Moore Industries 531 User manual

M531 V7, MARCH 207
5 3 1
5 3 1
PLC, DCS, PC CONTROL BACKUP STATION
USER'SMANUAL

531 User's Manual Table of Contents i
Contents
page About This Manual:
ThroughoutthisUser’sManualwill
appearNOTEs,CAUTIONs and
WARNINGs,usuallyinboldface.
Pleaseheedthesesafetyand good
practicenoticesforthe protection of
youandyourequipment.
CONTENTS
FIGURE LIST .......................................................................................... iii
CHAPTER 1
INTRODUCTION ............................................................................. 1
Conforming What Is Included.......................................................... 1
Order Code ...................................................................................... 2
Basic Operation ............................................................................... 3
Where To Go Next........................................................................... 3
Text Formatting in This Manual ...................................................... 3
CHAPTER 2
INTERFACE & BASIC OPERATION ............................................. 5
Displays............................................................................................ 5
Icons................................................................................................. 5
Keys ................................................................................................. 6
Basic Operating Procedures ........................................................... 7
Alarms .............................................................................................. 8
CHAPTER 3
HARDWARE CONFIGURATION.................................................... 9
Accessing and Changing Jumpers ............................................... 11
Adding or Changing Output Modules............................................ 12
Where to Go Next.......................................................................... 13
CHAPTER 4
MOUNTING AND WIRING............................................................ 15
System Planning............................................................................ 15
Mounting the Station...................................................................... 15
Wiring the 531 Inputs..................................................................... 16
A. AC Power .......................................................................... 17
B. Process Variable............................................................... 17
C.Digital Inputs ..................................................................... 18
D.Remote Setpoint Indicator................................................ 19
Wiring the 531 Outputs.................................................................. 19
A. CV Output ......................................................................... 19
B Mechanical Relay Output ................................................. 19
C Solid State Relay (Triac) Output ...................................... 19
D.DC Logic (SSR Drive) Output .......................................... 19
Wiring for Serial Communications................................................. 20
Where to Go Next.......................................................................... 20
CHAPTER 5
SOFTWARE CONFIGURATION .................................................. 21
Mode Overview.............................................................................. 21
Menus............................................................................................. 22
Smart Menus.................................................................................. 22
Software Configuration Procedures.............................................. 23
Guide to Set up Parameters.......................................................... 25
CONFIG................................................................................. 25
LOCAL OUT. ......................................................................... 28
PV INPUT .............................................................................. 29
CUST. LINR. ......................................................................... 31

Contents
ii Table of Contents 531 User's Manual
page
RSP INPUT ............................................................................ 32
ALARMS ................................................................................ 33
SECURITY ............................................................................. 35
SER. COMM........................................................................... 36
OPERATION .......................................................................... 37
Parameter Value Charts.................................................................. 39
CHAPTER 6
531 APPLICATIONS ...................................................................... 45
531 Operation ................................................................................. 45
Alarms............................................................................................. 46
Digital Inputs ................................................................................... 50
WatchdogMonitor........................................................................... 51
Process Variable and Setpoint ........................................................ 51
InputLinearization........................................................................... 53
Thermocouple and RTD Linearization .................................... 53
Square Root Linearization ...................................................... 53
CustomLinearization.............................................................. 53
Ramp to a Control Value................................................................. 54
Security........................................................................................... 55
Process Variable Reading Correction ............................................. 56
SerialCommunications ................................................................... 56
APPENDIX A
MODE, MENU & PARAMETER FLOWCHART............................ A-1
APPENDIX B
PARTS LIST................................................................................. B-1
APPENDX C
TROUBLESHOOTING ................................................................. C-1
APPENDIX D
CALIBRATION ............................................................................. D-1
RegardingCalibration ................................................................... D-1
RTD and VmA Input Calibration .................................................... D-2
Thermocouple & Cold Junction Calibration ................................... D-3
Milliamp Output Calibration ........................................................... D-4
Reset Menu Data .......................................................................... D-4
Hardware Scan ............................................................................. D-5
Quick Calibration Procedure ......................................................... D-5
APPENDIX E
SPECIFICATIONS........................................................................ E-1

