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
Hardware Configuration
ADDING AND CHANGING OUTPUT MODULES
The 545 has provisions for four output modules. A controller ordered with output
module options already has the modules properly installed. Follow these instructions to add modules, change module type(s) or change module location(s).
Equipment needed: Wrist grounding strap
1. With power off, loosen two front screws, and remove them.
2. Slide the chassis out of the case by pulling firmly on the bezel.
3. Use a flat screwdriver to carefully pry apart the clips that hold the front face
4. As shown in Photo 4, carefully pry apart, using hands or a small flat screw-
5. To change modules 1, 2 or 3:
Phillips screwdriver (#2)
Small flat blade screwdriver
Wire cutters
assembly to the chassis, as in Photo 3. Separate the printed circuit board
assembly from the front face assembly. Use care not to break the clips or
scratch the circuit boards.
driver, the smaller Option board and the Power Supply board (the one with
3 modules).
Output modules 1, 2, and 3 are firmly held in place by a retention plate and
tie wrap. Carefully snip the tie wrap with a wire cutter. To prevent damage to
the surface mount components, ALWAYS snip the tie wrap on TOP of the
Retention Plate, as shown in Photo 5.
Remove the retention plate.
3. Pry Clips
24 Chapter 4 545 User's Manual
4. Separate Boards
5. Remove Retention Plate
6. To change module 4:
Output Module 4 (on the Option board) is also held in place by a tie wrap.
Snip tie wrap to remove module as shown in Photo 6.
7. Figure 4.3 shows a representation of an output module. Inspect the
module(s) to make sure that the pins are straight.
8. To install any module, align its pins with the holes in the circuit board, and
carefully insert the module in the socket. Press down on the module until it
is firmly seated; refer to Photo 7.
Hardware Configuration
Figure 4.3
Representation of Module
7. Add/Change Module6. Snip Tie Wrap
9. Replace tie wraps for all the modules (the Retention Plate and Output Module 4) with new ones before reassembling the controller.
Failure to use the tie wraps may result in loosening of the module and eventual failure. All separately ordered modules should come with a tie wrap. Extra
sets of tie wraps are available by ordering Part #545-665.
NOTE: For greatest accuracy, calibrate all milliamp modules added for
retransmission as per the instructions in Appendix 2.
10. Rejoin the circuit boards by aligning the pins of their connectors, then squeezing the board(s) together. Make sure that all three printed circuit boards are
properly seated against one another; check along side edges for gaps. Make
sure the cable assemblies are not pinched.
11. To reattach the board assembly to the front face assembly, align the boards
(with the open area on top) into the slots of the font face assembly. The clips
should snap into place.
12.To reassemble the controller, properly orient the chassis with board 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.
13. 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 25
Hardware Configuration
Insert module onto connectors
Front of controller
(circuits boards still attached to front face)
2ND
REMOTE SP
CONFIGURATION
TB2
EPROM
BATTERY
P2
P1
V
MA
TCs
RTD
TCt
SPECIAL COMMUNICATIONS MODULE
A special communications module is available for the 545; see order code in
Chapter 1 for details.
Equipment needed: Wrist grounding strap
1. Before installing the communications module, set up the hardware wiring
2. With power off, loosen two front screws, and remove them.
3. Slide the chassis out of the case by pulling firmly on the bezel. Do not detach
4. Orient the Communications Module as shown, and attach it to Connectors
Phillips screwdriver (#2)
Small flat blade screwdriver
for the application. See Chapter 4 for details.
the board assembly from the front face of the controller.
P1 and P2 as shown in Figure 4.4.
Figure 4.4
Install Communications Module
onto Microcontroller Board
5. To reassemble the controller, properly orient the chassis with board opening
on top. Align the circuit boards into the grooves on the top and bottom of the
case. Press firmly on the front face assembly until the chassis is all the way
into the case.
If it is difficult to slide the chassis in all the way, make sure the screws have
been removed (they can block proper alignment), and that the chassis is
properly oriented.
6. Carefully insert and align screws. Tighten them until the bezel is seated firmly
against the gasket. Do not overtighten.
26 Chapter 4 545 User's Manual
CHAPTER 5
SOFTWARE CONFIGURATION
The software configuration menus of the 545 contain user-selected variables that
define the action of the controller. Read through this section before making any
parameter adjustments to the controller.
When initially setting up the
controller, cycle through all the
parameters in each Menu.
Press the MENU+FAST to
advance to the next menu.
Press MENU to advance to the
next parameter (this also sets
the value for the current
parameter. Use arrow keys to
select a value).
Use the arrows keys to
enter numerical values,
and/or move through the
selection group.
press:
MENU/FAST
CONFIG.
press:
MENU
INDICATOR
press:
press MENU/FAST
Go to next Menu Block:
(D)
This is a Menu.
Its name will show in the 2nd display.
This is a menu Parameter.
The name shows in the 3rd display.
In this manual, independent parameters
appear as white text on black, and
dependent parameters appear as black
This is a parameter Value.
These values appear in the 3rd display,
replacing the parameter name.
In this manual, parameter graphics
indicate the default (factory) setting.
If the default value is dependent on other
variables, (D) is shown.
Software Configuration
Figure 5.1
Parts of the Menu Block
MENUS
In SETUP mode, there are 12 sets of options that control different aspects of 545
operation; in TUNING mode, there is one. Each set of options is called a menu.
When traversing the two modes, the menu names appear in the 2nd display.
Most of the menus are loop dependent, that is, each loop has its own set of
parameters for that menu. Three of the menus are global, that is, one set of
parameters applies to both loops.
CONFIG (Global) Mode selection and input/output hardware assignments
PV INPUT Process variable input options
CUST. LINR. Linearization curve options for PV input.
CONTROL Control options
ALARMS Alarm options
REM. SETPT. (Global) Controller remote setpoint options
RETRANS. (Global) Retransmission output options
SELF TUNE Self tune algorithm options
SPECIAL Special feature options
SECURITY (Global) Security functions
SER.COMM. (Glob al) Serial Communications options (requires comm. board)
and
TUNING Tuning parameters configuration (see Chapter 6)
CAUTION!
All software changes occur in real time;
always perform set up functions under
manual operation.
NOTE:
For information about the Tuning
menu/mode, refer to Chapter 6. For
more information about set up
parameters and 545 applications,
refer to Chapter 7.
545 User's Manual Chapter 5 27
Software Configuration
FAST
DISPLAY
TUNE PT.
AUTOMATIC
CONTACT 1
MANUAL
Figure 5.2
Independent vs. Depedent
Parameters
Figure 5.3
Configuration Flowchart
MANUAL
OPERATION
+
or
to return to
OPERATION
mode
for Loop 1
SET UP mode
PARAMETERS
Within each menu are parameters for particular control functions. Select val-
ues for each parameter depending on the specific application. Use the MENU
key to access parameters for a particular menu; the parameter name will replace the menu name in the 2nd display, and the parameter value will show in
the 3rd display.
This chapter outlines all the available parameters for the 5 45. Some parameters
are independent of any special configuration, and others are dependent on
the individual configuration. This manual displays these two types of parameters differently; refer to Figure 5.2. A special feature of the 545, called Smart
Menus, determines the correct parameters to display for the specific configuration, so not all the listed parameters will appear.
+
to move background loop to displayed loop
for
TUNING mode
TUNING
or
for
OPERATION mode
SET UP
CONFIG
PV INPUT
CUST. LINR.
CONTROL
ALARMS
for Loop 1
SET UP mode
+
to toggle through
menu blocks
in SET UP mode
+
SET UP
mode
for
TUNING mode
OPERATION mode
SET UP
CONFIG
PV INPUT
CUST. LINR.
CONTROL
ALARMS
REM. SETPT.
RETRANS.
SELF TUNE
SPECIAL
SECURITY
SER. COMM.
or
for
TUNING
+
for Loop 2
SET UP mode
+
to toggle through
menu blocks
in SET UP mode
MANUAL
OPERATION
or
to return to
OPERATION
for Loop 2
mode
+
LOOP 2
REM. SETPT.
RETRANS.
SELF TUNE
SPECIAL
SECURITY
SER. COMM.
LOOP 1
28 Chapter 5 545 User's Manual
CONFIGURATION AND OPERATION
Figure 5.3 shows the relationships among the different modes of the 545 and
the configuration menus:
• Parameter changes can only be made to the loop in the foreground
(Loop 1 upon power up). To bring the background loop into the foreground
to view and make changes, hold down FAST and press DISPLAY.
• SET UP menus can only be accessed from manual control. To transfer the
545 from automatic to manual control, press MANUAL.
• To access the SET UP menus, hold down FAST and press MENU. The
MENU key will illuminate; and CONFIG will appear in the 2nd display.
• To access the parameters for a particular menu, press MENU.
▲▲
• To select a parameter value, use
next parameter, or FAST+MENU to advance to the next menu.
• To advance to the next menu, press FAST+MENU.
• TUNING mode (and the TUNING menu) can be accessed from either automatic or manual control. To access the tuning menu, press MENU .
• To return controller to manual control, press DISPLAY or SET PT.
A key to these functions (as shown below) appears at the bottom of every page
in the menu section of this chapter.
▼▼
▲ and
▼. Press MENU to advance to the
▲▲
▼▼
Software Configuration
Access Set Up Next menu Next p arameter Next value Access Tuning Retur n to Operation Switch Loops
+
FAST MENU
MENU MENU
+
▲ ▼
MENU
DISPLAYFAST
+
FAST DISPLAY
WHERE TO GO NEXT
• For information about all the software menus and parameters, continue reading this chapter. Refer to Appendix 1 for a
quick-reference flowchart of all menus and parameters.
• For information about the installed options on the 54 5, compare the product label on top of the controller to the order code
in Chapter 1.
• To mount the controller and configure the wiring of the 545 for inputs and outputs, see Chapter 3.
• To alter the output module and jumper configuration, see Chapter 4.
• For more information about the Tuning function of the 545, see Chapter 6.
• For more information about application for the 545, see Chapter 7.
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%
545 User's Manual Chapter 5 29
Software Configuration
STEP-BY-STEP GUIDE TO SETUP PARAMETERS
CONFIG.
CTRL. TYPE
ONE LOOP
LOOP1 OUT
STANDARD
LOOP2 OUT
STANDARD
CONFIG.
For configuring the input and output hardware assignments. (GLOBAL)
1. CTRL. TYPE
Defines the fundamental controller setup.
D ONE LOOP Single PV, Single Control Output
• DUAL LOOP Two PV, with Control Output for each
• RATIO Two loops with Set Points rationed
• CASCADE Two PV with single Control Output
• FFWD.SUM Single loop control, 2nd PV added to or subtracted from output value
• FFWD.MULT Single loop control, 2nd PV multiplies output
value
2. LOOP1 OUT
Defines standard configuration for Loop 1.
D STANDARD Standard control output
• DUPLEX Duplex outputs (Refer to Chapter 7)
• STAGED Staged outputs (Refer to Chapter 7)
• POS.PROP. Position proportioning control output
3. LOOP2 OUT
Defines standard configuration for Loop 2.
D STANDARD Standard control output
• DUPLEX Duplex outputs (Refer to Chapter 7)
• STAGED Staged outputs (Refer to Chapter 7)
• POS.PROP. Position proportioning control output
• NONE Allows second loop to function as an indicator
LINE FREQ.
60 HZ
OUTPUT:2
OFF
Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops
+
FAST MENU
30 Chapter 5 545 User's Manual
MENU MENU
+
4. LINE FREQ
Specifies the power source frequency
D 60 Hz
• 50 Hz
5. OUTPUT:2
Defines the function of the second output.
D OFF Completely deactivates output
• ALM.RLY:ON
• ALM.RLY:OFF
• RETRANS. Retransmission
• COMM. ONLY Output addressable only through communications
▲ ▼
MENU
DISPLAYFAST
FAST
+
DISPLAY
6. OUTPUT:3
Defines the function of the third output.
D OFF Completely deactivates output
• ALM.RLY:ON
• ALM.RLY:OFF
• RETRANS. Retransmission
• COMM. ONLY Output addressable only through communications
Software Configuration
OUTPUT:3
Off
7. OUTPUT:4
Defines the function of the fourth output.
D OFF Completely deactivates output
• ALM.RLY:ON
• ALM.RLY:OFF
• RETRANS. Retransmission
• COMM. ONLY Output addressable only through communications
8. ANLG. RNG.:1
Defines the output signal for the first output.
D 4–20mA
• 0–20mA
• 20-4mA
• 20-0mA
9. ANLG. RNG.:2
Defines the output signal for the second output.
D 4–20mA
• 0–20mA
• 20-4mA
• 20-0mA
OUTPUT:4
OFF
ANLG.RNG.:1
4-20mA
ANLG.RNG.:2
4-20mA
10. ANLG. RNG.:3
Defines the output signal for the third output.
D 4–20mA
• 0–20mA
• 20-4mA
• 20-0mA
11. ANLG. RNG.:4
Defines the output signal for the fourth output.
D 4–20mA
• 0–20mA
• 20-4mA
• 20-0mA
Access Set Up Next menu Next parameter Next value Access Tuning Retur n to Op eration Switch Loops
+
FAST MENU
545 User's Manual Chapter 5 31
+
MENU MENU
▲ ▼
ANLG.RNG.:3
4-20mA
ANLG.RNG.:4
4-20mA
+
MENU DISPLAYFAST
FAST
DISPLAY
Software Configuration
12. CONTACT 1
CONTACT 1
L1.MAN
Defines the operation of the first digital input, for Loop 1.
D L1. MAN. Trips the controller to manual control
• L1.2ND. SP. Makes the second setpoint active
• L1. 2ND. PID. Makes the second set of PID values active
• L1. ALARM ACK. Acknowledges alarms
• L1. RST. INH. Deactivates the reset term
• L1. D.A./R.A. Switches the control action
• L1. NO. A/T Suspends the adaptive tune function
• L1. LCK. MAN Locks controller in manual control
• UP KEY Remote
• DOWN KEY Remote
▲▲
▲ function
▲▲
▼▼
▼ function
▼▼
• DISP KEY Toggle between SP DEV or OUT%
• FAST KEY Actives FAST key
• MENU KEY Activates MENU key
• COMM. ONLY Status readable only through communications
• L1.SP. 1-4 Assigns the first two digital inputs to select
setpoints 1 through 4 via BCD signal
• L1. REM. SP. Makes the remote setpoint active
CONTACT 2
L1.REM.SP
13. CONTACT 2
Defines the operation of the second digital input, for Loop 1.
• L1. MAN. Trips the controller to manual control
• L1.2ND. SP. Makes the second setpoint active
• L1. 2ND. PID. Makes the second set of PID values active
• L1. ALARM ACK. Acknowledges alarms
• L1. RST. INH. Deactivates the reset term
• L1. D.A./R.A. Switches the control action
• L1. NO. A/T Suspends the adaptive tune function
• L1. LCK. MAN Locks controller in manual control
• UP KEY Remote
• DOWN KEY Remote
• DISP KEY Toggles between SP DEV or OUT%
• FAST KEY Actives FAST key
• MENU KEY Activates MENU key
• COMM. ONLY Status readable only through communications
D L1. REM. SP. Makes the remote setpoint active
▲▲
▲ function
▲▲
▼▼
▼ function
▼▼
Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops
+
FAST MENU
MENU MENU
+
32 Chapter 5 545 User's Manual
▲ ▼
MENU
+
DISPLAYFAST
FAST
DISPLAY
14. CONTACT 3
Defines the operation of the third digital input, for Loop 1.
• L1. MAN. Trips the controller to manual control
D L1.2ND. SP. Makes the second setpoint active
• L1. 2ND. PID. Makes the second set of PID values active
• L1. ALARM ACK. Acknowledges alarms
• L1. RST. INH. Deactivates the reset term
• L1. D.A./R.A. Switches the control action
• L1. NO. A/T Suspends the adaptive tune function
• L1. LCK. MAN Locks controller in manual control
• UP KEY Remote
• DOWN KEY Remote
• DISP KEY Toggle between SP DEV or OUT%
• FAST KEY Actives FAST key
• MENU KEY Activates MENU key
• COMM. ONLY Status readable only through communications
• L1. REM. SP. Makes the remote setpoint active
▲▲
▲ function
▲▲
▼▼
▼ function
▼▼
Software Configuration
CONTACT 3
L1.2ND.SP
15. CONTACT 4
Defines the operation of the fourth digital input, for Loop 2.
