Moore Industries 532 User Manual
5 3 2
MooRE
INDUSTRIES
M532 V8, Ma
rch
2017
page
Contents ..................................................................................................... i
CHAPTER 1
INTRODUCTION .............................................................................. 1
General Description.......................................................................... 1
532 Auto/Manual Backup Station .................................................... 1
Confirming What Is Included ........................................................... 2
Where to Begin ................................................................................. 2
Overview of the 532 Modes ............................................................. 2
Where To Go Next ........................................................................... 2
Order Codes ..................................................................................... 3
CHAPTER 2
BASIC OPERATION ........................................................................ 4
532 Operator Interface ..................................................................... 4
Displays ................................................................................... 4
Icons ........................................................................................ 5
Keys......................................................................................... 5
532 Operating Procedures ............................................................... 6
532 Alarm Operation ........................................................................ 7
Alarm Indication....................................................................... 7
Alarm Acknowledgment ........................................................... 7
Latching Alarms ....................................................................... 8
Limit Sequence ........................................................................ 8
More on Alarms ....................................................................... 8
Contents
About This Manual:
For your safety and information, when
using this Manual we have highlighted NOTEs, CAUTIONs and
WARNINGs. Please heed these
safety and good practice notices for
the protection of you and your equipment.
CHAPTER 3
HARDWARE SET UP ...................................................................... 9
Hardware Settings ............................................................................ 9
A. Process Variable Indicator Type ...................................... 10
B. Mechanical Relays ............................................................ 11
Hardware Adjustments ................................................................... 11
A. Accessing and Changing Jumpers ................................... 11
B. Adding or Changing Output Modules ................................ 12
CHAPTER 4
INSTALLATION & WIRING ........................................................... 15
System Planning ............................................................................ 15
A. Consider the Noise Factor ................................................ 15
B. Wiring Practice Resources ............................................... 15
Installation ...................................................................................... 15
A. Make the panel cutout....................................................... 15
B. Establish a waterproof seal............................................... 16
C. Mount station into panel.................................................... 16
Input Wiring for the 532.................................................................. 17
A. AC Power ........................................................................... 17
B. Process Variable Indicator ................................................ 18
C. Digital Inputs ..................................................................... 19
D. Setpoint or Valve Position Indicator ................................. 19
Output Wiring for the 532 ............................................................... 20
A. CV Output .......................................................................... 20
B Mechanical Relay Output .................................................. 20
C Solid State Relay (Triac) Output....................................... 20
D. DC Logic (SSR Drive) Output ........................................... 20
532 User’s Manual Table of Contents i
Contents
page
Wiring the Serial Communications Option ..................................... 21
Where to Go Next .......................................................................... 21
CHAPTER 5
SOFTWARE SET UP ..................................................................... 22
Mode Overview .............................................................................. 22
Menus ............................................................................................. 22
Smart Menus .................................................................................. 22
Set Up Procedures ......................................................................... 23
Step-by-Step Guide to Software Set Up ........................................ 24
CONFIG. ................................................................................ 24
LOCAL OUT. .......................................................................... 25
PV INPUT .............................................................................. 26
CUST. LINR. .......................................................................... 27
SP INPUT .............................................................................. 28
VP INPUT .............................................................................. 29
ALARMS ................................................................................ 29
SECURITY ............................................................................. 33
SER. COMM. ......................................................................... 33
OPERATION .......................................................................... 34
Software Set Up Charts ................................................................ 36
CHAPTER 6
APPLICATIONS ............................................................................. 41
532 Auto/Manual Station ............................................................... 41
Alarm Set Up .................................................................................. 42
A. Set the Alarm Type ........................................................... 42
B. Set the Alarm Parameters ................................................ 43
Digital Inputs .................................................................................. 47
PV, SP and VP Indication ............................................................. 48
A. Choose the Type of Display(s) ......................................... 48
