Moore Industries 545 User manual

5 4 5
1/4 DIN PROCESS CONTROLLER
USER’S MANUAL
5 4 5
M545 V 8 , MA RCH 2 01 7

545 User's Manual Table of Contents i
Table of Contents
Table of Contents
PAGE
CHAPTER 1
INTRODUCTION ............................................................................... 1
545 Modes ......................................................................................... 2
Order Code, Packaging Information ..................................................... 2
Where To Go Next .............................................................................. 2
Text Formatting in This Manual ............................................................ 2
CHAPTER 2
CONTROLLER OPERATION ............................................................ 5
Displays ............................................................................................. 5
Icons ................................................................................................. 5
Keys .................................................................................................. 6
Basic Operation Procedures ............................................................... 7
Alarm Operation ................................................................................. 8
CHAPTER 3
INSTALLATION AND WIRING ........................................................ 11
Mounting the Controller ..................................................................... 11
Wiring .............................................................................................. 12
AC Power Input ....................................................................... 12
Process Variable Input ............................................................. 13
Digital Input(s) ......................................................................... 16
Remote Setpoint Option ........................................................... 16
Output Modules ....................................................................... 17
Serial Communications ............................................................ 19
CHAPTER 4
HARDWARE CONFIGURATION ..................................................... 21
Hardware Input Types ...................................................................... 21
Accessing and Changing Jumpers .................................................... 23
Adding and Changing Output Modules ............................................... 24
Special Communications Module ...................................................... 26
CHAPTER 5
SOFTWARE CONFIGURATION ...................................................... 27
Menus ............................................................................................. 27
Parameters ...................................................................................... 28
Configuration and Operation ............................................................. 29
Where to Go Next ............................................................................. 29
Text Formatting in This Manual .......................................................... 29
Step-by-Step Guide to Set-Up Parameters ......................................... 30
CONFIG.................................................................................. 30
PV INPUT ............................................................................... 35
CUST. LINR. ........................................................................... 37
CONTROL .............................................................................. 38
ALARMS ................................................................................. 41
REM. SETPT. .......................................................................... 45
RETRANS............................................................................... 46
SELF TUNE ............................................................................ 48
SPECIAL ................................................................................ 49
About This Manual:
Throughout this User’s Manual
information appears along the
margins, in the form of NOTEs,
CAUTIONs and WARNINGs, usually
in boldface. Please heed these
safety and good practice notices for
the protection of you and your
equipment.

Table of Contents
ii Table of Contents 545 User's Manual
PAGE
Step-by-Step Guide to Set-Up Parameters (continued)
SECURITY.............................................................................. 51
SER. COMM. .......................................................................... 52
Parameter Value Charts ................................................................... 54
CHAPTER 6
TUNING .......................................................................................... 63
Overview ......................................................................................... 63
TUNING Parameter Guide ................................................................ 64
TUNING Value Chart ........................................................................ 68
Self Tune Messages and Troubleshooting ......................................... 70
CHAPTER 7
APPLICATIONS .............................................................................. 71
A. Control Type ................................................................................ 71
B. Alarms ......................................................................................... 72
C. Duplex Control ............................................................................. 76
D. Slidewire Position Proportioning Control ........................................ 81
E. Velocity Position Proportioning Control .......................................... 82
F. Staged Outputs ............................................................................ 83
G. Retransmission ............................................................................ 83
H. Digital Inputs ................................................................................ 84
I. Remote Setpoint ............................................................................ 88
J. Multiple Setpoints .......................................................................... 88
K. Multiple Sets of PID Values ........................................................... 89
L. Powerback ................................................................................... 90
M. Self Tune—POWERTUNE®........................................................................ 90
N. Ramp-to-Setpoint ......................................................................... 96
O. Input Linearization ........................................................................ 97
Thermocouple and RTD Linearization ....................................... 97
Square Root Linearization ........................................................ 97
Custom Linearization ............................................................... 98
P. Load Line ..................................................................................... 98
Q. Security ....................................................................................... 99
R. Reset Inhibition .......................................................................... 100
S. Process Variable Reading Correction .......................................... 100
T. Serial Communications ............................................................... 101
U. Cascade Control ........................................................................ 102
V. Ratio Control .............................................................................. 104
Ratio Control with One Wild Stream ........................................ 104
Ratio Control with Combined Discharge Monitoring .................. 105
W. Feed Forward/Feedback Control ................................................ 107
X. Lag Time .................................................................................... 108
Fixed Lag .............................................................................. 108
Variable Lag .......................................................................... 109

