Moore 535 PROFILER User Manual

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Page 1

535

PROFILER

5 3 5 P R O F I L E R

1/4 DIN PROFILE CONTROLLER USER'S MANUAL

M535-PROF V6, © JULY 20

Page 2

Isolation Block Diagram

535-PROF User's Manual Appendix 7 A-23

Page 3

TABLE OF CONTENTS

CHAPTER 1

INTRODUCTION ............................................................................... 1

535 Profile Controller Modes .............................................................. 1

Order Code, Packaging Information ................................................... 2

Where to Go Next ............................................................................... 2

Text Formatting in this Manual ........................................................... 2

CHAPTER 2

BASIC INTERFACE .......................................................................... 4

Displays ............................................................................................ 4

Icons (Lit) .......................................................................................... 5

Keys.................................................................................................. 5

Basic Profile Controller Operating Procedures .................................... 7

To Enter the RECIPE SET UP Mode .......................................... 7

To Enter the SET UP Mode ....................................................... 7

To Run a Recipe ........................................................................ 7

To Hold a Recipe ....................................................................... 7

To Abort a Recipe and Switch to Manual Control ........................ 7

To Abort a Recipe and Control to the Idle Setpoint ...................... 7

To Display the Setpoint (SP) while a Recipe Is Running ............. 8

To Display the Recipe Number .................................................. 8

Basic Process Controller Operating Procedures ................................. 8

To Select/Change a Setpoint ..................................................... 8

To Change from Auto to Manual Control (Bumpless Transfer) ..... 8

To Change from Manual to Auto ................................................. 8

To Change Manual Output Values ............................................. 8

To Override Security ................................................................. 8

To Display Control Output Value ................................................ 9

To Display the Active PID Set ................................................... 9

Alarm Operation ................................................................................. 9

Alarm Indication ........................................................................ 9

To Acknowledge an Alarm(s) ................................................... 10

Latching Alarms ...................................................................... 10

Limit Sequence ....................................................................... 10

More On Alarms ...................................................................... 10

Table of Contents

PAGE

About This Manual:

Throughout this User’s Manual information appears along the margins (NOTE: CAUTION! and WARNING!). Please heed these safety and good practice notices for the protection of you and your equipment.

CHAPTER 3

INSTALLATION .............................................................................. 11

Mounting the Controller .................................................................... 11

Wiring .............................................................................................. 12

AC Power Input ....................................................................... 13

Process Variable Input ............................................................ 13

Digital Input(s) ......................................................................... 16

1. Digital Inputs with a Switch or Relay ................................ 16

2. Digital Inputs with an Open Collector ............................... 16

Remote Setpoint Option .......................................................... 16

Output Modules ....................................................................... 17

1. Mechanical Relay Output ................................................ 17

2. Solid State Relay (Triac) Output ...................................... 17

535-PROF User's Manual Table of Contents i

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Table of Contents

CHAPTER 3

INSTALLATION (CONTINUED)

Output Modules

3. DC Logic (SSR Drive) Output .......................................... 18

4. Milliamp Output .............................................................. 18

5. Position Proportioning Output ......................................... 18

Serial Communications ........................................................... 19

Limit Control ............................................................................ 20

CHAPTER 4

HARDWARE SET UP ...................................................................... 21

Hardware Input Types ...................................................................... 21

The Process Variable ....................................................................... 21

The Remote Setpoint ....................................................................... 22

Mechanical Relays .......................................................................... 22

Accessing and Changing Jumpers ................................................... 23

Adding and Changing Output Modules .............................................. 24

Special Communications Module ..................................................... 26

CHAPTER 5

SOFTWARE CONFIGURATION ...................................................... 27

Menus ............................................................................................. 27

Parameters ...................................................................................... 29

Configuration and Operation ............................................................. 29

Where to Go Next ............................................................................. 29

Software Menus and Parameters ..................................................... 31

CONFIG.................................................................................. 31

REC. CONF. ........................................................................... 37

PV1 INPUT ............................................................................. 39

PV2 INPUT ............................................................................. 41

CUST. LINR. ........................................................................... 43

CONTROL .............................................................................. 44

ALARMS................................................................................. 46

REM. SETPT. ......................................................................... 50

RETRANS. ............................................................................. 51

SELF TUNE ............................................................................ 53

SPECIAL ................................................................................ 54

SECURITY ............................................................................. 56

SER. COMM. .......................................................................... 57

RECIPE # ............................................................................... 58

Parameter Value Charts ................................................................... 61

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ii Table of Contents 535-PROF User's Manual

CHAPTER 6

TUNING .......................................................................................... 71

Overview ......................................................................................... 71

Tuning Parameters .......................................................................... 72

Tuning Value Chart .......................................................................... 76

Self Tune Messages and Troubleshooting ........................................ 78

CHAPTER 7

APPLICATIONS .............................................................................. 79

A. Profile Control.............................................................................. 79

Software Configuration ............................................................ 80

Digital Inputs ........................................................................... 84

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Table of Contents

CHAPTER 7

APPLICATIONS (CONTINUED)

A. Profile Control

Master/Slave Operation ........................................................... 84

Hardware Configuration ....................................................... 85

B. Control Type ................................................................................ 85

Software Configuration ............................................................ 85

C. Alarms ........................................................................................ 86

Software Configuration ............................................................ 86

D. Duplex Control ............................................................................. 90

Hardware Configuration ........................................................... 90

Software Configuration ............................................................ 90

Duplex Output State Examples ............................................... 91

Duplex with Reverse and Direct Acting Outputs ................... 91

Duplex with Direct and Reverse Acting Outputs ................... 91

Duplex with 2 Reverse Acting Outputs ................................. 92

Duplex with a Gap Between Outputs .................................... 92

Duplex with a Overlapping Outputs and Output Limits .......... 93

Duplex with Various Relative Gain Settings ......................... 93

Duplex with One On/Off Output ........................................... 94

Duplex with Two On/Off Outputs ......................................... 94

E. Slidewire Position Proportioning Control ....................................... 95

Hardware Configuration ........................................................... 95

Software Configuration ............................................................ 95

F. Velocity Position Proportioning Control ........................................ 96

Hardware Configuration ........................................................... 96

Software Configuration ............................................................ 96

G. Staged Outputs ........................................................................... 97

Hardware Configuration ........................................................... 97

Software Configuration ............................................................ 97

H. Retransmission ........................................................................... 97

Hardware Configuration ........................................................... 97

Software Configuration ............................................................ 97

I. Digital Inputs................................................................................. 98

Hardware Configuration ........................................................... 98

Software Configuration ............................................................ 98

Basic Operating Procedures .................................................. 100

J. Remote Setpoint ........................................................................ 100

Hardware Configuration ......................................................... 100

Software Configuration .......................................................... 100

Basic Operating Procedures .................................................. 101

K. Multiple Setpoints ...................................................................... 101

Software Configuration .......................................................... 101

Basic Operating Procedures .................................................. 101

L. Multiple Sets of PID Values ....................................................... 101

Software Configuration .......................................................... 101

Basic Operating Procedures .................................................. 102

Using with Adaptive and Pretune ........................................... 102

M. Powerback ................................................................................ 102

Software Configuration .......................................................... 103

N. Self Tune— Powertune® ........................................................... 103

Pretune ................................................................................. 103

Adaptive Tune ....................................................................... 103

PAGE

535-PROF User's Manual Table of Contents iii

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Table of Contents

CHAPTER 7

APPLICATIONS (CONTINUED)

N. Self Tune—Powertune®

Software Configurations ........................................................ 104

Pretune by Itself................................................................ 104

Pretune Type 1 & Adaptive Tune ....................................... 104

Pretune Type 2 or 3 & Adaptive Tune ................................ 106

Adaptive Tune by Itself ..................................................... 106

Self Tuning with Multiple Sets of PID ................................. 108

Self Tune with Time Proportioning Outputs ........................ 108

Self Tune with Control Valves ........................................... 108

O. Ramp-to-Setpoint ...................................................................... 109

Software Configuration .......................................................... 109

P. Input Linearization ..................................................................... 109

Thermocouple and RTD Linearization .................................... 109

Square Root Linearization ...................................................... 109

Hardware Configuration ..................................................... 110

Software Configuration ...................................................... 110

Custom Linearization ............................................................. 110

Software Configuration ...................................................... 110

Q. Load Line .................................................................................. 111

R. Security .................................................................................... 111

Software Configuration .......................................................... 111

Basic Operating Procedures .................................................. 112

S. Reset Inhibition ......................................................................... 112

Software Configuration .......................................................... 112

T. Process Variable Reading Correction ......................................... 112

U. Serial Communications .............................................................. 113

Hardware Configuration ......................................................... 113

Software Configuration .......................................................... 113

V. Cascade Control ........................................................................ 114

Hardware Configuration ......................................................... 116

Software Configuration .......................................................... 116

Tuning Cascade Control ........................................................ 116

W. Ratio Control ............................................................................. 117

Hardware Configuration ......................................................... 118

Software Configuration .......................................................... 118

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iv Table of Contents 535-PROF User's Manual

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Table of Contents

APPENDIX 1

MENU FLOWCHARTS .. .... .............................................................A-1

APPENDIX 2

PARTS LIST .................................................................................. A-3

APPENDIX 3

TROUBLESHOOTING ................................................................... A-4

APPENDIX 4

CALIBRATION ............................................................................... A-6

Preparation For All Input Calibrations .............................................. A-7

Thermocouple Cold Junction Calibration ......................................... A-8

Analog Milliamp Input Calibration .................................................... A-8

Milliamp Output Calibration ............................................................. A-9

Reset Menu Data .......................................................................... A-10

Hardware Scan ..................................................................... A-11

Slidewire Test ............................................................................... A-11

Quick Calibration Procedure .......................................................... A-11

APPENDIX 5

SPECIFICATIONS ....................................................................... A-12

APPENDIX 6

GLOSSARY ................................................................................. A-17

APPENDIX 7

ISOLATION BLOCK DIAGRAM .................................................... A-22

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535-PROF User's Manual Table of Contents v

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Table of Contents

LIST OF FIGURES

PAGE

Figure 2.1 ....... Operator Interface ................................................................ 4

Figure 2.2 ....... Before and After Acknowledging An Alarm ............................. 9

Figure 3.1 ....... Instrument Panel & Cutout Dimensions ............................... 11

Figure 3.2 ....... Attaching Mounting Collar................................................... 11

Figure 3.3 ....... All 535-PROF Terminal Assignments .................................. 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 ..................................... 15

Figure 3.8 ....... Digital Inputs Wiring with A Switch or Relay .......................... 16

Figure 3.9 ....... Digital Input Wiring with An Open Collector ........................... 16

Figure 3.10 ...... Remote Setpoint Terminals ................................................ 16

Figure 3.11 ...... Mechanical Relay Output Wiring . ........................................ 17

Figure 3.12 ...... SSR Relay Output Wiring ................................................... 17

Figure 3.13 ...... DC Logic Output Wiring ...................................................... 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-PROF Wiring with Limit Control ..................................... 20

Figure 4.1 ....... Location of Printed Circuit Boards for

Hardware Configuration ...................................................... 21

Figure 4.2 ....... (From the Top) the Microcontroller Circuit Board,

the Option Board, and the Power Supply Board .................... 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 Up ................................................. 27

Figure 5.2 ....... Configuration Flowchart ...................................................... 28

Figure 5.3 ....... Independent vs. Dependent Parameters .............................. 29

Figure 6.1 ....... Access the Tuning Menu Block .......................................... 71

Figure 7.1 ....... Contacts for Recipe Selection ............................................. 84

Figure 7.2 ....... Alarm Examples ................................................................ 89

Figure 7.3 ....... Duplex with Reverse and Direct Acting Outputs ................... 91

Figure 7.4 ....... Duplex with Direct and Reverse Acting Outputs ................... 91

Figure 7.5 ....... Duplex with Two Reverse Acting Outputs ............................ 92

Figure 7.6 ....... Duplex with A Gap Between Outputs ................................... 92

Figure 7.7 ....... Duplex with Overlapping Outputs and Output Limits ............. 93

Figure 7.8 ....... Duplex with Various Relative Gain Settings .......................... 93

Figure 7.9 ....... Duplex with One On/Off Output ........................................... 94

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Figure 7.10 ...... Duplex with Two On/Off Outputs . ....... ....... .......................... 94

Figure 7.11 ...... Staged Outputs Example ................................................... 97

Figure 7.12 ...... Combinations of Closed Digital Inputs for

Each Setpoint (Based on BCD Logic) .................................. 98

Figure 7.13 ...... Pretune Type 1, Type 2 and Type 3 with

Adaptive Tune ................................................................. 105

Figure 7.14 ...... Noise Band Calculation Example ...................................... 107

Figure 7.15 ...... Noise Band Values for Temperature Inputs ........................ 107

Figure 7.16 ...... Deadtime and Time Constant ........................................... 108

Figure 7.17 ...... Square Root Linearization Formula .................................... 110

Figure 7.18 ...... 15-point Linearization Curve .............................................. 110

Figure 7.19 ...... Load Line Example .......................................................... 111

Figure 7.20 ...... Heat Exchanger Control Loop for Steam Supply ................. 114

Figure 7.21 ...... Cascade Control of Product Temperature .......................... 115

Figure 7.22 ...... Ratio Control In Mixing Applicatoin .................................... 117

Figure A4.1 ..... 535 Rear Terminals for Calibration ...................................... A-6

Figure A4.2 ..... Flowchart Calibration Menus .............................................. A-6

Figure A4.3 ..... Jumper Locations on the Microcontroller Circuit Board ......... A-7

Figure A4.4 ..... Input Calibration Wiring ......................................................A-7

Figure A4.5 ..... Thermocouple/Cold Junction Calibration Wiring .................. A-8

Figure A4.6 ..... Analog mA Input Calibration Wiring .................................... A-9

Figure A4.7 ..... Analog mA Input Jumper Positions .................................... A-9

Figure A4.8 ..... Milliamp Output Calibration Wiring .................................... A-10

Figure A4.9 ..... Output Module Menu Cycle ............................................. A-10

Figure A4.10 ... Slidewire Test Wiring ...................................................... A-11

Table of Contents

535-PROF User's Manual Table of Contents vii

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CHAPTER 1 INTRODUCTION

Introduction

From its surge-resistant power supply to its rugged construction, the 535 Profile Controller is designed to ensure the integrity of your process with maximum reliability — hour after hour, day after day. The isolated inputs and outputs guard against the dangers of electrical interference, the front face meets NEMA 4X standards for watertight operation and exposure to corrosive environments, and the solid metal housing and sturdy rubber keys enhance durability and ESD protection.

The 535 Profile Controller has been engineered to be the industry’s most user– friendly process controller. With three digital display areas — two offering up to 9 characters of true alphanumerics — the controller effectively eliminates the cryptic messages that could confuse even the most experienced operator. The bright, crisp display is vacuum fluorescent, and offers much better readability than any other display technology. Additional operator–friendly features include: custom programmable alarm messages, illuminated keys, and an easy–to–use menu system.

The 535 Profile Controller is the most accurate instrument in its class. With a sampling rate of ten times per second, it is ideal for demanding pressure and flow applications. The controller also offers a universal process input and modular, field interchangeable outputs that allow more flexibility than ever before. The RS-485 serial communications interface allows the controller to utilize sophisticated software routines and high speed hardware to provide exceptionally fast and accurate transmission of data. The 535 Profile Controller also offers sophisticated control algorithms, including exclusive Adaptive Tune which constantly analyzes your process and makes modifications to the tuning parameters to ensure you’re always under control.

Thank you for selecting the 535 Profile Controller — the most sophisticated instrument in its class. It will provide you with years of reliable, trouble-free performance.

535 PROFILE CONTROLLER MODES

There are four operating modes for the 535 profile controller: OPERATION, the default mode of the controller. When the 535-PROF is oper-

ating, you can run recipes, change setpoints, select manual control and change output level, acknowledge alarms and monitor conditions.

535-PROF User’s Manual Chapter 1 1

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Introduction

SET UP, also referred to as configuration. Here the basic functions of the instru-

ment are configured, such as input and output assignments, alarm types and special functions.

TUNING, where control function parameters for Proportional, Integral and Derivation (PID) are configured. Use this mode periodically to optimize the control performance of the instrument.

RECIPE SET UP, where the ramps, dwells and events for each recipe are configured.

ORDER CODE, PACKAGING INFORMATION

Compare the product number to the ordering code on page 3 to determine the outputs and options installed on the controller. The product number is printed on the label on the top of the controller case.

Included with this 535 Profile Controller are:

• a 535 Profile Controller User’s Manual

• mounting hardware

• 1 sheet of Engineering unit adhesive labels

WHERE TO GO NEXT

• To become familiar with the controller interface, continue to Chapter 2.

• For important hardware installation guidelines, see Chapters 3 and 4.

• For a detailed description of all the software menus and parameters, 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 RUN DISPLAY

RUN DISPLAY

ICONS OUT, ALM MENUS CONFIG., TUNING, PARAMETERS CYCLE TM:1, MIN.OUT2

PARAMETER VALUES OFF, SETPOINT, LAST OUT. DISPLAY MESSAGES TOO HOT, OUT%

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Order

Output 1: Control Code

None 0 Mechanical Relay (5 amp) 1 Analog (milliamp) 2 Solid State Relay (triac) (1 amp) 3 DC Logic (SSR drive) 4

Output 2: Control, Alarm, or Retransmission

None 0 Mechanical Relay (5 amp) 1 Analog (milliamp) 2 Solid State Relay (triac) (1 amp) 3 DC Logic (SSR drive) 4

Output 3: Control, Alarm, Retransmission, or Loop Power

None 0 Mechanical Relay (5 amp) 1 Analog (milliamp) 2 Solid State Relay (triac) (1 amp) 3 DC Logic (SSR drive) 4 Loop Power 5

Introduction

535 – 00

Output 4: Alarm, Retransmission, or Loop Power

None 0 Mechanical Relay (0.5 amp, 24 V) 1 Analog (milliamp) 2 Solid State Relay (triac) (0.5 amp, 24 V) 3 DC Logic (SSR drive) 4 Loop Power 5

Options

Enter “0” if not desired

Slidewire Feedback for Position Proportioning Output A 24 VAC/24 VDC Operation F Slidewire and 24 VAC/24 VDC G

Remote Setpoint B Profile Controller Option C Remote Setpoint and Profile E

Set of Five Digital Inputs D Certification H Five Digital Inputs and Certification J

Serial Communications

Enter “0” if not desired

RS-485 Serial Communications S

Note 1: Capability for position proportioning output is specified by ordering 535-11xxAxxx00, 535-33xxAxxx00, or 535-44xxAxxx00. Note 2: Capability for

velocity proportioning output is specified by ordering 535-11xxxxxx00, 535-33xxxxxx00, or 535-44xxxxxx00. alarms. when used as the fourth output.

