Moore 535 PROFILER User manual

M535-PROF V 6 , © JULY 20 17
1/4 DIN PROFILE CONTROLLER
USER'S MANUAL
5 3 5 P R O F I L E R
535
PROFILER

535-PROF User's Manual Appendix 7 A-23
Isolation Block Diagram

535-PROF User's Manual Table of Contents i
Table of Contents
TABLE OF CONTENTS
PAGE
CHAPTER1
INTRODUCTION ............................................................................... 1
535 Profile Controller Modes .............................................................. 1
Order Code, Packaging Information ................................................... 2
Where to Go Next............................................................................... 2
Text Formatting in this Manual ........................................................... 2
CHAPTER2
BASICINTERFACE .......................................................................... 4
Displays ............................................................................................ 4
Icons (Lit) .......................................................................................... 5
Keys.................................................................................................. 5
Basic Profile Controller Operating Procedures .................................... 7
To Enter the RECIPE SET UP Mode.......................................... 7
To Enter the SET UP Mode ....................................................... 7
To Run a Recipe ........................................................................ 7
To Hold a Recipe ....................................................................... 7
To Abort a Recipe and Switch to Manual Control ........................ 7
To Abort a Recipe and Control to the Idle Setpoint ...................... 7
To Display the Setpoint (SP) while a Recipe Is Running ............. 8
To Display the Recipe Number .................................................. 8
Basic Process Controller Operating Procedures ................................. 8
To Select/Change a Setpoint ..................................................... 8
To Change from Auto to Manual Control (Bumpless Transfer) ..... 8
To Change from Manual to Auto................................................. 8
To Change Manual Output Values ............................................. 8
To Override Security ................................................................. 8
To Display Control Output Value ................................................ 9
To Display the Active PID Set ................................................... 9
Alarm Operation ................................................................................. 9
Alarm Indication ........................................................................ 9
To Acknowledge an Alarm(s) ................................................... 10
Latching Alarms ...................................................................... 10
Limit Sequence ....................................................................... 10
More On Alarms ...................................................................... 10
CHAPTER3
INSTALLATION .............................................................................. 11
Mounting the Controller .................................................................... 11
Wiring .............................................................................................. 12
AC Power Input ....................................................................... 13
Process Variable Input ............................................................ 13
Digital Input(s) ......................................................................... 16
1. Digital Inputs with a Switch or Relay ................................ 16
2. Digital Inputs with an Open Collector ............................... 16
Remote Setpoint Option .......................................................... 16
Output Modules ....................................................................... 17
1. Mechanical Relay Output ................................................ 17
2. Solid State Relay (Triac) Output ...................................... 17
About This Manual:
Throughout this User’s Manual
information appears along the
margins (NOTE: CAUTION! and
WARNING!). Please heed these
safety and good practice notices for
the protection of you and your
equipment.

ii Table of Contents 535-PROF User's Manual
Table of Contents
CHAPTER3
INSTALLATION(CONTINUED)
Output Modules
3. DC Logic (SSR Drive) Output .......................................... 18
4. Milliamp Output .............................................................. 18
5. Position Proportioning Output ......................................... 18
Serial Communications ........................................................... 19
Limit Control ............................................................................ 20
CHAPTER4
HARDWARE SET UP ...................................................................... 21
Hardware Input Types ...................................................................... 21
The Process Variable ....................................................................... 21
The Remote Setpoint ....................................................................... 22
Mechanical Relays .......................................................................... 22
Accessing and Changing Jumpers ................................................... 23
Adding and Changing Output Modules .............................................. 24
Special Communications Module ..................................................... 26
CHAPTER5
SOFTWARECONFIGURATION ...................................................... 27
Menus ............................................................................................. 27
Parameters ...................................................................................... 29
Configuration and Operation ............................................................. 29
Where to Go Next............................................................................. 29
Software Menus and Parameters ..................................................... 31
CONFIG.................................................................................. 31
REC. CONF. ........................................................................... 37
PV1 INPUT ............................................................................. 39
PV2 INPUT ............................................................................. 41
CUST. LINR. ........................................................................... 43
CONTROL .............................................................................. 44
ALARMS................................................................................. 46
REM. SETPT. ......................................................................... 50
RETRANS. ............................................................................. 51
SELF TUNE ............................................................................ 53
SPECIAL ................................................................................ 54
SECURITY ............................................................................. 56
SER. COMM. .......................................................................... 57
RECIPE # ............................................................................... 58
Parameter Value Charts ................................................................... 61
CHAPTER6
TUNING .......................................................................................... 71
Overview ......................................................................................... 71
Tuning Parameters .......................................................................... 72
Tuning Value Chart .......................................................................... 76
Self Tune Messages and Troubleshooting ........................................ 78
CHAPTER7
APPLICATIONS .............................................................................. 79
A. Profile Control.............................................................................. 79
Software Configuration ............................................................ 80
Digital Inputs ........................................................................... 84
PAGE

