Moore Industries 545 User Manual
5 4 5
5 4 5
1/4 DIN PROCESS CONTROLLER
USER’S MANUAL
M545 V 8, MA
RCH 2 017
Table of Contents
Table of Contents
CHAPTER 1
INTRODUCTION ............................................................................... 1
545 Modes ......................................................................................... 2
Order Code, Packaging Information ..................................................... 2
Where To Go Next .............................................................................. 2
Text Formatting in This Manual ............................................................ 2
CHAPTER 2
CONTROLLER OPERATION ............................................................ 5
Displays ............................................................................................. 5
Icons ................................................................................................. 5
Keys .................................................................................................. 6
Basic Operation Procedures ............................................................... 7
Alarm Operation ................................................................................. 8
CHAPTER 3
INSTALLATION AND WIRING ........................................................ 11
Mounting the Controller ..................................................................... 11
Wiring .............................................................................................. 12
AC Power Input ....................................................................... 12
Process Variable Input ............................................................. 13
Digital Input(s) ......................................................................... 16
Remote Setpoint Option ........................................................... 16
Output Modules ....................................................................... 17
Serial Communications ............................................................ 19
PAGE
About This Manual:
Throughout this User’s Manual
information appears along the
margins, in the form of NOTEs,
CAUTIONs and WARNINGs, usually
in boldface. Please heed these
safety and good practice notices for
the protection of you and your
equipment.
CHAPTER 4
HARDWARE CONFIGURATION ..................................................... 21
Hardware Input Types ...................................................................... 21
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
Text Formatting in This Manual .......................................................... 29
Step-by-Step Guide to Set-Up Parameters ......................................... 30
CONFIG.................................................................................. 30
PV INPUT ............................................................................... 35
CUST. LINR. ........................................................................... 37
CONTROL .............................................................................. 38
ALARMS ................................................................................. 41
REM. SETPT. .......................................................................... 45
RETRANS............................................................................... 46
SELF TUNE ............................................................................ 48
SPECIAL ................................................................................ 49
545 User's Manual Table of Contents i
Table of Contents
Step-by-Step Guide to Set-Up Parameters (continued)
SECURITY.............................................................................. 51
SER. COMM. .......................................................................... 52
Parameter Value Charts ................................................................... 54
CHAPTER 6
TUNING .......................................................................................... 63
Overview ......................................................................................... 63
TUNING Parameter Guide ................................................................ 64
TUNING Value Chart ........................................................................ 68
Self Tune Messages and Troubleshooting ......................................... 70
CHAPTER 7
APPLICATIONS .............................................................................. 71
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 ............................................................................ 88
J. Multiple Setpoints .......................................................................... 88
K. Multiple Sets of PID Values ........................................................... 89
L. Powerback ................................................................................... 90
M. Self Tune—POWERTUNE
®
........................................................................ 90
N. Ramp-to-Setpoint ......................................................................... 96
O. Input Linearization ........................................................................ 97
Thermocouple and RTD Linearization ....................................... 97
Square Root Linearization ........................................................ 97
Custom Linearization ............................................................... 98
P. Load Line ..................................................................................... 98
Q. Security ....................................................................................... 99
R. Reset Inhibition .......................................................................... 100
S. Process Variable Reading Correction .......................................... 100
T. Serial Communications ............................................................... 101