D L2. MAN. Trips the controller to manual control
• L2.2ND. SP. Makes the second setpoint active
• L2. 2ND. PID. Makes the second set of PID values active
• L2. ALARM ACK. Acknowledges alarms
• L2. RST. INH. Deactivates the reset term
• L2. D.A./R.A. Switches the control action
• L2. NO. A/T Suspends the adaptive tune function
• L2. LCK. MAN Locks controller in manual control
• UP KEY Remote
• DOWN KEY Remote
• DISP KEY Toggles between SP DEV or OUT%
• FAST KEY Actives FAST key
• MENU KEY Activates MENU key
• COMM. ONLY Status readable only through communications
• L2.SP. 1-4 Assigns DIN 4 and 5 to select setpoints 1
through 4 via BCD signal
• L2. REM. SP. Makes the remote setpoint active
▲▲
▲ function
▲▲
▼▼
▼ function
▼▼
CONTACT 4
L2.MAN.
Access Set Up Next menu Next parameter Next value Access Tuning Retur n to Op eration Switch Loops
+
FAST MENU
545 User's Manual Chapter 5 33
+
MENU MENU
▲ ▼
+
MENU DISPLAYFAST
FAST
DISPLAY
Software Configuration
16. CONTACT 5
CONTACT 5
L2.REM.SP.
Defines the operation of the fifth digital input, for the Loop 2.
• L2. MAN. Trips the controller to manual control
• L2.2ND. SP. Makes the second setpoint active
• L2. 2ND. PID. Makes the second set of PID values active
• L2. ALARM ACK. Acknowledges alarms
• L2. RST. INH. Deactivates the reset term
• L2. D.A./R.A. Switches the control action
• L2. NO. A/T Suspends the adaptive tune function
• L2. LCK. MAN Locks controller in manual control
• UP KEY Remote
• DOWN KEY Remote
• DISP KEY Toggle between SP DEV or OUT%
• FAST KEY Activates FAST key
• MENU KEY Activates MENU key
• COMM. ONLY Status readable only through communications
D L2. REM. SP. Makes the remote setpoint active
▲▲
▲ function
▲▲
▼▼
▼ function
▼▼
RSP ASSN.
NONE
SLIDEWIRE
NONE
NAME L1.
LOOP ONE
17. RSP ASSN.
Defines the loop that uses the Remote Set Point.
• LOOP 1
D NONE
• LOOP 2
• BOTH
18. SLIDEWIRE
Defines the loop that uses the Slidewire Feedback.
• LOOP 1
• LOOP 2
(D) NONE
19. NAME L1.
A 9-character message associated with Loop 1. The first character of the 3rd
display will be flashing. To enter message, press
through character set. Press FAST to enter the selection and move to next
digit. Press MENU to advance to next parameter.
D LOOP ONE.
▲▲
▲ and
▲▲
▼▼
▼ keys to scroll
▼▼
Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops
+
FAST MENU
34 Chapter 5 545 User's Manual
MENU MENU
+
▲ ▼
MENU
+
DISPLAYFAST
FAST
DISPLAY
20. NAME L2.
A 9-character message associated with Loop 2. The first character of the 3rd
▲▲
display will be flashing. To enter message, press
through character set. Press FAST to enter the selection and move to next
digit. Press MENU to advance to next parameter.
D LOOP TWO.
▲ and
▼ ▼
▼ keys to scroll
▲▲
▼ ▼
Software Configuration
NAME L2.
LOOP TWO
PV INPUT
For configuring the process variable (PV) input.
1. PV TYPE
Selects the particular sensor or input range.
T/C RTD Voltage Current (mA)
D J T/C D DIN RTD D 1-5 V D 4-20 mA
• E T/C • JIS RTD • 0-5 V • 0-20 mA
• K T/C • SAMA RTD • 0-10 mV
• B T/C • 0-30 mV
• N T/C • 0-60 mV
• R T/C • 0-100 mV
• S T/C • +/-25 mV
• T T/C
• W T/C
• W5 T/C
• PLAT.II T/C
2. DEG. F/C/K
Selects the temperature unit if using a thermocouple or RTD.
D FAHR.
• CELSIUS
• KELVIN
PV INPUT
PV TYPE
(D)
CAUTION!
Set parameter values in the
presented order—dependent
parameters are dynamically related
and changing values of one can alter
the value of another.
For example, if SP LO LIM. is set to
0, and the thermocouple type is
changed to B T/C, the SP LO LIM.
value will change to 104° (the low
limit of a type B thermocouple).
DEG. F/C/K
FAHR
3. DECIMAL
Specifies the decimal point position.
D XXXXX
• XXXX.X
• XXX.XX
• XX.XXX
• X.XXXX
4. LINEARIZE
Specifies if the input is to be linearized (automactic for T/C’s and RTD’s).
D NONE
• SQR. ROOT Square root linearization is activated.
• CUSTOM
Access Set Up Next menu Next parameter Next value Access Tuning Retur n to Op eration Switch Loops
+
FAST MENU
545 User's Manual Chapter 5 35
+
15-point custom linearization curve is activated.
MENU MENU
▲ ▼
Decimal
xxxxx
LINEARIZE
NONE
+
MENU DISPLAYFAST
FAST
DISPLAY
Software Configuration
5. LOW RANGE
LOW RANGE
(D)
6. HI RANGE
HI RANGE
(D)
7. SP LO LIM.
SP LO LIM.
(D)
8. SP HI LIM.
SP HI LIM.
(D)
Specifies the engineering unit value corresponding to the lowest input value,
e.g. 4mA.
R –9999 to 99999 Maximum is HI RANGE
D Dependent on Input Selection
Specifies the engineering unit value corresponding to the highest input value,
e.g. 20mA.
R –9999 to 99999 Minimum is LOW RANGE
D Dependent on Input Selection.
Defines the lowest setpoint value that can be entered from the front panel only.
R –9999 to 99999
D Dependent on LOW RANGE
Defines the highest setpoint value that can be entered from the front panel
only.
R –9999 to 99999
D Dependent on HI RANGE
Minimum is LOW RANGE, Maximum is SP HI LIM
Minimum is SP LO. LIM., Maximum is HI RANGE
SP RAMP
OFF
FILTER
0
PV OFFSET
0
PV GAIN
1.000
NOTE
Refer to Chapter 7 for more information
on Offset and Gain.
9. SP RAMP
Defines the rate of change for setpoint changes.
R 1 to 99999 units/hour
D OFF (Deactives the function)
10. FILTER
Defines the setting for the low pass input filter.
R 0 to 120 seconds
D0
11. PV OFFSET
Defines the offset to the process variable in engineering units.
R –9999 to 99999 units
D0
12. PV GAIN
This defines the gain to the process variable.
R 0.100 to 10.000 units
D 1.000
Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops
+
FAST MENU
36 Chapter 5 545 User's Manual
MENU MENU
+
▲ ▼
MENU
+
DISPLAYFAST
FAST
DISPLAY
13.PV RESTOR.
Defines the control mode when a broken process variable signal is restored.
D LAST MODE
• MANUAL
• AUTOMATIC
Software Configuration
PV RESTOR.
LAST MODE
CUST. LINR.
Defines a custom linearization curve for the process variable input. Points 1 and 15 are
fixed to the low and high end of the input range, and require only setting a corresponding PV value. Points 2 through 14 (the Xth points) require setting both the
input and PV values.
It is not necessary to use all 15 points. Whenever the XTH INPUT becomes the
high end of the range, that will be the last point in the lineraization table.
1. 1ST. INPUT
Specifies the input signal for to the first point.
D The low end of the appropriate input range (e.g. 4.00mA)
2. 1ST. PV
Specifies the engineering unit value for to the first point.
R –9999 to 99999
D0
3. XTH. INPUT
Specifies the input signal for to the XTH point (X is 2 to 14) .
R Any value greater than the first input
D The low end of the appropriate input range (e.g. 4.00mA)
4. XTH. PV
Specifies the engineering unit value for to the XTH point (X is 2 to 14).
R –9999 to 99999
D0
CUST. LINR.
1ST.INPUT
(D)
1ST. PV
0
XTH.INPUT
(D)
XTH. PV
0
5. 15TH. INPT.
Specifies the input signal for to the 15th point.
R –9999 to 99999
D The high end of the appropriate input range (e.g. 20.00mA)
6. 15TH. PV
Specifies the engineering unit value for to the 15th point.
R –9999 to 99999 Minimum is [XTH-1] INPUT
D0
Access Set Up Next menu Next parameter Next value Access Tuning Retur n to Op eration Switch Loops
+
FAST MENU
545 User's Manual Chapter 5 37
+
MENU MENU
▲ ▼
15TH. INPUT
(D)
15TH. PV
0
+
MENU DISPLAYFAST
FAST
DISPLAY
Software Configuration
CONTROL
ALGORITHM
PID
D.SOURCE
PV
ACTION:1
REVERSE
CONTROL
For configuring choices for the control algorithm.
1. ALGORITHM
Defines the control algorithm used.
DPID
•PI
•PD
•P
• ON/OFF
• PID:ON/OFF For duplex applications using PID for the first
output and on/off for the second output
2. D. SOURCE
Selects the variable used to determine the derivative action.
D PV “D” term will not react when you change the
setpoint
• DEVIATION “D” term will react when you change the
setpoint
3. ACTION:1
Defines the action of the first control output.
• DIRECT
D REVERSE
4. FIXED LAG
FIXED LAG
0
Defines the fixed amount of lag between control iterations.
R 0 to 14400 seconds
D 0 seconds
5. VARBL. LAG
VARBL. LAG
0
Defines the variable amound of lag between control iterations.
R 0 to 14400 seconds
D 0 seconds
6. MAX. LAG
MAX. LAG
0
Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops
+
FAST MENU
MENU MENU
+
Sets the maximum lag time as a result of PV2 action
R 0 to 14400 seconds
D 0 seconds
▲ ▼
MENU
DISPLAYFAST
FAST
+
DISPLAY
38 Chapter 5 545 User's Manual
Software Configuration
7. PV BREAK
Defines the manual output level if the process variable input is lost.
Standard Velocity Prop.
R -5 to 105 % D CW
D 0 • CCW
• OUTS.OFF
On/Off Dual On/Off PID On/Off
• ON • 1:ON, 2:ON R (-5 to 105%), 2:ON
D OFF • 1:ON, 2:OFF R (-5 to 105%), 2:OFF
• 1:OFF, 2:ON D 0 %, 2:OFF
D 1:OFF, 2:OFF
Feed Forward Loop 1 Feed Forward Loop 2
R -5 to 105% R -100 to 100%
• FEED FWD. D 0%
D0%
8. LOW OUT.
Defines the lowest output value that can be achieved in automatic control.
R 0 – 100% Maximum is HIGH OUT
D 0%.
9. HIGH OUT.
Defines the highest output value that can be achieved in automatic control.
R 0 – 100% Minimum is LOW OUT
D 100%
PV BREAK
(D)
LOW OUT.
0%
HIGH OUT.
100%
10. FF LO LIM.
Defines the low limit for the feed forward output contribution when
Loop 2 is in AUTO mode.
R -100 to 100%
D -100%
FF LO LIM.
-100%
11. FF HI LIM.
Defines the high limit for the feed forward output contribution when Loop 2 is in
AUTO mode.
R -100 to 100%
D 100%
FF HI LIM.
100%
12. ACTION:2
Defines the action of the second control output.
D DIRECT
• REVERSE
Access Set Up Next menu Next parameter Next value Access Tuning Retur n to Op eration Switch Loops
+
FAST MENU
MENU MENU
+
▲ ▼
MENU DISPLAYFAST
ACTION:2
DIRECT
FAST
+
DISPLAY
545 User's Manual Chapter 5 39
Software Configuration
13. CCW TIME
CCW TIME
60
14. CW TIME
CW TIME
60
15. MIN. TIME
MIN. TIME
0.1
16. S/W RANGE
S/W RANGE
100
Defines the time it takes a motor to fully stroke counterclockwise.
R 1 to 200 seconds
D 60 seconds
Defines the time it takes a motor to fully stroke clockwise.
R 1 to 200 seconds
D 60 seconds
Defines the minimum amount of time the controller must specify for the motor to
be on before it takes action.
R 0.1 to 10.0 seconds
D 0.1 seconds
Specifies the full range resistance of the slide (e.g., 100 ohms)
R 0 –1050 Ohms
D 100 Ohms
OPEN F/B
(D)
CLOSE F/B
100
OUT1 STOP
50
OUT2 STRT.
50
17. OPEN F/B
Defines the feedback ohm value corresponding to full open (100% output).
R 0 to S/W RANGE
D Dependent upon S/W RANGE value
18. CLOSE F/B
Defines the feedback ohm value corresponding to full close (0% output).
R 0 to S/WRANGE
D 100
19. OUT1 STOP
Defines the stopping point for control output 1 when staging outputs.
R 1 to 100%
D 50%
20. OUT2 STRT.
Defines the starting point for control output 2 when staging outputs.
R 0 to 99%
D 50%
Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops
+
FAST MENU
40 Chapter 5 545 User's Manual
MENU MENU
+
▲ ▼
MENU
+
DISPLAYFAST
FAST
DISPLAY
Software Configuration
ALARMS
For configuring alarms.
1. ALM. TYPE:1
Defines the type of alarm for alarm 1.
• HIGH ALRM.
• LOW ALARM
• HIGH/LOW Separate High and Low alarm setpoints in one
alarm
• BAND
• DEVIATION
• MANUAL Causes an alarm when in manual control
• REMOTE SP Causes an alarm when in Remote Setpoint
• RATE Selects a rate-of-change alarm
D OFF Deactivates the first alarm
2. ALM. SRC:1
Selects the source of the value being monitored by a HIGH, LOW or HI GH/LOW
alarm 1.
DPV
•SP
• RAMP SP
• DEVIATION
• OUTPUT
ALARMS
ALM. TYPE:1
OFF
ALM. SRC:1
PV
3. ALARM SP:1
Specifies the alarm set point for alarm 1.
For HIGH or LOW alarms:
If ALM.SRC.:1=OUTPUT If ALM.SRC.:1=any other type
R 0.0% to 100.0% R LOW RANGE to HI RANGE
D 0.0% D 0
For BAND alarms:
R 1 to 99999
D0
For DEVIATION or RATE alarms:
R -9999 to 99999
D0
ALARM SP:1
(D)
4A. HIGH SP:1
Specifies the high alarm set point for alarm 1.
If ALM.SRC.:1=OUTPUT If ALM.SRC.:1=any other type
R 0.0% to 100.0% R LOW RANGE to HI RANGE
D 0.0% D 0
Access Set Up Next menu Next parameter Next value Access Tuning Retur n to Op eration Switch Loops
+
FAST MENU
MENU MENU
+
▲ ▼
MENU DISPLAYFAST
HIGH SP:1
(D)
FAST
+
DISPLAY
545 User's Manual Chapter 5 41
Software Configuration
4B. LOW SP:1
LOW SP:1
(D)
5. DEADBAND:1
DEADBAND:1
(D)
6. ALM.:1 OUT.
ALM.:1 OUT.
NONE
Specifies the low alarm setpoint for alarm 1.
If ALM.SRC.:1=OUTPUT If ALM.SRC.:1=any other type
R 0.0% to 100.0% R LOW RANGE to HI RANGE
D 0.0% D 0
Defines the deadband for alarm 1.
If ALM.SRC.:1=OUTPUT If ALM.SRC.:1=any other type
R 0.1% to 100.0% R 1 to 9999
D 0.2% D 2
Selects the output number for alarm 1.
