Moore 500 Series User manual

Installation
InstallationGuide 500 Series 1
500 SERIES
Process Controllers
Hardware Installation
and Modification
Manual
for Electronic Products
Series 531, 532,
535, 545, 555
Model 2
5 0 0
Form M500 V7
M500 V 7, APRIL 2016

2500 Series Installation Guide
Installation
INTRODUCTION
This technical brochure provides hardware installation and modification instructions for our controllers:
Series 531, 532, 535, 545, and 555. Use these instructions with the following kits:
EPROMKits
531-740................531EPROMKit
532-740 ...............532 EPROM Kit
535-741................535EPROMKit(RSP)
535-775 ...............535 Profiler EPROM Kit (No RSP)
535-776 ...............535 Profiler EPROM Kit (RSP)
535-740................535EPROMKit(NoRSP)
545-740................545EPROMKit(NoRSP)
545-741................545EPROMKit(RSP)
555-740................555EPROMKit
Microcontroller(MCU)BoardKits
535-731 ...............MCU Board Kit
545-733 ...............MCU Board Kit with CE Option
Option Board Kits
535-720 ...............531, 532, 535, 545 Option Board Kit
(No Options)
535-721 ...............531, 532, 535, 545 Option Board Kit
(Digital Inputs)
535-722 ...............535, 545 Option Board Kit
(Slidewire Feedback)
535-723 ...............535, 545 Option Board Kit
(Digital Inputs and Slidewire Feedback)
545-724 ...............531, 532, 535, 545, 555 Option Board Kit
(RSP)
545-725 ...............531, 532, 535, 545, 555 Option Board Kit
(Digital Inputs and RSP)
545-726 ...............535, 545, 555 Option Board Kit
(Slidewire Feedback and RSP)
545-727 ...............535, 545, 555 Option Board Kit
(Digital Inputs, Slidewire Feedback,
and RSP)
DisplayAssemblyKits
531-632 ...............531 Display Assembly Kit
532-632 ...............532 Display Assembly Kit
535-632 ...............535 Display Assembly Kit
545-634 ...............545 Display Assembly Kit
555-632 ...............555 Display Assembly Kit
Output and Communications Module Kits
532-600 ...............531, 532 Analog Module Kit
535-600*..............Mechanical Relay Module Kit
535-601*..............Milliamp Module Kit
535-602*..............SSR Module Kit
535-603*..............SSR Drive Module Kit
535-604*..............Loop Power Module Kit
535-705*..............RS-485 Communications Module Kit
Power Supply Kit
535-730*..............90 to 250VAC Power Supply Kit
535-732 ...............24VAC/VDC Power Supply Kit
Mounting Kit
535-761*..............Mounting Kit
Miscellaneous Kits
532-100 ...............531, 532 Bypass Board Kit
535-188*..............Rear Terminal Upgrade Kit
535-660 ...............531, 532, 535, 545, 555 Jumper Kit
535-662*..............Gasket Kit
(1 Panel Gasket, 1 Bezel Gasket)
535-763*..............Bezel Retention Screw Kit
535-664*..............Module Retention Kit
(Retention Plate and Tie Wrap)
535-665*..............Module Retention Tie Wrap Kit
093-128*..............Lithium Battery
HOWTO USETHIS MANUAL:
A. CAUTION: Static discharge will cause damage to equipment. Always ground yourself with a wrist grounding
strap when handling electronics to prevent static discharge.
B. Before removing or inserting any hardware on the controller, copy down all configuration parameters. Also,
replacing the battery, EPROM or MCU Board will erase parameter settings and they will need to be reset.
C. For all hardware adjustments, perform steps 1, 2 and 3.
D. Follow the guide and complete any additional steps as required by your particular application.
E. Complete your hardware adjustments with steps 15, 16, 17, 18, 19 & 20.
EQUIPMENT
To make any hardware changes to the units, you will need the following equipment:
• Wrist grounding strap • Phillips screwdriver (#2)
• Small flat blade screwdriver • Wire cutters
• I.C. Extractor (if changing the EPROM)
* Universal Kit (can be used with all 500 Series Controllers)