U. Cascade Control ........................................................................ 102
V. Ratio Control .............................................................................. 104
Ratio Control with One Wild Stream ........................................ 104
Ratio Control with Combined Discharge Monitoring .................. 105
W. Feed Forward/Feedback Control ................................................ 107
X. Lag Time .................................................................................... 108
Fixed Lag .............................................................................. 108
Variable Lag .......................................................................... 109
PAGE
ii Table of Contents 545 User's Manual
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
Table of Contents
PAGE
APPENDIX 5
SPECIFICATIONS ........................................................................A-13
APPENDIX 6
GLOSSARY ................................................................................. A-17
APPENDIX 7
ISOLATION BLOCK DIAGRAM ...................................................A-23
545 User's Manual Table of Contents iii
Table of Contents
List of Figures
FIGURE DESCRIPTION PAGE
2.1 ................. Operator Interface ............................................................... 5
2.2 ................. Before and After Acknowledging an Alarm ............................ 9
3.1 ................. Instrument Panel & Cutout Dimensions ............................... 11
3.2 ................. Attaching Mounting Collar .................................................. 11
3.3 ................. Terminal Assignments ....................................................... 12
3.4 ................. AC Power Input Terminals ................................................. 13
3.5 ................. Process Variable Terminals ............................................... 13
3.6 ................. PV1 and PV2 Wiring for Milliamp, RTD and Voltage Inputs ... 14
3.7 ................. PV1 and PV2 Wiring for Milliamp Inputs
with Internal and External Power Supply ............................. 15
3.8 ................. Digital Input Wiring with a Switch or Relay ........................... 16
3.9 ................. Digital Input Wiring with an Open Collector .......................... 16
3.10 ............... Remote Setpoint Terminals ................................................ 16
3.11 ............... Mechanical Relay Output Wiring ......................................... 17
3.12 ............... SSR Relay Output Wiring ................................................... 17
3.13 ............... DC Logic Output Wiring ..................................................... 18
3.14 ............... Milliamp Output Wiring ....................................................... 18
3.15 ............... Position Proportioning Output Wiring .................................. 18
3.16 ............... Serial Communications Terminals ...................................... 19
4.1 ................. Location of Printed Circuit Boards ....................................... 21
4.2 ................. The Microcontroller Circuit Board, the Option Board,
and the Power Supply Board .............................................. 22
4.3 ................. Representation of Module .................................................. 25
4.4 ................. Install Communications Module .......................................... 26
5.1 ................. Parts of the Menu Block ..................................................... 27
5.2 ................. Independent vs. Dependent Parameters ............................. 28
5.3 ................. Configuration Flowchart ..................................................... 28
6.1 ................. Access the Tuning Menu Block .......................................... 63
7.1 ................. Alarm Examples ................................................................ 75
7.2 ................. Duplex With Reverse and Direct Acting Outputs .................. 77
7.3 ................. Duplex With Direct and Reverse Acting Outputs .................. 77
7.4 ................. Duplex With Two Reverse Acting Outputs ........................... 78
7.5 ................. Duplex With a Gap Between Outputs .................................. 78
7.6 ................. Duplex With Overlapping Outputs and Output Limits ............ 79
7.7 ................. Duplex With Various Relative Gain Settings ........................ 79
7.8 ................. Duplex With One ON/OFF Output ...................................... 80
7.9 ................. Duplex With Two ON/OFF Outputs..................................... 80
7.10 ............... Staged Outputs Example ................................................... 83
7.11 ............... Combinations of Closed Digital Inputs ................................. 84
7.12 ............... Pretune TYPE 1, 2 and 3 with Adaptive Tune....................... 93
7.13 ............... Noise Band Calculation Example ........................................ 94
7.14 ............... Noise Band Values for Temperature Inputs ......................... 95
7.15 ............... Deadtime and Time Constant ............................................. 95
7.16 ............... Square Root Linearization Formula .................................... 97
7.17 ............... 15-point Linearization Curve ............................................... 98
iv Table of Contents 545 User's Manual
FIGURE DESCRIPTION PAGE
7.18 ............... Load Line Example............................................................ 99
7.19 ............... Cascade Control of Product Temperature -
Functional View ............................................................... 102
7.20 ............... Cascade Control of Produce Temperature -
Wiring View ..................................................................... 103
7.21 ............... The Functions of Cascade Control ................................... 103
