Plc, Dcs, Pc Control Backup Station User`s Manual

5 3 1

M531 V5, MAY 2002

5 3 1

PLC, DCS, PC CONTROL BACKUP STATION

USER'S MANUAL

Contents

page

CONTENTS

FIGURE LIST .......................................................................................... iii

CHAPTER 1

INTRODUCTION ............................................................................. 1

Conforming What Is Included .......................................................... 1

Order Code ...................................................................................... 2

Basic Operation ............................................................................... 3

Where To Go Next ........................................................................... 3

Text Formatting in This Manual ...................................................... 3

About This Manual:

Throughout this User’s Manual will appear NOTEs, CAUTIONs and

WARNINGs, usually in boldface.

Please heed these safety and good practice notices for the protection of you and your equipment.

CHAPTER 2

INTERFACE & BASIC OPERATION ............................................. 5

Displays ............................................................................................ 5

Icons ................................................................................................. 5

Keys ................................................................................................. 6

Basic Operating Procedures ........................................................... 7

Alarms .............................................................................................. 8

CHAPTER 3

HARDWARE CONFIGURATION .................................................... 9

Accessing and Changing Jumpers ............................................... 11

Adding or Changing Output Modules ............................................ 12

Where to Go Next .......................................................................... 13

CHAPTER 4

MOUNTING AND WIRING ............................................................ 15

System Planning ............................................................................ 15

Mounting the Station ...................................................................... 15

Wiring the 531 Inputs ..................................................................... 16

A. AC Power .......................................................................... 17

B. Process Variable ............................................................... 17

C. Digital Inputs ..................................................................... 18

D. Remote Setpoint Indicator ................................................ 19

Wiring the 531 Outputs .................................................................. 19

A. CV Output ......................................................................... 19

B Mechanical Relay Output ................................................. 19

C Solid State Relay (Triac) Output ...................................... 19

D. DC Logic (SSR Drive) Output .......................................... 19

Wiring for Serial Communications ................................................. 20

Where to Go Next .......................................................................... 20

CHAPTER 5

SOFTWARE CONFIGURATION .................................................. 21

Mode Overview .............................................................................. 21

Menus ............................................................................................. 22

Smart Menus .................................................................................. 22

Software Configuration Procedures .............................................. 23

Guide to Set up Parameters .......................................................... 25

CONFIG. ................................................................................ 25

LOCAL OUT. ......................................................................... 28

PV INPUT .............................................................................. 29

CUST. LINR. ......................................................................... 31

531 User's Manual

Table of Contents

i

ii

Contents

page

RSP INPUT ............................................................................ 32

ALARMS ................................................................................ 33

SECURITY ............................................................................. 35

SER. COMM. .......................................................................... 36

OPERATION .......................................................................... 37

Parameter Value Charts .................................................................. 39

CHAPTER 6

531 APPLICATIONS ...................................................................... 45

531 Operation ................................................................................. 45

Alarms ............................................................................................. 46

Digital Inputs ................................................................................... 50

Watchdog Monitor ........................................................................... 51

Process Variable and Setpoint ........................................................ 51

Input Linearization ........................................................................... 53

Thermocouple and RTD Linearization .................................... 53

Square Root Linearization ...................................................... 53

Custom Linearization .............................................................. 53

Ramp to a Control Value ................................................................. 54

Security ........................................................................................... 55

Process Variable Reading Correction ............................................. 56

Serial Communications ................................................................... 56

APPENDIX A

MODE, MENU & PARAMETER FLOWCHART ............................ A-1

APPENDIX B

PARTS LIST ................................................................................. B-1

APPENDX C

TROUBLESHOOTING ................................................................. C-1

APPENDIX D

CALIBRATION ............................................................................. D-1

Regarding Calibration ................................................................... D-1

RTD and VmA Input Calibration .................................................... D-2

Thermocouple & Cold Junction Calibration ................................... D-3

Milliamp Output Calibration ........................................................... D-4

Reset Menu Data .......................................................................... D-4

Hardware Scan ............................................................................. D-5

Quick Calibration Procedure ......................................................... D-5

APPENDIX E

SPECIFICATIONS ........................................................................ E-1


531 User's Manual

Figure ............. Title ............................................................................ Page

Figure 2.1 ...... 531 Operator Interface ......................................................... 5

Figure 2.2 ...... Before and After Acknowledging an Alarm ............................. 8