531 User's Manual Table of Contents iii
Contents
Figure.............Title ............................................................................ Page
Figure2.1 ......531OperatorInterface ......................................................... 5
Figure2.2 ......BeforeandAfterAcknowledginganAlarm ............................. 8
Figure 3.1......LocationofPrintedCircuitBoards ......................................... 9
Figure 3.2......JumperLocationsonMicrocontrollerBoard ......................... 10
Figure 3.3......TheOptionCircuitBoard .................................................... 10
Figure 3.4......ThePowerSupplyCircuitBoard ......................................... 10
Figure 3.5......OutputModule ................................................................... 13
Figure4.1 ......531InstrumentPanelandCutoutDimensions ..................... 15
Figure4.2 ......MountingBrackets ............................................................. 16
Figure4.3 ......531RearTerminals ............................................................ 17
Figure4.4 ......OutputWiringforthe531 .................................................... 19
Figure4.5 ......SerialCommunicationsTerminals....................................... 20
Figure5.1 ......MenuFlowchartforSetUp ................................................. 21
Figure5.2 ......Independentvs.DependentParameters ............................. 22
Figure5.3 ......KeystoEnterandMoveThrough SetUpMode.................... 23
Figure6.1 ......AlarmExamples................................................................. 49
Figure6.2 ......SquareRootLinearizationFormula ..................................... 53
Figure6.3 ......CustomLinearizationCurve................................................ 54
FigureD.1 .....FlowcharttoAccessPartsofCalibrationMenuBlock ......... D-1
FigureD.2 .....MicrocontrollerCircuitBoard............................................. D-2
FigureD.3 .....CalibrationWiring............................................................. D-2
FigureD.3a ...CalibrationWiring(continued) ........................................... D-3
FigureD.4 .....Thermocouple&ColdJunctionCalibrationWiring.............. D-3
FigureD.5 .....MilliampCalibrationWiring................................................ D-4

Contents
iv Table of Contents 531 User's Manual

531 User's Manual Chapter 1, Introduction 1
Introduction
CHAPTER 1
INTRODUCTION
The 531 PID Backup Station ensures the integrity of your processes with
maximumreliability.Isolatedinputsandoutputsguardagainstelectricalinter-
ference,thefrontfacemeetsNEMA4Xstandardsforwatertightoperation,and
therugged caseand sturdy rubber keys enhancedurability.
The531hasthreedigitaldisplayareas,twoofwhichofferupto9charactersof
truealphanumerics.Thebright,crispvacuumfluorescentdisplaysofferbetter
readabilitythananyotherdisplaytechnology.Additionaloperatorfriendlyfea-
tures include: custom programmable alarm messages, keys that illuminate
whenin use,and aneasy-to-use menu system.
The531automaticallyprovidesPIDbackupcontrolforcriticalcontrolloops.In
Host Mode, the control signal passes from the Host device through the 531
withoutanydegradation.AHostdevice maybeaPLC,DCS,orprocesscon-
troller. The 531 switches to Automatic (PID) Mode upon keypad selection,
digitalinput,orlossoftheHostsignal,andgeneratesacontrolsignalbasedon
its own PID calculations. The control setpoint may be one or two preset
setpoints,or transmittedtothe531.The531canalsobe switchedtoManual
Mode,inwhichtheoperatorcanmanuallyadjusttheoutput.The531willtrans-
fer/returntoHostModeuponkeypadselection,openingofthedigitalinputor
returnof the Hostsignal.
CONFIRMINGWHAT IS INCLUDED
Withyour 531 PIDBackup Station,you should have received:
• 1531 User’s Manual
• Mountinghardwareset
• 1sheetofengineering unit adhesivelabels
• 1Terminallabel
Youcandeterminetheinstalledoutputsofyourstationbycomparingyourproduct
numbertotheOrderCodebelow.Theproductnumberisprintedonthelabelon
thetopof the controllercase.
OUT
1 2
ALM
1 2
INPUTS
HOST Signal
Process Variable
Remote Setpoint
Digital Inputs
Serial Communications
OUTPUTS
HOST Signal
Control Output
Alarm(s)
Serial Communications
Thankyoufor selecting the531
PIDBackupStation. It isthe most
sophisticatedinstrumentinits
classand will provideyou with
yearsofreliable,trouble-free
performance.
Specifications and information subject to change without notice.
Note:thatthe531PIDBackupStation
isnotapointoffailure;removingitfrom
the case or powering down while in
Host Mode will not disturb the Host
signal.

