Moore Industries 531 User Manual
5 3 1
5 3 1
PLC, DCS, PC CONTROL BACKUP STATION
USER'S MANUAL
M531 V7, MARCH 207
page
CONTENTS
FIGURE LIST .......................................................................................... iii
CHAPTER 1
INTRODUCTION ............................................................................. 1
Conforming What Is Included.......................................................... 1
Order Code ...................................................................................... 2
Basic Operation ............................................................................... 3
Where To Go Next........................................................................... 3
Text Formatting in This Manual ...................................................... 3
CHAPTER 2
INTERFACE & BASIC OPERATION ............................................. 5
Displays ............................................................................................ 5
Icons................................................................................................. 5
Keys ................................................................................................. 6
Basic Operating Procedures ........................................................... 7
Alarms .............................................................................................. 8
Contents
About This Manual:
Throughout this User’s Manual will
appear NOTEs, CAUTIONs and
WARNINGs, usually in boldface.
Please heed these safety and good
practice notices for the protection of
you and your equipment.
CHAPTER 3
HARDWARE CONFIGURATION.................................................... 9
Accessing and Changing Jumpers ............................................... 11
Adding or Changing Output Modules............................................ 12
Where to Go Next.......................................................................... 13
CHAPTER 4
MOUNTING AND WIRING............................................................ 15
System Planning............................................................................ 15
Mounting the Station...................................................................... 15
Wiring the 531 Inputs..................................................................... 16
A.AC Power .......................................................................... 17
B.Process Variable............................................................... 17
C.Digital Inputs ..................................................................... 18
D.Remote Setpoint Indicator................................................ 19
Wiring the 531 Outputs.................................................................. 19
A.CV Output ......................................................................... 19
B Mechanical Relay Output ................................................. 19
C Solid State Relay (Triac) Output...................................... 19
D.DC Logic (SSR Drive) Output ..........................................19
Wiring for Serial Communications................................................. 20
Where to Go Next.......................................................................... 20
CHAPTER 5
SOFTWARE CONFIGURATION .................................................. 21
Mode Overview.............................................................................. 21
Menus............................................................................................. 22
Smart Menus..................................................................................22
Software Configuration Procedures.............................................. 23
Guide to Set up Parameters.......................................................... 25
CONFIG................................................................................. 25
LOCAL OUT. ......................................................................... 28
PV INPUT .............................................................................. 29
CUST. LINR. ......................................................................... 31
531 User's Manual Table of Contents i
Contents
page
RSP INPUT ............................................................................ 32
ALARMS ................................................................................ 33
SECURITY ............................................................................. 35
SER. COMM........................................................................... 36
OPERATION .......................................................................... 37
Parameter Value Charts.................................................................. 39
CHAPTER 6
531 APPLICATIONS ...................................................................... 45
531 Operation ................................................................................. 45
Alarms............................................................................................. 46
Digital Inputs ................................................................................... 50
Watchdog Monitor........................................................................... 51
Process Variable and Setpoint ........................................................ 51
Input Linearization........................................................................... 53
Thermocouple and RTD Linearization .................................... 53
Square Root Linearization ...................................................... 53
Custom Linearization.............................................................. 53
Ramp to a Control Value................................................................. 54
Security........................................................................................... 55
Process Variable Reading Correction ............................................. 56
Serial Communications ................................................................... 56
APPENDIX A
MODE, MENU & PARAMETER FLOWCHART............................ A-1
APPENDIX B
PARTS LIST................................................................................. B-1
APPENDX C
TROUBLESHOOTING ................................................................. C-1
APPENDIX D
CALIBRATION ............................................................................. D-1
Regarding Calibration ................................................................... D-1
RTD and VmA Input Calibration .................................................... D-2
Thermocouple & Cold Junction Calibration ................................... D-3
Milliamp Output Calibration ........................................................... D-4
Reset Menu Data .......................................................................... D-4
Hardware Scan ............................................................................. D-5
Quick Calibration Procedure ......................................................... D-5
APPENDIX E
SPECIFICATIONS........................................................................ E-1
ii Table of Contents 531 U ser's Manual
Figure.............Title ............................................................................ Page
Figure 2.1 ......531 Operator Interface .........................................................5
Figure 2.2 ......Before and After Acknowledging an Alarm ............................. 8
Figure 3.1......Location of Printed Circuit Boards ......................................... 9
Figure 3.2......Jumper Locations on Microcontroller Board ......................... 10
Figure 3.3......The Option Circuit Board .................................................... 10
Figure 3.4......The Power Supply Circuit Board ......................................... 10
Figure 3.5......Output Module ................................................................... 13
Figure 4.1 ......531 Instrument Panel and Cutout Dimensions ..................... 15
Figure 4.2 ......Mounting Brackets ............................................................. 16
Figure 4.3 ......531 Rear Terminals ............................................................ 17
Figure 4.4 ......Output Wiring for the 531 .................................................... 19
Figure 4.5 ......Serial Communications Terminals....................................... 20
Figure 5.1 ......Menu Flowchart for Set Up ................................................. 21
Figure 5.2 ......Independent vs. Dependent Parameters ............................. 22
Figure 5.3 ......Keys to Enter and Move Through Set Up Mode.................... 23
Figure 6.1 ......Alarm Examples................................................................. 49
Figure 6.2 ......Square Root Linearization Formula ..................................... 53
Figure 6.3 ......Custom Linearization Curve................................................ 54
Figure D.1 .....Flowchart to Access Parts of Calibration Menu Block ......... D-1
Figure D.2 .....Microcontroller Circuit Board ............................................. D-2
Figure D.3 .....Calibration Wiring ............................................................. D-2
Figure D.3a ...Calibration Wiring (continued) ........................................... D-3
Figure D.4 .....Thermocouple & Cold Junction Calibration Wiring .............. D-3
Figure D.5 .....Milliamp Calibration Wiring................................................ D-4
Contents
531 User's Manual Table of Contents iii
Contents
iv Table of Contents 531 User's Manual
CHAPTER 1
INTRODUCTION
Introduction
The 531 PID Backup Station ensures the integrity of your processes with
maximum reliability. Isolated inputs and outputs guard against electrical interference, the front face meets NEMA 4X standards for watertight operation, and
the rugged case and sturdy rubber keys enhance durability.
