Moore Industries 535 User manual

M535 V5, © MAY 2002
5 3 5
1/4 DIN PROCESS CONTROLLER
USER'S MANUAL
5 3 5

535 User's Manual Table of Contents i
Table of Contents
Table of Contents
PAGE
CHAPTER 1
INTRODUCTION .............................................................................. 1
535Modes ........................................................................................ 1
OrderCode,PackagingInformation .................................................. 2
WhereTo GoNext ............................................................................ 2
Textformattingin thismanual............................................................ 2
CHAPTER 2
BASIC INTERFACE ......................................................................... 5
Displays ............................................................................................ 5
Icons(Lit) .......................................................................................... 5
Keys.................................................................................................. 6
BasicOperatingProcedures ............................................................. 7
AlarmOperation................................................................................ 8
CHAPTER 3
INSTALLATION ............................................................................. 11
MountingtheController ................................................................... 11
Wiring ............................................................................................. 12
ACPower Input ...................................................................... 13
ProcessVariableInput ........................................................... 13
DigitalInput(s) ........................................................................ 16
1.Digital Inputswith aSwitch orRelay ............................... 16
2.Digital Inputswith anOpen Collector .............................. 16
RemoteSetpointOption ......................................................... 16
OutputModules ...................................................................... 17
1.MechanicalRelayOutput ............................................... 17
2.Solid StateRelay(Triac) Output ..................................... 17
3.DCLogic (SSR Drive)Output ......................................... 18
4.MilliampOutput .............................................................. 18
5.PositionProportioningOutput......................................... 18
SerialCommunications........................................................... 19
LimitControl ........................................................................... 20
CHAPTER 4
HARDWARE SET UP ..................................................................... 21
HardwareInput Types..................................................................... 21
TheProcess Variable...................................................................... 21
TheRemoteSetpoint ...................................................................... 22
MechanicalRelays.......................................................................... 22
Accessingand changingjumpers.................................................... 23
AddingandChangingoutputmodules............................................. 24
SpecialCommunicationsModule .................................................... 26
CHAPTER 5
SOFTWARECONFIGURATION .................................................... 27
Menus............................................................................................. 27
Parameters ..................................................................................... 28
ConfigurationandOperation ........................................................... 29
Whereto GoNext............................................................................ 29
About This Manual:
Throughout this User’s Manual
information appears along the
margins (NOTE:, CAUTION! and
WARNING!). Please heed these
safetyand goodpractice noticesfor
the protection of you and your
equipment.

ii Table of Contents 535 User's Manual
Table of Contents
CHAPTER5
CONTROLLERSETUP (cont’d)
TextFormattinginThisManual.......................................................... 29
SoftwareMenusandParameters ...................................................... 30
CONFIG.................................................................................. 30
PV1INPUT ............................................................................. 34
PV2INPUT ............................................................................. 36
CUST.LINR. ........................................................................... 38
CONTROL .............................................................................. 39
ALARMS................................................................................. 41
REM.SETPT........................................................................... 46
RETRANS............................................................................... 47
SELFTUNE ............................................................................ 48
SPECIAL ................................................................................ 50
SECURITY.............................................................................. 51
SER.COMM. .......................................................................... 52
ParameterValueCharts ................................................................... 50
CHAPTER6
TUNING .......................................................................................... 63
Overview ......................................................................................... 63
TUNINGMenuParameters............................................................... 64
TUNINGParameterValueChart ....................................................... 68
SelfTuneMessagesandTroubleshooting ......................................... 70
CHAPTER7
APPLICATIONS .............................................................................. 71
A. ControlType ................................................................................ 71
B. Alarms......................................................................................... 72
C. DuplexControl ............................................................................. 76
Duplexwithreverseanddirectactingoutputs ............................ 77
Duplexwithdirectandreverseactingoutputs ............................ 77
Duplexwith2reverseactingoutputs ......................................... 78
Duplexwithagapbetweenoutputs ........................................... 78
Duplexwith overlapping outputsandoutputlimits ...................... 79
Duplexwithvariousrelative gainsettings ................................... 79
DuplexwithoneON/OFFoutput ............................................... 80
DuplexwithtwoON/OFFoutputs.............................................. 80
D. SlidewirePositionProportioningControl ........................................ 81
E. VelocityPositionProportioningControl .......................................... 82
F. StagedOutputs............................................................................ 83
G.Retransmission............................................................................ 83
H. DigitalInputs ................................................................................ 84
I. RemoteSetpoint .......................................................................... 86
J. MultipleSetpoints ......................................................................... 87
K. MultipleSetsofPIDValues ........................................................... 87
L. Powerback .................................................................................. 88
M.SelfTune—PowersPOWERTUNE® ............................................ 89
PretunebyItself ....................................................................... 89
PretuneTYPE1and AdaptiveTune .......................................... 91
PretuneTYPE2orTYPE3andAdaptvieTune .......................... 91
AdaptiveTunebyItself ............................................................. 92
SelfTunewithMultipleSetsofPID ............................................ 94
SelfTunewithTimeProportioningOutputs ................................ 94
PAGE

