Moore Industries 535 User Manual
5 3 5
5 3 5
1/4 DIN PROCESS CONTROLLER
USER'S MANUAL
M535 V5, © MAY 2002
T able of Contents
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
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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
or
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
+
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
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.
More on Alarms
For more details on how to set up alarms and for examples of various ways
alarms can be set up, refer to the section on Alarms in Chapter 7.
Operation
535 User's Manual Chapter 2, Controller Operation 9
Operation
10 Chapter 2, Controller Operation 535 U ser's Manual
CHAPTER 3
INSTALLATION
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
s
t
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.
L1
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
10
S/W 2
11
S/W 3
12
RSP–
13
RSP+
14
OUT 4–
15
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
26
27
28
29
30
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
30
–
31
+
32
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
–
31
+
32
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
–
–
15
16
31
32
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
–
–
15
16
28
29
MILLIAMP INPUT
4-wire transmitter with
loop power supply
15
16
28
29
–
–
–
+
+
+
+
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
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
DIN
17
18
19
20
21
22 30
17
18
19
20
21
22 30
25
26
27
28
29
25
26
27
28
29
25
26
27
28
29
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
13
14
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
3
4
Recommend use of both MOV and snubber
Terminals used
with Output
Module 1
3
Load
4
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
3
4
Line Power
+
-
Load
+
Terminals used
with Output
Module 2
5
6
Terminals used
with Output
Module 2
5
6
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
_
3
Load
4
+
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
3
COMCWCCW
4
CW
Winding
5
COM
CCW
Slidewire Wiper
0–1050 Ohm
CW
6
OUTPUT
10
11
12
• 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
PC
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
26
27
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
L1
0.5 AMP, 250 V,
FAST ACTING
FUSE
L2
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
17
27
9
10
1
11
2
12
3
13
4
5
6
7
8
18
28
19
29
20
21
22
14
15
16
23
24
T.C.
30
INPUT
31
32
L1
L2
LOAD
POWER
FAST ACTING
FUSE
HEAT
LOAD
PROCESS SENSOR
LIMIT SENSOR
MERCURY
RELAY
FOR CONTROL
HIGH LIMIT
MECHANICAL
CONTACTOR
COIL
L2
RELAY/
CONTACTOR
COIL POWER
T/C INPUT
N.O.
OPTIONAL
MOMENTARY SWITCH
MANUAL RESET
FOR LIMIT CONTROL
1
+
2
3
-
4
5
6
7
8
9
10
20
19
18
17
16
15
14
13
12
11
353 LIMIT CONTROLLER
FAST
ACTING
FUSE
L2
INDICATOR ON
WHEN LIMIT TRIPS
LIMIT CONTROLLER
AC POWER
L2
L1
FUSE
L1
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
▼▼
TC
▼ Thermocouple with downscale burnout
▼▼
▲ ▲
TC
▲ 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
P1
P2
V
V
V
MA
MA
MA
TC
TC
TC t
TC
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
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
1
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
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