The 531 has three digital display areas, two of which offer up to 9 characters of
true alphanumerics. The bright, crisp vacuum fluorescent displays offer better
readability than any other display technology. Additional operator friendly features include: custom programmable alarm messages, keys that illuminate
when in use, and an easy-to-use menu system.
INPUTS
OUT
HOST Signal
Process Variable
Remote Setpoint
Digital Inputs
Serial Communications
1 2
ALM
1 2
Thank you for selecting the 531
PID Backup Station. It is the most
sophisticated instrument in its
class and will provide you with
years of reliable, trouble-free
performance.
OUTPUTS
HOST Signal
Control Output
Alarm(s)
Serial Communications
The 531 automatically provides PID backup control for critical control loops. In
Host Mode, the control signal passes from the Host device through the 531
without any degradation. A Host device may be a PLC, DCS, or process controller. The 531 switches to Automatic (PID) Mode upon keypad selection,
digital input, or loss of the Host signal, and generates a control signal based on
its own PID calculations. The control setpoint may be one or two preset
setpoints, or transmitted to the 531. The 531 can also be switched to Manual
Mode, in which the operator can manually adjust the output. The 531 will transfer/return to Host Mode upon keypad selection, opening of the digital input or
return of the Host signal.
CONFIRMING WHA T IS INCLUDED
With your 531 PID Backup Station, you should have received:
• 1 531 User’s Manual
• Mounting hardware set
• 1 sheet of engineering unit adhesive labels
• 1 Terminal label
You can determine the installed outputs of your station by comparing your product
number to the Order Code below. The product number is printed on the label on
the top of the controller case.
Specifications and information subject to change without notice.
Note: that the 531 PID Backup Station
is not a point of failure; removing it from
the case or powering down while in
Host Mode will not disturb the Host
signal.
531 User's Manual Chapter 1, Introduction 1
Introduction
ORDER CODE*
BASIC OPERA TION
There are three operating modes for the 531:
531 -
OUTPUT 1 —
(ALARM ONLY)
None .........................................................................................0
Mechanical relay .......................................................................1
Solid state relay (1 amp triac) ...................................................3
DC logic (SSR drive) .................................................................4
OPTIONS
ENTER “0” IF NOT DESIRED
None .........................................................................................0
24 VAC Operation .....................................................................F
ENTER “0” IF NOT DESIRED
None .........................................................................................0
Set of five digital inputs .............................................................D
Certification ..........................................................................H
Set of five digital inputs and
SERIAL COMMUNICATIONS
ENTER “0” IF NOT DESIRED
None .........................................................................................0
RS-485 serial communications .................................................S
Certification .............................J
ORDER CODE
11B002
* Note: Base instrument contains universal PV input, remote setpoint input and 4-20 mA CV (control) output with
internal hard wired by-pass relays.
NOTE:
Altering the factory configuration of the
modules will render the product label
code invalid.
2 Chapter 1, Introduction 531 User's Manual
Host Mode: The 531 operates as a remote station that passes a CV directly from a host to a controlled device. In this mode, the SP but not the CV
(output) can be altered. Special “set up” parameters can be accessed, and
the 531 can be transferred into either of the other operating modes.
Automatic Mode: The 531 sends output to the final device as provided by
its own PID calculations. In this mode, the SP but not the CV (output) can
be altered. The “set up” parameters may not be accessed, but the 531 can
be transferred to either of the other operating modes.
Manual Mode. An operator provides manual output to the controlled device. Both the SP and the CV can be altered, and the 531 can be transferred
to either of the other two operating modes.
The 531 also has a set up, or “configuration” mode in which the user configures
the special functions of the 531, like inputs and outputs, alarms and PID operation. There are 9 menus in set up mode: eight are for instrument set up, and the
ninth, OPERATION, configures the operational aspects of the 531.
WHERE TO GO NEXT
• First time users should read through this entire manual. Continue to Chapter 2 for basic interface and operation information. Then read Chapter 3 for
important installation guidelines.
• Experienced users may continue on to Chapter 5 for details on the configuration features of the 531.
• Appendix 1 contains flowchart references for all 531 parameters, menus
and modes.
Introduction
TEXT FORMA TTING IN THIS MANU AL
Feature Format
Mode Automatic, Manual, Host Mode
KEYS SET PTDISPLAY
or
SET PT
ICONS OUT, ALM
MENUS CONFIG., TUNING
PARAMETERS CYCLE TM:1, MIN.OUT2
PARAMETER VALUES OFF, SETPOINT, LAST OUT.
