Moore Industries 535 User Manual

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1/4 DIN PROCESS CONTROLLER USER'S MANUAL

M535 V5, © MAY 2002

T able of Contents

PAGE

CHAPTER 1

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

535 Modes ........................................................................................ 1

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

Where To Go Next ............................................................................ 2

Text formatting in this manual............................................................ 2

CHAPTER 2

BASIC INTERFACE ......................................................................... 5

Displays ............................................................................................ 5

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

Keys.................................................................................................. 6

Basic Operating Procedures ............................................................. 7

Alarm Operation................................................................................ 8

CHAPTER 3

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

About This Manual:

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

CHAPTER 4

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

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

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

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

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

Accessing and changing jumpers.................................................... 23

Adding and Changing output modules............................................. 24

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

CHAPTER 5

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

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

Parameters ..................................................................................... 28

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

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

535 User's Manual Table of Contents i

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CHAPTER 5

CONTROLLER SET UP (cont’d)

Text Formatting in This Manual.......................................................... 29

Software Menus and Parameters ...................................................... 30

CONFIG.................................................................................. 30

PV1 INPUT ............................................................................. 34

PV2 INPUT ............................................................................. 36

CUST. LINR. ........................................................................... 38

CONTROL .............................................................................. 39

ALARMS................................................................................. 41

REM. SETPT........................................................................... 46

RETRANS............................................................................... 47

SELF TUNE ............................................................................ 48

SPECIAL ................................................................................ 50

SECURITY.............................................................................. 51

SER. COMM. .......................................................................... 52

Parameter Value Charts ................................................................... 50

CHAPTER 6

TUNING .......................................................................................... 63

Overview ......................................................................................... 63

TUNING Menu Parameters............................................................... 64

TUNING Parameter Value Chart ....................................................... 68

Self Tune Messages and Troubleshooting ......................................... 70

CHAPTER 7

APPLICATIONS .............................................................................. 71

A. Control Type ................................................................................ 71

B. Alarms......................................................................................... 72

C. Duplex Control ............................................................................. 76

Duplex with reverse and direct acting outputs ............................ 77

Duplex with direct and reverse acting outputs ............................ 77

Duplex with 2 reverse acting outputs ......................................... 78

Duplex with a gap between outputs ........................................... 78

Duplex with overlapping outputs and output limits ...................... 79

Duplex with various relative gain settings ................................... 79

Duplex with one ON/OFF output ............................................... 80

Duplex with two ON/OFF outputs.............................................. 80

D. Slidewire Position Proportioning Control ........................................ 81

E. Velocity Position Proportioning Control .......................................... 82

F. Staged Outputs ............................................................................ 83

G.Retransmission............................................................................ 83

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

I. Remote Setpoint .......................................................................... 86

J. Multiple Setpoints......................................................................... 87

K. Multiple Sets of PID Values ........................................................... 87

L. Powerback .................................................................................. 88

M.Self Tune—Powers POWERTUNE® ............................................ 89

Pretune by Itself ....................................................................... 89

Pretune TYPE 1 and Adaptive Tune .......................................... 91

Pretune TYPE 2 or TYPE 3 and Adaptvie Tune.......................... 91

Adaptive Tune by Itself ............................................................. 92

Self Tune with Multiple Sets of PID ............................................ 94

Self Tune with Time Proportioning Outputs ................................ 94

PAGE

ii Table of Contents 535 User's Manual

T able of Contents

CHAPTER 7

APPLICATIONS (cont’d)

Self Tune with Control Valves ................................................... 94

N. Ramp-to-Setpoint......................................................................... 94

O.Input Linearization........................................................................ 95

Thermocouple and RTD Linearization ....................................... 95

Square Root Linearization ........................................................ 95

Custom Linearization ............................................................... 96

P. Load Line..................................................................................... 97

Q.Security ....................................................................................... 97

R. Reset Inhibition ............................................................................ 98

S. Process Variable Reading Correction ............................................ 98

T. Serial Communications ................................................................ 99

U. Cascade Control ........................................................................ 100

V. Ratio Control.............................................................................. 103

APPENDIX 1

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

APPENDIX 2

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

APPENDIX 3

TROUBLESHOOTING .................................................................. A-5

APPENDIX 4

CALIBRATION.............................................................................. A-7

Preparation for all Input Calibrations .................................................A-8

Thermocouple Cold Junction Calibration...........................................A-9

Analog Milliamp Input Calibration ......................................................A-9

Milliamp Output Calibration ............................................................A-10

Reset Menu Data ..........................................................................A-11

Hardware Scan .............................................................................A-12

Slidewire Test ...............................................................................A-12

Quick Calibration Procedure ..........................................................A-12

PAGE

APPENDIX 5

SPECIFICATIONS........................................................................A-13

APPENDIX 6

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

APPENDIX 7

ISOLATION BLOCK DIAGRAM ...................................................A-23

535 User's Manual Table of Contents iii

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List of Figures

FIGURE DESCRIPTION PAGE

Figure 2.1 .......Operator Interface ............................................................... 5

Figure 2.2 .......Before and After Acknowledging an Alarm ............................ 8

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

Figure 3.2 .......Attaching mounting collar................................................... 11

Figure 3.3 .......All 535 Terminal Assignments ............................................ 12

Figure 3.4 .......AC P ower I nput Terminals ................................................. 13

Figure 3.5 .......Process Variable Terminals ............................................... 13

Figure 3.6 .......PV1 and PV2 Wiring for Milliamp, RTD and Voltage Inputs ... 14

Figure 3.7 .......PV1 and PV2 Wiring for Milliamp Inputs with Internal and

External Power Supply ...................................................... 15

Figure 3.8 .......Digital input Wiring with a Switch or Relay............................ 16

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

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

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

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

Figure 3.13 .....DC Logic Output Wiring ..................................................... 18

Figure 3.14 .....Milliamp Output Wiring....................................................... 18

Figure 3.15 .....Position Proportioning Output Wiring .................................. 18

Figure 3.16 .....Serial Communications Terminals ...................................... 19

Figure 3.17 .....535 Wiring with Limit Control .............................................. 20

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

Configuration .................................................................... 21

Figure 4.2 .......The Microcontroller Circuit Board, the Option Board, and the

Power Supply Board.......................................................... 22

Figure 4.3 .......Representation of Module .................................................. 25

Figure 4.4 .......Install Communications Module onto

Microcontroller Board ........................................................ 26

Figure 5.1 .......Menu Flowchart for Set Up................................................. 27

Figure 5.2 .......Independent vs. Dependent Parameters............................. 28

Figure 5.3 .......Configuration Flowchart ..................................................... 28

Figure 6.1 .......Access the Tuning Menu Block .......................................... 63

Figure 7.1 .......Alarm Examples................................................................ 75

Figure 7.2 .......Duplex with reverse and direct acting outputs ...................... 77

Figure 7.3 .......Duplex with direct and reverse acting outputs ...................... 77

Figure 7.4 .......Duplex with two reverse acting outputs ............................... 78

Figure 7.5 .......Duplex with a gap between outputs..................................... 78

Figure 7.6 .......Duplex with overlapping outputs and output limits ................ 79

Figure 7.7 .......Duplex with various relative gain settings ............................ 79

Figure 7.8 .......Duplex with one ON/OFF output......................................... 80

Figure 7.9 .......Duplex with two ON/OFF outputs ....................................... 80

Figure 7.10 .....Staged Outputs Example ................................................... 83

Figure 7.11 .....Combinations of Closed Digital Inputs for Each Setpoint (based

on BCD logic) .................................................................... 84

Figure 7.12 .....Pretune TYPE 1, 2 and 3 with Adaptive Tune....................... 90

Figure 7.13 .....Noise Band Calculation Example........................................ 92

iv Table of Contents 535 User's Manual

FIGURE DESCRIPTION PAGE

Figure 7.14 .....Noise Band Values for Temperature Inputs ......................... 93

Figure 7.15 .....Deadtime and Time Constant............................................. 93

Figure 7.16 .....Square Root Linearization Formula .................................... 95

Figure 7.17 .....15-point Linearization Curve............................................... 96

Figure 7.18 .....Load Line Example............................................................ 97

Figure 7.19 .....Heat Exchanger Control Loop for Steam Supply ................ 100

Figure 7.20 .....Cascade Control of Product Temperature ......................... 101

Figure 7.21 .....Ratio Control in Mixing Application .................................... 103

Figure A4.1.....535 Rear Terminals for Calibration........................................ 7

Figure A4.2.....Flowchart Calibration Menus ................................................ 7

Figure A4.3.....Jumper Locations on the Microcontroller Circuit Board ........... 8

Figure A4.4.....Input Calibration Wiring ........................................................ 8

Figure A4.5.....Thermocouple/Cold Junction Calibration Wiring .................... 9

Figure A4.6.....Analog mA Input Calibration Wiring ..................................... 10

Figure A4.7.....Analog mA Input Jumper Positions ..................................... 10

Figure A4.8.....Milliamp Output Calibration Wiring ...................................... 11

Figure A4.9.....Output Module Menu Cycle ................................................ 11

Figure A4.10... Slidewire Test Wiring ......................................................... 12

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535 User's Manual Table of Contents v

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vi Table of Contents 535 User's Manual

CHAPTER 1 INTRODUCTION

Introduction

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

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

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

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

Specifications and information subject to change without notice.

535 User’s Manual Chapter 1 1

Introduction

535 MODES

There are three operating modes for the 535 controller: OPERATION, the default mode of the controller. When the 535 is operating,

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

SET UP, also referred to as configuration. Here you set up the basic functions of the instrument such as input and output assignments, alarm types and special functions.

TUNING, where you configure control function parameters for Proportional, Integral and Derivation (PID). Use periodically to optimize the control performance of the instrument.

ORDER CODE, PA CKA GING INFORMATION

Compare the product number to the ordering code on page 3 to determine the outputs and options installed on the 535. The product number is printed on the label on the top of the controller case.

Included with this 535 are:

• a 535 User’s Manual

• mounting hardware

• 1 sheet of Engineering unit adhesive labels

WHERE TO GO NEXT

• To become more familiar with the 535 interface, continue to Chapter 2.

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

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

535, follow through Chapters 5 and 6. Appendix 1 can be used as a basic guideline to these parameters.

TEXT FORMA TTING IN THIS MANU AL

Feature Format KEYS SET PT DISPLAY

SET PT DISPLAY

ICONS OUT, ALM MENUS CONFIG., TUNING, PARAMETERS CYCLE TM:1, MIN.OUT2 PARAMETER VALUES OFF, SETPOINT, LAST OUT. DISPLAY MESSAGES TOO HOT, OUT%,

2 Chapter 1 535 User’s Manual

Order

Output 1: Control Code

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

Output 2: Control, Alarm, or Retransmission

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

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

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

Introduction

535 – 00

Output 4: Alarm, Retransmission, or Loop Power

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

Options

Enter “0” if not desired

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

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

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

Serial Communications

Enter “0” if not desired

RS-485 Serial Communications S

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

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

535 User’s Manual Chapter 1 3

Note 4: All outputs are interchangeable modules. Note 5: The mechanical relay and solid state relay modules are derated to 0.5 amp at 24 Vac

Note 3: Up to two outputs may be used for

Introduction

4 Chapter 1 535 User’s Manual

CHAPTER 2 BASIC INTERF A CE

Operation

Icons

OUT 1 2 ALM 1 2

535

Displays:

1st

2nd 3rd

Location for

MANUAL DISPLAY SET PT

identification label

ACK MENU FAST

Keys

DISPLAYS

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

1st Display (five 7-segment digits)

• For the process variable value.

2nd Display (nine 14-segment digits)

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

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

• Upon power up, indicates the current setpoint.

3rd Display (nine 14-segment digits)

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

• In TUNING or SET UP mode, the value or choice of parameter shown in the 2nd display.

Figure 2.1 Operator Interface

ICONS (LIT)

OUT Indicates either 1) relay output is energized; or 2) analog output is

greater than 0%.

ALM1 Indicates the respective alarm (one) is active. ALM2 Indicates the respective alarm (two) is active.

535 User's Manual Chapter 2, Controller Operation 5

OUT OUT OUT 1212

ALM ALM ALM 1212

Operation

KEYS

FAST

MANUAL

SET PT

DISPLAY

▲▲

▲

▲▲

▲

▲▲

▼▼

▼

▼▼

FAST: Has no independent function. Press to modify the function of another key (see below).

MANUAL : Press to toggle between manual and automatic control. When lit, indicates the unit is under manual control.

SET PT : Press to select the active SP. When lit, indicates that a setpoint other than the primary (e.g., RSP, SP2) is

active.

DISPLAY : Press to toggle through values in the 2nd display for setpoint, ramping setpoint, deviation, PV1, PV2, output and valve position (each, if available).

In Tuning or Set Up mode, press to return controller to Operation mode (display will show current setpoint).

▲▲

▲ : Press to increase the value or selection of displayed parameter.

▲▲

FAST+

▼▼

▼ : Press to decrease the value or selection of displayed parameter.

▼▼

▲▲

▲ : Press to scroll through values at a faster rate.

▲▲

FAST

▼▼

▼

▼▼

ACK

FAST+

▼▼

▼ : Press to scroll through values at a faster rate.

▼▼

ACK : Press to acknowledge (an) alarm(s). When lit, indicates there is an acknowledgeable alarm.

MENU : In Operation Mode, press to access the Tuning Menu.

In Set Up or Tuning mode, press to advance through a menu’s parameters. (Use FAST+MENU to advance to the next menu.)

When lit, indicates the controller is in Set Up mode.

MENUFAST

FAST+MENU : Press to access the Set Up menus. In Set Up mode, press to advance through menus. (Use MENU by itself to

access the parameters of a particular menu.)

6 Chapter 2, Controller Operation 535 U ser's Manual

Operation

BASIC OPERATING PROCEDURES

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

To select /change a setpoint

1. Use DISPLAY key to toggle display to SetPoint.

2. Use SET PT key to toggle to active setpoint. Before the newly selected setpoint is made active, there is a two-second

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

3. To change value, press ▲ or ▼ .

To change from auto to manual control (bumpless transfer)

1. When in automatic control, press the MANUAL key at any time, except while in the TUNING mode.

2. The MANUAL key will light in red, and the 2nd display will immediately change to indicate current output level.

To change from manual to auto

1. When in manual control, press MANUAL at any time except while in the TUNING or SET UP mode.

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

To change manual output values

1. Make sure the controller is under manual control.

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

3. Use the ▲ or ▼ key to change the value.

To override security

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

1. Use the in the 3rd display. The starting value is 0.

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

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

4. If code is incorrect, INCORRECT appears in the 3rd display. INCORRECT will disappear after two seconds, and a new security code can then be entered.

5. The controller will revert back to full security lock after one minute of key inactivity.

▲▲

▲ and

▲▲

To display control output value

1. Toggle DISPLAY key until the 2nd display shows OUT followed by the output percentage. This value is the PID output.

• In duplex applications, this value does not directly refer to the output

signal (refer to the Chapter 7 section on Duplex Control for details.)

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

• For duplex applications with two on/off outputs, the OUT tag is not

shown. In this case, the status of both outputs is shown in the following manner: 1:ON 2:OFF (1 and 2 are the respective outputs).

▼▼

▼ keys to quickly enter the security code, which will show

▼▼

NOTE:

See the glossary in Appendix 6 for explanation of ramping and target setpoint. Also refer to the applications in Chapter 7.

535 User's Manual Chapter 2, Controller Operation 7

Operation

To display the active PID set

1. Press MENU to reach Tuning Mode.

2. In TUNING Mode, press MENU to reach the correct Menu parameter.

3. The active PID set will have an asterisk (*) on both sides of the value.

NOTE:

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

Figure 2.2 Before and After Acknowledging an Alarm

ALARM OPERATION

Alarms may be used in systems to provide warnings of unsafe conditions. All 535 operators must know how the alarms are configured, the consequences of acknowledging an alarm and how to react to alarm conditions.

Alarm Indication

• lit icons ALM 1 and/or ALM 2

• lit ACK key

• displayed alarm message

Acknowledgable alarms meet the first two of these conditions. Non-acknowledgable alarms only meet the first condition (only icon is lit).

BEFORE

OUT 1 ALM 1

MANUAL DISPLAY SET PT

535

▲

AFTER

OUT 1

MANUAL DISPLAY SET PT

535

▲

NOTE:

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

ACK MENU FAST

▼

To acknowledge an alarm(s):

1. To acknowledge Alarm 1, press ACK once.

2. To acknowledge Alarm 2, press ACK twice.

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

ACK MENU FAST

▼

again to acknowledge Alarm 2.

4. The message and alarm icon dissappear.

Latching Alarms

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

8 Chapter 2, Controller Operation 535 U ser's Manual

Limit Sequence

An alarm can be configured to be both latching and non-acknowledgeable. In this case, the alarm is acknowledgeable only after the process has left the alarm condition. This is similar to the function of a limit controller.

MOUNTING THE CONTROLLER

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

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

2. Figure 3.1 shows the controller and panel dimensions. The panel cutout must be precise, and the edges free from burrs and waves.

7.180 (182.37) OVERALL LENGTH

3.770 (95.76)

OUT 1 2 ALM 1 2

535

PANEL

1.180 (29.97)

Install / Wire

Figure 3.1 Instrument Panel & Cutout Dimensions

3.622 (92.00) MIN.

3.653 (92.80) MAX.

3.622 (92.00) MIN.

3.653 (92.80) MAX.

3.770 (95.76)

MANUAL DISPLAY SET PT

ACK MENU FAST

FRONT

BEZEL GASKET

6.000 (152.40)

SIDE

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

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

5. Slide the mounting collar over the back of the case, as shown in Figure 3.2. The collar clip edges will lock with matching edges on the controller case.

Mounting Clip

3.585 (91.06)

CUTOUT

Figure 3.2 Attaching mounting collar

Front Panel

Mounting Collar

535 User's Manual Chapter 3 11

Collar Screws (1 of 4)

Install / Wire

CAUTION!

The enclosure into which the 535 Controller is mounted must be grounded according to CSA standard C22.2 No. 0.4.