535-PROF User's Manual Table of Contents iii
Table of Contents
CHAPTER7
APPLICATIONS(CONTINUED)
A. Profile Control
Master/Slave Operation ........................................................... 84
HardwareConfiguration ....................................................... 85
B. Control Type ................................................................................ 85
Software Configuration ............................................................ 85
C. Alarms ........................................................................................ 86
Software Configuration ............................................................ 86
D. Duplex Control ............................................................................. 90
HardwareConfiguration ........................................................... 90
Software Configuration ............................................................ 90
Duplex Output State Examples ............................................... 91
Duplex with Reverse and Direct Acting Outputs ................... 91
Duplex with Direct and Reverse Acting Outputs ................... 91
Duplex with 2 Reverse Acting Outputs................................. 92
Duplex with a Gap Between Outputs.................................... 92
Duplex with a Overlapping Outputs and Output Limits .......... 93
Duplex with Various Relative Gain Settings ......................... 93
Duplex with One On/Off Output ........................................... 94
Duplex with Two On/Off Outputs ......................................... 94
E. Slidewire Position Proportioning Control ....................................... 95
HardwareConfiguration ........................................................... 95
Software Configuration ............................................................ 95
F. Velocity Position Proportioning Control ........................................ 96
HardwareConfiguration ........................................................... 96
Software Configuration ............................................................ 96
G. Staged Outputs ........................................................................... 97
HardwareConfiguration ........................................................... 97
Software Configuration ............................................................ 97
H. Retransmission ........................................................................... 97
HardwareConfiguration ........................................................... 97
Software Configuration ............................................................ 97
I. Digital Inputs................................................................................. 98
HardwareConfiguration ........................................................... 98
Software Configuration ............................................................ 98
Basic Operating Procedures .................................................. 100
J. Remote Setpoint ........................................................................ 100
HardwareConfiguration ......................................................... 100
Software Configuration .......................................................... 100
Basic Operating Procedures .................................................. 101
K. Multiple Setpoints ...................................................................... 101
Software Configuration .......................................................... 101
Basic Operating Procedures .................................................. 101
L. Multiple Sets of PID Values ....................................................... 101
Software Configuration .......................................................... 101
Basic Operating Procedures .................................................. 102
Using with Adaptive and Pretune ........................................... 102
M. Powerback ................................................................................ 102
Software Configuration .......................................................... 103
N. Self Tune— Powertune® ........................................................... 103
Pretune ................................................................................. 103
Adaptive Tune ....................................................................... 103
PAGE

iv Table of Contents 535-PROF User's Manual
Table of Contents
CHAPTER7
APPLICATIONS(CONTINUED)
N. Self Tune—Powertune®
Software Configurations ........................................................ 104
Pretune by Itself................................................................ 104
Pretune Type 1 & Adaptive Tune ....................................... 104
Pretune Type 2 or 3 & Adaptive Tune ................................ 106
Adaptive Tune by Itself ..................................................... 106
Self Tuning with Multiple Sets of PID ................................. 108
Self Tune with Time Proportioning Outputs ........................ 108
Self Tune with Control Valves ........................................... 108
O. Ramp-to-Setpoint ...................................................................... 109
Software Configuration .......................................................... 109
P. Input Linearization ..................................................................... 109
Thermocouple and RTD Linearization .................................... 109
Square Root Linearization ...................................................... 109
HardwareConfiguration ..................................................... 110
Software Configuration ...................................................... 110
Custom Linearization ............................................................. 110
Software Configuration ...................................................... 110
Q. Load Line .................................................................................. 111
R. Security .................................................................................... 111
Software Configuration .......................................................... 111
Basic Operating Procedures .................................................. 112
S. Reset Inhibition ......................................................................... 112
Software Configuration .......................................................... 112
T. Process Variable Reading Correction ......................................... 112
U. Serial Communications .............................................................. 113
HardwareConfiguration ......................................................... 113
Software Configuration .......................................................... 113
V. Cascade Control ........................................................................ 114
HardwareConfiguration ......................................................... 116
Software Configuration .......................................................... 116
Tuning Cascade Control ........................................................ 116
W. Ratio Control............................................................................. 117
HardwareConfiguration ......................................................... 118
Software Configuration .......................................................... 118
PAGE