535-PROF User’s Manual Chapter 1 3

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

Note 3: Up to two outputs may be used for

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Operation

CHAPTER 2 BASIC INTERFACE

Icons

OUT 1 2 ALM 1 2

535

Displays:

1st

2nd

3rd

Location for

MANUAL DISPLAY RUN

identification label

ACK MENU FAST

DISPLAYS

The display strategy of the 535 Profile Controller is the same for all modes.

1st Display (five 7-segment digits)

• For the process variable value.

2nd Display (nine 14-segment digits)

• For the setpoint, deviation, output level or valve position (if available)

• In RECIPE SET UP, TUNING or SET UP mode, for the parameter name.

• Upon power up, indicates the current setpoint.

• In OPERATION Mode, displays program operating values:

a. The target soak setpoint value for this segment, for example:

SP 1425 means “the final [soak] setpoint during this segment is 1425”

b. The current setpoint value, for example:

RAMP 300 means “the current ramping setpoint value is 300” SOAK 1425 means “the current soak segment setpoint value is 1425”

3rd Display (nine 14-segment digits)

• For alarm messages, loop name, errors, etc.

• In RECIPE SET UP, TUNING or SET UP mode, the value or choice of

parameter shown in the 2nd display.

• In OPERATION Mode, displays recipe status values and messages. It

will alternate every two seconds between the selected recipe status value and the next message ( if any messages are active).

a. The ramp or soak segment number being run or held, for example:

RAMP 10/11 means “using ramp segment 10 of 11 segments in this recipe”

SOAK 3/4 means “using soak segment 3 of 4 segments in this recipe”

Figure 2.1 Operator Interface

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Operation

b. The amount of time left in the current ramp or soak segment or the amount

of time the soak segment has been waiting to run or continue due to guaranteed soak, for example:

15:03 LEFT means “15:03 is remaining in this segment’s current cycle” WAIT 12:37 means “the soak segment has been waiting for 12:37”

c. The status of events will be displayed. Active events will be indicated

by a ‘1’ and inactive events by a ‘0’, for example: EVENT 000 means “events 1, 2, and 3 are inactive” EVENT 100 means “event 1 is active and events 2 and 3 are inactive” EVENT 111 means “events 1, 2, and 3 are active”

d. The current cycle number and the total number of cycles will be dis-

played, for example: CYCLE 1/1 means “the first and only cycle is currently active” CYCLE 13/99 means “the thirteenth of 99 cycles is currently active” CYCLE 246 means “the 246th cycle [in continual cycling] is currently

active”

e. The current recipe number will be displayed, for example:

RECIPE 6 means “the sixth recipe is currently active”

FAST

MANUAL

RUN

ICONS (LIT)

OUT Indicates either the relay output is energized, or the analog output is

greater than 0%.

ALM1 Indicates the respective alarm (one) is active. ALM2 Indicates the respective alarm (two) is active. ALM Indicates an alarm wihtout an assigned output is active.

KEYS

FAST

No independent function. Press to modify the function of another key.

MANUAL

Press to toggle between manual and automatic control. When lit, indicates the unit is under manual control. Press to abort a running or held recipe and return controller to manual control.

RUN (For Profile Control) Press to Run, Hold or Abort a recipe. When a recipe is active, press to prompt a display message for selecting the

recipe nuumber (1 through 20). When lit, indicates a recipe is running. When blinking, indicates a recipe is on hold.

FAST

535 User's Manual Chapter 2, Controller Operation 5

RUN

FAST+RUN

When a recipe is running or held, press to advance to next segment.

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Operation

DISPLAY

Press to toggle through values in the 2nd display for setpoint, ramping setpoint (if available), deviation, PV1 (If PV source is not PV1), PV2 (if PV Source is not PV1), output and valve position (if available).

In RECIPE SET UP, TUNING, SET UP mode, press to return controller to

OPERATION mode (display will show current setpoint).

FAST+DISPLAY

When a recipe is running or held, press to select recipe status. When no recipe is running or held, press to display EVENT 000 message.

Press to increase the value or selection of displayed parameter.

FAST+

Press to scroll through values at a faster rate.

Press to decrease the value or selection of displayed parameter.

FAST+

Press to scroll through values at a faster rate.

DISPLAY

FAST

DISPLAY

ACK

Press to acknowledge (an) alarm(s). Press to acknowledge Run, Abort and next segment commands. When lit, indicates there is an acknowledgeable alarm or an event is being held

at the end of a recipe.

FAST+ACK

For events held at the end of a recipe, press to acknowledge and disable the events.

In OPERATION mode, press to access the TUNING mode/menu. In RECIPE SET UP, SET UP or TUNING mode, press to advance through a

menu’s parameters. (Use FAST+MENU to advance to to the next menu.)

FAST+MENU

In Automatic control, press to enter RECIPE SET UP mode. In Manual control, press to enter the SET UP mode.

In SET UP mode, press to advance through menus. (Use MENU by itself to access the parameters of a particular menu.)

ACK

FAST

ACK

MENUFAST

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Operation

BASIC PROFILE CONTROLLER OPERATING PROCEDURES

Use the following as a quick guide to key operating functions of the 535-PROF.

To Enter the RECIPE SET UP Mode

1. To enter the RECIPE SET UP mode from any other mode, hold down FAST and press MENU. The MENU key will illuminate. The 2nd display line will indicate RECIPE #, where # represents the recipe number.

2. Use the or key to select the recipe number.

3. Press MENU by itself. The first parameter of this menu for this recipe will appear in the 2nd display, replacing RECIPE # , while the choices or selections appear in the 3rd display.

4. Pressing DISPLAY at any time exits the RECIPE SET UP mode and returns you to OPERATION mode.

To Enter the SET UP Mode

1. If you are not in MANUAL control, press MANUAL. The MANUAL key will illuminate.

2. Hold down FAST and press MENU. The MENU key will illuminate. RECIPE # will appear alone in the 2nd display. Entering the SET UP mode first gives you access to the RECIPE SET UP mode.

3. Hold down FAST and press MENU. CONFIG appears alone in the 2nd display. You are now in the SET UP mode. See Chapter 5 for a list of all Set Up parameters, and Chapter 7 for applications.

To run a recipe:

1. Pressing the RUN key prompts the choice of recipe number.

2. Use the or key to select the proper recipe.

3. Press the ACK key to start the recipe.

To hold a recipe:

1. While a recipe is running (indicated when the RUN key is lit red), briefly press the RUN key. The key will blink on and off and the 3rd display will indicate HOLDING.

2. Press the RUN key again to resume the recipe.

To abort a recipe and place the controller in MANUAL mode:

1. While a recipe is running (indicated when the RUN key is lit red), press the MANUAL key. The 2nd display line will show REC. ABORT and the 3rd display will show PRESS ACK.

2. Press the ACK key within 5 seconds to abort the recipe and place the controller in MANUAL mode. The manual output value will be the last output at the point the recipe was aborted. The raise and lower keys may be used to modify the output.

To abort a recipe and control to the IDLE setpoint:

1. While a recipe is running (indicated when the RUN key is lit red), press the RUN key and hold until the 2nd display line shows REC. ABORT and the 3rd

display will show PRESS ACK.

2. Press the ACK key within 5 seconds to abort the recipe and the controller

535 User's Manual Chapter 2, Controller Operation 7

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Operation

will control to the IDLE setpoint. The raise and lower keys may be used to adjust the setpoint.

To display the setpoint (SP), ramping setpoint (RAMP), deviation (DEV) or output % (OUT %) while a recipe is running:

1. Toggle the DISPLAY key until the appropriate selection appears on the 2nd

display line.

To display the recipe number, the current ramp or soak segment, the time left in the segment, the event status or the number of recipe cycles completed:

1. Press the FAST key and toggle the DISPLAY key until the appropriate se-

lection appears on the 3rd display line.

BASIC PROCESS CONTROLLER OPERATING PROCEDURES

This is a guide to controller operation when not using the profile options.

To select /change a setpoint

1. Press the MENU key twice to display SP SELECT in the TUNING mode.

2. Use the or key to toggle the active setpoint. Before the newly selected setpoint is made active, there is two-second de-

lay to prevent any disruptive bumps.If the setpoint displayed is ramping, RAMPING will show the 3rd display.

3. To change the setpoint value, press or while the setpoint is shown in the 2nd display.

To change from auto to manual control (bumpless transfer)

1. When in automatic 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 SET UP mode.

2. The 2nd display will not change, and the MANUAL key will no longer be lit once control changes.

To change manual output values

1. Make sure the controller is under manual control.

2. Use the DISPLAY key to toggle 2nd display to output level.

3. Use the or key to change the value.

To override security

If a locked operation is attmpted, SECURITY appears in the 2nd display for two seconds).

1. Use the and keys to quickly enter the security code, which will show in the 3rd display. The starting value is 0.

Note: Two seconds of key inactivity will clear the display.

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Operation

535

MANUAL DISPLAY RUN

ACK MENU FAST

OUT 1 ALM 1

BEFORE

AFTER

535

MANUAL DISPLAY RUN

ACK MENU FAST

OUT 1

2. If the code is correct, CORRECT appears in the 3rd display. The display will clear after two seconds, allowing full access.

4. If code is incorrect, INCORRECT appears in the 3rd display. This 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.)

• For on/off outputs, the output value shown is either ON or OFF.

• 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).

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

• lit icons 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).

Figure 2.2 Before and After Acknowledging an Alarm

535 User's Manual Chapter 2, Controller Operation 9

Page 19

Operation

To acknowledge an alarm(s):

1. To acknowledge Alarm 1, press ACK once.

2. To acknowledge Alarm 2, press ACK twice.

3. If both alarms are activated, press ACK once to acknowledge Alarm 1, then

again to acknowledge Alarm 2.

4. The message and alarm icon dissappear. Refer to

Figure 2.2

Latching Alarms

If an alarm is set up to be latching (for details, see Chapter 5) then, in general, it must be acknowledged in order to clear the alarm and release the relay (if applicable). A non-latching alarm will clear itself as soon as the process leaves the alarm condition.

Limit Sequence

An alarm can be configured to be both latching and non-acknowledgeable. In this case, the alarm is acknowledgeable only after the process has 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.

NOTE:

All alarms are software alarms unless tied to an output relay in the SET UP mode. See Chapters 5 and 7 for details on alarms.

NOTE:

Powering down the 535 acknowledges/clears all latched alarms. When powering up, all alarms will be reinitialized.

10 Chapter 2, Controller Operation 535 User's Manual

Page 20

CHAPTER 3 INSTALLATION

MOUNTING THE CONTROLLER

The 535-PROF front face is NEMA 4X rated (waterproof). To obtain a waterproof seal between the controller and the panel, follow these directions:

1. The 535-PROF fits in a standard 1/4 DIN cutout. Mount the 535-PROF in any panel with a thickness from .06 in. to .275 in. (1.5 mm to 7.0 mm).

Figure 3.1

be precise, and the edges free from burrs and waves.

shows the controller and panel dimensions. The panel cutout must

7.180 (182.37) OVERALL LENGTH

1.180 (29.97)

3.770 (95.76)

OUT 1 2 ALM 1 2

5 3 5

PANEL

Install / Wire

Figure 3.1 Instrument Panel & Cutout Dimensions

3.622 (92.00) MIN.

3.653 (92.80) MAX.

3.622 (92.00) MIN.

3.653 (92.80) MAX.

3.770 (95.76)

6.000 (152.40)

SIDE

FRONT

BEZEL GASKET

3. Place bezel gasket around the controller case (starting at the back of controller). Then, slide the gasket against the back of the bezel.

4. With the bezel gasket in place, insert the 535-PROF into the panel cutout from the front of the panel.

5. Slide the mounting collar over the back of the case, as shown in

Figure 3.2.

The collar clip edges will lock with matching edges on the controller case.

6. Insert the four mounting collar screws from the rear of the collar. Gradually

Mounting Clip

Bezel

3.585 (91.06)

CUTOUT

Figure 3.2 Attaching mounting collar

Mounting Collar

535-PROF User's Manual Chapter 3 11

Collar Screws (1 of 4)

Page 21

Install / Wire

AUTION!

The enclosure into which the 535PROF Controller is mounted must be grounded.

WARNING! Avoid electrical shock. Do not connect

AC power wiring at the source distribution panel until all wiring connections are complete.

tighten the screws (using a Phillips #2 screwdriver) to secure the controller against the panel.

7. If there is difficulty with any of the mounting requirements, apply a bead of caulk or silicone sealant behind the panel around the perimeter of the case

WIRING

535-PROF controllers are thoroughly tested, calibrated and “burned in” at the factory, so the controller is ready to install. Before beginning, read this chapter thoroughly and take great care in planning a system. A properly designed system can help prevent problems such as electrical noise disturbances and dangerous extreme conditions.

1. For improved electrical noise immunity, install the 535-PROF as far away as possible from motors, relays and other similar noise generators.

2. 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.

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 for wiring different types of process inputs. The shaded areas on the diagrams show which rear terminals are used for that type of wiring.

Figure 3.3 All 535-PROF Terminal Assignments Actual 535-PROF device only has top and bottom numbers of each column of terminals marked.

WARNING! ELECTRIC SHOCK HAZARD!

Terminals 1 and 2 carry live power. DO NOT touch these terminals when power is on.

WARNING! Terminal 9 must be grounded to avoid

potential shock hazard, and improved noise immunity to your system.

LINE

NEUTRAL

OUT 1–

OUT 1+

OUT 2–

OUT 2+

OUT 3–

OUT 3+

TOP (as viewed from back of controller)

816

EARTH

917

GND

S/W 1

S/W 2

S/W 3

RSP–

RSP+

OUT 4–

OUT 4+

DIN

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

COLD

JUNC–

COLD

JUNC+

24 32

not used

COMM–

COMM+

PV2–

PV2+

RTD 3RD

PV1–

PV1+

12 Chapter 3 535-PROF User's Manual

Page 22

AC Power Input

Terminals 1 and 2 are for power. Terminal 9 is the earth ground. Use a 0.5 Amp, 250 V, fast-acting fuse in line with your AC power connection.

TOP

Install / Wire

EARTH/

917

GROUND

24 32

POWER

816

Screws must be tight to ensure good electrical connection

Process Variable Input

The 535-PROF 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

(terminals 28 and 29).

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.

917

816

535-PROF User's Manual Chapter 3 13

24 32

Figure 3.5 Process Variable Terminals

PV 2-

PV2+

RTD 3rd

PV 1-

PV1 +

Page 23

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.

For PV1

THERMOCOUPLE INPUT

For PV2

THERMOCOUPLE INPUT

14 Chapter 3 535-PROF User's Manual

Page 24

Install / Wire

For PV1

MILLIAMP INPUT

2-wire transmitter with separate power supply

– External + Power Supply

– Transmitter +

MILLIAMP INPUT

2-wire transmitter with loop power supply

2-wire

transmitter +

Input power

for transmitter

4-20 mA output

from transmitter

MILLIAMP INPUT

4-wire transmitter with loop power supply

For PV2

MILLIAMP INPUT

2-wire transmitter with separate power supply

External + Power Supply

Transmitter +

MILLIAMP INPUT

2-wire transmitter with loop power supply

—

MILLIAMP INPUT

4-wire transmitter with loop power supply

—

2-wire transmitter

—

Input power for transmitter

4-20 mA output

—

from transmitter

Figure 3.7 PV1 and PV2 Wiring for Milliamp Inputs with Internal and External Power Supply

NOTE:

To use loop power, there must be a loop power module is installed in the 3rd or 4th output socket. Compare the controller product number with the order code in Chapter 1 to determine if the 535-PROF has a loop power module installed. To install a loop power module, refer to Chapter 4

535-PROF User's Manual Chapter 3 15

Page 25

Install / Wire

Figure 3.8 Digital inputs Wiring with a Switch or Relay

Digital Input(s)

Digital inputs can be activated in three ways: a switch (signal type), closure of a relay, 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

Wire the switch/relay between terminal 17 and the specific digital input terminal (

Figure 3.8

Screws must be tight to ensure electrical connection

DIN

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

24 32

Figure 3.9 Digital Input Wiring with an Open Collector

Screws must be tight to ensure electrical connection

DIN

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

24 32

DIN GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

22 30

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

GND

DIN

22 30

2. Digital Inputs with an Open Collector

An open collector is also called a transistor. Wire the transistor between terminal 17 and the specified digital input terminal (

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

DIN

22 30

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

DIN

22 30

Remote Setpoint Option

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

DIN

22 30

DIN

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

22 30

Figure 3.9

DIN

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

22 30

)

Figure 3.10 Remote Setpoint Terminals

16 Chapter 3 535-PROF User's Manual

Use terminals 13 and 14 to connect the remote setpoint signal (see

Figure 3.10

Source

Page 26

OUTPUT MODULES

The 535-PROF output modules are used for control, alarms and retransmission. The four output module types are: Mechanical Relay, Solid State Relay (Triac), DC Logic (SSR Drive) and Analog (Milliamp)

To install these modules, plug them into any of the four output sockets on the printed circuit boards (refer to Chapter 4). The wiring is the same whether the modules are used for control, alarm or retransmission.