WARNING! Avoid electrical shock. Do not

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

6. Insert the four mounting collar screws from the rear of the collar. Gradually tighten the screws (using a Phillips #2 screwdriver) to secure the controller against the panel.

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

WIRING

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

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

2. Do not run low power (sensor input) lines in the same bundle as AC power lines. Grouping these lines in the same bundle can create electrical noise interference.

3. All wiring and fusing should conform to the National Electric Code and to any locally applicable codes.

4. An excellent resource about good wiring practices is the IEEE Standard No. 518-1982 and is available from IEEE, Inc., 345 East 47th Street, New York, NY 10017, (212) 705-7900.

Diagrams on the next three pages serve as guides for wiring different types of process inputs. The shaded areas on the diagrams show which rear terminals are used for that type of wiring.

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

WARNING! ELECTRIC SHOCK HAZARD!

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

WARNING! Terminal 9 must be grounded to

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

L2/N

OUT 1–

OUT 1+

OUT 2–

OUT 2+

OUT 3–

OUT 3+

TOP (as viewed from back of controller)

1 2 3

4 5 6 7 816

EARTH

917

GND

S/W 1

S/W 2

S/W 3

RSP–

RSP+

OUT 4–

OUT 4+

DIN

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

COLD

JUNC–

COLD

JUNC+

25 18 19

20 21 22 23

31 24 32

not used

COMM–

COMM+

PV2–

PV2+

RTD 3RD

PV1–

PV1+

12 Chapter 3 535 User's Manual

A C Po wer Input

Install / Wire

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

TOP

EARTH/

917

GROUND

10 11 12 13 14 15

18 19 20 21 22 23 24 32

25 26 27 28 29 30 31

POWER

1 2 3 4 5 6 7 816

Screws must be tight to ensure good electrical connection

Process V ariable Input

NOTE:

When wiring to a 240 Volt system, an additional 0.5 Amp, 250V, fast-acting fuse is required on L2.

Figure 3.4 AC Power Input Terminals

CAUTION! Do not run low power (sensor input)

lines in the same bundle as AC power lines. Grouping these lines in the same bundle can create electrical noise interference.

The 535 accommodates the following types of process variable inputs:

• Thermocouple Input

• RTD Input

• Voltage Input

• Milliamp Input with External Power Supply

• Milliamp Input with Internal Power Supply Each type of input can be wired for PV1 (terminals 31 and 32) or for PV2 (ter-

minals 28 and 29).

1 2 3 4 5 6 7 816

917 10 11 12 13 14 15

18 19 20 21 22 23

25 26 27 28 29 30 31

24 32

PV 2–

PV 2+

RTD 3rd

PV 1–

PV 1+

Figure 3.5 Process Variable Terminals

535 User's Manual Chapter 3 13

Install / Wire

–

THERMOCOUPLE INPUT

28 29

2-WIRE RTD

RTD

Jumper wire

28 29 30

4-WIRE RTD

Same color

28 29 30

3-WIRE RTD

RTD

Third leg of RTD

Same color

28 29 30

Third leg

of RTD

Do NOT connect 4th leg

VOLTAGE INPUT

–

Transmitter

–

28 29

NOTE: Typically, in the U.S., negative leads

are red.

Figure 3.6 PV1 and PV2 Wiring for Milliamp, RTD and Voltage Inputs.

For PV1

THERMOCOUPLE INPUT

–

2-WIRE RTD

Jumper wire

30 31 32

3-WIRE RTD

RTD

For PV2

Same color

Third leg of RTD

30 31 32

4-WIRE RTD

Same color

–

Transmitter

Same color Third leg of RTD

30 31 32

DO NOTconnect 4th leg

VOLTAGE INPUT

–

14 Chapter 3 535 User's Manual

Install / Wire

For PV1

MILLIAMP INPUT 2-wire transmitter with

separate power supply

– External + Power Supply

31 32

– Transmitter +

MILLIAMP INPUT

2-wire transmitter with loop power supply

–

MILLIAMP INPUT

4-wire transmitter with loop power supply

15 16

31 32

–

2-wire transmitter

–

Input power for transmitter

4-20 mA output

–

from transmitter

For PV2

MILLIAMP INPUT 2-wire transmitter with

separate power supply

– External + Power Supply

28 29

– Transmitter +

MILLIAMP INPUT

2-wire transmitter with loop power supply

–

MILLIAMP INPUT

4-wire transmitter with loop power supply

–

– +

2-wire transmitter

–

Input power for transmitter

4-20 mA output

–

from transmitter

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

NOTE:

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

535 User's Manual Chapter 3 15

Install / Wire

Figure 3.8 Digital input Wiring with a Switch or Relay

Digital Input(s)

Digital inputs can be activated in three ways: a switch (signal type), closure of a relay, or an open collector transistor. Digital inputs are only functional when that option is installed (via hardware) The controller detects the hardware and supplies the appropriate software menu.

1. Digital Inputs with a switch or relay

Wire the switch/relay between terminal 17 and the specific digital input terminal (Figure 3.8).

1 2 3 4 5 6 7 8

DIN GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

17 18 19 20 21 22 23 24 32

9 10 11 12 13 14 15 16

25 26 27 28 29 30 31

Figure 3.9 Digital Input Wiring with an Open Collector

1 2 3 4 5 6 7 8

Screws must be tight to ensure electrical connection

DIN

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

17 18 19 20 21 22 23 24 32

9 10 11 12 13 14 15 16

25 26 27 28 29 30 31

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

DIN

17 18 19 20 21 22 30

25 26 27 28 29

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

DIN

17 18 19 20 21 22 30

25 26 27 28 29

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

DIN

17 18 19 20 21 22 30

2. Digital Inputs with an Open Collector

An open collector is also called a transistor. Wire the transistor between terminal 17 and the specified digital input terminal (Figure 3.9)

17 18 19 20 21 22 30

25 26 27 28 29

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

DIN

17 18 19 20 21 22 30

25 26 27 28 29

DIN

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

17 18 19 20 21 22 30

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

GND

DIN

17 18 19 20 21 22 30

25 26 27 28 29

Remote Setpoint Option

Use terminals 13 and 14 to connect the remote setpoint signal (see Figure 3.10).

–

Figure 3.10 Remote Setpoint Terminals

Source

– +

16 Chapter 3 535 User's Manual

OUTPUT MODULES

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

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

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

1. Mechanical Relay Output

• Output 1 is always Control 1.

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

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

Install / Wire

NOTE:

Refer to Figure 4.2 for location of the corresponding jumpers.

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

Line Power

Recommend use of both MOV and snubber

Terminals used

with Output

Module 1

Load

2. Solid State Relay (Triac) Output

• Output 1 is always Control 1.

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

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

Terminals used

with Output

Module 1

3 4

Line Power

Load

Terminals used

with Output

Module 2

5 6

Terminals used

with Output

Module 2

Terminals used

with Output

Module 3

7 8

Terminals used

with Output

Module 3

7 8

Terminals used

with Output

Module 4

15 16

Terminals used

with Output

Module 4

15 16

Figure 3.11 Mechanical Relay Output wiring

Figure 3.12 SSR Relay Output Wiring

Recommend use of both MOV and snubber

535 User's Manual Chapter 3 17

Install / Wire

3. DC Logic (SSR Drive) Output

• Output 1 is always Control 1.

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

• Output 4 is always configured for normally open.

Figure 3.13 DC Logic Output Wiring

Figure 3.14 Milliamp Output Wiring

Terminals used

with Output

Module 1

3 4

_ +

Load

3 4

Terminals used

with Output

Module 2

5 6

Terminals used

with Output

Module 3

7 8

Terminals used

4. Milliamp Output

• Output 1 is always Control 1.

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

Terminals used

with Output

Module 1

Terminals used

with Output

Module 2

Terminals used

with Output

Module 3

Load

3 4

5 6

7 8

5. Position Proportioning Output

with Output

Module 4

15 16

Terminals used

with Output

Module 4

15 16

(with or without Slidewire Feedback)

POSITION PROPORTIONING

Electric Motor Actuator

CCW Winding

Figure 3.15 Position Proportioning Output Wiring

18 Chapter 3 535 User's Manual

Actuator Supply Current

COMCWCCW

CW Winding

COM

CCW

Slidewire Wiper 0–1050 Ohm

OUTPUT

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

• When using velocity control (no slidewire feedback), there are no connections at terminals 10, 11 and 12.

• Use of the slidewire feedback is optional

Serial Communications

A twisted shielded pair of wires should be used to interconnect the host and field units. Belden #9414 foil shield or #8441 braid shield 22-gauge wire are acceptable for most applications. The foil shielded wire has superior noise rejection characteristics. The braid shielded wire has more flexibility. The maximum recommended length of the RS 485 line is 4000 feet. Termination resistors are required at the host and the last device on the line. Some RS 485 cards/converters already have a terminating resistor. We recommend using our RS-232/RS-485 converter. The communication protocol is asynchronous bidirectional half-duplex, hence the leads are labelled Comm + and Comm – .

Install / Wire

or other host

RS-485

port

535

Terminals

Twisted, shielded

Comm –

Comm +

The shield needs to be connected continuously but only tied to one ground at the host. Failure to follow these proper wiring practices could result in transmission errors and other communications problems.

CAUTION

Figure 3.16 Serial Communications Terminals

To "Comm –" terminal of next Moore Industries device

To "Comm +" terminal of next Moore Industries device

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

535 User's Manual Chapter 3 19

Install / Wire

Figure 3.17 535 Wiring with Limit Control

535 PROCESS CONTROLLER

CONTROLLER

AC POWER

0.5 AMP, 250 V, FAST ACTING FUSE

Limit Control

Temperature applications where abnormally high or low temperature conditions pose potential hazards for damage to equipment, product and operator. For such applications, we recommend the use of an FM-approved temperature limit device in conjunction with the process controller. This wiring example illustrates a typical application using the 535 Process Controller with a 353 Limit Controller.

EARTH GROUND

25 26

9 10

5 6 7

14 15 16

23 24

T.C.

INPUT

LOAD

POWER

FAST ACTING

FUSE

HEAT LOAD

PROCESS SENSOR

LIMIT SENSOR

MERCURY

RELAY

FOR CONTROL

HIGH LIMIT MECHANICAL CONTACTOR

COIL

RELAY/ CONTACTOR COIL POWER

T/C INPUT

N.O.

OPTIONAL

MOMENTARY SWITCH

MANUAL RESET

FOR LIMIT CONTROL

20 19 18

12 11

353 LIMIT CONTROLLER

FAST

ACTING

FUSE

INDICATOR ON

WHEN LIMIT TRIPS

LIMIT CONTROLLER

AC POWER

FUSE

20 Chapter 3 535 User's Manual

CHAPTER 4 HARDW ARE SET UP

Hardware Set Up

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

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

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

• Relay outputs set to normally open.

Altering the factory configuration of the 535, requires accessing the circuit boards, and locating the jumpers and output modules (see Figure 4.1).

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

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

FRONT FACE

MICROCONTROLLER

BOARD

POWER SUPPLY

BOARD

NOTE: Hardware configuration of the controller is available at the factory; Consult a Moore Industries application engineer for details.

Figure 4.1 Location of Printed Circuit Boards for Hardware Configuration

OPTION BOARD

A detailed view of the circuit boards appears in Figure 4.2. After configuring the hardware, or if no changes are necessary, continue set-

ting up the process as needed.

HARDW ARE INPUT TYPES

The Process Variable

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

The jumpers for the process variable are located on the Microcontroller Circuit Board (see Figure 4.2). The factory default is Milliamp. Locations are marked as follows:

V Voltage MA Milliamp

▼▼

▼ Thermocouple with downscale burnout

▼▼

▲ ▲

▲ Thermocouple with upscale burnout

▲ ▲

RTD RTD

535 User's Manual Chapter 4 21

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

Hardware Set Up

NOTE:

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

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

The Remote Setpoint

Figure 4.2 shows the location of the remote setpoint jumper. The factory default is milliamp. Choose from the following settings:

V Remote setpoint with voltage signal (jumper removed)

MA Remote setpoint with milliamp signal (jumper installed)

Mechanical Relays

There are three output module sockets on the Power Supply Circuit Board, and one output module on the Option Board (see Figure 4.2). The mechanical relay on the Power Supply Board may be configured for either normally open (NO) or normally closed (NC). A jumper located next to each socket determines this configuration. All relay outputs are factory set to NO (normally open).

EPROM

BATTERY

5-Pin Connector

Female 22-Pin ConnectorFemale 22-Pin Connector

V MA

MA TC

TC t TC

TC s RTD

RTD

RTD V

MA TC t TC s RTD

TB2

2ND

PV1

TB1

Remote Setpoint Jumper

Male 22-Pin

Connector

5-Pin Connector

Output 4

Female 34-Pin Connector

Male 22-Pin

Connector

Male 34-Pin Connector

Module

Retention

over Outputs 1,2,3

Plate

3 2

NO J3 NC

NO J2 NC

NO J1 NC

Jumpers

NO and NC

22 Chapter 4 535 User's Manual

Hardware Set Up

ACCESSING AND CHANGING JUMPERS

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

Equipment needed: Needle-nose pliers (optional)

Phillips screwdriver (#2) Wrist grounding strap

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

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

3. Use Figure 4.2 to locate the jumper connector to change.

4. Using the needle nose pliers (or fingers), pull straight up on the connector and remove it from its pins, as shown in Photo 4. Be careful not to bend the pins.

CAUTION!!

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

4. Remove Jumpers

5. Find the new location of the jumper connector (again, refer to Figure 3.2). Carefully place it over the pins, then press connector straight down. Make sure it is seated firmly on the pins.

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

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

7. To reassemble the controller, properly orient the chassis with board opening on top. Align the circuit boards into the grooves on the top and bottom of the case. Press firmly on the front face assembly until the chassis is all the way into the case.

If it is difficult to slide the chassis in all the way, make sure the screws have been removed (they can block proper alignment), and that the chassis is properly oriented.

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

535 User's Manual Chapter 4 23

Hardware Set Up

ADDING AND CHANGING OUTPUT MODULES

The 535 has provisions for four output modules. A controller ordered with output module options already has the modules properly installed. Follow these instructions to add modules, change module type(s) or change module location(s).

Equipment needed: Wrist grounding strap

Phillips screwdriver (#2) Small flat blade screwdriver Wire cutters

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

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

3. Use a flat screwdriver to carefully pry apart the clips that hold the front face assembly to the chassis, as in Photo 3. Separate the printed circuit board assembly from the front face assembly. Use care not to break the clips or scratch the circuit boards.

4. As shown in Photo 4, carefully pry apart, using hands or a small flat screwdriver, the smaller Option board and the Power Supply board (the one with 3 modules).

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

tie wrap. Carefully snip the tie wrap with a wire cutter. To prevent damage to the surface mount components, ALWAYS snip the tie wrap on TOP of the Retention Plate, as shown in Photo 5.

Remove the retention plate.

3. Pry Clips

24 Chapter 4 535 User's Manual

4. Separate Boards

5. Remove Retention Plate

6. To change module 4: Output Module 4 (on the Option board) is also held in place by a tie wrap.

Snip tie wrap to remove module as shown in Photo 6.

7. Figure 4.3 shows a representation of an output module. Inspect the module(s) to make sure that the pins are straight.

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

Hardware Set Up

Figure 4.3 Representation of Module

8. Add/Change Module6. Snip Tie Wrap

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

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

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

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

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

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

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

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

ing on top. Align the circuit boards into the grooves on the top and bottom of the case. Press firmly on the front face assembly until the chassis is all the way into the case.

If it is difficult to slide the chassis in all the way, make sure the screws have been removed (they can block proper alignment), and that the chassis is properly oriented.

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

against the gasket. Do not overtighten.

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

SPECIAL COMMUNICA TIONS MODULE

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

535 User's Manual Chapter 4 25

Hardware Set Up

Insert module onto connectors

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

2ND

REMOTE SP

CONFIGURATION

TB2

EPROM

BATTERY

V MA

TCs RTD

TCt

Equipment needed: Wrist grounding strap

Phillips screwdriver (#2) Small flat blade screwdriver

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

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

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

4. Orient the Communications Module as shown, and attach it to Connectors P1 and P2 as shown in Figure 4.4.

5. To reassemble the controller, properly orient the chassis with board opening on top. Align the circuit boards into the grooves on the top and bottom

Figure 4.4 Install Communications Module onto Microcontroller Board

of the case. Press firmly on the front face assembly until the chassis is all the way into the case.

If it is difficult to slide the chassis in all the way, make sure the screws have been removed (they can block proper alignment), and that the chassis is properly oriented.

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

26 Chapter 4 535 User's Manual

CHAPTER 5 SOFTWARE CONFIGURATION

Controller Set Up

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

When initially setting up the

controller, cycle through all the

parameters in each Menu.

Press the MENU+FAST to

advance to the next Menu.

Press MENU to advance to the

next parameter (this also sets the

value for the current parameter.

Use arrow keys to select a value).

Use the arrows keys to enter

numerical values, and/or move

through the selection group.

press:

MENU/FAST

press:

CONFIG.

INDICATOR

(D)

press MENU/FAST

Go to next Menu Block:

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

This is a menu Parameter. The name shows in the 3rd display. In this manual, independent parameters appear as white text on black, and dependent parameters appear as black text on white.

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

the default (factory) setting.

If the default value is dependent on other variables, (D) is shown.

Figure 5.1 Menu Flowchart for Set Up

MENUS

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

CONFIG Mode selection and input/output hardware assignments PV1 INPUT 1st process variable input options PV2 INPUT 2nd process variable input options CUST. LINR. Linearization curve options for PV1 input. CONTROL Control options ALARMS Alarm options REM. SETPT. Controller remote setpoint options RETRANS. Retransmission output options SELF TUNE Self tune algorithm options SPECIAL Special feature options SECURITY Security functions SER.COMM. Serial Communications options (requires comm. board)

and

TUNING Tuning parameters configuration (see Chapter 6)

CAUTION!

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

NOTE: For information about the Tuning menu/mode, refer to Chapter 6. For more information about set up parameters and 535 applications, refer to Chapter 7.