D NONE
•2
•3
•4
LATCHING:1
LATCH
ACK.:1
ENABLED
POWER UP:1
NORMAL
MESSAGE:1
ALARM 1
7. LATCHING:1
Defines the latching sequence of alarm 1.
D LATCH
• NO LATCH
8. ACK.:1
Defines whether alarm 1 may be acknowledged.
D ENABLED This allows the alarm to be acknowledged
• DISABLED This prevents the alarm from being acknowledged while in alarm condition
9. POWER UP:1
Defines how alarm 1 will be treated on power up.
D NORMAL Alarm depends on process variable
• ALARM Always power up in alarm regardless of PV
• DELAYED Must leave alarm condition and reenter before
activating the alarm
10. MESSAGE:1
A 9- character message associated with alarm 1. The first character of the 3rd
display will be flashing. To enter message, press arrow keys to scroll through
character set. Press FAST key to enter the selection and move to next digit.
Press MENU key to advance to next parameter.
D ALARM 1
Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops
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42 Chapter 5 545 User's Manual
MENU MENU
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▲ ▼
MENU
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DISPLAYFAST
FAST
DISPLAY
11. ALM. TYPE:2
Defines the type of alarm for alarm 2.
• HIGH ALRM.
• LOW ALARM
• HIGH/LOW Separate High and Low alarm setpoints in one
alarm
• BAND
• DEVIATION
• MANUAL Causes an alarm when in manual control
• REMOTE SP Causes an alarm when in Remote Setpoint
• RATE Selects a rate-of-change alarm
D OFF Deactivates the first alarm
12. ALM. SRC:2
Selects the source of the value being monitored by a HIGH, LOW or HIGH/LOW
alarm 2.
DPV
•SP
• RAMP SP
• DEVIATION
• OUTPUT
Software Configuration
ALM. TYPE:2
OFF
ALM.SRC:2
PV
13. ALARM SP:2
Specifies the alarm setpoint for alarm 2.
For HIGH or LOW alarms:
If ALM.SRC.:2 = OUTPUT If ALM.SRC.:2 = any other type
R 0.0% to 100.0% R LOW RANGE to HI RANGE
D 0.0% D 0
For BAND alarms:
R 1 to 99999
D0
For DEVIATION or RATE alarms:
R -9999 to 99999
D0
14A. HIGH SP:2
Specifies the high alarm setpoint for alarm 1.
If ALM.SRC.:2 = OUTPUT If ALM.SRC.:2 = any other type
R 0.0% to 100.0% R LOW RANGE to HI RANGE
D 0.0% D 0
ALARM SP:2
(D)
HIGH SP:2
(D)
Access Set Up Next menu Next parameter Next value Access Tuning Retur n to Op eration Switch Loops
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FAST
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Software Configuration
14B. LOW SP:2
LOW SP:2
(D)
15. DEADBAND:2
DEADBAND:2
2
16. ALM.:2 OUT.
ALM.:2 OUT.
NONE
Specifies the low alarm set point for alarm 2.
If ALM.SRC.:2 = OUTPUT If ALM.SRC.:2 = any other type
R 0.0% to 100.0% R LOW RANGE to HI RANGE
D 0.0% D 0
Defines the deadband for alarm 2.
If ALM.SRC.:2 = OUTPUT If ALM.SRC.:2 = any other type
R 0.1% to 100.0% R 1 to 9999
D 0.2% D 2
Selects the output number for alarm 2.
D NONE
•2
•3
•4
LATCHING:2
LATCH
ACK.:2
ENABLED
POWER UP:2
NORMAL
MESSAGE:2
ALARM 2
17. LATCHING:2
Defines the latching sequence of alarm 2.
D LATCH
• NO LATCH
18. ACK.:2
Defines whether alarm 2 may be acknowledged.
D ENABLED Allows the alarm to be acknowledged
• DISABLED Prevents alarm acknowledgment while alarm
condition exists.
19. POWER UP:2
Defines how alarm 2 will be treated on power up.
D NORMAL Alarm depends on process variable
• ALARM Always power up in alarm regardless of PV
• DELAYED Must leave & reenter alarm condition before
activating alarm
20. MESSAGE:2
A 9-character message associated with alarm 2. The first character of the 3rd
display will be flashing. To enter message, press arrow keys to scroll through
character set. Press FAST key to enter the selection and move to next digit.
Press MENU key to advance to next parameter.
D ALARM 2
Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops
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44 Chapter 5 545 User's Manual
MENU MENU
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▲ ▼
MENU
+
DISPLAYFAST
FAST
DISPLAY
21. FAULT
Defines whether either of the alarm relays will trip if a fault condition (lost process variable) is detected.
Only appears if at least one alarm relay is installed.
D OFF
• ALARM 1
• ALARM 2
Software Configuration
FAULT
OFF
22. OUTPUT
Defines whether a rate-of-change alarm will be interpreted as a lost or broken
process variable (causing a trip to manual output).
• P.V. BREAK
D NO ACTION
23. RATE TIME
Defines the time period over which a rate-of-change alarm condition will be
determined.
R 1 to 3600 seconds
D 5 seconds
REM. SETPT.
For configuring the remote setpoint. (GLOBAL)
1. TYPE V/mA
Specifies the type of input signal that will be used for remote setpoint.
D 1-5/4-20 Volts, mA
• 0-5/0-20 Volts, mA
2. RSP:LO RNG.
Specifies the engineering unit value corresponding to the lowest remote
setpoint input value, e.g. 4mA.
R -9999 to 99999
D0
OUTPUT
NO ACTION
RATE TIME
5
REM. SETPT.
TYPE V/MA
1-5/4-20
RSP:LO RNG.
0
3. RSP:HI RNG.
Specifies the engineering unit value corresponding to the highest remote
setpoint input value, e.g. 20mA.
R –9999 to 99999
D 1000
4. TRACKING
Defines whether the local setpoints 1 to 8 will track the remote setpoint.
DNO
• YES
Access Set Up Next menu Next parameter Next value Access Tuning Retur n to Op eration Switch Loops
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545 User's Manual Chapter 5 45
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MENU MENU
▲ ▼
RSP:HI RNG.
1000
TRACKING
NO
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MENU DISPLAYFAST
FAST
DISPLAY
Software Configuration
5. BIAS LOW
BIAS LOW
-1000
6. BIAS HIGH
BIAS HIGH
1000
7. RSP FIXED
RSP. FIXED
LOCAL
Defines the lowest bias value that may be entered.
R –9999 to 99999 (Maximum is BIAS HIGH)
D –1000
Defines the highest bias value that may be entered.
R –9999 to 99999 (Minimum value BIAS LOW)
D 1000
Defines what happens if remote setpoint is lost while it is active and then is restored.
• REMOTE SP Returns to remote setpoint when it is restored
D LOCAL Local SP remains active when remote SP is re-
stored
RETRANS.
TYPE:2
PV1
LO RANGE:2
(D)
HI RANGE:2
(D)
RETRANS.
For configuring the retransmission output. (GLOBAL)
1. TYPE:2
Defines what is to be retransmitted for output 2.
D PV1 Linearized process variable 1
• SP1 Target setpoint 1
• RAMP SP1 Ramping (actual) setpoint 1
• OUT L1 Control output 1
• PV2 Linearized process variable 2
• SP2 Target setpoint 2
• RAMP SP2 Ramping (actual) setpoint 2
• OUT L2 Control output 2
2. LO RANGE:2
Defines the low end of the range of output 2 in engineering units.
R –9999 to 99999
D Dependent upon process variable range
3. HI RANGE:2
Defines the high end of the range of output 2 in engineering units.
R –9999 to 99999
D Dependent on the process variable range
Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops
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FAST
DISPLAY
4. TYPE:3
Defines what is to be retransmitted for output 3.
D PV1 Linearized process variable 1
• SP1 Target setpoint 1
• RAMP SP1 Ramping (actual) setpoint 1
• OUT L1 Control output 1
• PV2 Linearized process variable 2
• SP2 Target setpoint 2
• RAMP SP2 Ramping (actual) setpoint 2
• OUT L2 Control output 2
5. LO RANGE:3
Defines the low end of the range for output 3 in engineering units.
R –9999 to 99999
D Dependent upon process variable range
6. HI RANGE:3
Defines the high end of the range for output 3 in engineering units.
R –9999 to 99999
D Dependent on the process variable range
Software Configuration
TYPE:3
PV1
LO RANGE:3
(D)
HI RANGE:3
(D)
7. TYPE:4
Defines what is to be retransmitted for output 4.
D PV1 Linearized process variable 1
• SP1 Target setpoint 1
• RAMP SP1 Ramping (actual) setpoint 1
• OUT L1 Control output 1
• PV2 Linearized process variable 2
• SP2 Target setpoint 2
• RAMP SP2 Ramping (actual) setpoint 2
• OUT L2 Control output 2
8. LO RANGE:4
Defines the low end of the range for output 4 in engineering units.
R –9999 to 99999
D Dependent upon process variable range
9. HI RANGE:4
Defines the high end of the range for output 4 in engineering units.
R –9999 to 99999
D Dependent on the process variable range
TYPE:4
PV1
LO RANGE:4
(D)
HI RANGE:4
(D)
Access Set Up Next menu Next parameter Next value Access Tuning Retur n to Op eration Switch Loops
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MENU DISPLAYFAST
FAST
DISPLAY
Software Configuration
SELF TUNE
TYPE
DISABLED
PRETUNE
TYPE 1
TYPE
AUTOMATIC
SELF TUNE
For configuring the self tune algorithm.
1. TYPE
Defines the type of self tuning algorithm that is available.
• PRETUNE Allows the operator to initiate Pretune only
• ADAPTIVE Allows the operator to initiate Adaptive Tune
only
• BOTH Allows the operator to initiate both Pretune and
Adaptive Tune
D DISABLED Both Pretune and Adaptive Tune are disabled
2. PRETUNE
Defines the type of pretune algorithm that is available.
D TYPE 1 Normally used with slower thermal processes
• TYPE 2 Normally used with faster fluid or pressure processes
• TYPE 3 Normally used with level control applications.
3. TUNE PT.
Defines the PV value at which the output with switch off during a TYPE 1
pretune, which helps prevent overshoot.
D AUTOMATIC Controller defines this point
• XXX.X Enter any value within PV RANGE
4. OUT. STEP
OUT. STEP
10.0
Defines the output step size in absolute percent during TYPE 2 or TYPE 3
pretune.
R -50.0 to 50.0%
D 10.0%
5. LOW LIMIT
LOW LIMIT
(D)
Defines the lower limit the process variable can reach during pretune before
aborting.
R The process variable range
D Dependent on the process variable range
6. HI LIMIT
HI LIMIT
(D)
Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops
+
FAST MENU
MENU MENU
+
Defines the upper limit the process variable can reach during pretune before
aborting.
R The process variable range
D Dependent on the process variable range
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DISPLAY
48 Chapter 5 545 User's Manual
7. TIMEOUT
Defines the execution time limit for pretune before aborting.
R 8 to 1500 minutes
D 1500 minutes
8. MODE
Defines the control mode after pretune is completed.
• MANUAL
D AUTOMATIC
9. NOISE BND.
Defines the noise band to be used by the adaptive tuning algorithm, as a percentage of the process variable range.
R 0.1 to 10%
D 0.2%
10. RESP. TIME
Defines response time to be used by the adaptive tuning algorithm.
R 10 to 32000 seconds
D 7200 seconds
Software Configuration
TIMEOUT
1500
MODE
AUTOMATIC
NOISE BND.
0.2
RESP. TIME
7200
11. DEAD TIME
Defines the amount of time the process runs before controller responds to an
output change (POWER BACK feature).
R 0.1 to 7200.0 seconds
D 0.1 seconds
SPECIAL
For configuring special features.
1. AUTO. TRIP
Defines the condition under which the 545 will automatically trip to automatic
control from manual control upon start up.
D OFF Deactivates this function
• RISING PV Will trip when a rising process variable is within
the specified deviation from the setpoint
• FALLNG. PV Will trip when a falling process variable is
within the specified deviation from the setpoint
2. TRIP DEV.
Defines the deviation from setpoint at which the controller trips to automatic.
If AUTO.TRIP = RISING PV If AUTO.TRIP = FALLING PV
R -99999 to 0 R 0 to 99999
D0 D0
DEAD TIME
0.1
SPECIAL
AUTO. TRIP
OFF
TRIP DEV.
(D)
Access Set Up Next menu Next parameter Next value Access Tuning Retur n to Op eration Switch Loops
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MENU DISPLAYFAST
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Software Configuration
3. DES.OUT.N (N = 1 to 5)
DES.OUT.N
(D)
4. POWER UP
POWER UP
LAST MODE
5. PWR. UP:OUT.
PWR. UP:OUT
(D)
Designates the output value the corresponding digital input has placed the controller in manual mode. Choose values based on your process.
Standard Control On/Off Control Velocity Prop Control
• –5 to 105% • ON • CW
D LAST OUT D OFF • CCW
D OUTS. OFF
Defines the control mode upon power up.
D LAST MODE Power up in the same mode prior to power down
• MANUAL
• AUTOMATIC
• PRETUNE Will Pretune on every power up (recommended
for TYPE 1 pretune only).
Defines the output of the controller if powering up in manual mode. Choose values based on your process.
Standard Control On/Off Control Velocity Prop Control
• –5 to 105% • ON • CW
D LAST OUT D OFF • CCW
D OUTS. OFF
6. PWR. UP:SP
PWR. UP:SP
LAST SP
This defines the setpoint upon power up.
D LAST SP Will power up with the same setpoint (local or re-
mote) that was active prior to power down
• LOCAL Will power up using primary local setpoint
• REMOTE Will power up using remote setpoint, if available
7. NO. OF SP
Defines the number of local setpoints (up to 8) to be stored for selection by the
front SET PT key or (up to 4) for selection by BCD (Binary Coded Decimal)
NO. OF SP
1
Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops
+
FAST MENU
MENU MENU
+
digital inputs.
R 1 to 8 digits
D1
▲ ▼
MENU
+
DISPLAYFAST
FAST
DISPLAY
50 Chapter 5 545 User's Manual
Software Configuration
SECURITY
For configuring the security function. (GLOBAL)
1. SEC. CODE
Defines the security code for temporarily unlocking the instrument.
R –9999 to 99999.
D0
2. SP ADJUST
Defines lockout status for setpoint changes.
D UNLOCKED
• LOCKED
3. AUTO./MAN.
Defines lockout status for MANUAL key.
D UNLOCKED
• LOCKED
4. SP SELECT
Defines lockout status for SET PT key.
D UNLOCKED
• LOCKED
SECURITY
SEC. CODE
0
SP ADJUST
UNLOCKED
AUTO./MAN.
UNLOCKED
SP SELECT
UNLOCKED
5. ALARM ACK.
Defines lockout status for ACK key.
D UNLOCKED
• LOCKED
6. TUNING
Defines lockout status for adjusments to tuning parameters.
D UNLOCKED
• LOCKED
7. CONFIGURE
Defines lockout status for configuration parameters.
D UNLOCKED
• LOCKED
ALARM ACK.
UNLOCKED
TUNING
UNLOCKED
CONFIGURE
UNLOCKED
Access Set Up Next menu Next parameter Next value Access Tuning Retur n to Op eration Switch Loops
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MENU DISPLAYFAST
FAST
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Software Configuration
SER. COMM.
STATION
1
BAUD RATE
9600
CRC
YES
SER. COMM.
For configuring the serial communications features. (GLOBAL)
1. STATION
Defines the unit’s station address (one address for both loops in dual loop
mode).
R1 to 99
• OFF (Disables the communications function)
D1
2. BAUD RATE
Defines the baud rate.
• 1200 BPS
• 2400 BPS
• 4800 BPS
D 9600 BPS
• 19200 BPS
3. CRC
Defines whether CRC (cyclic redundancy check) is being calculated.
D YES
•NO
SHED TIME
OFF
SHED MODE
LAST MODE
SHED OUT
(D)
4. SHED TIME
Defines the time interval between communications activity before the controller determines that communications is lost (“sheds”).
R 1 to 512 seconds
D OFF
5. SHED MODE
Defines the state of the controller if communications is lost (“sheds”).