Introduction
2Chapter 1, Introduction 531 User's Manual
BASIC OPERATION
Therearethreeoperatingmodesfor the 531:
ORDER CODE*
531 -
ORDERCODE
OUTPUT 1 —
(ALARM ONLY)
None .........................................................................................0
Mechanical relay .......................................................................1
Solid state relay (1 amp triac) ...................................................3
DC logic (SSR drive) .................................................................4
OPTIONS
ENTER “0” IF NOT DESIRED
None .........................................................................................0
24 VAC Operation .....................................................................F
ENTER “0” IF NOT DESIRED
None .........................................................................................0
Set of five digital inputs .............................................................D
Certification ..........................................................................H
Set of five digital inputs and Certification .............................J
SERIAL COMMUNICATIONS
ENTER “0” IF NOT DESIRED
None .........................................................................................0
RS-485 serial communications .................................................S
*Note: Base instrument contains universal PV input, remote setpoint input and 4-20 mA CV (control) output with
internal hard wired by-pass relays.
NOTE:
Alteringthefactoryconfigurationofthe
moduleswillrender theproductlabel
codeinvalid.
11B002

531 User's Manual Chapter 1, Introduction 3
Introduction
Host Mode: The 531 operates as a remote station that passes a CV di-
rectlyfromahosttoacontrolleddevice.Inthismode,theSPbutnottheCV
(output)canbealtered.Special“setup”parameterscanbeaccessed,and
the531canbetransferred into either oftheotheroperatingmodes.
AutomaticMode:The531sendsoutputtothefinaldeviceasprovidedby
itsownPIDcalculations. In this mode,theSPbut not the CV(output)can
bealtered.The“setup”parametersmaynotbeaccessed,butthe531can
betransferredtoeitheroftheotheroperatingmodes.
Manual Mode. An operator provides manual output to the controlled de-
vice.BoththeSPandtheCVcanbealtered,andthe531canbetransferred
toeitheroftheothertwooperatingmodes.
The531alsohasasetup,or“configuration”modeinwhichtheuserconfigures
thespecialfunctionsofthe531,likeinputsandoutputs,alarmsandPIDopera-
tion.Thereare9menusinsetupmode:eightareforinstrumentsetup,andthe
ninth,OPERATION,configurestheoperationalaspectsofthe531.
WHERETO GO NEXT
•Firsttimeusersshouldreadthroughthisentiremanual.ContinuetoChap-
ter2forbasicinterfaceandoperationinformation.ThenreadChapter3for
importantinstallationguidelines.
•ExperiencedusersmaycontinueontoChapter5fordetailsontheconfigu-
rationfeaturesofthe531.
•Appendix 1 contains flowchart references for all 531 parameters, menus
andmodes.
TEXT FORMATTING INTHIS MANUAL
Feature Format
Mode Automatic,Manual, Host Mode
KEYS SET PT DISPLAY
or
ICONS OUT, ALM
MENUS CONFIG.,TUNING
PARAMETERS CYCLETM:1,MIN.OUT2
PARAMETERVALUES OFF,SETPOINT, LASTOUT.
DISPLAYMESSAGES TOOHOT, OUT%,
SET PT DISPLAY