535 User's Manual Chapter 5 27

Controller Set Up

TUNE PT.

AUTOMATIC

Figure 5.2 Independent vs. Dependent Parameters

Figure 5.3 Configuration Flowchart

CONTACT 1

MANUAL

PARAMETERS

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

This chapter outlines all the available parameters for the 535. Some parameters are independent of any special configuration, and others are dependent on the individual configuration. This manual displays these two types of parameters differently; refer to Figure 5.2. A special feature of the 535, called Smart Menus, determines the correct parameters to display for the specific configuration, so not all the listed parameters will appear.

for TUNING mode

for

OPERATION mode

TUNING

+ for SET UP mode

to return to

OPERATION

mode

MANUAL

OPERATION

for SET UP

mode

SET UP

CONFIG

PV1 INPUT

PV2 INPUT

CUST. LINR.

CONTROL

ALARMS

REM. SETPT.

RETRANS.

SELF TUNE

SPECIAL

SECURITY

SER. COMM.

+ to toggle through the 12 menu blocks in SET UP mode

28 Chapter 5 535 User's Manual

CONFIGURA TION AND OPERATION

Figure 5.3 shows the relationships among the different modes of the 535 and the configuration menus:

• SET UP menus can only be accessed from manual control. To transfer the 535 from automatic to manual control, press MANUAL.

• To access the SET UP menus, hold down FAST and press MENU. The MENU key will illuminate; and CONFIG will appear in the 2nd display.

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

▲▲

• To select a parameter value, use next parameter, or FAST+MENU to advance to the next menu.

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

• TUNING mode (and the TUNING menu) can be accessed from either automatic or manual control. To access the tuning menu, press MENU .

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

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

▼▼

▲ and

▼. Press MENU to advance to the

▲▲

▼▼

Controller Set Up

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

FAST MENU

DISPLAY

MENU MENU

▲ ▼

DISPLAYFAST

WHERE T O GO NEXT

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

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

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

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

• For more information about applications for the 535, see Chapter 6.

• For more information about the Tuning function of the 535, see Chapter 7.

535 User's Manual Chapter 5 29

Controller Set Up

CONFIG.

CTRL. TYPE

STANDAR D

LINE FREQ

60 Hz

PV SOURCE

PV1

NOTE:

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

SOFTW ARE MENUS AND PARAMETERS CONFIG.

1. CTRL. TYPE

Defines the type of control output(s).

D STANDARD Standard control output, no special algorithms

• POS. PROP. Position proportioning control output

• STAGED Staged outputs

• DUPLEX Duplex outputs

2. LINE FREQ

Defines the power source frequency.

• 50 HZ D 60 HZ

3. PV SOURCE

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

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

• 1/2:BACKUP Use PV2 if PV1 is broken

• PV1–PV2 Use PV1–PV2

• PV1+PV2 Use PV1+PV2

• AVG. PV Use the average of PV1 and PV2

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

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

REM. SETPT.

DISABLED

4. REM. SETPT.

Selects function of the remote setpoint. D DISABLED

• ENABLED

5. OUTPUT 2

Defines the function of the second output.

OUTPUT 2

OFF

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

FAST MENU

30 Chapter 5 535 User's Manual

DISPLAY

• ALM.RLY:ON

• ALM.RLY:OFF

• RETRANS. Retransmission

• COMM. ONLY Output addressable through communication D OFF Completely deactivates the output

MENU MENU

▲ ▼

MENU DISPLAYFAST

6. OUTPUT 3

Defines the function of the third output.

• ALM.RLY:ON

• ALM.RLY:OFF

• RETRANS. Retransmission

• COMM. ONLY Output addressable through communications D OFF Completely deactivates the output

7. OUTPUT 4

Defines the function of the fourth output.

• ALM.RLY:ON

• ALM.RLY:OFF

• RETRANS. Retransmission

• COMM. ONLY Output addressable through communications D OFF Completely deactivates the output

8. ANLG. RNG.:1

Defines the output signal for the first output. D 4–20 mA

• 0–20 mA

• 20–4 mA

• 20–0 mA

Controller Set Up

OUTPUT 3

OFF

OUTPUT 4

OFF

ANLG.RNG.:1

4-20 mA

9. ANLG. RNG.:2

Defines the output signal for the second output. D 4–20 mA

• 0–20 mA

• 20–4 mA

• 20–0 mA

10. ANLG. RNG.:3

Defines the output signal for the third output.

D 4–20 mA

• 0–20 mA

• 20–4 mA

• 20–0 mA

11. ANLG. RNG.:4

Defines the output signal for the fourth output. D 4–20 mA

• 0–20 mA

• 20–4 mA

• 20–0 mA

ANLG.RNG.:2

4-20mA

ANLG.RNG.:3

4-20mA

ANLG.RNG.:4

4-20mA

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

FAST MENU

535 User's Manual Chapter 5 31

DISPLAY

MENU MENU

▲ ▼

MENU DISPLAYFAST

Controller Set Up

CONT A CT 1

MANUAL

12. CONTACT 1

Defines the operation of the first digital input.

• SETPT. 1–8 Assigns the first four digital inputs to select setpoints 1 through 8 via BCD signal

• REM. SETPT. Makes the remote setpoint active

D MANUAL Trips the controller to manual control

• 2ND. SETPT. Makes the second setpoint active

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

• ALARM ACK. Acknowledges alarms

• RST. INHBT. Deactivates the reset term

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

• STOP A/T Suspends the adaptive tune function

• LOCK. MAN. Locks controller in manual control

• UP KEY Remote

• DOWN KEY Remote

• DISP KEY Toggle between SP DEV or OUT%

• FAST KEY Activates FAST key

• MENU KEY Activates MENU key.

• COMM. ONLY Status readable only through communications

• PV2.SWITCH Switches between PV1 and PV2

▲▲

▲ function

▲▲ ▼ ▼

▼ function

▼ ▼

CONT A CT 2

REM.SETPT.

13. CONTACT 2

Defines the operation of the second digital input. D REM. SETPT. Makes the remote setpoint active

• MANUAL Trips the controller to manual control

• 2ND. SETPT. Makes the second setpoint active

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

• ALARM ACK. Acknowledges alarms

• RST. INHBT. Deactivates the reset term

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

• STOP A/T Suspends the adaptive tune function

• LOCK. MAN. Locks controller in manual control

• UP KEY Remote

• DOWN KEY Remote

• DISP KEY Toggle between SP DEV or OUT%

• FAST KEY Activates FAST key

• MENU KEY Activates MENU key.

• COMM. ONLY Status readable only through communications

• PV2.SWITCH Switches between PV1 and PV2

▲▲

▲ function

▲▲ ▼ ▼

▼ function

▼ ▼

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

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▲ ▼

MENU DISPLAYFAST

14. CONTACT 3

Defines the operation of the third digital input.

• REM. SETPT. Makes the remote setpoint active

• MANUAL Trips the controller to manual control D 2ND. SETPT. Makes the second setpoint active

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

• ALARM ACK. Acknowledges alarms

• RST. INHBT. Deactivates the reset term

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

• STOP A/T Suspends the adaptive tune function

• LOCK. MAN. Locks controller in manual control

• UP KEY Remote

• DOWN KEY Remote

• DISP KEY Toggle between SP DEV or OUT%

• FAST KEY Activates FAST key

• MENU KEY Activates MENU key.

• COMM. ONLY Status readable only through communications

• PV2.SWITCH Switches between PV1 and PV2

▲▲

▲ function

▲▲ ▼ ▼

▼ function

▼ ▼

Controller Set Up

CONT A CT 3

2ND. SETPT.

15. CONTACT 4

Defines the operation of the fourth digital input.

• REM. SETPT. Makes the remote setpoint active

• MANUAL Trips the controller to manual control

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

• ALARM ACK. Acknowledges alarms

• RST. INHBT. Deactivates the reset term

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

• STOP A/T Suspends the adaptive tune function

• LOCK. MAN. Locks controller in manual control

• UP KEY Remote

• DOWN KEY Remote

• DISP KEY Toggle between SP DEV or OUT%

• FAST KEY Activates FAST key

• MENU KEY Activates MENU key.

• COMM. ONLY Status readable only through communications

• PV2.SWITCH Switches between PV1 and PV2

▲▲

▲ function

▲▲ ▼▼

▼ function

▼▼

CONT A CT 4

2ND. PID

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

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▲ ▼

MENU DISPLAYFAST

Controller Set Up

CONT A CT 5

ALARM ACK.

16. CONTACT 5

This defines the operation of the fifth digital input.

• REM. SETPT. Makes the remote setpoint active

• MANUAL Trips the controller to manual control

• 2ND. SETPT. Makes the second setpoint active

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

D ALARM ACK. Acknowledges alarms

• RST. INHBT. Deactivates the reset term

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

• STOP A/T Suspends the adaptive tune function

• LOCK. MAN. Locks controller in manual control

• UP KEY Remote

• DOWN KEY Remote

• DISP KEY Toggle between SP DEV or OUT%

• FAST KEY Activates FAST key

• MENU KEY Activates MENU key.

• COMM. ONLY Status readable only through communications

▲▲

▲ function

▲▲ ▼▼

▼ function

▼▼

LOOP NAME

LOOP ONE

PV INPUT

PV1 TYPE

J T/C

CAUTION!

Set parameter values in the presented order—dependent parameters are dynamically related and changing values of one can alter the value of another.

For example, if SP LO LIM. is set to 0, and then thermocouple type is changed to B T/C, the SP LO LIM. value will change to 104° (the low limit of a type B thermocouple).

17. LOOP NAME

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

D LOOP ONE

▲▲

▲ and

▲▲

▼▼

▼ keys to scroll

▼▼

PV1 INPUT

1. PV1 TYPE

Specifies the particular sensor range or input range for PV1. T/C RTD VOLTAGE CURRENT (mA) D J T/C D DIN RTD D 1-5 V D 4-20mA

• E T/C • JIS RTD • 0-5 V • 0-20mA

• K T/C • SAMA RTD • 0-10 mV

• B T/C • 0-30 mV

• N T/C • 0-60 mV

• R T/C • 0-100 mV

• S T/C • +/– 25 mV

• T T/C

•W T/C

• W5 T/C

• PLAT.II T/C

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

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MENU DISPLAYFAST

2. DEG. F/C/K

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

• CELSIUS

• KELVIN

Controller Set Up

DEG. F/C/K

FAHR

3. DECIMAL

Specifies the PV1 decimal point position. D XXXXX

• XXXX.X

• XXX.XX

• XX.XXX

• X.XXXX

4. LINEARIZE

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

D NONE

• SQR. ROOT Square root linearization is activated.

• CUSTOM 15-point custom linearization curve is activated.

5. LOW RANGE

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

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

6. HI RANGE

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

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

7. SP LO LIM.

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

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

8. SP HI LIM.

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

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

DECIMAL

XXXXX

LINEARIZE

NONE

LO W RANGE

(D)

HI RANGE

(D)

SP LO LIM.

(D)

SP HI LIM.

(D)

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

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MENU DISPLAYFAST

Controller Set Up

SP RAMP

OFF

FILTER

OFFSET

9. SP RAMP

Defines the rate of change for setpoint changes.

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

10. FILTER

Specifies the setting for the low pass PV1 input filter.

R 0 to 120 seconds D 0 seconds

11. OFFSET

Defines the offset to PV1 in engineering units.

R –9999 to 99999 D 0

GAIN

1.000

RESTORE

LAST MODE

PV2 INPUT

PV2 SETUP

SAME.AS.PV1

12. GAIN

Defines the gain to PV1.

R 0.100 to 10.000 D 1.000

13. RESTORE

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

• MANUAL

• AUTOMATIC

PV2 INPUT

1. PV2 SETUP

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

as PV1 (no further parameters will appear)

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

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

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▲ ▼

MENU DISPLAYFAST

2. PV2 TYPE

Selects the particular sensor or input range for PV2

T/C RTD VOLTAGE CURRENT (mA) D J T/C D DIN RTD D 1-5 V D 4-20mA

• E T/C • JIS RTD • 0-5 V • 0-20mA

• K T/C • SAMA RTD • 0-10 mV

• B T/C • 0-30 mV

• N T/C • 0-60 mV

• R T/C • 0-100 mV

• S T/C • +/– 25 mV

• T T/C

•W T/C

• W5 T/C

• PLAT.II T/C

3. DECIMAL

Specifies the PV2 decimal point position. D XXXXX

• XXXX.X

• XXX.XX

• XX.XXX

• X.XXXX

Controller Set Up

PV2 TYPE

J/TC

DECIMAL

XXXXX

4. LINEARIZE

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

D NONE

• SQR. ROOT Square root linearization is activated.

5. LOW RANGE

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

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

6. HI RANGE

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

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

7. FILTER

Setting for the low pass PV2 input filter.

R 0 to 120 seconds D 0 seconds

LINEARIZE

NONE

LOW RANGE

(D)

HI RANGE

(D)

FILTER

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

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▲ ▼

MENU DISPLAYFAST

Controller Set Up

OFFSET

GAIN

1.000

RESTORE

LAST MODE

8. OFFSET

Defines the offset to PV2 in engineering units.

R –9999 to 99999 D 0

9. GAIN

Defines the gain for PV2.

R 0.100 to 10.000 D 1.000

10. RESTORE

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

• MANUAL

• AUTOMATIC

CUST . LINR.

1ST . INPUT

(D)

1ST . PV

XTH INPUT

(D)

XTH PV

CUST . LINR.

Defines a custom linearization curve for PV1, if selected. Points 1 and 15 are fixed to the low and high end of the input range and require only setting a corresponding PV value. Points 2 through 14 (the Xth points) require setting both the input and PV values.

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

1. 1ST. INPUT

Specifies the input signal corresponding to the first point.

D The low end of the appropriate input range (e.g. 4.00 mA)

2. 1ST. PV

Specifies the engineering unit value corresponding to the first point.

R –9999 to 99999 D 0

3. XTH. INPUT

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

R Any value greater than the first input D The low end of the appropriate input range (e.g. 4.00 mA)

4. XTH. PV

Specifies the unit value corresponding to the XTH point (X is 2 to 14).

R –9999 to 99999 D 0

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MENU DISPLAYFAST

5. 15TH. INPT.

Specifies the input signal corresponding to the 15th point.

R –9999 to 99999 Minimum is [XTH-1] INPUT D The high end of the appropriate input range (e.g. 20.00 mA)

6. 15TH. PV

Specifies the engineering unit value corresponding to the 15th point.

R –9999 to 99999 D 0

Controller Set Up

15TH INPT .

(D)

15TH PV

CONTROL

For configuring the choices for the control algorithm.

1. ALGORITHM

Defines the type of control algorithm. D PID

•PI

•PD

•P

• ON/OFF

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

2. D. SOURCE

Selects the variable for the derivative action. D PV Derivative term will not react when setpoint changes

• DEVIATION Derivative term will react when setpoint changes

3. ACTION:1

Defines the action of the first control output.

• DIRECT

D REVERSE

CONTROL

ALGORITHM

PID

D. SOURCE

ACTION:1

REVERSE

4. PV BREAK

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

Standard Control On/Off Control Velocity Prop Control

• –5 to 105% • ON • CW

D 0 D OFF • CCW

D OUTS. OFF

PV BREAK

(D)

5. LOW OUT.

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

R 0 – 100% Max is HIGH OUT D 0%

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

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▲ ▼

LO W OUT

MENU DISPLAYFAST

Controller Set Up

HIGH OUT .

100

A CTION:2

DIRECT

P.P. TYPE

(D)

CCW TIME

6. HIGH OUT.

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

R 0 – 100% Min is LOW OUT D 100%

7. ACTION:2

Defines the action of the second control output. D DIRECT

• REVERSE

8. P.P. TYPE

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

Feedback option installed Feedback option not installed D SLIDEWIRE • SLIDEWIRE

• VELOCITY D VELOCITY

9. CCW TIME

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

R 1 to 200 seconds D 60 seconds

CW TIME

MIN. TIME

0.1

S/W RANGE

100

OPEN F/B

(D)

10. CW TIME

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

R 1 to 200 seconds D 60 seconds

11. MIN. TIME

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

R 0.1 to 10.0 seconds D 0.1 seconds

12. S/W RANGE

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

R 0–1050 Ohms D 100 Ohms

13. OPEN F/B

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

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

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

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14. CLOSE F/B

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

R 0 to S/W RANGE D 100 Ohms

Controller Set Up

CLOSE F/B

100

15. OUT1 STOP

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

R 1 to 100% D 50%

16. OUT2 STRT.

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

R 0 to 99% D 50%

ALARMS

1. ALM. TYPE:1

Defines the type of alarm for alarm 1.

• HIGH ALRM.

• LOW ALARM

• HIGH/LOW Separate High & Low alarm setpoints in one

alarm

• BAND

• DEVIATION

• MANUAL Causes an alarm when in manual control

• REMOTE SP Causes an alarm when in Remote Setpoint

• RATE Selects a rate-of-change alarm

D OFF Deactivates the first alarm

OUT1 STOP

OUT2 STRT .

ALARMS

ALM. TYPE:1

OFF

2. ALM. SRC:1

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

D PV

•SP

• RAMP SP

• DEVIATION

• OUTPUT

• PV2

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

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▲ ▼

ALM. SRC:1

MENU DISPLAYFAST

Controller Set Up

ALARM SP:1

0.0%

HIGH SP:1

0.0%

3. ALARM SP:1

Specifies the alarm set point for alarm 1 (except HIGH/LOW)

For HIGH or LOW alarms: If ALM.SRC.:1 = OUTPUT If ALM.SRC.:1 = any other type

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

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

R -9999 to 99999 D 0

4A.HIGH SP:1

Specifies the high alarm set point for alarm 1 of type HIGH/LOW. If ALM.SRC.:1 = OUTPUT If ALM.SRC.:1 = any other type

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

LO W SP:1

0.0%

DEADBAND:1

ALM.:1 OUT

NONE

LATCHING:1

NONE

4B.LOW SP:1

Specifies the low alarm set point for alarm 1 of type HIGH/LOW. If ALM.SRC.:1 = OUTPUT If ALM.SRC.:1 = any other type

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

5. DEADBAND:1

Defines the deadband for alarm 1. If ALM.SRC.:1 = OUTPUT If ALM.SRC.:1 = any other type

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

6. ALM.:1 OUT.

Selects the output number for alarm 1. D NONE

•2

•3

•4

7. LATCHING:1

Defines the latching sequence of alarm 1. D LATCH

• NO LATCH

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8. ACK.:1

Defines whether alarm 1 may be acknowledged. D ENABLED Allows the alarm to be acknowledged

• DISABLED Prevents the alarm from being acknowledged

while in alarm condition

9. POWER UP:1

Defines how alarm 1 will be treated on power up. D NORMAL Alarm depends on process variable

• ALARM Always power up in alarm regardless of PV

• DELAYED Must leave alarm condition and reenter before

activating the alarm

10. MESSAGE:1

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

D ALARM 1.