Figure 3.1 ...... Location of Printed Circuit Boards ......................................... 9

Figure 3.2 ...... Jumper Locations on Microcontroller Board ......................... 10

Figure 3.3 ...... The Option Circuit Board .................................................... 10

Figure 3.4 ...... The Power Supply Circuit Board ......................................... 10

Figure 3.5 ...... Output Module ................................................................... 13

Figure 4.1 ...... 531 Instrument Panel and Cutout Dimensions ..................... 15

Figure 4.2 ...... Mounting Brackets ............................................................. 16

Figure 4.3 ...... 531 Rear Terminals ............................................................ 17

Figure 4.4 ...... Output Wiring for the 531 .................................................... 19

Figure 4.5 ...... Serial Communications Terminals ....................................... 20

Figure 5.1 ...... Menu Flowchart for Set Up ................................................. 21

Figure 5.2 ...... Independent vs. Dependent Parameters ............................. 22

Figure 5.3 ...... Keys to Enter and Move Through Set Up Mode .................... 23

Figure 6.1 ...... Alarm Examples ................................................................. 49

Figure 6.2 ...... Square Root Linearization Formula ..................................... 53

Figure 6.3 ...... Custom Linearization Curve ................................................ 54

Figure D.1 ..... Flowchart to Access Parts of Calibration Menu Block ......... D-1

Figure D.2 ..... Microcontroller Circuit Board ............................................. D-2

Figure D.3 ..... Calibration Wiring ............................................................. D-2

Figure D.3a ... Calibration Wiring (continued) ........................................... D-3

Figure D.4 ..... Thermocouple & Cold Junction Calibration Wiring .............. D-3

Figure D.5 ..... Milliamp Calibration Wiring ................................................ D-4

Contents

531 User's Manual


iii

Contents

iv


531 User's Manual

Introduction

CHAPTER 1

INTRODUCTION

The 531 PID Backup Station ensures the integrity of your processes with maximum reliability. Isolated inputs and outputs guard against electrical interference, the front face meets NEMA 4X standards for watertight operation, and the rugged case and sturdy rubber keys enhance durability.

The 531 has three digital display areas, two of which offer up to 9 characters of true alphanumerics. The bright, crisp vacuum fluorescent displays offer better readability than any other display technology. Additional operator friendly features include: custom programmable alarm messages, keys that illuminate when in use, and an easy-to-use menu system.

Thank you for selecting the 531

PID Backup Station. It is the most sophisticated instrument in its class and will provide you with years of reliable, trouble-free performance.

INPUTS

HOST Signal

Process Variable

Remote Setpoint

Digital Inputs

Serial Communications

OUT

1 2

ALM

1 2

OUTPUTS

HOST Signal

Control Output

Alarm(s)

Serial Communications

The 531 automatically provides PID backup control for critical control loops. In

Host Mode, the control signal passes from the Host device through the 531 without any degradation. A Host device may be a PLC, DCS, or process controller. The 531 switches to Automatic (PID) Mode upon keypad selection, digital input, or loss of the Host signal, and generates a control signal based on its own PID calculations. The control setpoint may be one or two preset setpoints, or transmitted to the 531. The 531 can also be switched to Manual

Mode, in which the operator can manually adjust the output. The 531 will transfer/return to Host Mode upon keypad selection, opening of the digital input or return of the Host signal.

Note: that the 531 PID Backup Station is not a point of failure; removing it from the case or powering down while in

Host Mode will not disturb the Host signal.

CONFIRMING WHAT IS INCLUDED

With your 531 PID Backup Station, you should have received:

• 1 531 User’s Manual

• Mounting hardware set

• 1 sheet of engineering unit adhesive labels

• 1 Terminal label

You can determine the installed outputs of your station by comparing your product number to the Order Code below. The product number is printed on the label on the top of the controller case.

Specifications and information subject to change without notice.

531 User's Manual

Chapter 1, Introduction

1

2

Introduction

BASIC OPERATION

There are three operating modes for the 531:

ORDER CODE *

531 -

OUTPUT 1 —

(ALARM ONLY)

ORDER CODE

None ......................................................................................... 0

Mechanical relay ....................................................................... 1

Solid state relay (1 amp triac) ...................................................3

DC logic (SSR drive) ................................................................. 4

OPTIONS

ENTER “0” IF NOT DESIRED

None ......................................................................................... 0

24 VAC Operation ..................................................................... F

2 1 1 B


None ......................................................................................... 0

Set of five digital inputs ............................................................. D

Certification .......................................................................... H

Set of five digital inputs and Certification .............................J

SERIAL COMMUNICATIONS


None ......................................................................................... 0

RS-485 serial communications .................................................S

0 0

* Note: Base instrument contains universal PV input, remote setpoint input and 4-20 mA CV (control) output with internal hard wired by-pass relays.