Introduction
4Chapter 1, Introduction 531 User's Manual

Interface/Operation
531 User's Manual Chapter 2, Interface and Basic Operation 5
MANUAL DISPLAY ACK
FAST
MENU
HOST
OUT
1 2
ALM
1 2
Location for
identification label
1
st
Display
2
nd
Display
3
rd
Display
Icons
Keys
531
CHAPTER 2
INTERFACE AND BASIC OPERATION
Theindividualsoftwareandhardwareoptionsofyourstationdeterminethein-
formationitdisplays.ComparetheproductnumberontheunitlabeltotheOrder
Codein Chapter 1 for moreinformation. A“smart menu” featureof the531 al-
lowsonlythosemessagesrelevanttoyourindividualhardware(andsoftware)
configurationto appear in the displays.
1st Display
• 5digits,sevensegments.Heightis 15mm (0.6in).
• NormallydisplaystheProcessVariable (PV).
Ifstationloses signal,“--------”displays.
2nd Display
• 9characters,14 segment alphanumeric. Height is 6mm (0.25in).
• DisplaystheCVoutput(OUT)orthesetpoint(SP).Tochangethedisplayed
value,pressthe DISPLAY key.
• Whenin configuration menus,displaysthemenuandparameternames
3rd Display
• 9characters,14segment.Heightis 6mm (0.25in).
• Displaysuser-selectablestationnameifnoalarmsare queued.
• Displaysanyerroror alarm intwo-secondalternatingmessages.
• Whenin configurationmenus,displaystheparametervalues.
ICONS:
ALM1,ALM2: Indicatesrespective alarm(s) is/are active.
OUT1, OUT2:Indicates respectiveoutput(s)is/are active.
NOTE::
Anymodificationstothefactory
settingsoftheoutputmoduleswill
altertheModelNumberdisplayed
uponpower-up from the original the
ProductCodeonthelabel.
Figure 2.1
531 Operator Interface
ALM ALM ALM
1212
OUT OUT OUT
1212

Interface/Operation
6Chapter 2, Interface and Basic Operation 531 User's Manual
MANUAL
HOST
DISPLAY
MENU
ACK
FAST
▲
▲
▲
FAST
▲
FAST
FAST MENU
NOTE:
Refer to Chapter 3, or Appendix 1 for
details on menu, mode and parameter
transitions
IlluminatedKey
StationisinManualMode.When
notilluminated,thestationisin
eitherHostorAutomaticMode.
531 is passingHost signal
through.
Keydoesnotlight.
531isinconfiguration (set up)
mode.
Anacknowledgablealarmexists.
Keydoesnotlight.
Keysdonotlight.
N/A
N/A
Press Key (s)
Transfersstation from Host or
AutomaticModetoManualMode,
orfromManual toAutomatic.
TogglesbetweenHost and either
Automaticor Manual Mode
(dependingonvalidityofthePV).
Exitstheconfiguration(setup)
menusandreturnsstationto
operatingmode.
Providesentryintothe OPERA-
TIONsetup menu.
Acknowledgesalarms.
Functionsas a “shift”key or foruse
withotherkeys.
Increasesor decreases the value or
selectionof thecurrentparameter.
Changesparameter valueor
selectionata faster rate.
InHost orManualMode, provides
entryintothe other eightsetup
menus.Whenunderconfiguration,
advancesfrommenutomenu.
or
+
or
+
+
KEYS