The diagrams on the next two pages are a guide for properly connecting the various outputs. To find out which module(s) have been installed in the controller, compare the product number on the controller label with the section Order Code in Chapter 1. This section also includes a diagram of how to wire a position proportioning output, a special application using two mechanical or two solid state relays.

1. Mechanical Relay Output

• Output 1 is always Control 1.

• Outputs 1, 2 and 3 are jumper selectable for normally open and normally closed on the power supply circuit board.

• Output 4 is always configured for normally open and has reduced voltage and current ratings (see Specifications).

Install / Wire

NOTE:

Refer to corresponding jumpers.

Second input jumper connector on the option board must be in either (milliamp) or V (voltage) position.

Figure 4.2

for location of the

Line Power

Load

Recommend use of both MOV and snubber

Terminals used

with Output

Module 1

Terminals used

with Output

Module 2

Terminals used

with Output

Module 3

2. Solid State Relay (Triac) Output

• Output 1 is always Control 1.

• Respective jumper J1, J2 or J3 must be set to normally open for SSR (Triac) output.

• Output 4 is always configured for normally open and has reduced voltage and current ratings (see Specifications).

Terminals used

with Output

Module 3

Line Power

Load

Terminals used

with Output

Module 1

Terminals used

with Output

Module 2

Terminals used

with Output

Module 4

Terminals used

with Output

Module 4

Figure 3.11 Mechanical Relay Output wiring

Figure 3.12 SSR Relay Output Wiring

Recommend use of both MOV and snubber

535-PROF User's Manual Chapter 3 17

Page 27

Install / Wire

3. DC Logic (SSR Drive) Output

• Output 1 is always Control 1.

• Respective jumper J1, J2 or J3 must be set to normally open for DC Logic output.

• Output 4 is always configured for normally open.

Figure 3.13 DC Logic Output Wiring

Figure 3.14 Milliamp Output Wiring

Terminals used

with Output

Module 1

Load

Terminals used

with Output

Module 2

Terminals used

with Output

Module 3

Terminals used

with Output

4. Milliamp Output

• Output 1 is always Control 1.

• Respective jumper J1, J2 or J3 must be set to normally open for Milliamp output.

Terminals used

with Output

Module 1

Terminals used

with Output

Module 2

Terminals used

with Output

Module 3

Terminals used

with Output

Module 4

Load

5. Position Proportioning Output

Module 4

(with or without Slidewire Feedback)

POSITION PROPORTIONING

Electric Motor Actuator

Figure 3.15 Position Proportioning Output Wiring

CCW Winding

Actuator Supply Current

COMCWCCW

CW Winding

COM

CCW

Slidewire Wiper 0–1050 Ohm

18 Chapter 3 535-PROF User's Manual

OUTPUT

Page 28

• Mechanical relay or solid state relay modules must be installed in output sockets 1 and 2.

• When using velocity control (no slidewire 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 at the host and the last device on the line. Some RS 485 cards/converters already have a terminating resistor. We recommend using RS-232/RS-485 converter (Product #500-485). The communication protocol is asynchronous bidirectional half-duplex, hence the leads are labelled and

Comm –

535

Terminals

Comm +

Install / Wire

Figure 3.16 Serial Communications Terminals

or other host

RS-485

Twisted, shielded

port

Comm -

Comm +

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.

To "Comm -" terminal of next Powers device

To "Comm +" terminal of next device

Use a 60 to 100 Ohm terminating resistor connected to the two data terminals of the final Powers device on the line.

535-PROF User's Manual Chapter 3 19

Page 29

Install / Wire

Figure 3.17 535-PROF Wiring with Limit Control

535 PROFILE

CONTROLLER

AC POWER

0.5 AMP, 250 V, FAST ACTING FUSE

Limit Control

Temperature applications where abnormally high or low temperature 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 a typical application using the 535-PROF Process Controller with a 353 Limit Controller.

EARTH GROUND

T.C.

INPUT

LOAD

POWER

FAST ACTING

FUSE

HEAT

LOAD

PROCESS SENSOR

LIMIT SENSOR

MERCURY

RELAY

FOR CONTROL

HIGH LIMIT MECHANICAL CONTACTOR

COIL

RELAY/ CONTACTOR COIL POWER

T/C INPUT

N.O.

OPTIONAL

MOMENTARY SWITCH

MANUAL RESET

FOR LIMIT CONTROL

353 LIMIT CONTROLLER

FAST

ACTING

FUSE

INDICATOR ON

WHEN LIMIT TRIPS

LIMIT CONTROLLER

AC POWER

FUSE

20 Chapter 3 535-PROF User's Manual

Page 30

CHAPTER 4 HARDWARE SET UP

Hardware configuration determines the available outputs as well as the type of input signal. The 535-PROF controller comes factory set with the following:

• All specified module and options installed (for details, refer to the Order Code in Chapter 1).

• Process variable and remote setpoint set to accept a milliamp input

• Relay outputs set to normally open.

Alter the factory configuration of the 535-PROF, requires accessing the circuit boards, and locating the jumpers and output modules (see

Figure 4.1

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

Hardware Set Up

NOTE: Hardware configuration of the

controller is available at the factory; Consult an application engineer for details.

MICROCONTROLLER

BOARD

A detailed view of the circuit boards appears in

OPTION BOARD

Figure 4.2

After configuring the hardware, or if no changes are necessary, continued setting up the process as needed.

HARDWARE INPUT TYPES

The Process Variable

The 535-PROF accepts several different types of process variable signals. Set a jumper location to specify the type of input signal. Set the signal range in the software (see Chapter 5 for software menus, or Chapter 7 for applications).

The jumpers for the process variable are located on the Microcontroller Circuit Board (see as follows:

Figure 4.2

). The factory default is Milliamp. Locations are marked

V Voltage MA Milliamp TC Thermocouple with downscale burnout TC Thermocouple with upscale burnout RTD RTD

Figure 4.1 Location of Printed Circuit Boards for Hardware Configuration

NOTE: Thermocouple downscale and upscale burnout offers a choice in which direction the controller would react in the event of thermocouple failure. For example, in heat applications, typically, it is desirable to fail upscale (TC ) so that the system does not apply more heat.

535-PROF User's Manual Chapter 4 21

Page 31

Hardware Set Up

BATTERY

EPROM

NOTE:

Changing the jumpers means moving the jumper connector. The jumper connector slips over the pins, straddling two rows of pins. The printed circuit boards are labeled next to the jumpers.

Figure 4.2 (from the top) The Microcontroller Circuit Board, the Option Board, and the Power Supply Board

The Remote Setpoint

Figure 4.2

fault is milliamp. Choose from the following settings:

MA Remote setpoint with milliamp signal (jumper installed)

shows the location of the remote setpoint jumper. The factory de-

V Remote setpoint with voltage signal (jumper removed)

Mechanical Relays

There are three output module sockets on the Power Supply Circuit Board, and one output module on the Option Board (see on the Power Supply Board may be configured for either normally open (NO) or normally closed (NC). A jumper located next to each socket determines this configuration. All relay output are factory set to NO (normally open).

EPROM

BATTERY

5-Pin Connector

Female 22-Pin ConnectorFemale 22-Pin Connector

Figure 4.2

). The mechanical relay

TB2

V MA

MA TC

TC ▼ TC

TC ▲

2ND

RTD

V MA TC ▼ TC ▲

PV1

RTD

TB1

Remote Setpoint Jumper

Male 22-Pin

Connector

5-Pin Connector

Output 4

Female 34-Pin Connector

Male 22-Pin

Connector

Male 34-Pin Connector

Module

Retention

over Outputs 1,2,3

Plate

3 2

NO J3 NC

NO J2 NC

NO J1 NC

Jumpers

NO and NC

22 Chapter 4 535-PROF User's Manual

Page 32

Hardware Set Up

ACCESSING AND CHANGING JUMPERS

Follow these instruction to change jumpers for the Process Variable, Remote Setpoint and Digital Inputs:

Equipment needed: Needle-nose pliers (optional)

Phillips screwdriver (#2) Wrist grounding strap

1. With power off, loosen the four front screws, and remove them.

2. Side the chassis out of the case by pulling firmly on the bezel.

3. Use

4. Using the needle nose pliers (or fingers), pull straight up on the connector

Figure 4.2

and remove it from its pins, as shown in pins.

to locate the jumper connector to change.

Photo 2

. Be careful not to bend the

CAUTION!!

Static discharge can cause damage to equipment. Always use a wrist grounding strap when handling electronics to prevent static discharge.

2. Remove Jumpers

5. Find the new location of the jumper connector (again, refer to Carefully place it over the pins, then press connector straight down. Make sure it is seated firmly on the pins.

6. Make any other jumper changes as needed. To alter output modules,

please refer to the next section, starting with Step #3.

7. To reassemble the controller, properly orient the chassis with board opening 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. Carefully insert and align screws. Tighten them until the bezel is seated firmly against the gasket. Do not overtighten.

535-PROF User's Manual Chapter 4 23

Figure 3.2

Page 33

Hardware Set Up

ADDING AND CHANGING OUTPUT MODULES

The 535-PROF has provisions for four output modules. A controller ordered with output module options already has the modules properly installed. Follow these instruction 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 the four front screws, and remove them.

2. Side the chassis out of the case by pulling firmly on the bezel.

3. Use a flat 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. As shown in driver, the smaller Option board and the Power Supply board (the one with 3 modules).

5. To change modules 1, 2 or 3: Output modules 1, 2, and 3 are firmly held in place by a retention plate and

tie wrap. Carefully snip the tie wrap with a wire cutter. To prevent damage to the surface mount components, ALWAYS snip the tie wrap on TOP of the Retention Plate, as shown in

Remove the retention plate.

Photo 4

, carefully pry apart, using hands or a small flat screw-

Photo 5

3. Pry Clips

24 Chapter 4 535-PROF User's Manual

4. Separate Boards

5. Remove Retention Plate

Page 34

6. To 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

Figure 4.3

to make sure that the pins are straight.

8. To install any module, align its pins with the holes in the circuit board, and carefully insert the module in the socket. Press down on the module until it is firmly seated; refer to

shows a representation of an output module. Inspect the module(s)

Photo 7

Photo 6

Hardware Set Up

Figure 4.3 Representation of Module

7. Add/Change Module6. Snip Tie Wrap

9. Replace tie wraps for all the modules (the Retention Plate and Output Mod-

ule 4) with new ones before reassembling the controller. Failure to use the tie wraps may result in loosening of the module and even-

tual failure. All separately ordered modules should come with a tie wrap. Extra sets of tie wraps are available by ordering Part #535-PROF-665.

NOTE: For greatest accuracy, calibrate all milliamp modules added for retransmission as per the instructions in Appendix 2.

10. Rejoin the circuit boards by aligning the pins of their connectors, then squeez-

ing the board(s) together. Make sure that all three printed circuit boards are properly seated against one another; check along side edges for gaps. Make sure the cable assemblies are not pinched.

11. To reattach the board assembly to the front face assembly, align the boards

(with the open area on top) into the slots of the font face assembly. The clips should snap into place.

12.To reassemble the controller, properly orient the chassis with board open-

ing 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.

13. Carefully insert and align screws. Tighten them until the bezel is seated firmly

against the gasket. Do not overtighten.

535-PROF User's Manual Chapter 4 25

Page 35

Hardware Set Up

SPECIAL COMMUNICATIONS MODULE

A special communications module is available for the 535-PROF; see order code in Chapter 1 for details.

Equipment needed: Wrist grounding strap

Phillips screwdriver (#2) Small flat blade screwdriver

1. Before installing the communications module, set up the hardware wiring for the application. See Chapter 4 for details.

2. With power off, loosen the four front screws, and remove them.

3. Side the chassis out of the case by pulling firmly on the bezel. Do not detach the board assembly form the front face of the controller.

4. Orient the Communications Module as shown, and attach it to Connectors P1 and P2 as shown in

Figure 4.4

Insert module onto connectors

Figure 4.4 Install Communications Module onto Microcontroller Board

Front of controller (circuits boards still attached to front face)

EPROM

TB2

BATTERY

5. To reassemble the controller, properly orient the chassis with board open-

REMOTE SP

CONFIGURATION

PV INPUT JUMPER

CONFIGURATION

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.

ASS'Y 535-607

MA TCt TCs RTD

V MA TCt TCs RTD

2ND

PV1

TB1

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. Carefully insert and align screws. Tighten them until the bezel is seated firmly against the gasket. Do not overtighten.

26 Chapter 4 535-PROF User's Manual

Page 36

CHAPTER 5 SOFTWARE CONFIGURATION

The software configuration menus of the 535-PROF contain user-selected variables that define the action of the controller. Read through this section before making any parameter adjustments to the controller.

Controller Set Up

Figure 5.1 Menu Flowchart for Set Up

When initially setting up the

controller, cycle through all the

parameters in each Menu.

Press the MENU+FAST to

advance to the next Menu.

➤

press:

MENU/FAST

➤

Press MENU to advance to the

next parameter (this also sets

the value for the current

parameter. Use arrow keys

to select a value).

Use the arrow keys to enter

numerical values, and/or move

through the selection group.

➤

press:

Go to next Menu Block

press:

CONFIG.

➤

INDICATOR

(D)

press MENU/FAST

➤

MENUS

In Set Up mode, there are 13 sets of options that control different aspects of 535PROF operation; in Tuning mode, there is one. Each set of options is a menu. When traversing the two modes, the menu names appear in the 2nd display.

CONFIG Mode selection and input/output hardware assignments REC. CONF. General recipe options PV1 INPUT 1st process variable input options PV2 INPUT 2nd process variable input options CUST. LINR. Linearization curve options for PV1 input. CONTROL Control algorithm options ALARMS Alarm options REM. SETPT. Controller re mote 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) RECIPE # Individual recipe configuration TUNING Tuning parameters configuration (see Chapter 6)

This is a Menu. Its name will show in the 2nd display.

This is a menu Parameter. The name shows in the 3rd display. In this manual, independent parameters

appear as white text on black, and dependent parameters appear as black text on white.

This is a parameter Value. These values appear in the 3rd display, replacing the parameter name. In this manual, parameter graphics

indicate the default (factory) setting.

If the default value is dependent on other variables, (D) is shown. A range of values is indicated by (R).

CAUTION!

All software changes occur in real time; always perform set up functions under manual operation.

NOTE: For information about the Tuning menu/mode, refer to Chapter

6. For more information about set up parameters and 535-PROF applications, refer to Chapter 7.

535-PROF User's Manual Chapter 5 27

Page 37

Controller Set Up

Figure 5.2 Configuration Flowchart

MANUAL

to place controller

under Manual Control

MANUAL

OPERATION

TUNING

DISPLAY

FAST + MENU

DISPLAY

to return to

operation mode

RECIPE #

FAST + MENU

SET UP

(Configuration) Menus

CONFIG.

REC. CONF.

PV1 INPUT

PV2 INPUT

CUST. LINR.

CONTROL

ALARMS

to scroll

thru recipes

Set Up Mode is only accessible if controller is under Manual Control.

* Define # of recipes in REC. CONF. menu

FAST + MENU

to scroll through the menu blocks

28 Chapter 5 535-PROF User's Manual

REM. SETPT.

RETRANS.

SELF TUNE

SPECIAL

SECURITY

SER. COMM.

Page 38

Controller Set Up

PARAMETERS

Within each menu are parameters for particular control functions. Select values for each parameter depending on the specific application. Use the MENU key to access parameters for a particular menu; the parameter name will replace the menu name in the 2nd display, and the parameter value will show in the 3rd display.

This chapter outlines all the available parameters for the 535-PROF. Some parameters are independent of any special configuration, and others are depen- dent on the individual configuration. This manual displays these two types of parameters differently; refer to

Figure 5.3

. A special feature of the 535-PROF,

called Smart Menus, determines the correct parameters to display for the spe- cific configuration, so not all the listed parameters will appear.

CONFIGURATION AND OPERATION

Figure 5.3

and the configuration menus:

• SET UP menus can only be accessed from manual control. To transfer the

• To access the SET UP menus, hold down FAST and press MENU until

• To access the parameters for a particular menu, press MENU.

• To select a parameter value, use and . Press MENU to advance to the

• To advance to the next menu, press FAST+MENU.

• TUNING mode (and the TUNING menu) can be accessed from either auto-

• RECIPE SET UP mode (and the RECIPE # menu) can be accessed from

• To access the RECIPE # menu, press FAST+MENU.

• To return controller to manual control, press DISPLAY or SET PT.

shows the relationships among the different modes of the 535-PROF

535-PROF from automatic to manual control, press MANUAL.

CONFIG appears in the 2nd display. The MENU key will also illuminate.

next parameter, or FAST+MENU to advance to the next menu.

matic or manual control. To access the tuning menu, press MENU .

either automatic or manual control.

TUNE PT.

AUTOMATIC

Figure 5.3 Independent vs. Dependent Parameters

CONTACT 1

MANUAL

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

A key to these functions (as shown below) appears at the bottom of every page in the menu section of this chapter.

WHERE TO GO NEXT

• For information about all the software menus and parameters, continue reading this chapter. Refer to Appendix D for a quick-reference flowchart of all menus and parameters.

• For information about the installed options on the 535-PROF, compare the product label on top of the controller to the order code in Chapter 1.

• To mount the controller and configure the wiring of the 535-PROF for inputs and outputs, see Chapter 3.

• To alter the output module and jumper configuration of the controller, see Chapter 4.

535-PROF User's Manual Chapter 5 29

FAST MENU

▲ ▼

DISPLAY

Page 39

Controller Set Up

• For information about applications for the 535-PROF, see Chapter 7.

• For more information about the Tuning function of the 535-PROF, see Chapter 6.

