralgorithms using the derivative function D choose the conditions for the derivative term 535 User s Manual Chapter 7 71 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 72 Scroll to parameter
160. te instrument in its class With a sampling rate of tentimes per second itis ideal for demanding pressure andflow applications The 535 also offers a universal process input and modular field interchange able outputs that allow more flexibility than ever before The RS 485 serial communications interface allows the controllerto utilize sophisticated software routines and high speed hardware to provide exceptionally fast and accurate transmission of data The 535 also offers sophisticated control algorithms including Moore Industries exclusive Adaptive Tune which constantly ana lyzes your process and makes modifications to the tuning parameters to en sure you re always under control Specifications and information subject to change without notice 535 User s Manual Chapter 1 1 introduction 535 MODES There are three operating modes for the 535 controller OPERATION the default mode of the controller When the 535 is operating you can change setpoints select manual control and change output level ac knowledge alarms and monitor conditions SET UP also referred to as configuration Here you set up the basic functions ofthe instrument such as input and output assignments alarm types and spe cial functions TUNING where you configure control function parameters for Proportional Integral and Derivation PID Use periodically to optimize the control perfor mance of the instrument ORDER CODE PACKAGING INFORMAT
161. there is an acknowledgeable alarm MENU In Operation Mode press to access the Tuning Menu In Set Up or Tuning mode press to advance through a menu s parameters Use FAST MENU to advance to the next menu When lit indicates the controller is in Set Up mode FAST MENU Press to access the Set Up menus In Set Up mode press to advance through menus Use MENU by itself to access the parameters of a particular menu Chapter 2 Controller Operation 535 User s Manual Operation BASIC OPERATING PROCEDURES Use the following as a quick guide to key operating functions of the 535 To select change a setpoint 1 Use DISPLAY key to toggle display to SetPoint 2 Use SET PT key to toggle to active setpoint Before the newly selected setpoint is made active there is a two second delay to prevent any disruptive bumps If the setpoint displayed is ramping RAMPING will show the 3rd display 3 Tochange value press A or V To change from auto to manual control bumpless transfer 1 Wheninautomatic control press the MANUAL key at any time except while in the TUNING mode 2 The MANUAL key will light in red and the 2nd display will immediately change to indicate current output level To change from manual to auto 1 When in manual control press MANUAL at any time except while in the TUNING or SET UP mode 2 The 2nd display will not change and the MANUAL key will no longer be lit once control changes To change man
162. to Operation Next menu Next parameter Next value Access Tuning Return to Operation Eras wes ww men 30 Chapter 5 535 User s Manual Controller Set Up Set Up 6 OUTPUT3 Defines the function of the third output OUTPUT 3 ALM RLY ON e ALM RLY OFF e RETRANS Retransmission e COMM ONLY Output addressable through communications D OFF Completely deactivates the output 7 OUTPUT 4 Defines the function of the fourth output OUTPUT 4 e ALM RLY ON e ALM RLY OFF RETRANS Retransmission COMM ONLY Output addressable through communications D OFF Completely deactivates the output 8 ANLG RNG 1 Defines the output signal for the first output ANLG RNG 1 D 4 20mA i 0 20 4 20 e 204mA 20 0 9 ANLG RNG 2 Defines the output signal forthe second output ANLG RNG 2 _4 20 0 20 e 20 4 e 20 0 10 ANLG RNG 3 Defines the output signal for the third output D 420mA ANLG RNG 3 dios 4 20mA e 20 4mA 20 0 11 ANLG RNG 4 Defines the output signal for the fourth output ANLG RNG 4 QA 4 20mA e 0 20 20 4mA 20 0 Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Ew ww ew ejes JO 535 User s Manual Chapter 5 31 Controller Set Up Set Up CONTACT 1 MANUAL 12 CONTAC