Interface/Operation
531 User's Manual Chapter 2, Interface and Basic Operation 7
BASIC OPERATING PROCEDURES
To transfer from Host to Automatic Mode
1. Press the HOST key once. The 531 will transfer to Automatic Mode as
longas the PVinput is valid(else,it transfersto Manual Mode).
2. The HOSTkey and MANUAL keywill be off.
3. The 531 stops passing the Host signal, and transmits its own output that
basedonPID,with a bumplesstransfer.
To transfer from Host to Manual Mode
1. Pressthe MANUAL key.The 531 willtransfer toManual Mode.
2. The HOSTkey willextinguish,and theMANUAL key will light.
3. The 531 stops passing the Host signal, and transmits a manual output to
thefinalcontrolelement.Thiswill be a bumplesstransfer.
To transfer from Automatic to Manual Mode
1. Whenin Automatic Mode,press theMANUAL key.
2. TheMANUAL key willlight.
3. The531stopstransmitting the PID outputandtransmitsamanualoutput
tothefinalcontrol element. This willbeabumplesstransfer.
To transfer from Automatic/Manual Mode to Host Mode
1. PresstheHOSTkey.The531willtransfertoHostModeaslongastheCV
signalisvalid(otherwise, it remainsintheprevious mode).
2. The531willstoptransmittingitsownoutput(CV)signal,andpassthesig-
nal from the Host device to the final control element. This will be a direct
transfer.
3. Toprovidearampedtransfer,therampingrate(HOSTRAMP)canbeset
intheOPERATION menu.
To change output values
1. PressMANUAL key to shift toManual Mode fromAutomatic or Host.
2. Thesecond displaywilldisplay OUT%.
3. Use ▲▲
▲▲
▲and ▼▼
▼▼
▼keysto change the output (CV)value.
Tooverride security or reset the controller
1. If someone attempts a locked operation, SECURITY appears in the 2nd
display,and a securitycode prompt (0)appears in the3rd display.
2. Use ▲▲
▲▲
▲and ▼▼
▼▼
▼keysto selecta codevalue. Thevalue willbe enteredafter
twoseconds ofkey inactivity.
•If no code was entered (value left at 0), SECURITY disappears and
thestationresumesoperation.
•Ifthevalueisincorrect,INCORRECTappearsinthe3rddisplay.After
2seconds, the stationprompts you toenter a newcode.
•Ifthecodeiscorrect,CORRECTappearsinthe3rddisplay.Aftertwo
seconds,alldisplaysclearandyouhavetemporaryaccesstoallpre-
viously locked features. Security will automatically rearm (lock) the
stationonceafterone minute ofkeyinactivity.
•IfthecorrectSecurityOverrideCodeisentered,RESETappearsin
the3rd display. After two seconds, all displays clearand the stations
functionsareresetto their factory defaults(unlocked).
NOTE:
Formore information onSecurity
functions,seeChapter6.
NOTE:
For more information on operating
modes,seeChapter6.

Interface/Operation
8Chapter 2, Interface and Basic Operation 531 User's Manual
ALARMS
IMPORTANT! Alarms can be used to provide warnings of unsafe conditions.
Therefore,all531 operators mustknow how thealarmsare configured, howto
reacttoalarmconditions,andtheconsequencesofacknowledging(notingand
clearing)analarm.
The 531 indicates alarms by:
•Lightingicons
•Displayingmessages; and
•Lightingthe ACK key, ifan alarmis in anacknowledgeable state.
To acknowledge an alarm:
1. Press the ACK key to acknowledge Alarm 1. This clears the alarm (and
releasestherelay,ifapplicable.
2. Boththeiconandmessageindicatorsdisappear,andtherelay(ifapplicable)
changesstate.
3. Ifasecondalarmisactiveandacknowledgeable,presstheACKkeyagain
toacknowledgeAlarm2.
Figure 2.2 shows the controller face during an alarm condition, and after the
alarmhas been acknowledged.
Latching Alarms
Alatchingalarmholdsitsalarmstateevenaftertheprocessleavesthealarm
condition.Thisisusefulforstationsthatwill notbecontinuouslymonitoredby
anoperator.Alatchingalarmcanbeconfiguredtobeacknowledgeablewhile
inthealarmcondition,ORonlyaftertheprocessleavesthealarmcondition.A
non-latching alarm will clear itself as soon as the process leaves the alarm
condition.
Limit Sequence
Analarm can beconfigured to be both latching and not acknowledgeable.In
thiscase,thealarmisacknowledgeableonlyaftertheprocesshasleftthealarm
condition.This is often referred toas alimit sequence.
Formore onalarms, see Chapter 6.
NOTE:
Powering down the controller acknowl-
edges/clears all latched alarms. When
poweringup, allalarms will bereset ac-
cording to their power-up configuration
(see Chapter 6).
Figure 2.2
Before and After Acknowledging
an Alarm
NOTE:
Allalarmsareinternalalarmsunlesstied
to an output relay in the set up mode.
BEFORE AFTER
MANUAL DISPLAY ACK
FAST
MENU
HOST
531
MANUAL DISPLAY ACK
FAST
MENU
HOST
531
OUT
1 2
ALM
1
OUT
1 2