B. Select the Process Variable Display Range .................... 48
C. Set Point Display Range ................................................... 49
D. Valve Position Display Range .......................................... 49
Input Linearization .......................................................................... 49
A. Thermocouple and RTD Linearization .............................. 49
B. Square Root Linearization ................................................ 50
C. Custom Linearization ........................................................ 50
Ramp to Control Value ................................................................... 52
Security .......................................................................................... 52
Process Variable Reading Correction ............................................ 53
Serial Communications .................................................................. 54
APPENDIX A
MENU & PARAMETER FLOWCHARTS ..................................... A-1
APPENDIX B
PARTS LIST ................................................................................ B-1
APPENDIX C
TROUBLESHOOTING ................................................................. C-1
APPENDIX D
CALIBRATION ............................................................................. D-1
ii Table of Contents 532 User’s Manual
Regarding Calibration ................................................................... D-1
RTD, VmA Input Calibration ........................................................ D-2
Thermocouple & Cold Junction Calibration ................................. D-3
Milliamp Output Calibration .......................................................... D-4
Hardware Scan ............................................................................. D-6
APPENDIX E
SPECIFICATIONS ....................................................................... E-1
APPENDIX F
ISOLATION BLOCK DIAGRAM ................................................... F-1
Contents
page
532 User’s Manual Table of Contents iii
Contents
Figure ....... Title ...................................................................................Page
2.1 ............ 532 Operator Interface .............................................................. 4
2.2 ............ Before and After Acknowledging an Alarm ................................. 8
3.1 ............ Location of Printed Circuit Boards ............................................. 9
3.2 ............ The Microcontroller Circuit Board ............................................ 10
3.3 ............ The Option Circuit Board ......................................................... 10
3.4 ............ The Power Supply Circuit Board .............................................. 10
3.5 ............ Representation of Module (view of bottom) ............................... 13
4.1 ............ 532 instrument panel and cutout dimensions ............................ 15
4.2 ............ Mounting Brackets ................................................................. 16
4.3 ............ 532 Rear Terminals ................................................................ 17
4.4 ............ Output Wiring for the 532 ........................................................ 20
4.5 ............ Serial Communications Terminals ........................................... 21
5.1 ............ Menu Flowchart for Set Up ...................................................... 22
5.2 ............ Independent Parameters versus Dependent Parameters .......... 23
5.3 ............ Keys to Enter and Move through Set Up Mode ......................... 23
6.1 ............ Alarm Examples .................................................................... 46
6.2 ............ Square Root Linearization Formula .......................................... 50
6.3 ............ Custom Linearization Curve .................................................... 51
D.1 ............ Flowchart to Access the Calibration Menus ............................. D-1
D.2 ............ Microcontroller Circuit Board .................................................. D-2
D.3 ............ RTD, VmA Calibration Wiring ................................................. D-3
D.4 ............ Thermocouple & Cold Junction Calibration Wiring .................... D-3
D.5 ............ Milliamp Calibration Wiring ..................................................... D-5
D.6 ............ Flowchart for Access to Reset and Hardware Scan Menus ....... D-6
iv Table of Contents 532 User’s Manual
CHAPTER 1
INTRODUCTION
Introduction
INPUTS
Two Process Variables
OUT
1 2
ALM
1 2
532
Remote Setpoint
Digital Inputs
Serial Communications
General Description
The 532 Auto/Manual Station ensures the integrity of your processes with
maximum reliability. Isolated inputs and outputs guard against electrical
interference, the front faces meet NEMA 4X standards for watertight operation, and solid metal housings and sturdy rubber keys enhance durability.
The station 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.
OUTPUTS
Control Outputs
Alarm(s)
Retransmission
Serial Communications
Thank you for selecting the 532
Auto/Manual Backup Station.
It is the most sophisticated instrument in its class, and will provide
you with years of reliable, troublefree performance.
532 Auto/Manual Backup Station
The 532 has been engineered to be the industry’s most user friendly and
comprehensive Auto/Manual Backup Station. The 532 provides automatic
and manual control backup for critical control loops. In Auto or Remote mode,
the control signal passes from the Host device through the 532 without any
degradation. A Host device may be a PLC, DCS or process controller. The 532
switches to Local mode upon keypad selection, digital input or loss of the
Host signal. The 532 generates a control signal based on a predetermined
control value (CV), or the last known CV from the Host. The operator can
modify the CV with the and keys. The 532 will transfer to Remote mode
upon keypad selection, opening of the digital input or return of the Host signal.
Removal of the 532 from its case or powering down while in Remote mode will
not disturb the Host signal; the 532 is not a point of failure!
532 User’s Manual Chapter 1, Introduction 1
Introduction
With your controller,
you should have received:
1. 532 User’s Manual
2. Mounting hardware
3. Test sheet
4. Engineering unit adhesive
labels (1 sheet)
5. Terminal label
NOTE:
This manual may refer to the 532
Auto/Manual Station as the “532” or
either simply as “the station.”
NOTE:
If you alter the factory configuration of the
modules, this product label code will no
longer be valid.
Confirming What Is Included
You can determine which outputs have been installed in your station by
comparing your product number to the Order Code on the next page. This
product number is printed on the label located on the top of the controller case.