▲▲

▲ and

▲▲

▼▼

▼ keys to scroll

▼▼

Controller Set Up

A CK.:1

ENABLED

PO WER UP:1

NORMAL

MESSAGE:1

ALARM 1

11. ALM. TYPE:2

Defines the type of alarm for alarm 2.

• HIGH ALRM.

• LOW ALARM

• HIGH/LOW Separate High & Low alarm setpoints in one

alarm

• BAND

• DEVIATION

• MANUAL Causes an alarm when in manual control

• REMOTE SP Causes an alarm when in Remote Setpoint

• RATE Selects a rate-of-change alarm

D OFF Deactivates the first alarm

12. ALM. SRC:2

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

D PV

•SP

• RAMP SP

• DEVIATION

• OUTPUT

• PV2

ALM. TYPE:2

OFF

ALM.SRC.:2

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

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MENU DISPLAYFAST

Controller Set Up

ALARM SP:2

(D)

HIGH SP:2

0.0%

13. ALARM SP:2

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

For HIGH or LOW alarms: If ALM.SRC.:2 = OUTPUT If ALM.SRC.:2 = any other type

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

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

R -9999 to 99999 D 0

14A. HIGH SP:2

Specifies the high alarm set point for alarm 2 of type HIGH/LOW. If ALM.SRC.:2 = OUTPUT If ALM.SRC.:2 = any other type

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

LO W SP:2

0.0%

DEADBAND:2

ALM.:2 OUT .

NONE

LATCHING:2

LATCH

14B. LOW SP:2

Specifies the low alarm set point for alarm 2 of type HIGH/LOW. If ALM.SRC.:2 = OUTPUT If ALM.SRC.:2 = any other type

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

15. DEADBAND:2

Defines the deadband for alarm 2. If ALM.SRC.:2 = OUTPUT If ALM.SRC.:2 = any other type

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

16. ALM.:2 OUT.

Selects the output number for alarm 2. D NONE

•2

•3

•4

17. LATCHING:2

Defines the latching sequence of alarm 2. D LATCH

• NO LATCH

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

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18. ACK.:2

Defines whether alarm 2 may be acknowledged. D ENABLED Allows the alarm to be acknowledged

• DISABLED Prevents the alarm from being acknowledged

while in alarm condition

19. POWER UP:2

Defines how alarm 2 will be treated on power up. D NORMAL Alarm depends on process variable

• ALARM Always power up in alarm regardless of

process variable

• DELAYED Must leave alarm condition and reenter before

activating the alarm

20. MESSAGE:2

A 9-character message associated with alarm 2. To enter message: The first character of third display will be flashing. Press the through the character set. Press FAST key to advance to subsequent characters. Press MENU to advance to next parameter.

D ALARM 2.

▲▲

▲ and

▲▲

▼▼

▼ keys to scroll

▼▼

Controller Set Up

A CK.:2

ENABLED

POWER UP:2

NORMAL

MESSAGE:2

ALARM 2

21. FAULT

Defines whether either of the alarm relays will trip if a fault condition (lost process variable) is detected. Only appears if at least one alarm relay is installed.

D OFF

• ALARM 1

• ALARM 2

22. OUTPUT

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

• P.V. BREAK

D NO ACTION

23. RATE TIME

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

R 1 to 3600 seconds D 5 seconds

FAULT

OFF

OUTPUT

NO A CTION

RATE TIME

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

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Controller Set Up

REM. SETPT .

RSP . TYPE

1-5 4-20

RSP:LO RNG.

RSP:HI RNG.

1000

RSP:LO W

(D)

RSP:HIGH

(D)

TRACKING

BIAS LOW

-1000

BIAS HIGH

1000

REM. SETPT .

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

1. TYPE V/mA

Specifies the type of input signal that will be used for remote setpoint. D 1-5 /4-20 1–5 volt or 4–20 mA remote setpoint

• 0-5/0-20 0–5 volt or 0–20 mA remote setpoint

2. RSP:LO RNG.

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

R -9999 to 99999 D 0

3. RSP:HI RNG.

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

R –9999 to 99999 D 1000

4. RSP: LOW

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

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

5. RSP: HIGH

Defines the highest setpoint value from a remote setpoint source.

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

6. TRACKING

Defines whether the local setpoints 1 to 8 will track the remote setpoint. D NO

• YES

7. BIAS LOW

Defines the lowest bias value that may be entered.

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

8. BIAS HIGH

Defines the highest bias value that may be entered.

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

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

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9. RSP FIXED

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

• REMOTE SP Returns to remote setpoint when it is restored

D LOCAL Local setpoint remains active when RSP is

restored

RETRANS.

Controller Set Up

RSP: FIXED

LOCAL

RETRANS.

1. TYPE:2

Defines what is to be retransmitted for output 2 D PV This refers to the linearized process variable

• SETPOINT This is the target setpoint

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

setpoint is ramping

• CTRL. OUT This is the control output value

2. LOW RANGE:2

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

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

3. HI RANGE:2

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

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

4. TYPE:3

Defines what is to be retransmitted for output 3 D PV This refers to the linearized process variable

• SETPOINT This is the target setpoint

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

setpoint is ramping

• CTRL. OUT This is the control output value

TYPE:2

LO RANGE:2

(D)

HI RANGE:2

(D)

TYPE:3

5. LOW RANGE:3

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

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

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

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▲ ▼

LO RANGE:3

(D)

MENU DISPLAYFAST

Controller Set Up

HI RANGE:3

(D)

TYPE:4

6. HI RANGE:3

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

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

7. TYPE:4

Defines what is to be retransmitted for output 4 D PV This refers to the linearized process variable

• SETPOINT This is the target setpoint

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

• CTRL. OUT This is the control output value

LO RANGE:4

(D)

HI RANGE:4

(D)

SELF TUNE

TYPE

DISABLED

PRETUNE

TYPE 1

8. LOW RANGE:4

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

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

9. HI RANGE:4

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

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

SELF TUNE

1. TYPE

Defines the type of self tuning algorithm that is available.

• PRETUNE Allows the operator to initiate Pretune only

• ADAPTIVE Allows the operator to initiate Adaptive Tune only

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

D DISABLED Both Pretune and Adaptive Tune are disabled

2. PRETUNE

Defines the type of pretune algorithm that is available. D TYPE 1 Normally used with slower thermal processes

• TYPE 2 Normally used with faster fluid or pressure processes

• TYPE 3 Normally used with level control applications

3. TUNE PT.

TUNE PT .

AUTOMATIC

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

FAST MENU

48 Chapter 5 535 User's Manual

DISPLAY

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

R Any value in PV input range D AUTOMATIC (Controller defines this point, low end for Automatic)

MENU MENU

▲ ▼

MENU DISPLAYFAST

4. OUT. STEP

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

R –50% to 50.0% D 10.0%

5. LOW LIMIT

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

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

6. HI LIMIT

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

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

Controller Set Up

OUT.STEP

10.0

LO W LIMIT

(D)

HI LIMIT

(D)

7. TIMEOUT

This defines the execution time limit for pretune before aborting.

R 8 to 1500 minutes D 1500 minutes

8. MODE

Defines the control mode after pretune is completed or aborted.

• MANUAL

D AUTOMATIC

9. NOISE BND.

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

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

10. RESP. TIME

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

R 10 to 32000 seconds D 7200 seconds

11. DEAD TIME

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

R 0.1 seconds to 7200.0 seconds D 0.1 seconds

TIMEOUT

1500

MODE

A UTOMATIC

NOISE BND.

0.2

RESP. TIME

DEAD TIME

0.1

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

FAST MENU

535 User's Manual Chapter 5 49

DISPLAY

MENU MENU

▲ ▼

MENU DISPLAYFAST

Controller Set Up

SPECIAL

AUTO. TRIP

OFF

TRIP DEV .

(D)

DES. OUTPT .

(D)

SPECIAL

1. AUTO. TRIP

Defines the condition under which the 535 will automatically trip to automatic control from manual control upon start up.

D OFF Deactivates this function

• RISING PV Will trip when a rising process variable is within

the specified deviation from the setpoint

• FALLNG. PV Will trip when a falling process variable is within

the specified deviation from the setpoint

2. TRIP DEV.

Defines the deviation from setpoint at which the controller will trip to automatic. For AUTO. TRIP = RISING PV For AUTO. TRIP = FALLING PV

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

3. DES. OUTPT.

If a digital input is defined to trip the controller to manual mode, this designates the output value after the trip. LAST OUT means that the output value will be equal to the last output value while in automatic. Choose values based on the process.

Standard Control On/Off Control Velocity Prop Control

• –5 to 105% • ON • CW

D LAST OUT D OFF • CCW

D OUTS. OFF

4. POWER UP

PO WER UP

LAST MODE

Defines the control mode upon power up. D LAST MODE Will power up in the same mode prior to power

down

• PRETUNE Will Pretune on every power up.

(Recommended for TYPE 1 pretune only.)

• MANUAL

• AUTOMATIC

5. PWR. UP:OUT.

PWR.UP:OUT.

(D)

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

FAST MENU

DISPLAY

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

Standard Control On/Off Control Velocity Prop Control

• –5 to 105% • ON • CW

D LAST OUT D OFF • CCW

D OUTS. OFF

MENU MENU

▲ ▼

MENU DISPLAYFAST

50 Chapter 5 535 User's Manual

6. PWR. UP:SP

Defines the setpoint upon power up. D LAST SP Powers up with the same setpoint (local or

remote) that was active prior to power down

• LOCAL Powers up using primary local setpoint

• REMOTE Powers up using remote setpoint, if available

7. NO. OF SP

Defines the number of local setpoints (up to 8) to be stored for selection by BCD (binary coded decimal), digital inputs, or front SET PT key.

R 1 through 8 D 1

SECURITY

Controller Set Up

PWR. UP:SP

LAST SP

NO. OF SP

SECURITY

For configuring the security function.

1. SEC. CODE

Defines the security code temporarily unlocking the instrument.

R –9999 to 99999 D 0

2. SP ADJUST

Defines lockout status setpoint changes. D UNLOCKED

• LOCKED

3. AUTO./MAN.

Defines lockout status of the MANUAL key. D UNLOCKED

• LOCKED

4. SP SELECT

Defines lockout status of the SET PT key. D UNLOCKED

• LOCKED

5. ALARM ACK.

Defines lockout status of the ACK key. D UNLOCKED

• LOCKED

SEC. CODE

SP ADJUST

UNLOCKED

A UTO./MAN.

UNLOCKED

SP SELECT

UNLOCKED

ALARM ACK

UNLOCKED

6. TUNING

Defines lockout status of the tuning parameters. D UNLOCKED

• LOCKED

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

FAST MENU

535 User's Manual Chapter 5 51

DISPLAY

MENU MENU

▲ ▼

TUNING

UNLOCKED

MENU DISPLAYFAST

Controller Set Up

CONFIGURE

UNLOCKED

7. CONFIGURE

Defines lockout status of the configuration parameters. D UNLOCKED

• LOCKED

SER. COMM.

STATION

BA UD RA TE

9600

CRC

YES

SHED TIME

OFF

SER. COMM.

1. STATION

Defines the unit’s station address. R 1 to 99

• OFF Disables the communications function

D 1

2. BAUD RATE

Defines the baud rate.

• 1200 BPS

• 2400 BPS

• 4800 BPS

D 9600 BPS

• 19200 BPS

3. CRC

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

•NO

4. SHED TIME

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

R 1 to 512 seconds D OFF

5. SHED MODE

SHED MODE

LAST MODE

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

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

before losing communications)

• MANUAL Trip to manual control

• AUTOMATIC Trip to automatic control

6. SHED OUT.

SHED OUT .

(D)

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

FAST MENU

52 Chapter 5 535 User's Manual

DISPLAY

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

Standard Control On/Off Control Velocity Prop Control

• –5 to 105% • ON • CW

D LAST OUT D OFF • CCW

D OUTS. OFF

MENU MENU

▲ ▼

MENU DISPLAYFAST

7. SHED SP

Defines the setpoint status if communications is lost. D LAST SP Continues to use setpoint that was active prior

to losing communications

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

Controller Set Up

SHED SP

LAST SP

8. DESIG. SP

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

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

DESIG. SP

(D)

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

FAST MENU

535 User's Manual Chapter 5 53

DISPLAY

MENU MENU

▲ ▼

MENU DISPLAYFAST

Controller Set Up

PARAMETER VALUE CHARTS

This section of value charts is provided for logging in the actual parameter values and selections for the process. It is recommended that these pages be photocopied so there will always be a master.

CONFIG

Parameter Description Values

1. CTRL. TYPE Defines fundamental controller Set Up 2 LINE FREQ. Defines the power source frequency 3 PV SOURCE Defines how PV input is derived from PV1 and PV2 4 REM. SETPT. Selects function of the remote setpoint 5 OUTPUT 2 Function of the second output 6 OUTPUT 3 Function of the third output 7 OUTPUT 4 Function of the fourth output 8 ANLG.RNG.:1 Output signal for the first output 9 ANLG.RNG.:2 Output signal for the second output 10 ANLG.RNG.:3 Output signal for the third output 11 ANLG.RNG.:4 Output signal for the fourth output 12 CONTACT 1 Operation of the first digital input 13 CONTACT 2 Operation of the second digital input 14 CONTACT 3 Operation of the third digital input 15 CONTACT 4 Operation of the fourth digital input 16 CONTACT 5 Operation of the fifth digital input 17 LOOP NAME Nine character message associated with control loop

54 Chapter 5 535 User's Manual

PV1 INPUT

Parameter Description Value

1 PV1 TYPE PV1 sensor or range to be used 2 DEG. F/C/K PV1 temperature engineering unit 3 DECIMAL PV1 decimal point position 4 LINEARIZE Type of PV1 input linearization 5 LOW RANGE Engineering unit value for lowest PV1 input value 6 HI RANGE Engineering unit value for highest PV1 input value 7 SP LO LIM. Lowest setpoint value that can be entered 8 SP HI LIM. Highest setpoint value that can be entered 9 SP RAMP Rate of change for setpoint changes 10 FILTER Setting for the low pass PV1 input filter (in seconds)

Controller Set Up

11 OFFSET Offset to PV1 in engineering units 12 GAIN Gain to PV1 13 RESTORE Control mode when a broken PV1 is restored

PV2 INPUT

Parameter Description Value

1 PV2 SETUP 2 PV2 TYPE PV2 sensor or range to be used 3 DECIMAL PV2 decimal point position 4 LINEARIZE Type of PV2 input linearization 5 LOW RANGE Engineering unit value for lowest PV2 input value 6 HI RANGE Engineering unit value for highest PV2 input value 7 FILTER Setting for the low pass PV2 input filter (in seconds) 8 OFFSET Offset to the PV2 in engineering units 9 GAIN Gain to PV2

Makes PV2 input parameters match PV1, or user definable.

10 RESTORE Control mode when a broken PV2 is restored

535 User's Manual Chapter 5 55

Controller Set Up

ALARMS

Parameter Description Value

1 ALM. TYPE:1 Type of alarm for alarm 1 2 ALM. SRC.:1 Source of value monitored by HIGH, LOW or HIGH/LOW

alarm 1 3 ALARM SP:1 Alarm setpoint for alarm 1 (except for HIGH/LOW) 4A HIGH SP:1 High alarm setpoint for HIGH/LOW alarm 1 4A LOW SP:1 Low alarm setpoint for HIGH/LOW alarm 1 5 DEADBAND:1 Deadband for alarm 1 6 ALM.:1 OUT. Output number for alarm 1 7 LATCHING:1 Latching sequence for alarm 1 8 ACK.:1 Whether alarm 1 may be acknowledged 9 POWER UP:1 How alarm 1 will be treated upon power up 10 MESSAGE:1 Nine character message associated with alarm 1 11 ALM. TYPE:2 Type of alarm for alarm 2 12 ALM. SRC.:2 Source of value monitored by HIGH, LOW or HIGH/LOW

alarm 2 13 ALARM SP:2 Alarm setpoint for alarm 2 (except for HIGH/LOW) 14A HIGH SP:2 High alarm setpoint for HIGH/LOW alarm 2 14B LOW SP:2 Low alarm setpoint for HIGH/LOW alarm 2 15 DEADBAND :2 Deadband for alarm 2 16 ALM.:2 OUT. Output number for alarm 2 17 LATCHING :2 Latching sequence for alarm 2 18 ACK.:2 Whether alarm 2 may be acknowledged 19 POWER UP:2 How alarm 2 will be treated upon power up 20 MESSAGE:2 Nine character message associated with alarm 2 21 FAULT Alarm relay status if fault condition is detected 22 OUTPUT Output if the rate-of-change alarm is tripped 23 RATE TIME Time period over which a rate-of-change alarm is

determined

56 Chapter 5 535 User's Manual

CUST . LINR.