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

30 Chapter 5 535-PROF User's Manual

▲ ▼

DISPLAY

Page 40

SOFTWARE MENUS AND PARAMETERS

Controller Set Up

CONFIG.

1. CTRL. TYPE

Defines the type of control output(s).

D STANDARD Standard control output, no special algorithms

• POS. PROP. Position proportioning control output

• STAGED Staged outputs

• DUPLEX Duplex outputs

2. LINE FREQ

Defines the power source frequency.

• 50 HZ

D 60 HZ

3. PV SOURCE

Defines how the PV input is derived from PV1 and PV2.

D PV1 Use PV1

• 1/2:SWITCH Use PV1 until contact/com selects PV2

• 1/2:BACKUP Use PV2 if PV1 is broken

• PV1–PV2 Use PV1–PV2

• PV1+PV2 Use PV1+PV2

• AVG. PV Use the average of PV1 and PV2

• HI SELECT Use PV1 or PV2 (whichever is greater)

• LO SELECT Use PV1 or PV2 (whichever is less)

CONFIG.

CTRL. TYPE

STANDARD

LINE FREQ

60 Hz

PV SOURCE

PV1

NOTE:

PV1 and PV2 can be of different types and different range.

4. REM. SETPT.

Selects function of the remote setpoint.

D DISABLED

• ENABLED

REM. SETPT.

DISABLED

5. OUTPUT 2

Defines the function of the second output.

• ALM/EV:ON For an alarm or event output

• ALM/EV:OFF For an alarm or event output

• RETRANS. Retransmission

• COMM. ONLY Output addressable only through communication

D OFF Completely deactivates the output

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

535-PROF User's Manual Chapter 5 31

DISPLAY

FAST MENU

▲ ▼

OUTPUT 2

OFF

DISPLAY

Page 41

Controller Set Up

OUTPUT 3

OFF

6. OUTPUT 3

Defines the function of the third output.

• ALM/EV:ON For an alarm or event output

• ALM/EV:OFF For an alarm or event output

• RETRANS. Retransmission

• COMM. ONLY Output addressable only through communications

D OFF Completely deactivates the output

OUTPUT 4

OFF

ANLG.RNG.:1

4-20 mA

ANLG.RNG.:2

4-20mA

7. OUTPUT 4

Defines the function of the fourth output.

• ALM/EV:ON For an alarm or event output

• ALM/EV:OFF For an alarm or event output

• RETRANS. Retransmission

• COMM. ONLY Output addressable only through communications

D OFF Completely deactivates the output

8. ANLG. RNG.:1

Defines the output signal for the first output.

D 4–20 mA

• 0–20 mA

• 20–4 mA

• 20–0 mA

9. ANLG. RNG.:2

Defines the output signal for the second output.

D 4–20 mA

• 0–20 mA

• 20–4 mA

• 20–0 mA

ANLG.RNG.:3

4-20mA

ANLG.RNG.:4

4-20mA

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

32 Chapter 5 535-PROF User's Manual

DISPLAY

FAST MENU

10. ANLG. RNG.:3

Defines the output signal for the third output.

D 4–20 mA

• 0–20 mA

• 20–4 mA

• 20–0 mA

11. ANLG. RNG.:4

Defines the output signal for the fourth output.

D 4–20 mA

• 0–20 mA

• 20–4 mA

• 20–0 mA

▲ ▼

DISPLAY

Page 42

12. CONTACT 1

Defines the operation of the first digital input.

• RECIPE. 1–7 Chooses the recipe number (uses Binary contact 1-3)

• SETPT. 1–8 Chooses Local setpoint 1–8 (uses BCD contacts 1–4)

• REM. SETPT. Makes the remote setpoint active

D MANUAL Trips the controller to manual control

• 2ND. SETPT. Makes the second setpoint active

• 2ND. PID Makes the second set of PID values active

• ALARM ACK. Acknowledges alarms

• RST. INHBT. Deactivates the reset term

• D.A./R.A. Switches the control action

• STOP A/T Suspends the adaptive tune function

• LOCK. MAN. Locks controller in manual control

• UP KEY Remote function

• DOWN KEY Remote function

• MENU KEY Remote MENU key function

• FAST KEY Remote FAST key function

• DISP KEY Toggle between SP DEV or OUT%

• COMM. ONLY Status readable only through communications

• START REC. Runs the most recently selected recipe (default is RECIPE 1). Aborts recipe when deactivated.

• HOLD REC. Holds running recipe at current position. Resumes running of recipe when deactivated.

• RESET REC. Resets a running or held recipe to the beginning. For linked recipes, resets to the beginning of the first linked recipe. No action when deactivated.

• ABORT REC. Aborts running or held recipe. No action when deactivated.

• NEXT SEG. Advances running or held recipe to the end of the current ramp or soak segment. No action when deactivated

• PV2.SWITCH Switches between PV1 and PV2

Controller Set Up

CONTACT 1

MANUAL

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

535-PROF User's Manual Chapter 5 33

DISPLAY

FAST MENU

▲ ▼

DISPLAY

Page 43

Controller Set Up

CONTACT 2

REM. SETPT.

13. CONTACT 2

Defines the operation of the second digital input.

D REM. SETPT.

• MANUAL

• 2ND. SETPT.

• 2ND. PID

• ALARM ACK.

• RST. INHBT.

• D.A./R.A.

• STOP A/T

• LOCK. MAN.

• UP KEY

• DOWN KEY

• MENU KEY

• FAST KEY

• DISP KEY

• COMM. ONLY

• START REC.

• HOLD REC.

• RESET REC.

• ABORT REC.

• NEXT SEG.

• PV2.SWITCH

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

34 Chapter 5 535-PROF User's Manual

▲ ▼

DISPLAY

Page 44

14. CONTACT 3

Defines the operation of the third digital input.

• REM. SETPT.

• MANUAL

D 2ND. SETPT.

• 2ND. PID

• ALARM ACK.

• RST. INHBT.

• D.A./R.A.

• STOP A/T

• LOCK. MAN.

• UP KEY

• DOWN KEY

• MENU KEY

• FAST KEY

• DISP KEY

• COMM. ONLY

• START REC.

• HOLD REC.

• RESET REC.

• ABORT REC.

• NEXT SEG.

• PV2.SWITCH

Controller Set Up

CONTACT 3

2ND. SETPT.

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

535-PROF User's Manual Chapter 5 35

DISPLAY

FAST MENU

▲ ▼

DISPLAY

Page 45

Controller Set Up

CONTACT 4

2ND. PID

15. CONTACT 4

Defines the operation of the fourth digital input.

• REM. SETPT.

• MANUAL

• 2ND. SETPT. D 2ND. PID

• ALARM ACK.

• RST. INHBT.

• D.A./R.A.

• STOP A/T

• LOCK. MAN.

• UP KEY

• DOWN KEY

• MENU KEY

• FAST KEY

• DISP KEY

• COMM. ONLY

• START REC.

• HOLD REC.

• RESET REC.

• ABORT REC.

• NEXT SEG.

• PV2.SWITCH

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

36 Chapter 5 535-PROF User's Manual

▲ ▼

DISPLAY

Page 46

16. CONTACT 5

This defines the operation of the fifth digital input.

• REM. SETPT.

• MANUAL

• 2ND. SETPT.

• 2ND. PID

D ALARM ACK.

• RST. INHBT.

• D.A./R.A.

• STOP A/T

• LOCK. MAN.

• UP KEY

• DOWN KEY

• MENU KEY

• FAST KEY

• DISP KEY

• COMM. ONLY

• START REC.

• HOLD REC.

• RESET REC.

• ABORT REC.

• NEXT SEG.

• PV2.SWITCH

Controller Set Up

CONTACT 5

ALARM ACK.

17. LOOP NAME

A 9-character message associated with the loop. The first character of the 3rd display will be flashing. To enter message, press and keys to scroll through character set. Press FAST key to enter the selection and move to next digit. Press MENU key to advance to next parameter.

D LOOP ONE

REC. CONF.

LOOP NAME

LOOP ONE

REC. CONF.

1. RECIPES

Defines the number of recipes available in the 535.

• NONE

R 1 to 20 D 1

RECIPES

2. TIME BASE

Defines time base units for recipes.

D HOURS:MIN.

• MIN:SEC.

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

▲ ▼

TIME BASE

HOUR:MIN.

DISPLAY

535-PROF User's Manual Chapter 5 37

Page 47

Controller Set Up

RAMP UNIT

TIME

SP START

GUAR.SOAK

OFF

3. RAMP UNIT

Defines ramp segment terms.

D TIME

• RATE

4. SP START

Defines initial value for the first ramp segment’s setpoint.

• IDLE SP the IDLE SP is the first value

D PV The starting value will be adjusted to account for

the initialPV value

5. GUAR. SOAK

Selects whether guaranteed soak is used during each soak segment.

D OFF guaranteed soak will not occur

• START SEG. guaranteed soak can occur only at the start of a soak segment

• WHOLE SEG. guaranteed soak can occur at the start of or at anytime during a soak segment

EVT.:1 OUT.

NONE

EVT.:2 OUT.

NONE

EVT.:3 OUT.

NONE

6. EVT.:1 OUT.

Selects which output is assigned to event 1. To assign a numerical value (nondefault), the corresponding output needs to be set to ALM/EV:ON or ALM/EV:OFF.

D NONE

•2

•3

•4

7. EVT.:2 OUT.

Selects which output is assigned to event 2. To assign a numerical value (non-default), the corresponding output needs to be set to ALM/EV:ON or ALM/EV:OFF.

D NONE

•2

•3

•4

8. EVT.:3 OUT.

Selects which output is assigned to event 3. In order to assign a numerical value (non-default), the corresponding output needs to be configured as ALM/ EV:ON or ALM/EV:OFF.

D NONE

•2

•3

•4

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

38 Chapter 5 535-PROF User's Manual

DISPLAY

FAST MENU

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DISPLAY

Page 48

9. HOLD EVT.

Selects whether or not the last segment’s event(s) will be held active after the recipe has been successfully completed.

D DISABLED

• ENABLED

PV1 INPUT

1. PV1 TYPE

Specifies the particular sensor range or input range for PV1.

T/C RTD VOLTAGE CURRENT (mA)

D J T/C D DIN RTD D 1-5 V D 4-20mA

• E T/C • JIS RTD • 0-5 V • 0-20mA

• K T/C • SAMA RTD • 0-10 mV

• B T/C • 0-30 mV

• N T/C • 0-60 mV

• R T/C • 0-100 mV

• S T/C • +/– 25 mV

• T T/C

• W T/C

• W5 T/C

• PLAT.II T/C

Controller Set Up

HOLD EVT.

DISABLED

PV1 INPUT

PV1 TYPE

J T/C

2. DEG. F/C/K

Selects the PV1 temperature units if using a thermocouple or RTD.

D FAHR.

• CELSIUS

• KELVIN

3. DECIMAL

Specifies the PV1 decimal point position.

D XXXXX

• XXXX.X

• XXX.XX

• XX.XXX

• X.XXXX

4. LINEARIZE

Specifies if the PV1 input is to be linearized. NOTE: T/C’s and RTD’s are automatically linearized.

D NONE

• SQR. ROOT Square root linearization is activated.

• CUSTOM 15-point custom linearization curve is activated.

DEG. F/C/K

FAHR

DECIMAL

XXXXX

LINEARIZE

NONE

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

535-PROF User's Manual Chapter 5 39

DISPLAY

FAST MENU

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DISPLAY

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Controller Set Up

LOW RANGE

(D)

HI RANGE

(D)

SP LO LIM.

(D)

SP HI LIM.

(D)

5. LOW RANGE

Specifies the engineering unit value corresponding to the lowest PV1 input value, e.g. 4 mA.

R –9999 to 99999 Max. is HI RANGE D Dependent on the input selection

6. HI RANGE

Specifies the engineering unit value corresponding to the highest PV1 input value, e.g., 20mA.

R -9999 to 99999 Min. is LOW RANGE D Dependent on the input selection

7. SP LO LIM.

Defines the lowest setpoint value that can be entered from the front panel only.

R –9999 to 99999 Max. is SP HI LIM. Min. is LOW RANGE D Dependent on the LOW RANGE value.

8. SP HI LIM.

Defines the highest setpoint value that can be entered from the front panel only.

R –9999 to 99999 Min. is SP LO. LIM. Maximum is HI RANGE D Dependent on HI RANGE

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 LIM. 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).

SP RAMP

OFF

FILTER

OFFSET

9. SP RAMP

Defines the rate of change for setpoint changes.

D OFF Deactivates this function R 1 to 99999 units per hour

10. FILTER

Setting for the low pass PV1 input filter.

R 0 to 120 seconds D 0 seconds

11. OFFSET

Defines the offset to PV1 in engineering units.

R –9999 to 99999 D 0

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

40 Chapter 5 535-PROF User's Manual

DISPLAY

FAST MENU

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DISPLAY

Page 50

12. GAIN

Defines the gain to PV1.

R 0.100 to 10.000 D 1.000

13. RESTORE

Defines the control mode when a broken PV1 signal is restored.

D LAST MODE

• MANUAL

• AUTOMATIC

• START REC.

• RESUME.REC.

• HOLD REC.

Controller Set Up

GAIN

1.000

RESTORE

LAST MODE

PV2 INPUT

1. PV2 SETUP

Defines function of PV2

D SAME.AS.PV1 All PV2 parameters are set to the same values

as PV1 (no further parameters will appear)

• NOT PV1 Enables user to enter different values for the following PV2 parameters

2. PV2 TYPE

Selects the particular sensor or input range for PV2

T/C RTD VOLTAGE CURRENT (mA)

D J T/C D DIN RTD D 1-5 V D 4-20mA

• E T/C • JIS RTD • 0-5 V • 0-20mA

• K T/C • SAMA RTD • 0-10 mV

• B T/C • 0-30 mV

• N T/C • 0-60 mV

• R T/C • 0-100 mV

• S T/C • +/– 25 mV

• T T/C

• W T/C

• W5 T/C

• PLAT.II T/C

PV2 INPUT

PV2 SETUP

SAME.AS.PV1

PV2TYPE

J T/C

3. DECIMAL

Specifies the PV2 decimal point position.

D XXXXX

• XXXX.X

• XXX.XX

• XX.XXX

• X.XXXX

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

535-PROF User's Manual Chapter 5 41

DISPLAY

FAST MENU

▲ ▼

DECIMAL

XXXXX

DISPLAY

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Controller Set Up

LINEARIZE

NONE

4. LINEARIZE

Specifies if the PV2 input is to be linearized. Thermocouples and RTD’s are automatically linearized.

D NONE

• SQR. ROOT Square root linearization is activated.

LOW RANGE

(D)

HI RANGE

(D)

FILTER

OFFSET

GAIN

1.000

5. LOW RANGE

Specifies the engineering unit value corresponding to the lowest PV2 input value, e.g. 4 mA.

R –9999 to 99999 Max. is HI RANGE D Dependent on the input selection

6. HI RANGE

Specifies the engineering unit value corresponding to the highest PV2 input value, e.g. 20 mA.

R -9999 to 99999 Min. is LOW RANGE D Dependent on the input selection

7. FILTER

Setting for the low pass PV2 input filter.

R 0 to 120 seconds D 0 seconds

8. OFFSET

Defines the offset to PV2 in engineering units.

R –9999 to 99999 D 0

9. GAIN

Defines the gain for PV2.

R 0.100 to 10.000 D 1.000

RESTORE

LAST MODE

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

42 Chapter 5 535-PROF User's Manual

DISPLAY

FAST MENU

10. RESTORE

Defines the control mode when a broken PV2 signal is restored.

D LAST MODE

• MANUAL

• AUTOMATIC

• START REC.

• RESUME.REC.

• HOLD REC.

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Controller Set Up

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.

It is not necessary to use all 15 points. Whenever the XTH INPUT becomes the high end of the range, that will be the last point in the linearization table.

1. 1ST. INPUT

Specifies the input signal corresponding to the first point.

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.

R –9999 to 99999 D 0

3. XTH. INPUT

Specifies the input signal corresponding to the XTH point (X is 2 to 14).

R Any value greater than the first input D The low end of the 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).

R –9999 to 99999 D 0

5. 15TH. INPT.

Specifies the input signal corresponding to the 15th point.

R –9999 to 99999 Minimum is [XTH-1] INPUT 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.

R –9999 to 99999 D 0

CUST. LINR.

1ST. INPUT

(D)

1ST. PV

XTH INPUT

(D)

XTH PV

15TH INPT.

(D)

15TH PV

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

535-PROF User's Manual Chapter 5 43

DISPLAY

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DISPLAY

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Controller Set Up

CONTROL

ALGORITHM

PID

D. SOURCE

ACTION:1

REVERSE

CONTROL

For configuring the choices for the control algorithm.

1. ALGORITHM

Defines the type of control algorithm.

D PID

•PI

•PD

•P

• ON/OFF

• PID:ON/OFF For Duplex applications using PID for the first output and on/off for the second output

2. D. SOURCE

Selects the variable for the derivative action.

D PV Derivative term will not react when setpoint

changes

• DEVIATION Derivative term will react when setpoint changes

3. ACTION:1

Defines the action of the first control output.

• DIRECT

D REVERSE

4. PV BREAK

PV BREAK

(D)

LOW OUT

HIGH OUT.

100

ACTION:2

DIRECT

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

Defines the manual output level if the process variable input is lost. Choose values based on the process type.

Standard Control On/Off Control Velocity Prop Control

• –5 to 105% • ON • CW

D 0 D OFF • CCW

D OUTS. OFF

5. LOW OUT.

Defines the lowest output value that can be achieved in automatic control.

R 0 – 100% Max is HIGH OUT D 0%

6. HIGH OUT.

Defines the highest output value that can be achieved in automatic control.

R 0 – 100% Min is LOW OUT D 100%

7. ACTION:2

Defines the action of the second control output.