DISPLAY MESSAGES TOO HOT, OUT%,
DISPLAY
531 User's Manual Chapter 1, Introduction 3
Introduction
4 Chapter 1, Introduction 531 User's Manual
CHAPTER 2
INTERF A CE AND BASIC OPERA TION
The individual software and hardware options of your station determine the information it displays. Compare the product number on the unit label to the Order
Code in Chapter 1 for more information. A “smart menu” feature of the 531 allows only those messages relevant to your individual hardware (and software)
configuration to appear in the displays.
531
Icons
OUT
1 2
ALM
1 2
1st Display
nd
2
Display
rd
Display
3
Interface/Operation
NOTE::
Any modifications to the factory
settings of the output modules will
alter the Model Number displayed
upon power-up from the original the
Product Code on the label.
Figure 2.1
531 Operator Interface
Location for
identification label
MANUAL
DISPLAY
ACK
Keys
HOST
MENU
FAST
1st Display
• 5 digits, seven segments. Height is 15mm (0.6in).
• Normally displays the Process Variable (PV).
If station loses signal, “--------” displays.
2nd Display
• 9 characters, 14 segment alphanumeric. Height is 6mm (0.25in).
• Displays the CV output (OUT) or the setpoint (SP). To change the displayed
value, press the DISPLAY key.
• When in configuration menus, displays the menu and parameter names
3rd Display
• 9 characters, 14 segment. Height is 6mm (0.25in).
• Displays user-selectable station name if no alarms are queued.
• Displays any error or alarm in two-second alternating messages.
• When in configuration menus, displays the parameter values.
ICONS:
ALM 1, ALM2: Indicates respective alarm(s) is/are active.
OUT 1, OUT2: Indicates respective output(s) is/are active.
531 User's Manual Chapter 2, Interface and Basic Operation 5
ALM ALM ALM
1212
OUT OUT OUT
1212
Interface/Operation
KEYS
MANUAL
HOST
DISPLAY
MENU
ACK
FAST
Press Key (s)
Transfers station from Host or
Automatic Mode to Manual Mode,
or from Manual to Automatic.
Toggles between Host and either
Automatic or Manual Mode
(depending on validity of the PV).
Exits the configuration (set up)
menus and returns station to
operating mode.
Provides entry into the OPERATION set up menu.
Acknowledges alarms.
Functions as a “shift” key or for use
with other keys.
Illuminated Key
Station is in Manual Mode. When
not illuminated, the station is in
either Host or Automatic Mode.
531 is passing Host signal
through.
Key does not light.
531 is in configuration (set up)
mode.
An acknowledgable alarm exists.
Key does not light.
▲
FAST
or
+
or
▲
▲
▲
FAST
FAST
NOTE:
Refer to Chapter 3, or Appendix 1 for
details on menu, mode and parameter
transitions
+
+
MENU
Increases or decreases the value or
selection of the current parameter.
Changes parameter value or
selection at a faster rate.
In Host or Manual Mode, provides
entry into the other eight set up
menus. When under configuration,
advances from menu to menu.
Keys do not light.
N/A
N/A
6 Chapter 2, Interface and Basic Operation 531 User's Manual
BASIC OPERA TING PR OCEDURES
To transfer from Host to Automatic Mode
1. Press the HOST key once. The 531 will transfer to Automatic Mode as
long as the PV input is valid (else, it transfers to Manual Mode).
2. The HOST key and MANUAL key will be off.
3. The 531 stops passing the Host signal, and transmits its own output that
based on PID, with a bumpless transfer.
To transfer from Host to Manual Mode
1. Press the MANUAL key. The 531 will transfer to Manual Mode.
2. The HOST key will extinguish, and the MANUAL key will light.
3. The 531 stops passing the Host signal, and transmits a manual output to
the final control element. This will be a bumpless transfer.
To transfer from Automatic to Manual Mode
1. When in Automatic Mode, press the MANUAL key.
2. The MANUAL key will light.
3. The 531 stops transmitting the PID output and transmits a manual output
to the final control element. This will be a bumpless transfer.
To transfer from Automatic/Manual Mode to Host Mode
1. Press the HOST key. The 531 will transfer to Host Mode as long as the CV
signal is valid (otherwise, it remains in the previous mode).
2. The 531 will stop transmitting its own output (CV) signal, and pass the signal from the Host device to the final control element. This will be a direct
transfer.
3. To provide a ramped transfer, the ramping rate (HOST RAMP) can be set
in the OPERATION menu.
To change output values
1. Press MANUAL key to shift to Manual Mode from Automatic or Host.
2. The second display will display OUT%.
▲▲
3. Use
To override security or reset the controller
1. If someone attempts a locked operation, SECURITY appears in the 2nd
display, and a security code prompt (0) appears in the 3rd display.
2. Use
two seconds of key inactivity.
• If no code was entered (value left at 0), SECURITY disappears and
the station resumes operation.
• If the value is incorrect, INCORRECT appears in the 3rd display. After
2 seconds, the station prompts you to enter a new code.
• If the code is correct, CORRECT appears in the 3rd display. After two
seconds, all displays clear and you have temporary access to all previously locked features. Security will automatically rearm (lock) the
station once after one minute of key inactivity.
• If the correct Security Override Code is entered, RESET appears in
the 3rd display. After two seconds, all displays clear and the stations
functions are reset to their factory defaults (unlocked).
▲ and
▲▲
▲▲
▲ and
▲▲
▼▼
▼ keys to change the output (CV) value.
▼▼
▼▼
▼ keys to select a code value. The value will be entered after
▼▼
Interface/Operation
NOTE:
For more information on operating
modes, see Chapter 6.
