Moore Industries 532 User manual

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INDUSTRIES
M532 V 8 , Ma rch 2017
5 3 2
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532 User’s Manual Table of Contents i
Contents
page
About This Manual:
For your safety and information, when
using this Manual we have high-
lighted NOTEs, CAUTIONs and
WARNINGs. Please heed these
safety and good practice notices for
the protection of you and your equip-
ment.
Contents ..................................................................................................... i
CHAPTER 1
INTRODUCTION .............................................................................. 1
General Description.......................................................................... 1
532 Auto/Manual Backup Station .................................................... 1
Confirming What Is Included ........................................................... 2
Where to Begin ................................................................................. 2
Overview of the 532 Modes ............................................................. 2
Where To Go Next ........................................................................... 2
Order Codes ..................................................................................... 3
CHAPTER 2
BASIC OPERATION ........................................................................ 4
532 Operator Interface ..................................................................... 4
Displays ................................................................................... 4
Icons ........................................................................................ 5
Keys......................................................................................... 5
532 Operating Procedures ............................................................... 6
532 Alarm Operation ........................................................................ 7
Alarm Indication....................................................................... 7
Alarm Acknowledgment ........................................................... 7
Latching Alarms ....................................................................... 8
Limit Sequence ........................................................................ 8
More on Alarms ....................................................................... 8
CHAPTER 3
HARDWARE SET UP ...................................................................... 9
Hardware Settings ............................................................................ 9
A. Process Variable Indicator Type ...................................... 10
B. Mechanical Relays ............................................................ 11
Hardware Adjustments ................................................................... 11
A. Accessing and Changing Jumpers ................................... 11
B. Adding or Changing Output Modules ................................ 12
CHAPTER 4
INSTALLATION & WIRING ........................................................... 15
System Planning ............................................................................ 15
A. Consider the Noise Factor ................................................ 15
B. Wiring Practice Resources ............................................... 15
Installation ...................................................................................... 15
A. Make the panel cutout....................................................... 15
B. Establish a waterproof seal............................................... 16
C. Mount station into panel .................................................... 16
Input Wiring for the 532.................................................................. 17
A. AC Power........................................................................... 17
B. Process Variable Indicator ................................................ 18
C. Digital Inputs ..................................................................... 19
D. Setpoint or Valve Position Indicator ................................. 19
Output Wiring for the 532 ............................................................... 20
A. CV Output .......................................................................... 20
B Mechanical Relay Output .................................................. 20
C Solid State Relay (Triac) Output....................................... 20
D. DC Logic (SSR Drive) Output ........................................... 20

Contents
ii Table of Contents 532 User’s Manual
page
Wiring the Serial Communications Option ..................................... 21
Where to Go Next .......................................................................... 21
CHAPTER 5
SOFTWARE SET UP ..................................................................... 22
Mode Overview .............................................................................. 22
Menus ............................................................................................. 22
Smart Menus .................................................................................. 22
Set Up Procedures ......................................................................... 23
Step-by-Step Guide to Software Set Up ........................................ 24
CONFIG. ................................................................................ 24
LOCAL OUT. .......................................................................... 25
PV INPUT .............................................................................. 26
CUST. LINR. .......................................................................... 27
SP INPUT .............................................................................. 28
VP INPUT .............................................................................. 29
ALARMS ................................................................................ 29
SECURITY ............................................................................. 33
SER. COMM. ......................................................................... 33
OPERATION .......................................................................... 34
Software Set Up Charts ................................................................ 36
CHAPTER 6
APPLICATIONS ............................................................................. 41
532 Auto/Manual Station ............................................................... 41
Alarm Set Up .................................................................................. 42
A. Set the Alarm Type ........................................................... 42
B. Set the Alarm Parameters ................................................ 43
Digital Inputs .................................................................................. 47
PV, SP and VP Indication ............................................................. 48
A. Choose the Type of Display(s) ......................................... 48
B. Select the Process Variable Display Range .................... 48
C. Set Point Display Range ................................................... 49
D. Valve Position Display Range .......................................... 49
Input Linearization .......................................................................... 49
A. Thermocouple and RTD Linearization .............................. 49
B. Square Root Linearization ................................................ 50
C. Custom Linearization ........................................................ 50
Ramp to Control Value ................................................................... 52
Security .......................................................................................... 52
Process Variable Reading Correction ............................................ 53
Serial Communications .................................................................. 54
APPENDIX A
MENU & PARAMETER FLOWCHARTS ..................................... A-1
APPENDIX B
PARTS LIST ................................................................................ B-1
APPENDIX C
TROUBLESHOOTING ................................................................. C-1
APPENDIX D
CALIBRATION ............................................................................. D-1