535-PROF User's Manual Table of Contents v
Table of Contents
APPENDIX 1
MENUFLOWCHARTS ................................................................... A-1
APPENDIX 2
PARTS LIST ..................................................................................A-3
APPENDIX 3
TROUBLESHOOTING ...................................................................A-4
APPENDIX 4
CALIBRATION ...............................................................................A-6
Preparation For All Input Calibrations ..............................................A-7
Thermocouple Cold Junction Calibration ......................................... A-8
Analog Milliamp Input Calibration ....................................................A-8
Milliamp Output Calibration .............................................................A-9
Reset Menu Data .......................................................................... A-10
HardwareScan ..................................................................... A-11
Slidewire Test ............................................................................... A-11
Quick Calibration Procedure .......................................................... A-11
APPENDIX 5
SPECIFICATIONS ....................................................................... A-12
APPENDIX 6
GLOSSARY ................................................................................. A-17
APPENDIX 7
ISOLATION BLOCK DIAGRAM .................................................... A-22
PAGE

vi Table of Contents 535-PROF User's Manual
Table of Contents
LIST OF FIGURES
PAGE
Figure2.1 ....... Operator Interface ................................................................ 4
Figure2.2 ....... Before and After Acknowledging An Alarm ............................. 9
Figure3.1 ....... Instrument Panel & Cutout Dimensions ............................... 11
Figure3.2 ....... Attaching Mounting Collar ................................................... 11
Figure3.3 ....... All535-PROFTerminalAssignments .................................. 12
Figure3.4 ....... ACPowerInputTerminals .................................................. 13
Figure3.5 ....... Process Variable Terminals ................................................ 13
Figure3.6 ....... PV1 and PV2 Wiring for Milliamp, RTD and
Voltage Inputs. .................................................................. 14
Figure3.7 ....... PV1 and PV2 Wiring for Milliamp Inputs with
Internaland External Power Supply ..................................... 15
Figure3.8 ....... Digital Inputs Wiring with A Switch or Relay .......................... 16
Figure3.9 ....... Digital Input Wiring with An Open Collector ........................... 16
Figure 3.10 ...... RemoteSetpoint Terminals ................................................ 16
Figure 3.11 ...... MechanicalRelay Output Wiring ......................................... 17
Figure 3.12 ...... SSRRelay Output Wiring ................................................... 17
Figure 3.13 ...... DCLogicOutput Wiring ...................................................... 18
Figure 3.14 ...... MilliampOutput Wiring ....................................................... 18
Figure 3.15 ...... PositionProportioning OutputWiring ................................... 18
Figure 3.16 ...... SerialCommunications Terminals ...................................... 19
Figure 3.17 ...... 535-PROFWiring with LimitControl ..................................... 20
Figure4.1 ....... Location of Printed Circuit Boards for
HardwareConfiguration ...................................................... 21
Figure4.2 ....... (From the Top) the Microcontroller Circuit Board,
the Option Board, and the Power Supply Board .................... 22
Figure4.3 ....... Representation of Module ................................................... 25
Figure4.4 ....... InstallCommunicationsModule onto
MicrocontrollerBoard ......................................................... 26
Figure5.1 ....... Menu Flowchart for Set Up ................................................. 27
Figure5.2 ....... Configuration Flowchart ...................................................... 28
Figure5.3 ....... Independent vs. DependentParameters .............................. 29
Figure6.1 ....... Access the Tuning Menu Block .......................................... 71
Figure7.1 ....... Contacts for Recipe Selection ............................................. 84
Figure7.2 ....... Alarm Examples ................................................................ 89
Figure7.3 ....... Duplex with Reverse and Direct Acting Outputs ................... 91
Figure7.4 ....... Duplex with Direct and Reverse Acting Outputs ................... 91
Figure7.5 ....... Duplex with Two Reverse Acting Outputs ............................ 92
Figure7.6 ....... Duplex with A Gap Between Outputs ................................... 92
Figure7.7 ....... Duplex with Overlapping Outputs and Output Limits ............. 93
Figure7.8 ....... Duplex with Various Relative Gain Settings .......................... 93
Figure7.9 ....... Duplex with One On/Off Output ........................................... 94