7.22 ............... Ratio Control in Mixing Application “Wild Stream” -
Wiring View ..................................................................... 104
7.23 ............... Ratio Control in Mixing Application “Controlled Stream” -
Functional View ............................................................... 105
7.24 ............... Ratio Control in Mixing Application “Controlled Stream” -
Wiring View ..................................................................... 106
7.25 ............... Feed Forward Control in Mixing Application -
Wiring View ..................................................................... 107
7.26 ............... Feed Forward Control in Mixing Application -
Functional View ............................................................... 107
7.27 ............... Fixed and Variable Lag Example -
Compound Loop Chlorine Control .................................... 108
A4.1 ............... 545 Rear Terminals for Calibration ....................................... 7
A4.2 ............... Flowchart Calibration Menus ............................................... 7
A4.3 ............... Jumper Locations on the Microcontroller Circuit Board .......... 8
A4.4 ............... Input Calibration Wiring ....................................................... 8
A4.5 ............... Thermocouple/Cold Junction Calibration Wiring ................... 9
A4.6 ............... Analog mA Input Calibration Wiring .................................... 10
A4.7 ............... Analog mA Input Jumper Positions ..................................... 10
A4.8 ............... Milliamp Output Calibration Wiring ..................................... 11
A4.9 ............... Output Module Menu Cycle ............................................... 11
A4.10 ............. Slidewire Test Wiring ......................................................... 12
Table of Contents
545 User's Manual Table of Contents v
Table of Contents
vi Table of Contents 545 User's Manual
CHAPTER 1
INTRODUCTION
Introduction
From its surge-resistant power supply to its rugged construction, the 545
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 545 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 545 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 545 is the most accurate instrument in its class. With a sampling rate of
eight times per second, it is ideal for demanding pressure and flow applications. The 545 also offers two universal process inputs and modular, field
interchangeable outputs that allow more flexibility than ever before. With
two independent full feature control loops, the 545 can take the place of two
PID controllers; additionally, preprogrammed functions can be called for
cascade, ratio and feed forward applications.
The 545 uses foreground and background loops that facilitate straight
forward operator interface in any of the dual loop modes. It also offers
sophisticated control algorithms, including heuristic adaptive tuning, split
range and duplex outputs (control), and open or closed loop electric actuator control (velocity control).
Thank you for selecting the dual
loop Process Controller. The 545 is
user-configurable for any of the
following functions:
• Two independent PID loops
• Single Station Cascade Control
• Single Station Ratio Control
• Feed Forward Control
Specifications and information subject to change without notice.
545 User's Manual Chapter 1 1
Introduction
545 MODES
There are three operating modes for the 545 controller:
OPERATION, the default mode of the controller. When the 545 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 function parameters for Proportional, Integral
and Derivation (PID) control. Use this mode periodically to optimize the
control performance of the instrument.
ORDER CODE, PACKAGING INFORMATION
Comparing the product number to the ordering code on page 3 to determine
the outputs and options installed on the 545. The product number is printed
on the label on the top of the controller case.
Included with the 545 are:
• a 545 User’s Manual
• mounting hardware
• 1 sheet engineering unit adhesive labels
WHERE TO GO NEXT
• To become more familiar with the 545 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 545, follow through Chapter 5 and 6. Appendix 1 can be used as a
guide to these parameters.
TEXT FORMATTING IN THIS MANUAL
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 1 545 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
Output 4: Control, 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/24VDC Operation F
Slidewire and 24 VAC/24VDC G
Remote Setpoint B
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
545 – 00
Introduction
Note 1: Capability for position proportioning output with slidewire feedback is specifed by ordering 545-11xxAxxx00, 545-33xxAxxx00,
or 545-44xxAxxx00. (Slidewire not required for velocity proportioning.)
outputs are interchangeable modules.
when used as the fourth output.
545 User's Manual Chapter 1 3
Note 4: The mechanical relay and solid state relay modules are derated to 0.5 amp at 24 Vac
Note 2: Up to three outputs may be used for alarms. Note 3: All
Introduction
4 Chapter 1 545 User's Manual
CHAPTER 2
CONTROLLER OPERATION
Basic Interface
Icons
PV2
OUT
1 2
ALM
1 2
545
Displays:
1st
2nd
3rd
Location for
MANUAL DISPLAY SET PT
identification
label
ACK MENU FAST
Keys
DISPLAYS
The display strategy of the 545 Process Controller is the same for all control
modes: Dual Loop, Cascade, Ratio and Feed Forward.
1st Display (five 7-segment digits)
• For the process variable value.
2nd Display (nine 14-segment digits)
• For the setpoint, deviation, output value 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)
• Name of current foreground loop
• For alarm messages, errors, etc.
• In TUNING or SET UP mode, for the value or choice of parameter shown in
the 2nd display.
Figure 2.1
Operator Interface
ICONS (LIT)
PV2 Loop 2 is in the foreground (on display); Loop 1 is in the background.