NOTE:

Altering the factory configuration of the modules will render the product label code invalid.


531 User's Manual

Host Mode: The 531 operates as a remote station that passes a CV directly from a host to a controlled device. In this mode, the SP but not the CV

(output) can be altered. Special “set up” parameters can be accessed, and the 531 can be transferred into either of the other operating modes.

Automatic Mode: The 531 sends output to the final device as provided by its own PID calculations. In this mode, the SP but not the CV (output) can be altered. The “set up” parameters may not be accessed, but the 531 can be transferred to either of the other operating modes.

Manual Mode. An operator provides manual output to the controlled device. Both the SP and the CV can be altered, and the 531 can be transferred to either of the other two operating modes.

The 531 also has a set up, or “configuration” mode in which the user configures the special functions of the 531, like inputs and outputs, alarms and PID operation. There are 9 menus in set up mode: eight are for instrument set up, and the ninth, OPERATION, configures the operational aspects of the 531.

WHERE TO GO NEXT

• First time users should read through this entire manual. Continue to Chapter 2 for basic interface and operation information. Then read Chapter 3 for important installation guidelines.

• Experienced users may continue on to Chapter 5 for details on the configuration features of the 531.

• Appendix 1 contains flowchart references for all 531 parameters, menus and modes.

TEXT FORMATTING IN THIS MANUAL

Feature

Mode

KEYS

Format

Automatic, Manual, Host Mode

SET PT DISPLAY

or

SET PT

DISPLAY

ICONS

MENUS

PARAMETERS

PARAMETER VALUES

DISPLAY MESSAGES

OUT, ALM

CONFIG., TUNING

CYCLE TM:1, MIN.OUT2

OFF, SETPOINT, LAST OUT.

TOO HOT, OUT%,

Introduction

531 User's Manual


3

Introduction

4


531 User's Manual

Interface/Operation

CHAPTER 2

INTERFACE AND BASIC OPERATION

The individual software and hardware options of your station determine the information it displays. Compare the product number on the unit label to the Order

Code in Chapter 1 for more information. A “smart menu” feature of the 531 allows only those messages relevant to your individual hardware (and software) configuration to appear in the displays.

NOTE::

Any modifications to the factory settings of the output modules will alter the Model Number displayed upon power-up from the original the

Product Code on the label.

531

Icons

OUT

1 2

ALM

1 2

MANUAL DISPLAY ACK

HOST MENU

FAST

1 st

Display

2 nd

Display

3 rd

Display

Location for identification label

Figure 2.1

531 Operator Interface

Keys

1st Display

• 5 digits, seven segments. Height is 15mm (0.6in).

• Normally displays the Process Variable (PV).

If station loses signal, “--------” displays.

2nd Display

• 9 characters, 14 segment alphanumeric. Height is 6mm (0.25in).

• Displays the CV output (OUT) or the setpoint (SP). To change the displayed value, press the DISPLAY key.

• When in configuration menus, displays the menu and parameter names

3rd Display

• 9 characters, 14 segment. Height is 6mm (0.25in).

• Displays user-selectable station name if no alarms are queued.

• Displays any error or alarm in two-second alternating messages.

• When in configuration menus, displays the parameter values.

ICONS:

ALM 1, ALM2: Indicates respective alarm(s) is/are active.

OUT 1, OUT2: Indicates respective output(s) is/are active.

531 User's Manual Chapter 2, Interface and Basic Operation

ALM

1

OUT

1

ALM

2

OUT

2

ALM

1 2

OUT

1 2

5


6

KEYS

MANUAL

HOST

DISPLAY

MENU

ACK

FAST

▲ o r

FAST

+ o r

FAST

+

▲

▲

▲

FAST

+

MENU

Press Key (s)

Transfers station from Host or

Automatic Mode to Manual Mode, or from Manual to Automatic.

Toggles between Host and either

Automatic or Manual Mode

(depending on validity of the PV).

Exits the configuration (set up) menus and returns station to operating mode.