535 User's Manual Table of Contents iii
Table of Contents
CHAPTER7
APPLICATIONS(cont’d)
SelfTunewithControlValves ................................................... 94
N. Ramp-to-Setpoint......................................................................... 94
O.InputLinearization ........................................................................ 95
ThermocoupleandRTDLinearization ....................................... 95
SquareRootLinearization ........................................................ 95
CustomLinearization ............................................................... 96
P. LoadLine..................................................................................... 97
Q.Security ....................................................................................... 97
R. ResetInhibition ............................................................................ 98
S. ProcessVariableReadingCorrection ............................................ 98
T. SerialCommunications ................................................................ 99
U. CascadeControl ........................................................................ 100
V. RatioControl.............................................................................. 103
APPENDIX1
MENUFLOWCHARTS .................................................................. A-1
APPENDIX2
PARTSLIST.................................................................................. A-3
APPENDIX3
TROUBLESHOOTING .................................................................. A-5
APPENDIX4
CALIBRATION.............................................................................. A-7
PreparationforallInputCalibrations .................................................A-8
ThermocoupleColdJunctionCalibration...........................................A-9
AnalogMilliampInputCalibration ......................................................A-9
MilliampOutputCalibration ............................................................A-10
ResetMenuData ..........................................................................A-11
HardwareScan .............................................................................A-12
SlidewireTest ...............................................................................A-12
QuickCalibrationProcedure ..........................................................A-12
APPENDIX5
SPECIFICATIONS........................................................................A-13
APPENDIX6
GLOSSARY .................................................................................A-17
APPENDIX7
ISOLATIONBLOCKDIAGRAM ...................................................A-23
PAGE

iv Table of Contents 535 User's Manual
Table of Contents
List of Figures
FIGURE DESCRIPTION PAGE
Figure2.1 .......OperatorInterface ............................................................... 5
Figure2.2 .......BeforeandAfterAcknowledginganAlarm ............................ 8
Figure3.1 .......InstrumentPanel&CutoutDimensions............................... 11
Figure3.2 .......Attachingmountingcollar ................................................... 11
Figure3.3 .......All535TerminalAssignments ............................................ 12
Figure3.4 .......ACPowerInputTerminals ................................................. 13
Figure3.5 .......ProcessVariableTerminals ............................................... 13
Figure3.6 .......PV1andPV2WiringforMilliamp,RTDandVoltageInputs ... 14
Figure3.7 .......PV1andPV2WiringforMilliampInputswithInternaland
ExternalPowerSupply ...................................................... 15
Figure3.8 .......DigitalinputWiringwithaSwitchorRelay............................ 16
Figure3.9 .......DigitalInputWiringwithanOpenCollector .......................... 16
Figure3.10 .....RemoteSetpointTerminals................................................ 16
Figure3.11 .....MechanicalRelayOutputWiring......................................... 17
Figure3.12 .....SSRRelayOutputWiring................................................... 17
Figure3.13 .....DCLogicOutputWiring ..................................................... 18
Figure3.14 .....MilliampOutputWiring....................................................... 18
Figure3.15 .....PositionProportioningOutputWiring .................................. 18
Figure3.16 .....SerialCommunicationsTerminals ...................................... 19
Figure3.17 .....535WiringwithLimitControl .............................................. 20
Figure4.1 .......LocationofPrintedCircuitBoardsforHardware
Configuration .................................................................... 21
Figure4.2 .......TheMicrocontrollerCircuitBoard,theOptionBoard,andthe
PowerSupplyBoard.......................................................... 22
Figure4.3 .......RepresentationofModule .................................................. 25
Figure4.4 .......InstallCommunicationsModuleonto
MicrocontrollerBoard ........................................................ 26
Figure5.1 .......MenuFlowchartforSetUp ................................................. 27
Figure5.2 .......Independentvs.DependentParameters............................. 28
Figure5.3 .......ConfigurationFlowchart ..................................................... 28
Figure6.1 .......AccesstheTuningMenuBlock .......................................... 63
Figure7.1 .......AlarmExamples ................................................................ 75
Figure7.2 .......Duplexwithreverseanddirectactingoutputs ...................... 77
Figure7.3 .......Duplexwithdirectandreverseactingoutputs ...................... 77
Figure7.4 .......Duplexwithtworeverseactingoutputs ............................... 78
Figure7.5 .......Duplexwithagapbetweenoutputs..................................... 78
Figure7.6 .......Duplexwithoverlappingoutputsandoutputlimits ................ 79
Figure7.7 .......Duplexwithvariousrelativegainsettings ............................ 79
Figure7.8 .......DuplexwithoneON/OFFoutput ......................................... 80
Figure7.9 .......DuplexwithtwoON/OFFoutputs ....................................... 80
Figure7.10 .....StagedOutputsExample ................................................... 83
Figure7.11 .....CombinationsofClosedDigitalInputsforEachSetpoint(based
onBCDlogic) .................................................................... 84
Figure7.12 .....PretuneTYPE1,2and3withAdaptiveTune....................... 90
Figure7.13 .....NoiseBandCalculationExample........................................ 92