Parameter Description Value

1 1st INPUT Input signal for the 1st point (of the 15 point curve) 2 1st PV Engineering unit value for the 1st point 3 Xth INPUT Input signal for the Xth Point (of the 15 point curve) 4 Xth PV Engineering unit value for the Xth point 5 2nd INPUT Input signal for the 2nd point (of the 15 point curve) 6 2nd PV Engineering unit value for the 2nd point 7 3rd INPUT Input signal for the 3rd point (of the 15 point curve) 8 3rd PV Engineering unit value for the 3rd point 9 4th INPUT Input signal for the 4th point (of the 15 point curve) 10 4th PV Engineering unit value for the 4th point

Controller Set Up

11 5th INPUT Input signal for the 5th point (of the 15 point curve) 12 5th PV Engineering unit value for the 5th point 13 6th INPUT Input signal for the 6th point (of the 15 point curve) 14 6th PV Engineering unit value for the 6th point 15 7th INPUT Input signal for the 7th point (of the 15 point curve) 16 7th PV Engineering unit value for the 7th point 17 8th INPUT Input signal for the 8th point (of the 15 point curve) 18 8th PV Engineering unit value for the 8th point 19 9th INPUT Input signal for the 9th point (of the 15 point curve) 20 9th PV Engineering unit value for the 9th point 21 10th INPUT Input signal for the 10th point (of the 15 point curve) 22 10th PV Engineering unit value for the 10th point 23 11th INPUT Input signal for the 11th point (of the 15 point curve) 24 11th PV Engineering unit value for the 11th point 25 12th INPUT Input signal for the 12th point (of the 15 point curve) 26 12th PV Engineering unit value for the 12th point 27 13th INPUT Input signal for the 13th point (of the 15 point curve) 28 13th PV Engineering unit value for the 13th point 29 14th INPUT Input signal for the 14th point (of the 15 point curve) 30 14th PV Engineering unit value for the 14th point 31 15th INPUT Input signal for the15th point (of the 15 point curve) 32 15th PV Engineering unit value for the 15th point

535 User's Manual Chapter 5 57

Controller Set Up

CONTROL

Parameter Description Value

1 ALGORITHM Control algorithm used 2 D. SOURCE Variable used to determine the derivative value 3 ACTION:1 Action of the first control output 4 PV BREAK Output level if the process variable input is lost 5 LOW OUT. Lowest output value that can be achieved in automatic control 6 HIGH OUT. Highest output value that can be achieved in automatic control 7 ACTION:2 Action of the second control output 8 P.P. TYPE Type of position proportioning algorithm 9 CCW TIME Time it takes a motor to fully stroke in the CCW direction 10 CW TIME Time it takes a motor to fully stroke in the CW direction 11 MIN. TIME Minimum time for the motor to be on before taking action 12 S/W RANGE Full range resistance of the slidewire 13 OPEN F/B Feedback ohm value when the valve is open 14 CLOSE F/B Feedback ohm value when the valve is closed 15 OUT1 STOP Stopping point for control output 1 when staging outputs 16 OUT2 STRT Starting point for control output 2 when staging outputs

58 Chapter 5 535 User's Manual

ALARMS

Parameter Description Value

1 ALM. TYPE:1 Type of alarm for alarm 1 2 ALM. SRC.:1 Source of value being monitored by HIGH or LOW

alarm 1 3 ALARM SP:1 Alarm setpoint alarm 1 4 DEADBAND:1 Dead band for alarm 1 5 ALM.:1 OUT. Output number for alarm 1 6 LATCHING:1 Latching sequence for alarm 1 7 ACK.:1 Whether alarm 1 may be acknowledged 8 POWER UP:1 How alarm 1 will be treated upon power up 9 MESSAGE:1 Nine character mesage associated with alarm 1

Controller Set Up

10 ALM. TYPE:2 Type of alarm for alarm 2 11 ALM. SRC.:2 Source of value being monitored by HIGH or LOW

alarm 2 12 ALARM SP:2 Alarm setpoint for alarm 2 13 DEADBAND :2 Dead band for alarm 2 14 ALM.:2 OUT. Output number for alarm 2 15 LATCHING :2 Latching sequence for alarm 2 16 ACK.:2 Whether alarm 2 may be acknowledged 17 POWER UP:2 How alarm 2 will be treated upon power up 18 MESSAGE:2 Nine character message associated with alarm 2 19 FAULT Alarm status if a fault condition is detected 20 OUTPUT Output if the rate-of-change alarm is tripped 21 RATE TIME Time period over which a rate-of-change will be

determined

535 User's Manual Chapter 5 59

Controller Set Up

REM. SETPT.

Parameter Description Values

1 TYPE V/mA Input signal to be used for remote setpoint 2 RSP: LO RNG. Eng. unit value for low remote setpoint input value 3 RSP: HI RNG. Eng. unit value for high remote setpoint input value 4 RSP: LOW Lowest accepted setpoint value from remote setpoint

source

5 RSP: HIGH Highest accepted setpoint value from remote setpoint

source 6 TRACKING Whether the local setpoint will track the remote setpoint 7 BIAS LOW Lowest bias value that may be entered 8 BIAS HIGH Highest bias value that may be entered 9 RSP FIXED Status upon restoration of lost remote setpoint

RETRANS.

Parameter Description Values

1 TYPE:2 What is to be retransmitted for retransmission output 2 2 LOW RANGE:2 Low end of range in eng. units for retransmission output 2 3 HI RANGE:2 High end of range in eng. units for retransmission output 2 4 TYPE:3 What is to be retransmitted for retransmission output 3 5 LOW RANGE:3 Low end of range in eng. units for retransmission output 3 6 HI RANGE:3 High end of range in engl units for retransmission output 3 7 TYPE:4 What is to be retransmitted for retransmission output 4 8 LOW RANGE:4 Low end of range in eng. units for retransmission output 4 9 HI RANGE:4 High end of range in eng. units for retransmission output 4

60 Chapter 5 535 User's Manual

SELF TUNE

Parameter Description Value

1 TYPE Type of self tuning algorithm that is available 2 PRETUNE Output step size in absolute percent 3 TUNE PT. TYPE 1: Defines the PV value at which the output

switches off 4 OUT. STEP TYPE 2 & 3: Defines output step size in absolute percent 5 LOW LIMIT Lower limit PV can reach during Pretune before aborting 6 HI LIMIT Upper limit PV can reach during Pretune before aborting 7 TIMEOUT Execution time limit for Pretune before aborting 8 MODE Control mode after Pretune is completed or aborted 9 NOISE BND. Noise band to be used by adaptive tuning algorithm

Controller Set Up

10 RESP. TIME Response time to be used by adaptive tune 11 DEAD TIME Time required to wait before responding to output change

SPECIAL

Parameter Description Value

1 AUTO. TRIP How controller automatically trips to auto control for

manual 2 TRIP DEV. Deviation from setpoint at which controller will trip to auto 3 DES. OUTPT. Output value on a trip to manual 4 POWER UP Control mode upon power up 5 PWR. UP:OUT. Output of the controller is powering up in manual control 6 PWR. UP: SP Setpoint upon power up 7 NO. OF SP #of setpoints stored for selection by digital input or SET

PT key

535 User's Manual Chapter 5 61

Controller Set Up

SECURITY

Parameter Description Values

1 SEC. CODE Security code for temporarily unlocking the instrument 2 SP ADJUST Lockout status for setpoint changes 3 AUTO./MAN. Lockout status of the MANUAL key 4 SP SELECT Lockout status of the SET PT key 5 ALARM ACK. Lockout status of the ACK key 6 TUNING Lockout status for adjustment of tuning parameters 7 CONFIGURE Lockout status for Set Up parameters

SER COMM.

Parameter Description Values

1 STATION The unit’s station address 2 BAUD RATE Baud rate 3 CRC Whether CRC is being calculated 4 SHED TIME Time between communications before controller sheds 5 SHED MODE State of the controller if communications is lost (sheds) 6 SHED OUT. Output if the unit sheds 7 SHED SP Setpoint status if communications is lost 8 DESIG. SP Value of the setpoint if controller sheds

62 Chapter 5 535 User's Manual

CHAPTER 6 TUNING

OVERVIEW

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

TYPE 1 - for slow thermal processes. TYPE 2 - for fast fluid or pressure processes.

TYPE 3 - for level control applications. You choose the type of Pretune in the SELF TUNE menu. The Pretune and Adaptive Tune components may be used separately or

together. On the following pages is the step by step guide to the TUNING menu

parameters.

Tuning

NOTE:

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

to return to

OPERATION

mode

OPERATION

Either Manual or

Automatic Control

for SET

UP mode

for TUNING mode

for OPERATION mode

SET UP

…

SELF TUNE

…

TUNING

+ for SET UP mode

Figure 6.1 Access the Tuning Menu Block

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

FAST MENU

535 User's Manual Chapter 6 63

DISPLAY

MENU MENU

▲ ▼

MENU DISPLAYFAST

Tuning

TUNING

AD APTIVE

DISABLED

PRETUNE

POWR. BACK

DISABLED

PROP. BND.:1

50.0

RESET:1

RATE:1

TUNING

1. ADAPTIVE

Activates the self tune algorithm (upon transfer to automatic control). D DISABLED

• ENABLED

2. PRETUNE

Activates the pretune algorithm (if unit is under manual control).

▲▲

To initiate the Pretune cycle, press the within two seconds.

D NO

3. POWR. BACK

Reduces setpoint overshoot at power up or after setpoint changes. D DISABLED

• ENABLED

4. PROP. BND.:1

Defines the proportional band for PID set 1.

R 0.1 to 999.0% D 50.0%

5. RESET:1

Defines the integral time for PID set 1.

R 1 to 9999 seconds D 20 seconds

6. RATE:1

Defines the derivative time for PID set 1.

R 0 to 600 seconds D 1 second

▼▼

▲ or

▼. Confirm by pressing ACK

▲▲

▼▼

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

Defines the manual reset for PID set 1. If using automatic reset, then this

MAN. RST .:1

CYCLE TM.:1

15.0

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

FAST MENU

64 Chapter 6 535 User's Manual

DISPLAY

specifies the load line out value.

R 0 to 100% D 0%

8. CYCLE TM.:1

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

R 0.3 to 120.0 seconds D 15.0 seconds

MENU MENU

▲ ▼

MENU DISPLAYFAST

9. DEADBAND:1

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

R 1 to 99999 in engineering units D 2

10. P. PROP. D.B.

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

R 0.5 to 10.0% D 2.0%

11. A. PID OFST.:1

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

R –50.0% to 50.0% D 0.0%

Tuning

DEADBAND:1

P.PROP.D.B.

2.0

PID OFST .:1

11B. ON OFST.:1

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

R -9999 to 99999 in engineering units D 0

12A. PID OFST.:2

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

R –50.0% to 50.0% D 0.0%

12B. ON OFST.:2

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

R -9999 to 99999 in engineering units D 0

13. REL. GAIN:2

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

R 0.1 to 10.0 D 1.0

14. CYCLE TM.:2

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

R 0.3 to 120.0 seconds. D 15.0 seconds

ON/OFST.:1

PID OFST .:2

ON/OFST.:2

REL. GAIN:2

1.0

CYCLE TM.:2

15.0

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

FAST MENU

535 User's Manual Chapter 6 65

DISPLAY

MENU MENU

▲ ▼

MENU DISPLAYFAST

Tuning

DEADBAND:2

RSP RA TIO

1.00

RSP BIAS

(D)

NO. OF PID

PID TRIP

SP VALUE

15. DEADBAND:2

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

R 1 to 99999 in engineering units D 2

16. RSP RATIO

Defines the multiplier applied to the remote set point.

R -99.99 to 99.99 D 1.00

17. RSP BIAS

Defines the bias (additive term) applied to the remote set point. R Any value in engineering units (minimum is BIAS LOW; maximum is

BIAS HIGH)

D Dependent on the BIAS LOW and BIAS HIGH values

18. NO. OF PID

Defines the number of PID sets that will be stored and available for use. R 1 to 8 For numbers>1, PID TRIP defines tripping between

the PID sets

• SP NUMBER Number of PID sets = number of local setpoints (specified in NO. OF SP). Each PID set has a respective SP NUMBER.

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

D 1

19. PID TRIP

For NO. OF PID > 1, defines the variable used to select the various PID sets.

• PV VALUE PID set selection based on process variable

D SP VALUE PID set selection based on setpoint

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

TRIP:1

(D)

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

FAST MENU

66 Chapter 6 535 User's Manual

DISPLAY

20. TRIP:1

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

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

FOR EACH SET OF PID 2 THROUGH 8, you need to set up the following

group of parameters (X represents the PID set number). Set up the parameters as they appear for each set of PID. The controller designates the

values for the active PID parameter in the third display with an “*” on either side.

MENU MENU

▲ ▼

MENU DISPLAYFAST

21. PROP. BND.:X

Defines the proportional band for PID set X.

R 0.1 to 999.0% D 50.0%

22. RESET:X

Defines the integral time for PID set X.

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

23. RATE:X

Defines the derivative time for PID set X.

R 0 to 600 seconds D 1 seconds

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

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

R 0 to 100% D 0%

Tuning

PROP.BND.:X

(D)

RESET:X

(D)

RATE:X

MAN.RST.:X

25. TRIP:X

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

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

TRIP:X

(D)

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

FAST MENU

535 User's Manual Chapter 6 67

DISPLAY

MENU MENU

▲ ▼

MENU DISPLAYFAST

Tuning

TUNING

Parameter Definition Values

1. ADAPTIVE Activates the self tune algorithm.

2. PRETUNE Activates the pretune algorithm.

3. POWR. BACK Reduces setpoint overshoot.

4. PROP. BND.:1 Defines the proportional band for PID set 1.

5. RESET:1 Defines the integral time for PID set 1.

6. RATE:1 Defines the derivative time for PID set 1.

7. MAN. RST.:1 Defines the manual reset for PID set 1.

8. CYCLE TM.:1 Defines the cycle time for control output 1.

9. DEADBAND:1 Defines the dead band for control output 1.

10.P. PROP. D.B. Defines the dead band setting for a slidewire output. 11A. PID OFST.:1 For duplex applications, defines the offset for the first output. 11B. ON OFST.:1 For On/Off applications, defines the offset for the first output. 12A. PID OFST.:2 For duplex applications, defines the offset for the 2nd output. 12B. ON OFST.:2 For On/Off applications, defines the offset for the 2nd output.

13.REL. GAIN:2 Defines the adjustment factor for the output 2 prop. band.

14.CYCLE TM.:2 Defines the cycle time for control output 2.

15.DEADBAND:2 Defines the dead band for control output 2.

16.RSP RATIO Defines the multiplier applied to the remote set point.

17.RSP BIAS Defines the bias (additive term) applied to the remote set point.

18.NO. OF PID Defines the number of stored and available PID sets.

19.PID TRIP Defines the variable used to select the various PID sets.

20.TRIP:1 Defines the value that triggers a change to primary PID set.

21.PROP. BND.:2 Defines the proportional band for PID set 2.

22.RESET:2 Defines the integral time for PID set 2.

23.RATE:2 Defines the derivative time for PID set 2.

24.MAN. RST.:2 Defines the manual reset (or load line) for PID set 2.

25.TRIP:2 Defines the value that triggers a change to the 2nd PID set.

26.PROP. BND.:3 Defines the proportional band for PID set 3.

27.RESET:3 Defines the integral time for PID set 3.

28.RATE:3 Defines the derivative time for PID set 3.

29.MAN. RST.:3 Defines the manual reset (or load line) for PID set 3.

68 Chapter 6 535 User's Manual

30.TRIP:3 Defines the value that triggers a change to the 3rd PID set.

31.PROP. BND.:4 Defines the proportional band for PID set 4.

32.RESET:4 Defines the integral time for PID set 4.

33.RATE:4 Defines the derivative time for PID set 4.

34.MAN. RST.:4 Defines the manual reset (or load line) for PID set 4.

35.TRIP:4 This defines the value that triggers a change to the 4th PID set.

36.PROP. BND.:5 Defines the proportional band for PID set 5.

37.RESET:5 Defines the integral time for PID set 5.

38.RATE:5 Defines the derivative time for PID set 5.

39.MAN. RST.:5 Defines the manual reset (or load line) for PID set 5.

40.TRIP:5 This defines the value that triggers a change to the 5th PID set.

41.PROP. BND.:6 Defines the proportional band for PID set 6.

Tuning

42.RESET:6 Defines the integral time for PID set 6.

43.RATE:6 Defines the derivative time for PID set 6.

44.MAN. RST.6 Defines the manual reset (or load line) for PID set 6.

45.TRIP:6 This defines the value that triggers a change to the 6th PID set.

46.PROP. BND.:7 Defines the proportional band for PID set 7.

47.RESET:7 Defines the integral time for PID set 7.

48.RATE:7 Defines the derivative time for PID set 7.

49.MAN. RST.:7 Defines the manual reset (or load line) for PID set 7.

50.TRIP:7 This defines the value that triggers a change to the 7th PID set.

51.PROP. BND.:8 Defines the proportional band for PID set 8.

52.RESET:8 Defines the integral time for PID set 8.

53.RATE:8 Defines the derivative time for PID set 8.

54.MAN. RST.:8 Defines the manual reset (or load line) for PID set 8.

55.TRIP:8 This defines the value that triggers a change to the 8th PID set.

535 User's Manual Chapter 6 69

Tuning

SELF TUNE MESSAGES AND TROUBLESHOOTING

Refer to Chapter 7 for more information on the Self Tune function of the 535 controller.

When the Pretune function terminates, one of the following messages will appear:

Message

COMPLETED

ABORTED LIMIT ERR.

TIME OUT

NOISE ERR.

INPUT ERR.

OUT. ERROR

DATA ERR. ZERO ERR. DEV. ERROR

RETRY

Pretune

Type

2, 3

1, 2, 3

2, 3

1, 2, 3

1, 2, 3 1, 2, 3 1, 2, 3 1, 2, 3

2,3 2,3

1, 2, 3

Conclusion/Problem

PRETUNE has generated initial PID and the Dead Time values.

PRETUNE has generated initial PID, Response Time, Noise Band and the Dead Time values.

User has aborted PRETUNE before completion. The Process Variable went beyond the HI LIMIT or LOW

LIMIT. The Process Variable went beyond the HI LIMIT or LOW

LIMIT. The initial Process Variable was near or beyond the HI

LIMIT or LOW LIMIT. TIMEOUT limit was reached before PRETUNE completed.