OUT1 For this output, either the relay output is energized or the analog
output is greater than 0%.
OUT2 For this output, either the relay output is energized or the analog
output is greater than 0%.
If control output is analog, indicates the output is greater than 0%.
ALM 1 The respective alarm (one) is active.
ALM 2 The respective alarm (two) is active.
ALM An alarm is active but no output is assigned.
545 User's Manual Chapter 2 5
PV2
OUT OUT OUT
1212
ALM ALM ALM
1212
Basic Interface
KEYS
FAST
+
FAST
MANUAL
SET PT
DISPLAY
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 setpoint.
In SET UP or TUNING mode, press to return controller to OPERATION mode.
When lit, indicates that a setpoint other than the local SP1 is active.
DISPLAY: Press to toggle through values in the 2nd display for setpoint, ramping setpoint (if available), deviation, output. background PV, lag (if available)
and valve position (if available).
In SET UP or TUNING mode, press to return controller to OPERATION mode
(with display showing current setpoint).
When lit, Loop 2 is in the foreground.
FAST+DISPLAY: Toggles between the background loop and foreground loop.
▲▲
▲ : Press to increase the value or selection of displayed parameter.
▲▲
FAST
FAST
▲
+
▼
+
▼
ACK
FAST+
▼▼
▼ : Press to decrease the value or selection of displayed parameter.
▼▼
FAST+
ACK: Press to acknowledge (an) alarm(s).
▲▲
▲ : Press to scroll through values at a faster rate.
▲▲
▼▼
▼ : Press to scroll through values at a faster rate.
▼▼
When lit, indicates there is an acknowledgeable alarm.
MENU
MENU : In OPERATION Mode, press to access the TUNING mode and 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 ac-
cess the parameters of a particular menu.)
6 Chapter 2 545 User's Manual
BASIC OPERATION PROCEDURES
A Quick Explanation of Dual Loop Operation
Upon power up, Loop 1 is in the foreground (displayed), and Loop 2 is in the
“background” (hidden). Set up changes only affect the foreground loop; to make
changes to the operation of the background loop, it must be brought to the foreground.
The controller helps the user identify the foreground and background loops with
the following:
• When Loop 2 is in foreground DISPLAY key and the PV2 icon are lit
• The third display will show a message identifying the foreground loop.
Use the following as a quick guide to key operating functions of your 545. Most
of these procedures will affect whichever loop is in the foreground at the time
you execute the procedures. Those that are specified by the word GLOBAL will
affect both loops (the whole controller).
To switch the foreground and background loops
1. Press FAST+DISPLAY.
To select /change a setpoint
1. Use DISPLAY key to toggle display to Set Point.
2. Use SET PT key to toggle to active setpoint.
Before the newly selected setpoint is made active, there is a two-second de-
lay to prevent any disruptive bumps. If the setpoint displayed is ramping,
RAMPING will show the 3rd display.
▲▲
3. To change value, press
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
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.
▼▼
▲ and
▼ keys to quickly enter the security code, which will show in
▲▲
▼▼
▲ or
▲▲
▼ ▼
▼ .
▼ ▼
Basic Interface
NOTE:
See the glossary in Appendix 6 for
explanation of
setpoint
Chapter 7.
. Also refer to the section in
ramping
and
target
545 User's Manual Chapter 2 7
Basic Interface
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.
To display control output value
1. Toggle DISPLAY key until the 2nd display shows OUT followed by the out-
put percentage. This value is the PID output.
• In duplex applications, this value does not directly refer to the output
signal (refer to the Chapter 7 section on Duplex Control for details.)
• For on/off outputs, the output value shown is either ON or OFF.
• For duplex applications with two on/off outputs, the OUT tag is not shown.
In this case, the status of both outputs is shown in the following manner:
1:ON 2:OFF (1 and 2 are the respective outputs).
To display the active PID set
1. Select the desired foreground loop (hold FAST, press DISPLAY).
2. Press MENU to reach Tuning Mode.
3. In TUNING Mode, press MENU to reach the correct Menu parameter.
4. 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 Chapter 5 and Chapter 7 for
more details on alarms.