535-PROF User's Manual Table of Contents vii
Table of Contents
Figure 7.10 ...... Duplex with Two On/Off Outputs ......................................... 94
Figure 7.11 ...... StagedOutputs Example ................................................... 97
Figure 7.12 ...... Combinations of Closed Digital Inputs for
Each Setpoint (Based on BCD Logic) .................................. 98
Figure 7.13 ...... Pretune Type 1, Type 2 and Type 3 with
AdaptiveTune ................................................................. 105
Figure 7.14 ...... NoiseBand Calculation Example ...................................... 107
Figure 7.15 ...... Noise Band Values for Temperature Inputs ........................ 107
Figure 7.16 ...... Deadtimeand Time Constant ........................................... 108
Figure 7.17 ...... SquareRootLinearization Formula .................................... 110
Figure 7.18 ...... 15-pointLinearizationCurve .............................................. 110
Figure 7.19 ...... LoadLine Example .......................................................... 111
Figure 7.20 ...... HeatExchanger Control Loop for Steam Supply ................. 114
Figure 7.21 ...... CascadeControl of Product Temperature .......................... 115
Figure 7.22 ...... RatioControlInMixingApplicatoin .................................... 117
FigureA4.1 ..... 535 Rear Terminals forCalibration ...................................... A-6
FigureA4.2 ..... Flowchart Calibration Menus .............................................. A-6
FigureA4.3 ..... Jumper Locations on the Microcontroller Circuit Board ......... A-7
FigureA4.4 ..... Input CalibrationWiring ...................................................... A-7
FigureA4.5 ..... Thermocouple/Cold Junction CalibrationWiring .................. A-8
FigureA4.6 ..... Analog mA Input Calibration Wiring .................................... A-9
FigureA4.7 ..... Analog mA Input Jumper Positions .................................... A-9
FigureA4.8 ..... MilliampOutput Calibration Wiring .................................... A-10
FigureA4.9 ..... OutputModuleMenu Cycle ............................................. A-10
FigureA4.10 ... Slidewire Test Wiring ...................................................... A-11

535-PROF User’s Manual Chapter 1 1
Introduction
CHAPTER 1
INTRODUCTION
Thank you for selecting the 535 Profile
Controller — the most sophisticated
instrument in its class. It will provide
you with years of reliable, trouble-free
performance.
From its surge-resistant power supply to its rugged construction, the 535 Profile
Controller is designed to ensure the integrity of your process with maximum reli-
ability — hour after hour, day after day. The isolated inputs and outputs guard
against the dangers of electrical interference, the front face meets NEMA 4X stan-
dards for watertight operation and exposure to corrosive environments, and the
solid metal housing and sturdy rubber keys enhance durability and ESD protec-
tion.
The 535 Profile Controller has been engineered to be the industry’s most user–
friendly process controller. With three digital display areas — two offering up to 9
charactersof true alphanumerics — thecontroller 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 535 Profile Controller is the most accurate instrument in its class. With a sam-
pling rate of ten times per second, it is ideal for demanding pressure and flow ap-
plications. The controller also offers a universal process input and modular, field
interchangeable outputs that allow more flexibility than ever before. The RS-485
serial communications interface allows the controller to utilize sophisticated soft-
ware routines and high speed hardware to provide exceptionally fast and accu-
rate transmission of data. The 535 Profile Controller also offers sophisticated
controlalgorithms, including exclusive AdaptiveTune whichconstantly analyzes
your process and makes modifications to the tuning parameters to ensure you’re
always under control.
535 PROFILE CONTROLLER MODES
There are four operating modes for the 535 profile controller:
OPERATION, the default mode of the controller. When the 535-PROF is oper-
ating, you can run recipes, change setpoints, select manual control and change
output level, acknowledge alarms and monitor conditions.