D LAST MODE The 545 remains in either automatic or manual
control
• MANUAL Trips to manual control
• AUTOMATIC Trips to automatic control
6. SHED OUT.
Defines the output if the unit sheds and trips to manual control. Choose values
based on your process.
Standard Control On/Off Control Velocity Prop Control
• –5 to 105% • ON • CW
D LAST OUT D OFF • CCW
D OUTS. OFF
Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops
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DISPLAYFAST
FAST
DISPLAY
7. SHED SP
Defines the setpoint status if communications is lost.
D LAST SP Continues to use the setpoint that was active
prior to communications being lost.
• DESIG. SP Goes to a designated setpoint value if communications is lost.
8. DESIG. SP
Defines the value of the designated setpoint if communications is lost.
R The process variable range
D Dependent on the process variable range
Software Configuration
SHED SP
LAST SP
DESIG. SP
(D)
Access Set Up Next menu Next parameter Next value Access Tuning Retur n to Op eration Switch Loops
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545 User's Manual Chapter 5 53
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MENU DISPLAYFAST
FAST
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Software Configuration
PARAMETER VALUE CHARTS
This section of value charts is provided for logging the actual parameters values and selections for the process. It is
recommended that these pages be photocopies so there will always be a master.
CONFIG (Global)
Parameter Description Value
1 CTRL. TYPE Defines fundamental controller Set Up
2 LINE FREQ. Defines the power source frequency
3 LOOP1 OUT Defines standard configuration for Loop 1
4 LOOP2 OUT Defines standard configuration for Loop 2
5 OUTPUT:2 Function of the second output
6 OUTPUT:3 Function of the third output
7 OUTPUT:4 Function of the fourth output
8 ANLG.RNG.:1 Output signal for the first output
9 ANLG.RNG.:2 Output signal for the second output
10 ANLG.RNG.:3 Output signal for the third output
11 ANLG.RNG.:4 Output signal for the fourth output
12 CONTACT 1 Operation of the first digital input for Loop 1
13 CONTACT 2 Operation of the second digital input for Loop 1
14 CONTACT 3 Operation of the third digital input for Loop 1
15 CONTACT 4 Operation of the fourth digital input for Loop 2
16 CONTACT 5 Operation of the fifth digital input for Loop 2
17 RSP ASSN. Defines which loop uses the Remote Set Point
18 SLIDEWIRE Defines which loop uses Slidewire Feedback
19 NAME L1 Allows 9 character message to name Loop 1
20 NAME L2 Allows 9 character message to name Loop 2
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Software Configuration
PV INPUT
Parameter Description Value Loop 1 Value Loop 2
1 PV TYPE Sensor or range to be used
2 DEG. F/C/K Temperature engineering unit
3 DECIMAL Decimal point position
4 LINEARIZE Type of input linearization
5 LOW RANGE Engineering unit value for lowerst input value
6 HI RANGE Engineering unit value for highest input value
7 SP LO LIM. Lowest setpoint value that can be entered from front panel
8 SP HI LIM. Highest setpoint value that can be entered from front panel
9 SP RAMP Rate of change for setpoint changes
10 FILTER Setting for the low pass input filter
11 PV OFFSET Offset to the PV in engineering units
12 PV GAIN Gain to the PV
13 PV RESTOR. Control mode when a broken PV is restored
545 User's Manual Chapter 5 55
Software Configuration
CUST. LINR.
Parameter Description Value Loop 1 Value Loop 2
1 1st INPUT Input signal for the 1st point (of the 15 point curve)
2 1st PV Engineering unit value for the 1st point
3 2nd INPUT Input signal for the 2nd point (of the 15 point curve)
4 2nd PV Engineering unit value for the 2nd point
5 Xth INPUT Input signal for the Xth (last) point (of the 15 point curve)
6 Xth PV Engineering unit value for the Xth (last point)
7 3rd INPUT Input signal for the 3rd point (of the 15 point curve)
8 3rd PV Engineering unit value for the 3rd point
9 4th INPUT Input signal for the 4th point (of the 15 point curve)
10 4th PV Engineering unit value for the 4th point
11 5th INPUT Input signal for the 5th point (of the 15 point curve)
12 5th PV Engineering unit value for the 5th point
13 6th INPUT Input signal for the 6th point (of the 15 point curve)
14 6th PV Engineering unit value for the 6th point
15 7th INPUT Input signal for the 7th point (of the 15 point curve)
16 7th PV Engineering unit value for the 7th point
17 8th INPUT Input signal for the 8th point (of the 15 point curve)
18 8th PV Engineering unit value for the 8th point
19 9th INPUT Input signal for the 9th point (of the 15 point curve)
20 9th PV Engineering unit value for the 9th point
21 10th INPUT Input signal for the 10th point (of the 15 point curve)
22 10th PV Engineering unit value for the 10th point
23 11th INPUT Input signal for the 11th point (of the 15 point curve)
24 11th PV Engineering unit value for the 11th point
25 12th INPUT Input signal for the 12th point (of the 15 point curve)
26 12th PV Engineering unit value for the 12th point
27 13th INPUT Input signal for the 13th point (of the 15 point curve)
28 13th PV Engineering unit value for the 13th point
29 14th INPUT Input signal for the 14th point (of the 15 point curve)
30 14th PV Engineering unit value for the 14th point
31 15th INPUT Input signal for the15th point (of the 15 point curve)
32 15th PV Engineering unit value for the 15th point
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Software Configuration
CONTROL
Parameter Description Value Loop 1 Value Loop 2
1 ALGORITHM Control algorithm used
2 D. SOURCE Variable used to determine the derivative value
3 ACTION:1 Action of the first control output
4 FIXED LAG Fixed amount of lag between control iterations
5 VARBL. LAG Variable amount of lag between control iterations
6 MAX. LAG Maximum as result of PV2 action.
7 PV BREAK Output level if the process variable input is lost
8 LOW OUT. Lowest output value in automatic control
9 HIGH OUT. Highest output value in automatic control
10 FF LO LIM. Low limit for feed forward output contribution
when Loop 2 is in automatic control
11 FF HI LIM. High limit for feed forward output contribution
when Loop 2 is in automatic control
12 ACTION:2 Action of the second control output
13 CCW TIME Time for motor to fully stroke in the CCW direction
14 CW TIME TIme for motor to fully stroke in the CW direction
15 MIN. TIME Minimum on-time for the motor before taking action
16 S/W RANGE Full range resistance of the slidewire
17 OPEN F/B Feedback ohm value when the valve is open
18 CLOSE F/B Feedback ohm value when the valve is closed
19 OUT1 STOP Stopping point for control output 1 when staging outputs
20 OUT2 STRT. Starting point for control output 2 when staging outputs
545 User's Manual Chapter 5 57
Software Configuration
ALARMS
Parameter Description Value Loop 1 Value Loop 2
1 ALM. TYPE:1 Type of alarm for alarm 1
2 ALM. SRC.:1 Source of value monitored by HIGH, LOW or HIGH/LOW alarm 1
3 ALARM SP:1 Alarm setpoint for alarm 1 (except for HIGH/LOW)
4A HIGH SP:1 High alarm setpoint for HIGH/LOW alarm 1
4B LOW SP:1 Low alarm setpoint for HIGH/LOW alarm 1
5 DEADBAND:1 Deadband for alarm 1
6 ALM.:1 OUT. Output number for alarm 1
7 LATCHING:1 Latching sequence for alarm 1
8 ACK.:1 Whether alarm 1 may be acknowledged
9 POWER UP:1 How alarm 1 will be treated upon power up
10 MESSAGE:1 Nine character message associated with alarm 1
11 ALM. TYPE:2 Type of alarm for alarm 2
12 ALM. SRC.:2 Source of value monitored by HIGH, LOW or HIGH/LOW alarm 2
13 ALARM SP:2 Alarm setpoint for alarm 1 (except for HIGH/LOW)
14A HIGH SP:2 High alarm setpoint for HIGH/LOW alarm 2
14B LOW SP:2 Low alarm setpoint for HIGH/LOW alarm 2
15 DEADBAND :2 Deadband for alarm 2
16 ALM.:2 OUT. Output number for alarm 2
17 LATCHING :2 Latching sequence for alarm 2
18 ACK.:2 Whether alarm 2 may be acknowledged
19 POWER UP:2 How alarm 2 will be treated upon power up
20 MESSAGE:2 Nine character message associated with alarm 2
21 FAULT Alarm relay status if fault condition is detected
22 OUTPUT Output if the rate-of-change alarm is tripped
23 RATE TIME Time period over which a rate-of-change alarm is determined
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Software Configuration
REM. SETPT. (Global)
Parameter Description Value
1 TYPE V/mA Input signal to be used for remote setpoint
2 RSP: LO RNG. Engineering unit value corresponding to low remote setpoint input value
3 RSP: HI RNG. Engineering unit value corresponding to high remote setpoint input value
4 RSP: LOW Lowest setpoint value to be accepted from the remote setpoint source
5 RSP: HIGH Highest setpoint value to be accepted from the remote setpoint source
6 TRACKING Whether the local setpoint will track the remote setpoint
7 BIAS LOW Lowest bias value that may be entered
8 BIAS HIGH Highest bias value that may be entered
9 RSP FIXED What happens if remote setpoint is lost while active and then restored
RETRANS. (Global)
Parameter Description Value
1 TYPE:2 What is to be retransmitted for output 2
2 LO RANGE:2 Low end of the range of output 2 in engineering units
3 HI RANGE:2 High end of the range of output 2 in engineering units
4 TYPE:3 What is to be retransmitted for output 3
5 LO RANGE:3 Low end of the range of output 3 in engineering units
6 HI RANGE:3 High end of the range of output 3 in engineering units
7 TYPE:4 What is to be retransmitted for output 4
8 LO RANGE:4 Low end of the range of output 4 in engineering units
9 HI RANGE:4 High end of the range of output 4 in engineering units
545 User's Manual Chapter 5 59
Software Configuration
SELF TUNE
Parameter Description Value Loop 1 Value Loop 2
1 TYPE Type of self tuning algorithm that is available
2 PRETUNE Output step size in absolute percent
3 TUNE PT. TYPE 1: Defines the PV value at which the output switches off
4 OUT. STEP TYPE 2 & 3: Defines output step size in absolute percent
5 LOW LIMIT Lower limit PV can reach during Pretune before aborting
6 HI LIMIT Upper limit PV can reach during Pretune before aborting
7 TIMEOUT Execution time limit for Pretune before aborting
8 MODE Control mode after Pretune is completed or aborted
9 NOISE BND. Noise band to be used by adaptive tuning algorithm
10 RESP. TIME Response time to be used by adaptive tune
11 DEAD TIME Process run time before controller responds to output change
SPECIAL
Parameter Description Value Loop 1 Value Loop 2
1 AUTO. TRIP Manual to Auto Control trip method
2 TRIP DEV. Deviation from setpoint at which controller will trip to auto
3 DES. OUT. N Output value for a designated digital input on trip to manual
4 POWER UP Control mode upon power up
5 PWR. UP:OUT. Output of the controller is powering up in manual control
6 PWR. UP: SP Setpoint upon power up
7 NO. OF SP Number of stored setpoints stored for selection
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Software Configuration
SECURITY (Global)
Parameter Description Value
1 SEC. CODE Security code for temporarily unlocking the instrument
2 SP ADJUST Lockout status for setpoint changes
3 AUTO./MAN. Lockout status for MANUAL key
4 SP SELECT Lockout status for SETPT key
5 ALARM ACK. Lockout status for ACK key
6 TUNING Lockout status for adjustment of tuning parameters
7 CONFIGURE Lockout status for Set Up Parameters
SER COMM. (Global)
Parameter Description Value
1 STATION The unit’s station address
2 BAUD RATE Baud rate
3 CRC Whether CRC is being calculated
4 SHED TIME Time interval between communications activity before controller sheds
5 SHED MODE State of the controller if communications is lost (sheds)
6 SHED OUT. Output if the unit sheds
7 SHED SP Setpoint status if communications is lost
8 DESIG. SP Value of the setpoint if controller sheds
545 User's Manual Chapter 5 61
Software Configuration
62 Chapter 5 545 User's Manual
CHAPTER 6
DISPLAY
FAST
TUNING
OVERVIEW
The self tune function of the 545 consists of two distinct components — Pretune
and Adaptive Tune. In addition, you may choose from three type of Pretune:
TYPE 1 - for slow thermal processes.
TYPE 2 - for fast fluid or pressure processes.
TYPE 3 - for level control applications.
• Choose the type of Pretune in the SELF TUNE menu.
• Pretune and Adaptive Tune may be used separately or together. Refer to
Chapter 7 for more information.
• Each control loop has its own set of TUNING parameters.
On the following pages is the step by step guide to the tuning parameters.
Tuning
NOTE:
For more information about Pretune
and Adaptive Tune, refer to section
on Tuning applications in Chapter 7.
NOTE:
Loop 1 is in the foreground upon
power up. When Loop 2 is in the
foreground, both the PV2 icon and
DISPLAY key will be lit.
or
to return to
OPERATION
mode
LOOP 1
OPERATION
Either Manual or
Automatic Control
+
for Loop 1
SET UP mode
+
to move background loop to displayed loop
for TUNING mode
or
for OPERATION mode
SET UP
…
SELF TUNE
…
TUNING
for Loop 1
SET UP mode
OPERATION
Either Manual or
Automatic Control
or
to return to
OPERATION
SET UP mode
mode
LOOP 2
+
Figure 6.1
+
for Loop 2
for TUNING mode
for OPERATION mode
SET UP
…
SELF TUNE
…
or
TUNING
+
for Loop 2
SET UP mode
Access the Tuning Menu Block
Access Set Up Next menu Next p arameter Next value Access Tuning Return to Operation Switch Loops
+
FAST MENU
545 User's Manual Chapter 6 63
+
MENU MENU
▲ ▼
+
MENU DISPLAYFAST
FAST
DISPLAY
Tuning
TUNING
ADAPTIVE
DISABLED
PRETUNE
NO
POWR. BACK
DISABLED
PROP. BND.:1
50.0
RESET:1
20
RATE:1
1
TUNING
1. ADAPTIVE
Activates the self tune algorithm (upon transfer to automatic control).
D DISABLED
• ENABLED
2. PRETUNE
Activates the pretune algorithm (if unit is under manual control).
▲▲
To initiate the Pretune cycle, press the
within two seconds.
DNO
3. POWR. BACK
Reduces setpoint overshoot at power up or after setpoint changes.
D DISABLED
• ENABLED
4. PROP. BND.:1
Defines the proportional band for PID set 1.
R 0.1 to 999.0%
D 50.0%
5. RESET:1
Defines the integral time for PID set 1.
R 1 to 9999 seconds
D 20 seconds
6. RATE:1
Defines the derivative time for PID set 1.
R 0 to 600 seconds
D 1 second
▼▼
▲ or
▼. Confirm by pressing ACK
▲▲
▼▼
MAN. RST.:1
0
CYCLE TM.:1
15.0
Access Set Up Next menu Next p arameter Next value Access Tuning Return to Operation Switch Loops
+
FAST MENU
64 Chapter 6 545 User's Manual
MENU MENU
+
7. MAN. RST.:1 (or LOADLINE:1)
Defines the manual reset for PID set 1. If using automatic reset, then this
specifies the load line out value.
R 0 to 100%
D0%
8. CYCLE TM.:1
Defines the cycle time for control output 1 when using a time proportioning
output.
R 0.3 to 120.0 seconds
D 15.0 seconds
▲ ▼
MENU DISPLAYFAST
FAST
+
DISPLAY
9. CTRL. D.B.
Defines the control deadband when using PID, PI, PD, P or PID On/Off Control.
R Any positive value
D 15.0 seconds
10. DEADBAND:1
Defines the dead band for control output 1 when using on/off control.
R 1 to 99999 in engineering units
D2
11. P. PROP. D.B.
Defines the dead band setting for a slidewire position proportioning output.
R 0.5 to 10.0%
D 2.0%
12A. PID OFST.:1
For duplex applications, defines the offset for the first output.