Where to Begin
If you are a first time user of a 532 Auto/Manual Station, we recommend that
you read through the entire manual. A variety of special functions to enhance
your control capability are detailed throughout the manual.
Overview of the 532 Modes
Operating The 532 is in Operating Mode when you turn it on and usually
while operating. From this mode, you can initiate the transition
between Remote and Local modes, acknowledge alarms and
monitor conditions. You can also access parameters that
directly relate to the transfer functions.
Set Up This sometimes referred to as
configure the basic function of the station, like input and output
assignments, alarm types and special functions.
configuration
. In Set Up you
Where To Go Next
• First time users, continue to Chapter 2 for information on the operator
interface and basic controller operation.
• Chapter 3 contains important installation guidelines.
• Chapter 5 details the controller menus and parameters. Use the flowchart
in Appendix A as a graphic guideline when you configure your controller.
2 Chapter 1, Introduction 532 User’s Manual
0
1
3
4
2
D
S
None
Mechanical relay
Solid state relay (triac) (1 amp)
DC logic (SSR drive)
One 4-20mA output included
Set of 3 digital inputs
RS-485 serial communications
OUTPUT 1 — ALARM
OPTIONAL INPUTS
ENTER "0" IF NOT DESIRED
SERIAL COMMUNICATIONS
ENTER "0" IF NOT DESIRED
00B0112532 -
Order Codes
532 - AUTO/MANUAL BACKUP STATION
Introduction
532 User’s Manual Chapter 1, Introduction 3
Operation
CHAPTER 2
BASIC OPERATION
The individual software and hardware options of your station determine which
information it will display. Compare the product number (on the product label) to
the Order Code in Chapter 1.
532 Operator Interface
532
Icons
Displays:
1st Display
• 5 digits, seven segments. 15mm (0.6in) high.
• Normally displays CV in tenths of a percent.
• If PV option is chosen, will display PV.
2nd Display
• 9 characters, 14 segment alphanumeric. 6mm (0.25 in) high.
• If only PV option is chosen, displays CV.
• If only 2nd input option is chosen, shows SP or VP (valve position).
• If PV and 2nd input options are chosen, automatically alternates
between CV and the SP (or VP) at 2 second intervals. Pressing the
or key to change the output value immediately stops the
alternating and displays the CV. Alternating resumes if there is no
key activity for 2 seconds.
• During Set Up, displays configuration information.
3rd Display
• 9 characters, 14 segment. 6mm (0.25 in) high.
• If no alarm messages are queued, displays user-selectable
station name.
• If errors or alarms are queued, displays messages that alternate every
2 seconds.
• During Set Up, displays configuration information.
OUT
1 2
ALM
1 2
LOCAL
HOST
DISPLAY
MENU
ACK
FAST
1st Display
nd
Display
2
rd
3
Display
Location for
identification label
Keys
NOTE:
Any modifications to the factory settings
of the output modules will render the
product label code invalid.
NOTE:
The 532 features smart menus; only
those messages relevant to your
hardware and software configuration
will appear. See Chapter 5 for details.
Figure 2.1
532 Operator Interface
NOTE:
If the station loses the PV, SP or VP
signal, “--------” will appear in place of
the numeric value in the 1st or 2nd
display. Refer to Appendix C for more
information.
4 Chapter 2, Basic Operation 532 User’s Manual
Operation
ALM ALM ALM
1 2 1 2
Icons:
Keys:
LOCAL
HOST
DISPLAY
MENU
ALM1 and ALM2 Icons:
Indicates respective alarm is active.
LOCAL
Press key: Transfers station between Local and Remote modes.
Illuminated: Station is in Local mode.
HOST
Press key: Has no effect; used for indication only.
Illuminated: 532 senses CV signal from the Host.
DISPLAY
Press key: Exits the configuration menus and returns station to operation
mode.
Key does not light.
MENU
Press key: Accesses the Operation menus.
Illuminated: Station is in Set Up (configuration) mode.
FAST
FAST
FAST
ACK
FAST
or
+
+
+
MENU
ACK
Press key: Acknowledges alarms.
Illuminated: When an acknowledgeable alarm exists.
FAST
Press key: Functions as a “shift” key; for use with other keys.
Key does not light.
or
Press key: Increases or decreases the value or selection of the current
parameter.
Keys do not light.
FAST + / FAST +
Press keys: Changes parameter value or selection with a larger increment.
FAST + MENU
(Hold down FAST, press MENU) In Local or Remote mode, provides entry
into the Set Up mode. In Set Up, advances from Menu to Menu .
