Moore 545 Series, 532 Series, 531 Series, 535 Series, 531-632 Hardware Installation And Modification Manual

500 SERIES

Process Controllers

5 0 0

Installation

Form M500 V7

Hardware Installation

and Modification

Manual

for Electronic Products

Series 531, 532,

535, 545, 555

Model 2

Installation Guide 500 Series 1

M500 V 7, APRIL 2016

Installation

INTRODUCTION

This technical brochure provides hardware installation and modification instructions for our controllers:

Series 531, 532, 535, 545, and 555. Use these instructions with the following kits:

Display Assembly Kits

531-632 ...............531 Display Assembly Kit

532-632 ...............532 Display Assembly Kit

535-632 ...............535 Display Assembly Kit

545-634 ...............545 Display Assembly Kit

555-632 ...............555 Display Assembly Kit

Output and Communications Module Kits

532-600 ...............531, 532 Analog Module Kit

535-600* .............. Mechanical Relay Module Kit

535-601* .............. Milliamp Module Kit

535-602* .............. SSR Module Kit

535-603* .............. SSR Drive Module Kit

535-604* .............. Loop Power Module Kit

535-705* .............. RS-485 Communications Module Kit

Power Supply Kit

535-730* .............. 90 t o 250VAC Power Supply Kit

535-732 ...............24VAC/VDC Power Supply Kit

Mounting Kit

535-761* .............. Mounting Kit

Miscellaneous Kits

532-100 ...............531, 532 Bypass Board Kit

535-188* .............. Rear Terminal Upgrade Kit

535-660 ...............531, 532, 535, 545, 555 Jumper Kit

535-662* .............. Gasket Kit

(1 Panel Gasket, 1 Bezel Gasket)

535-763* .............. Bezel Retention Screw Kit

535-664* .............. Module Retention Kit

(Retention Plate and Tie Wrap)

535-665* .............. Module Retention Tie Wrap Kit

093-128* .............. Lithium Battery

EPROM Kits

531-740................531 EPROM Kit

532-740 ...............532 EPROM Kit

535-741................ 535 EPROM Kit (RSP)

535-775 ...............535 Profiler EPROM Kit (No RSP)

535-776 ...............535 Profiler EPROM Kit (RSP)

535-740................ 535 EPROM Kit (No RSP)

545-740................ 545 EPROM Kit (No RSP)

545-741................ 545 EPROM Kit (RSP)

555-740................ 555 EPROM Kit

Microcontroller (MCU) Board Kits

535-731 ...............MCU Board Kit

545-733 ...............MCU Board Kit with CE Option

Option Board Kits

535-720 ...............531, 532, 535, 545 Option Board Kit

(No Options)

535-721 ...............531, 532, 535, 545 Option Board Kit

(Digital Inputs)

535-722 ...............535, 545 Option Board Kit

(Slidewire Feedback)

535-723 ...............535, 545 Option Board Kit

(Digital Inputs and Slidewire Feedback)

545-724 ...............531, 532, 535, 545, 555 Option Board Kit

(RSP)

545-725 ...............531, 532, 535, 545, 555 Option Board Kit

(Digital Inputs and RSP)

545-726 ...............535, 545, 555 Option Board Kit

(Slidewire Feedback and RSP)

545-727 ...............535, 545, 555 Option Board Kit

(Digital Inputs, Slidewire Feedback,
and RSP)

* Universal Kit (can be used with all 500 Series Controllers)

HOW T O USE THIS MANUAL:

A. CAUTION: Static discharge will cause damage to equipment. Always ground yourself with a wrist grounding

strap when handling electronics to prevent static discharge.

B. Before removing or inserting any hardware on the controller, copy down all configuration parameters. Also,

replacing the battery, EPROM or MCU Board will erase parameter settings and they will need to be reset.