R –50.0% to 50.0%
D 0.0%
Tuning
CTRL. D.B.
15.0
DEADBAND:1
2
P.PROP.D. B.
2.0
PID OFST.:1
0
12B. ON OFST.:1
For On/Off applications, defines the offset for the first output.
R -9999 to 99999 in engineering units
D0
13A. PID OFST.:2
For duplex applications, defines the offset for the second output.
R –50.0% to 50.0%
D 0.0%
13B. ON OFST.:2
For On/Off applications, defines the offset for the second output.
R -9999 to 99999 in engineering units
D0
14. REL. GAIN:2
Defines the adjustment factor for the second output’s proportional band. It is
multiplied by the effective gain of output 1 to obtain the second output's proportional band.
R 0.1 to 10.0
D1.0
ON/OFST.:1
0
PID OFST.:2
0
ON/OFST.:2
0
REL. GAIN:2
1.0
Access Set Up Next menu Next p arameter Next value Access Tuning Return to Operation Switch Loops
+
FAST MENU
545 User's Manual Chapter 6 65
+
MENU MENU
▲ ▼
+
MENU DISPLAYFAST
FAST
DISPLAY
Tuning
CYCLE TM.:2
15.0
15. CYCLE TM.:2
Defines the cycle time for control output 2 when using a time proportioning
output.
R 0.3 to 120.0 seconds.
D 15.0 seconds
DEADBAND:2
2
RSP RATIO
1.00
RSP BIAS
(D)
FFWD. GAIN
1.00
FFWD. ZERO
0
16. DEADBAND:2
Defines the dead band for control output 2 when using on/off control.
R 1 to 99999 in engineering units
D2
17. RSP RATIO
Defines the multiplier applied to the remote set point.
R -99.99 to 99.99
D 1.00
18. RSP BIAS
Defines the bias (additive term) applied to the remote set point.
R
Any value in engineering units (minimum is BIAS LOW; maximum is BIAS HIGH)
D Dependent on the BIAS LOW and BIAS HIGH values
19. FFWD GAIN
Multiplier applied to the feed forward input.
R -99.99 to 99.99
D 1.00
20. FFWD ZERO
Zero point of the feed forward output contribution.
R -9999 to 99999
D0
FF.BRK.GN
1.00
FF.BRK.ZR.
0
NO. OF PID
1
Access Set Up Next menu Next p arameter Next value Access Tuning Return to Operation Switch Loops
+
FAST MENU
66 Chapter 6 545 User's Manual
MENU MENU
+
21. FF.BRK.GN
Multiplier applied to the feed forward input if PV is broken.
R -99.99 to 99.99
D 1.00
22. FF.BRK.ZR.
Zero point of the feed forward input contribution if PV is broken.
R -9999 to 99999
D0
23. NO. OF PID
Defines the number of PID sets that will be stored and available for use.
R 1 to 8
• SP NUMBER
D1
▲ ▼
For numbers>1, PID TRIP defines tripping between the PID sets
Number of PID sets = number of local setpoints (specified in NO.
OF SP). Each PID set has a respective SP NUMBER.
MENU DISPLAYFAST
FAST
+
DISPLAY
24. PID TRIP
For NO. OF PID > 1, defines the variable used to select the various PID sets.
• PV VALUE PID set selection based on process variable
D SP VALUE PID set selection based on setpoint
• DEV. VALUE PID set selection based on deviation from setpoint
25. TRIP:1
Defines the value that triggers a change to the primary set (#1) of PID values.
R The process variable range
D Dependent on the process variable range
FOR EACH SET OF PID 2 THROUGH 8, you need to set up the following
group of parameters (X represents the PID set number). Set up the parameters as they appear for each set of PID. The controller designates the val-
ues for the active PID parameter in the third display with an “*” on either
side.
26. PROP. BND.:X
Defines the proportional band for PID set X.
R 0.1 to 999.0%
D 50.0%
Tuning
PID TRIP
SP VALUE
TRIP:1
(D)
PROP.BND.:X
50.0
27. RESET:X
Defines the integral time for PID set X.
R 1 to 9999 seconds (increments of 1)
D 20 seconds
28. RATE:X
Defines the derivative time for PID set X.
R 0 to 600 seconds
D 1 second
29. MAN. RST.:X (or LOADLINE:X)
Defines the manual reset (or load line) for PID set X.
R 0 to 100%
D0%
30. TRIP:X
This defines the value that triggers a change to the Xth set of PID values.
R The process variable range
D Dependent on the process variable range
RESET:X
20
RATE:X
1
MAN.RST.:X
0
TRIP:X
(D)
Access Set Up Next menu Next p arameter Next value Access Tuning Return to Operation Switch Loops
+
FAST MENU
545 User's Manual Chapter 6 67
+
MENU MENU
▲ ▼
+
MENU DISPLAYFAST
FAST
DISPLAY
Tuning
TUNING
Parameter Definition Value Loop 1 Value Loop 2
1. ADAPTIVE Activates the self tune algorithm
2. PRETUNE Activates the pretune algorithm
3. POWR. BACK Reduces setpoint overshoot
4. PROP. BND.:1 Defines the proportional band for PID set 1
5. RESET:1 Defines the integral time for PID set 1
6. RATE:1 Defines the derivative time for PID set 1
7. MAN. RST.:1 Defines the manual reset for PID set 1
8. CYCLE TM.:1 Defines the cycle time for control output 1
9. CTRL. D.B. Control deadband for PID, PI, PD, P or PID On/Off
10. DEADBAND:1 Defines the dead band for control output 1
11. P. PROP. D.B. Defines the dead band setting for a slidewire output
12A. PID OFST.:1 For duplex applications, defines the offset for the first output
12B. ON OFST.:1 For On/Off applications, defines the offset for the first output
13A. PID OFST.:2 For duplex applications, defines the offset for the 2nd output
13B. ON OFST.:2 For On/Off applications, defines the offset for the 2nd output
14. REL. GAIN:2 Defines the adjustment factor for the output 2 prop. band
15. CYCLE TM.:2 Defines the cycle time for control output 2
16. DEADBAND:2 Defines the dead band for control output 2
17. RSP RATIO Defines the multiplier applied to the remote set point
18. RSP BIAS Defines the bias (additive term) applied to the remote set point
19. FFWD GAIN Adjustment factor for feed forward input
20. FFWD ZERO Zero point of feed forward output contribution
21. FF.BRK.GN Adjustment factor for feed forward input if PV is broken
22. FF.BRK.ZR. Zero point for feed forward output contribution if PV is broken
23. NO. OF PID Defines the number of stored and available PID sets
24. PID TRIP Defines the variable used to select the various PID sets
25. TRIP:1 Defines the value that triggers a change to primary PID set
26. PROP. BND.:2 Defines the proportional band for PID set 2
27. RESET:2 Defines the integral time for PID set 2
28. RATE:2 Defines the derivative time for PID set 2
68 Chapter 6 545 User's Manual
29. MAN. RST.:2 Defines the manual reset (or load line) for PID set 2
30. TRIP:2 Defines the value that triggers a change to the 2nd PID set
31. PROP. BND.:3 Defines the proportional band for PID set 3
32. RESET:3 Defines the integral time for PID set 3
33. RATE:3 Defines the derivative time for PID set 3
34. MAN. RST.:3 Defines the manual reset (or load line) for PID set 3
35. TRIP:3 Defines the value that triggers a change to the 3rd PID set
36. PROP. BND.:4 Defines the proportional band for PID set 4
37. RESET:4 Defines the integral time for PID set 4
38. RATE:4 Defines the derivative time for PID set 4
39. MAN. RST.:4 Defines the manual reset (or load line) for PID set 4
40. TRIP:4 This defines the value that triggers a change to the 4th PID set
Tuning
41. PROP. BND.:5 Defines the proportional band for PID set 5
42. RESET:5 Defines the integral time for PID set 5
43. RATE:5 Defines the derivative time for PID set 5
44. MAN. RST.:5 Defines the manual reset (or load line) for PID set 5
45. TRIP:5 This defines the value that triggers a change to the 5th PID set
46. PROP. BND.:6 Defines the proportional band for PID set 6
47. RESET:6 Defines the integral time for PID set 6
48. RATE:6 Defines the derivative time for PID set 6
49. MAN. RST.6 Defines the manual reset (or load line) for PID set 6
50. TRIP:6 This defines the value that triggers a change to the 6th PID set
51. PROP. BND.:7 Defines the proportional band for PID set 7
52. RESET:7 Defines the integral time for PID set 7
53. RATE:7 Defines the derivative time for PID set 7
54. MAN. RST.:7 Defines the manual reset (or load line) for PID set 7
55. TRIP:7 This defines the value that triggers a change to the 7th PID set
56. PROP. BND.:8 Defines the proportional band for PID set 8
57. RESET:8 Defines the integral time for PID set 8
58. RATE:8 Defines the derivative time for PID set 8
59. MAN. RST.:8 Defines the manual reset (or load line) for PID set 8
60. TRIP:8 This defines the value that triggers a change to the 8th PID set
545 User's Manual Chapter 6 69
Tuning
SELF TUNE MESSAGES AND TROUBLESHOOTING
Refer to Chapter 7 for more information on the Self Tune function of the 545 controller.
When the Pretune function terminates, one of the following messages will appear:
Message
COMPLETED
ABORTED
LIMIT ERR.
TIME OUT
NOISE ERR.
INPUT ERR.
OUT. ERROR
DATA ERR.
ZERO ERR.
DEV. ERROR
RETRY
Pretune
Type
1
2, 3
1, 2, 3
1
2, 3
1, 2, 3
1, 2, 3
1, 2, 3
1, 2, 3
1, 2, 3
1, 2, 3
1, 2, 3
1, 2, 3
2,3
2,3
1
1, 2, 3
Conclusion/Problem
PRETUNE has generated initial PID and the Dead Time
values.
PRETUNE has generated initial PID, Response Time,
Noise Band and the Dead Time values.
User has aborted PRETUNE before completion.
The Process Variable went beyond the HI LIMIT or LOW
LIMIT.
The Process Variable went beyond the HI LIMIT or LOW
LIMIT.
The initial Process Variable was near or beyond the HI
LIMIT or LOW LIMIT.
TIMEOUT limit was reached before PRETUNE completed.
Too much PV noise was detected.
PV or Cold Junction break detected during PRETUNE.
PV HIGH or PV LOW detected during PRETUNE.
SLIDEWIRE break detected during PRETUNE.
REMOTE SP break detected during PRETUNE.
The initial control output is outside the high and low limits
defined in the Control Menu.
The PV moved too quickly to be Analyzed.
One or more model parameters are calculated to be zero.
The initial PV is too close to the TUNE PT.
The Process Variable went beyond the HI LIMIT or LOW
LIMIT.
Corrective Action
Change the HI LIMIT and LOW LIMIT, or the HIGH OUT
and LOW OUT, and run PRETUNE again.
Change the HI LIMIT and LOW LIMIT, or the OUT.STEP
size, and run PRETUNE again.
Change the manual output percentage, or the HI LIMIT and
LOW LIMIT, and run PRETUNE again.
Set a longer TIMEOUT period and/or increase the
OUT.STEP size, and run PRETUNE again.
Eliminate the noise source (if possible) or increase the
OUT.STEP and run PRETUNE again.
Check the described conditions and make corrections or
repairs.
Change the manual output percent and run PRETUNE again.
Increase the OUT.STEP size and run PRETUNE again.
Increase the OUT.STEP size and run PRETUNE again.
Move Tune PT. (or the set point if TUNE PT. is automatic)
farther from the process variable and run PRETUNE again.
Check if any PID values are generated and if they are
acceptable. If not, eliminate noise sources (if possible) and
run PRETUNE again.
If Pretune and Adaptive Tune do not generate optimal PID values for control, check the following menu entries:
Message
RESPONSE
TIME
NOISE BAND
PRETUNE
Potential Problem
Adaptive Tune cannot run if RESPONSE TIME is inaccurate
Adaptive Tune cannot compensate for PV oscillation due to
hysteresis of output device (e.g., a sticky valve).
Pretune does not develop optimum PID parameters.
70 Chapter 6 545 User's Manual
Corrective Action
Run TYPE 2 or TYPE 3 Pretune to obtain the correct value,
or enter it manually.
Set NOISE BAND large enough to prevent Adaptive Tune
from acting on the oscillation. If oscillation is not acceptable,
consider replacing valve.
Wrong Pretune TYPE selected. Refer to Chapter 7, the
Section on Self Tune.
CHAPTER 7
APPLICATIONS
The 545 controller provides a variety of user-programmable control features
and capabilities. The following topics are included in this chapter:
Applications
NOTE:
Controller capabilities depend upon
the specified hardware option.
A. Control Type ............................................... 71
B. Alarms ......................................................... 72
C. Duplex Control ............................................ 76
D. Slidewire Position Proportioning Control ..... 81
E. Velocity Position Proportioning Control ....... 82
F. Staged Outputs ........................................... 83
G. Retransmission ........................................... 83
H. Digital Inputs ............................................... 84
I. Remote Setpoint ........................................... 88
J. Multiple Setpoints ........................................ 88
K. Multiple Sets of PID Values ......................... 89
L. Powerback .................................................. 90
M. Self Tune— POWERTUNE
N. Ramp-to-Setpoint ........................................ 96
O. Input Linearization ...................................... 97
P. Load Line .................................................... 98
®
...................................
A. CONTROL TYPE
Each of the control loops in the 545 can be independently configured.
Software Configuration
1. Go to the CONTROL menu.
2. For the parameter ALGORITHM, select the type of 545 control:
• ON-OFF
“Crude” control similar to a household thermostat. Used primarily
on slow, stable processes where moderate deviation (cycling)
around setpoint is tolerable. Only available with SSR, SSR Drive,
and relay outputs.
•P
Proportional only control. Provides much better control than on/off.
Used on processes that are less stable or require tighter control, but
have few load variations and do not require a wide range of setpoints.
•PI
Proportional plus integral control. In addition to proportional control,
it compensates for control errors due to a wide range of setpoints or
load requirements. The integral term works to eliminate offsets.
•PD
Proportional plus derivative control. In addition to proportional control, it compensates for control errors due to fast load variations.
•PID
Proportional plus integral plus derivative control. In addition to proportional control, it compensates for changes in setpoint, load requirements and process variations.
• PID/ON-OFF
Only available with Duplex control. First output uses the PID algorithm, while second output uses on/off control.
Q. Security ...................................................... 99
R. Reset Inhibition ......................................... 100
S. Process Variable Reading Correction ........ 100
T. Serial Communications ............................. 101
U. Cascade Control ....................................... 102
90
V. Ratio Control ............................................. 104
W. Feed Forward/Feedback Control .............. 107
X. Lag Time ................................................... 108
545 User's Manual Chapter 7 71
Applications
3. For algorithms using the derivative function (D), choose the conditions for
the derivative term:
Scroll to parameter D. SOURCE
• For derivative action based on error, or deviation from setpoint, choose
DEVIATION
• For derivative action based on PV changes, choose PV.
B. ALARMS
Each loop of the 545 controller has two extremely flexible and powerful software
alarms (4 alarms total). The number of available outputs limits how alarms are
linked to relays. A Global Alarm feature allows all alarms to be assigned to the
same relay.
The 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).
NOTE:
The ability to base alarms on
parameters other than PV greatly
expands the alarm capacity.
Software Configuration
1. Access the ALARM menu.
2. Set values for the following parameters. All possible values are shown.
Remember: there are 2 alarms for each loop (use FAST+DISPLAY to switch
loops).
ALM.TYPE:1 and ALM. TYPE:2
Specifies the type of alarm to implement. Selection includes:
• HIGH ALARM
High process variable alarm. Occurs when the process variable exceeds the alarm setpoint.
• LOW ALARM
Low process variable alarm. Occurs when the process variable goes
below the alarm setpoint.
• HIGH/LOW
Combination of high and low alarms. Occurs when the PV exceeds
the individually set high or low setpoint.