163. tor from using the and W and keys to change the setpoint value It does not preventthe operator from changing setpoints via the SET PT key 4 AUTO MAN locks out the MANUAL key preventing the operator from transferring between automatic control and manual control 535 User s Manual Chapter 7 97 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 ifthe security codeis left at zero 0 NOTE Security does not prevent the operation from the digital inputs or serialcommunications NOTE PV GAIN is only available if using a linear voltage or current input 98 5 SP SELECT locks out the SET PT key This prevents the operator from changing among the various local setpoints or changing to remote setpoint Itdoes not prevent the operator from changing the setpoint value viathe A and V keys 6 ALARM ACK locks out the ACK key preventing an operator from acknowledging any alarms 7 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 8 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 overridd
164. tpoint 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 be low 450 select an alarm setpoint of 50 Chapter 7 535 User s Manual Applications 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 RATE Alarm occurs when the process variable changes at a rate greater than whatis specified by the alarm setpoint and time base This alarm helps to anticipate problems before the process variable can reach an undesirable level For example if the alarm setpoint is 10 with a time base of 5 sec onds an alarm occurs whenever achange 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 PV PV2 SP e RAMPSP DEVIATION OUT
165. tput The acknowledge key is active for alarms associated with either loop 535 User s Manual Specifications 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 eSelect either direct or reverse control action Select remote setpoint Select manual control Select second local setpoint Disable adaptive tuning Select a second set of PID values Addressable through serial communications only e Acknowledge alarms Inhibit the reset term Lock controller in manual mode Select PV1 or PV2 Simulate A and V keys Simulate DISPLAY FAST and MENU keys 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 SET PT key or digital contact s FAULT OUTPUT One of the alarm outputs may be designated to also energize if the input signal is lost 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 c
166. tput 4 9 HIRANGE 4 High end of range in eng units for retransmission output 4 60 Chapter 5 535 User s Manual Controller Set Up Set Up SELF TUNE Parameter Description Value 1 TYPE Type of self tuning algorithm that is available 2 PRETUNE Output step size in absolute percent 3 TUNEPT TYPE 1 Defines the PV value at which the output switches off 4 OUT STEP TYPE 2 amp 3 Defines output step size in absolute percent 5 LOWLIMIT Lower limit PV can reach during Pretune before aborting 6 HILIMIT Upper limit PV can reach during Pretune before aborting 7 TIMEOUT Execution time limit for Pretune before aborting 8 MODE Control mode after Pretune is completed or aborted 9 NOISE BND Noise band to be used by adaptive tuning algorithm 10 RESP TIME Response time to be used by adaptive tune 11 DEAD TIME Time required to wait before responding to output change SPECIAL Parameter Description Value 1 AUTO TRIP How controller automatically trips to auto control for manual 2 TRIP DEV Deviation from setpoint at which controller will trip to auto 3 DES OUTPT Output value on a trip to manual 4 POWERUP Control mode upon power up 5 PWR UP OUT Output of the controller is powering up in manual control 6 PWR UP SP Setpoint upon power up 7 NO OFSP tof setpoints stored for selection by digital input or SET PT key 535 User s Manual Chapter 5 61 Controller Set Up Set Up
167. tput Modules tt got t eii 17 1 Mechanical Relay 17 2 Solid State Relay Triac 17 3 DC Logic SSR Drive 18 4 Millia Mp ettet et nete Ln e 18 5 Position Proportioning 18 Serial 19 Limit COnirol AR 20 CHAPTER 4 HARDWARE SET tee eerte eene ns 21 Hardware Input 21 The Process Variable 21 The Remote eic esce ia coepta ue 22 Mechanical 22 Accessing and changing 23 Adding and Changing output modules 24 Special Communications Module 26 CHAPTER 5 SOFTWARE CONFIGURATION 27 VISUM 27 Parameters tese tec pir 28 Configuration and 29 Where to Go 29 535 User s Manual Table of Contents About This Manual Throughout this User s Manual information appears along the margins NOTE CAU