545 User's Manual Table of Contents iii
Table of Contents
PAGE
APPENDIX 1
MENU FLOWCHARTS .................................................................. A-1
APPENDIX 2
PARTS LIST .................................................................................. A-3
APPENDIX 3
TROUBLESHOOTING .................................................................. A-5
APPENDIX 4
CALIBRATION .............................................................................. A-7
Preparation for all Input Calibrations .................................................A-8
Thermocouple Cold Junction Calibration ........................................... A-9
Analog Milliamp Input Calibration ......................................................A-9
Milliamp Output Calibration ............................................................ A-10
Reset Menu Data .......................................................................... A-11
Hardware Scan ............................................................................. A-12
Slidewire Test ............................................................................... A-12
Quick Calibration Procedure .......................................................... A-12
APPENDIX 5
SPECIFICATIONS ........................................................................A-13
APPENDIX 6
GLOSSARY .................................................................................A-17
APPENDIX 7
ISOLATION BLOCK DIAGRAM ...................................................A-23

Table of Contents
iv Table of Contents 545 User's Manual
List of Figures
FIGURE DESCRIPTION PAGE
2.1 ................. Operator Interface ............................................................... 5
2.2 ................. Before and After Acknowledging an Alarm ............................ 9
3.1 ................. Instrument Panel & Cutout Dimensions ............................... 11
3.2 ................. Attaching Mounting Collar .................................................. 11
3.3 ................. Terminal Assignments ....................................................... 12
3.4 ................. AC Power Input Terminals ................................................. 13
3.5 ................. Process Variable Terminals ............................................... 13
3.6 ................. PV1 and PV2 Wiring for Milliamp, RTD and Voltage Inputs ... 14
3.7 ................. PV1 and PV2 Wiring for Milliamp Inputs
with Internal and External Power Supply ............................. 15
3.8 ................. Digital Input Wiring with a Switch or Relay ........................... 16
3.9 ................. Digital Input Wiring with an Open Collector .......................... 16
3.10 ............... Remote Setpoint Terminals ................................................ 16
3.11 ............... Mechanical Relay Output Wiring ......................................... 17
3.12 ............... SSR Relay Output Wiring ................................................... 17
3.13 ............... DC Logic Output Wiring ..................................................... 18
3.14 ............... Milliamp Output Wiring ....................................................... 18
3.15 ............... Position Proportioning Output Wiring .................................. 18
3.16 ............... Serial Communications Terminals ...................................... 19
4.1 ................. Location of Printed Circuit Boards ....................................... 21
4.2 ................. The Microcontroller Circuit Board, the Option Board,
and the Power Supply Board .............................................. 22
4.3 ................. Representation of Module .................................................. 25
4.4 ................. Install Communications Module .......................................... 26
5.1 ................. Parts of the Menu Block ..................................................... 27
5.2 ................. Independent vs. Dependent Parameters ............................. 28
5.3 ................. Configuration Flowchart ..................................................... 28
6.1 ................. Access the Tuning Menu Block .......................................... 63
7.1 ................. Alarm Examples ................................................................ 75
7.2 ................. Duplex With Reverse and Direct Acting Outputs .................. 77
7.3 ................. Duplex With Direct and Reverse Acting Outputs .................. 77
7.4 ................. Duplex With Two Reverse Acting Outputs ........................... 78
7.5 ................. Duplex With a Gap Between Outputs .................................. 78
7.6 ................. Duplex With Overlapping Outputs and Output Limits ............ 79
7.7 ................. Duplex With Various Relative Gain Settings ........................ 79
7.8 ................. Duplex With One ON/OFF Output ...................................... 80
7.9 ................. Duplex With Two ON/OFF Outputs ..................................... 80
7.10 ............... Staged Outputs Example ................................................... 83
7.11 ............... Combinations of Closed Digital Inputs ................................. 84
7.12 ............... Pretune TYPE 1, 2 and 3 with Adaptive Tune ....................... 93
7.13 ............... Noise Band Calculation Example ........................................ 94
7.14 ............... Noise Band Values for Temperature Inputs ......................... 95
7.15 ............... Deadtime and Time Constant ............................................. 95
7.16 ............... Square Root Linearization Formula .................................... 97
7.17 ............... 15-point Linearization Curve ............................................... 98