NOTE:
For more information on Security
functions, see Chapter 6.
531 User's Manual Chapter 2, Interface and Basic Operation 7
Interface/Operation
NOTE:
Powering down the controller acknowledges/clears all latched alarms. When
powering up, all alarms will be reset according to their power-up configuration
(see Chapter 6).
NOTE:
All alarms are internal alarms unless tied
to an output relay in the set up mode.
ALARMS
IMPORTANT! Alarms can be used to provide warnings of unsafe conditions.
Therefore, all 531 operators must know how the alarms are configured, how to
react to alarm conditions, and the consequences of acknowledging (noting and
clearing) an alarm.
The 531 indicates alarms by:
• Lighting icons
• Displaying messages; and
• Lighting the ACK key, if an alarm is in an acknowledgeable state.
To acknowledge an alarm:
1. Press the ACK key to acknowledge Alarm 1. This clears the alarm (and
releases the relay, if applicable.
2. Both the icon and message indicators disappear, and the relay (if applicable)
changes state.
3. If a second alarm is active and acknowledgeable, press the ACK key again
to acknowledge Alarm 2.
Figure 2.2 shows the controller face during an alarm condition, and after the
alarm has been acknowledged.
OUT
1 2
ALM
1
BEFORE
531
OUT
1 2
AFTER
531
Figure 2.2
Before and After Acknowledging
an Alarm
MANUAL
DISPLAY
MENU
ACK
FAST
MANUAL
HOST
DISPLAY
MENU
ACK
FAST
HOST
Latching Alarms
A latching alarm holds its alarm state even after the process leaves the alarm
condition. This is useful for stations that will not be continuously monitored by
an operator. A latching alarm can be configured to be acknowledgeable while
in the alarm condition, OR only after the process leaves the alarm condition. 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 not acknowledgeable. In
this case, the alarm is acknowledgeable only after the process has left the alarm
condition. This is often referred to as a limit sequence.
For more on alarms, see Chapter 6.
8 Chapter 2, Interface and Basic Operation 531 User's Manual
CHAPTER 3
HARDWARE CONFIGURA TION
Hardware
The 531 hardware configuration determines which outputs are available and
the types of indicator signals that will be used.
Your station comes factory set with the following:
• All the specified modules and options installed (see product label and
compare to Order Code in Chapter 1).
• Process variable and remote setpoint inputs set to accept a milliamp
input.
CAUTION!
Static discharge will cause damage to equipment. Always ground yourself with a wrist grounding strap when handling electronics to prevent
static discharge.
• Relay outputs set to normally open
The locations of certain jumpers and modules on the printed circuit boards
will allow different types of inputs and outputs to be connected to the stations. Figure 3.1 shows the position of these circuit boards inside the station.
To access these boards:
1. With power off, loosen the two captive front screws with a Phillips
screwdriver.
2. Gently slide the chassis out of the case by pulling on the front face plate
assembly at the bezel. Remove the two screws.
NOTE:
If you would like your controller configured at the factory, please consult
an application engineer.
NOTE:
Your hardware configuration will
influence the available set up options
in Chapter 5.
NOTE:
Any changes you make to the output
modules will render the code on the
product label invalid.
MICROCONTROLLER
BOARD
POWER SUPPLY
BOARD
531 User's Manual Chapter 3, Hardware Configuration 9
Figure 3.1
Location of Printed Circuit Boards for
Hardware Configuration
OPTION
BOARD
Hardware
Process Variable Indicator Type
The 531 will accept several different types of Process Variable Signals. You
specify the type of signal by adjusting the PV jumper location on the Micro-
controller Circuit Board, as shown in Figure 3.2. You will also need to set the
particular sensor range in the software (Chapter 5).
V Voltage signal
MA Milliamp
TC t Thermocouple with downscale burnout
TC s Thermocouple with upscale burnout
RTD RTD
EPROM
Figure 3.2
Jumper Locations on
Microcontroller Board
Figure 3.3
The Option Circuit Board, with Output 4
CAUTION!!
Do not change configuration of outputs
2, 3, and 4. Do not change position of
jumpers J2 and J3.
Figure 3.4
The Power Supply Circuit Board,
with Outputs 1 through 3
BATTERY
5-Pin Connector
Male 22-Pin
Connector
4-Pin Connector
Output 4
Female 44-Pin Connector
4
Retransmitted (Remote) SP
PV Input Jumper
Female 22-Pin ConnectorFemale 22-Pin Connector
Male 22-Pin
Connector
Male 44-Pin
Connector
Module
Retention
over Outputs 1,2,3
Configuration
Configuration
Plate
3
2
1
V
MA
V
MA
TC
TC
RTD
TB2
2ND
PV1
TB1
NO J3 NC
NO J2 NC
NO J1 NC
10 Chapter 3, Hardware Configuration 531 User's Manual
Jumpers
NO and NC
Setpoint Type (retransmitted)
You specify the type of retransmitted setpoint by adjusting the jumper location
on the Microcontroller Board, as shown in Figure 3.2:
V Voltage signal
MA Milliamp signal (factory default)
Mechanical Relays
There is one output module socket on the Option Board (Figure 3.3), and three
on the Power Supply Circuit Board (Figure 3.4). The position of the jumper next
to each socket determines whether the relay is configured for Normally Open
(NO) or Normally Closed (NC). The output on the options board is always factory set to Normally Open (NO).
Only the Output 1 relay (if used) may be configured for normally open or normally closed. Do not make any changes to J2 and J3.