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44 Chapter 5 535-PROF User's Manual

Page 54

D DIRECT

• REVERSE

8. P.P. TYPE

Defines the type of position proportioning algorithm. Choose values based on the process.

Feedback option installed Feedback option not installed

D SLIDEWIRE • SLIDEWIRE

• VELOCITY D VELOCITY

9. CCW TIME

Defines the time it takes a motor to fully stroke counter clockwise.

R 1 to 200 seconds D 60 seconds

10. CW TIME

Defines the time it takes a motor to fully stroke clockwise .

R 1 to 200 seconds D 60 seconds

Controller Set Up

P.P. TYPE

(D)

CCW TIME

CW TIME

11. MIN. TIME

Defines the minimum amount of time the controller must specify for the motor to be on before it takes action.

R 0.1 to 10.0 seconds D 0.1 seconds

12. S/W RANGE

Specifies the full range resistance of the slide (e.g., 100 ohms)

R 0–1050 Ohms D 100 Ohms

13. OPEN F/B

Defines the feedback ohm value corresponding to full open (100% output).

R 0 to S/W RANGE D Dependent on S/W RANGE value

14. CLOSE F/B

Defines the feedback ohm value corresponding to full close (0% output).

R 0 to S/W RANGE D 100 Ohms

15. OUT1 STOP

This defines the stopping point for control output 1 when staging outputs.

R 1 to 100% D 50%

MIN. TIME

0.1

S/W RANGE

100

OPEN F/B

(D)

CLOSE F/B

100

OUT1 STOP

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

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Controller Set Up

OUT2 STRT.

16. OUT2 STRT.

Defines the starting point for control output 2 when staging outputs.

R 0 to 99% D 50%

ALARMS

ALM. TYPE:1

OFF

ALM. SRC:1

ALARMS

1. ALM. TYPE:1

Defines the type of alarm for alarm 1.

• HIGH ALRM.

• LOW ALARM

• HIGH/LOW Separate High & 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

2. ALM. SRC:1

Selects the source of the value being monitored by HIGH, LOW or HIGH/LOW alarm 1.

D PV

•SP

• RAMP SP

• DEVIATION

• OUTPUT

• PV2

ALARM SP:1

0.0%

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46 Chapter 5 535-PROF User's Manual

DISPLAY

FAST MENU

3. 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

R 0.0% to 100.0% R LOW RANGE to HI RANGE D 0.0% D 0 For BAND alarms:

R 1 to 99999 D 0 For DEVIATION or RATE alarms:

R -9999 to 99999 D 0

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4A. 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

R 0.0% to 100.0% R 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.

If ALM.SRC.:1 = OUTPUT If ALM.SRC.:1 = any other type

R 0.0% to 100.0% R LOW RANGE to HI RANGE D 0.0% D 0

5. DEADBAND:1

Defines the deadband for alarm 1.

If ALM.SRC.:1 = OUTPUT If ALM.SRC.:1 = any other type

R 0.1% to 100.0% R 1 to 99999 D 2 D 2

Controller Set Up

HIGH SP:1

0.0%

LOW SP:1

0.0%

DEADBAND:1

6. ALM.:1 OUT.

Selects the output number for alarm 1.

D NONE

•2

•3

•4

7. LATCHING:1

Defines the latching sequence of alarm 1.

D LATCH

• NO LATCH

8. ACK.:1

Defines whether alarm 1 may be acknowledged.

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.

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

ALM.:1 OUT

NONE

LATCHING:1

NONE

ACK.:1

ENABLED

POWER UP:1

NORMAL

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

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Controller Set Up

MESSAGE:1

ALARM 1

10. MESSAGE:1

A 9-character message associated with alarm 1. To enter message: The first character of third display will be flashing. Press the and keys to scroll through the character set. Press FAST key to advance to subsequent characters. Press the MENU to advance to next parameter.

D ALARM 1.

ALM. TYPE:2

OFF

ALM.SRC.:2

ALARM SP:2

(D)

11. ALM. TYPE:2

Defines the type of alarm for alarm 2.

• HIGH ALRM.

• LOW ALARM

• HIGH/LOW Separate High & 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

Selects the source of the value being monitored by HIGH, LOW or HIGH/LOW alarm 2.

D PV

•SP

• RAMP SP

• DEVIATION

• OUTPUT

• PV2

13. ALARM SP:2

Specifies the alarm set point for alarm 2 (except HIGH/LOW)

For HIGH or LOW alarms:

If ALM.SRC.:2 = OUTPUT If ALM.SRC.:2 = any other type

R 0.0% to 100.0% R LOW RANGE to HI RANGE D 0.0% D 0 For BAND alarms:

R 1 to 99999 D 0 For DEVIATION or RATE alarms:

R -9999 to 99999 D 0

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14A. 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

R 0.0% to 100.0% R LOW RANGE to HI RANGE D 0.0% D 0

Controller Set Up

HIGH SP:2

0.0%

14B. LOW SP:2

Specifies the low alarm set point for alarm 2 of type HIGH/LOW.

If ALM.SRC.:2 = OUTPUT If ALM.SRC.:2 = any other type

R 0.0% to 100.0% R LOW RANGE to HI RANGE D 0.0% D 0

15. DEADBAND:2

Defines the deadband for alarm 2.

If ALM.SRC.:2 = OUTPUT If ALM.SRC.:2 = any other type

R 0.1% to 100.0% R 1 to 99999 D 2 D 2

16. ALM.:2 OUT.

Selects the output number for alarm 2.

D NONE

•2

•3

•4

17. LATCHING:2

Defines the latching sequence of alarm 2.

D LATCH

• NO LATCH

LOW SP:2

0.0%

DEADBAND:2

ALM.:2 OUT.

NONE

LATCHING:2

LATCH

18. ACK.:2

Defines whether alarm 2 may be acknowledged.

D ENABLED Allows the alarm to be acknowledged

• DISABLED Prevents the alarm from being acknowledged

19. POWER UP:2

Defines how alarm 2 will be treated on power up.

D NORMAL Alarm depends on process variable

• ALARM Always power up in alarm regardless of process

• DELAYED Must leave alarm condition and reenter before

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DISPLAY

while in alarm condition

variable

activating the alarm

FAST MENU

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ACK.:2

ENABLED

POWER UP:2

NORMAL

DISPLAY

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Controller Set Up

MESSAGE:2

ALARM 2

FAULT

OFF

OUTPUT

NO ACTION

20. MESSAGE:2

A 9-character message associated with alarm 2. To enter message: The first character of third display will be flashing. Press the and 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

• ALARM 1

• ALARM 2

22. OUTPUT

Defines whether a rate-of-change alarm is interpreted as a lost or broken process variable (causing a trip to manual output).

• P.V. BREAK

D NO ACTION

RATE TIME

REM. SETPT.

RSP. TYPE

1-5 4-20

RSP:LO RNG.

RSP:HI RNG.

1000

23. RATE TIME

Defines the time period over which a rate-of-change alarm condition is determined.

R 1 to 3600 seconds D 5 seconds

REM. SETPT.

This menu appears only if parameter REM. SETPT (of the CONFIG. menu) = ENABLED.

1. TYPE V/mA

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

2. RSP:LO RNG.

Specifies the engineering unit value corresponding to the lowest remote setpoint input value, e.g. 4 mA.

R -9999 to 99999 D 0

3. RSP:HI RNG.

Specifies the engineering unit value corresponding to the highest remote setpoint input value, e.g. 20 mA.

R –9999 to 99999

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D 1000

4. RSP: LOW

Defines the lowest setpoint value to be accepted from the remote setpoint source.

R –9999 to 99999. D Dependent on RSP:LO.RNG. value.

Controller Set Up

RSP:LOW

(D)

5. RSP: HIGH

Defines the highest setpoint value from a remote setpoint source.

R –9999 to 99999 D Dependent on RSP:HI.RNG. value

6. TRACKING

Defines whether the local setpoints 1 to 8 will track the remote setpoint.

D NO

• YES

7. BIAS LOW

Defines the lowest bias value that may be entered.

R –9999 to 99999. Maximum value is BIAS HIGH. D –1000

8. BIAS HIGH

Defines the highest bias value that may be entered.

R –9999 to 99999. Minimum value is BIAS LOW. D 1000

9. RSP FIXED

Defines what happens if remote setpoint is lost while it is active and then is restored.

• REMOTE SP Returns to remote setpoint when it is restored D LOCAL Local setpoint remains active when RSP is

restored

RSP:HIGH

(D)

TRACKING

BIAS LOW

-1000

BIAS HIGH

1000

RSP: FIXED

LOCAL

RETRANS.

1. 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 This is the ramping, or actual setpoint, when the

• CTRL. OUT This is the control output value

2. LOW RANGE:2

Defines the low end of the range for output 2 in engineering units. Does not appear for

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setpoint is ramping

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TYPE:2

LO RANGE:2

(D)

DISPLAY

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Controller Set Up

type CTRL.OUT.

R –9999 to 99999 D Dependent on the process variable range

HI RANGE:2

(D)

TYPE:3

LO RANGE:3

(D)

HI RANGE:3

(D)

3. HI RANGE:2

Defines the high end of the range for out put 2 in engineering units. Does not appear for type CTRL.OUT.

R –9999 to 99999 D Dependent on the process variable range

4. TYPE:3

Defines what is to be retransmitted for output 3

D PV This refers to the linearized process variable

• SETPOINT This is the target setpoint

• RAMP SP This is the ramping, or actual setpoint, when the setpoint is ramping

• CTRL. OUT This is the control output value

5. LOW RANGE:3

Defines the low end of the range for output 3 in engineering units. Does not appear for type CTRL.OUT.

R –9999 to 99999 D Dependent on the process variable range

6. HI RANGE:3

Defines the high end of the range for outpu t 3 in engineering units. D oes not appear for type CTRL.OUT.

R –9999 to 99999 D Dependent on the process variable range

TYPE:4

LO RANGE:4

(D)

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7. TYPE:4

Defines what is to be retransmitted for output 4

D PV This refers to the linearized process variable

• SETPOINT This is the target setpoint

• RAMP SP This is the ramping, or actual setpoint, when the setpoint is ramping

• CTRL. OUT This is the control output value

8. LOW RANGE:4

Defines the low end of the range for output 4 in engineering units. Does not appear for type CTRL.OUT.

R –9999 to 99999 D Dependent on the process variable range

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9. HI RANGE:4

Defines the high end of the range for out put 4 in engineering units. D oes not appear for type CTRL.OUT.

R –9999 to 99999 D Dependent on the process variable range

SELF TUNE

Controller Set Up

HI RANGE:4

(D)

SELF TUNE

1. TYPE

This defines the type of self tuning algorithm that is available.

• PRETUNE Allows the operator to initiate Pretune only

• ADAPTIVE Allows the operator to initiate Adaptive Tune only

• BOTH Allows the operator to initiate both Pretune and Adaptive Tune

D DISABLED Both Pretune and Adaptive Tune are disabled

2. PRETUNE

Defines the type of pretune algorithm that is available.

D TYPE 1 Normally used with slower thermal processes

• TYPE 2 Normall y used with faster fluid or pressure processes

• TYPE 3 Normally used with level control applications

3. TUNE PT.

Defines the PV value at which the output will switch off during a TYPE 1 pretune. Helps prevent overshoot.

R Any value in PV input range D AUTOMATIC (Controller defines this point)

4. OUT. STEP

Defines the output step size in absolute percent during a TYPE 2 or TYPE 3 pretune.

R –50% to 50.0% D 10.0%

TYPE

DISABLED

PRETUNE

TYPE 1

TUNE PT.

AUTOMATIC

OUT.STEP

10.0

5. LOW LIMIT

Defines the lower most limit the process variable can reach during pretune before aborting.

R Any value in the process variable range D Dependent on the process variable range

6. HI LIMIT

Defines the upper most limit the process variable can reach during pretune before aborting.

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

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LOW LIMIT

(D)

HI LIMIT

(D)

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Controller Set Up

TIMEOUT

1500

MODE

AUTOMATIC

NOISE BND.

0.2

R Any value in the process variable range D Dependent on the process variable range

7. TIMEOUT

This defines the execution time limit for pretune before aborting.

R 8 to 1500 minutes D 1500 minutes

8. MODE

Defines the control mode after pretune is completed or aborted.

• MANUAL Go to Manual mode after pretune has completed

D AUTOMATIC Go to Automatic mode after pretune has

completed

R RECIPE 1 to 20 Run the designated recipe after pretune has

completed

9. NOISE BND.

Defines the noise band to be used by the adaptive tuning algorithm.

R 0.1% to 10% of the process variable range D 0.2%

RESP. TIME

DEAD TIME

0.1

SPECIAL

AUTO. TRIP

OFF

10. RESP. TIME

Defines response time to be used by the adaptive tuning algorithm.

R 10 to 32000 seconds D 7200 seconds

11. DEAD TIME

Defines the amount of time required for process to begin to respond to an output change (used by POWERBACK algorithm).

R 0.1 seconds to 7200.0 seconds D 0.1 seconds

SPECIAL

1. AUTO. TRIP

This defines the condition under which the 535-PROF will automatically trip to automatic control from manual control upon start up.

D OFF Deactivates this function

• RISING PV Will trip when a rising process variable is within the specified deviation from the setpoint

• FALLNG. PV Will trip when a falling process variable is within the specified deviation from the setpoint

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2. TRIP DEV.

This defines the deviation from setpoint at which the controller will trip to automatic.

For AUTO. TRIP = RISING PV For AUTO. TRIP = FALLING PV

R -99999 to 0 R 0 to 99999 D 0 D 0

3. DES. OUTPT.

If a digital input is 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 O n/Off Control Velocity Prop Control

• –5 to 105% • ON • CW

D LAST OUT D OFF • CCW

D OUTS. OFF

4. POWER UP

This defines the control mode upon power up.

• MANUAL

• AUTOMATIC D LAST MODE Will power up in the same mode prior to power

down

• PRETUNE Will Pretune on every power up. (Recommended for TYPE 1 pretune only.)

• RECIPE

Controller Set Up

TRIP DEV.

(D)

DES. OUTPT.

(D)

POWER UP

LAST MODE

5. PWR. UP:REC.

Selects the recipe to use after power up. Appears only if

POWER UP = RECIPE.

D LAST REC. Last recipe used R RECIPE 1 to 20 Select recipe number

PWR.UP:REC.

LAST. REC.

6. PWR. UP:RUN

Specified how to use the selected recipe after power up. Appears only if POWER UP = RECIPE.

• START REC. Start from the beginning of the recipe

D RESUME REC. Resume recipe from where it left off before

power down

• HOLD REC. Hold recipe from where it left off before power down

PWR.UP:RUN

RESUME REC.

7. PWR. UP: OUT.

Defines the output of the controller if powering up in manual mode. LAST OUT means the output value will be equal to the last output value while in automatic. Choose values based on your process.

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

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DISPLAY

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PWR.UP:OUT.

(D)

DISPLAY

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Controller Set Up

PWR. UP:SP

LAST SP

NO. OF SP

Standard Control O n/Off Control Velocity Prop Control

• –5 to 105% • ON • CW

D LAST OUT D OFF • CCW

D OUTS. OFF

8. PWR. UP:SP

Defines the setpoint upon power up.

D LAST SP Powers up with the same setpoint (local or re-

mote) that was active prior to power down

• LOCAL Powers up using the primary local setpoint

• REMOTE Powers up using the remote setpoint, if available

9. 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. Only applicable when a recipe is not running or held.

R 1 through 8 D 1

SECURITY

SEC. CODE

SP ADJUST

UNLOCKED

AUTO./MAN.

UNLOCKED

SP SELECT

UNLOCKED

SECURITY

For configuring the security function.

1. SEC. CODE

Defines the security code temporarily unlocking the instrument.

R –9999 to 99999 D 0

2. SP ADJUST

Defines lockout status setpoint changes.

D UNLOCKED

• LOCKED

3. AUTO./MAN.

Defines lockout status of the MANUAL key.

D UNLOCKED

• LOCKED

4. SP SELECT

Defines lockout status of the SP SELECT parameter in the TUNING menu.

D UNLOCKED

• LOCKED

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5. RUN KEY

Defines lockout status of the RUN key.

D UNLOCKED

• LOCKED

6. ALARM ACK.

Defines lockout status of the ACK key.

D UNLOCKED

• LOCKED

7. TUNING

Defines lockout status of the tuning parameters.

D UNLOCKED

• LOCKED

8. RECIPES

Defines lockout status of the RECIPE # menu.

D UNLOCKED

• LOCKED

Controller Set Up

RUN KEY

UNLOCKED

ALARM ACK

UNLOCKED

TUNING

UNLOCKED

RECIPES

UNLOCKED

9. CONFIGURE

Defines lockout status of the configuration parameters.

D UNLOCKED

• LOCKED

SER. COMM.

1. STATION

Defines the unit’s station address.

R 1 to 99

• OFF Disables the communications function

D 1

2. BAUD RATE

Defines the baud rate.

• 1200 BPS

• 2400 BPS

• 4800 BPS D 9600 BPS

• 19200 BPS

3. CRC

Defines whether CRC (cyclic redundancy check) is being calculated.

D YES

•NO

CONFIGURE

UNLOCKED

SER. COMM.

STATION

BAUD RATE

9600

CRC

YES

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SHED TIME

OFF

SHED MODE

LAST MODE

SHED OUT.

(D)

4. SHED TIME

Defines the time interval between communications activity before the controller determines that communications is lost (“sheds”).

R 1 to 512 seconds D OFF

5. SHED MODE

Defines the state of the controller if communications is lost (“sheds”).

D LAST MODE Remain in automatic or manual control (last mode before

losing communications)

• MANUAL Tr ip to manual control

• AUTOMATIC Trip to automatic control

6. SHED OUT.

Defines the output if the unit sheds and trips to manual control. Choose values based on the process.