535 User's Manual Table of Contents v
Table of Contents
FIGURE DESCRIPTION PAGE
Figure7.14 .....NoiseBandValuesforTemperatureInputs ......................... 93
Figure7.15 .....DeadtimeandTimeConstant ............................................. 93
Figure7.16 .....SquareRootLinearizationFormula .................................... 95
Figure7.17 .....15-pointLinearizationCurve............................................... 96
Figure7.18 .....LoadLineExample ............................................................ 97
Figure7.19 .....HeatExchangerControlLoopforSteamSupply ................ 100
Figure7.20 .....CascadeControlofProductTemperature ......................... 101
Figure7.21 .....RatioControlinMixingApplication .................................... 103
FigureA4.1.....535RearTerminalsforCalibration........................................ 7
FigureA4.2.....FlowchartCalibrationMenus ................................................ 7
FigureA4.3.....JumperLocationsontheMicrocontrollerCircuitBoard ........... 8
FigureA4.4.....InputCalibrationWiring ........................................................ 8
FigureA4.5.....Thermocouple/ColdJunctionCalibrationWiring .................... 9
FigureA4.6.....AnalogmAInputCalibrationWiring..................................... 10
FigureA4.7.....AnalogmAInputJumperPositions ..................................... 10
FigureA4.8.....MilliampOutputCalibrationWiring ...................................... 11
FigureA4.9.....OutputModuleMenuCycle................................................ 11
FigureA4.10 ... SlidewireTestWiring ......................................................... 12

vi Table of Contents 535 User's Manual
Table of Contents

535 User’s Manual Chapter 1 1
Introduction
Thank you for selecting the 535
Process Controller — the most
sophisticated instrument in its class.
It will provide you with years of
reliable,trouble-free performance.
Fromitssurge-resistantpowersupplytoitsruggedconstruction,the535pro-
cess controller is designed to ensure the integrity of your process with maxi-
mumreliability— hourafterhour,day afterday. Theisolatedinputs andout-
putsguardagainstthedangersofelectricalinterference,thefrontfacemeets
NEMA4Xstandardsforwatertightoperationandexposuretocorrosiveenvi-
ronments,andthesolidmetalhousingandsturdyrubberkeysenhancedura-
bilityandESD protection.
The535hasbeenengineeredtobetheindustry’smostuser–friendlyprocess
controller. Withthreedigitaldisplayareas—twoofferingupto9charactersof
truealphanumerics—the535effectivelyeliminatesthecrypticmessagesthat
couldconfuseeventhemostexperiencedoperator. Thebright,crispdisplay
isvacuum fluorescent, andoffers muchbetter readability thanany otherdis-
play technology. Additional operator–friendly features include: custom pro-
grammable alarm messages, illuminated keys, and an easy–to–use menu
system.
The 535 is the most accurate instrument in its class. With a sampling rate of
tentimespersecond,itisidealfordemandingpressureandflowapplications.
The535alsooffersauniversalprocessinputandmodular,fieldinterchange-
able outputs that allow more flexibility than ever before. The RS-485 serial
communicationsinterfaceallowsthecontrollertoutilizesophisticatedsoftware
routinesandhighspeedhardwaretoprovideexceptionallyfastandaccurate
transmission of data. The 535 also offers sophisticated control algorithms,
includingMooreIndustries’exclusiveAdaptiveTunewhichconstantlyana-
lyzes your process and makes modifications to the tuning parameters to en-
sureyou’re alwaysundercontrol.
CHAPTER 1
INTRODUCTION
Specifications and information subject to change without notice.