Provides entry into the OPERA-

TION set up menu.

Illuminated Key

Station is in Manual Mode. When not illuminated, the station is in either Host or Automatic Mode.

531 is passing Host signal through.

Key does not light.

Acknowledges alarms.

Functions as a “shift” key or for use with other keys.

531 is in configuration (set up) mode.

An acknowledgable alarm exists.

Key does not light.

Increases or decreases the value or selection of the current parameter.

Keys do not light.

Changes parameter value or selection at a faster rate.

N/A

In Host or Manual Mode, provides entry into the other eight set up menus. When under configuration, advances from menu to menu.

N/A

NOTE:

Refer to Chapter 3, or Appendix 1 for details on menu, mode and parameter transitions

Chapter 2, Interface and Basic Operation 531 User's Manual


BASIC OPERATING PROCEDURES

To transfer from Host to Automatic Mode

1.

Press the HOST key once. The 531 will transfer to Automatic Mode as long as the PV input is valid (else, it transfers to Manual Mode).

2.

The HOST key and MANUAL key will be off.

3.

The 531 stops passing the Host signal, and transmits its own output that based on PID, with a bumpless transfer.

To transfer from Host to Manual Mode

1.

Press the MANUAL key. The 531 will transfer to Manual Mode.

2.

The HOST key will extinguish, and the MANUAL key will light.

3.

The 531 stops passing the Host signal, and transmits a manual output to the final control element. This will be a bumpless transfer.

To transfer from Automatic to Manual Mode

1.

When in Automatic Mode, press the MANUAL key.

2.

The MANUAL key will light.

3.

The 531 stops transmitting the PID output and transmits a manual output to the final control element. This will be a bumpless transfer.

To transfer from Automatic/Manual Mode to Host Mode

1.

Press the HOST key. The 531 will transfer to Host Mode as long as the CV signal is valid (otherwise, it remains in the previous mode).

2.

The 531 will stop transmitting its own output (CV) signal, and pass the signal from the Host device to the final control element. This will be a direct transfer.

3.

To provide a ramped transfer, the ramping rate (HOST RAMP) can be set in the OPERATION menu.

To change output values

1.

Press MANUAL key to shift to Manual Mode from Automatic or Host.

2.

The second display will display OUT%.

3.

Use

▲

and

▼

keys to change the output (CV) value.

To override security or reset the controller

1.

If someone attempts a locked operation, SECURITY appears in the 2nd display, and a security code prompt (0) appears in the 3rd display.

2.

Use

▲

and

▼

keys to select a code value. The value will be entered after two seconds of key inactivity.

• If no code was entered (value left at 0), SECURITY disappears and the station resumes operation.

• If the value is incorrect, INCORRECT appears in the 3rd display. After

2 seconds, the station prompts you to enter a new code.

• If the code is correct, CORRECT appears in the 3rd display. After two seconds, all displays clear and you have temporary access to all previously locked features. Security will automatically rearm (lock) the station once after one minute of key inactivity.

• If the correct Security Override Code is entered, RESET appears in the 3rd display. After two seconds, all displays clear and the stations functions are reset to their factory defaults (unlocked).

NOTE:

For more information on operating modes, see Chapter 6.

NOTE:

For more information on Security functions, see Chapter 6.

531 User's Manual Chapter 2, Interface and Basic Operation

7

8


NOTE:

Powering down the controller acknowledges/clears all latched alarms. When powering up, all alarms will be reset according to their power-up configuration

(see Chapter 6).

NOTE:

All alarms are internal alarms unless tied to an output relay in the set up mode.

ALARMS

IMPORTANT! Alarms can be used to provide warnings of unsafe conditions.

Therefore, all 531 operators must know how the alarms are configured, how to react to alarm conditions, and the consequences of acknowledging (noting and clearing) an alarm.

•

The 531 indicates alarms by:

Lighting icons

•

• Displaying messages; and

Lighting the ACK key, if an alarm is in an acknowledgeable state.

To acknowledge an alarm:

1.

Press the ACK key to acknowledge Alarm 1. This clears the alarm (and releases the relay, if applicable.

2.

Both the icon and message indicators disappear, and the relay (if applicable) changes state.

3.

If a second alarm is active and acknowledgeable, press the ACK key again to acknowledge Alarm 2.

Figure 2.2 shows the controller face during an alarm condition, and after the alarm has been acknowledged.