ALARM OPERATION
Alarms may be used in systems to provide warnings of unsafe conditions. All
545 operators must know how the alarms are configured, the consequences of
acknowledging an alarm, and how to react to alarm conditions.
Alarm Indication
Depending on how the system is configured, the 545 indicates an alarm
condition(s) for the foreground loop by:
• Lit icons ALM 1 and/or ALM 2
• Lit ACK key
• Displayed alarm message
The 545 indicates an alarm condition(s) for the background loop by:
• Showing the (user defined) message for one or both alarms in the third display
(alternate displays for simultaneous alarms).
To acknowledge an alarm(s):
An acknowledgeable alarm has both a lit icon and a lit ACK key.
A non-acknowledgeable alarm has only a lit icon.
Figure 2.2 demonstrates acknowledging an alarm.
1. If the alarm is in the background, bring that loop forward using
FAST+DISPLAY.
2. To acknowledge Alarm 1, press ACK once.
3. To acknowledge Alarm 2, press ACK twice.
4. If both alarms are activated, press ACK once to acknowledge Alarm 1, then
again to acknowledge Alarm 2.
5. The message and alarm icon disappear.
8 Chapter 2 545 User's Manual
Basic Interface
BEFORE
OUT
1
ALM
1
MANUAL DISPLAY SET PT
ACK MENU FAST
545
MANUAL DISPLAY SET PT
AFTER
OUT
1
ACK MENU FAST
545
Latching Alarms
If an alarm is set up to be latching (for details, see Chapter 5) then, in general,
it must be acknowledged in order to clear the alarm and release the relay (if
applicable). A non-latching alarm will clear itself as soon as the process leaves
the alarm condition.
Limit Sequence
An alarm can be configured to be both latching and non-acknowledgeable. In
this case, the alarm is acknowledgeable only after the process has left the alarm
condition. This is similar to the function of a limit controller.
More on Alarms
For more details on how to set up alarms and for examples of various ways alarms
can be set up, refer to the section on Alarms in Chapter 7.
NOTE:
Powering down the 545 acknowledges/
clears all latched alarms. When powering
up, all alarms will be reinitialized.
Figure 2.2
Before and After Acknowledging an
Alarm
545 User's Manual Chapter 2 9
Basic Interface
10 Chapter 2 545 User's Manual
CHAPTER 3
INSTALLATION AND WIRING
MOUNTING THE CONTROLLER
The 545 front face is NEMA 4X rated (waterproof). To obtain a waterproof
seal between the controller and the panel, follow these directions:
1. The 545 fits in a standard 1/4 DIN cutout. Mount the 545 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)
PV2
OUT
1 2
ALM
1 2
545
PANEL
1.180 (29.97)
Installation
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 545 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
545 User's Manual Chapter 3 11
Collar Screws (1 of 4)
Installation
AUTION !
C
The enclosure into which the 545
Controller is mounted must be
grounded.
WARNING!
Avoid electrical shock. Do not
connect AC power wiring at the
source distribution panel until all
wiring connections are complete.
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
Our 545 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 545 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
Terminal Assignments
Actual 545 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 reduced
noise immunity to your system.
AC Power Input
LINE
1
NEUTRAL
OUT 1–
OUT 1+
OUT 2–
OUT 2+
OUT 3–
OUT 3+
2
3
4
5
6
7
816
TOP (as viewed from back of controller)
EARTH
917
GND
S/W
10
CCW
S/W 2
11
S/W 3
12
RSP–
13
RSP+
14
OUT 4–
15
OUT 4+
DIN
GND
DIN 1
18
DIN 2
19
DIN 3
20
DIN 4
21
DIN 5
22
COLD
23
JUNC–
COLD
24 32
JUNC+
25
26
27
28
29
30
31
(NOT
USED)
COMM–
COMM+
PV2–
PV2+
RTD 3RD
PV1–
PV1+
12 Chapter 3 545 User's Manual
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.
Process Variable Input
TOP
Installation
POWER
1
2
3
4
5
6
7
816
Screws must be tight to ensure good electrical connection
The 545 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 (termi-
nals 28 and 29).
EARTH/
917
GROUND
10
11
12
13
14
15
18
19
20
21
22
23
25
26
27
28
29
30
31
24 32
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.