ACCESSING AND CHANGING JUMPERS
Jumper connectors either slip over adjacent pins, or have pins which insert into
adjacent holes. “Changing the jumper” means moving the jumper connectors
to alternate pins/holes.
Equipment needed:
• Needle-nose pliers (optional)
• Phillips screwdriver (#2)
• Wrist grounding strap
1. With power off, loosen two captive front screws with a Phillips screwdriver.
2. Slide the chassis out of the case by pulling on front face plate assembly at
the bezel. Remove the two screws now. You will not need to disassemble
the chassis to make these adjustments.
3. Refer to Figures 3.2 and 3.4 to locate the jumper connector you want to
change.
4. With either your fingers or the needle nose pliers, pull the jumper connector
straight up, being careful not to bend the pins (see Photo 4)
5. Move the jumper connector over the desired location and press it straight
down, making sure it is seated firmly. Repeat steps 3 and 4 for any other
jumpers you wish to change.
6. When you are ready to reassemble the unit, align the boards on the chassis
with the case's top and bottom grooves. Press firmly to slide the chassis
into the case. If you have difficulty, check that you have properly oriented
the chassis and that there are no screws interfering with the case.
7. Carefully insert and align screws. Tighten them until the bezel is seated firmly
against the gasket. Do not overtighten.
Hardware
CAUTION!!
Static discharge will cause damage to
equipment. Always ground yourself
with a wrist grounding strap when
handling electronics to prevent static
discharge.
4. REMOVE JUMPERS
531 User's Manual Chapter 3, Hardware Configuration 11
Hardware
CAUTION!!
Static discharge will cause damage to
equipment. Always ground yourself
with a wrist grounding strap when
handling electronics to prevent static
discharge.
ADDING OR CHANGING OUTPUT MODULES
The 531 has provisions for four output modules. The units come factory configured with specified modules installed in appropriate locations. You can make
field adjustments by properly removing and/or plugging the modules into the
appropriate sockets.
Important Notes:
• Only the Output 1 relay (if used) may be changed.
• Output modules 2, 3 and 4, and Jumpers J2 and J3 must not be changed
from their factory installation.
• Any output module with a sold state relay or analog module MUST have its
jumper set at normally open (NO).
• Output 4 is always normally open (NO).
Three of the output sockets are located on the Power Supply Circuit Board. A
fourth output socket is located on the Option Board.
Equipment needed:
• Wrist grounding strap
• Phillips screwdriver (#2)
• Small flat blade screwdriver
• Wire cutters or scissors
1. With power off, loosen two captive front screws with a Phillips screwdriver.
2. Slide the chassis out of the case by pulling on front face plate assembly at
the bezel. Remove the two screws now.
3. Locate the retention clips holding the front face assembly to the rest of the
chassis. Pry apart these retention clips gently with a screwdriver to separate the printed circuit board group from the front face assembly. Take care
not to break the clips or scratch the circuit board. See Photo 3.
The Microcontroller Board and Power Supply Board remain attached to the
Operator Interface Assembly by wired connectors.
4. See Photo 4. The Microcontroller and Power Supply board are attached to
either side of the Option board by male/female pin connectors. Use a gentle
rocking motion and carefully apply pressure to separate the larger two
boards from the Option Board.
CAUTION!
Do not scratch the boards or bend the
pins of the connectors.
12 Chapter 3, Hardware Configuration 531 User's Manual
3. PRY CLIPS
4. SEPARATE BOARDS
5. A retention plate and tie wrap hold Output modules 1, 2, and 3 (on the Power
Supply board) firmly in place. To remove the retention plate, snip the tie
wrap with wire cutters (or scissors) as shown in Photo 5.
Always snip the tie wrap on top of the Retention Plate to prevent
damage to the surface mount components.
6. A disposable tie wrap holds Output module 4 (on the Option board) in place.
To remove the module, snip tie wrap like in Photo 6.
7. Inspect each module before installation to make sure the pins are straight
(Figure 3.5). Align the pins with the socket holes and carefully insert the
module. Press down to seat it firmly on the board (see Photo 7).
Hardware
Figure 3.5
Output Module
5. REMOVE RETENTION PLATE
8. Use new tie wraps to secure the Retention Plate and Output Module 4.
Failure to use the tie warps may result in the module loosening
and eventual failure. All individually ordered modules come with
tie wraps. Extra sets of tie wraps are available; order Part #535-
665.
9. To reassemble the unit: Align the connector pins on the Option Board with
the connector sockets on the Microcontroller and Power Supply boards.
Squeeze them together, making certain all three are properly seated against
one another. Check along the side edges for gaps. Also, check that the cable
assemblies are not pinched.
10. Align the board assembly with the front face assembly, with the Option board
at the bottom (see Figure 3.1). Reinstall the retention clips. Align the boards
into the slots of the front face assembly and the clips will snap into place.
11. When you are ready to reassemble the unit, align the boards on the chassis
with the top and bottom grooves on the case. Press firmly to slide the chassis into the case. If you have difficulty, check that you have properly oriented
the chassis, and there are no screws interfering with the case.
12. Carefully insert and align screws. Tighten them until the bezel is seated firmly
against the gasket. Do not overtighten.
6. SNIP TIE WRAP 7. ADD/CHANGE MODULE
WHERE T O GO NEXT
For a step-by-step guide on mounting and wiring your 531 PID Backup Station,
see Chapter 4.