Introduction
2Chapter 1 535 User’s Manual
535 MODES
Thereare threeoperating modesforthe 535controller:
OPERATION,the defaultmodeofthe controller.When the535 isoperating,
youcanchangesetpoints,selectmanualcontrolandchangeoutputlevel,ac-
knowledgealarmsandmonitorconditions.
SETUP,alsoreferredtoasconfiguration.Hereyousetupthebasicfunctions
oftheinstrument suchasinputandoutputassignments,alarmtypesandspe-
cialfunctions.
TUNING, where you configure control function parameters for Proportional,
Integral and Derivation (PID). Use periodically to optimize the control perfor-
manceoftheinstrument.
ORDER CODE,PACKAGING INFORMATION
Comparetheproductnumbertotheorderingcodeonpage3todetermine the
outputsandoptionsinstalledonthe535.Theproductnumberisprintedonthe
labelon thetop of thecontroller case.
Includedwith this535 are:
•a535 User’sManual
•mountinghardware
•1sheet ofEngineeringunit adhesivelabels
WHERETO GO NEXT
•Tobecome morefamiliar withthe535 interface,continue toChapter 2.
•Forimportanthardware installationguidelines, seeChapters3 and4.
•Foradetaileddescriptionofallthesoftwaremenusandparametersofthe
535,followthrough Chapters 5and 6. Appendix 1can be used asa basic
guidelinetotheseparameters.
TEXT FORMATTING INTHIS MANUAL
Feature Format
KEYS SET PT DISPLAY
or
ICONS OUT,ALM
MENUS CONFIG.,TUNING,
PARAMETERS CYCLETM:1,MIN.OUT2
PARAMETERVALUES OFF, SETPOINT,LAST OUT.
DISPLAYMESSAGES TOO HOT, OUT%,
SET PT DISPLAY

535 User’s Manual Chapter 1 3
Introduction
Note 1: Capability for position proportioning output is specifed by ordering 535-11xxAxxx00, 535-33xxAxxx00, or 535-44xxAxxx00. Note 2: Capability for
velocity proportioning output is specifed by ordering 535-11xxxxxx00, 535-33xxxxxx00, or 535-44xxxxxx00. Note 3: Up to two outputs may be used for
alarms. Note 4: All outputs are interchangeable modules. Note 5: The mechanical relay and solid state relay modules are derated to 0.5 amp at 24 Vac
when used as the fourth output.
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: Alarm, Retransmission, or Loop Power
None 0
Mechanical Relay (0.5 amp, 24 V) 1
Analog (milliamp) 2
Solid State Relay (triac) (0.5 amp, 24 V) 3
DC Logic (SSR drive) 4
Loop Power 5
Options
Enter “0” if not desired
Slidewire Feedback for Position
Proportioning Output A
24 VAC/24 VDC Operation F
Slidewire and 24 VAC/24 VDC G
Remote Setpoint B
Profile Controller Option C
Remote Setpoint and Profile E
Set of Five Digital Inputs D
Certification H
Five Digital Inputs and Certification J
Serial Communications
Enter “0” if not desired
RS-485 Serial Communications S
535 – 00

Introduction
4Chapter 1 535 User’s Manual

Operation
535 User's Manual Chapter 2, Controller Operation 5
CHAPTER 2
BASIC INTERFACE
DISPLAYS
The display strategy of the 535 Process Controller is the same for all control
modes.
1st Display (five 7-segment digits)
• Forthe process variablevalue.
2nd Display (nine 14-segment digits)
• Forthe setpoint,deviation,output levelor valveposition (ifavailable)
• InTUNING orSETUP mode,for theparameter name.
• Uponpower up,indicatesthecurrentsetpoint.
3rd Display (nine 14-segment digits)
• Foralarm messages,loop name,errors, etc.
• InTUNINGorSETUPmode,thevalueorchoiceofparametershownin
the2nddisplay.
ICONS (LIT)
OUT Indicates either 1) relay output is energized; or 2) analog output is
greaterthan0%.
ALM1 Indicatesthe respectivealarm (one)isactive.
ALM2 Indicatesthe respectivealarm(two) isactive.
Figure 2.1
Operator Interface
OUT OUT OUT
1212
535
MANUAL DISPLAY SET PT
ACK MENU FAST
OUT
1 2
ALM
1 2
Icons 1st
Keys
2nd
3rd
Location for
identification
label
Displays:
ALM ALM ALM
1212