545 User's Manual Table of Contents v
Table of Contents
FIGURE DESCRIPTION PAGE
7.18 ............... Load Line Example............................................................ 99
7.19 ............... Cascade Control of Product Temperature -
Functional View............................................................... 102
7.20 ............... Cascade Control of Produce Temperature -
Wiring View ..................................................................... 103
7.21 ............... The Functions of Cascade Control ................................... 103
7.22 ............... Ratio Control in Mixing Application “Wild Stream” -
Wiring View ..................................................................... 104
7.23 ............... Ratio Control in Mixing Application “Controlled Stream” -
Functional View............................................................... 105
7.24 ............... Ratio Control in Mixing Application “Controlled Stream” -
Wiring View ..................................................................... 106
7.25 ............... Feed Forward Control in Mixing Application -
Wiring View ..................................................................... 107
7.26 ............... Feed Forward Control in Mixing Application -
Functional View............................................................... 107
7.27 ............... Fixed and Variable Lag Example -
Compound Loop Chlorine Control .................................... 108
A4.1 ............... 545 Rear Terminals for Calibration ....................................... 7
A4.2 ............... Flowchart Calibration Menus ............................................... 7
A4.3 ............... Jumper Locations on the Microcontroller Circuit Board .......... 8
A4.4 ............... Input Calibration Wiring ....................................................... 8
A4.5 ............... Thermocouple/Cold Junction Calibration Wiring ................... 9
A4.6 ............... Analog mA Input Calibration Wiring .................................... 10
A4.7 ............... Analog mA Input Jumper Positions ..................................... 10
A4.8 ............... Milliamp Output Calibration Wiring ..................................... 11
A4.9 ............... Output Module Menu Cycle ............................................... 11
A4.10 ............. Slidewire Test Wiring ......................................................... 12

Table of Contents
vi Table of Contents 545 User's Manual

545 User's Manual Chapter 1 1
Introduction
CHAPTER 1
INTRODUCTION
Thank you for selecting the dual
loop Process Controller. The 545 is
user-configurable for any of the
following functions:
• Two independent PID loops
• Single Station Cascade Control
• Single Station Ratio Control
• Feed Forward Control
From its surge-resistant power supply to its rugged construction, the 545
process controller is designed to ensure the integrity of your process with
maximum reliability — hour after hour, day after day. The isolated inputs
and outputs guard against the dangers of electrical interference, the front
face meets NEMA 4X standards for watertight operation and exposure to
corrosive environments, and the solid metal housing and sturdy rubber keys
enhance durability and ESD protection.
The 545 has been engineered to be the industry’s most user–friendly
process controller. With three digital display areas — two offering up to 9
characters of true alphanumerics — the 545 effectively eliminates the
cryptic messages that could confuse even the most experienced operator.
The bright, crisp display is vacuum fluorescent, and offers much better
readability than any other display technology. Additional operator–friendly
features include: custom programmable alarm messages, illuminated keys,
and an easy to use menu system.
The 545 is the most accurate instrument in its class. With a sampling rate of
eight times per second, it is ideal for demanding pressure and flow applica-
tions. The 545 also offers two universal process inputs and modular, field
interchangeable outputs that allow more flexibility than ever before. With
two independent full feature control loops, the 545 can take the place of two
PID controllers; additionally, preprogrammed functions can be called for
cascade, ratio and feed forward applications.
The 545 uses foreground and background loops that facilitate straight
forward operator interface in any of the dual loop modes. It also offers
sophisticated control algorithms, including heuristic adaptive tuning, split
range and duplex outputs (control), and open or closed loop electric actua-
tor control (velocity control).
Specifications and information subject to change without notice.