531 User's Manual Chapter 3, Hardware Configuration 13
Hardware
14 Chapter 3, Hardware Configuration 531 User's Manual
CHAPTER 4
MOUNTING AND WIRING
The 531 PID Backup Station is thoroughly tested, calibrated and “burned in”
at the factory, so your station is ready to install. But before you begin, read
this chapter carefully and take great care in planning your system. A properly
designed system can help prevent problems such as electrical noise disturbances and dangerous conditions.
SYSTEM PLANNING
A. Consider the Noise Factor
• For improved electrical noise immunity, install the station as far
away as possible from motors, relays and other similar noise
generators.
• 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.
B. Wiring Practice Resources
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.
Mount/Wire
WARNING!
To avoid electric shock, DO NOT
connect AC power wiring at the
source distribution panel until all
wiring connections are complete.
To avoid shock hazard and reduced
noise immunity for your system,
terminal 9 must be grounded.
MOUNTING THE STA TION
A. Make the panel cutout
The station fits in a standard 1/4 DIN cutout. You may mount your station
in any panel with a thickness from .06 to .275 inches (1.5 mm to 7.0
mm). See Figure 4.1 for dimensions.
If you make a mistake in the panel cutout, you can use a “Goof Plate”
(Repair Part #512-014).
B. Establish a waterproof seal
The station front face (keys, display, and bezel) are NEMA 4X rated
(waterproof).
7.180 (182.37) OVERALL LENGTH
1.180 (29.97)
PANEL
PV2
OUT
1 2
ALM
1 2
3.770 (95.76)
3.770 (95.76)
Figure 4.1
531 Instrument Panel and Cutout
Dimensions
3.622 (92.00) MIN.
3.653 (92.80) MAX.
3.653 (92.80) MAX.
3.585 (91.06)
3.622 (92.00) MIN.
BEZEL
FRONT
531 User's Manual Chapter 4, Mounting and Wiring 15
GASKET
6.000 (152.40)
SIDE
CUTOUT
Mount/Wire
To obtain a waterproof seal between the station and the panel, make sure:
1. The panel cutout is precise.
2. You use a fresh gasket.
3. The edge of the cutout is free from burrs and “waves”.
4. The case of the station are centered in the cutout.
If you require a waterproof seal but have difficulty with these requirements,
apply a bead of caulk or silicone sealant behind the panel around the perimeter of the case.
Figure 4.2
Mounting Brackets
Bezel
MOUNTING BRACKET
(1 EA. SIDE)
C. Mount station into panel:
The instrument enclosure mounting must be grounded.
You will need a long Phillips screw driver (#2).
1. Place bezel gasket around the station case (starting at the back of the
station). Then, slide the gasket against the back of the bezel.
2. With the bezel gasket in place, insert the station into the panel cutout
from the front of the panel.
3. From behind the panel, insert the mounting clips (one on each side),
as shown in Figure 4.2.
4. Gradually tighten the mounting bracket screws.
5. Tighten the screws securely and check bezel gasket to ensure a tight,
even seal.
Housing
Slide gasket
on from this
end.
NOTE:
All wiring and fusing should conform to
the National Electric Code and to any
locally applicable codes.
16 Chapter 4, Mounting and Wiring 531 User's Manual
WIRING THE 531 INPUTS
Figure 4.3 shows the rear terminal configurations for the 531. The actual instrument has only the top and bottom numbers of each column marked. Refer to
this diagram for the following input and output wiring instructions.
IMPORTANT!!
When wiring the 531 terminals, DO NOT use alligator clips (they create an
open circuit).
AC Power
LINE
Mount/Wire
Optional Contact Inputs
from HOST (if installed)
1
9
EARTH
GND
DIN
GND
17
25
NC
NEUTRAL
Optional Local Flag
to HOST
or Alarm
4–20 mA
Control
Signal
–
+
I
P
Any Final Control Element
A. AC Power
Terminals 1 and 2 are for power.Terminal 9 is earth ground.
POWER
OUT 1–
OUT 1+
CV OUT –
CV OUT+
1
2
NC
NC
2
3
4
5
6
7
8
9
GROUND
NC
10
NC
11
NC
12
NC
13
CV IN+
14
CV IN–
15
NC
16
PC, PLC, DCS
DIN 1
18
DIN 2
19
DIN 3
20
DIN 4
21
DIN 5
22
N/A
23
N/A
24 32
4–20 mA Control Signal
HOST
COMM–
26
COMM+
27
SP IND.–
28
SP. IND+
29
RTD 3rd
30
PV IND.–
31
PV IND.+
A special PC Board covers
terminals 5,6,7,8,13,14,15, and 16.
Figure 4.3
531 Rear Terminals
NOTE:
Use a 0.5 Amp, 250 V, fast-acting fuse
in line with your AC power connection
(terminal 1).
RSP
from HOST
PV Sensor
B. Process Variable
The station accommodates the following types of process variable inputs:
Thermocouple, RTD , Voltage, Milliamp, Voltage and Millivolt.
1. Thermocouple Input
Use terminals 31 and 32 as shown.
–
31
+
32
531 User's Manual Chapter 4, Mounting and Wiring 17
T/C Input
Mount/Wire
2. RTD Input
For 2, 3 or 4 wire RTD, use terminals 30, 31 and 32 as shown.
RTD INPUT 2-WIRE
Jumper wire
30
31
RTD
32
RTD INPUT 3-WIRE
Same color
Third leg
of RTD
RTD INPUT 4-WIRE
30
31
32
DO NOT connect 4th leg
3. Voltage Input
Use terminals 31 and 32 as shown.