Operation
6Chapter 2, Controller Operation 535 User's Manual
KEYS
FAST: Has no independent function. Press to modify the function of another
key(see below).
MANUAL: Presstotoggle betweenmanual andautomatic control.
Whenlit, indicatestheunit isunder manualcontrol.
SET PT : Press to select the active SP.
When lit, indicates that a setpoint other than the primary (e.g., RSP, SP2) is
active.
DISPLAY:Presstotogglethroughvaluesinthe2nddisplayforsetpoint,ramp-
ingsetpoint,deviation,PV1,PV2,outputandvalveposition(each,ifavailable).
In Tuning or Set Up mode, press to return controller to Operation mode (dis-
playwill showcurrent setpoint).
▲▲
▲▲
▲:Press to increasethe valueor selection ofdisplayed parameter.
FAST+▲▲
▲▲
▲ :Press toscroll through valuesat a fasterrate.
▼▼
▼▼
▼:Press to decreasethe valueor selection ofdisplayed parameter.
FAST+▼▼
▼▼
▼:Press to scroll throughvalues at afaster rate.
ACK :Press to acknowledge (an)alarm(s).
Whenlit,indicates thereisan acknowledgeablealarm.
MENU :In Operation Mode,press toaccess the TuningMenu.
In Set Up or Tuning mode, press to advance through a menu’s parameters.
(UseFAST+MENU to advanceto thenextmenu.)
When lit,indicatesthe controlleris inSet Up mode.
FAST+MENU :Pressto access theSet Up menus.
In Set Up mode, press to advance through menus. (Use MENU by itself to
accessthe parametersof aparticular menu.)
FAST
MANUAL
SET PT
DISPLAY
▲▲
▲▲
▲
▲▲
▲▲
▲
▼▼
▼▼
▼
▼▼
▼▼
▼
ACK
FAST
FAST
MENU
MENUFAST
+
+
+

Operation
535 User's Manual Chapter 2, Controller Operation 7
BASIC OPERATING PROCEDURES
Usethe following asa quickguideto keyoperating functions ofthe 535.
To select /change a setpoint
1. Use DISPLAYkey totoggle displayto SetPoint.
2. Use SET PT key to toggletoactive setpoint.
Beforethe newly selectedsetpoint ismade active,thereis atwo-second
delayto preventany disruptive bumps.If thesetpoint displayedis
ramping,RAMPING willshow the3rddisplay.
3. To change value, press ▲or ▼ .
To change from auto to manual control (bumpless transfer)
1. Wheninautomaticcontrol,presstheMANUALkeyatanytime,exceptwhile
in the TUNINGmode.
2. The MANUAL key will light in red, and the 2nd display will immediately
changetoindicate currentoutput 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. The2nddisplaywillnotchange,andtheMANUALkeywillnolongerbelit
oncecontrolchanges.
To change manual output values
1. Makesure thecontroller isunder manualcontrol.
2. Usethe DISPLAY key to toggle2nd display tooutput level.
3. Use the ▲or ▼key to change the value.
To override security
Ifa lockedoperationis attempted,SECURITYappearsinthe 2nddisplayfor
twoseconds).
1. Usethe ▲▲
▲▲
▲and ▼▼
▼▼
▼ keystoquickly enterthe securitycode, whichwill show
inthe 3rd display.The starting valueis 0.
Note: Two seconds ofkey inactivity willclearthe display.
2. If the code is correct, CORRECT appears in the 3rd display. The display
willclear after twoseconds, allowingfull access.
4. Ifcodeisincorrect,INCORRECTappears inthe3rddisplay. 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. ToggleDISPLAYkeyuntilthe2nddisplayshowsOUTfollowedbytheoutput
percentage.This valueis thePID output.
•In duplex applications, this value does not directly refer to the output
signal(refer to theChapter 7section on DuplexControl for details.)
•Foron/off outputs, theoutput value shownis either ONor OFF.
•For duplex applications with two on/off outputs, the OUT tag is not
shown.Inthiscase,thestatusofbothoutputsisshowninthefollowing
manner: 1:ON 2:OFF (1and 2are therespective outputs).
NOTE:
See the glossary in Appendix 6 for
explanation of ramping and target
setpoint.Alsorefertotheapplications
inChapter7.