Installation
InstallationGuide 500 Series 3
oneof the larger two boards from the Option
Board (Photo 4). Be careful not to bend the
connector pins. Separate the other board in the
same manner.
Figure2(oppositepage)showstheMicrocontroller
Board,OptionBoardandPowerSupply Board.
To Add or Change Output Modules
The 500 Series units have provisions for four output
modules. The units come factory configured with
specified modules installed in appropriate locations.
You can make field modifications by properly remov-
ing and/or adding the modules into the appropriate
sockets.
Three of the output sockets are located on the Power
Supply Circuit Board. A fourth output socket is
located on the Option Board (refer to Figure 2).
5. A retention plate
and tie wrap hold
Output modules 1, 2,
and 3 (on the Power
Supply board) firmly
in place. To remove
the retention plate,
snip the tie wrap
with wire cutters
(Photo 5).
6. A disposable tie wrap
holds Output module
4 (on the Option
board) in place. To
remove the module,
snip the tie wrap
(Photo 6).
7. Inspect each module
before installation to
make sure the pins
are straight. Align
the pins with the
socket holes and
carefully insert the
module. Press down on the module to seat it
firmly on the board.
INSTRUCTIONS
To Disassemble the Unit
Foranyhardwaremodifications,disassembletheunit.
1. With power off, loosen four captive front screws with
a Phillips screwdriver. Remove the four screws.
2. Slide the chassis out of the case by pulling on front
face plate assembly at the bezel (see Figure 1).
3. Locate the retention
clips holding the front
face assembly to the
rest of the chassis.
Pry apart these
retention clips gently
with a screwdriver to
separate the printed
circuit board group
from the front face
assembly (Photo 3).
Take care not to
break the clips or
scratch the circuit board.
The Microcontroller Board and Power Supply Board
remain attached to the Operator Interface Assem-
bly by wired connectors.
4. The Microcontroller
and Power Supply
board are attached
to either side of the
Option board by
male/female pin
connectors. Use a
gentle rocking motion
and carefully apply
pressure in a uniform
direction to separate
Figure 1
Location of Printed Circuit Boards for Hardware
Configuration
Photo 3.Pry Clips
Photo 4. Separate Boards
Photo 5.
Remove Retention Plate
Photo 6.
Snip Tie Wrap on Mod. 4
CAUTION: Always snip the tie wrap on top of the
Retention Plate, as shown in photo 5, to prevent
damage to the surface mount components.

4500 Series Installation Guide
Installation
Figure 2
Microntroller Board,
Option Board, and
Power Supply Board
NOTE:
If you replace the EPROM chip, you
must align the notch facing the front
oftheunit.
NOTE:
The 5- and 22-Pin connnectors on
the boards are all keyed so they
will only align one correct way.
Front of Unit Back of Unit
(toward Operator Interface) (toward rear terminals)
Male 22-Pin
Connector Male 22-Pin
Connector
Male 12-Pin
Connector Male 22-Pin
Connector
Output 4
5-Pin Connector
Female 22-Pin Connector Female 22-Pin Connector
5-Pin Connector
Module
Retention
Plate
over Outputs 1,2,3
12-Pin Female
Connector 22-Pin Female
Connector
Jumpers
NO and NC
V
MA
V
MA
TC
TC
RTD
NO J1 NC NO J2 NC NO J3 NC
TB1
PV1 2ND
TB2
TC
TC
RTD
Remote Setpoint Jumper
EPROM
BATTERY