4. Milliamp Input -External Power Supply
Use terminals 31 and 32 with a 2-Wire transmitter.
31
32
–
–
Transmitter
+
+
Same color
Third leg
of RTD
30
31
32
Same color
MILLIAMP INPUT - EXT. POWERVOLTAGE INPUT
– External +
31
32
Power Supply
– Transmitter +
C. Digital Inputs
1. With a Switch
Use terminal 17 with the appropriate digital input terminal as shown.
2. With a Relay (dry contact)
Signal-type relay is recommended. Use terminal 17 with the appropriate
digital input terminal as shown.
3. With an Open Collector (transistor)
11mA typical. 50 Ω max. resistance. 50 Ω max. loop resistance. Use terminals 17with the appropriate digital input terminal as shown.
SWITCH / RELAY
17
#
DIN 1
18
DIN 2
19
DIN GND
DIN #
OPEN COLLECTOR
DIN 3
20
DIN 4
21
17
#
DIN GND
DIN #
DIN 5
22
18 Chapter 4, Mounting and Wiring 531 User's Manual
D. Remote Setpoint Indicator
3
4
_
+
Load
_
+
DC LOGIC (SSR DRIVE)
3
4
Line Power
Load
MECHANICAL RELAY
3
4
Line Power
Load
-
+
+
SSR (TRIAC)
5
6
_
+
CV
CV OUTPUT
7
8
Use terminals 28 and 29 as shown.
–
28
29
–
Source
+
+
Mount/Wire
WIRING THE 531 OUTPUTS
• Output 1 is available for use as an ALARM or HOST FLAG with installation of a Mechanical Relay, Solid State Relay (Triac) module, or SSR
Drive.
• The 531 is factory configured with an Analog module in Output 2.
• The 531 is factory configured with Mechanical Relays in Outputs 3 and 4.
• The 531 cannot be wired for retransmission.
• A small PC board fits over rear terminals 5 to 8 and 13 to 16.
These instructions explain proper wiring of the 531 for any output module. If
you do not know which module(s) have been installed in your station,
compare the number on the product label with the Order Code on page 3.
To add or change position of jumper 1 or output module 1, refer to Chapter 3.
A. CV Output
• Use terminals 5 and 8 for CV Output as shown in Figure 4.4.
• Use terminals 14 and 15 for CV Input.
B. Mechanical Relay Output
• Use terminals 3 and 4 as shown in Figure 4.4.
• Jumper J1 can be set to normally open (NO) or normally closed (NC)
as desired.
C. Solid State Relay (Triac) Output
• Use terminals 3 and 4 as shown in Figure 4.4.
• Jumper J1 must be set to normally open (NO).
D. DC Logic (SSR Drive) Output
• Use terminals 3 and 4 as shown in Figure 4.4.
• Jumper J1 must be set to normally open (NO).
WARNING!
DO NOT make any modifications to the
factory setting of output modules 2, 3 and
4; this will place the product in an invalid
and undefined state.
Figure 4.4
Output Wiring for the 531
531 User's Manual Chapter 4, Mounting and Wiring 19
Mount/Wire
531 Terminals
PC
or other host
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 communication problems.
Figure 4.5
Serial Communications Terminals
To "Comm –" terminal of
next Powers device
To "Comm +" terminal of
next Powers device
RS-485
port
Twisted, shielded
Comm Ð
Comm +
26
27
Use a 60Ω to 100Ω terminating resistor
connected to the two data terminals
of the final device on the line.
WIRING FOR SERIAL COMMUNICA TIONS
You must have this option installed on your 531 in order to use serial communications. Refer to Figure 4.5.
• Use a twisted shielded pair of wires to connect the host and field units.
Belden #9414 foil shield has superior noise rejection characteristics. #8441
braid shield 22-gauge wire has more flexibility.
• The maximum recommended length of the RS 485 line is 4000 ft.
• 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 (prod. no. 500-485).
WHERE T O GO NEXT
For a step-by-step guide on setting up the software features for your controller, see Chapter 5.
20 Chapter 4, Mounting and Wiring 531 User's Manual
CHAPTER 5
SOFTW ARE CONFIGURATION
MODE OVERVIEW
Upon power up, as well as during “normal” operation, the 531 is in one of its
operating modes - Host, Automatic or Manual.
The 531 also has a set up (configuration) mode that lets you access options
for adjusting the operation and display of the station. “Set up” is divided into
two groups; one for the first eight menus (as listed below), and another for
the OPERATIONS menu by itself.
Figure 5.1 illustrates the relationships among the three operating modes and
nine set up menus.
The 8 set up menus can by accessed only when the 531 is in Host or Manual
Mode. The OPERATIONS set up menu can be accessed when the 531 is in
Automatic, Host or Manual Mode.
Software
AUTOMATIC operating mode
HOST or MANUAL operating modes
DISPLAY
to return to
operating
modes
OPERATIONS
DISPLAY
or ACK
to return
to
operating
modes
MENU +
FAST
for other
set up
menus
8 set up menus
CONFIG.
LOCAL OUT.
PV INPUT
CUST. LINR.
RSP INPUT
1 set up menu
MENU + FAST
for other
set up menus
MENU +
FAST
to move
from
menu to
menu
MENU for
Operations
set up menu
Figure 5.1
Menu Flowchart for Set Up
531 User's Manual Chapter 5, Software Configuration 21
ALARMS
SECURITY
SER. COMM.