Hardware
531 User's Manual Chapter 3, Hardware Configuration 9
CHAPTER 3
HARDWARE CONFIGURATION
The531 hardwareconfiguration determineswhich outputsareavailable and
thetypes ofindicatorsignalsthat will beused.
Your station comes factory set with the following:
• Allthespecifiedmodulesandoptionsinstalled(seeproductlabeland
comparetoOrder Code inChapter1).
• Processvariableandremotesetpoint inputs settoacceptamilliamp
input.
• Relayoutputssettonormally open
Thelocationsofcertain jumpers and modulesontheprinted circuit boards
willallowdifferent types ofinputsand outputs tobeconnected to thesta-
tions.Figure 3.1showstheposition of thesecircuitboardsinsidethe station.
Toaccess theseboards:
1. Withpower off, loosenthe two captivefrontscrews with aPhillips
screwdriver.
2. Gentlyslide thechassis out ofthe case bypulling onthe front faceplate
assemblyat the bezel.Remove the twoscrews.
NOTE:
Yourhardwareconfigurationwill
influencethe available set up options
inChapter5.
NOTE:
Ifyou would likeyour controller con-
figuredatthefactory,please consult
anapplicationengineer.
MICROCONTROLLER
BOARD
POWER SUPPLY
BOARD
OPTION
BOARD
Figure 3.1
Location of Printed Circuit Boards for
HardwareConfiguration
CAUTION!
Staticdischargewillcausedamagetoequipment.Alwaysgroundyour-
self with a wrist grounding strap when handling electronics to prevent
staticdischarge.
NOTE:
Anychangesyou maketothe output
moduleswillrenderthe code onthe
productlabelinvalid.

10 Chapter 3, Hardware Configuration 531 User's Manual
Hardware
Process Variable Indicator Type
The 531 will accept several different types of Process Variable Signals. You
specify thetype of signal by adjusting the PV jumper location on the Micro-
controllerCircuitBoard, as showninFigure 3.2.You will alsoneedto set the
particularsensor range inthe software (Chapter5).
V Voltagesignal
MA Milliamp
TC t Thermocouplewith downscaleburnout
TC s Thermocouplewith upscaleburnout
RTD RTD
Figure 3.4
The Power Supply Circuit Board,
with Outputs 1 through 3
Figure 3.2
Jumper Locations on
MicrocontrollerBoard
Figure 3.3
The Option Circuit Board, with Output 4
NO J1 NC NO J2 NC NO J3 NC
Module
Retention
Plate
over Outputs 1,2,3
Jumpers
NO and NC
1
2
3
4-Pin Connector
Male 22-Pin
Connector
Male 22-Pin
Connector
Male 44-Pin
Connector
4
Output 4
5-Pin Connector
EPROM
BATTERY
V
MA
TC
RTD
TC
TB1
PV1 2ND
TB2
V
MA
Female 22-Pin ConnectorFemale 22-Pin Connector
Female 44-Pin Connector
Retransmitted (Remote) SP
Configuration
PV Input Jumper
Configuration
CAUTION!!
Donotchangeconfigurationofoutputs
2,3,and 4. Donotchangeposition of
jumpersJ2 and J3.

Hardware
531 User's Manual Chapter 3, Hardware Configuration 11
SetpointType (retransmitted)
Youspecifythetypeofretransmittedsetpointbyadjustingthejumperlocation
ontheMicrocontrollerBoard,asshowninFigure 3.2:
V Voltagesignal
MA Milliampsignal(factorydefault)
Mechanical Relays
ThereisoneoutputmodulesocketontheOptionBoard(Figure 3.3),andthree
onthePowerSupplyCircuitBoard(Figure 3.4).Thepositionofthejumpernext
toeach socketdetermines whetherthe relayis configured for Normally Open
(NO)orNormallyClosed(NC).Theoutputontheoptionsboardisalwaysfac-
toryset to NormallyOpen (NO).
Only the Output 1 relay (if used) may be configured for normally open or nor-
mally closed. Do notmake anychanges toJ2 andJ3.
ACCESSING AND CHANGING JUMPERS
Jumperconnectorseitherslipoveradjacentpins,orhavepinswhichinsertinto
adjacentholes.“Changing the jumper”meansmovingthejumper connectors
toalternatepins/holes.
Equipmentneeded:
•Needle-nosepliers(optional)
•Phillipsscrewdriver(#2)
•Wristgroundingstrap
1. Withpoweroff,loosentwocaptivefrontscrewswithaPhillipsscrewdriver.
2. Slidethechassisoutofthecasebypullingonfrontfaceplateassemblyat
thebezel. Removethetwoscrewsnow.Youwill notneedtodisassemble
thechassistomake these adjustments.
3. Refer to Figures 3.2 and 3.4 to locate the jumper connector you want to
change.
4. Witheitheryourfingersortheneedlenosepliers,pullthejumperconnector
straightup,being careful nottobend the pins(seePhoto 4)
5. Movethejumperconnectorover the desired locationandpressitstraight
down, making sure it is seated firmly. Repeat steps 3 and 4 for any other
jumpersyouwish to change.
6. Whenyouarereadytoreassembletheunit,aligntheboardsonthechassis
with the case's top and bottom grooves. Press firmly to slide the chassis
intothe case.If youhave difficulty, check that you have properly oriented
thechassis and thatthere are noscrews interferingwith the case.
7. Carefullyinsertandalignscrews.Tightenthemuntilthebezelisseatedfirmly
againstthegasket. Do not overtighten.
CAUTION!!
Staticdischargewillcausedamageto
equipment. Always ground yourself
with a wrist grounding strap when
handling electronics to prevent static
discharge.
4. REMOVE JUMPERS