Introduction
2Chapter 1 545 User's Manual
545 MODES
There are three operating modes for the 545 controller:
OPERATION, the default mode of the controller. When the 545 is operating,
you can change setpoints, select manual control and change output level,
acknowledge alarms and monitor conditions.
SET UP, also referred to as configuration. Here you set up the basic func-
tions of the instrument such as input and output assignments, alarm types
and special functions
TUNING, where you configure function parameters for Proportional, Integral
and Derivation (PID) control. Use this mode periodically to optimize the
control performance of the instrument.
ORDER CODE, PACKAGING INFORMATION
Comparing the product number to the ordering code on page 3 to determine
the outputs and options installed on the 545. The product number is printed
on the label on the top of the controller case.
Included with the 545 are:
• a 545 User’s Manual
• mounting hardware
• 1 sheet engineering unit adhesive labels
WHERETO GO NEXT
• To become more familiar with the 545 interface, continue to Chapter 2.
• For important hardware installation guidelines, see Chapters 3 and 4.
• For a detailed description of all the software menus and parameters of
the 545, follow through Chapter 5 and 6. Appendix 1 can be used as a
guide to these parameters.
TEXT FORMATTING INTHIS MANUAL
Feature Format
KEYS SET PT DISPLAY
or
ICONS OUT, ALM
MENUS CONFIG., TUNING,
PARAMETERS CYCLE TM:1, MIN.OUT2
PARAMETER VALUES OFF, SETPOINT, LAST OUT.
DISPLAY MESSAGES TOO HOT, OUT%
SET PT DISPLAY

545 User's Manual Chapter 1 3
Introduction
Note 1:Capability for position proportioning output with slidewire feedback is specifed by ordering 545-11xxAxxx00, 545-33xxAxxx00,
or 545-44xxAxxx00. (Slidewire not required for velocity proportioning.) Note 2: Up to three outputs may be used for alarms. Note 3: All
outputs are interchangeable modules. Note 4: 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: Control, Alarm, Retransmission, or Loop Power
None 0
Mechanical Relay (0.5 amp, 24 V) 1
Analog (milliamp) 2
Solid State Relay (triac) (0.5 amp, 24 V) 3
DC Logic (SSR drive) 4
Loop Power 5
Options
Enter “0” if not desired
Slidewire Feedback for Position
Proportioning Output A
24 VAC/24VDC Operation F
Slidewire and 24 VAC/24VDC G
Remote Setpoint B
Set of Five Digital Inputs D
Certification H
Five Digital Inputs and Certification J
Serial Communications
Enter “0” if not desired
RS-485 Serial Communications S
545 – 00

Introduction
4Chapter 1 545 User's Manual

Basic Interface
545 User's Manual Chapter 2 5
CHAPTER 2
CONTROLLER OPERATION
Figure 2.1
Operator Interface
545
MANUAL DISPLAY SET PT
ACK MENU FAST
PV2
OUT
1 2
ALM
1 2
Icons 1st
Keys
2nd
3rd
Location for
identification
label
Displays:
OUT OUT OUT
1212
ALM ALM ALM
1212
PV2
DISPLAYS
The display strategy of the 545 Process Controller is the same for all control
modes: Dual Loop, Cascade, Ratio and Feed Forward.
1st Display (five 7-segment digits)
• For the process variable value.
2nd Display (nine 14-segment digits)
• For the setpoint, deviation, output value or valve position (if available).
• In TUNING or SET UP mode, for the parameter name.
• Upon power up, indicates the current setpoint.
3rd Display (nine 14-segment digits)
• Name of current foreground loop
• For alarm messages, errors, etc.
• In TUNING or SET UP mode, for the value or choice of parameter shown in
the 2nd display.
ICONS (LIT)
PV2 Loop 2 is in the foreground (on display); Loop 1 is in the background.
OUT1 For this output, either the relay output is energized or the analog
output is greater than 0%.
OUT2 For this output, either the relay output is energized or the analog
output is greater than 0%.
If control output is analog, indicates the output is greater than 0%.
ALM 1 The respective alarm (one) is active.
ALM 2 The respective alarm (two) is active.
ALM An alarm is active but no output is assigned.