532 User’s Manual Chapter 2, Basic Operation 5
Operation
532 Operating Procedures
This is a quick guide to key operating functions of the 532.
1. To change from REMOTE to LOCAL mode
a. Press the LOCAL key to shift from Remote to Local. The LOCAL key
remains lit while in Local mode.
b. The 532 stops passing the Remote (Host) signal, and transmits its own
signal. This will be either the last known Host signal or one of two
predetermined outputs.
c. If you have selected a predetermined CV, you may specify (during Set
Up) the rate of change from the remote value to the new value (also
known as a RAMP).
2. To change from LOCAL to REMOTE mode
a. Press the LOCAL key to shift from Local to Remote. The LOCAL key
will extinguish.
b. The 532 will stop transmitting its own signal and pass the signal from
the Host device to the final control element
c. The transfer will be direct unless a ramp rate was chosen during setup.
3. To change output values in LOCAL mode
a. Press LOCAL key to shift from Remote to Local.
b. Press to increase, or to decrease the CV value.
4. To override security
a. If someone attempts a locked operation, the word SECURITY appears
in the 2nd display, and the security code starting value (0) appears in
the 3rd display.
b. Select the security code using and . To “enter” the displayed value
as a code, leave the keys inactive for 2 seconds.
c. If no code was entered (value left at 0), the Security message
disappears and the station resumes operation.
d. If the code is incorrect, INCORRECT appears in the 3rd display. After
2 seconds, the station returns you to step 4b to enter another code.
e. If the code is correct, CORRECT appears in the 3rd display. After 2
seconds, the displays clear and you have temporary access to all
previously locked features. Security will automatically rearm (lock) the
station once you leave the keys inactive for 1 minute.
f. If the Security Override Code is entered, RESET appears in the 3rd
display. After 2 seconds, the displays clear and the station’s security
functions are all reset to their factory defaults (all unlocked).
NOTE:
For more information on Security
functions, see Chapter 6.
6 Chapter 2, Basic Operation 532 User’s Manual
Operation
NOTE:
Powering down the controller
acknowledges/clears all latched
alarms. When powering up, all alarms
will be reset according to their powerup configuration (see Chapter 6).
NOTE:
All alarms are internal alarms unless tied
to an output relay in the Set Up mode.
532 Alarm Operation
IMPORTANT NOTICE!
Alarms can be used to provide warnings of unsafe conditions.
Therefore, all 532 operators must know how the alarms are configured, how to react to alarm conditions, and the consequences of
acknowledging (noting and clearing) an alarm.
Alarm Indication
The 532 indicates alarms by:
• Lighting icons
• Displaying messages; and
• Lighting the ACK key, if an alarm is in an acknowledgeable state.
Alarm Acknowledgment
An alarm is acknowledgeable only when the ACK key is illuminated. 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 then, after the
alarm has been acknowledged.
532 User’s Manual Chapter 2, Basic Operation 7
Operation
OUT
1
ALM
1
LOCAL
HOST
BEFORE
DISPLAY
MENU
ACK
FAST
532
OUT
1
LOCAL
HOST
AFTER
DISPLAY
MENU
532
ACK
FAST
Latching Alarms
A latching alarm will hold its alarm state even after the process leaves the alarm
condition. This is useful for stations that will not be continually 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.
Figure 2.2
Before and After Acknowledging
an Alarm
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 often referred to as a limit sequence because it behaves like
a limit controller.
More on Alarms
For more on alarm types and set ups, see Chapter 6.
8 Chapter 2, Basic Operation 532 User’s Manual
CHAPTER 3
HARDWARE SET UP
The configuration of the 532 hardware 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, setpoint and/or valve position inputs set to accept a
milliamp input;
• Relay outputs set to normally open.
If you need to change any modules or any other settings, read the rest of this
chapter. Otherwise, move on to Chapter 4
CAUTION!
Static discharge will cause damage to equipment. Always
ground yourself with a wrist grounding strap when handling
electronics to prevent static discharge.
.
Hardware Set Up
NOTE:
If you would like your controller
configured at the factory, please
consult an application engineer.
NOTE:
Any changes you make to the output
modules will render the code on the
product label invalid.
Hardware Settings
The locations of certain jumpers and module 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. Slide the chassis out of the case by pulling on front face plate assembly at
the bezel. Remove the two screws now.
M
IC
R
O
B
POWER SUPPLY
BOARD
C
O
O
A
N
R
T
D
R
O
L
L
E
R
NOTE:
Your hardware configuration will
influence the available software
options in Chapter 5.