Standard Control O n/Off Control Velocity Prop Control

• –5 to 105% • ON • CW

D LAST OUT D OFF • CCW

D OUTS. OFF

SHED SP

LAST SP

DESIG. SP

(D)

RECIPE #

CYCLES

CONTINUAL

7. SHED SP

This defines the setpoint status if communications is lost.

D LAST SP Continues to use setpoint that was active prior

to losing communications

• DESIG. SP Goes to a designated setpoint value if communications is lost.

8. DESIG. SP

Defines the value of the designated setpoint if communications is lost.

R Any value in the process variable range D Dependent on the process variable range

RECIPE #

(# = 1 to 20) For each recipe number (as determined by the RECIPES parameter in the REC. CONF. menu), you will set values for the following parameters:

1. CYCLES

Defines the number of times the recipe will run before ending or going to the next linked recipe.

• CONTINUAL

R 1 to 99 D 1

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2. NEXT LINK

Defines which (if any) recipe will run after the current recipe has ended. Also can place the output in manual at a specified percentage.

D NONE R 1 to # of configured recipes

• NO OUTPUT

3. IDLE SP

Selects the setpoint to be used when the recipe starts or after it has completed.

D LAST SP use the previous setpoint

• REMOTE SP use the remote setpoint (if option is installed and enabled)

R -9999 to 99999 (decimal point defined by DECIMAL param-

eter)

4. SOAK HYST.

Defines the absolute value of the maximum allowable deviation from setpoint either when a soak segment starts (if GUAR.SOAK = START SEG.) or anytime during a soak segment (if GUAR.SOAK = WHOLE SEG.). If the deviation exceeds this value, guaranteed soak will occur.

D OFF R 1 to 99999 (decimal point defined by DECIMAL param-

eter)

NEXT LINK

OFF

IDLE SP

LAST SP

SOAK HYST.

OFF

5. RAMP RT:##

For RAMP UNIT = RATE, defines the rate of rise or fall of the setpoint during ramp segment ##, while approaching soak setpoint ##.

If TIME BASE = HOURS:MIN If TIME BASE = MIN:SEC

D OFF D OFF R 1 to 99999/MIN R 1 to 99999/SEC

The decimal point is defined by the DECIMAL parameter.

6. RAMP TM:##

For RAMP UNIT = TIME, defines the time for ramp segment ## to reach soak setpoint ##.

If TIME BASE = HOURS:MIN If TIME BASE = MIN:SEC

D OFF D OFF R 00:01 to 99:59 HR:MN R 00:01 to 99:59 MN:SC

7. RAMP EV:##

Defines which events will be activated during ramp segment ##.

D NONE

• EVENT 1

• EVENT 2

• EVENT 12

RAMP RT:##

OFF

NOTE:

To end programming, set RAMP RT:### or RAMP TIM:## to OFF.

RAMP TM:##

OFF

RAMP EV:##

NONE

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SOAK SP:##

SOAK TM:##

OFF

SOAK EV:##

NONE

• EVENT 3

• EVENT 13

• EVENT 23

• EVENT 123

8. SOAK SP:##

Defines the setpoint after ramp segment ## has completed.

D 0 R -9999 to 99999 decimal point defined by DECIMAL parameter

9. SOAK TM:##

Defines the length of soak segment ## (units defined by TIME BASE parameter in REC. CONF. menu).

If TIME BASE = HOURS:MIN If TIME BASE = MIN:SEC

D OFF D OFF R 00:01 to 99:59 HR:MN R 00:01 to 99:59 MN:SC

10. SOAK EV:##

Defines which events will be activated during soak segment ##.

D NONE

• EVENT 1

• EVENT 2

• EVENT 12

• EVENT 3

• EVENT 13

• EVENT 23

• EVENT 123

11. PID SET:##

PID SET:##

LAST SET

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If NO. OF PID = SEG.SELECT, defines which PID set to use during ramp and soak segments ##.

D LAST SET R 1 to 8

After PID SET:##, you will return to the RAMP RT:## or RAMP TM:## param- eter.

To continue programming within this recipe, set a value for this segment, and you will scroll through the subsequent parameters of this menu.

To end programming, set RAMP RT:## or RAMP TM:## to OFF.

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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 Type of control output(s)

2. LINE FREQ Power source frequency

3. PV SOURCE PV input derivation

4. REM. SETPT. Remote setpoint function

Controller Set Up

5. OUTPUT 2 Second output function

6. OUTPUT 3 Third output function

7. OUTPUT 4 Fourth output function

8. ANLG. RNG.:1 First output signal

9. ANLG. RNG.:2 Second output signal

10. ANLG. RNG.:3 Third output signal

11. ANLG. RNG.:4 Fourth output signal

12. CONTACT 1 First digital i nput operation

13. CONTACT 2 Second digital input operation

14. CONTACT 3 Third digital input operation

15. CONTACT 4 Fourth digital input operation

16. CONTACT 5 Fifth digital input operation

17. LOOP NAME Message associated with the loop

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Controller Set Up

REC. CONF

Parameter Description Values

1. RECIPES the number of recipes available in the 535

2. TIME BASE Time base units for recipes

3. RAMP UNIT Ramp segment definition (time or rate)

4. SP START Initial value for the first ramp segment’s setpoint

5. GUAR.SOAK Selects whether guaranteed soak is used

6. EVT.:1 OUT. Output assigned to event 1

7. EVT.:2 OUT. Output assigned to event 2

8. EVT.:3 OUT. Output assigned to event 3

9. HOLD EVT. Hold status last segment’s event(s)

PV1 INPUT

Parameter Description Values

1. PV1 TYPE Sensor/input range for PV1

2. DEG. F/C/K PV1 temperature units

3. DECIMAL PV1 decimal point position

4. LINEARIZE PV1 input linearization

5. LOW RANGE Engineering unit value for lowest PV1 input

6. HI RANGE Engineering unit value for highest PV1 input

7. SP LO LIM. Lowest setpoint value for front panel entry

8. SP HI LIM. Highest setpoint value for front panel entry

9. SP RAMP Rate of change for setpoint changes

10. FILTER Low pass PV1 input filter setting

11. OFFSET PV1 offset in engineering units

12. GAIN PV1 gain

13. RESTORE Control mode when a broken PV1 signal is restored

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PV2 INPUT

Parameter Description Values

1. PV2 SETUP PV2 function

2. PV2 TYPE Sensor/input range for PV2

3. DECIMAL PV2 decimal point position

4. LINEARIZE PV2 input linearization

5. LOW RANGE Engineering unit value for lowest PV2 input

6. HI RANGE Engineering unit value for highest PV2 input

7. FILTER Low pass PV2 input filter setting

8. OFFSET PV2 offset in engineering units

9. GAIN PV2 gain

10. RESTORE Control mode when a broken PV2 signal is restored

Controller Set Up

535-PROF User's Manual Chapter 5 63

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Controller Set Up

CUST. LINR

Parameter Description Values

1. 1ST. INPUT 1st point input signal

2. 1ST. PV 1st point engineering unit value

3. XTH. INPUT XTH point input signal (X is 2 to 14)

4. XTH. PV XTH point engineering unit value

5. 2ND. INPUT 2nd point input signal

6. 2ND. PV 2nd point engineering unit value

7. 3RD. INPUT 3rd point input signal

8. 3RD. PV 3rd point engineering unit value

9. 4TH. INPUT 4th point input signal

10. 4TH. PV 4th point engineering unit value

11. 5TH. INPUT 5th point input signal

12. 5TH. PV 5th point engineering unit value

13. 6TH. INPUT 6th point input signal

14. 6TH. PV 6th point engineering unit value

15. 7TH. INPUT 7th point input signal

16. 7TH. PV 7th point engineering unit value

17. 8TH. INPUT 8th point input signal

18. 8TH. PV 8th point engineering unit value

19. 9TH. INPUT 9th point input signal

20. 9TH. PV 9th point engineering unit value

21. 10TH. INPUT 10th point input signal

22. 10TH. PV 10th point engineering unit value

23. 11TH. INPUT 11th point input signal

24. 11TH. PV 11th point engineering unit value

25. 12TH. INPUT 12th point input signal

26. 12TH. PV 12th point engineering unit value

27. 13TH. INPUT 13th point input signal

28. 13TH. PV 13th point engineering unit value

29. 14TH. INPUT 14th point input signal

30. 14TH PV 14th point engineering unit value

31. 15TH. INPT. 15th point input signal

32. 15TH. PV 15th point engineering unit value

64 Chapter 5 535-PROF User's Manual

Page 74

CONTROL

Parameter Description Values

1. ALGORITHM Control algorithm Type

2. D. SOURCE Derivative action variable

3. ACTION:1 First control output action

4. PV BREAK Manual output level upon PV input loss

5. LOW OUT. L owest output value in automatic control

6. HIGH OUT. Highest output value in automatic control

7. ACTION:2 Second control output action

8. P.P. TYPE Position proportioning algorithm

9. CCW TIME Counter clockwise motor stroke time

10. CW TIME Clockwise motor stroke time

Controller Set Up

11. MIN. TIME Motor “on” time (minimum value)

12. S/W RANGE Full range resistance of the slidewire

13. OPEN F/B Feedback ohm value for full open

14.CLOSE F/B Feedback ohm value for full close

15. OUT1 STOP Control output 1 stop point for staging outputs

16. OUT2 STRT. Control output 2 start point for staging outputs

535-PROF User's Manual Chapter 5 65

Page 75

Controller Set Up

ALARMS

Parameter Description Values

1. ALM. TYPE:1 Alarm 1 type

2. ALM. SRC:1 Value monitored by alarm 1

3. ALARM SP:1 Set point for alarm 1 (except HIGH/LOW)

4A.HIGH SP:1 High alarm set point for alarm 1 of type HIGH/LOW

4B.LOW SP:1 Low alarm set point for alarm 1 of type HIGH/LOW

5. DEADBAND:1 Deadband for alarm 1

6. ALM.:1 OUT. Output number for alarm 1

7. LATCHING:1 the latching sequence of alarm 1

8. ACK.:1 Acknowledge status of alarm 1

9. POWER UP:1 Alarm 1 power up status

10. MESSAGE:1 9-character message for with alarm 1

11. ALM. TYPE:2 Alarm 2 type

12. ALM. SRC:2 Value monitored by alarm 2

13. ALARM SP:2 Alarm set point for alarm 2 (except HIGH/LOW)

14A. HIGH SP:2 High alarm set point for alarm 2 of type HIGH/LOW

14B. LOW SP:2 Low alarm set point for alarm 2 of type HIGH/LOW

15. DEADBAND:2 Deadband for alarm 2

16. ALM.:2 OUT. Output number for alarm 2

17. LATCHING:2 Latching sequence of alarm 2

18 ACK.:2 Acknoledge status of alarm 2

19. POWER UP:2 Alarm 2 power up status

20. MESSAGE:2 9-character message for with alarm 2

21. FAULT Alarm status for fault condition (lost PV)

22. OUTPUT Rate-of-change alarm effect on trip to manual output)

23. RATE TIME Time period over for a rate-of-change alarm condition

66 Chapter 5 535-PROF User's Manual

Page 76

REM. SETPT

Parameter Description Values

1. TYPE V/mA Remote setpoint input signal type

2. RSP:LO RNG. Lowest remote setpoint input value egineering unit value

3. RSP:HI RNG. Highest remote setpoint input value engineering unit value

4. RSP: LOW Lowest setpoint value from remote setpoint source

5. RSP: HIGH Highest setpoint value from a remote setpoint source

6. TRACKING Local setpoint track status of remote setpoint

7. BIAS LOW Lowest bias value that may be entered

8. BIAS HIGH Highest bias value that may be entered

9. RSP FIXED Remote setpoint restoration status

Controller Set Up

RETRANS

Parameter Description Values

1. TYPE:2 Output 2 transmission type

2. LOW RANGE:2 Low end of the range for output 2 in engineering units

3. HI RANGE:2 High end of the range for output 2 in engineering units

4. TYPE:3 Output 3 transmission type

5. LOW RANGE:3 Low end of the range for output 3 in engineering units

6. HI RANGE:3 High end of the range for output 3 in engineering units

7. TYPE:4 Output 4 transmission type

8. LOW RANGE:4 Low end of the range for output 4 in engineering units

9. HI RANGE:4 High end of the range for output 4 in engineering units

535-PROF User's Manual Chapter 5 67

Page 77

Controller Set Up

SELF TUNE

Parameter Description Values

1. TYPE Self tuning algorithm type

2. PRETUNE Pretune algorithm type

3. TUNE PT. PV value at which output switches off (TYPE 1)

4. OUT. STEP Output step size in absolute percent (TYPE 2 or 3)

5. LOW LIMIT Lower limit for PV during pretune (before aborting)

6. HI LIMIT Upper limit for PV 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 for adaptive tuning algorithm

10. RESP. TIME Response time for the adaptive tuning algorithm

11. DEAD TIME Wait time for process initiation (POWERBACK)

SPECIAL

Parameter Description Values

1. AUTO. TRIP Trip to automatic control from manual control upon start up

2. TRIP DEV Deviation from setpoint for a trip to automatic

3. DES. OUTPT. Output value after the trip

4. POWER UP Control mode upon power up

5. PWR. UP:REC. Recipe to use after power up.

6. PWR. UP:RUN Selected recipe status after power up

7. PWR. UP: OUT. Output of the controller if powering up in manual mode

8. PWR. UP:SP Setpoint upon power up

9. NO. OF SP Number of local setpoints (up to 8) to be stored for selection

68 Chapter 5 535-PROF User's Manual

Page 78

SECURITY

Parameter Description Values

1. SEC. CODE Security code for temporarily unlocking the instrument.

2. SP ADJUST Lockout status for setpoint changes

3. AUTO./MAN. Lockout status of the MANUAL key

4. SP SELECT Lockout status of the SET PT key

5. RUN KEY Lockout status of the RUN key

6. ALARM ACK. Lockout status of the ACK key

7. TUNING Lockout status of the tuning parameters

8. RECIPES Lockout status of the RECIPE # menu

9. CONFIGURE Lockout status of the configuration parameters

Controller Set Up

SER. COMM

Parameter Description Values

1. STATION Unit’s station address

2. BAUD RATE Baud rate

3. CRC Cyclic redundancy check

4. SHED TIME Time interpreted as communications loss (shed)

5. SHED MODE State of the controller if communications is lost (“sheds”)

6. SHED OUT. Output if the unit sheds and trips to manual control.

535-PROF User's Manual Chapter 5 69

Page 79

Controller Set Up

RECIPE #

Parameter Description Values

1. CYCLES Number of recipe cycles

2. NEXT LINK Next recipe to run

3. IDLE SP Initial or ending setpoint for recipe

4. SOAK HYST. Absolute value of the max. deviation from setpoint for soak

5. RAMP RT:## Rate of rise or fall of setpoint during ramp segment ##

6. RAMP TM:## Time for ramp segment ## to reach soak setpoint ##

7. RAMP EV:## Events activated during ramp segment ##

8. SOAK SP:## Setpoint after ramp segment ## has completed

9. SOAK TM:## Length of soak segment ##

10. SOAK EV:## Events activated during soak segment ##.

11. PID SET:## PID set for ramp and soak segments ##.

70 Chapter 5 535-PROF User's Manual

Page 80

CHAPTER 6 TUNING

OVERVIEW

Tuning

The self tune function of the 535 consists of two distinct components — Pretune and Adaptive Tune. In addition, you may choose from three type of Pretune:

TYPE 1 - for slow thermal processes. TYPE 2 - for fast fluid or pressure processes. TYPE 3 - for level control applications.

You choose the type of Pretune in the SELF TUNE menu. The Pretune and Adaptive Tune components may be used separately or together. On the following pages is the step by step guide to the TUNING menu paramters.

MANUAL

to place controller

under Manual Control

MANUAL

OPERATION

DISPLAY

TUNING

FAST + MENU

NOTE:

For more information about Pretune and Adaptive Tune, refer to section on Tuning applications in Chapter 7.

Figure 6.1 Access the Tuning Menu Block

DISPLAY

to return to

eration mode

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

535-PROF User's Manual Chapter 6 71

DISPLAY

RECIPE #

FAST + MENU

SET UP

(Configuration) Menus

FAST MENU

to scroll

thru recipes

Set Up Mode is only accessible if controller is under Manual Control.

▲ ▼

DISPLAY

Page 81

Tuning

TUNING

SP SELECT

REMOTE SP

ADAPTIVE DISABLED

PRETUNE

TUNING

1. SP SELECT

Replaces function of the SET PT key. Selects the setpoint used when a recipe is not running or held.

D REMOTE SP Only if RSP option is installed

• LOCAL SP

• LOCAL SP2 NO. OF SP has to be 2

• LOCAL SP3 NO. OF SP has to be 3

• LOCAL SP4 NO. OF SP has to be 4

• LOCAL SP5 NO. OF SP has to be 5

• LOCAL SP6 NO. OF SP has to be 6

• LOCAL SP7 NO. OF SP has to be 7

• LOCAL SP8 NO. OF SP has to be 8

2. ADAPTIVE

Activates the self tune algorithm (upon transfer to automatic control). Only allowed to operate during soak segments.

D DISABLED

• ENABLED

3. PRETUNE

Activates the pretune algorithm (if unit is under manual control). Not selectable if a recipe is running or holding

To initiate the Pretune cycle, press the or . Confirm by pressing ACK within two seconds.

D NO

4. POWR. BACK

POWR. BACK

DISABLED

Reduces setpoint overshoot at power up or after setpoint changes.

D DISABLED

• ENABLED

5. PROP. BND.:1

PROP. BND.:1

50.0

Defines the proportional band for PID set 1.

R 0.1 to 999.0% D 50.0%

6. RESET:1

RESET:1

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

72 Chapter 6 535-PROF User's Manual

DISPLAY

Defines the integral time for PID set 1.