Basic Interface
6Chapter 2 545 User's Manual
KEYS
FAST: Has no independent function. Press to modify the function of another
key (see below).
MANUAL: Press to toggle between manual and automatic control.
When lit, indicates the unit is under manual control.
SET PT: Press to select the active setpoint.
In SET UP or TUNING mode, press to return controller to OPERATION mode.
When lit, indicates that a setpoint other than the local SP1 is active.
DISPLAY: Press to toggle through values in the 2nd display for setpoint, ramp-
ing setpoint (if available), deviation, output. background PV, lag (if available)
and valve position (if available).
In SET UP or TUNING mode, press to return controller to OPERATION mode
(with display showing current setpoint).
When lit, Loop 2 is in the foreground.
FAST+DISPLAY: Toggles between the background loop and foreground loop.
▲▲
▲▲
▲:Press to increase the value or selection of displayed parameter.
FAST+▲▲
▲▲
▲:Press to scroll through values at a faster rate.
▼▼
▼▼
▼:Press to decrease the value or selection of displayed parameter.
FAST+▼▼
▼▼
▼:Press to scroll through values at a faster rate.
ACK: Press to acknowledge (an) alarm(s).
When lit, indicates there is an acknowledgeable alarm.
MENU : In OPERATION Mode, press to access the TUNING mode and menu.
In Set Up or Tuning mode, press to advance through a menu’s parameters. (Use
FAST+MENU to advance to the next menu.)
When lit, indicates the controller is in SET UP mode.
FAST+MENU: Press to access the Set Up menus.
In SET UP mode, press to advance through menus. (Use MENU by itself to ac-
cess the parameters of a particular menu.)
FAST
MANUAL
SET PT
DISPLAY
▲
▼
▼
ACK
FAST
FAST
MENU
MENUFAST
+
+
+
DISPLAY
FAST +
▲▲
▲▲
▲

Basic Interface
545 User's Manual Chapter 2 7
BASIC OPERATION PROCEDURES
A Quick Explanation of Dual Loop Operation
Upon power up, Loop 1 is in the foreground (displayed), and Loop 2 is in the
“background” (hidden). Set up changes only affect the foreground loop; to make
changes to the operation of the background loop, it must be brought to the fore-
ground.
The controller helps the user identify the foreground and background loops with
the following:
• When Loop 2 is in foreground DISPLAY key and the PV2 icon are lit
• The third display will show a message identifying the foreground loop.
Use the following as a quick guide to key operating functions of your 545. Most
of these procedures will affect whichever loop is in the foreground at the time
you execute the procedures. Those that are specified by the word GLOBAL will
affect both loops (the whole controller).
To switch the foreground and background loops
1. Press FAST+DISPLAY.
To select /change a setpoint
1. Use DISPLAY key to toggle display to Set Point.
2. Use SET PT key to toggle to active setpoint.
Before the newly selected setpoint is made active, there is a two-second de-
lay to prevent any disruptive bumps. If the setpoint displayed is ramping,
RAMPING will show the 3rd display.
3. To change value, press ▲▲
▲▲
▲or ▼▼
▼▼
▼ .
To change from auto to manual control (bumpless transfer)
1. When in automatic control, press the MANUAL key at any time, except while
in the TUNING mode.
2. TheMANUAL key will light in red, and the 2nd display will immediately change
to indicate current output level.
To change from manual to auto
1. When in manual control, press MANUAL at any time except while in the
TUNING or SET UP mode.
2. The 2nd display will not change, and the MANUAL key will no longer be lit
once control changes.
To change manual output values
1. Make sure the controller is under manual control.
2. Use the DISPLAY key to toggle 2nd display to output level.
3. Use the ▲▲
▲▲
▲or ▼▼
▼▼
▼ key to change the value.
To override security
If a locked operation is attempted, SECURITY appears in the 2nd display for
two seconds.
1. Use the ▲▲
▲▲
▲ and ▼▼
▼▼
▼ keys to quickly enter the security code, which will show in
the 3rd display. The starting value is 0.
Note: Two seconds of key inactivity will clear the display.
2. If the code is correct, CORRECT appears in the 3rd display. The display will
clear after two seconds, allowing full access.
NOTE:
See the glossary in Appendix 6 for
explanation of ramping and target
setpoint . Also refer to the section in
Chapter 7.