Too much PV noise was detected.

PV or Cold Junction break detected during PRETUNE.

PV HIGH or PV LOW detected during PRETUNE. SLIDEWIRE break detected during PRETUNE. REMOTE SP break detected during PRETUNE. The initial control output is outside the high and low limits

defined in the Control Menu. The PV moved too quickly to be Analyzed. One or more model parameters are calculated to be zero. The initial PV is too close to the TUNE PT.

The Process Variable went beyond the HI LIMIT or LOW LIMIT

Corrective Action

Change the HI LIMIT and LOW LIMIT, or the HIGH OUT and LOW OUT, and run PRETUNE again.

Change the HI LIMIT and LOW LIMIT, or the OUT.STEP size, and run PRETUNE again.

Change the manual output percentage, or the HI LIMIT and LOW LIMIT, and run PRETUNE again.

Set a longer TIMEOUT period and/or increase the OUT.STEP size, and run PRETUNE again.

Eliminate the noise source (if possible) or increase the OUT.STEP and run PRETUNE again.

Check the described conditions and make corrections or repairs.

Change the manual output percent and run PRETUNE again.

Increase the OUT.STEP size and run PRETUNE again. Increase the OUT.STEP size and run PRETUNE again. Move Tune PT. (or the set point if TUNE PT. is automatic)

farther from the process variable and run PRETUNE again. Check if any PID values are generated and if they are

acceptable. If not, eliminate noise sources (if possible) and run PRETUNE again.

If Pretune and Adaptive Tune do not generate optimal PID values for control, check the following menu entries:

Message

RESPONSE TIME

NOISE BAND

PRETUNE

Potential Problem

Adaptive Tune cannot run if RESPONSE TIME is inaccurate

Adaptive Tune cannot compensate for PV oscillation due to hysteresis of output device (e.g., a sticky valve).

Pretune does not develop optimum PID parameters.

Corrective Action

Run TYPE 2 or TYPE 3 Pretune to obtain the correct value, or enter it manually.

Set NOISE BAND large enough to prevent Adaptive Tune from acting on the oscillation. If oscillation is not acceptable, consider replacing valve.

Wrong Pretune TYPE selected. Refer to Chapter 7, the Section on Self Tune.

70 Chapter 6 535 User's Manual

CHAPTER 7 APPLICATIONS

The 535 controller provides a variety of user-programmable control features and capabilities. The following topics are included in this chapter:

Applications

NOTE: Controller capabilities depend

upon the specified hardware option.

A. Control Type......................................... 71

B. Alarms ................................................. 72

C. Duplex Control ...................................... 76

D. Slidewire Position Proportioning Control .. 81

E. Velocity Position Proportioning Control .... 82

F. Staged Outputs .................................... 83

G. Retransmission .................................... 83

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

I. Remote Setpoint................................... 86

J. Multiple Setpoints.................................. 87

K. Multiple Sets of PID Values .................... 87

L. Powerback........................................... 88

M. Self Tune—POWERTUNE® ................. 89

N. Ramp-to-Setpoint ................................. 94

O. Input Linearization................................. 95

P. L oa d L i n e ............................................. 97

A. CONTR OL TYPE Software Configuration

1. Go to the CONTROL menu.

2. For the parameter ALGORITHM, select the type of 535 control:

• ON-OFF “Crude” control similar to a household thermostat. Used primarily

on slow, stable processes where moderate deviation (cycling) around setpoint is tolerable. Only available with SSR, SSR Drive, and relay outputs.

•P Proportional only control. Provides much better control than on/off.

Used on processes that are less stable or require tighter control, but have few load variations and do not require a wide range of setpoints.

•PI Proportional plus integral control. In addition to proportional control,

it compensates for control errors due to wide range of setpoints or load requirements. The integral term works to eliminate offsets.

•PD Proportional plus derivative control. In addition to proportional con-

trol, it compensates for control errors due to fast load variations.

• PID Proportional plus integral plus derivative control. In addition to pro-

portional control, it compensates for changes in setpoint, load requirements and process variations.

• PID/ON-OFF Only available with Duplex control. First output uses the PID algo-

rithm, while second output uses on/off control.

3. For algorithms using the derivative function (D), choose the conditions for the derivative term:

Q. Security ............................................... 97

R. Reset Inhibition ..................................... 98

S. Process Variable Reading Correction ..... 98

T. Serial Communications ......................... 99

U. Cascade Control ................................. 100

V. Ratio Control ...................................... 10 3

535 User's Manual Chapter 7 71

Applications

NOTE: Specifying a variable other than the setpoint (SP) to HIGH ALARM and LOW ALARM allows for

greater flexibility in creating alarm and control strategies.

Scroll to parameter D. SOURCE

• For derivative action based on error, or deviation from setpoint, choose DEVIATION

• For derivative action based on process variable changes, choose PV.

B. ALARMS

The 535 controller has two extremely flexible and powerful software alarms. The number of available outputs limits how alarms are linked to relays. A Global Alarm feature allows all alarms to be assigned to the same relay.

The 535 indicates an alarm condition by:

• Lighting up the alarm icon(s)

• Displaying a custom message in the 3rd display

• Illuminating the ACK key (if the alarm is acknowledgeable)

Software Configuration

1. Access the ALARM menu.

2. Set values for the following parameters. All possible values are shown.

ALM.TYPE:1 and ALM. TYPE:2

Specifies the type of alarm to implement. Selection includes:

• HIGH ALARM High process variable alarm. Occurs when the process variable ex-

ceeds the alarm setpoint.

• LOW ALARM Low process variable alarm. Occurs when the process variable goes

below the alarm setpoint.

• HIGH/LOW Combination of high and low alarms. Occurs when the PV exceeds

the individually set high or low setpoint.

• BAND Creates a band centered around the control setpoint, that is twice

the alarm setpoint. Alarm occurs when the process variable travels outside of this band. The alarm is dependent on the control setpoint. As the control setpoint changes, the band adjusts accordingly.

For example, if the control setpoint is 500 and the alarm setpoint is 25, then the band extends from 475 to 525.

• DEVIATION Similar to the band alarm but creates a band only on one side of the

control setpoint. Alarm occurs when the process variable deviates from the control setpoint by an amount greater than the alarm setpoint. This alarm is dependent on the control setpoint; as the control setpoint changes, the alarm point changes.

For example, if the control setpoint is 500 and the alarm setpoint is +50, then an alarm occurs when the process variable exceeds 550. In order for an alarm to occur when the process variable drops below 450, select an alarm setpoint of –50.

72 Chapter 7 535 User's Manual

• MANUAL Alarm occurs when the controller is put into manual mode of opera-

tion. This may be useful for security purposes or to alert the operator that 535 is no longer under automatic control.

• RATE Alarm occurs when the process variable changes at a rate greater

than what is specified by the alarm setpoint and time base. This alarm helps to anticipate problems before the process variable can reach an undesirable level.

For example, if the alarm setpoint is 10 with a time base of 5 seconds, an alarm occurs whenever a change in process variable greater than 10 occurs in 5 seconds.

ALM.SRC.:1 and ALM.SRC.:2

For HIGH , LOW or HIGH/LOW alarms, specifies the variable (source) upon which a selected alarm is based. Selection includes:

•PV

• PV2

•SP

• RAMP SP

• DEVIATION

• OUTPUT

ALARM SP:1 and ALARM SP:2

Defines the point at which an alarm occurs. For a RATE (rate of change) alarm, it specifies the amount of change (per RATE TIME period) that must occur before the alarm activates. A negative value specifies a negative rate-of-change. Does not apply to HIGH/LOW alarms.

HIGH SP:1 and HIGH SP:2

For a HIGH/LOW alarm, defines the high setpoint at which an alarm occurs.

LOW SP:1 and LOW SP:2

For a HIGH/LOW alarm, defines the low setpoint at which an alarm occurs.

DEADBAND:1 and DEADBAND:2

Specifies the range through which the process variable must travel before leaving an alarm condition (see alarm examples at the end of this section). Prevents frequent alarm oscillation or “chattering” if the process variable has stabilized around the alarm point.

ALM.1 OUT and ALM.2 OUT

For any enabled alarm, selects the output number to which the selected alarm will be assigned. It is possible to assign both alarms to the same output relay, thus creating a “global” alarm application.

LATCHING:1 and LATCHING:2

A latching (YES) alarm will remain active after leaving the alarm condition unless it is acknowledged. A non-latching (NO) alarm will return to the non-alarm state when leaving the alarm condition without being acknowledged.

Applications

535 User's Manual Chapter 7 73

Applications

Alarm Parameters Reference For Alarm 1

Parameter Description ALM. TYPE:1 Type ALM. SRC.:1 Source ALARM SP:1 Setpoint HIGH SP:1 High setpoint LOW SP:1 Low setpoint DEADBAND:1 Deadband ALM.:1 OUT. Output number LATCHING:1 Latching sequence ACK.:1 Acknowledging POWER UP:1 Status on power up MESSAGE:1 Message

For Alarm 2

Parameter Description ALM. TYPE:2 Type ALM. SRC.:2 Source ALARM SP:2 Setpoint HIGH SP:2 High setpoint LOW SP:2 Low setpoint DEADBAND:2 Deadband ALM.:2 OUT. Output number LATCHING:2 Latching sequence ACK.:2 Acknowledging POWER UP:2 Status on power up MESSAGE:2 Message

For either alarm

(depending on choices) Parameter Description FAULT Fault assignment OUTPUT Output action for rate RATE TIME Time base for rate

ACK.:1 and ACK.:2

For any enabled alarm, enables or disables operator use of the ACK key to acknowledge an alarm at any time, even if the control process is still in the alarm condition.

A latching alarm can always be acknowledged when it is out of the alarm condition. When either alarm is available to be acknowledged, the ACK key will be illuminated. If both alarms are acknowledgeable, pressing ACK will first acknowledge alarm #1. Pressing ACK a second time will acknowledge alarm #2.

POWER UP:1 and POWER UP:2

For any enabled alarm, selects the alarm condition upon power up. Choices are:

• NORMAL Controller will power up in alarm only if it is in alarm condition.

• ALARM: Controller always powers up in alarm regardless of system’s alarm

condition. This is an excellent way to activate an alarm if there has been a power failure.

• DELAYED Controller will never power up in alarm, regardless of system’s alarm

condition. The system must leave and reenter the alarm condition before the alarm will activate. This is typically used to avoid alarms during start up.

MESSAGE:1 and MESSAGE:2

Allows user to specify a nine-character message to be displayed when the respective alarm is active. If both alarms are active or any other diagnostic message is present, the messages will alternate.

FAULT

Activates an alarm if the process variable signal is lost. Assign this function to either Alarm 1 or Alarm 2 (not both). This action is in addition to the selected alarm type (additive alarm function).

OUTPUT

For a RATE alarm, selects the output action. Use to obtain early indication of a possible break in the process variable signal. Select PV BREAK to have rate-of-change alarm take the same action as a detection of a break in the process variable signal (where it trips to manual control at a predetermined output).

RATE TIME

For RATE alarms, defines the time period over which a discrete change in process variable must occur for the rate alarm to be activated. The amount of change is defined by the alarm setpoint. The rate-of-change is defined as the amount of change divided by the time period.

Example A. If the alarm setpoint is set to 10 and the time base is set to 1 second,

the rate of change is 10 units per second.

B. If the alarm setpoint is set to 100 and the time base set to 10, the rate

of change is also 10 units per second.

74 Chapter 7 535 User's Manual

Applications

In example A, the process variable would only have to experience a ten unit change over a short period of time, while in Example B, it would require a 100 unit change over a ten second period. Example A is much more sensitive than Example B. In general, for a given rate-of-change, the shorter the time period, the more sensitive the rate alarm.

BAND ALARM HIGH PROCESS VARIABLE ALARM

Figure 7.1 Alarm Examples

IN ALARM

CONDITION

C.SP + A.SP

IN ALARM CONDITION

C.SP

RELAY ENERGIZED

ICON OFF NO ALARM CANNOT

RELAY DE-ENERGIZED

ICON ON CANNOT

ACKNOWLEDGE

RELAY ENERGIZED

ICON OFF NO ALARM

PARAMETER SETTINGS:

OUTPUT N = ALM.RLY:OFF (N = 2 to 4) ALM. TYPE:1 = BAND ALM.:1 OUT. = N (N= 2 to 4) LATCHING = NO LATCH ACK.:1 = DISABLED

TIME

RELAY DE-ENERGIZED

ICON ON

ACKNOWLEDGE

C.SP

- A.SP

RELAY DE-ENERGIZED

ICON OFF NO ALARM

PARAMETER SETTINGS:

OUTPUT N = ALM.RLY:ON (N = 2 to 4) ALM. TYPE:1 = HIGH ALRM. ALM.:1 OUT. = N (N = 2 to 4) LATCHING = NO LATCH ACK.:1 = ENABLED

DEVIATION ALARM POWER UP ALARM

IN ALARM

C.SP

CONDITION

A.SP

IN ALARM CONDITION

RELAY ENERGIZED

ICON ON

MAY ACKNOWLEDGE

TIME

RELAY DE-ENERGIZED

ICON OFF NO ALARM

A.SP

C.SP

TIME

+ A.SP

ALARM

UNIT POWER UP

RELAY ENERGIZED

ICON ON

MAY ACKNOWLEDGE

CONDITION

RELAY ENERGIZED

ICON ON CANNOT

ACKNOWLEDGE

PARAMETER SETTINGS:

OUTPUT N = ALM.RLY:ON (N = 2 to 4) ALM. TYPE:1 = HIGH ALM. ALM.:1 OUT. = N (N = 2 to 4) LATCHING:1 = LATCH ACK.:1 = DISABLED POWER UP:1 = ALARM

TIME

RELAY ENERGIZED

ICON ON

MAY ACKNOWLEDGE

RELAY DE-ENERGIZED

ICON OFF NO ALARM

RELAY ENERGIZED

ICON ON MAY

ACKNOWLEDGE

PARAMETER SETTINGS:

OUTPUT N = ALM.RLY:ON (N = 2 to 4) ALM. TYPE:1 = DEVIATION ALM.:1 OUT. = N (N = 2 to 4) LATCHING = LATCH ACK.:1 = ENABLED ALARM SP:1 = (<0)

MUST ACKNOWLEDGE TO SHUT OFF ICON AND DE-ENERGIZE RELAY

535 User's Manual Chapter 7 75

Applications

NOTE: The duplex output states vary

depending upon:

1. Control Type (PID, On/Off, etc.)

2. Control Action (DA, RA)

3. Output Limits

4. Output Gap or Overlay, and

5. Ouput 2 Relative Gain and PID% Output.

Please refer to the output state examples in this section to confirm that the configuration is appropriate for the process.

NOTE: Set manual reset/load line parameters to 50% when using Duplex control (MAN. RST.:X parameter is in the TUNING menu.)

C. DUPLEX CONTR OL

The Duplex control algorithm enables two discrete control outputs for the control loop. Duplex control is commonly used for applications that require both heating and cooling or when 2 control elements are needed to achieve the desired result.

Hard ware Configuration

• The controller must have two output modules assigned to the loop (any combination of output modules).

Software Configuration

1. Go to the CONFIG . menu. Set CTRL.TYPE to DUPLEX.

2. To use different algorithms for each output (PID for the first, and On/Off for the second):

Go to the CONTROL menu. Set ALGORITHM to PID:ON/OFF.

3. To make the control action for each output independent of the other: Go to the CONTROL menu. Set ACTION:1 or ACTION:2 to either DIRECT or REVERSE action based

on the diagrams in the output examples section (Figures 7.2 through 7.8).

4. Go to the TUNING menu. Set values for PID OFST:1 (or ON OFST:1) and PID OFST:2 (or ON

OFST:2). These parameters allow the user to independently offset the point at which output 1 and output 2 become active. PID OFSET units are in percent (%) of control output; ON OFST is in engineering units. The settings can be used to make sure there is a dead band, i.e., no controller output around setpoint. They can also be used to overlap output 1 and output 2 so that both are “on” in a small band around setpoint.

5. Set MAN. RESET (manual reset) term to 50%. This causes the PID output to be 50% when there is zero error. This term is still active as a “load line” setting when using automatic reset (integral), so set it to 50% whether using automatic reset or not.

6. REL. GAIN (relative gain) changes the gain of Output 2 relative to Output

1. Note that the relative gain can limit the maximum output available for Output 2 when using PID control.

7. Go to the CONTROL menu. Set LOW OUT. and HIGH OUT. to limit the maximum or minimum outputs

from Output 1 and Output 2. The actual limitation on the outputs is dependent on the offset settings, the relative gain setting and the control action.

Duplex Output State Examples

The following Duplex examples represent a variety of ways this function can be set up. PID control examples show the PID output percentage on the horizontal axis, and On/Off control examples show the process variable on the horizontal axis. The vertical axes are the output of each physical output. Most of these examples use the first output as heating and the second output as cooling.

When using PID control, the 535 controller actually displays the PID output. To relate this output to the actual physical output, locate the PID output on the

76 Chapter 7 535 User's Manual

horizontal axis. Draw a vertical line at that point. At the intersection of this vertical line and the respective output line, draw a horizontal line. The physical output is the value where this horizontal line intersects the respective axis.

The illustrations assumes a manual reset/load line term of 50%. Therefore, at zero error (process variable equals setpoint) the PID output is 50%.

Duplex with reverse and direct acting outputs

A reverse acting output 1 and a direct acting output 2 with: no offset, no restrictive outputs limits, and a neutral relative gain with PID control.

PARAMETER SETTINGS

ACTION:1 = REVERSE ACTION:2 = DIRECT PID OFST.:1 = 0 PID OFST.:2 = 0 LOW OUT = 0 HIGH OUT = 100 REL. GAIN = 1.0

100%

Out 1

Out 2

100%

Out 2

Applications

Figure 7.2 Duplex with Reverse and Direct Acting Outputs

50%100% 0%

PID OUTPUT

Duplex with direct and reverse acting outputs

A reverse acting output 1 and a direct acting output 2 with: no offset, no restrictive output limits, and a neutral relative gain with PID control.