Installation
InstallationGuide 500 Series 5
Note: When adding Option board for 5
digital inputs, associated screw terminal in
the rear terminal block must be installed.
(See information on page 1 for ordering a
Screw Kit.)
To Change the Power Supply or
Microcontroller (CPU) Board
10. For the Microcontroller Board, disconnect the 5-pin
female connector that wires it to the Display
Assembly. Reattach the connector to the new
board. You can only orient the connector one way.
For the Power Supply Board, disconnect the 5-pin
female connector that wires it to the Display
Assembly. Reattach the connector to the new
board. You can only orient the connector one way.
To Change the Display Assembly
11. Disconnect the 5-pin female connector that wires
the Microcontroller Board to the Display Assembly.
Disconnect the 5-pin female connector that wires
the Power Supply Board to the Display Assembly.
12. Attach the new Display Assembly to the boards at
the appropriate connectors.
To Change the EPROM
13. The EPROM is located on the Microcontroller
Circuit board (Figure 2). It has a white label that
list the part number and software revision level.
Use an I.C. Extractor to carefully remove the
EPROM. If you do not have an I.C. extractor,
gently use a small flat blade screwdriver to pry up
the EPROM. DO Not bend the EPROM legs.
14. Carefully insert the new EPROM. To position
correctly, match the notched end of the EPROM to
the markings on the board. The notched end will
face towards the display. Make sure all pins are in
the socket.
To Reassemble the Unit
15. (See Figure 2) Align the connector pins on the
Option Board with the connector sockets on the
Microcontroller and Power Supply boards.
Squeeze them together, making certain all three
are properly seated against one another. Check
along the side edges for gaps. Make sure the
conector is properly aligned. Also, check that the
cable assemblies are not pinched.
16. (See Figure 2) Align the board assembly with the
front face assembly, with the Option board at the
bottom (see Figure 1). Reinstall the retention
clips. Align the boards into the slots of the front
face assembly and the clips will snap into place.
17. When you are ready to reassemble the unit, align
the boards in the chassis with the case's top and
bottom grooves. Press firmly to slide the chassis
into the case. If you have difficulty, check that you
have properly oriented the chassis, and there are
no screws interfering with the case.
18. Carefully insert and align screws. Tighten them
until the bezel is seated firmly against the gasket.
DO NOT OVERTIGHTEN.
19. If may be necessary to re-configure the software
features of your controller or station. Please refer
to your User’s Manual.
20. To maintain NEMA 4X Rating, you may need new
mounting gaskets, order part #535-662. Refer to
your user’s manual.
8. Replace tie wraps for the Retention Plate and for
Output Module 4 with new ones.
Failure to use these devices may result in a
loosening of the module and eventual
failure. If you ordered a module separately,
it should have come with a tie wrap. An
extra set of tie wraps is available by order-
ing Part #535-665.
Note: For greatest accuracy, milliamp
modules added for retransmission must be
calibrated per instructions in Operator's
Manual.
To Change the Option Board
9. (See Photos 3 and 4) Replace the existing Option
board with the NEW one.
CAUTION
Do not scratch the boards or bend the pins of the
connectors.
CAUTION
Static discharge will cause damage to equip-
ment. Always ground yourself with a wrist
grounding strap when handling electronics
to prevent static discharge.