C. For all hardware adjustments, perform steps 1, 2 and 3.
D. Follow the guide and complete any additional steps as required by your particular application.
E. Complete your hardware adjustments with steps 15, 16, 17, 18, 19 & 20.

EQUIPMENT

To make any hardware changes to the units, you will need the following equipment:

• Wrist grounding strap • Phillips screwdriver (#2)

• Small flat blade screwdriver • Wire cutters

• I.C. Extractor (if changing the EPROM)

2 500 Series Installation Guide

Installation

INSTRUCTIONS

To Disassemble the Unit

For any hardware modifications, disassemble the unit.

1. With power off, loosen four captive front screws with
a Phillips screwdriver. Remove the four screws.

Figure 1

Location of Printed Circuit Boards for Hardware
Configuration

2. Slide the chassis out of the case by pulling on front
face plate assembly at the bezel (see Figure 1).

3. Locate the retention
clips holding the front
face assembly to the
rest of the chassis.
Pry apart these
retention clips gently
with a screwdriver to
separate the printed
circuit board group
from the front face
assembly (Photo 3).
Take care not to
break the clips or
scratch the circuit board.

The Microcontroller Board and Power Supply Board
remain attached to the Operator Interface Assem­bly by wired connectors.

Photo 3. Pry Clips

one of the larger two boards from the Option
Board (Photo 4). Be careful not to bend the
connector pins. Separate the other board in the
same manner.

Figure 2 (opposite page) shows the Microcontroller
Board, Option Board and Power Supply Board.

To Add or Change Output Modules

The 500 Series units have provisions for four output
modules. The units come factory configured with
specified modules installed in appropriate locations.
You can make field modifications by properly remov­ing and/or adding the modules into the appropriate
sockets.

Three of the output sockets are located on the Power
Supply Circuit Board. A fourth output socket is
located on the Option Board (refer to Figure 2).

5. A retention plate
and tie wrap hold
Output modules 1, 2,
and 3 (on the Power
Supply board) firmly
in place. To remove
the retention plate,
snip the tie wrap
with wire cutters
(Photo 5).

Photo 5.

Remove Retention Plate

CAUTION: Always snip the tie wrap on top of the
Retention Plate, as shown in photo 5, to prevent
damage to the surface mount components.

6. A disposable tie wrap

holds Output module
4 (on the Option
board) in place. To
remove the module,
snip the tie wrap
(Photo 6).

4. The Microcontroller
and Power Supply
board are attached
to either side of the
Option board by
male/female pin
connectors. Use a
gentle rocking motion
and carefully apply
pressure in a uniform
direction to separate

Photo 4. Separate Boards

Installation Guide 500 Series 3

7. Inspect each module
before installation to
make sure the pins
are straight. Align
the pins with the
socket holes and
carefully insert the
module. Press down on the module to seat it
firmly on the board.

Photo 6.

Snip Tie Wrap on Mod. 4

Installation

Front of Unit Back of Unit
(toward Operator Interface) (toward rear terminals)

EPROM

TB2

BATTERY

5-Pin Connector

Female 22-Pin Connector

Female 22-Pin Connector

V

MA
TC
TC

RTD

V

MA
TC

TC

RTD

2ND

PV1

TB1

NOTE:

If you replace the EPROM chip, you
must align the notch facing the front
of the unit.

NOTE:

The 5- and 22-Pin connnectors on
the boards are all keyed so they
will only align one correct way.

Male 22-Pin
Connector

Male 12-Pin
Connector

12-Pin Female
Connector

5-Pin Connector

Remote Setpoint Jumper

Output 4

Male 22-Pin
Connector

Male 22-Pin
Connector

22-Pin Female
Connector

Module

Retention

Plate

over Outputs 1,2,3

Figure 2

Microntroller Board,
Option Board, and
Power Supply Board

NO J2 NC NO J3 NC

NO J1 NC

Jumpers

NO and NC

4 500 Series Installation Guide

Installation

8. Replace tie wraps for the Retention Plate and for
Output Module 4 with new ones.

Failure to use these devices may result in a
loosening of the module and eventual
failure. If you ordered a module separately,
it should have come with a tie wrap. An
extra set of tie wraps is available by order­ing Part #535-665.