Figure 3.1
Location of Printed Circuit Boards for
Hardware Configuration
OPTION BOARD
532 User’s Manual Chapter 3, Hardware Set Up 9
Hardware Set Up
EPROM
Figure 3.2
The Microcontroller Circuit Board
Figure 3.3
The Option Circuit Board
Figure 3.4
The Power Supply Circuit Board
station
front of
BATTERY
5-Pin Connector
Male 22-Pin
Connector
4-Pin Connector
Jumper Configuration
Female 22-Pin ConnectorFemale 22-Pin Connector
Output 4
Female 44-Pin Connector
4
SP/VP Indicator
PV Input Jumper
Configuration
Male 22-Pin
Connector
Male 44-Pin
Connector
Module
Retention
Plate
over Outputs 1,2,3
3
2
1
V
MA
V
MA
TC
TC
RTD
TB2
2ND
PV1
TB1
NO J3 NC
NO J2 NC
NO J1 NC
Jumpers
NO and NC
A. Process Variable Indicator Type
The 532 will accept several different types of Process Variable Signals. You
specify the type of signal by adjusting the PV jumper location on the Microcontroller Circuit Board, and setting the particular sensor range in the software. The
jumper locations for the process variable are marked as follows (see Figure 3.2).
V Voltage signal
MA Milliamp
TC Thermocouple with downscale burnout
TC Thermocouple with upscale burnout
RTD RTD
10 Chapter 3, Hardware Set Up 532 User’s Manual
B. 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 Normally Open
(NO).
On the 532, 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.
Hardware Adjustments
A. 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.
3. You will not need to disassemble the chassis to make these adjustments.
Refer to Figure 3.3 and Figure 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, as shown in Photo 1. Be careful not to bend the pins.
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 others you
wish to change.
6. When you are ready to reassemble the unit, align the boards on the chassis
with the cases's top and bottom grooves. Press firmly to slide the chassis into
the case. If you have difficulty, check that you have properly oriented the
chassis, and there are no screws interfering with the case.
7. Carefully insert and align screws. Tighten them until the bezel is seated firmly
against the gasket.
Hardware Set Up
CAUTION!
Static discharge will cause damage to
equipment. Always ground yourself
with a wrist grounding strap when handling electronics to prevent static discharge.
1. Removing jumpers
532 User’s Manual Chapter 3, Hardware Set Up 11
Hardware Set Up
B. Adding or Changing Output Modules
The 532 has provisions for four output modules. The unit comes 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:
• 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
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 (Photo 2). Take
care not to break the clips or scratch the circuit board.
The Microcontroller Board and Power Supply Board remain attached to the
Operator Interface Assembly by wired connectors.
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 (Photo 3).
Figures 3.2, 3.3 and 3.4 show the Microcontroller Board, Option Board and
Power Supply Board.
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 cutter (Photo
4).
CAUTION! 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
2. Pry Clips
12 Chapter 3, Hardware Set Up 532 User’s Manual
module 4 (on the Option board) in place. To remove the module, snip tie wrap
(Photo 5).
7. Inspect each module before installation to make sure the pins are straight (see
Figure 3.5). Align the pins with the socket holes and carefully insert the
module. Press down on the module to seat it firmly on the board (Photo 6).
8. Replace tie wraps for the Retention Plate and for Output Module 4 with new
ones.
Failure to use these devices may result in a loosening of the
module and eventual failure. If you ordered a module separately, it should have come with a tie wrap. An extra set of tie
wraps is available by ordering Part #535-665.
9. To reassemble the unit: Align the connector pins on the Option Board with the
Hardware Set Up
CAUTION!
Do not scratch the boards or bend the
pins of the connectors.
3. Separate Boards
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
4. Remove Retention Plate
6. Add/Change Module5. Snip Tie Wrap
Figure 3.5
Representation of Module (view of
bottom)
532 User’s Manual Chapter 3, Hardware Set Up 13
Hardware Set Up
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.
After you have configured the hardware, you may go on to Chapter 4 for installing
and wiring the controller.
14 Chapter 3, Hardware Set Up 532 User’s Manual
CHAPTER 4
INSTALLATION & WIRING
The 532 Auto/Manual 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 thoroughly 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.
Install & Wire
CAUTION!
For safety consideration, DO NOT run
low power (sensor input) lines in the
same bundle as AC power lines.
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.
Installation
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 (1.5mm to 7.0mm).
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).