R 1 to 9999 seconds D 20 seconds

FAST MENU

▲ ▼

DISPLAY

Page 82

Tuning

7. RATE:1

Defines the derivative time for PID set 1.

R 0 to 600 seconds D 1 second

8. MAN. RST.:1 (or LOADLINE:1)

Defines the manual reset for PID set 1. If using automatic reset, then this specifies the load line out value.

R 0 to 100% D 0%

9. CYCLE TM.:1

Defines the cycle time for control output 1 when using a time proportioning output.

R 0.3 to 120.0 seconds D 15.0 seconds

10. DEADBAND:1

Defines the dead band for control output 1 when using on/off control.

R 1 to 99999 in engineering units D 2

11. P. PROP. D.B.

Defines the dead band setting for a slidewire position proportioning output.

R 0.5 to 10.0% D 2.0%

RATE:1

MAN. RST.:1

CYCLE TM.:1

15.0

DEADBAND:1

P.PROP.D.B.

2.0

12A. PID OFST.:1

For duplex applications, defines the offset for the first output.

R –50.0% to 50.0% D 0.0%

PID OFST.:1

12B. ON OFST.:1

For On/Off applications, defines the offset for the first output.

R -9999 to 99999 in engineering units D 0

ON/OFST.:1

13A. PID OFST.:2

For duplex applications, defines the offset for the second output.

R –50.0% to 50.0% D 0.0%

PID OFST.:2

13B. ON OFST.:2

For On/Off applications, defines the offset for the second output.

R -9999 to 99999 in engineering units D 0

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

▲ ▼

ON/OFST.:2

DISPLAY

535-PROF User's Manual Chapter 6 73

Page 83

Tuning

REL. GAIN:2

1.0

14. REL. GAIN:2

Defines the adjustment factor for the second output’s proportional band. It is multiplied by the effective gain of output 1 to obtain the second output's proportional band.

R 0.1 to 10.0 D 1.0

CYCLE TM.:2

15.0

DEADBAND:2

RSP RATIO

1.00

RSP BIAS

(D)

NO. OF PID

15. CYCLE TM.:2

Defines the cycle time for control output 2 when using a time proportioning output.

R 0.3 to 120.0 seconds. D 15.0 seconds

16. DEADBAND:2

Defines the dead band for control output 2 when using on/off control.

R 1 to 99999 in engineering units D 2

17. RSP RATIO

Defines the multiplier applied to the remote set point.

R -99.99 to 99.99 D 1.00

18. 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 BI AS HIGH)

D Dependent on the BIAS LOW and BIAS HIGH values

19. NO. OF PID

Defines the number of PID sets that will be stored and available for use.

R 1 to 8 For numbers>1, PID TRIP defines tripping be-

tween the PID sets

D 1

• SP NUMBER PID Set = current local setpoint (specified in NO. OF SP). Each PID set has a respective SP NUMBER.

• REC.NUMBER PID Set = current recipe #. If no recipe is running or held, previous PID set is used.

• SEG.SELECT PID Set = set assigned to the current recipe segment. If no recipe is running or held, previous PID set is used.

• PV NUMBER PID Set = process variable (PV1 or PV2) used when PV SOURCE = 1/2: SWITCH or PV SOURCE = 1/2:BACKUP

D 1

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

74 Chapter 6 535-PROF User's Manual

DISPLAY

FAST MENU

▲ ▼

DISPLAY

Page 84

Tuning

20. PID TRIP

For NO. OF PID > 1, defines the variable used to select the various PID sets. Not applicable for SP NUMBER, REC. NUMBER or SEG. SELECT.

• PV VALUE PID set selection based on process variable D SP VALUE PID set selection based on setpoint

• DEV. VALUE PID set selection based on deviation from setpoint

21. TRIP:1

Defines the value that triggers a change to the primary set (#1) of PID values.

R The process variable range D Dependent on the process variable range

For each set of PID 2 through 8 (or equals SP NUMBER, REC.NUMBER

or SEG.SELECT) set up the following group of parameters (X represents the PID set number), as they appear for each set of PID. The controller designates the values for the active PID parameter in the third display with this

symbol—*—on either side.

22. PROP. BND.:X

Defines the proportional band for PID set X.

R 0.1 to 999.0% D 50.0%

PID TRIP

SP VALUE

TRIP:1

(D)

PROP.BND.:X

(D)

23. RESET:X

Defines the integral time for PID set X.

R 1 to 9999 seconds (increments of 1) D 20 seconds

24. RATE:X

Defines the derivative time for PID set X.

R 0 to 600 seconds D 1 seconds

25. MAN. RST.:X (or LOADLINE:X)

Defines the manual reset (or load line) for PID set X.

R 0 to 100% D 0%

26. TRIP:X

This defines the value that triggers a change to the Xth set of PID values.

R The process variable range D Dependent on the process variable range

RESET:X

(D)

RATE:X

MAN.RST.:X

TRIP:X

(D)

Access Set Up Return to Operation Next menu Next paramet er Next value Access Tuning Return to Operation

FAST MENU

535-PROF User's Manual Chapter 6 75

DISPLAY

FAST MENU

▲ ▼

DISPLAY

Page 85

Tuning

TUNING

Parameter Definition Values

1. SP SELECT Selects the setpoint used when a recipe is not running or held

2. ADAPTIVE Activates the self tune algorithm

3. PRETUNE Activates the pretune algorithm

4. POWR. BACK Reduces setpoint overshoot at power up or after setpoint changes

5. PROP. BND.:1 Proportional band for PID set 1

6. RESET:1 Integral time for PID set 1

7. RATE:1 Derivative time for PID set 1

8. MAN. RST.:1 Manual reset for PID set 1.

9. CYCLE TM.:1 Cycle time for control output 1 for time proportioning output

10. DEADBAND:1 Dead band for control output 1 for on/off control

11.P. PROP. D.B. Dead band setting for slidewire position proportioning output

12A. PID OFST.:1 Offset for the first output for duplex applications

12B. ON OFST.:1 Offset for first output for on/off applications

13A. PID OFST.:2 Offset for the second output for duplex applications

13B. ON OFST.:2 Offset for second output for on/off applications

14. REL. GAIN:2 Adjustment factor for the second output’s proportional band

15. CYCLE TM.:2 Cycle time for control output 2 for time proportioning output

16. DEADBAND:2 Dead band for control output 2 for on/off control

17. RSP RATIO Multiplier for remote set point

18. RSP BIAS Bias for remote set point

19. NO. OF PID Number of PID sets

20.PID TRIP For NO. OF PID > 1, variable used to select the various PID sets

21. TRIP:1 Value that triggers a change to the primary set (#1) of PID values

22. PROP. BND.:2 Proportional band for PID set 2

23. RESET:2 Integral time for PID set 2

24. RATE:2 Derivative time for PID set 2

25. MAN. RST.:2 Manual reset (or load line) for PID set 2

26. TRIP:2 Value that triggers a change to the 2nd set of PID values

27. PROP. BND.:3 Proportional band for PID set 3

76 Chapter 6 POWERS 535-PROF User's Manual

Page 86

28.RESET:3 Integral time for PID set 3

29. RATE:3 Derivative time for PID set 3

30.MAN. RST.:3 Manual reset (or load line) for PID set 3

31. TRIP:3 Value that triggers a change to the 3rdset of PID values

32. PROP. BND.:4 Proportional band for PID set 4

33.RESET:4 Integral time for PID set 4

34. RATE:4 Derivative time for PID set 4

35.MAN. RST.:4 Manual reset (or load line) for PID set 4

36. TRIP:4 Value that triggers a change to the 4th set of PID values

37. PROP. BND.:5 Proportional band for PID set 5

38.RESET:5 Integral time for PID set 5

39. RATE:5 Derivative time for PID set 5

Tuning

40.MAN. RST.:5 Manual reset (or load line) for PID set 5

41. TRIP:5 Value that triggers a change to the 5th set of PID values

42. PROP. BND.:6 Proportional band for PID set 6

43.RESET:6 Integral time for PID set 6

44. RATE:6 Derivative time for PID set 6

45.MAN. RST.:6 Manual reset (or load line) for PID set 6

46. TRIP:6 Value that triggers a change to the 6th set of PID values

47. PROP. BND.:7 Proportional band for PID set 7

48.RESET:7 Integral time for PID set 7

49. RATE:7 Derivative time for PID set 7

50.MAN. RST.:7 Manual reset (or load line) for PID set 7

51. TRIP:7 Value that triggers a change to the 7th set of PID values

52. PROP. BND.:8 Proportional band for PID set 8

53.RESET:8 Integral time for PID set 8

54. RATE:8 Derivative time for PID set 8

55.MAN. RST.:8 Manual reset (or load line) for PID set 8

56. TRIP:8 Value that triggers a change to the 8th set of PID values

POWERS 535-PROF User's Manual Chapter 6 77

Page 87

Tuning

SELF TUNE MESSAGES AND TROUBLESHOOTING

Refer to Chapter 7 for more information on the Self Tune function of the 535 controller.

When the Pretune function terminates, one of the following messages will appear:

Message

COMPLETED

ABORTED

LIMIT ERR.

TIMEOUT

NOISE ERR.

INPUT ERR.

OUT. ERROR

DATA ERR.

ZERO ERR.

DEV. ERROR

RETRY

Pretune

Type

2,3

1,2,3

2,3

1,2,3

2,3

1,2,3

Conclusion/Problem

PRETUNE has generated initial PID and the Dead Time values

PRETUNE had generated initial PID, Response Time, Band Noise and the Dead Time values

User has aborted PRETUNE before completion

The Process variable went beyond the HI LIMIT or LOW LIMIT

The inital process variable was near or beyond the HI LIMIT or LOW LIMIT

TIMEOUT limit was reached before Pretune completed

Too much PV noise was detected

PV or Cold Junction break detected during Pretune

PV HIGH or PV LOW detected during Pretune

SLIDEWIRE break detected during Pretune

Remote SP Break detected during Pretune

The initial control output is outside the high and low limits defined in the Control menu

The PV moved too quickly to be analyzed

One or more model parameters are calculated to be zero

The initial PV is too close to the TUNE PT.

The Process variable went beyond the HI LIMIT or LOW LIMIT

Corrective Action

Change the HI LIMIT and LOW LIMIT, or the HIGH OUT and LOW OUT, and run Pretune again

Change the HI LIMIT and LOW LIMIT, or the OUT.STEP size and run Pretune again

Change the manual output percentage, or the HI LIMIT and LOW LIMIT, and run Pretune again

Set a longer TIMEOUT period and/or increase the OUT.STEP size, and run Pretune again.

Eliminate the noise source (if possible) or increase the OUT.STEP and run Pretune again

Check the described conditions and make corrections or repairs

Change the manual output percent and run Pretune again

Decrease the OUT.STEP size and run Pretune again

Increase the OUT.STEP size and run Pretune again

Move TUNE PT. (or the Setpoint if TUNE PT. is Automatic) farther from the process variable and run Pretune again

Check if any PID values were generated and if they are acceptable. If not, eliminate noise sources (if possible) and run Pretune again

If Pretune and Adaptive Tune do not generate optimal PID values for control, check the following menu entries:

Message

RESPONSE TIME

NOISE BAND

PRETUNE

Potential Problem

Adaptive Tune cannot run if RESPONSE TIME is inaccurate

Adaptive Tune cannot compensate for PV oscillation due to hysteresis of output device (e.g., a sticky valve)

Pretune does not develop optimum PID Parameters

78 Chapter 6 POWERS 535-PROF User's Manual

Corrective Action

Run TYPE 2 or TYPE 3 Pretune to obtain the correct value, or enter it manually

Set NOISE BAND large enought to prevent Adaptive Tune from acting on the oscillation. If oscillation is not acceptable, consider replacing valve

Wrong pretune TYPE selected. Refer to Chapter 7, the section on Self Tune

Page 88

CHAPTER 7 APPLICATIONS

The 535 controller provides a variety of user-programmable control features and capabilities. The following topics are included in this chapter:

Applications

NOTE: Controller capabilities depend

upon the specified hardware option.

A. Profile Control ................................................. 79

B. Control Type ................................................... 85

C. Alarm s ............................................................. 86

D. Duplex Control ................................................ 90

E. Slidewire Position Proportioning Control ..... 95

F. Veloc ity Po sition Proportioning Control ...... 9 6

G. Staged Outputs .............................................. 97

H. Retransmission .............................................. 97

I. Digital Inputs .................................................. 98

J. Remote Setpoint ........................................... 100

K. Multiple Setpoints ........................................ 101

L. Multiple Sets of PID Values ........................ 101

M. Powerback .................................................... 102

N. Self Tune—POWERTUNE

O. Ramp-to-Setpoint ......................................... 109

P. Input Linearization ....................................... 109

.............................

103

A. PROFILE CONTROL

The 535-PROF controller is capable of storing 20 separate recipes. Each recipe can consist of up to 12 ramps and 12 dwells. Individual recipes may be continuously run or be repeated up to 99 times. Recipes may be linked together to form longer, more complex recipes. Some profile control terms are:

Ramp

A rise or fall of the setpoint in a given segment. Ramps may be defined by the time it will take for the setpoint to be achieved or the rate of rise or fall necessary for the target (soak) setpoint to be achieved.

Dwell or Soak

The designated period of time in which the setpoint does not change after the ramp has been completed.

Guaranteed Soak

Guaranteed soak insures that the soak setpoint has been achieved before the soak segment starts.

Example: Ramp 1 is programmed for 2 hours. The Soak setpoint is 400° and the soak time is set for 4 hours. If 400° can not be achieved in the 2 hour ramp time, the timing of the soak will not start until the setpoint has been reached.

To use this feature,two parameters must be defined. The first one, GUAR.SOAK, defines whether guaranteed soak is used and how it is used. It is located in the REC.CONF. menu. The second parameter, SOAK HYST., is located in the RECIPE # menu. It defines the absolute value of the maximum allowable deviation from setpoint when a soak segment starts. If the deviation exceeds this value, guaranteed soak will stop the clock until the deviation is less than the soak hysteresis. Then the soak segment will begin. In addition, if the deviation exceeds the soak hysteresis value during the soak segment, the soak timing will stop until the deviation is less than the soak hysteresis value.

Cycles

Recipes may be repeated up to 99 times before completion or being linked to a different recipe. Recipes may also be set up to run continuously.

Q. Load Line ....................................................... 111

R. Security ......................................................... 111

S. Reset Inhibition ............................................ 112

T. Process Variable Reading Correction ........ 112

U. Serial Communications ................................ 113

V. Cascade Control ........................................... 114

W. Ratio Contro l ................................................. 117

NOTE:

Self Tune and Adaptive Tune may be used to optimize PID settings at varous PV/LOAD points, but should NOT be used while running a recipe.

Consult factory for further details.

535-PROF User's Manual Chapter 7 79

Page 89

Applications

Linking

Recipes may be linked together to form longer, more complicated programs.

Through the selective use of CYCLES and LINKING, complex recipes with subroutines can be created.

Events

For each ramp and dwell, 1, 2 or 3 available relays may be opened or closed. These may be used for a variety of purposes to include starting and stopping other process equipment. Upon recipe completion, events may be held until released by the operator (using FAST + ACK).

Programming recipes requires the user to make selections in the REC.

CONF. menu of the SET UP mode before programming the actual recipes.

Software Configuration

The controller must be configured for the profile option before accepting recipes:

1. Enter the SET UP mode. Select the REC. CONF. menu.

2. The first parameter is RECIPES. This parameter defines the number of

recipes available in the 535. Choices are:

D 1 R 1 through 20

3. The next parameter is TIME BASE. It defines whether recipes are timed in hours and minutes or in minutes and seconds. Choices are:

D HOURS:MIN

• MIN:SEC.

4. The next parameter is RAMP UNIT. It defines the times unit for ramp segments (hours:min or min:sec) or rate of change required to reach setpoint. If

TIME BASE=HOURS:MIN, the ramp unit will be in PV units per minute. If TIME BASE=MIN:SEC the ramp unit will be in PV units per second. Choices are:

D TIME

• RATE

5. The next parameter is SP START. It selects whether the first ramp segment’s setpoint must start at the IDLE setpoint or if it can be adjusted to account for the initial PV value (thus allowing the ramp segment to be shortened). Choices are:

• IDLE SP the IDLE SP will be the starting setpoint of the first ramp segment

• PV the first ramp’s starting setpoint can be adjusted

6. The next parameter is GUAR.SOAK. It selects whether the guaranteed soak feature will be used. Its choices are:

D OFF guaranteed soak will not occur

• START SEG. guaranteed soak can occur only at the start of a soak segment

• WHOLE SEG. guaranteed soak can occur at the start of or at anytime during

soak segment

7. The next 3 parameters are EVT.:1 OUT, EVT.:2 OUT and EVT.:3 OUT. These select which outputs are assigned to each events. Choices are:

D NONE

•2

•3

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•4 The numerical choices only appear if the corresponding output is config-

ured as ALM.EVT:ON or ALM.EVT:OFF in the CONFIG. menu.

8. The next parameter is HOLD EVT. It determines whether the last

segment’s event(s) will be held active after the recipe has successfully completed. Choices are:

D DISABLE

• ENABLE

Now the recipes can be programmed:

1. Enter the RECIPE SET UP mode. The display will indicate RECIPE #

(# =recipe number) in the 2nd line.

Use and to select the recipe to be programmed. Use MENU to advance through the parameters.

2. The first parameter is CYCLES. It selects the number of times the recipe

will run before ending or going to the next linked recipe. Choices are:

• CONTINUAL

D 1 R 1 - 99

3. The next parameter is NEXT LINK. It defines which recipe will run next

after the current recipe has completed. Choices are:

D NONE R 1 to # of configured recipes

• NO OUTPUT

4. The next parameter is IDLE SP. It defines the setpoint to be used when

the recipe starts or after it has completed. Choices are:

D LAST SP use the previous setpoint [default] R -9999 to 99999

• REMOTE SP use the remote setpoint (only if option installed an enabled)

The decimal point is defined by the DECIMAL parameter.