To return equipment to Moore Industries for repair, follow these four steps:
1. CallMoore Industries and request a Returned Material Authorization(RMA) number.
Warranty Repair –
If you are unsure if your unit is still under warranty, we can use the unit’s serial number
to verify the warranty status for you over the phone. Be sure to include the RMA
numberonalldocumentation.
Non-WarrantyRepair–
If your unit is out of warranty, be prepared to give us a Purchase Order number when
you call. In most cases, we will be able to quote you the repair costs at that time.
The repair price you are quoted will be a “NotTo Exceed”price, which means that the
actual repair costs may be less than the quote. Be sure to include the RMA number on
alldocumentation.
2. Provideuswiththefollowingdocumentation:
a) A note listing the symptoms that indicate the unit needs repair
b) Completeshippinginformationforreturnoftheequipmentafterrepair
c) The name and phone number of the person to contact if questions arise at the factory
3. Use sufficient packing material and carefully pack the equipment in a sturdy shipping
container.
4. Ship the equipment to the Moore Industries location nearest you.
The returned equipment will be inspected and tested at the factory. A Moore Industries
representative will contact the person designated on your documentation if more information is
needed. The repaired equipment, or its replacement, will be returned to you in accordance with
theshippinginstructionsfurnishedinyour documentation.
WARRANTY DISCLAIMER
THECOMPANYMAKESNOEXPRESS, IMPLIEDORSTATUTORY WARRAN-
TIES(INCLUDINGANYWARRANTYOFMERCHANTABILITY OROFFITNESS
FORA PARTICULARPURPOSE)WITHRESPECTTOANYGOODSORSER-
VICESSOLDBYTHECOMPANY. THECOMPANYDISCLAIMSALLWARRAN-
TIESARISING FROMANYCOURSE OFDEALING ORTRADE USAGE,AND
ANYBUYER OFGOODS ORSERVICES FROMTHE COMPANYACKNOWL-
EDGES THAT THERE ARE NO WARRANTIES IMPLIED BY CUSTOM OR
USAGEIN THETRADEOFTHEBUYERANDOF THECOMPANY, ANDTHAT
ANYPRIORDEALINGSOFTHE BUYERWITHTHE COMPANYDO NOTIM-
PLYTHAT THECOMPANY WARRANTSTHEGOODSORSERVICESINANY
WAY.
ANYBUYEROFGOODSORSERVICESFROMTHECOMPANYAGREES
WITHTHECOMPANY THATTHESOLE ANDEXCLUSIVEREMEDIES FOR
BREACHOFANYWARRANTYCONCERNING THEGOODS ORSERVICES
SHALLBE FORTHE COMPANY,ATITSOPTION,TOREPAIRORREPLACE
THE GOODS OR SERVICES OR REFUND THE PURCHASE PRICE. THE
COMPANYSHALLINNOEVENT BELIABLEFORANYCONSEQUENTIALOR
INCIDENTALDAMAGESEVEN IFTHE COMPANYFAILSIN ANYATTEMPT
TOREMEDY DEFECTSINTHEGOODSOR SERVICES,BUTINSUCH CASE
THEBUYERSHALL BEENTITLEDTO NOMORE THAN AREFUND OFALL
MONIESPAID TOTHECOMPANYBYTHE BUYERFORPURCHASEOFTHE
GOODSOR SERVICES.
RETURN PROCEDURES
ANYCAUSEOFACTIONFOR BREACHOFANYWARRANTYBYTHE
COMPANY SHALL BE BARRED UNLESS THE COMPANY RECEIVES
FROMTHE BUYERA WRITTENNOTICE OFTHE ALLEGEDDEFECT OR
BREACHWITHINTENDAYSFROMTHEEARLIESTDATEONWHICHTHE
BUYERCOULD REASONABLYHAVE DISCOVEREDTHEALLEGEDDE-
FECTORBREACH,ANDNO ACTIONFOR THEBREACHOF ANYWAR-
RANTY SHALL BE COMMENCED BY THE BUYER ANY LATER THAN
TWELVEMONTHS FROMTHE EARLIESTDATEONWHICHTHEBUYER
COULDREASONABLY HAVEDISCOVEREDTHEALLEGEDDEFECTOR
BREACH.
RETURN POLICY
Foraperiod of thirty-six (36)monthsfrom the dateofshipment, and under
normalconditions ofuseandservice,Moore Industries("The Company")will
atitsoption replace,repairor refundthepurchase priceforany of itsmanu-
facturedproducts found,upon returnto theCompany (transportationcharges
prepaidandotherwiseinaccordance withthe returnproceduresestablished
byTheCompany), to bedefectivein material or workmanship. Thispolicy
extendstothe originalBuyer only andnot toBuyer'scustomers ortheusers
ofBuyer's products,unlessBuyer isan engineeringcontractor inwhichcase
thepolicyshallextendto Buyer'simmediate customeronly. Thispolicyshall
notapplyif theproduct has beensubject toalteration,misuse, accident,ne-
glect or improper application, installation, or operation. THE COMPANY
SHALL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSE-
QUENTIALDAMAGES.
United States • [email protected]
Tel: [phone] • FAX: [phone]
Australia • [email protected]
Tel: [phone] • FAX: [phone]
Belgium • [email protected]
Tel: [phone] • FAX: [phone]
The Netherlands • [email protected]
Tel: [phone] • FAX: [phone]
China • [email protected]
Tel: [phone] • FAX: [phone]
United Kingdom • [email protected]
Tel: [phone] • FAX: [phone]
Specifications and Information subject to change without notice.
©2006MooreIndustries-International,Inc.

User’s Manual Supplement
500 Series
Process Controllers
531, 532, 535, 545, 555
April 2016
Purpose
This supplement is to address the updated Micro
Controller Board with removable Lithium Battery. Older
models required to be serviced by Moore Industries
to replace Lithium Battery which was soldered directly
on the board, this is an inconvenience and has been
resolved with a Micro Controller Board that has a
replaceable Lithium Battery slot.
To replace battery in your 500 Series unit follow
previous instructions found in M500 V6. Use a flat head
screwdriver to release battery and replace.
The Interface Solution Experts www.miinet.com
BATTERY
EPROM
5-Pin Connector
INSERT FLAT
HEAD SCREWDRIVER
TIP HERE TO
RELEASE BATTERY
Female 22-Pin ConnectorFemale 22-Pin Connector
Figure 1. Removable Lithium Battery
You can order replacement directly fro Moore Industries
using this part number 800-867-52 or an equivalent
CR2450 3V Coin Cell Lithium Battery.