7.180 in (182.37mm) OVERALL LENGTH
1.180 in (29.97mm)
3.770 in (95.76mm)
PV2
OUT
)
1 2
ALM
m
1 2
m
6
.7
5
(9
in
0
7
.7
3
532
PANEL
Figure 4.1
532 instrument panel and cutout
dimensions
3.622 in (92.00mm) MIN.
3.653 in (92.80mm) MAX.
3.585 in (91.06mm)
3.622 in (92.00mm) MIN.
3.653 in (92.80mm) MAX.
BEZEL
FRONT
532 User’s Manual Chapter 4, Installation & Wiring 1 5
GASKET
6.000 in (152.40mm)
SIDE
CUTOUT
Install & Wire
B. Establish a waterproof seal.
The station front face (keys, display, and bezel) are NEMA 4X rated
(waterproof). 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.
C. Mount station into panel:
The instrument enclosure mounting MUST BE GROUNDED.
You will need a long Phillips screw driver (#2).
1. Turn the instrument with the back towards you. Now slide the
gasket around the back of the case, all the way up to 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.
.
BEZEL
HOUSING
Figure 4.2
Mounting Brackets
MOUNTING BRACKET
(1 EA. SIDE)
16 Chapter 4, Installation & Wiring 532 User’s Manual
Slide on
gasket from
this end.
Install & Wire
Input Wiring for the 532
Figure 4.3 shows the rear terminal configuration for the 532. The actual
instrument has only the top and bottom numbers of each column marked.
Refer to this diagram when using the following input and output wiring
instructions.
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.
532 (TOP)
AC LINE
AC NEUTRAL
OUT 1–
OUT 1+
1
2
3
4
9
10
11
12
EARTH
GND
NC
NC
NC
DIN
GND
DIN 1
DIN 2
DIN 3
17
18
19
20
25
26
27
28
NC
COMM–
COMM+
SP IND.–
NOTE:
All wiring and fusing should conform to
the National Electric Code and to any
locally applicable codes.
Figure 4.3
532 Rear Terminals
LOC. OUT CALIB.–
CV OUT–
LOC OUT CALIB.+
CV OUT+
NC
5
6
7
8
A. AC Power
Terminals 1 and 2 are the power terminals.
Terminal 9 is the earth ground terminal.
AC POWER
POWER
NC
13
CV IN+
14
CV IN–
15
NC
16
1
2
9
NC
21
NC
22
CJ –
23
CJ +
24 32
GROUND
29
30
31
SP IND.+
RTD 3RD
PVIND.–
PV IND.+
A special PC Board covers
terminals 5, 6, 7, 8, 13, 14, 15, and
16.
532 User’s Manual Chapter 4, Installation & Wiring 1 7
Install & Wire
r
NOTE:
Use a 0.5 Amp, 250 V, fast-acting fuse
in line with your AC power connection
(terminal 1).
B. Process Variable Indicator
The station accommodates the following types of process variable
inputs: Thermocouple, RTD , Voltage, Milliamp (external power supply)
and Milliamp (internal power supply).
The following wiring diagrams show how to wire the stations for these
different types of process variable.
1. Thermocouple Input
Use terminals 30, 31 and 32 as shown.
T/C INPUT
30
–
31
+
32
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
Third leg
of RTD
30
31
32
3. Voltage Input
Use terminals 31 and 32 as shown.
VOLTAGE INPUT
4. Milliamp Input -External Power Supply
Use terminals 31 and 32 as shown.
mA INPUT
2-Wire transmitter with separate power supply
Same color
–
31
+
32
External
–
Power Supply
31
RTD INPUT 4-WIRE
30
31
32
DO NOT connect 4th leg
–
Transmitter
+
+
Same color
Third leg
of RTD
Same colo
–
32
18 Chapter 4, Installation & Wiring 532 User’s Manual
Transmitter
+
i ml
I_
1 �
i �
Install & Wire
Output Wiring for the 532
• Output 1 is available for use as an alarm with installation of a
Mechanical relay or Solid State Relay (Triac) module.
• The 532 is factory configured with an Analog module in Output 2.
• The 532 is factory configured with Mechanical relays in Outputs 3 and 4.
• The 532 cannot be wired for retransmission.
• A small PC board fits over rear terminals 5, 6, 7, 8, 13, 14, 15 & 16.
The following instructions explain how to properly wire the 532 for any
particular output module. If you do not know which module(s) have been
installed in your station, compare the product number on the product label
with the Order Code in Chapter 1.