532 User’s Manual Table of Contents iii
Contents
page
Regarding Calibration ................................................................... D-1
RTD, VmA Input Calibration ........................................................ D-2
Thermocouple & Cold Junction Calibration ................................. D-3
Milliamp Output Calibration .......................................................... D-4
Hardware Scan ............................................................................. D-6
APPENDIX E
SPECIFICATIONS ....................................................................... E-1
APPENDIX F
ISOLATION BLOCK DIAGRAM ................................................... F-1

Contents
iv Table of Contents 532 User’s Manual
2.1 ............ 532Operator Interface .............................................................. 4
2.2 ............ Beforeand After Acknowledging an Alarm ................................. 8
3.1 ............ Location of Printed Circuit Boards ............................................. 9
3.2 ............ TheMicrocontroller Circuit Board ............................................ 10
3.3 ............ The Option Circuit Board......................................................... 10
3.4 ............ The Power Supply Circuit Board .............................................. 10
3.5 ............ Representation of Module (view of bottom) ............................... 13
4.1 ............ 532 instrument panel and cutout dimensions ............................ 15
4.2 ............ Mounting Brackets ................................................................. 16
4.3 ............ 532Rear Terminals ................................................................ 17
4.4 ............ Output Wiring for the 532 ........................................................ 20
4.5 ............ SerialCommunications Terminals ........................................... 21
5.1 ............ Menu Flowchart for Set Up ...................................................... 22
5.2 ............ IndependentParametersversusDependent Parameters .......... 23
5.3 ............ Keys to Enter and Move through Set Up Mode ......................... 23
6.1 ............ Alarm Examples .................................................................... 46
6.2 ............ SquareRoot LinearizationFormula .......................................... 50
6.3 ............ CustomLinearization Curve .................................................... 51
D.1 ............ Flowchart to Access the Calibration Menus ............................. D-1
D.2 ............ MicrocontrollerCircuitBoard .................................................. D-2
D.3 ............ RTD,VmACalibrationWiring ................................................. D-3
D.4 ............ Thermocouple&ColdJunctionCalibration Wiring .................... D-3
D.5 ............ Milliamp Calibration Wiring ..................................................... D-5
D.6 ............ Flowchart for Access to Reset and Hardware Scan Menus ....... D-6
Figure ....... Title ................................................................................... Page

532 User’s Manual Chapter 1, Introduction 1
Introduction
CHAPTER 1
INTRODUCTION
OUT
1 2
ALM
1 2
INPUTS
Two Process Variables
Remote Setpoint
Digital Inputs
Serial Communications
OUTPUTS
Control Outputs
Alarm(s)
Retransmission
Serial Communications
532
Thank you for selecting the 532
Auto/Manual Backup Station.
It is the most sophisticated instru-
ment in its class, and will provide
you with years of reliable, trouble-
free performance.
General Description
The 532 Auto/Manual Station ensures the integrity of your processes with
maximum reliability. Isolated inputs and outputs guard against electrical
interference, the front faces meet NEMA 4X standards for watertight opera-
tion, and solid metal housings and sturdy rubber keys enhance durability.
The station has three digital display areas, two of which offer up to 9 characters
of true alphanumerics. The bright, crisp vacuum fluorescent displays offer
better readability than any other display technology. Additional operator
friendly features include: custom programmable alarm messages, keys that
illuminate when in use and an easy-to-use menu system.
532 Auto/Manual Backup Station
The 532 has been engineered to be the industry’s most user friendly and
comprehensive Auto/Manual Backup Station. The 532 provides automatic
and manual control backup for critical control loops. In Auto or Remote mode,
the control signal passes from the Host device through the 532 without any
degradation. A Hostdevice may be a PLC, DCS or process controller. The 532
switches to Local mode upon keypad selection, digital input or loss of the
Host signal. The 532 generates a control signal based on a predetermined
control value (CV), or the last known CV from the Host. The operator can
modify the CV with the and keys . The 532 will transfer to Remote mode
upon keypad selection, opening of the digital input or return of the Host signal.
Removal of the 532 from its case or powering down while in Remote mode will
not disturb the Host signal; the 532 is not a point of failure!