Note: For greatest accuracy, milliamp
modules added for retransmission must be
calibrated per instructions in Operator's
Manual.

To Change the Option Board

9. (See Photos 3 and 4) Replace the existing Option

board with the NEW one.

Note: When adding Option board for 5
digital inputs, associated screw terminal in
the rear terminal block must be installed.
(See information on page 1 for ordering a
Screw Kit.)

To Change the Power Supply or
Microcontroller (CPU) Board

10. For the Microcontroller Board, disconnect the 5-pin

female connector that wires it to the Display
Assembly. Reattach the connector to the new
board. You can only orient the connector one way.

For the Power Supply Board, disconnect the 5-pin
female connector that wires it to the Display
Assembly. Reattach the connector to the new
board. You can only orient the connector one way.

To Change the Display Assembly

11. Disconnect the 5-pin female connector that wires

the Microcontroller Board to the Display Assembly.
Disconnect the 5-pin female connector that wires
the Power Supply Board to the Display Assembly.

12. Attach the new Display Assembly to the boards at
the appropriate connectors.

CAUTION

Static discharge will cause damage to equip­ment. Always ground yourself with a wrist
grounding strap when handling electronics
to prevent static discharge.

To Change the EPROM

13. The EPROM is located on the Microcontroller

Circuit board (Figure 2). It has a white label that
list the part number and software revision level.
Use an I.C. Extractor to carefully remove the
EPROM. If you do not have an I.C. extractor,
gently use a small flat blade screwdriver to pry up
the EPROM. DO Not bend the EPROM legs.

14. Carefully insert the new EPROM. To position
correctly, match the notched end of the EPROM to
the markings on the board. The notched end will
face towards the display. Make sure all pins are in
the socket.

To Reassemble the Unit

15. (See Figure 2) Align the connector pins on the

Option Board with the connector sockets on the
Microcontroller and Power Supply boards.
Squeeze them together, making certain all three
are properly seated against one another. Check
along the side edges for gaps. Make sure the
conector is properly aligned. Also, check that the
cable assemblies are not pinched.

16. (See Figure 2) Align the board assembly with the
front face assembly, with the Option board at the
bottom (see Figure 1). Reinstall the retention
clips. Align the boards into the slots of the front
face assembly and the clips will snap into place.

17. When you are ready to reassemble the unit, align
the boards in the chassis with the case's top and
bottom grooves. Press firmly to slide the chassis
into the case. If you have difficulty, check that you
have properly oriented the chassis, and there are
no screws interfering with the case.

18. Carefully insert and align screws. Tighten them
until the bezel is seated firmly against the gasket.
DO NOT OVERTIGHTEN.

19. If may be necessary to re-configure the software
features of your controller or station. Please refer
to your User’s Manual.

20. To maintain NEMA 4X Rating, you may need new
mounting gaskets, order part #535-662. Refer to
your user’s manual.

CAUTION
Do not scratch the boards or bend the pins of the
connectors.

Installation Guide 500 Series 5

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 giv e us a Purchase Order n umber 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.

2. Provide us with the following documentation:

a ) A note listing the symptoms that indicate the unit needs repair
b ) Complete shipping information for return of the equipment after repair
c) The name and phone number of the person to contact if questions arise at the factory

3. Use sufficient packing material and carefully pack the equipment in a sturdy shipping

container.

4. Ship the equipment to the Moore Industries location nearest you.

The returned equipment will be inspected and tested at the factory. A Moore Industries
representative will contact the person designated on your documentation if more information is
needed. The repaired equipment, or its replacement, will be returned to you in accordance with
the shipping instructions furnished in your documentation.