To add or change position of jumpers or output modules, 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
NOTE:
Any modifications to the factory settings
of the output modules will render the
product label code invalid.
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).
CV OUTPUT
5
6
7
8
MECHANICAL RELAY
_
CV
3
Line Power
Load
4
+
Recommend use of both MOV and snubber
SSR (TRIAC)
3
4
Recommend use of both MOV and snubber
Line Power
_
+
Figure 4.4
Output Wiring for the 532
DC LOGIC (SSR DRIVE)
3
_
+
Load
4
+
_
Load
+
20 Chapter 4, Installation & Wiring 532 User’s Manual
Figure 4.5
Serial Communications Terminals
Install & Wire
Wiring the Serial Communications Option
Refer to Figure 4.5 for Wiring Diagram.
• 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).
532 Terminals
PC
or other host
RS-485
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
Twisted, shielded
port
Comm –
Comm +
26
27
Where to Go Next
For a step-by-step guide on setting up the software features for your
controller, see Chapter 5.
To "Comm –" terminal of
next Powers device
To "Comm +" terminal of
next Powers device
Use a 60ohm to 100ohm
terminating resistor connected to
the two data terminals of the final
device on the line.
532 User’s Manual Chapter 4, Installation & Wiring 21
Software Set Up
T
CHAPTER 5
SOFTWARE SET UP
Mode Overview
The 532 will be in Operating Mode upon power up, and will remain in Operating
Mode most of the time it is performing its functions. This is not the same as
the OPERATIONS menu.
In Set Up Mode, you can access menus of operation parameters that affect
the display and adjustment of the stations.
Figure 5.1 illustrates the relationships between the different modes of the 532
station, and the different Set Up menus.
Menus
A menu is a group of Set Up parameters. The name of a menu appears in the
2nd display of the 532 station during your set up. Once inside a menu, the
different parameters will appear in the 2nd display. The values/options for
each parameters will appear in the 3rd display. On the station, the menu name
appears in the display at the beginning of the cycle of the menu.
These are the possible menu for your station, and their applications.
CONFIG.: To configure the input and output hardware assignments.
LOCAL OUT.: To configure the local output control.
PV INPUT: To configure the process variable (PV) indicator.
CUST. LINR: To configure the custom linearization curve for the PV indicator.
SP INPUT: To configure the set point indicator.
VP INPUT: To configure the valve position indicator.
ALARMS: To configure alarms.
SECURITY: To configure the security function.
SER. COMM.: To configure serial communications.
OPERATIONS: To make adjustments to the transition [between Remote
(Host) and Local control] functions of the station.
Smart Menus
This chapter outlines, in sequence, all menus, parameters, and selections
available for the 532 station. However, the “smart menu” feature of the
stations allows only those menu 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.
NOTE TO ALL USERS:
Be sure to read and understand the next
two pages, which contain important information on how to use this guide to
help you to set up the instrument. The
Parts of the Menu
graphic used in the Set Up and Tuning
configuration sections.
section explains the
Figure 5.1
Menu Flowchart for Set Up
OPERATING
DISPLAY
for Operating
OPERATIONS
MENU + FAST for Set Up
MENU
for Operations
MENU + FAS
for Set Up
SET UP
to toggle from menu block to menu block in set up
CONFIG.
LOCAL OUT.
PV INPUT
DISPLAY or ACK to return to Operating
CUST. LINR.
SP INPUT
VP INPUT
ALARMS
SECURITY
SER. COMM.
MENU + FAST
22 Chapter 5, Software Set Up 532 User’s Manual
PV TYPE
MENU
FAST
(D)
INDICATOR
NONE
Figure 5.2
Independent Parameters versus
Dependent Parameters
Software Set Up
1. Parameters that apply to all configurations of the 532 appear in this
manual as a white on white box (Figure 5.2,
parameters are independent of your configuration.
2. Parameters that depend on the configuration of the individual station
appear as a black on white box (Figure 5.2,
Be aware that changing one parameter’s selection (or value) may affect
another parameter. See the PV INPUT menu section for an example on how
this can affect your low and high range values.
Set Up Procedures
On the bottom of each page is a guide to the keypad, to use during the Set
Up procedure.
To Enter the Set Up Mode
1. Hold down the FAST and press MENU. (
will illuminate. The first menu, CONFIG., appears alone in the 2nd
display.
see
left portion
right portion
). These
).
Figure 5.3). The MENU key
MENU
Figure 5.3
Keys to Enter and Move through
Set Up Mode
To Advance through Menus
2. Press FAST + MENU to advance to the next menu. The name will appear
in the 2nd display.