• BAND
Creates a band centered around the control setpoint, that is twice
the alarm setpoint. Alarm occurs when the process variable travels
outside of this band. The alarm is dependent on the control setpoint.
As the control setpoint changes, the band adjusts accordingly.
For example, if the control setpoint is 500 and the alarm setpoint is
25, then the band extends from 475 to 525.
• DEVIATION
Similar to the band alarm but creates a band only on one side of the
control setpoint. Alarm occurs when the process variable deviates
from the control setpoint by an amount greater than the alarm setpoint. This alarm is dependent on the control setpoint; as the control
72 Chapter 7 545 User's Manual
setpoint changes, the alarm point changes.
For example, if the control setpoint is 500 and the alarm setpoint is
+50, then an alarm occurs when the process variable exceeds 550.
In order for an alarm to occur when the process variable drops below
450, select an alarm setpoint of –50.
• MANUAL
Alarm occurs when the controller is put into manual mode of operation. This may be useful for security purposes or to alert the operator
that 545 is no longer under automatic control.
• RATE
Alarm occurs when the process variable changes at a rate greater
than what is specified by the alarm setpoint and time base. This alarm
helps to anticipate problems before the process variable can reach
an undesirable level.
For example, if the alarm setpoint is 10 with a time base of 5 seconds,
an alarm occurs whenever a change in process variable greater than
10 occurs in 5 seconds.
ALM.SRC.:1 and ALM.SRC.:2
For HIGH , LOW or HIGH/LOW alarms, specifies the variable (source)
upon which a selected alarm is based. Selection includes:
•PV
• PV2
•SP
• RAMP SP
• DEVIATION
• OUTPUT
ALARM SP:1 and ALARM SP:2
Defines the point at which an alarm occurs. For a RATE (rate of change)
alarm, it specifies the amount of change (per RATE TIME period) that
must occur before the alarm activates. A negative value specifies a negative rate-of-change. Does not apply to HIGH/LOW alarms.
HIGH SP:1 and HIGH SP:2
For a HIGH/LOW alarm, defines the high setpoint at which an alarm occurs.
LOW SP:1 and LOW SP:2
For a HIGH/LOW alarm, defines the low setpoint at which an alarm occurs.
DEADBAND:1 and DEADBAND:2
Specifies the range through which the process variable must travel before leaving an alarm condition (see alarm examples at the end of this
section). Prevents frequent alarm oscillation or “chattering” if the process
variable has stabilized around the alarm point.
ALM.1 OUT and ALM.2 OUT
For any enabled alarm, selects the output number to which the selected
alarm will be assigned. It is possible to assign both alarms to the same
output relay, thus creating a “global” alarm .
Applications
545 User's Manual Chapter 7 73
Applications
Alarm Parameters Reference
For Alarm 1
Parameter Description
ALM. TYPE:1 Type
ALM. SRC.:1 Source
ALARM SP:1 Setpoint
HIGH SP:1 High setpoint
LOW SP:1 Low setpoint
DEADBAND:1 Deadband
ALM.:1 OUT. Output number
LATCHING:1 Latching sequence
ACK.:1 Acknowledging
POWER UP:1 Status on power up
MESSAGE:1 Message
For Alarm 2
Parameter Description
ALM. TYPE:2 Type
ALM. SRC.:2 Source
ALARM SP:2 Setpoint
HIGH SP:2 High setpoint
LOW SP:2 Low setpoint
DEADBAND:2 Deadband
ALM.:2 OUT. Output number
LATCHING:2 Latching sequence
ACK.:2 Acknowledging
POWER UP:2 Status on power up
MESSAGE:2 Message
For either alarm
(depending on choices)
Parameter Description
FAULT Fault assignment
OUTPUT Output action for rate
RATE TIME Time base for rate
NOTE:
Each of the two loops has two alarms.
LATCHING:1 and LATCHING:2
A latching (YES) alarm will remain active after leaving the alarm condition unless it is acknowledged. A non-latching (NO) alarm will return to
the non-alarm state when leaving the alarm condition without being acknowledged.
ACK.:1 and ACK.:2
For any enabled alarm, enables or disables operator use of the ACK key
to acknowledge an alarm at any time, even if the control process is still
in the alarm condition.
A latching alarm can always be acknowledged when it is out of the alarm
condition. When either alarm is available to be acknowledged, the ACK
key will be illuminated. If both alarms are acknowledgeable, pressing ACK
will first acknowledge alarm #1. Pressing ACK a second time will acknowl-
edge alarm #2.
POWER UP:1 and POWER UP:2
For any enabled alarm, selects the alarm condition upon power up.
Choices are:
• NORMAL
Controller will power up in alarm only if it is in alarm condition.
• ALARM:
Controller always powers up in alarm regardless of system’s alarm
condition. This is an excellent way to activate an alarm if there has
been a power failure.
• DELAYED
Controller will never power up in alarm, regardless of system’s alarm
condition. The system must leave and reenter the alarm condition
before the alarm will activate. This is typically used to avoid alarms
during start up.
MESSAGE:1 and MESSAGE:2
Allows user to specify a nine-character message to be displayed when
the respective alarm is active. If both alarms are active or any other diagnostic message is present, the messages will alternate.
FAULT
Activates an alarm if the process variable signal is lost. Assign this function to either Alarm 1 or Alarm 2 (not both). This action is in addition the
selected alarm type (additive alarm function).
OUTPUT
For a RATE alarm, selects the output action. Use to obtain early indication of a possible break in the process variable signal. Select PV BREAK
to have rate-of-change alarm take the same action as a detection of a
break in the process variable signal (where it trips to manual control at a
predetermined output).
RATE TIME
For RATE alarms, defines the time period over which a discrete change
in process variable must occur for the rate alarm to be activated. The
amount of change is defined by the alarm setpoint. The rate-of-change
is defined as the amount of change divided by the time period.
74 Chapter 7 545 User's Manual
Example
A. If the alarm setpoint is set to 10 and the time base is set to 1
second, the rate of change is 10 units per second.
B. If the alarm setpoint is set to 100 and the time base set to 10, the
rate of change is also 10 units per second.
In example A, the process variable would only have to experience a
ten unit change over a short period of time, while in Example B, it
would require a 100 unit change over a ten second period. Example A
is much more sensitive than Example B. In general, for a given rateof-change, the shorter the time period, the more sensitive the rate
Figure 7.1
Alarm Examples
alarm.
BAND ALARM HIGH PROCESS VARIABLE ALARM
Applications
IN ALARM
CONDITION
DB
PV
C.SP
DB
RELAY
ENERGIZED
ICON OFF
NO ALARM CANNOT
RELAY
DE-ENERGIZED
ICON ON
CANNOT
ACKNOWLEDGE
RELAY
ENERGIZED
ICON OFF
NO ALARM
PARAMETER SETTINGS:
OUTPUT N = ALM.RLY:OFF (N = 2 to 4)
ALM. TYPE:1 = BAND
ALM.:1 OUT. = N (N= 2 to 4)
LATCHING = NO LATCH
ACK.:1 = DISABLED
IN ALARM
CONDITION
TIME
RELAY
DE-ENERGIZED
ICON ON
ACKNOWLEDGE
C.SP
+ A.SP
C.SP
- A.SP
DB
RELAY
DE-ENERGIZED
ICON OFF
NO ALARM
PARAMETER SETTINGS:
OUTPUT N = ALM.RLY:ON (N = 2 to 4)
ALM. TYPE:1 = HIGH ALRM.
ALM.:1 OUT. = N (N = 2 to 4)
LATCHING = NO LATCH
ACK.:1 = ENABLED
DEVIATION ALARM POWER UP ALARM
IN ALARM
C.SP
CONDITION
A.SP
IN ALARM
CONDITION
PV
RELAY
ENERGIZED
ICON ON
MAY
ACKNOWLEDGE
PV
TIME
RELAY
DE-ENERGIZED
ICON OFF
NO ALARM
A.SP
DB
DB
PV
RELAY
DE-ENERGIZED
ICON OFF
NO ALARM
RELAY
ENERGIZED
ICON ON
MAY
ACKNOWLEDGE
MUST
ACKNOWLEDGE
TO SHUT OFF
ICON AND
DE-ENERGIZE
RELAY
PARAMETER SETTINGS:
OUTPUT N = ALM.RLY:ON (N = 2 to 4)
ALM. TYPE:1 = DEVIATION
ALM.:1 OUT. = N (N = 2 to 4)
LATCHING = LATCH
ACK.:1 = ENABLED
ALARM SP:1 = (<0)
545 User's Manual Chapter 7 75
TIME
C.SP
+ A.SP
ALARM
UNIT
POWER UP
RELAY
ENERGIZED
ICON ON
MAY
ACKNOWLEDGE
CONDITION
RELAY
ENERGIZED
ICON ON
CANNOT
ACKNOWLEDGE
PARAMETER SETTINGS:
OUTPUT N = ALM.RLY:ON (N = 2 to 4)
ALM. TYPE:1 = HIGH ALM.
ALM.:1 OUT. = N (N = 2 to 4)
LATCHING:1 = LATCH
ACK.:1 = DISABLED
POWER UP:1 = ALARM
TIME
RELAY
ENERGIZED
ICON ON
MAY
ACKNOWLEDGE
Applications
NOTE: The duplex output states vary
depending upon:
1. Control Type (PID, On/Off, etc.)
2. Control Action (DA, RA)
3. Output Limits
4. Output Gap or Overlay, and
5. Output 2 Relative Gain and PID%
Output.
Please refer to the output state
examples in this section to confirm
that the configuration is appropriate
for the process.
NOTE: Set manual reset/load line
parameters to 50% when using Duplex
control (MAN. RST.:X parameter is in
the TUNING menu.)
C. DUPLEX CONTROL
The Duplex control algorithm enables two discrete control outputs for the control
loop. Duplex control is commonly used for applications that require both heating
and cooling or when 2 control elements are needed to achieve the desired result.
Hardware Configuration
• The controller must have two output modules assigned to the loop (any
combination of output modules).
Software Configuration
1. Go to the CONFIG. menu.
Set LOOP1 OUT or LOOP2 OUT. to DUPLEX.
2. To use different algorithms for each output (PID for the first, and On/Off for
the second):
Go to the CONTROL menu.
Set ALGORITHM to PID:ON/OFF.
3. To make the control action for each output independent of the other:
Go to the CONTROL menu.
Set ACTION:1 or ACTION:2 to either DIRECT or REVERSE action based
on the diagrams in the output examples section (Figures 7.2 through 7.8).
4. Go to the TUNING menu.
Set values for PID OFST:1 (or ON OFST:1) and PID OFST:2
(or ON OFST:2). These parameters allow the user to independently offset
the point at which output 1 and output 2 become active. PID OFSET units
are in percent (%) of control output; ON OFST is in engineering units. The
settings can be used to make sure there is a dead band, i.e., no controller
output around setpoint. They can also be used to overlap output 1 and output 2 so that both are “on” in a small band around setpoint.
5. Set MAN. RESET (manual reset) term to 50%. This causes the PID output
to be 50% when there is zero error. This term is still active as a “load line”
setting when using automatic reset (integral), so set it to 50% whether using
automatic reset or not.
6. REL. GAIN (relative gain) changes the gain of Output 2 relative to Output 1.
Note that the relative gain can limit the maximum output available for Output 2 when using PID control.
7. Go to the CONTROL menu.
Set LOW OUT. and HIGH OUT. to limit the maximum or minimum outputs
from Output 1 and Output 2. The actual limitation on the outputs is dependent on the offset settings, the relative gain setting and the control action.
76 Chapter 7 545 User's Manual
Duplex Output State Examples
The following Duplex examples represent a variety of ways this function can be
set up. PID control examples show the PID output percentage on the horizontal
axis, and On/Off control examples show the process variable on the horizontal
axis. The vertical axes are the output of each physical output. Most of these
examples use the first output as heating and the second output as cooling.
When using PID control, the 545 controller actually displays the PID output. To
relate this output to the actual physical output, locate the PID output on the
horizontal axis. Draw a vertical line at that point. At the intersection of this vertical
line and the respective output line, draw a horizontal line. The physical output is
the value where this horizontal line intersects the respective axis.
The illustrations assume a manual reset/load line term of 50%. Therefore, at
zero error (process variable equals setpoint) the PID output is 50%.
Duplex with reverse and direct acting outputs
A reverse acting output 1 and a direct acting output 2 with: no offset, no restrictive
outputs limits, and a neutral relative gain with PID control.
PARAMETER SETTINGS
ACTION:1 = REVERSE
ACTION:2 = DIRECT
PID OFST.:1 = 0
PID OFST.:2 = 0
LOW OUT = 0
HIGH OUT = 100
REL. GAIN = 1.0
Out 1
100%
Out 1
Out 2
100%
Out 2
Applications
Figure 7.2
Duplex with Reverse and Direct
Acting Outputs
0%
0%
50%100% 0%
PID OUTPUT
Duplex with direct and reverse acting outputs
A reverse acting output 1 and a direct acting output 2 with: no offset, no restrictive
output limits, and a neutral relative gain with PID control.
PARAMETER SETTINGS
ACTION:1 = DIRECT
ACTION:2 = REVERSE
PID OFST.:1 = 0
PID OFST.:2 = 0
LOW OUT = 0
HIGH OUT = 100
REL. GAIN = 1.0
Out 1
(Heat)
100%
0%
Out 1
Out 2
PID OUTPUT
Out 2
Out 1
(Cool)
Out 2
50%100% 0%
100%
0%
Figure 7.3
Duplex with Direct and Reverse
Acting Outputs
545 User's Manual Chapter 7 77
Applications
PID OUTPUT
100%
PARAMETER SETTINGS
ACTION:1 = REVERSE
ACTION:2 = REVERSE
PID OFST.:1 = 0
PID OFST.:2 = 0
LOW OUT = 0
HIGH OUT = 100
REL. GAIN = 1.0
100%
50%100% 0%
Out 1
(Heat)
Out 2
(Cool)
Out 2
0%
0%
Out 1
Figure 7.4
Duplex with Two Reverse Acting
Outputs
Duplex with 2 reverse acting outputs
Two reverse acting outputs with: no offset, no restrictive output limits, and a
neutral relative gain with PID control.
Figure 7.5
Duplex with a Gap Between
Outputs
Duplex with a gap between outputs
A reverse acting output 1 and a direct acting output 2 react with: a positive offset
for output 1 and a negative offset for output 2 (assume no restrictive output limits
and a neutral relative gain with PID control).
On the graph, a positive offset refers to an offset to the left of 50%; a negative
offset is to the right of 50%.
PARAMETER SETTINGS
ACTION:1 = REVERSE
ACTION:2 = DIRECT
PID OFST.:1 = + VALUE
PID OFST.:2 = – VALUE
LOW OUT = 0
HIGH OUT = 100
REL. GAIN = 1.0
Out 1
(Heat)
100%
Out 1
0%
100% 0%
Offset 1
50%
PID OUTPUT
Out 2
Offset 2
Out 2
(Cool)
100%
0%
78 Chapter 7 545 User's Manual
Duplex with a overlapping outputs and output limits
A reverse acting output 1 and a direct acting output 2 with: a negative offset for
output 1, a positive offset for output 2, and restrictive high and low output limits
with PID control.
This combination of offsets results in an overlap where both outputs are active
simultaneously when the PID output is around 50%.
The output limits are applied directly to the PID output. This in turn limits the actual
output values. In this example, the high output maximum limits the maximum
value for output 1, while the low output minimum limits the maximum value for
output 2. The value the actual outputs are limited to depends on offset settings,
control action and relative gain setting with PID control.
PARAMETER SETTINGS
ACTION:1 = REVERSE
ACTION:2 = DIRECT
PID OFST.:1 = – VALUE
PID OFST.:2 = + VALUE
LOW OUT = 10%
HIGH OUT = 85%
REL. GAIN = 1.0
Out 1
(Heat)
100%
Out 1
Out 2
(Cool)
100%
Out 2
Applications
Figure 7.6
Duplex with Overlapping Outputs
and Output Limits
0%
85%
50%100%
10%
0%
0%
PID OUTPUT
Duplex with various relative gain settings
A reverse acting output 1 and a direct acting output 2 with: various relative gain
settings (assume no offset or restrictive outputs) with PID control.