Operation
8Chapter 2, Controller Operation 535 User's Manual
535
MANUAL DISPLAY SET PT
▲
▼
ACK MENU FAST
OUT
1
ALM
1
BEFORE AFTER
535
MANUAL DISPLAY SET PT
▲
▼
ACK MENU FAST
OUT
1
Figure 2.2
Before and After Acknowledging
an Alarm
To display the active PID set
1. PressMENU toreach Tuning Mode.
2. InTUNING Mode, pressMENU toreach the correctMenu parameter.
3. TheactivePID set will havean asterisk (*) onboth sides of thevalue.
ALARM OPERATION
Alarmsmaybeused insystemstoprovide warningsofunsafeconditions. All
535operators mustknow how thealarms areconfigured, theconsequences
ofacknowledging analarm and howto react toalarm conditions.
Alarm Indication
•lit icons ALM 1 and/orALM 2
•lit ACK key
•displayedalarmmessage
Acknowledgablealarms meetthefirst twoof theseconditions.
Non-acknowledgable alarmsonly meet thefirst condition (onlyicon islit).
To acknowledge an alarm(s):
1. Toacknowledge Alarm 1,pressACK once.
2. Toacknowledge Alarm 2,pressACK twice.
3. Ifbothalarmsareactivated,pressACKoncetoacknowledgeAlarm1,then
againtoacknowledge Alarm2.
4.The messageand alarmicon dissappear.
Latching Alarms
Ifanalarmissetuptobelatching(fordetails,seeChapter5) then,ingeneral,
it must be acknowledged in order to clear the alarm and release the relay (if
applicable).Anon-latchingalarmwillclearitselfassoonastheprocessleaves
thealarmcondition.
NOTE:
Allalarmsaresoftwarealarmsunless
tied to an output relay in the SET UP
mode.SeeChapters5and7fordetails
onalarms.
NOTE:
Poweringdownthe535
acknowledges/clearsalllatched
alarms.Whenpoweringup,all
alarmswillbereinitialized.

Operation
535 User's Manual Chapter 2, Controller Operation 9
Limit Sequence
Analarmcanbeconfiguredtobebothlatchingandnon-acknowledgeable.In
thiscase,thealarmisacknowledgeableonlyaftertheprocesshasleftthealarm
condition.This issimilar tothe functionof alimit controller.
More on Alarms
For more details on how to set up alarms and for examples of various ways
alarmscan be setup, refer tothe section onAlarmsin Chapter7.

Operation
10 Chapter 2, Controller Operation 535 User's Manual

Install /Wire
535 User's Manual Chapter 3 11
CHAPTER 3
INSTALLATION
MOUNTINGTHE CONTROLLER
The535frontface isNEMA4Xrated(waterproof).Toobtainawaterproofseal
betweenthecontroller andthepanel, followthesedirections:
1. The535fitsinastandard1/4DINcutout. Mountthe535inanypanelwith
athickness from .06in. to .275in. (1.5 mmto 7.0mm).
2. Figure 3.1 shows the controller and panel dimensions. The panel cutout
mustbe precise, andthe edges freefrom burrs andwaves.
3. Placebezelgasketaroundthecontrollercase(startingatthebackofcon-
troller).Then, slidethegasket againstthe backof thebezel.
4. Withthebezelgasketinplace,insertthe535intothepanelcutoutfromthe
frontof thepanel.
5. Slidethemountingcollaroverthebackofthecase,asshowninFigure3.2.
Thecollarclip edgeswilllockwith matchingedgesonthecontrollercase.
Figure 3.1
Instrument Panel & Cutout
Dimensions
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
3.622 (92.00) MIN.
3.653 (92.80) MAX.
3.622 (92.00) MIN. 3.653 (92.80) MAX.
CUTOUT
FRONT
BEZEL
GASKET
535
MANUAL DISPLAY SET PT
s
t
ACK MENU FAST
OUT
1 2
ALM
1 2
MountingClip
Collar Screws (1 of 4)
MountingCollar
FrontPanel
Figure 3.2
Attaching mounting collar