To Enter a Menu and Advance through Parameters
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 MENU to advance to next parameter.
To Advance through Values/Selections for a Parameter
1. Press or .
To Return to Operating Mode
1. If you are in Set Up Mode, press the DISPLAY key. The 532 will return
to Operation Mode.
WARNING!!
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 WHILE ON LINE (DURING
OPERATION).
Escape to Operation Mode Next Parameter Next Block Next value or+
532 User’s Manual Chapter 5, Software Set Up 23
MENU FASTDISPLAY
MENU
▲
▲
Software Set Up
Step-by-Step Guide to Software Set Up
REMEMBER: Only parameters and selections relevant to your hardware
and other software selections will appear on your station.
(D) Indicates Default Setting
(R) Indicates a range of values
CONFIG.
For configuring the input and output hardware assignments.
1. INDICATOR
Enables indicator for PV and/or a 2nd input.
(D) NONE No display
• PV Display Process Variable
• 2ND Enable 2ND INPUT parameter
• PV/2ND Display PV and enable 2ND INPUT
2. 2ND INPUT
Chooses indicator for 2nd input, a retransmitted VP or SP (provided 2ND or
PV/2ND selection is made in INDICATOR parameter).
(D) VP Display Valve Position
• SP Display Setpoint
3. LINE FREQ
Specifies the power source frequency
(D) 60 Hz
• 50 Hz
4. OUTPUT 1
Defines the function of the first output.
(D) OFF Completely deactivates output
• ALARM Digital only
• COMM. ONLY Output addressable only through communications
CONFIG
INDICATOR
NONE
2ND INPUT
VP
LINE FREQ
60
OUTPUT 1
OFF
5. CONTACT 1
Defines the operation of the 1st digital input.
(D) LOCAL.LAST Switch to Local, hold last out value seen from host
• LOCAL.PRE1 Switch to Local, set LOCAL OUT to Preset 1 value
• LOCAL.PRE2 Switch to Local, set LOCAL OUT to Preset 2 value
• ALARM ACK. Acknowledges alarms
• UP KEY Remote function
• DOWN KEY Remote function
• COMM.ONLY Makes status readable through communicatoins.
Escape to Operation Mode Next Parameter Next Block Next value or+
24 Chapter 5, Software Set Up 532 User’s Manual
MENU FASTDISPLAY
CONTACT 1
LOCAL.LAST
MENU
▲
▲
CONFIG
Software Set Up
CONTACT 2
LOCAL.PRE1
CONTACT 3
LOCAL.PRE2
STN.NAME
BYPASSER
6. CONTACT 2
Defines the operation of the 2nd digital input.
• LOCAL.LAST Switch to Local, hold last out value seen from host
(D) LOCAL.PRE1 Switch to Local, set LOCAL OUT to Preset 1 value
• LOCAL.PRE2 Switch to Local, set LOCAL OUT to Preset 2 value
• ALARM ACK. Acknowledges alarms
• UP KEY Remote function
• DOWN KEY Remote function
• COMM.ONLY Makes status readable through communications.
7. CONTACT 3
Defines the operation of the 3rd digital input.
• LOCAL.LAST Switch to Local, hold last out value seen from host
• LOCAL.PRE1 Switch to Local, set LOCAL OUT to Preset 1 value
(D) LOCAL.PRE2 Switch to Local, set LOCAL OUT to Preset 2 value
• ALARM ACK. Acknowledges alarms
• UP KEY Remote function
• DOWN KEY Remote function
• COMM.ONLY Makes status readable through communications.
8. STN.NAME
Allows you to enter a nine character message to name the station. The first
character of the 3rd display will be flashing. Press arrow keys to scroll through
character set. Press FAST to enter the selection and move to next digit. Press
MENU to advance to next parameter.
(D) BYPASSER
LOCAL OUT.
LOCAL OUT.
To configure the local output control.
1. LOW LIMIT
LOW LIMIT
0.0
Selects how low the output can be manually adjusted.
(R) -5.0% to 105%
(D) 0.0%
2. HIGH.LIMIT
HIGH.LIMIT
100.0
Selects how high the output can be manually adjusted.
(R) -5.0% to 105%
(D) 100.0%
3. PWR.UP:MODE
PWR.UP:MODE
LAST
Escape to Operation Mode Next Parameter Next Block Next value or+
532 User’s Manual Chapter 5, Software Set Up 25
Selects the power-up mode.
(D) LAST
MENU FASTDISPLAY
MENU
▲
▲
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