12 Chapter 3, Hardware Configuration 531 User's Manual
Hardware
CAUTION!!
Staticdischargewillcausedamageto
equipment. Always ground yourself
with a wrist grounding strap when
handling electronics to prevent static
discharge.
4. SEPARATE BOARDS
3. PRY CLIPS
CAUTION!
Donotscratchtheboardsorbendthe
pinsofthe connectors.
ADDING OR CHANGING OUTPUT MODULES
The531hasprovisionsforfouroutputmodules.Theunitscomefactoryconfig-
uredwith specified modulesinstalled inappropriate locations. Youcan make
field adjustments by properly removing and/or plugging the modules into the
appropriatesockets.
Important Notes:
•Onlythe Output 1relay (if used)may be changed.
•Outputmodules2,3and4,andJumpersJ2andJ3mustnotbechanged
fromtheirfactoryinstallation.
•AnyoutputmodulewithasoldstaterelayoranalogmoduleMUSThaveits
jumpersetatnormallyopen (NO).
•Output4 is alwaysnormally open (NO).
Three of the output sockets are located on the Power Supply Circuit Board. A
fourthoutputsocketislocatedontheOptionBoard.
Equipment needed:
•Wristgroundingstrap
•Phillipsscrewdriver(#2)
•Smallflatbladescrewdriver
•Wirecuttersor scissors
1. Withpoweroff,loosentwocaptivefrontscrewswithaPhillipsscrewdriver.
2. Slidethechassisoutofthecasebypullingonfrontfaceplateassemblyat
thebezel. Remove thetwo screws now.
3. Locatetheretentionclipsholdingthefrontfaceassemblytotherestofthe
chassis.Pry apart these retention clips gently withascrewdrivertosepa-
ratetheprintedcircuitboardgroupfromthefrontfaceassembly.Takecare
notto break theclips orscratch the circuitboard. SeePhoto 3.
TheMicrocontrollerBoardandPowerSupplyBoardremainattachedtothe
OperatorInterfaceAssemblybywiredconnectors.
4. SeePhoto4.TheMicrocontrollerandPowerSupplyboardareattachedto
eithersideoftheOptionboardbymale/femalepinconnectors.Useagentle
rocking motion and carefully apply pressure to separate the larger two
boardsfromtheOptionBoard.