Install /Wire
12 Chapter 3 535 User's Manual
Figure 3.3
All 535 Terminal Assignments
Actual 535 device only has top and
bottom numbers of each column of
terminals marked.
6. Insertthefourmountingcollarscrewsfromtherearofthecollar.Gradually
tightenthescrews(usingaPhillips#2screwdriver)tosecurethecontroller
againstthepanel.
7. Ifthereisdifficultywithanyofthemountingrequirements,applyabeadof
caulkorsiliconesealantbehindthepanelaroundtheperimeterofthecase.
WIRING
Powers535controllersarethoroughlytested,calibratedand“burnedin”atthe
factory,sothecontrollerisreadytoinstall.Beforebeginning,readthischapter
thoroughlyandtakegreatcareinplanningasystem.Aproperlydesignedsystem
canhelppreventproblemssuchaselectricalnoisedisturbancesanddangerous
extremeconditions.
1. For improved electrical noise immunity, install the 535 as far away as
possiblefrom motors,relaysandothersimilar noisegenerators.
2. Donotrunlowpower(sensorinput)linesinthesamebundleasACpower
lines.Groupingtheselinesinthesamebundlecancreate electricalnoise
interference.
3. All wiring and fusing should conform to the National Electric Code and to
anylocally applicablecodes.
4. An excellent resource about good wiring practices is the IEEE Standard
No.518-1982andisavailablefromIEEE,Inc.,345East47thStreet,New
York,NY10017,[phone].
Diagramsonthenextthreepagesserveasguidesforwiringdifferenttypesof
processinputs.Theshadedareasonthediagramsshowwhichrearterminals
areused for thattype of wiring.
CAUTION!
Theenclosure intowhichthe 535
Controllerismountedmust be
groundedaccordingtoCSA
standardC22.2No. 0.4.
WARNING!
Terminal9must begroundedto
avoidpotentialshock hazard,and
improvednoiseimmunityto your
system.
WARNING!
Avoidelectrical shock.Do not
connectAC powerwiring atthe
sourcedistributionpaneluntilall
wiringconnectionsarecomplete.
WARNING!
ELECTRIC SHOCK HAZARD!
Terminals1 and2 carrylivepower.
DONOT touchthese terminalswhen
poweris on.
TOP (as viewed from back of controller)
1
2
3
4
5
6
7
816
15
14
13
12
11
10
917
18
19
20
21
22
23
24 32
31
30
29
28
27
26
25
L1
L2/N
OUT 1–
OUT 1+
OUT 2–
OUT 2+
OUT 3–
OUT 3+
EARTH
GND
S/W 1
S/W 2
S/W 3
RSP–
RSP+
OUT 4–
OUT 4+
DIN
GND
DIN 1
DIN 2
DIN 3
DIN 4
DIN 5
COMM–
COMM+
PV2–
PV2+
RTD 3RD
PV1–
PV1+
COLD
JUNC–
COLD
JUNC+
not
used

Install /Wire
535 User's Manual Chapter 3 13
Figure 3.4
AC Power Input Terminals
Figure 3.5
Process Variable Terminals
AC Power Input
Terminals1 and 2are for power.Terminal 9is the earth ground.
Usea0.5Amp,250V,fast-actingfuseinlinewithyourACpowerconnection.
ProcessVariable Input
The535 accommodatesthe followingtypes ofprocess variableinputs:
•ThermocoupleInput
•RTDInput
•VoltageInput
•MilliampInputwith ExternalPower Supply
•MilliampInputwithInternalPower Supply
Eachtype of inputcanbe wired forPV1 (terminals 31and 32) orfor PV2 (ter-
minals28 and29).
TOP
1
2
3
4
5
6
7
816
15
14
13
12
11
10
917
18
19
20
21
22
23
24 32
31
30
29
28
27
26
25
Screws must be tight to ensure good electrical connection
EARTH/
GROUND
POWER
CAUTION!
Donot runlow power(sensor input)
linesin thesame bundleas AC
powerlines.Grouping theselinesin
thesamebundle cancreateelectrical
noiseinterference.
1
2
3
4
5
6
7
816
15
14
13
12
11
10
917
18
19
20
21
22
23
24 32
31
30
29
28
27
26
25
PV 1–
PV 1+
PV 2–
PV 2+
RTD 3rd
NOTE:
Whenwiring toa 240Volt system,an
additional0.5Amp,250V,fast-acting
fuseis requiredon L2.