5. The next parameter is SOAK HYST. It defines the absolute value of the

maximum allowable deviation from the setpoint when a soak segment starts. If the deviation exceeds this value, Guaranteed Soak will occur. This parameter appears only if GUAR.SOAK is not OFF. Choices are:

D OFF R 1 to 99999

The decimal point is defined by the DECIMAL parameter in the PV1

INPUT menu

6. The next parameter is RAMP RT:## (## = 1 to 12). It defines the rate of

rise or fall of the setpoint during ramp segment ## while approaching soak setpoint ##. This parameter will only appear if RAMP UNIT = RATE. Choices are:

D OFF ends recipe progrmming R 1 to 99999/MIN if TIME BASE = HOURS:MIN R 1 to 99999/SEC. if TIME BASE = MIN:SEC

Applications

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Applications

The decimal point is defined by the DECIMAL parameter.

7. The next parameter is RAMP TM:## (## = 1 to 12). It defines the time for the current ramp segment (##) to reach the current soak setpoint (##). This parameter will only appear if RAMP UNIT = TIME. Choices are:

D OFF ends recipe programming R 00:01 to 99:59 HR:MN if TIME BASE = HOURS:MIN R 00:01 to 99:59 MN:SC if TIME BASE = MIN:SEC IMPORTANT: For each RAMP segment, you will scroll through and set

values for the next six parameters. However, choosing OFF for either RAMP RT.## or RAMP TM## will conclude the programming.

8. The next parameter is RAMP EV:## (## = 1 to 12). It selects which events will be activated during the current ramp segment. Choices are:

D NONE

• EVENT 1 event output 1 is selected

• EVENT 2 event output 2 is selected

• EVENT 12 event outputs 1 and 2 are selected

• EVENT 3 event output 3 is selected

• EVENT 13 event outputs 1 and 3 are selected

• EVENT 23 event outputs 2 and 3 are selected

• EVENT 123 event outputs 1, 2 and 3 are selected

9. The next parameter is SOAK SP:## (## = 1 to 12). It defines the setpoint after the current ramp segment (##) has completed. Choices are:

• -9999 to 99999 R Dependent upon process variable range

The decimal point defined by the DECIMAL parameter

10. The next parameter is SOAK TM:## (## = 1 to 12). It defines the length of the current soak segment. Time units are defined by the TIME BASE parameter in the REC. CONF. menu. Choices are:

D OFF Selecting off eliminates the SOAK and makes possible 2 or more ramps to different setpoints.

R 00:01 to 99:59 HR:MN if TIME BASE = HOURS:MIN R 00:01 to 99:59 MN:SC if TIME BASE = MIN:SEC

11. The next parameter is SOAK EV:## (## =1 to 12). It defines which events will be activated during this soak segment. This parameter will only appear if SOAK TM:## is not OFF. Choices are:

D NONE

• EVENT 1 event output 1 is selected

• EVENT 2 event output 2 is selected

• EVENT 12 event outputs 1 and 2 are selected

• EVENT 3 event output 3 is selected

• EVENT 13 event outputs 1 and 3 are selected

• EVENT 23 event outputs 2 and 3 are selected

• EVENT 123 event outputs 1, 2 and 3 are selected

12. The last parameter is PID SET:## (## =1 to 12). It selects which PID set to use during the current ramp and soak segments. This parameter only appears if NO. OF PID = SEG SELECT (in the TUNING menu). Choices are:

D LAST SET

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Applications

Use this chart to set up your recipe(s).

RAMP TIME

SOAK TIME

SOAK HYS.

EVENT 1

EVENT 2

EVENT 3

PID SET

RATE

END SETPOINT

Ramp

Soak

Ramp

Soak

Ramp

Soak

Ramp

Soak

Ramp

Soak

RECIPE #: Start From Time Base

PROCESS

T I M E

Idle Setpoint: Process Variable HRS/MIN: MIN/SEC:

PROFILE CONTROLLER SET-UP WORKSHEET

Ramp

Soak

Ramp

Soak

Ramp

Soak

Ramp

Soak

Ramp

Soak

Ramp

Soak

Ramp

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Soak

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Applications

Figure 7.1 Contacts for Recipe Selection

ber

Recipe Num

None

O = Open

● = Closed

NOTE: The 535 Profile Controller can store

20 recipes, but only recipes 1 through 7 may be selected remotely. This will use three of the five input contacts. The two remaining can be used to start or abort a recipe (START REC.) or hold the recipe (HOLD REC.). See

Section I for other input options.

Contact 1

●

Contact 2

●

Contact 3

●

R 1 to 8

13. After parameter PID SET, the controller will cycle to the RAMP RT:## or RAMP TM:## parameter.

To end programming:

• Set either RAMP RT:## = OFF or RAMP TM:## = OFF.

To continue programming:

• Set a value for for RAMP RT:## or RAMP TM:##, and scroll

through subsequent parameters.

Digital Inputs

Special digital input capabilities are available for 535 as a Profile Controller (see Section I in this chapter for information on standard Digital Input options). Profile Control digital input options are:

• RECIPE. 1-7 Selects recipe number (1through 7 using binary contacts 1, 2 and 3) for

the next time a recipe is run. The recipe number selected must be be tween 1 and the number of recipes selected in the REC. CONF. menu. Note that a binary value of “0” (zero) is inactive, and values of 1 to 7 select recipes 1 to 7 respectively.

• START REC. (Active = Start Recipe; Inactive = Abort Recipe) When activated, the most recently selected recipe will start running. When deactivated, a running or held recipe will be aborted. This action will take place if a recipe is not running or held at the time of the contact

closure.

• HOLD REC. (Active = Hold Recipe; Inactive = Resume Recipe) When activated, a running recipe will be held at its current position.

When deactivated, a held recipe will resume running from its current position.

• RESET REC. When activated, a running or held recipe is reset to the beginning. If the

recipe is linked to other recipes, the beginning of the first linked recipe will be used. When deactivated, no action will be taken.

• ABORT REC. When activated, a running or held recipe will be aborted. When deacti

vated, no action will be taken.

• NEXT SEG. When activated, a running or held recipe will advance to the end of the

current segment. When deactivated, no action will be taken.

• PV2. SWITCH (only applicable if PV SOURCE = 1/2:SWITCH). When activated, causes

the controller to use PV2 as the PV input (instead of PV1).

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Master/Slave Operation

The 535 Controller with profile option Is capable of operating as a master setpoint generator controlling up to 4 standard (slave) 535 controllers. The 535 with profile option can retransmit the recipe setpoints to the remote setpoint inputs of up to 4 standard 535 controllers. Configured as such, a common recipe may be applied to 5 different control loops or heating/cooling zones.

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Hardware Configuration

• The 535 controller with profile option must be configured with an analog milliamp module in the first available output.

• See Section H in this chapter for instructions on configuring the retrans- mission feature.

• Up to four model 535 controllers can be used, each must be specified with the remote setpoint option.

• See Section J in this chapter for instructions on configuring the optional remote setpoint feature.

Applications

B. CONTROL TYPE

Software Configuration

1. Go to the CONTROL menu.

2. For the parameter ALGORITHM, select 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.

• P

Proportional only control. Provides much better control than on/off. Used on processes that are less stable or require tighter control, but have few load variations and do not require a wide range of setpoints.

• PI

Proportional plus integral control. In addition to proportional control, it compensates for control errors due to wide range of setpoints or load requirements. The integral term works to eliminate offsets.

• PD

Proportional plus derivative control. In addition to proportional control, it compensates for control errors due to fast load variations.

• PID

Proportional plus integral plus derivative control. In addition to proportional control, it compensates for changes in setpoint, load requirements and process variations.

• PID/ON-OFF

Only available with Duplex control. First output uses the PID algorithm, while second output uses on/off control.

3. For algorithms using the derivative function (D), choose the conditions for the derivative term:

Scroll to parameter D. SOURCE

• For derivative action based on error, or deviation from setpoint, choose DEVIATION

• For derivative action based on changes in the process variable, choose PV.

NOTE: Controller capabilities depend upon the specified hardware option.

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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.

C. ALARMS

The 535 controller has two extremely flexible and powerful software alarms. The number of available outputs limits how alarms are linked to relays. A Global Alarm feature allows all alarms to be assigned to the same relay.

The 535 indicates an alarm condition by:

• 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. Set values 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:

• HIGH ALARM

High process variable alarm. Occurs when the process variable exceeds the alarm setpoint.

• LOW ALARM

Low process variable alarm. Occurs when the process variable goes below the alarm setpoint.

• HIGH/LOW

Combination of high and low alarms. Occurs when the process variable exceeds the individually set high or low setpoint.

• BAND

Creates a band centered around the control setpoint, that is twice the alarm setpoint. Alarm occurs when the process variable travels outside of this band. The alarm is dependent on the control setpoint. As the control setpoint changes, the band adjusts accordingly.

For example, if the control setpoint is 500 and the alarm setpoint is 25, then the band extends from 475 to 525.

• DEVIATION

Similar to the band alarm but creates a band only on one side of the control setpoint. Alarm occurs when the process variable deviates from the control setpoint by an amount greater than the alarm setpoint. This alarm is dependent on the control setpoint; as the control setpoint changes, the alarm point changes.

For example, if the control setpoint is 500 and the alarm setpoint is +50, then an alarm occurs when the process variable exceeds 550. In order for an alarm to occur when the process variable drops below 450, select an alarm setpoint of –50.

• MANUAL

Alarm occurs when the controller is put into manual mode of operation. This may be useful for security purposes or to alert the operator that 535 is no longer under automatic control.

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• RATE

Alarm occurs when the process variable changes at a rate greater than what is 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 seconds, an alarm occurs whenever a change in process variable greater than 10 occurs in 5 seconds.

ALM.SRC.:1 and ALM.SRC.:2

For HIGH , LOW or HIGH/LOW alarms, specifies the variable (source) upon which a selected alarm is based. Selection includes:

•PV

• PV2

•SP

• RAMP SP

• DEVIATION

• OUTPUT

Applications

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 must occur before the alarm activates. A negative value specifies a negative rate-of-change. Does not apply to HIGH/LOW alarms.

HIGH SP:1 and HIGH SP:2

For a HIGH/LOW alarm, defines the high setpoint at which an alarm occurs.

LOW SP:1 and LOW SP:2

For a HIGH/LOW alarm, defines the low setpoint at which an alarm occurs.

DEADBAND:1 and DEADBAND:2

Specifies the range through which the process variable must travel before leaving an alarm condition (see alarm examples at the end of this section). Prevents frequent alarm oscillation or “chattering” if the process variable has stabilized around the alarm point.

ALM.1 OUT and ALM.2 OUT

For any enabled alarm, selects the output number to which the selected alarm will be assigned. It is possible to assign both alarms to the same output relay, thus creating a “global” alarm .

LATCHING:1 and LATCHING:2

A latching (YES) alarm will remain active after leaving the alarm condition unless it is acknowledged. A non-latching (NO) alarm will return to the non-alarm state when leaving the alarm condition without being acknowledged.

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Applications

Alarm Parameters Reference

For Alarm 1

Parameter Description ALM. TYPE:1 Type ALM. SRC.:1 Source ALARM SP:1 Setpoint HIGH SP:1 High setpoint LOW SP:1 Low setpoint DEADBAND:1 Deadband ALM.:1 OUT. Output number LATCHING:1 Latching sequence ACK.:1 Acknowledging POWER UP:1 Status on power up MESSAGE:1 Message

For Alarm 2

Parameter Description ALM. TYPE:2 Type ALM. SRC.: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 RATE TIME Tim e base for rate

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.

A latching alarm can always be acknowledged when it is 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 a second 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 it is in alarm condition.

• ALARM: Controller always powers up in alarm regardless of system’s alarm

condition. This is an excellent way to activate an alarm if there has been a power failure.

• DELAYED Controller will never power up in alarm, regardless of system’s alarm

condition. The system must leave and reenter the alarm condition before the alarm will activate. This is typically used to avoid alarms during start up.

MESSAGE:1 and MESSAGE:2

Allows user to specify a nine-character message to be displayed when the respective alarm is active. If both alarms are active or any other diagnostic message is present, the messages will alternate.

FAULT

Activates an alarm if the process variable signal is lost. Assign this function to either Alarm 1 or Alarm 2 (not both). This action is in addition the selected alarm type (additive alarm function).

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OUTPUT

For a RATE alarm, selects the output action. Use to obtain early indication of a possible break in the 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 a predetermined output).

RATE TIME

For RATE alarms, defines the time period over which a discrete change in process variable must occur for the rate alarm to be activated. The amount of change is defined by the alarm setpoint. The rate-of-change is defined as the amount of change divided by the time period.

Example A. If the alarm setpoint is set to 10 and the time base is set to 1 second,

the rate of change is 10 units per second.

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TIME

ICON OFF

NO ALARM

IN ALARM

CONDITION

MAY ACKNOWLEDGE

RELAY ENERGIZED

RELAY DE-ENERGIZED

ICON ON

RELAY DE-ENERGIZED

ICON OFF

NO ALARM

A.SP

PARAMETER SETTINGS:

OUTPUT N = ALM.RLY:ON (N = 2 to 4) ALM. TYPE:1 = HIGH ALRM. ALM.:1 OUT. = N (N = 2 to 4) LATCHING = NO LATCH ACK.:1 = ENABLED

TIME

ALARM

CONDITION

RELAY ENERGIZED

ICON ON

A.SP

UNIT POWER UP

RELAY ENERGIZED

ICON ON

MAY ACKNOWLEDGE

ICON ON

MAY ACKNOWLEDGE

CANNOT 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

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)

TIME

IN ALARM

CONDITION

MAY ACKNOWLEDGE

RELAY ENERGIZED

RELAY DE-ENERGIZED

ICON ON

MUST ACKNOWLEDGE TO SHUT OFF ICON AND DE-ENERGIZE RELAY

ICON OFF

NO ALARM

C.SP + A.SP

C.SP

TIME

ICON ON

IN ALARM

CONDITION

CANNOT ACKNOWLEDGE

RELAY DE-ENERGIZED

RELAY ENERGIZED

ICON ON

RELAY DE-ENERGIZED

ICON OFF

RELAY ENERGIZED

NO ALARM

NO ALARM CANNOT

ACKNOWLEDGE

C.SP + A.SP

C.SP

- A.SP

IN ALARM

CONDITION

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

BAND ALARM HIGH PROCESS VARIABLE ALARM

DEVIATION ALARM POWER UP ALARM

Applications

Figure 7.2 Alarm Examples

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Applications

NOTE: The duplex output states vary

depending upon:

1. Control Type (PID, On/Off, etc.)

2. Control Action (DA, RA)

3. Output Limits

4. Output Gap or Overlay, and

5. Ouput 2 Relative Gain and PID% Output.

Please refer to the output state examples in this section to confirm that the configuration is appropriate for the process.

NOTE: Set manual reset/load line parameters to 50% when using Duplex control (MAN. RST.:X parameter is in the TUNING menu.)

B. If the alarm setpoint is set to 100 and the time base set to 10, the rate

of change is also 10 units per second.

In example A, the process variable would only have to experience a ten unit change over a short period of time, while in Example B, it would require a 100 unit change over a ten second period. Example A is much more sensitive than Example B. In general, for a given rate-of-change, the shorter the time period, the more sensitive the rate alarm.

D. DUPLEX CONTROL

The Duplex control algorithm enables two discrete control outputs for the control loop. Duplex control is commonly used for applications that require both heating and cooling or when 2 control elements are needed to achieve the desired result.

Hardware Configuration

• The controller must have two output modules assigned to the loop (any

combination of output modules).

Software Configuration

1. Go to the CONFIG. menu. Set CTRL.TYPE to DUPLEX.

2. To use different algorithms for each output (PID for the first, and On/Off for the second):

Go to the CONTROL menu. Set ALGORITHM to PID:ON/OFF.

3. To make the control action for each output independent of the other: Go to the CONTROL menu. Set ACTION:1 or ACTION:2 to either DIRECT or REVERSE action based

on the diagrams in the output examples section (

4. Go to the TUNING menu. Set values for PID OFST:1 (or ON OFST:1) and PID OFST:2 (or ON OFST:2).

These parameters allow the user to independently offset the point at which output 1 and output 2 become active. PID OFSET units are in percent (%) 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 set it to 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. Go to the CONTROL menu. Set LOW OUT. and HIGH OUT. to limit the maximum or minimum outputs

from Output 1 and Output 2. The actual limitation on the outputs is dependent on the offset settings, the relative gain setting and the control action.

Figures 7.2 through 7.8

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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 horizontal axis. Draw a vertical line at that point. At the 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

A reverse acting output 1 and a direct acting output 2 with: no offset, no restrictive outputs limits, and a neutral relative gain with PID control.

PARAMETER SETTINGS

ACTION:1 = REVERSE ACTION:2 = DIRECT PID OFST.:1 = 0 PID OFST.:2 = 0 LOW OUT = 0 HIGH OUT = 100 REL. GAIN = 1.0

Out 1

100%

Out 1

Out 2

100%

Out 2

Applications

Figure 7.3 Duplex with reverse and direct acting outputs

50%100% 0%

PID OUTPUT

Duplex with direct and reverse acting outputs

A reverse acting output 1 and a direct acting output 2 with: no offset, no restrictive output limits, and a neutral relative gain with PID control.

PARAMETER SETTINGS

ACTION:1 = DIRECT ACTION:2 = REVERSE PID OFST.:1 = 0 PID OFST.:2 = 0 LOW OUT = 0 HIGH OUT = 100 REL. GAIN = 1.0

Out 1 (Heat)

100%

Out 1

Out 2

PID OUTPUT

Out 2

Out 1

50%100% 0%

(Cool)

Out 2

100%

Figure 7.4 Duplex with direct and reverse acting outputs

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