Hardware
531 User's Manual Chapter 3, Hardware Configuration 13
5. AretentionplateandtiewrapholdOutputmodules1,2,and3(onthePower
Supply board) firmly in place. To remove the retention plate, snip the tie
wrapwith wirecutters (or scissors) as shown in Photo5.
AlwayssnipthetiewrapontopoftheRetentionPlatetoprevent
damageto thesurfacemountcomponents.
6. AdisposabletiewrapholdsOutputmodule4(ontheOptionboard)inplace.
Toremovethe module, sniptiewrap like inPhoto 6.
7. Inspecteachmodulebeforeinstallationtomakesurethepinsarestraight
(Figure 3.5). Align the pins with the socket holes and carefully insert the
module.Pressdown toseatit firmly onthe board (seePhoto 7).
8. Usenew tie wrapstosecure the RetentionPlateand Output Module4.
Failuretousethetiewarpsmayresultinthemoduleloosening
andeventualfailure.Allindividuallyordered modulescomewith
tiewraps.Extrasetsoftiewrapsareavailable;orderPart#535-
665.
9. Toreassembletheunit:AligntheconnectorpinsontheOptionBoardwith
the connector sockets on the Microcontroller and Power Supply boards.
Squeezethemtogether,makingcertainallthreeareproperlyseatedagainst
oneanother.Checkalongthesideedgesforgaps.Also,checkthatthecable
assembliesare not pinched.
10. Aligntheboardassemblywiththefrontfaceassembly,withtheOptionboard
atthebottom(seeFigure 3.1).Reinstalltheretentionclips.Aligntheboards
intothe slots ofthe front faceassemblyand theclipswill snapintoplace.
11. Whenyouarereadytoreassembletheunit,aligntheboardsonthechassis
withthetopandbottomgroovesonthecase.Pressfirmlytoslidethechas-
sisintothecase.Ifyouhavedifficulty,checkthatyouhaveproperlyoriented
thechassis, and thereare no screwsinterfering withthe case.
12. Carefullyinsertandalignscrews.Tightenthemuntilthebezelisseatedfirmly
againstthegasket. Do not overtighten.
WHERETO GO NEXT
Forastep-by-stepguideonmountingandwiringyour531PIDBackupStation,
seeChapter4.
5. REMOVERETENTION PLATE 6. SNIPTIEWRAP 7. ADD/CHANGEMODULE
Figure 3.5
Output Module

14 Chapter 3, Hardware Configuration 531 User's Manual
Hardware

Mount/Wire
531 User's Manual Chapter 4, Mounting and Wiring 15
CHAPTER 4
MOUNTING ANDWIRING
The531PIDBackupStation is thoroughly tested,calibratedand“burnedin”
atthe factory, soyour station isready to install.But before youbegin, read
thischaptercarefully andtakegreat care inplanning your system.Aproperly
designedsystemcan help preventproblems such aselectricalnoise distur-
bancesanddangerousconditions.
SYSTEM PLANNING
A. Consider the Noise Factor
• Forimprovedelectricalnoiseimmunity,installthe station as far
awayaspossible from motors,relaysand other similarnoise
generators.
• Donot run lowpower (sensorinput) lines inthe same bundleas AC
powerlines.Groupingthese lines inthesame bundle can create
electricalnoiseinterference.
B. WiringPracticeResources
Anexcellentresourceabout good wiringpracticesistheIEEE Standard
No.518-1982andisavailable from IEEE, Inc.,345East47thStreet,
NewYork,NY10017,[phone].
MOUNTINGTHE STATION
A. Make the panel cutout
Thestationfits in astandard 1/4 DINcutout.You may mountyourstation
inany panel witha thickness from.06 to.275inches (1.5mm to 7.0
mm).See Figure 4.1 for dimensions.
Ifyou make amistake inthe panel cutout,you canuse a “GoofPlate”
(RepairPart#512-014).
B. Establisha waterproof seal
Thestation front face(keys,display, andbezel)are NEMA4Xrated
(waterproof).
3.770 (95.76)
3.770 (95.76)
1.180 (29.97)
6.000 (152.40)
7.180 (182.37) OVERALL LENGTH
3.585 (91.06)
PANEL
SIDE
BEZEL
GASKET
3.622 (92.00) MIN.
3.653 (92.80) MAX.
3.622 (92.00) MIN. 3.653 (92.80) MAX.
CUTOUT
FRONT
PV2
OUT
1 2
ALM
1 2
Figure 4.1
531 Instrument Panel and Cutout
Dimensions
WARNING!
Toavoid electric shock, DO NOT
connectACpower wiringatthe
sourcedistributionpaneluntilall
wiringconnectionsarecomplete.
Toavoid shock hazardand reduced
noiseimmunityforyour system,
terminal 9 must be grounded.