PARAMETER SETTINGS

ACTION:1 = DIRECT ACTION:2 = REVERSE PID OFST.:1 = 0 PID OFST.:2 = 0 LOW OUT = 0 HIGH OUT = 100 REL. GAIN = 1.0

100%

Out 1 (Heat)

Out 1

Out 2

Out 1

50%100% 0%

PID OUTPUT

Out 2 (Cool)

100%

Out 2

Figure 7.3 Duplex with Direct and Reverse Acting Outputs

535 User's Manual Chapter 7 77

Applications

PID OUTPUT

100%

PARAMETER SETTINGS

ACTION:1 = REVERSE ACTION:2 = REVERSE PID OFST.:1 = 0 PID OFST.:2 = 0 LOW OUT = 0 HIGH OUT = 100 REL. GAIN = 1.0

100%

50%100% 0%

Out 1 (Heat)

Out 2 (Cool)

Out 2

Out 1

Figure 7.4 Duplex with Two Reverse Acting Outputs

Duplex with 2 reverse acting outputs

Two reverse acting outputs with: no offset, no restrictive output limits, and a neutral relative gain with PID control.

Figure 7.5 Duplex with a Gap Between Outputs

Duplex with a gap between outputs

A reverse acting output 1 and a direct acting output 2 react with: a positive offset for output 1 and a negative offset for output 2 (assume no restrictive output limits and a neutral relative gain with PID control).

On the graph, a positive offset refers to an offset to the left of 50%; a negative offset is to the right of 50%.

PARAMETER SETTINGS

ACTION:1 = REVERSE ACTION:2 = DIRECT PID OFST.:1 = + VALUE PID OFST.:2 = – VALUE LOW OUT = 0 HIGH OUT = 100 REL. GAIN = 1.0

Out 1 (Heat)

100%

Out 1

100% 0%

Offset 1

50%

PID OUTPUT

Out 2

Offset 2

Out 2 (Cool)

100%

78 Chapter 7 535 User's Manual

Duplex with overlapping outputs and output limits

A reverse acting output 1 and a direct acting output 2 with: a negative offset for output 1, a positive offset for output 2, and restrictive high and low output limits with PID control.

This combination of offsets results in an overlap where both outputs are active simultaneously when the PID output is around 50%.

The output limits are applied directly to the PID output. This in turn limits the actual output values. In this example, the high output maximum limits the maximum value for output 1, while the low output minimum limits the maximum value for output 2. The value the actual outputs are limited to depends on offset settings, control action and relative gain setting with PID control.

PARAMETER SETTINGS

ACTION:1 = REVERSE ACTION:2 = DIRECT PID OFST.:1 = – VALUE PID OFST.:2 = + VALUE LOW OUT = 10% HIGH OUT = 85% REL. GAIN = 1.0

100%

Out 1 (Heat)

Out 1

Out 2 (Cool)

100%

Out 2

Applications

Figure 7.6 Duplex with Overlapping Outputs and Output Limits

85%

50%100%

10%

PID OUTPUT

Duplex with various relative gain settings

A reverse acting output 1 and a direct acting output 2 with: various relative gain settings (assume no offset or restrictive outputs) with PID control.

PARAMETER SETTINGS

ACTION:1 = REVERSE ACTION:2 = DIRECT PID OFST.:1 = 0 PID OFST.:2 = 0 LOW OUT = 0 HIGH OUT = 100 REL. GAIN REL. GAIN REL. GAIN

❶ = 2.0 ❷ = 1.0 ❸ = 0.5

100%

Out 1 (Heat)

Out 1

❶

Out 2 (Cool)

100%

Out 2

50%

❷

❸

50%100% 0%

PID OUTPUT

25%

Figure 7.7 Duplex with Various Relative Gain Settings

535 User's Manual Chapter 7 79

Applications

Figure 7.8 Duplex with One ON/OFF Output

Notice that the relative gain setting does not affect output 1. In this example, a relative gain setting of 2.0 (curve 1) results in output 2 reaching its maximum value at a PID output of 25%. A relative gain setting of 1.0 results in output 2 reaching its maximum value at a PID output of 0%. A relative gain setting of 0.5 results in output 2 reaching a maximum of 50% at a PID output of 0%.

Duplex with one ON/OFF output

A reverse acting output 1 and a direct acting, on/off output 2 with a positive offset. Relative gain does not apply when using duplex with an on/off output. The

deadband setting for output 2 works the same as the deadband in single on/off control (the deadband effect for output 2 is not illustrated here).

PARAMETER SETTINGS

ACTION:1 = REVERSE ACTION:2 = DIRECT PID OFST.:1 = 0 ON OFST.:2 = + VALUE LOW OUT = 0 HIGH OUT = 100

100%

Out 1 (Heat)

Out 1

Out 2 (Cool)

Out 2

Figure 7.9 Duplex with Two ON/OFF Outputs

100%

50%

PID OUTPUT

Out 2 Offset from Setpoint in Engineering Units

OFF

Duplex with two ON/OFF outputs

A reverse acting on/off output 1 and a direct acting on/off output 2 with a negative offset for output 1 and a positive offset for output 2.

Note that here the horizontal axis is expressed in terms of process variable rather than PID output.

PARAMETER SETTINGS

ACTION:1 = REVERSE ACTION:2 = DIRECT ON OFST.:1 = – VALUE ON OFST.:2 = + VALUE

Out 1 (Heat)

Out 2 (Cool)

Out 1

Out 2

OFF

Low Range

Offset 1

PROCESS VARIABLE

Offset 2

OFF

High Range

80 Chapter 7 535 User's Manual

Applications

D. SLIDEWIRE POSITION PROPORTIONING CONTR OL

Slidewire position proportioning utilizes a slidewire feedback signal to determine the actual position of the actuator being controlled.

Hardware Configuration

• The controller must have the Slidewire Feedback option installed. Refer to the order code in Chapter 1 for more information.

• The controller must have mechanical relays, solid state relays or DC logic modules installed in the first two output sockets.

• The Slidewire does NOT have to be wired to the controller in order to set up position proportioning.

Software Configuration

1. To configure the controller before wiring the slidewire feedback signal to the controller, complete these steps:

a. Go to the CONTROL menu. b. Set a value for PV BREAK. c. Go to the SPECIAL menu. d. Set a value for DES. OUTPT. e. Set a value for PWR.UP:OUT. f. Go to SER. COMM. menu. g. Set a value for SHED OUT.

2. Place the controller under manual control.

3. Go to the CONFIG . menu.

4. Set CTRL. TYPE to POS. PROP (position proportioning).

5. Set P.P. TYPE to SLIDEWIRE.

6. Go to the CONTROL menu.

7. For S/W RANGE, specify the full range resistance of the slidewire from end- to-end. With a 100 ohm slidewire, this parameter should be set to 100.

8. Scroll to OPEN F/B (Open feedback). Enter the ohm value when the actua- tor is fully open (0 to 1050 ohms).

9. Scroll to CLOSE F/B (Closed feedback). Enter the ohm value when the actuator is fully closed (0 to 1050 ohms).

10.Measure the actual slidewire value at the terminals (10 and 11). As an alternative, set up these two parameters dynamically. Before enter-

ing Set Up set the manual output at 100%. Enter Set Up and change the OPEN F/B value until the actuator just reaches its full open position.

Exit Set Up and set the manual output to 0%. Enter configuration and change the CLOSE F/B value until the actuator just reaches its full closed position.

11.Set the parameter P. PROP. D.B., which is used to eliminate cycling of the motor. A low deadband setting may result in motor overspin or cycling. A high deadband will result in reduction of sensitivity. To set:

a. Go to the TUNING menu. b. Set P. PROP. D.B. to .5%. c. Place controller under Manual control. d. Change the output percentage and observe if the valve stabilizes at

the new value.

CAUTION!

The relay in socket 1 drives the motor counterclockwise and the relay in output socket 2 drives the motor clockwise.

This is important for:

• Wiring the outputs

• Selecting the control ACTION:1 parameter, or

• Determining the normally open or normally closed relays,

The configuration choices influence the way the position proportioning algorithm works.

NOTE: OPEN F/B and CLOSE F/B values are always reference to the CCW end of the Slidewire.

NOTE: P.PROP.D.B. can only be configured if the Slidewire Feedback is wired to the controller.

535 User's Manual Chapter 7 81

Applications

NOTE: Adaptive tuning is not available

with velocity position proportioning control.

e. If the valve oscillates, increase the P.PROP.D.B. value by 0.5%; re-

peat until oscillation stops.

12.Set the parameter S/W BREAK to define the output value for when the slidewire breaks.

E. VELOCITY POSITION PR OPORTIONING CONTROL

Velocity position proportioning does not utilize direct feedback. It estimates the position of the actuator, based on time and the speed of the actuator.

In automatic control mode, the controller will display “CW” to refer to energizing of the clockwise relay, and “CCW” to refer to energizing of the counterclockwise relay. A blank display means that both relays are de-energized.

In manual control mode, the display is blank unless an output change is being

▲▲

made. Use the while the keys are being pressed. The display indicates the percentage change in valve position in real time. The rate of change is dependent on the values entered for CCW TIME and CW TIME.

The controller will transfer to manual control due to a lost process variable (PV. BREAK), a digital input closure (DES.OUTPT.), a power-up sequence (PWR.UP:OUT.), or lost communications (SHED OUT). In these cases, the output can be set to: remain at its last value with both relays de-energized (OUTS OFF); rotate fully counterclockwise (CCW); or rotate fully clockwise (CW). CCW and CW will energize the respective relay for a period two times that of the CCW TIME or CW TIME.

▼▼

▲ and

▼ keys to change the output; the relay is only energized

▲▲

▼▼

Hard ware Configuration

• The controller must have mechanical relay, solid state relay or DC logic modules installed in the first two output sockets.

Refer to the section on Chapter 1 for more information.

Software Configuration

1. Go to CONFIG. menu. Set CTRL. TYPE to POS. PROP.

2. Go to the CONTROL menu. Set P.P. TYPE to VELOCITY.

3. Set CCW TIME to the amount of time (in seconds) it takes for the actuator to fully rotate in the counterclockwise direction.

Set CW TIME to the amount of time (in seconds) it takes for the actuator to fully rotate in the clockwise direction.

Loads on the valve may affect the time required, therefore, it is best to measure these values when the valve is in service. As an alternative, enter the values specified by the actuator manufacturer and then make adjustments later.

5. Set MIN. TIME to the minimum amount of time the controller must specify for the motor to be on before it takes any action.

6. Set values for PV. BREAK, DES. OUTPT., PWR.UP:OUT. and SHED OUT.

82 Chapter 7 535 User's Manual

F. ST A GED OUTPUTS

With staged outputs, one analog output can vary its signal (e.g., 4-20 mA) over a portion of the PID output range. The second analog output then varies its signal over another portion of the PID output range. This is an excellent method to stage two control valves or two pumps using standard control signal ranges.

20 mA

Output 1

4 mA

Output 2

100%50%33%0%

PID Outpu

Applications

Figure 7.10 Staged Outputs Example OUT1 STOP was set to 33% and OUT2 STRT. was set to 50%.

Hardware Configuration

• The controller must have analog output modules installed in the first two output sockets.

Software Configuration

1. Go to the CONFIG . menu. Set CTRL. TYPE to STAGED.

2. Go to the CONTROL menu.

3. For OUT1 STOP, specify where the first output reaches 100%.

4. For OUT2 START, specify where the second output begins.

G. RETRANSMISSION

The retransmission feature may be used to transmit a milliamp signal corresponding to the process variable, target setpoint, control output, or actual setpoint to another device. A common application is to use it to record one of these variables with a recorder.

Hardware Configuration

• There must be an analog module installed in output socket 2, 3 or 4.

Software Configuration

Up to two outputs can be configured for retransmission. The menu will scroll through the configuration parameters for specified value “X” (2, 3 or 4).

1. Go to the CONFIG. menu.

2. For OUTPUT:2, OUTPUT:3 and OUTPUT:4 parameters, set one or two of them to RETRANS.

3. Go to the RETRANS. menu.

4. Set the corresponding parameter, TYPE:X, for the first retransmission output to define what is being transmitted: the process variable, setpoint, ramping setpoint or output.

NOTE: For an analog output module for retransmission that was not factoryinstalled, calibrate the output for maximum accuracy. Refer to Appendix 4 for details on calibration.

535 User's Manual Chapter 7 83

Applications

5. Set parameters LOW RANGE:X and HIGH RANGE:X for the first retransmission output, to define the range of the transmitted signal in engineering units. This can be useful in matching the input range of the receiving device.

6. For any other retransmission output, continue to scroll through this menu and set the TYPE:X, LOW RANGE:X and HIGH RANGE:X for the second retransmission output.

H. DIGITAL INPUTS

Digital inputs can be activated in three ways: A switch (signal type)—the recommended type, a relay, or an open collector transistor.

Digital inputs are only functional when that option is installed (via hardware). The controller detects the hardware type, and supplies the appropriate software menus (see the section on parameters in Chatper 5). There are 14 contact types for the up to 5 digital inputs.

Hard ware Configuration

• This optional feature is only available if ordered originally from the factory, Product #535xxxxxxDx00. The (up to ) five digital inputs share a common ground.

NOTE: To take advantage of multiple setpoints, make sure that the SP NUMBER parameter in the SPECIAL menu is set to a value greater than 1.

Figure 7.11 Combinations of Closed Digital Inputs for Each Setpoint (based on BCD logic)

X=closed contact 0=open contact

Software Configuration

1. Go to the CONFIG. menu.

2. Set parameters CONTACT:1 through CONTACT:5 (only those available will shown) by assigning the desired function to each output. Choices are:

• SETPT 1-8 (For CONTACT:1 only) Allows the controller to use the first four digital

inputs to select a setpoint (see Figure 7.11). If the state of these inputs remains constant, the controller will continue to use the selected setpoint unless overridden. Override the set of digital inputs by selecting a different setpoint (by using SET PT key or through communications), or by using the fifth digital input to select the remote or 2nd setpoint. To “rearm” this set of digital inputs, the DIN combination must change.

Setpoints DIN 1 DIN 2 DIN 3 DIN 4

SP XO OO SP2 OX OO SP3 XX OO SP4 OO XO SP5 XO XO SP6 OX XO SP7 XX XO SP8 OO OX

• REM. SETPT. Closing input changes active setpoint to remote setpoint. Opening

reverts controller to previous setpoint. Override by selecting a different setpoint via the SET PT key, a communications command, or

84 Chapter 7 535 User's Manual

Applications

other digital inputs.

• MANUAL Closing input trips the controller to manual. Opening input reverts

controller to automatic. Override by using MANUAL key, a commu- nications command, or “trip to automatic” function.

• 2ND. SETPT. Closing input changes active setpoint to the 2nd local setpoint. Open-

ing input reverts controller to previous setpoint digital input. Override by selecting a different setpoint via the SET PT key, a communications command, or other digital inputs.

• 2ND. PID Closing input changes active set of PID values to 2nd set. Opening

input bases active set of PID on rules defined in PID TRIP and TRIP:1 to TRIP:8. Override input only by directly linking PID set to the active setpoint and changing the active setpoint.

• ALARM ACK. Closing input acknowledges all active alarms. Opening input “re-

arms” the controller. If the digital input remains closed, it does not continue to immediately acknowledge alarms as they become active.

• RST. INHBT. Reset Inhibition. Closing input deactivates “I” (integral) term, regard-

less of the PID values being used. Opening input activates “I” term (if applicable).

• D.A./R.A. Direct Acting/Reverse Acting. Closing input reverses action of the

first control output (from direct to reverse, or reverse to direct). Opening reinstates original action.

• STOP A/T Closing input temporarily disables Adaptive Tuning. Opening input

enables it.

• LOCK. MAN. Closing contact places the controller in manual control at the desig-

nated output percentage. All locked manual contacts must be opened in order to return controller to automatic control.

• UP KEY / DOWN KEY

▲▲

Closing the contact mimics the designated troller is mounted behind a window; contact push-buttons can be used to change setpoint values.

• DISP. KEY Closing contact mimics the DISPLAY key; scroll through display of

the Setpoint, Deviation % and Output%.

• FAST KEY Closing contact mimics the FAST key . Use in conjunction with

▼▼

▼, DISPLAY and MENU keys.

▼▼

• MENU KEY Closing contact mimics the MENU key. In OPERATION Mode, pro-

vides entry to TUNING menu. In SET UP or TUNING Mode, ad-

▼▼

▲ or

▼ key. Useful if con-

▲▲

▼▼

NOTE: The second display does not change when tripping to manual from a closed digital input.

NOTE: Only alarms configured to be acknowledged are affected by this digital input.

▲▲

▲,

▲▲

535 User's Manual Chapter 7 85

Applications

vances through the menus.

• COMM. ONLY Makes input status readable through communications (but has no

effect on the controller itself).

• PV2.SWITCH (only applicable for PV SOURCE = 1/2:SWITCH). Closing contact

causes the 535 to use PV2 as the PV input (instead of PV1).

NOTE: There is a one-second delay before a closed digital input takes action.

Basic Operating Procedures

1. If more than one digital input closes and their actions conflict, the last digital input that closed has priority.

For example, if one digital input closes and selects 2nd setpoint, and then another digital input closes and selects a remote setpoint, the remote setpoint takes precedence.

2. Any digital input can be overridden by: another digital input, a keyboard operation, or an automatic function. If a closed digital input is overridden, then it must be opened in order to be rearmed.

For example, if one digital input closes and selects the 2nd setpoint, and then a different setpoint is selected through the keyboard, the keyboard selection takes precedence.

I. REMO TE SETPOINT

Remote setpoint limits are the same as setpoint limits.

Hard ware Configuration

• The optional feature is available only if ordered originally from the factory, Product #535-xxxxxBxx00 or #535-xxxxxExx00). Refer to the order code in Chapter 1.

• Before configuring the software, make sure the corresponding jumper is set properly. Refer to Chapter 4 to check or change jumper positions.