168. turn to manual control atthe output level prior to the initiation of pretune 100 High Out Limit TYPE 1 Pretune Adaptive Control Ato Bis ON OFF control to determine initial PID values is Pretune completed so Adaptive PID control beings if ENABLED 70 50 9 30 CONTROL Note Noise Band and Resp Time must be entered before Low Out Limit enabling Adaptive TUne 900 700 500 ee SNNT 100 TYPE 2 Pretune Adaptive Control Ato Bis a5 second noise band measurement Bto Cis an open loop bump test to determine initial PID values and response time Cis Pretune completed so Adaptive PID control begins if ENABLED 70 50 9 CONTROL OUTPUT o 900 700 500 300 10096 TYPE 3 Pretune Adaptive Control Ato Bis a5 second noise band measurement Bto Cis an impulse to determine initial PID values and response time Cis Pretune completed so Adaptive PID control begins if ENABLED 70 50 y 30 CONTROL OUTPUT o 900 700 500 SP 300 PV 0 ADAPTIVE A B TIM E Pretune Chapter 7 535 User s Manual Applications 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 abo
169. ual output values 1 Make sure the controller is under manual control 2 Usethe DISPLAY key to toggle 2nd display to output level 3 Usethe A or V key to change the value To override security If a locked operation is attempted SECURITY appears in the 2nd display for two seconds 1 Use the A and keys to quickly enter the security code which will show in the 3rd display The starting value is O Note Two seconds of key inactivity will clear the display 2 f the code is correct CORRECT appears in the 3rd display The display will clear after two seconds allowing full access 4 lfcodeis incorrect INCORRECT appears inthe 3rd display INCORRECT will disappear 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 refer to the Chapter 7 section on Duplex Control for details Foron off outputs the output value shown is either ON or OFF e For duplex applications with two on off outputs the OUT tag is not shown In this case the status of both outputs is shown in the following manner 1 ON 2 OFF 1 and 2 are the respective outputs 535 User s Manual Chapter 2 Controller Operation
170. until the bezel is seated firmly against the gasket Do not overtighten 535 User s Manual Chapter 4 23 Hardware Set Up Set Up 24 3 Pry Clips ADDING AND CHANGING OUTPUT MODULES The 535 has provisions for four output modules A controller ordered with output module options already has the modules properly installed Follow these in structions to add modules change module type s or change module location s Equipment needed Wrist grounding strap Phillips screwdriver 2 Small flat blade screwdriver Wire cutters 1 With power off loosen two front screws and remove them 2 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 orasmall flat screw driver the smaller Option board andthe Power Supply board the one with 3 modules 5 To change modules 1 2 or 3 Output modules 1 2 and 3 are firmly held in place by a retention plate and tie wrap Carefully snip the tie wrap with a wire cutter To prevent damage to the surface mount components ALWAYS snip the tie wrap on TOP of the Retention Plate as shown in Photo 5 Remove the retention plate 4 Separate Boards 5 Remove Retention Plat
171. urth digital input 16 CONTACT 5 Operation of the fifth digital input 17 LOOP NAME Nine character message associated with control loop 54 Chapter 5 535 User s Manual Controller Set Up Set Up PV1 INPUT Parameter Description 1 PV1TYPE PV1 sensor or range to be used 2 DEG F C K PV1 temperature engineering unit 3 DECIMAL PV1 decimal point position 4 LINEARIZE Type of PV1 inputlinearization 5 LOWRANGE Engineering unit value for lowest PV1 input value 6 HIRANGE Engineering unit value for highest PV1 input value 7 SPLOLIM Lowest setpoint value that can be entered 8 SPHILIM Highest setpoint value that can be entered 9 SPRAMP Rate of change for setpoint changes 10 FILTER Setting for the low pass PV1 input filter in seconds 11 OFFSET Offsetto PV1 in engineering units 12 GAIN Gain to PV1 13 RESTORE Control mode when a broken PV1 is restored PV2 INPUT Parameter Description Value 1 PV2SETUP Makes PV2 input parameters match PV1 or user definable 2 PV2TYPE PV2 sensor or range to be used 3 DECIMAL PV2 decimal point position 4 LINEARIZE Type of PV2 input linearization 5 LOWRANGE Engineering unit value for lowest PV2 input value 6 HIRANGE Engineering unit value for highest PV2 input value 7 FILTER Setting for the low pass PV2 input filter in seconds 8 OFFSET Offset to the PV2 in engineering units 9 GAIN Gain to PV2 10 RESTORE Control mode when a broken PV2 is resto