Digital Input(s)
1
2
3
4
5
6
7
917
10
11
12
13
14
15
816
545 User's Manual Chapter 3 13
TOP
25
18
19
20
21
22
23
26
27
28
29
30
31
24 32
Figure 3.5
Process Variable Terminals
PV 2–
PV 2+
RTD 3rd
PV 1–
PV 1+
Installation
–
+
THERMOCOUPLE INPUT
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 For PV2
THERMOCOUPLE INPUT
30
–
31
+
32
2-WIRE RTD
30
31
32
3-WIRE RTD
Third leg
of RTD
30
31
32
Jumper wire
RTD
Same color
2-WIRE RTD
3-WIRE RTD
28
29
30
Jumper wire
28
29
30
Third leg of RTD
RTD
RTD
Same
color
14 Chapter 3 545 User's Manual
4-WIRE RTD
Same color
–
Transmitter
+
Same color
Third leg
of RTD
30
31
32
DO NOT connect 4th leg
VOLTAGE INPUT
–
31
+
32
4-WIRE RTD
VOLTAGE INPUT
28
29
30
28
29
Same color
Third leg
of RTD
–
–
+
+
Do NOT
connect
4th leg
Transmitter
For PV1 For PV1
Installation
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
31
32
2-wire
transmitter
+
+
–
+
–
–
MILLIAMP INPUT
4-wire transmitter with
loop power supply
–
–
15
16
31
32
+
–
+
Input power
for transmitter
+
4-20 mA output
–
from transmitter
+
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
28
29
2-wire
transmitter
+
+
–
+
–
–
MILLIAMP INPUT
4-wire transmitter with
loop power supply
–
–
15
16
28
29
+
–
+
Input power
for transmitter
+
4-20 mA output
–
from transmitter
+
Figure 3.7
PV1 and PV2 Wiring for Milliamp
Inputs with Internal and External
+
+
Power Supply
NOTE:
To use loop power, there must be a
loop power module is installed in the
3rd or 4th output socket. Compare the
controller product number with the
order code in Chapter 1 to determine
if the 545 has a loop power module
installed. To install a loop power
module, refer to Chapter 4
.
545 User's Manual Chapter 3 15
Installation
Figure 3.8
Digital Input Wiring with a Switch or
Relay
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
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
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
DIN
GND
DIN 1
DIN 2
DIN 3
DIN 4
DIN 5
17
18
19
20
21
22 30
25
26
27
28
29
GND
DIN 1
DIN 2
DIN 3
DIN 4
DIN 5
DIN
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
DIN
GND
DIN 1
DIN 2
DIN 3
DIN 4
DIN 5
17
18
19
20
21
22 30
25
26
27
28
29
GND
DIN 1
DIN 2
DIN 3
DIN 4
DIN 5
DIN
Remote Setpoint Option
17
18
19
20
21
22 30
17
18
19
20
21
22 30
GND
DIN 1
DIN 2
DIN 3
DIN 4
DIN 5
DIN
DIN
GND
DIN 1
DIN 2
DIN 3
DIN 4
DIN 5
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
Figure 3.10
Remote Setpoint Terminals
16 Chapter 3 545 User's Manual
Use terminals 13 and 14 to connect the remote setpoint signal.
Source
–
–
+
+
13
14
Installation
OUTPUT MODULES
The 545 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).
Line Power
Terminals used
with Output
Module 1
Terminals used
with Output
Module 2
Terminals used
with Output
Module 3
Terminals used
with Output
Module 4
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.
3
Load
4
Recommend use of both MOV and snubber
3
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).
3
4
Line Power
-
+
-
Load
+
Terminals used
with Output
Module 1
3
4
5
6
Terminals used
with Output
Module 2
5
6
7
8
Terminals used
with Output
Module 3
7
8
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
545 User's Manual Chapter 3 17
Installation
Figure 3.13
DC Logic Output Wiring
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 3.14
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
with Output
15
16
4. Milliamp Output
• Output 1 is always Control 1.
• Respective jumper J1, J2 or J3 must be set to normally open for
Milliamp output.