PARAMETER SETTINGS
ACTION:1 = REVERSE
ACTION:2 = DIRECT
PID OFST.:1 = 0
PID OFST.:2 = 0
LOW OUT = 0
HIGH OUT = 100
❶
❷
❸
= 2.0
= 1.0
= 0.5
REL. GAIN
REL. GAIN
REL. GAIN
Out 1
(Heat)
100%
Out 1
❶
Out 2
(Cool)
100%
Out 2
50%
❷
❸
0%
50%100% 0%
PID OUTPUT
25%
0%
Figure 7.7
Duplex with Various Relative Gain
Settings
545 User's Manual Chapter 7 79
Applications
PID OUTPUT
100%
PARAMETER SETTINGS
ACTION:1 = REVERSE
ACTION:2 = DIRECT
PID OFST.:1 = 0
ON OFST.:2 = + VALUE
LOW OUT = 0
HIGH OUT = 100
ON
50%
100%
0%
Out 1
(Heat)
Out 2
(Cool)
Out 1
OFF
0%
Out 2
Out 2 Offset
from Setpoint
in Engineering Units
Figure 7.8
Duplex with One ON/OFF Output
Notice that the relative gain setting does not affect output 1. In this example, a
relative gain setting of 2.0 (curve 1) results in output 2 reaching its maximum
value at a PID output of 25%. A relative gain setting of 1.0 results in output 2
reaching its maximum value at a PID output of 0%. A relative gain setting of 0.5
results in output 2 reaching a maximum of 50% at a PID output of 0%.
Duplex with one ON/OFF output
A reverse acting output 1 and a direct acting, on/off output 2 with a positive offset.
Relative gain does not apply when using duplex with an on/off output. The
deadband setting for output 2 works the same as the deadband in single on/off
control (the deadband effect for output 2 is not illustrated here).
Figure 7.9
Duplex with Two ON/OFF Outputs
80 Chapter 7 545 User's Manual
Duplex with two ON/OFF outputs
A reverse acting on/off output 1 and a direct acting on/off output 2 with a negative
offset for output 1 and a positive offset for output 2.
Note that here the horizontal axis is expressed in terms of process variable rather
than PID output.
PARAMETER SETTINGS
ACTION:1 = REVERSE
ACTION:2 = DIRECT
ON OFST.:1 = – VALUE
ON OFST.:2 = + VALUE
Out 1
(Heat)
ON
OFF
Low
Range
Out 1
Out 2
Offset 1
SP
PROCESS VARIABLE
Offset 2
Out 2
(Cool)
ON
OFF
High
Range
Applications
D. SLIDEWIRE POSITION PROPORTIONING CONTROL
Slidewire position proportioning utilizes a slidewire feedback signal to determine
the actual position of the actuator being controlled. This option is only
available for one of the two control loops.
Hardware Configuration
• The controller must have the Slidewire Feedback option installed. Refer to
the order code in Chapter 1 for more information.
• The controller must have mechanical relays, solid state relays or DC logic
modules installed in the two output sockets corresponding to one control loop
(1 or 2).
• The Slidewire does NOT have to be wired to the controller in order to set up
position proportioning.
Software Configuration
1. To configure the controller before wiring the slidewire feedback signal to the
controller, complete these steps:
a. Go to the CONTROL menu.
b. Set a value for PV BREAK
c. Go to the SPECIAL menu.
d. Set a value for DES. OUTPT.
e. Set a value for PWR.UP:OUT.
f. Go to SER. COMM. menu.
g. Set a value for SHED OUT.
2. Place the controller under manual control.
3. Go to the CONFIG. menu.
4. Set either LOOP1 OUT or LOOP2 OUT to POS. PROP (position proportioning).
5. Set SLIDEWIRE to LOOP1 or LOOP2.
6. Go to the CONTROL menu.
7. For S/W RANGE, specify the full range resistance of the slidewire from endto-end. With a 100 ohm slidewire, this parameter should be set to 100.
8. Scroll to OPEN F/B (Open feedback). Enter the ohm value when the actuator
is fully open (0 to 1050 ohms).
9. Scroll to CLOSE F/B (Closed feedback). Enter the ohm value when the
actuator is fully closed (0 to 1050 ohms).
10. Measure the actual slidewire value at the terminals (10 and 11).
As an alternative, set up these two parameters dynamically. Before entering
Set Up set the manual output at 100%. Enter Set Up and change the OPEN
F/B value until the actuator just reaches its full open position.
Exit Set Up and set the manual output to 0%. Enter configuration and change
the CLOSE F/B value until the actuator just reaches its full closed position.
11. Set the parameter P. PROP. D.B., which is used to eliminate cycling of the
motor. A low deadband setting may result in motor overspin or cycling. A high
deadband will result in reduction of sensitivity. To set:
a. Go to the TUNING menu.
b. Set P. PROP. D.B. to .5%.
c. Place controller under Manual control.
CAUTION!
The relay in socket 1 drives the
motor counterclockwise and the
relay in output socket 2 drives the
motor clockwise.
This is important for:
• Wiring the outputs
• Selecting the control ACTION:1
parameter, or
• Determining the normally open or
normally closed relays.
The configuration choices influence
the way the position proportioning
algorithm works.
NOTE: OPEN F/B and CLOSE F/B
values are always reference to the
CCW end of the Slidewire.
NOTE: P.PROP.D.B. can only be
configured if the Slidewire Feedback
is wired to the controller.
545 User's Manual Chapter 7 81
Applications
NOTE: Adaptive tuning is not available
with velocity position proportioning
control.
d. Change the output percentage and observe if the valve stabilizes at
the new value.
e. If the valve oscillates, increase the P.PROP.D.B. value by 0.5%; re-
peat until oscillation stops.
E. VELOCITY POSITION PROPORTIONING CONTROL
Velocity position proportioning does not utilize direct feedback. It estimates the
position of the actuator, based on time and the speed of the actuator.
In automatic control mode, the controller will display “CW” to refer to energizing
of the clockwise relay, and “CCW” to refer to energizing of the counterclockwise
relay. A blank display means that both relays are de-energized.
In manual control mode, the display is blank unless an output change is being
▲▲
made. Use the
while the keys are being pressed. The display indicates the percentage change
in valve position in real time. The rate of change is dependent on the values
entered for CCW TIME and CW TIME.
The controller will transfer to manual control due to a lost process variable
(PV. BREAK), a digital input closure (DES.OUTPT.), a power-up sequence
(PWR.UP:OUT.), or lost communications (SHED OUT). In these cases, the
output can be set to: remain at its last value with both relays de-energized (OUTS
OFF); rotate fully counterclockwise (CCW); or rotate fully clockwise (CW). CCW
and CW will energize the respective relay for a period two times that of the CCW
TIME or CW TIME.
▼▼
▲ and
▼ keys to change the output; the relay is only energized
▲▲
▼▼
Hardware Configuration
• The controller must have mechanical relay, solid state relay or DC logic
modules installed in the first two output sockets.
Refer to the section on Chapter 1 for more information.
Software Configuration
1. Go to CONFIG. menu.
Set LOOP1 OUT or LOOP2 OUT to POS. PROP.
2. Go to the CONTROL menu.
Set SLIDEWIRE to NONE. Alternatively, set SLIDEWIRE to LOOP1 or
LOOP2, whichever does NOT have velocity position proporioning on it.
3. Set CCW TIME to the amount of time (in seconds) it takes for the actuator
to fully rotate in the counterclockwise direction.
Set CW TIME to the amount of time (in seconds) it takes for the actuator to
fully rotate in the clockwise direction.
Loads on the valve may affect the time required, therefore, it is best to measure
these values when the valve is in service. As an alternative, enter the values
specified by the actuator manufacturer and then make adjustments later.
4. Set MIN. TIME to the minimum amount of time the controller must specify
for the motor to be on before it takes any action.
5. Set values for PV. BREAK, DES. OUTPT., PWR.UP:OUT. and SHED OUT.
82 Chapter 7 545 User's Manual
F. STAGED OUTPUTS
t
With staged outputs, one analog output can vary its signal (e.g., 4-20 mA) over
a portion of the PID output range. The second analog output then varies its signal
over another portion of the PID output range. This is an excellent method to stage
two control valves or two pumps using standard control signal ranges.
20 mA
Output 1
4 mA
Output 2
100%50%33%0%
PID Outpu
Applications
Figure 7.10
Staged Outputs Example
OUT1 STOP was set to 33% and
OUT2 STRT. was set to 50%.
Hardware Configuration
• The controller must have analog output modules installed in the first two
output sockets.
Software Configuration
1. Go to the CONFIG. menu.
Set CTRL. TYPE to STAGED.
2. Go to the CONTROL menu.
3. For OUT1 STOP, specify where the first output reaches 100%.
4. For OUT2 START, specify where the second output begins.
G. RETRANSMISSION
The retransmission feature may be used to transmit a milliamp signal
corresponding to any of the following values: PV, SP1, Ramp SP1, Out L1, PV2,
SP2, Ramp SP2, OUTL2. A common application is to use it to record one of
these variables with a recorder.
Hardware Configuration
• There must be an analog module installed in output socket 2, 3 or 4.
Software Configuration
Up to two outputs can be configured for retransmission. The menu will scroll
through the configuration parameters for specified value “X” (2, 3 or 4).
1. Go to the CONFIG. menu.
2. For OUTPUT:2, OUTPUT:3 and OUTPUT:4 parameters, set one or two of
them to RETRANS.
3. Go to the RETRANS. menu.
4. Set the corresponding parameter, TYPE:X, for the first retransmission output to define what is being transmitted: the process variable, setpoint, ramping
setpoint or output.
NOTE:
For an analog output module for
retransmission that was not factoryinstalled, calibrate the output for
maximum accuracy. Refer to
Appendix 4 for details on calibration.
545 User's Manual Chapter 7 83
Applications
5. Set parameters LOW RANGE:X and HIGH RANGE:X for the first retransmission output, to define the range of the transmitted signal in engineering
units. This can be useful in matching the input range of the receiving device.
6. For any other retransmission output, continue to scroll through the this menu
and set the TYPE:X, LOW RANGE:X and HIGH RANGE:X for the second
retransmission output.
H. DIGITAL INPUTS
Digital inputs can be activated in three ways: A switch (signal type)—the recommended type, a relay, or and open collector transistor
Digital inputs are only functional when that option is installed (via hardware).
The controller detects the hardware type, and supplies the appropriate software
menus (see the section on parameters in Chapter 5). There are 14 contact types
for the five digital inputs.
Hardware Configuration
• This optional feature is only available if ordered originally from the factory,
Product #545xxxxxxDx00. The five digital inputs share a common ground.
NOTE: To take advantage of multiple
setpoints, make sure that the SP
NUMBER parameter in the SPECIAL
menu is set to a value greater than 1.
F
igure 7.11
Combinations of Closed Digital
Inputs for Each Setpoint (based on
BCD logic)
X=closed contact
0=open contact
Software Configuration
1. Go to the CONFIG. menu.
2. Set parameters CONTACT:1 through CONTACT:3 (only those available
will shown) by assigning the desired function to each output. Choices are:
• L1.SP.1-4
(CONTACT:1 only) Allows the controller to use the digital inputs 1
and 2 to select a setpoint for Loop 1 (see Figure 7.11). If the state of
these inputs remains constant, the controller will continue to use the
selected setpoint unless overridden. Override the set of digital inputs
by selecting a different setpoint (by using SET PT key or through
communications), or by using the fifth digital input to select the remote or 2nd setpoint. To “rearm” this set of digital inputs, the DIN combination must change.
Setpoints DIN 1 DIN 2 DIN 4 DIN 5
Loop 1 SP1 OO
Loop 1 SP2 XO
Loop 1 SP3 OX
Loop 1 SP4 XX
Loop 2 SP1 OO
Loop 2 SP2 XO
Loop 2 SP3 OX
Loop 2 SP4 XX
84 Chapter 7 545 User's Manual
• L1.REM.SP.
Closing input changes active setpoint to remote setpoint. Opening
reverts controller to previous setpoint. Override by selecting a different setpoint via the SET PT key, a communications command, or other
digital inputs.
Applications
• L1. MAN.
Closing input trips the controller to manual. Opening input reverts controller to automatic. Override by using MANUAL key, a communica-
tions command, or “trip to automatic” function.
• L1. 2ND. SP.
Closing input changes active setpoint to the 2nd local setpoint. Opening input reverts controller to previous setpoint digital input. Override
by selecting a different setpoint via the SET PT key, a communica-
tions command, or other digital inputs.
• L1. 2ND. PID.
Closing input changes active set of PID values to 2nd set. Opening
input bases active set of PID on rules defined in PID TRIP and TRIP:1
to TRIP:8. Override input only by directly linking PID set to the active
setpoint and changing the active setpoint.
• L1.ALARM ACK.
Closing input acknowledges all active alarms. Opening input “rearms”
the controller. If the digital input remains closed, it
to immediately acknowledge alarms as they become active.
• L1. RSP. INH.
Reset Inhibition. Closing input deactivates “I” (integral) term, regardless of the PID values being used. Opening input activates “I” term (if
applicable).
• L1. D.A./R.A.
Direct Acting/Reverse Acting. Closing input reverses action of the
first control output (from direct to reverse, or reverse to direct). Opening reinstates original action.
• L1. NO A/T
Closing input temporarily disables Adaptive Tuning. Opening input
enables it.
• L1. LCK. MAN
Closing contact places the controller in manual control at the designated output percentage. All locked manual contacts must be opened
in order to return controller to automatic control.
• UP KEY
Closing the contact mimics the
behind a window; contact push-buttons can be used to change
setpoint values.
• DOWN KEY
Closing the contact mimics the
behind a window; contact push-buttons can be used to change
setpoint values.
• DISP. KEY
Closing contact mimics the DISPLAY key; scroll through display of
the Setpoint, Deviation % and Output %.
• FAST KEY
Closing contact mimics the FAST key . Use in conjunction with
▼▼
▼, DISPLAY and MENU keys.
▼▼
▲▲
▲ key. Useful if controller is mounted
▲▲
▼▼
▼ key. Useful if controller is mounted
▼▼
does not
continue
NOTE: The second display does not
change when tripping to manual from
a closed digital input.
NOTE: Only alarms configured to be
acknowledged are affected by this
digital input.
▲▲
▲,
▲▲
545 User's Manual Chapter 7 85
Applications
• MENU KEY
Closing contact mimics the MENU key. In OPERATION Mode, pro-
vides entry to TUNING menu. In SET UP or TUNING Mode, advances through the menus.
• COMM. ONLY
Makes input status readable through communications (but has no
effect on the controller itself).
3. Set parameters CONTACT:4 and CONTACT:5 (only those available will
be shown) by assigning the desired function to each output. Choices are:
• L2.SP.1-4
(CONTACT:4 only) Allows the controller to use the digital inputs 4
and 5 to select a setpoint for Loop 2 (see Figure 7.11). If the state of
these inputs remains constant, the controller will continue to use the
selected setpoint unless overridden. Override the set of digital inputs by selecting a different setpoint (by using SET PT key or through
communications), or by using the fifth digital input to select the remote or 2nd setpoint. To “rearm” this set of digital inputs, the DIN
combination must change.
• L2.REM.SP.
Closing input changes active setpoint to remote setpoint. Opening
reverts controller to previous setpoint. Override by selecting a different setpoint via the SET PT key, a communications command, or
other digital inputs.
• L2. MAN.
Closing input trips the controller to manual. Opening input reverts
controller to automatic. Override by using MANUAL key, a commu-
nications command, or “trip to automatic” function.
• L2. 2ND. SP.
Closing input changes active setpoint to the 2nd local setpoint. Opening input reverts controller to previous setpoint digital input. Override by selecting a different setpoint via the SET PT key, a communications command, or other digital inputs.
• L2. 2ND. PID.