WARRANTY DISCLAIMER

THE COMPANY MAKES NO EXPRESS, IMPLIED OR STATUTORY WARRAN­TIES (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS
FOR A PARTICULAR PURPOSE) WITH RESPECT TO ANY GOODS OR SER­VICES SOLD BY THE COMPANY. THE COMPANY DISCLAIMS ALL WARRAN­TIES ARISING FROM ANY COURSE OF DEALING OR TRADE USAGE, AND
ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY ACKNOWL­EDGES THAT THERE ARE NO WARRANTIES IMPLIED BY CUSTOM OR
USAGE IN THE TRADE OF THE BUYER AND OF THE COMPANY, AND THAT
ANY PRIOR DEALINGS OF THE BUYER WITH THE COMPANY DO NOT IM­PLY 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.

ANY CAUSE OF ACTION FOR BREACH OF ANY WARRANTY BY THE
COMPANY SHALL BE BARRED UNLESS THE COMPANY RECEIVES
FROM THE BUYER A WRITTEN NOTICE OF THE ALLEGED DEFECT OR
BREACH WITHIN TEN DAYS FROM THE EARLIEST DATE ON WHICH THE
BUYER COULD REASONABLY HAVE DISCOVERED THE ALLEGED DE­FECT OR BREACH, AND NO ACTION FOR THE BREACH OF ANY WAR­RANTY SHALL BE COMMENCED BY THE BUYER ANY LATER THAN
TWELVE MONTHS FROM THE EARLIEST DATE ON WHICH THE BUYER
COULD REASONABLY HAVE DISCOVERED THE ALLEGED DEFECT OR
BREACH.

RETURN POLICY

For a period of thirty-six (36) months from the date of shipment, and under
normal conditions of use and service, Moore Industries ("The Company") will
at its option replace, repair or refund the purchase price for any of its manu­factured products found, upon return to the Company (transportation charges
prepaid and otherwise in accordance with the return procedures established
by The Company), to be defective in material or workmanship. This policy
extends to the original Buyer only and not to Buyer's customers or the users
of Buyer's products, unless Buyer is an engineering contractor in which case
the policy shall extend to Buyer's immediate customer only. This policy shall
not apply if the product has been subject to alteration, misuse, accident, ne­glect or improper application, installation, or operation. THE COMPANY
SHALL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSE­QUENTIAL DAMAGES.

Tel: [phone] • FAX: [phone]
Tel: [phone] • FAX: [phone]

© 2006 Moore Industries-International, Inc.

United States • [e-mail]

Australia • [e-mail]

Belgium • [e-mail]

Tel: [phone] • FAX: [phone]

Tel: [phone] • FAX: [phone]

The Netherlands • [e-mail]

Tel: [phone] • FAX: [phone]

Specifications and Information subject to change without notice.

China • [e-mail]

United Kingdom • [e-mail]

Tel: [phone] • FAX: [phone]

April 2016

User’s Manual Supplement

500 Series

Process Controllers

531, 532, 535, 545, 555

Purpose

This supplement is to address the updated Micro
Controller Board with removable Lithium Battery. Older
models required to be serviced by Moore Industries
to replace Lithium Battery which was soldered directly
on the board, this is an inconvenience and has been
resolved with a Micro Controller Board that has a
replaceable Lithium Battery slot.

To replace battery in your 500 Series unit follow
previous instructions found in M500 V6. Use a fl at head
screwdriver to release battery and replace.

Figure 1. Removable Lithium Battery

BATTERY

INSERT FLAT
HEAD SCREWDRIVER
TIP HERE TO
RELEASE BATTERY

You can order replacement directly fro Moore Industries
using this part number 800-867-52 or an equivalent
CR2450 3V Coin Cell Lithium Battery.

EPROM

5-Pin Connector

Female 22-Pin ConnectorFemale 22-Pin Connector

The Interface Solution Experts www.miinet.com