Software Configuration

1. Go to the REM. SETPT. menu.

2. RSP TYPE defines the input signal range (e.g. 4-20 mA).

3. RSP:LO. RNG. and RSP: HI RNG. define the range of the remote setpoint in engineering units. The correct range will be dependent on the source of the remote setpoint signal.

4. RSP:LOW and RSP:HIGH set limits on the remote setpoint value in engineering units.

5. TRACKING determines whether or not the controller will revert to a local setpoint if the remote setpoint signal is lost. This prevents a process upset due to a sudden change in setpoint.

6. BIAS LOW and BIAS HIGH set limits on an operator entered bias value.

7. RSP FIXED determines the signal to which the controller will revert when a lost RSP is restored (fixed). Options are to stay in local or automatically return to remote setpoint.

8. To bias or ratio the remote setpoint value:

a. Go to the TUNING menu. b. Set RSP BIAS and RSP RATIO values.

86 Chapter 7 535 User's Manual

Basic Operating Procedures

After configuring the hardware and software, select the remote input by:

• pressing the SET PT key until RSP shows in the display

• using a digital input

J. MULTIPLE SETPOINTS

The 535 can store up to eight local setpoints and use a remote setpoint. One application of this feature is configuring the controller to restrict operators to discrete setpoint choices. The 535 can also store multiple sets of PID parameters (see next section).

Software Configuration

1. Go to the SPECIAL menu.

2. Set NO. OF SP to the number of local setpoints desired.

3. Use the SET PT key to scroll to each local setpoint and set it to the desired value with the ▲ or ▼ keys.

4. To link the PID sets to the corresponding local setpoint: Go to the TUNING menu. Set NO. OF PID to SP NUMBER. For details on multiple sets of PID, refer to the next section in this chapter.

Applications

Basic Operating Procedures

To select a set point, toggle the SET PT key to scroll through the setpoints. The displayed setpoint becomes active after two second of key inactivity.

The digital inputs can also be used to select the active setpoints. A single digital input may be used for selecting the second setpoint, SP2. A set of four digital inputs may be used, to select up to 8 setpoints (see the section in this Chapter on Digital Inputs).

The SET PT key is lit when a setpoint other than the primary local setpoint is active.

K. MULTIPLE SETS OF PID VALUES

The 535 has the ability to store up to eight sets of PID values. This can be a valuable feature for operating the controller under conditions which require different tuning parameters for optimal control. There are various methods of selecting which set should be active. These methods are explained in this section.

Software Configuration

1. Go to the TUNING menu.

2. NO.OF PID is the desired number of PID sets to be stored. SP VALUE automatically sets this value equal to the number of stored local setpoints (each PID set will be active when its respective local setpoint is active).

3. PID TRIP determines which variable selects the various PID sets: process variable, setpoint or deviation from setpoint.

4. TRIP:X defines the point (in the PV range) at which that set of PID values become active.

535 User's Manual Chapter 7 87

Applications

Basic Operating Procedures

A PID set can be selected in one of four ways.

• For NO. OF PID = PV NUMBER, the PID set (1 or 2) is selected when PV1 or PV2 is used.

• For NO. OF PID = SP NUMBER, the active set of PID values is the same as the active setpoint. For example, if SP3 is active, then PID set #3 will be active.

• When using PID trip values, a PID set becomes active when the variable exceeds its trip point.

For example, if PID TRIP = SETPOINT, and TRIP:2 = 500, the second set of PID values becomes active when the setpoint exceeds 500, and remains active until the setpoint drops below 500 or exceeds the next highest trip point. The PID set with the lowest trip point is also active when the trip variable is less than the trip value. (The user can set the lowest trip point = the low end of the process variable range, but this is not required.)

• A digital input can be set to trip to the second set of PID upon closure, which overrides a selection based on trip points.

Using with Adaptive and Pretune

The 535 can be programmed to automatically set the PID values using the Pretune and Adaptive Tuning functions. For both functions, the tuned set of PID is that which is active upon initiation of the tuning function.

The controller cannot trip to other PID sets (based on trip point or the digital input contact) until Adaptive Tuning is disabled. However, if the PID set is tied to the corresponding local setpoint, the active PID set values will change with the local setpoint.

Each PID set has 5 parameters that control its function—proportional band, reset, rate, manual reset (or loadline), and trip point. For each set (2 thru 8), these values have to be manually set.

1. Press MENU to access the TUNING menu.

2. Set values for parameters 1 thru 20 (these include the first PID set)

3. Press MENU to access these parameters for each additional PID set (2 through 8): PROP. BND, RESET, RATE, MAN. RST. and TRIP.

L. POWERBACK

POWERBACK is a proprietary algorithm which, when invoked by the user, reduces or eliminates setpoint overshoot at power up or after setpoint changes. Powerback monitors the process variable to make predictive adjustments to control parameters, which in turn helps to eliminate overshoot of the Setpoint.

Software Configuration

1. Go to the TUNING menu.

2. Set POWR.BACK parameter to ENABLED.

3. Go to the SELF TUNE menu.

4. For DEAD TIME, set the value (time) that the controller should wait before invoking an output change. This value is typically the dead time of the process. Or, let Pretune calculate the dead time, then complete just steps 1 and 2 above.

88 Chapter 7 535 User's Manual

M. SELF TUNE—PO WERTUNE®

The Self Tune function of the 535 consists of two distinct components, Pretune and Adaptive Tune. These components may be used independently or in conjunction with one another. For best results, we recommend using them together.

Pretune

This algorithm has three versions. Choose the type that most closely matches the process to optimize the calculation of the PID parameters. The three Pretune types are:

• TYPE 1 Normally used for slow thermal processes

• TYPE 2 Normally used for fast fluid or pressure processes

• TYPE 3 Normally used for level control applications

Pretune is an on-demand function. Upon initiation, there is a five second period during which the controller monitors the activity of the process variable. Then the control output is manipulated and the response of the process variable is monitored. From this information, the initial Proportional Band, Reset and Rate (P, I and D values) and dead time are calculated. When using TYPE 2 or TYPE 3 Pretune, the Noise Band (NOISE BND.) and Response Time (RESP. TIME) will also be calculated.

In order to run this algorithm, the process must fulfill these requirements:

• The process must be stable with the output in the manual mode;

• For tuning a non-integrating process, the process must be able to reach a stabilization point after a manual step change; and

• The process should not be subject to load changes while Pretune operates.

If these conditions are not fulfilled, set the Adaptive Tune to run by itself.

Applications

Adaptive T une

Adaptive Tune continuously monitors the process and natural disturbances and makes adjustments in the tuning parameters to compensate for these changes. In order to make accurate calculations, Adaptive Tune needs noise band and response time values. Pretune TYPE 2 and TYPE 3 automatically calculate these values. These values may also be entered or changed manually in the SELF TUNE menu. For Pretune TYPE 1, Noise Band and Response Time parameters must be entered manually.

Figure 7.12 illustrates the relationship between Pretune and Adaptive Tune

Software Configurations

CAUTION!

Disable Adative Tuning before altering process conditions (e.g., for shutdown, tank draining, etc.). Otherwise, the 535 will attempt to adapt the Tuning parameters to the temporary process conditions.

Adaptive Tune can be disabled via digital input (if applicable—see Digital Inputs in this chapter), or via menus:

1.Go to the TUNING menu.

2.Go to parameter ADAPTIVE. Change the value to DISABLED.

Pretune by Itself

1. Go to the SELF TUNE menu (press MENU+FAST)

2. Set the TYPE parameter to PRETUNE.

3. Set the PRETUNE type to the one that best matches the process (see above section).

4. The next parameter, TUNE PT., appears only for TYPE 1 pretune. This parameter sets the PV point at which the output will switch off. In thermal processes, this will help prevent overshoot. The default is AUTOMATIC.

535 User's Manual Chapter 7 89

Applications

5. Set the value for OUT STEP. This parameter defines the size of bump to be used. The resulting disturbance must change the process variable by an amount that significantly exceeds the peak-to-peak process noise, but does not travel beyond the “normal” process variable range.

6. The next two parameters, LOW LIMIT and HI LIMIT, set the process variable boundaries. If these boundaries are exceeded during the Pretune, the pretune cycle will abort and return to manual control at the output level prior to the initiation of pretune.

Figure 7.12 Pretune TYPE 1, 2 and 3 with Adaptive Tune

CONTROL

OUTPUT

CONTROL

OUTPUT

100%

70% 50% 30%

900 700 500

300

100%

70% 50% 30%

0% 900

700 500

300

NOISE BUMP

➔

Pretune

PRETUNE

TIME

Out Step

➔

High Out Limit

Low Out Limit

ADAPTIVE

➔

ADAPTIVE

➔

TIME

TYPE 1 Pretune/Adaptive Control

• A to B is ON/OFF control to determine initial PID values.

• B is Pretune completed, so Adaptive PID control beings if ENABLED. Note: Noise Band and Resp. Time must be entered before

enabling Adaptive TUne)

TYPE 2 Pretune/Adaptive Control

• A to B is a 5 second noise band measurement.

• B to C is an open loop bump test to determine initial PID values and response time.

• C is Pretune completed, so Adaptive PID control begins if ENABLED.

CONTROL

OUTPUT

100%

70% 50% 30%

900 700 500

300

NOISE BUMP

➔

Pretune

Out Step

➔

• A to B is a 5 second noise band measurement.

• B to C is an impulse to determine initial PID values and response time.

• C is Pretune completed, so Adaptive PID control begins if ENABLED.

ADAPTIVE

TIME

TYPE 3 Pretune/Adaptive Control

90 Chapter 7 535 User's Manual

7. The next parameter, TIMEOUT, defines the maximum time in minutes within which pretune must complete its calculations before it is aborted.

The first time a pretune is performed, set TIMEOUT to its maximum value. Make note of the length of the pretune cycle. Then, adjust TIMEOUT to a value about twice the pretune time.

The purpose of this parameter is to prevent a Pretune cycle from continuing for an excessive time if a problem develops. The value has no impact on the PID values being calculated.

8. Next is MODE. This defines what mode the controller will enter when pretune is completed. Select MANUAL if there will be a need to review PID parameters before attempting to control with them; the default AUTOMATIC.

9. RESP. TIME defines the amount of damping for the process. The choices include FAST (results in approximately 20% overshoot), MEDIUM (results in approximately 10% overshoot), and SLOW (<1%).

10.Place the controller under manual control.

11.Access the TUNING menu (press MENU). Set the first parameter, ADAPTIVE, to DISABLED.

12.Activate the next parameter, PRETUNE.

13.Press ACK to begin Pretuning. The 3rd display will show the message EXECUTING.

14.When Pretune is complete, the 3rd display will show COMPLETED for two seconds and then return to the current menu display.

Applications

Pretune TYPE 1 & Adaptive Tune

1. Go to the SELF TUNE menu.

2. Set TYPE to BOTH.

3. Set PRETUNE to TYPE 1.

4. Set a value for OUTSTEP.

5. Set NOISE BND parameter.

6. Set the RESP. TIME parameter.

7. Make sure that the process is reasonably stable and place the controller under manual control.

8. Press MENU to access the TUNING menu. Set ADAPTIVE to ENABLED. The Adaptive Tuning cycle does not begin

the controller is under automatic control.

9. Activate the next parameter, PRETUNE.

10.Press ACK to begin Pretuning. The 3rd display will show the message EXECUTING.

11.When Pretune is complete, the 3rd display will show COMPLETED for two seconds and then return to the current menu display.

The controller will automatically transfer to automatic control upon completion of Pretune if set to do so, or upon manual transfer.

Figure 7.12 illustrates the operation of Pretune TYPE 1 with Adaptive Tune.

Pretune TYPE 2 or 3 & Adaptive Tune

1. Go to the SELF TUNE menu.

2. Set the TYPE parameter to BOTH.

535 User's Manual Chapter 7 91

Applications

–

NOTE: Adaptive tuning is not available for velocity position proportional control.

3. Set the PRETUNE parameter to TYPE 2 or TYPE 3.

4. DO NOT Enter values for NOISE BND and RESP TIME. The Pretune algorithm will calculate these values.

2. Make sure that the process is reasonably stable and place the controller under manual control.

3. Press MENU to access the TUNING menu.

4. Set parameter ADAPTIVE to ENABLED. The Adaptive Tuning cycle does not begin. The controller is under automatic control.

4. Activate the next parameter, PRETUNE.

5. Press ACK to begin Pretuning. The 3rd display will show the message EXECUTING.

6. When Pretune is complete, the 3rd display will show COMPLETED for two seconds and then return to the current menu display.

The controller will automatically transfer to automatic control upon completion of Pretune if set to do so, or upon manual transfer.

Figure 7.12 illustrates the operation of Pretunes TYPE 2 and TYPE 3 with Adaptive Tune.

CAUTION!

If the process conditions are temporarily changed, (e.g., during process shutdown, draining of a tank, etc.) disable adaptive tuning.

Otherwise, the controller will attempt to adapt its tuning parameters to the temporary process conditions.

Disable adaptive tuning by:

1. In the TUNING menu, change ADAPTIVE to DISABLED through the keypad; or

2. Closing the appropriate digital input (see Digital Input section in this chapter).

Figure 7.13 Noise Band Calculation Example

Adaptive Tune by Itself

1. Go to the SELF TUNE menu.

2. Set the TYPE parameter to ADAPTIVE.

3. Press MENU to access the TUNING menu.

4. Set the ADAPTIVE parameter to ENABLED. The Adaptive Tuning cycle does not begin. The controller is under automatic control.

If Pretune results are poor or process conditions do not allow Pretune to run, the Adaptive Tune parameters can be manually configured. Proper setting of the noise band and response time parameters will yield excellent adaptive control without running the Pretune function.

1. Go to the SELF TUNE menu.

2. Set NOISE BND. The noise band is chosen to distinguish between disturbances which affect

the process and process variable “noise.” The controller functions to compensate for disturbances (i.e., load changes), but it cannot compensate

752

(407 – 402)

[ 752 – (–352) ]

X 100 =

.5%

PROCESS

VARIABLE

Type T

Thermocouple

Range

328°F TO 752° F

401

409 408 407 406 405 404 403 402

400

NOISE BAND =

–328

40 80

120

TIME

160

200 240

(SECONDS)

92 Chapter 7 535 User's Manual

for process noise. Attempting to do this will result in degraded controller performance. The Noise Band is the distance the process deviates from the setpoint due to noise in percentage of full scale.

Figure 7.13 shows a typical process variable response in a steady-state situation. In this example, the process noise is within a band of about 0.5% of full scale.

A noise band that is too small will result in tuning parameter values based on noise rather than the effects of load (and setpoint) changes. If the noise band is set too small, then Adaptive Tune will attempt to retune the controller too often. This may result in the controller tuning cycling between desirable system tuning and overly sluggish tuning. While the result may be better than that achieved with a non-adaptive controller, this frequent retuning is not desirable.

If the noise band is set too large, the process variable will remain within the noise band, and the controller will not retune itself. With too large a noise band, important disturbances will be ignored, and the controller will be indifferent to sluggish and oscillatory behavior.

Noise band settings are generally between 0.1% and 1.0%, with most common settings of 0.2% or 0.3%. Figure 7.14 shows the conversion of peak-to-peak noise to an appropriate noise band for each T/C type & RTD.

Applications

INPUT TYPE

B E J K N R/S T W/WS PLATINEL RTD 0.1°RTD

0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1

0.1 0.1 0.1 0.1 0.1 0.1 0.2 0.1 0.1 0.1 0.2

0.1 0.2 0.2 0.1 0.1 0.1 0.3 0.1 0.2 0.2 0.3

0.1 0.2 0.2 0.1 0.1 0.1 0.4 0.1 0.2 0.2 0.5

0.2 0.2 0.2 0.2 0.2 0.2 0.5 0.1 0.2 0.3 0.6

0.2 0.3 0.3 0.2 0.2 0.2 0.6 0.1 0.3 0.3 0.7

0.2 0.3 0.3 0.2 0.3 0.2 0.6 0.2 0.3 0.4 0.8

0.2 0.4 0.4 0.3 0.3 0.3 0.7 0.2 0.4 0.4 0.9

0.3 0.4 0.4 0.3 0.3 0.3 0.8 0.2 0.4 0.5 1.0

Peak to Peak Noise °F

0.3 0.4 0.4 0.3 0.4 0.3 0.9 0.2 0.4 0.5 1.1

3. Set RESP. TIME. The response time is the most critical value in Adaptive Tuning. Response

time represents the time lag from a change in valve position (controller output) to a specific amount of change in process variable. Specifically, Response Time is equal to the Deadtime of the process plus one Time Constant. The Deadtime is the time between initiation of an input change and the start of an observable response in the process variable. The Time Constant is the interval of time between the start of that observable response and the point where the process variable reaches 63% of its final value. (See Figure 7.15).

Example

After a stimulus (e.g., valve movement), if it takes 300 seconds for a process to reach 63% of its new (expected) value, the response time is 300 seconds. If the response time is set too short, the process will be unstable and cycle

Figure 7.14 Noise Band Values for Temperature Inputs

Control Output

Time

➜

63% of Final PV

DT = Dead Time τ = Time Constant RT= Response Time

Figure 7.15 Deadtime and Time Constant

Final PV

535 User's Manual Chapter 7 93

Moore Industries 535 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

T able of Contents

List of Figures

535 MODES

DISPLAYS

BASIC OPERATING PROCEDURES

ALARM OPERATION

MOUNTING THE CONTROLLER

WIRING

A C Po wer Input

Process V ariable Input

Remote Setpoint Option

OUTPUT MODULES

Serial Communications

Limit Control

HARDW ARE INPUT TYPES

Mechanical Relays

ACCESSING AND CHANGING JUMPERS

ADDING AND CHANGING OUTPUT MODULES

SPECIAL COMMUNICA TIONS MODULE

MENUS

PARAMETERS

CONFIGURA TION AND OPERATION

CONFIG.

PV1 INPUT

PV2 INPUT

CUST . LINR.

CONTROL

ALARMS

REM. SETPT .

RETRANS.

SELF TUNE

SPECIAL

SECURITY

SER. COMM.

OVERVIEW

SELF TUNE MESSAGES AND TROUBLESHOOTING