BEFORE

AFTER

531

531

OUT

1 2

ALM

1

OUT

1 2

Figure 2.2

Before and After Acknowledging an Alarm

MANUAL DISPLAY ACK

HOST

MENU

FAST

MANUAL DISPLAY ACK

HOST MENU

FAST

Latching Alarms

A latching alarm holds its alarm state even after the process leaves the alarm condition. This is useful for stations that will not be continuously monitored by an operator. A latching alarm can be configured to be acknowledgeable while in the alarm condition, OR only after the process leaves the alarm condition. 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 not acknowledgeable. In this case, the alarm is acknowledgeable only after the process has left the alarm condition. This is often referred to as a limit sequence.

For more on alarms, see Chapter 6.

Chapter 2, Interface and Basic Operation 531 User's Manual

Hardware

CHAPTER 3

HARDWARE CONFIGURATION

The 531 hardware configuration determines which outputs are available and the types of indicator signals that will be used.

Your station comes factory set with the following:

• All the specified modules and options installed (see product label and compare to Order Code in Chapter 1).

• Process variable and remote setpoint inputs set to accept a milliamp input.

NOTE:

If you would like your controller configured at the factory, please consult an application engineer.

CAUTION!

Static discharge will cause damage to equipment. Always ground yourself with a wrist grounding strap when handling electronics to prevent static discharge.

NOTE:

Your hardware configuration will influence the available set up options in Chapter 5.

• Relay outputs set to normally open

The locations of certain jumpers and modules on the printed circuit boards will allow different types of inputs and outputs to be connected to the stations. Figure 3.1 shows the position of these circuit boards inside the station.

To access these boards:

1.

With power off, loosen the two captive front screws with a Phillips screwdriver.

2.

Gently slide the chassis out of the case by pulling on the front face plate assembly at the bezel. Remove the two screws.

NOTE:

Any changes you make to the output modules will render the code on the product label invalid.

MICROCONTROLLER

BOARD

POWER SUPPLY

BOARD

Figure 3.1

Location of Printed Circuit Boards for

Hardware Configuration

OPTION

BOARD

531 User's Manual Chapter 3, Hardware Configuration

9

Hardware

Figure 3.2

Jumper Locations on

Microcontroller Board

Process Variable Indicator Type

The 531 will accept several different types of Process Variable Signals. You specify the type of signal by adjusting the PV jumper location on the Microcontroller Circuit Board, as shown in Figure 3.2. You will also need to set the particular sensor range in the software (Chapter 5).

V

MA

Voltage signal

Milliamp

TC t

TC s

RTD

Thermocouple with downscale burnout

Thermocouple with upscale burnout

RTD

EPROM

BATTERY

5-Pin Connector

Female 22-Pin Connector

Retransmitted (Remote) SP

Configuration

PV Input Jumper

Configuration


V

MA

TB2

V

MA

TC

TC

RTD

TB1

Figure 3.3

The Option Circuit Board, with Output 4

CAUTION!!

Do not change configuration of outputs

2, 3, and 4. Do not change position of jumpers J2 and J3.

Male 22-Pin

Connector

Output 4

4

Figure 3.4

The Power Supply Circuit Board, with Outputs 1 through 3

Male 22-Pin

Connector

Male 44-Pin

Connector

4-Pin Connector


Module

Retention

Plate over Outputs 1,2,3

3

2

1

Jumpers

NO and NC

10

Chapter 3, Hardware Configuration 531 User's Manual

Hardware

Setpoint Type (retransmitted)

You specify the type of retransmitted setpoint by adjusting the jumper location on the Microcontroller Board, as shown in Figure 3.2:

V

MA

Voltage signal

Milliamp signal (factory default)

Mechanical Relays

There is one output module socket on the Option Board (Figure 3.3), and three on the Power Supply Circuit Board (Figure 3.4). The position of the jumper next to each socket determines whether the relay is configured for Normally Open

(NO) or Normally Closed (NC). The output on the options board is always factory set to Normally Open (NO).

Only the Output 1 relay (if used) may be configured for normally open or normally closed. Do not make any changes to J2 and J3.

ACCESSING AND CHANGING JUMPERS

Jumper connectors either slip over adjacent pins, or have pins which insert into adjacent holes. “Changing the jumper” means moving the jumper connectors to alternate pins/holes.

•

Equipment needed:

Needle-nose pliers (optional)

•

• Phillips screwdriver (#2)

Wrist grounding strap

1.