Terminals used
with Output
Module 1
Terminals used
with Output
Module 2
Terminals used
with Output
Module 3
Terminals used
with Output
_
3
Load
4
+
3
4
5
6
7
8
15
16
Module 4
Module 4
5. Position Proportioning Output
Figure 3.15
Position Proportioning Output
Wiring
18 Chapter 3 545 User's Manual
(with or without Slidewire Feedback)
Electric Motor Actuator
CCW
Winding
Actuator
Supply
Current
3
COMCWCCW
CW
Winding
4
5
COM
CCW
Slidewire
Wiper
0–1050 Ohm
CW
6
POSITION
PROPORTIONING
OUTPUT
10
11
12
• Mechanical relay or solid state relay modules must be installed in
PC
or other host
545
Terminals
RS-485
port
Twisted, shielded
To "Comm –" terminal of
next Moore Industries device
To "Comm +" terminal of
next Moore Industries device
Comm +
Comm –
Use a 60 to 100 Ohm terminating resistor
connected to the two data terminals of
the final device on the line.
CAUTION
The shield needs to be connected continuously
but only tied to one ground at the host.
Failure to follow these proper wiring practices
could result in transmission errors and other
communications problems.
26
27
output sockets 1 and 2.
• When using velocity control (no slidewire feedback), there are no connections at terminals 10, 11 and 12.
• Use of the slidewire feedback is optional
Serial Communications
A twisted shielded pair of wires should be used to interconnect the host and
field units. Belden #9414 foil shield or #8441 braid shield 22-gauge wire are
acceptable for most applications. The foil shielded wire has superior noise
rejection characteristics. The braid shielded wire has more flexibility. The
maximum recommended length of the RS 485 line is 4000 feet. Termination
resistors are required at the host and the last device on the line. Some RS
485 cards/converters already have a terminating resistor. We recommend
using RS-232/RS-485 converter (Product #500-485). The communication
protocol is asynchronous bidirectional half-duplex, hence the leads are
labelled
Comm +
and
Comm –
.
Installation
Figure 3.16
Serial Communications Terminals
545 User's Manual Chapter 3 19
Installation
20 Chapter 3 545 User's Manual
CHAPTER 4
HARDWARE CONFIGURATION
Hardware configuration determines the available outputs as well as the type of
input signal. The 545 controller comes factory set with the following:
• All specified module and options installed (for details, refer to the Order Code
in Chapter 1).
• Process variable and remote setpoint set to accept a milliamp input.
• Relay outputs set to normally open.
Alter the factory configuration of the 545, requires accessing the circuit boards,
and locating the jumpers and output modules (see Figure 4.1).
1. With the power off, loosen the four front screws, and remove them.
2. Slide chassis out of the case by pulling firmly on the bezel.
FRONT FACE
Hardware Configuration
NOTE:
Hardware configuration of the
controller is available at the factory;
Consult an application engineer for
details.
MICROCONTROLLER
BOARD
POWER SUPPLY
BOARD
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 setting
up the process as needed.
HARDWARE INPUT TYPES
The Process Variable
The 545 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
Figure 4.1
Location of Printed Circuit Boards for
Hardware Configuration
NOTE:
Thermocouple downscale and
upscale burnout offers a choice in
which direction the controller would
react in the event of thermocouple
failure. For example, in heat
applications, typically, it is desirable
to fail upscale (TC ▲) so that the
system does not apply more heat.
545 User's Manual Chapter 4 21
Hardware Configuration
BATTERY
EPROM
NOTE:
Changing the jumpers means moving
the jumper connector. The jumper
connector slips over the pins,
straddling two rows of pins. The
printed circuit boards are labeled next
to the jumpers.
Figure 4.2
(from the top) The Microcontroller
Circuit Board, the Option Board, and
the Power Supply Board
The Remote Setpoint
Figure 4.2 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 output 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 ▼
TC
TC
TC ▲
RTD
RTD
RTD
V
MA
TC ▼
TC ▲
RTD
TB2
2ND
PV1
TB1
Male 22-Pin
Connector
5-Pin Connector
Remote Setpoint Jumper
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
1
NO J3 NC
NO J2 NC
NO J1 NC
Jumpers
NO and NC
22 Chapter 4 545 User's Manual
Hardware Configuration
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 2. 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.
2. 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 1,
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.
545 User's Manual Chapter 4 23
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