Closing input changes active set of PID values to 2nd set. Opening
input bases active set of PID on rules defined in PID TRIP and TRIP:1
to TRIP:8. Override input only by directly linking PID set to the active setpoint and changing the active setpoint.
• L2.ALARM ACK.
Closing input acknowledges all active alarms. Opening input “rearms” the controller. If the digital input remains closed, it
continue to immediately acknowledge alarms as they become active.
• L2. RSP. INH.
Reset Inhibition. Closing input deactivates “I” (integral) term, regardless of the PID values being used. Opening input activates “I” term
(if applicable).
does not
86 Chapter 7 545 User's Manual
• L2. D.A./R.A.
Direct Acting/Reverse Acting. Closing input reverses action of the
first control output (from direct to reverse, or reverse to direct). Opening reinstates original action.
• L2. NO A/T
Closing input temporarily disables Adaptive Tuning. Opening input
enables it.
• L2. LCK. MAN
Closing contact places the controller in manual control at the designated output percentage. All locked manual contacts must be opened
in order to return controller to automatic control.
• UP KEY
Closing the contact mimics the
behind a window; contact push-buttons can be used to change
setpoint values.
• DOWN KEY
Closing the contact mimics the
behind a window; contact push-buttons can be used to change
setpoint values.
• DISP. KEY
Closing contact mimics the DISPLAY key; scroll through display of
the Setpoint, Deviation % and Output %.
• FAST KEY
Closing contact mimics the FAST key . Use in conjunction with
▼▼
▼, DISPLAY and MENU keys.
▼▼
• MENU KEY
Closing contact mimics the MENU key. In OPERATION Mode, pro-
vides entry to TUNING menu. In SET UP or TUNING Mode, advances
through the menus.
• COMM. ONLY
Makes input status readable through communications (but has no
effect on the controller itself).
▲▲
▲ key. Useful if controller is mounted
▲▲
▼▼
▼ key. Useful if controller is mounted
▼▼
▲▲
▲,
▲▲
Applications
Basic Operating Procedures
1. If more than one digital input closes and their actions conflict, the last digital
input that closed has priority.
For example, if one digital input closes and selects 2nd setpoint, and then
another digital input closes and selects a remote setpoint, the remote
setpoint takes precedence.
2. Any digital input can be overridden by: another digital input, a keyboard
operation, or an automatic function. If a closed digital input is overridden,
then it must be opened in order to be rearmed.
For example, if one digital input closes and selects the 2nd setpoint, and
then a different setpoint is selected through the keyboard, the keyboard
selection takes precedence.
545 User's Manual Chapter 7 87
Applications
NOTE: There is a one-second delay
before a closed digital input takes
action.
I. REMOTE SETPOINT
The Remote Setpoint can be assigned to Loop 1, Loop 2, or both. Remote setpoint
limits are the same as setpoint limits.
Hardware Configuration
• This optional feature is available only if ordered originally from the factory,
Product #545-xxxxxBxx00 or #545-xxxxxExx00). Refer to the order code in
Chapter 1.
• Before configuring the software, make sure the corresponding jumper is set
properly. Refer to Chapter 4 to check or change jumper positions.
Software Configuration
1. Go to the REM. SETPT. menu.
2. Set TYPE V/mA to define the input signal range (e.g. 4-20mA).
3. RSP:LO. RNG. and RSP: HI RNG. define the range of the remote setpoint
in engineering units. The correct range will be dependent on the source of
the remote setpoint signal.
4. RSP:LOW and RSP:HIGH set limits on the remote setpoint value in
engineering units.
5. TRACKING determines whether or not the controller will revert to a local
setpoint if the remote setpoint signal is lost. This prevents a process upset
due to a sudden change in setpoint.
6. BIAS LOW and BIAS HIGH set limits on an operator entered bias value.
7. RSP FIXED determines the signal to which the controller will revert when a
lost RSP is restored (fixed). Options are to stay in local or automatically return
to remote setpoint.
8. To bias or ratio the remote setpoint value:
a. Go to the TUNING menu.
b. Set RSP BIAS and RSP RATIO values.
88 Chapter 7 545 User's Manual
Basic Operating Procedures
After configuring the hardware and software, select the remote input by:
• pressing the SET PT key until RSP shows in the display
• using a digital input
J. MULTIPLE SETPOINTS
The 545 can store up to eight local setpoints and use a remote setpoint. One
application of this feature is configuring the controller to restrict operators to
discrete setpoint choices. The 545 can also store multiple sets of PID parameters
(see next section).
Software Configuration
1. Go to the SPECIAL menu.
2. Set NO. OF SP to the number of local setpoints desired.
3. Use the SET PT key to scroll to each local setpoint and set it to the desired
value with the ▲ or ▼ keys.
4. To link the PID sets to the corresponding local setpoint:
Go to the TUNING menu.
Set NO. OF PID to SP NUMBER.
For details on multiple sets of PID, refer to the next section in this chapter.
Basic Operating Procedures
To select a set point, toggle the SET PT key to scroll through the setpoints. The
displayed setpoint becomes active after two second of key inactivity.
The digital inputs can also be used to select the active setpoints. A single digital
input may be used for selecting the seconds setpoint, SP2. A set of two digital
inputs per loop may be used, to select up to 4 setpoints per loop (see the section
in this Chapter in Digital Inputs).
The SET PT key is lit when a setpoint other than the primary local setpoint is
active.
K. MULTIPLE SETS OF PID VALUES
The 545 has the ability to store up to eight sets of PID values. This can be a
valuable feature for operating the controller under conditions which require
different tuning parameters for optimal control. There are various methods of
selecting which set should be active. These methods are explained in this section.
Applications
Software Configuration
1. Go to the TUNING menu.
2. NO.OF PID is the desired number of PID sets to be stored. SP NUMBER
automatically sets this value equal to the number of stored local setpoints
(each PID set will be active when its respective local setpoint is active).
3. PID TRIP determines which variable selects the various PID sets: process
variable, setpoint or deviation from setpoint.
4. TRIP:X defines the point (in the PV range) at which that set of PID values
become active.
Basic Operating Procedures
A PID set can be selected in one of four ways.
• For NO. OF PID = SP NUMBER, the active set of PID values is the same
as the active setpoint. For example, if SP3 is active, then PID set #3 will be
active.
• When using PID trip values, a PID set becomes active when the variable
exceeds its trip point.
For example, if PID TRIP = SETPOINT, and TRIP:2 = 500, the second set
of PID values becomes active when the setpoint exceeds 500, and remains
active until the setpoint drops below 500 or exceeds the next highest trip
point. The PID set with the lowest trip point is also active when the trip
variable is less than the trip value. (The user can set the lowest trip point
= the low end of the process variable range, but this is not required.)
• A digital input can be set to trip to the second set of PID upon closure, which
overrides a selection based on trip points.
Using with Adaptive and Pretune
The 545 can be programmed to automatically set the PID values using the
Pretune and Adaptive Tuning functions. For both functions, the tuned set of PID
is that which is active upon initiation of the tuning function.
The controller cannot trip to other PID sets (based on trip point or the digital input
545 User's Manual Chapter 7 89
Applications
contact) until Adaptive Tuning is disabled. However, if the PID set is tied to the
corresponding local setpoint, the active PID set values will change with the local
setpoint.
Each PID set has 5 parameters that control its function—proportional band,
reset, rate, manual reset (or loadline), and trip point. For each set (2 thru 8),
these values have to be manually set.
1. Press MENU to access the TUNING menu.
2. Set values for parameters 1 thru 20 (these include the first PID set)
3. Press MENU to access these parameters for each additional PID set (2
through 8): PROP. BND, RESET, RATE, MAN. RST. and TRIP.
L. POWERBACK
POWERBACK is Moore Industries’ proprietary algorithm which, when invoked
by the user, reduces or eliminates setpoint overshoot at power up or after
setpoint changes. Powerback monitors the process variable to make predictive
adjustments to control parameters, which in turn helps to eliminate overshoot
of the Setpoint.
Software Configuration
1. Go to the TUNING menu.
2. Set POWR.BACK parameter to ENABLED.
3. Go to the SELF TUNE menu.
4. The DEAD TIME is the time between initiation of an input change and the
start of an observable response in the process variable. Pretune will
automatically calculate a value for this parameter. However, if Pretune is
not run, or results are poor, value choices are:
R 10 to 3200 seconds
D 7200 seconds
M. SELF TUNE—POWERTUNE
The Self Tune function of the 545 consists of two distinct components, Pretune
and Adaptive Tune. These components may be used independently or in
conjunction with one another. For best results, we recommend using them
together.
®
Pretune
This algorithm has three versions. Choose the type that most closely matches
the process to optimize the calculation of the PID parameters. The three Pretune
types are:
• TYPE 1 Normally used for slow thermal processes
• TYPE 2 Normally used for fast fluid or pressure processes
• TYPE 3 Normally used for level control applications
Pretune is an on-demand function. Upon initiation, there is a five second period
during which the controller monitors the activity of the process variable. Then
the control output is manipulated and the response of the process variable is
monitored. From this information, the initial Proportional Band, Reset and Rate
(P, I and D values) and Dead Time are cal culated. When using TYPE 2 or TYPE
3 Pretune, the Noise Band (NOISE BND.) and Response Time (RESP. TIME)
and DEAD TIME will also be calculated.
90 Chapter 7 545 User's Manual
In order to run this algorithm, the process must fulfill these requirements:
• The process must be stable with the output in the manual mode;
• For tuning a non-integrating process, the process must be able to reach
a stabilization point after a manual step change; and
• The process should not be subject to load changes while Pretune operates.
If these conditions are not fulfilled, set the Adaptive Tune to run by itself.
Applications
Adaptive Tune
Adaptive Tune continuously monitors the process and natural disturbances and
makes adjustments in the tuning parameters to compensate for these changes.
In order to make accurate calculations, Adaptive Tune needs noise band and
response time values. Pretune TYPE 2 and TYPE 3 automatically calculate these
values. These values may also be entered or changed manually in the SELF
TUNE menu. For Pretune TYPE 1, Noise Band, Response Time and Dead Time
parameters must be entered manually.
Figure 7.12 illustrates the relationship between Pretune and Adaptive Tune
Software Configurations
Pretune by Itself
1. Go to the SELF TUNE menu (press MENU+FAST)
2. Set the TYPE parameter to PRETUNE.
3. Set the PRETUNE type to the one that best matches the process (see above
section).
4. The next parameter, TUNE PT., appears only for TYPE 1 pretune. This
parameter sets the PV point at which the output will switch off. In thermal
processes, this will help prevent overshoot. The default is AUTOMATIC.
5. Set the value for OUT STEP. This parameter defines the size of bump to be
used. The resulting disturbance must change the process variable by an
amount that significantly exceeds the peak-to-peak process noise, but does
not travel beyond the “normal” process variable range.
6. The next two parameters, LOW LIMIT and HI LIMIT, set the process variable
boundaries. If these boundaries are exceeded during the Pretune, the
pretune cycle will abort and return to manual control at the output level prior
to the initiation of pretune.
7. The next parameter, TIMEOUT, defines the maximum time in minutes within
which pretune must complete its calculations before it is aborted.
The first time a pretune is performed, set TIMEOUT to its maximum value.
Make note of the length of the pretune cycle. Then, adjust TIMEOUT to a
value about twice the pretune time.
The purpose of this parameter is to prevent a Pretune cycle from continuing
for an excessive period of time if a problem develops. The value has no impact
on the PID values being calculated.
8. Next is MODE. This defines what mode the controller will enter when pretune
is completed. Select MANUAL if there will be a need to review PID parameters
before attempting to control with them; the default is AUTOMATIC.
9. If POWERBACK algorithm is being utilized, set a value for DEAD TIME.
10.Place the controller under manual control.
CAUTION!
Disable Adaptive Tuning before
altering process conditions (e.g., for
shutdown, tank draining, etc.).
Otherwise, the 545 will attempt to
adapt the Tuning parameters to the
temporary process conditions.
Adaptive Tune can be disabled via
digital input (if applicable—see Digital
Inputs in this chapter), or via menus:
1. Go to the TUNING menu.
2. Go to parameter ADAPTIVE.
Change the value to DISABLED.
545 User's Manual Chapter 7 91
Applications
11.Access the TUNING menu (press MENU).
Set the first parameter, ADAPTIVE, to DISABLED.
12.Activate the next parameter, PRETUNE.
13.Press ACK to begin Pretuning.
The 3rd display will show the message EXECUTING.
14.When Pretune is complete, the 3rd display will show COMPLETED for two
seconds and then return to the current menu display.
Pretune TYPE 1 & Adaptive Tune
1. Go to the SELF TUNE menu.
2. Set TYPE to BOTH.
3. Set PRETUNE to TYPE 1.
4. Set a value for TUNE PT.
5. Set NOISE BND parameter.
6. Set the RESP. TIME parameter.
7. Make sure that the process is reasonably stable and place the controller under
manual control.
8. Press MENU to access the TUNING menu.
Set ADAPTIVE to ENABLED. The Adaptive Tuning cycle does not begin
until the controller is under automatic control.
9. Activate the next parameter, PRETUNE.
10.Press ACK to begin Pretuning.
The 3rd display will show the message EXECUTING.
11.When Pretune is complete, the 3rd display will show COMPLETED for two
seconds and then return to the current menu display.
The controller will automatically transfer to automatic control upon completion
of Pretune if set to do so, or upon manual transfer.
Figure 7.12 illustrates the operation of Pretune TYPE 1 with Adaptive Tune.
92 Chapter 7 545 User's Manual
Pretune TYPE 2 or 3 & Adaptive Tune
1. Go to the SELF TUNE menu.
2. Set the TYPE parameter to BOTH.
3. Set the PRETUNE parameter to TYPE 2 or TYPE 3.
4. Set the value for OUTSTEP.
5. DO NOT Enter values for NOISE BND, RESP TIME and DEAD TIME. The
Pretune algorithm should calculate these values.
6. Make sure that the process is reasonably stable and place the controller under
manual control.
7. Press MENU to access the TUNING menu.
8. Set parameter ADAPTIVE to ENABLED. The Adaptive Tuning cycle does
not begin until the controller is under automatic control.
9. Activate the next parameter, PRETUNE.
10.Press ACK to begin Pretuning.
The 3rd display will show the message EXECUTING.
Applications
11.When Pretune is complete, the 3rd display will show COMPLETED for two
seconds and then return to the current menu display.
The controller will automatically transfer to automatic control upon completion
of Pretune if set to do so, or upon manual transfer.
Figure 7.12 illustrates the operation of Pretunes TYPE 2 and TYPE 3 with
Adaptive Tune.
CONTROL
OUTPUT
PV
CONTROL
OUTPUT
PV
100%
70%
50%
30%
0%
0%
900
700
500
300
100%
70%
50%
30%
900
700
500
300
0
0%
0%
0
➔
A
NOISE BUMP
➔
➔
A
Pretune
PRETUNE
Out Step
➔
B
TIME
High Out Limit
Low Out Limit
ADAPTIVE
➔
B
ADAPTIVE
➔
C
TIME
TYPE 1 Pretune/Adaptive Control
• A to B is ON/OFF control to determine initial PID values.
• B is Pretune completed, so Adaptive PID control beings if ENABLED.
Note: Noise Band and Resp. Time must be entered before
enabling Adaptive TUne)
SP
TYPE 2 Pretune/Adaptive Control
• A to B is a 5 second noise band measurement.
• B to C is an open loop bump test to determine initial PID values
and response time.
• C is Pretune completed, so Adaptive PID control begins if ENABLED.
SP
Figure 7.12
Pretune TYPE 1, 2 and 3 with
Adaptive Tune
100%
70%
CONTROL
OUTPUT
PV
50%
30%
900
700
500
300
0%
0%
0
➔
➔
A
NOISE BUMP
➔
B
Pretune
Out Step
➔
C
TIME
545 User's Manual Chapter 7 93
TYPE 3 Pretune/Adaptive Control
• A to B is a 5 second noise band measurement.
• B to C is an impulse to determine initial PID values and response
time.
• C is Pretune completed, so Adaptive PID control begins if ENABLED.
SP
ADAPTIVE
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