172. ut twice the pretune time The purpose of this parameter is to prevent a Pretune cycle from continuing for 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 is completed Select MANUAL if there will be a need to review PID parameters before attempting to control with them the default AUTOMATIC 9 RESP TIME defines the amount of damping for the process The choices include FAST results in approximately 20 overshoot MEDIUM results in approximately 10 overshoot and SLOW lt 1 10 Place the controller under manual control 11 Access the TUNING menu press MENU Set the first parameter ADAPTIVE to DISABLED 12 Activate the next parameter PRETUNE 13 Press ACK to begin Pretuning The 3rd display will show the message EXECUTING 14 When Pretune is complete the 3rd display will show COMPLETED for two seconds and then return to the current menu display Pretune TYPE 1 amp Adaptive Tune Go to the SELF TUNE menu Set TYPE to BOTH Set PRETUNE to TYPE 1 Set a value for OUTSTEP Set NOISE BND parameter Set the RESP TIME parameter Make sure that the process is reasonably stable and place the controller under manual control 8 Press MENU to access the TUNING menu Set ADAPTIVE to ENABLED The Adaptive Tuning cycle does not begin the controller is under automatic control 9 Activat
173. utput 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 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 Appendix 6 mechanical relay see relay menu see menu block menu block Groups of parameters arranged in the software microcontroller A large scale integrated circuit that has all the functions of a computer including memory and input output systems NEMA 4X 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 ON OFF control Control of temperature about a setpoint by turning the output full ON below setpoint and full OFF a
174. utput 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 Output 1 4 mA 0 33 50 100 PID Output Hardware Configuration controller must have analog output modules installed in the first two output sockets Software Configuration 1 Goto the 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 G RETRANSMISSION The retransmission feature may be used to transmit a milliamp signal corresponding to the process variable target setpoint control output or actual setpoint to another device A common application is to use itto record one of these variables with a recorder Hardware Configuration There must be an analog module installed in output socket 2 3 or 4 Software Configuration Up to two outputs can be configured for retransmission The menu will scroll through the configuration parameters for specified value X 2 3 or 4 1 Gotothe CONFIG menu 2 ForOUTPUT 2 OUTPUT 3 and OUTPUT 4 parameters set one or two of them to RETRANS 3 Gotothe RETRANS menu 4 Setthecorresponding parameter TYPE X forthe first retransmission out put to define whatis being transmitted the process variable setpoint ramp
175. utputs is depen dent on the offset settings the relative gain setting and the control action Duplex Output State Examples The following Duplex examples represent a variety of ways this function can be set up 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 Chapter 7 535 User s Manual Applications horizontal axis Draw a vertical line atthat point Atthe intersection of this vertical line and the respective output line draw a horizontal line The physical output is 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 and adirect 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 20 9 Figure 7 2 PID OFST 2 20 Duplex with Reverse and Direct LOW OUT 0 M
176. wire feedback there are no connections at terminals 10 11 and 12 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 acceptable for most applications The foil shielded wire has superior noise rejection characteristics The braid shielded wire has more flexibility The maximum recommended length of the RS 485 line is 4000 feet Termination resistors are required atthe host and the last device on the line Some RS 485 cards converters already have a terminating resistor We recommend using our RS 232 RS 485 converter The communication protocol is 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 Moore Industries device To Comm terminal of next Moore Industries device Use a 60 to 100 Ohm terminating resisto connected to the two data terminals of the final device on the line CAUTION The shield needs to be connected continuously but only tied to one ground at the host Failure to follow these proper wiring practices could result in transmission errors and other communications problems 535 User s Manual Chapter 3 19 Figure 3 17 535 Wiring with Limit Control 20 CONTROLL

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