Introduction
2Chapter 1, Introduction 532 User’s Manual
Confirming What Is Included
You can determine which outputs have been installed in your station by
comparing your product number to the Order Code on the next page. This
product number is printed on the label located on the top of the controller case.
Where to Begin
If you are a first time user of a 532 Auto/Manual Station, we recommend that
you read through the entire manual. A variety of special functions to enhance
your control capability are detailed throughout the manual.
Overview of the 532 Modes
Operating The 532 is in Operating Mode when you turn it on and usually
while operating. From this mode, you can initiate the transition
between Remote and Local modes, acknowledge alarms and
monitor conditions. You can also access parameters that
directly relate to the transfer functions.
Set Up This sometimes referred to as
configuration . In Set Up you
configure the basic function of the station, like input and output
assignments, alarm types and special functions.
Where To Go Next
• First time users, continue to Chapter 2 for information on the operator
interface and basic controller operation.
• Chapter 3 contains important installation guidelines.
• Chapter 5 details the controller menus and parameters. Use the flowchart
in Appendix A as a graphic guideline when you configure your controller.
With your controller,
you should have received:
1. 532 User’s Manual
2. Mounting hardware
3. Test sheet
4. Engineering unit adhesive
labels (1 sheet)
5. Terminal label
NOTE:
This manual may refer to the 532
Auto/Manual Station as the “532” or
either simply as “the station.”
NOTE:
If you alter the factory configuration of the
modules, this product label code will no
longer be valid.

532 User’s Manual Chapter 1, Introduction 3
Introduction
0
1
3
4
2
D
S
None
Mechanical relay
Solid state relay (triac) (1 amp)
DC logic (SSR drive)
One 4-20mA output included
Set of 3 digital inputs
RS-485 serial communications
OUTPUT 1 — ALARM
OPTIONAL INPUTS
ENTER "0" IF NOT DESIRED
SERIAL COMMUNICATIONS
ENTER "0" IF NOT DESIRED
00B0112532 -
Order Codes
532 - AUTO/MANUAL BACKUP STATION

Operation
4Chapter 2, Basic Operation 532 User’s Manual
Figure 2.1
532 Operator Interface
LOCAL DISPLAY ACK
FAST
MENU
HOST
OUT
1 2
ALM
1 2
Location for
identification label
1st Display
2nd Display
3rd Display
Icons
Keys
532
CHAPTER 2
BASIC OPERATION
The individual software and hardware options of your station determine which
information it will display. Compare the product number (on the product label) to
the Order Code in Chapter 1.
532 Operator Interface
Displays:
1st Display
• 5 digits, seven segments. 15mm (0.6in) high.
• Normally displays CV in tenths of a percent.
• If PV option is chosen, will display PV.
2nd Display
• 9 characters, 14 segment alphanumeric. 6mm (0.25 in) high.
• If only PV option is chosen, displays CV.
• If only 2nd input option is chosen, shows SP or VP (valve position).
• If PV and 2nd input options are chosen, automatically alternates
between CV and the SP (or VP) at 2 second intervals. Pressing the
or key to change the output value immediately stops the
alternating and displays the CV. Alternating resumes if there is no
key activity for 2 seconds.
• During Set Up, displays configuration information.
3rd Display
• 9 characters, 14 segment. 6mm (0.25 in) high.
• If no alarm messages are queued, displays user-selectable
station name.
• If errors or alarms are queued, displays messages that alternate every
2 seconds.
• During Set Up, displays configuration information.
NOTE:
If the station loses the PV, SP or VP
signal, “--------” will appear in place of
the numeric value in the 1st or 2nd
display. Refer to Appendix C for more
information.
NOTE:
Any modifications to the factory settings
of the output modules will render the
product label code invalid.
NOTE:
The 532 features smart menus; only
those messages relevant to your
hardware and software configuration
will appear. See Chapter 5 for details.

Operation
532 User’s Manual Chapter 2, Basic Operation 5
Icons:
ALM1 and ALM2 Icons:
Indicates respective alarm is active.
Keys:
LOCAL
Press key: Transfers station between Local and Remote modes.
Illuminated: Station is in Local mode.
HOST
Press key: Has no effect; used for indication only.
Illuminated: 532 senses CV signal from the Host.
DISPLAY
Press key: Exits the configuration menus and returns station to operation
mode.
Key does not light.
MENU
Press key: Accesses the Operation menus.
Illuminated: Station is in Set Up (configuration) mode.
ACK
Press key: Acknowledges alarms.
Illuminated: When an acknowledgeable alarm exists.
FAST
Press key: Functions as a “shift” key; for use with other keys.
Key does not light.
or
Press key: Increases or decreases the value or selection of the current
parameter.
Keys do not light.
FAST + / FAST +
Press keys: Changes parameter value or selection with a larger increment.
FAST + MENU
(Hold down FAST, press MENU) In Localor Remote mode, provides entry
into the Set Up mode. In Set Up, advances from Menu to Menu .
LOCAL
FAST
HOST
DISPLAY
MENU
ACK
ALM ALM ALM
1 212
FAST
FAST
FAST MENU
or
+
+
+