Software
MENUS
A menu is a group of configuration control parameters. While in these set up
menus, the name of the menu will appear in the 2nd display. The names of the
different parameters within that menu group will then replace the menu name
in the 2nd display. The values/options for each parameter will then appear in
the 3rd display. Figure 5.1 displays the parts of the menu as used by this manual.
The (possible) menus for the 531 are:
• OPERATIONS To set up special PID control parameters and make
adjustments to the transition functions (among operating modes)
of the station.
• CONFIG. To configure the input and output hardware assignments.
• LOCAL OUT. To configure the local output control.
• PV INPUT To configure the process variable.
• CUST. LINR To configure the custom linearization curve for the
process variable.
• RSP INPUT To configure the remote set point.
• ALARMS To configure alarms.
• SECURITY To configure the security function.
• SER. COMM. To configure serial communications.
Independent
Parameter
CONFIGURE
UNLOCKED
Figure 5.2
Independent vs. Dependent
Parameters
Dependent
Parameter
RSP TYPE
(D)
SMART MENUS
This chapter outlines, in sequence, all menus, parameters, and selections
available for the 531. However, the “smart menu” feature of the station allows
only those Menus and Parameters to appear that are relevant to your hardware and software configuration, i.e., parameters which do not apply to your
application will not appear on your station’s display.
• Parameters that apply to all configurations appear in this manual as a white
on white box (Figure 5.2, left). These parameters are independent of your
configuration.
• Parameters that depend on the configuration of the individual station ap-
pear as a black on white box (Figure 5.2, right).
Changing one parameter’s selection (or value) may affect another parameter.
Refer to the section on the PV INPUT menu for an example on how this can
affect your low and high range values.
22 Chapter 5, Software Configuration 531 User's Manual
Software
FAST
SOFTW ARE CONFIGURA TION PR OCEDURES
On the bottom of each page is a guide to the keypad, to use during your
configuration.
To access the 8 set up menus
1. Hold down the FAST key and press MENU. (see Figure 5.3). The MENU
key will illuminate. The first Menu, CONFIG., appears alone in the 2nd
display.
2. Press FAST + MENU to advance to the next menu. The menu name will
appear in the 2nd display.
To access the OPERATIONS set up menu
1. Press MENU. The MENU key will illuminate. OPERATION will appear in
the 2nd display.
To advance through parameters and select a parameter value
1. When you reach your chosen menu, press MENU. The first parameter of
this menu appears in the 2nd display, replacing the menu name. The first
values/selection for the particular parameter appears in the 3rd display.
▲▲
2. Press
3. Press MENU to advance to next parameter.
To return to operating mode from configuration
1. Press the DISPLAY key. The station will return to the operating mode.
Scrolling through the choices to make selections will affect the operation of the instrument since changes to parameter selections occur in
"real time" or immediately.
DO NOT MAKE ANY CHANGES DURING ON LINE OPERATION!
▼▼
▲ or
▼, with or without the FAST key.
▲▲
▼▼
WARNING!!
MENU
FAST
MENU
Figure 5.3
Keys to Enter and Move through Set
Up Mode
Escape to operating mode Next parameter Next menu Next value
531 User's Manual Chapter 5, Software Configuration 23
DISPLAY
MENU
MENU
+
▼
or
▲
Software
24 Chapter 5, Software Configuration 531 User's Manual
FAST
MENU
GUIDE TO SET UP PARAMETERS
Only parameters and selections relevant to your hardware and other software
selections will appear on your station.
• Parameter Value
(R) Parameter Range
(D) Default Setting
Software
CONFIG.
For configuring the input and output hardware assignments.
1. LOST HOST
Selects the type of local backup if 531 loses the host CV signal.
• MAN. OUT1 Switch to Manual Mode, use preset output MAN. OUT1
• MAN. OUT2 Switch to Manual Mode, use preset output MAN. OUT2
• MAN. LAST Go to Manual Mode using the last known output
(D) AUTO.LOCAL Go to Automatic (PID)Mode
• AUTO.TRACK Go to Automatic (PID)Mode using last PV as the local SP
2. HOST.RESTR.
Selects the 531 mode upon host CV restoration.
• LOCAL Remain in Manual (or Automatic) Mode
(D) HOST MODE Go to Host Mode
3. CONTACT 1
Defines the operation of the 1st digital input.
• MAN. LAST Switch to Local Manual Mode, use last output
• MAN. OUT1 Switch to Manual Mode, use preset output MAN. OUT1
• MAN. OUT2 Switch to Manual Mode, use preset output MAN. OUT2
• ALARM ACK. Acknowledge alarms
• UP KEY Remote
• DOWN KEY Remote
• COMM.ONLY Make status readable through communications
• DISP. KEY Remote DISPLAY key
• MENU KEY Remote MENU key
• FAST KEY Remote FAST key
• RST.INHBT. Inhibits PID reset action
• REMOTE SP Selects the Remote SP for Automatic Mode
• LOCAL SP Selects the Local SP for Automatic Mode
(D) AUTO.LOCAL Go to Automatic Mode
• HOST MODE Go to Host Mode
• WATCHDOG Monitors the Host device for failure.
▲▲
▲ key
▲▲
▼▼
▼ key
▼▼
CONFIG
LOST HOST
AUTO.LOCAL
HOST.RESTR.
HOST
CONTACT1
AUTO.LOCAL
NOTE:
Refer to Chapter 6 for more on the
Watchdog Monitor.
Escape to operating mode Next parameter Next menu Next value
531 User's Manual Chapter 5, Software Configuration 25
DISPLAY
MENU
+
▼
or
▲
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