Basic Interface
8Chapter 2 545 User's Manual
4. If code is incorrect, INCORRECT appears in the 3rd display. INCORRECT
will disappear after two seconds, and a new security code can then be en-
tered.
5. The controller will revert back to full security lock after one minute of key in-
activity.
To display control output value
1. Toggle DISPLAY key until the 2nd display shows OUT followed by the out-
put percentage. This value is the PID output.
• In duplex applications, this value does not directly refer to the output
signal (refer to the Chapter 7 section on Duplex Control for details.)
• For on/off outputs, the output value shown is either ON or OFF.
• For duplex applications with two on/off outputs, the OUT tag is not shown.
In this case, the status of both outputs is shown in the following manner:
1:ON 2:OFF (1 and 2 are the respective outputs).
To display the active PID set
1. Select the desired foreground loop (hold FAST, press DISPLAY).
2. Press MENU to reach Tuning Mode.
3. In TUNING Mode, press MENU to reach the correct Menu parameter.
4. The active PID set will have an asterisk (*) on both sides of the value.
ALARM OPERATION
Alarms may be used in systems to provide warnings of unsafe conditions. All
545 operators must know how the alarms are configured, the consequences of
acknowledging an alarm, and how to react to alarm conditions.
Alarm Indication
Depending on how the system is configured, the 545 indicates an alarm
condition(s) for the foreground loop by:
• Lit icons ALM 1 and/or ALM 2
• Lit ACK key
• Displayed alarm message
The 545 indicates an alarm condition(s) for the background loop by:
• Showing the (user defined) message for one or both alarms in the third display
(alternate displays for simultaneous alarms).
To acknowledge an alarm(s):
An acknowledgeable alarm has both a lit icon and a lit ACK key.
Anon-acknowledgeable alarm has only a lit icon.
Figure 2.2 demonstrates acknowledging an alarm.
1. If the alarm is in the background, bring that loop forward using
FAST+DISPLAY.
2. To acknowledge Alarm 1, press ACK once.
3. To acknowledge Alarm 2, press ACK twice.
4. If both alarms are activated, press ACK once to acknowledge Alarm 1, then
again to acknowledge Alarm 2.
5. The message and alarm icon disappear.
NOTE:
All alarms are software alarms unless
tied to an output relay in the SET UP
mode. See Chapter 5 and Chapter 7 for
more details on alarms.

Basic Interface
545 User's Manual Chapter 2 9
Figure 2.2
Before and After Acknowledging an
Alarm
NOTE:
Powering down the 545 acknowledges/
clears all latched alarms. When powering
up, all alarms will be reinitialized.
545
MANUAL DISPLAY SET PT
ACK MENU FAST
OUT
1
ALM
1
BEFORE AFTER
545
MANUAL DISPLAY SET PT
ACK MENU FAST
OUT
1
Latching Alarms
If an alarm is set up to be latching (for details, see Chapter 5) then, in general,
it must be acknowledged in order to clear the alarm and release the relay (if
applicable). A non-latching alarm will clear itself as soon as the process leaves
the alarm condition.
Limit Sequence
An alarm can be configured to be both latching and non-acknowledgeable. In
this case, the alarm is acknowledgeable only after the process has left the alarm
condition. This is similar to the function of a limit controller.
More on Alarms
For more details on how to set up alarms and for examples of various ways alarms
can be set up, refer to the section on Alarms in Chapter 7.

