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