Basic Interface
10 Chapter 2 545 User's Manual

Installation
545 User's Manual Chapter 3 11
CHAPTER 3
INSTALLATION AND WIRING
MOUNTINGTHE CONTROLLER
The 545 front face is NEMA 4X rated (waterproof). To obtain a waterproof
seal between the controller and the panel, follow these directions:
1. The 545 fits in a standard 1/4 DIN cutout. Mount the 545 in any panel
with a thickness from .06 in. to .275 in. (1.5 mm to 7.0 mm).
2. Figure 3.1 shows the controller and panel dimensions. The panel cutout
must be precise, and the edges free from burrs and waves.
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
545
MANUAL DISPLAY SET PT
ACK MENU FAST
PV2
OUT
1 2
ALM
1 2
3. Place bezel gasket around the controller case (starting at the back of
controller). Then, slide the gasket against the back of the bezel.
4. With the bezel gasket in place, insert the 545 into the panel cutout from
the front of the panel.
5. Slide the mounting collar over the back of the case, as shown in
Figure 3.2. The collar clip edges will lock with matching edges on the
controller case.
Mounting Clip
Collar Screws (1 of 4)
Mounting Collar
Front Panel
Figure 3.2
Attaching Mounting Collar

Installation
12 Chapter 3 545 User's Manual
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
LINE
NEUTRAL
OUT 1–
OUT 1+
OUT 2–
OUT 2+
OUT 3–
OUT 3+
EARTH
GND
S/W
CCW
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)
CAUTION !
The enclosure into which the 545
Controller is mounted must be
grounded.
WARNING!
Avoid electrical shock. Do not
connect AC power wiring at the
source distribution panel until all
wiring connections are complete.
WARNING!
Terminal 9 must be grounded to avoid
potential shock hazard, and reduced
noise immunity to your system.
6. Insert the four mounting collar screws from the rear of the collar. Gradu-
ally tighten the screws (using a Phillips #2 screwdriver) to secure the
controller against the panel.
7. If there is difficulty with any of the mounting requirements, apply a bead of
caulk or silicone sealant behind the panel around the perimeter of the case.
WIRING
Our 545 controllers are thoroughly tested, calibrated and “burned in” at the fac-
tory, so the controller is ready to install. Before beginning, read this chapter thor-
oughly and take great care in planning a system. A properly designed system
can help prevent problems such as electrical noise disturbances and danger-
ous extreme conditions.
1. For improved electrical noise immunity, install the 545 as far away as pos-
sible from motors, relays and other similar noise generators.
2. Do not run low power (sensor input) lines in the same bundle as AC power
lines. Grouping these lines in the same bundle can create electrical noise
interference.
3. All wiring and fusing should conform to the National Electric Code and to
any locally applicable codes.
4. An excellent resource about good wiring practices is the IEEE Standard No.
518-1982 and is available from IEEE, Inc., 345 East 47th Street, New York,
NY 10017, [phone].
Diagrams on the next three pages serve as guides for wiring different types of
process inputs. The shaded areas on the diagrams show which rear terminals
are used for that type of wiring.
AC Power Input
Figure 3.3
Terminal Assignments
Actual 545 device only has top and
bottom numbers of each column of
terminals marked.
WARNING!
Electric Shock Hazard! Terminals 1
and 2 carry live power. DO NOT touch
these terminals when power is on.

Installation
545 User's Manual Chapter 3 13
Figure 3.4
AC Power Input Terminals
Figure 3.5
Process Variable Terminals
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
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
PV 1–
PV 1+
PV 2–
PV 2+
RTD 3rd
Terminals 1 and 2 are for power. Terminal 9 is the earth ground.
Use a 0.5 Amp, 250 V, fast-acting fuse in line with your AC power connection.
Process Variable Input
The 545 accommodates the following types of process variable inputs:
• Thermocouple Input
• RTD Input
• Voltage Input
• Milliamp Input with External Power Supply
• Milliamp Input with Internal Power Supply
Each type of input can be wired for PV1 (terminals 31 and 32) or for PV2 (termi-
nals 28 and 29).
Digital Input(s)
CAUTION!
Do not run low power (sensor input)
lines in the same bundle as AC power
lines. Grouping these lines in the same
bundle can create electrical noise
interference.