With power off, loosen two captive front screws with a Phillips screwdriver.

2.

Slide the chassis out of the case by pulling on front face plate assembly at the bezel. Remove the two screws now. You will not need to disassemble the chassis to make these adjustments.

3.

Refer to Figures 3.2 and 3.4 to locate the jumper connector you want to change.

4.

With either your fingers or the needle nose pliers, pull the jumper connector straight up, being careful not to bend the pins (see Photo 4)

5.

Move the jumper connector over the desired location and press it straight down, making sure it is seated firmly. Repeat steps 3 and 4 for any other jumpers you wish to change.

6.

When you are ready to reassemble the unit, align the boards on 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 that there are no screws interfering with the case.

7.

Carefully insert and align screws. Tighten them until the bezel is seated firmly against the gasket. Do not overtighten.

CAUTION!!


4. REMOVE JUMPERS


11

Hardware

CAUTION!!


ADDING OR CHANGING OUTPUT MODULES

The 531 has provisions for four output modules. The units come factory configured with specified modules installed in appropriate locations. You can make field adjustments by properly removing and/or plugging the modules into the appropriate sockets.

Important Notes:

• Only the Output 1 relay (if used) may be changed.

• Output modules 2, 3 and 4, and Jumpers J2 and J3 must not be changed from their factory installation.

• Any output module with a sold state relay or analog module MUST have its jumper set at normally open (NO).

• Output 4 is always normally open (NO).

Three of the output sockets are located on the Power Supply Circuit Board. A fourth output socket is located on the Option Board.

Equipment needed:

•

•

•

Wrist grounding strap

Phillips screwdriver (#2)

Small flat blade screwdriver

• Wire cutters or scissors

1.

With power off, loosen two captive front screws with a Phillips screwdriver.

2.

Slide the chassis out of the case by pulling on front face plate assembly at the bezel. Remove the two screws now.

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. Take care not to break the clips or scratch the circuit board. See Photo 3.

The Microcontroller Board and Power Supply Board remain attached to the

Operator Interface Assembly by wired connectors.

4.

See Photo 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 to separate the larger two boards from the Option Board.

CAUTION!

Do not scratch the boards or bend the pins of the connectors.

12

3. PRY CLIPS

Chapter 3, Hardware Configuration

4. SEPARATE BOARDS

531 User's Manual

Hardware

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 (or scissors) as shown in Photo 5.

Always snip the tie wrap on top of the Retention Plate to prevent damage to the surface mount components.

6.

A disposable tie wrap holds Output module 4 (on the Option board) in place.

To remove the module, snip tie wrap like in Photo 6.

7.

Inspect each module before installation to make sure the pins are straight

(Figure 3.5). Align the pins with the socket holes and carefully insert the module. Press down to seat it firmly on the board (see Photo 7).

Figure 3.5

Output Module

5. REMOVE RETENTION PLATE

6. SNIP TIE WRAP

8.

Use new tie wraps to secure the Retention Plate and Output Module 4.

Failure to use the tie warps may result in the module loosening and eventual failure. All individually ordered modules come with tie wraps. Extra sets of tie wraps are available; order Part #535-

665.

9.

To reassemble the unit: 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. Also, check that the cable assemblies are not pinched.

10. Align the board assembly with the front face assembly, with the Option board at the bottom (see Figure 3.1). Reinstall the retention clips. Align the boards into the slots of the front face assembly and the clips will snap into place.

11. When you are ready to reassemble the unit, align the boards on the chassis with the top and bottom grooves on the case. 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.

12. Carefully insert and align screws. Tighten them until the bezel is seated firmly against the gasket. Do not overtighten.


For a step-by-step guide on mounting and wiring your 531 PID Backup Station, see Chapter 4.

7. ADD/CHANGE MODULE


13

Hardware

14

Chapter 3, Hardware Configuration 531 User's Manual

Mount/Wire

CHAPTER 4

MOUNTING AND WIRING

The 531 PID Backup Station is thoroughly tested, calibrated and “burned in” at the factory, so your station is ready to install. But before you begin, read this chapter carefully and take great care in planning your system. A properly designed system can help prevent problems such as electrical noise disturbances and dangerous conditions.

SYSTEM PLANNING

A. Consider the Noise Factor

• For improved electrical noise immunity, install the station as far away as possible from motors, relays and other similar noise generators.

• 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.

B. Wiring Practice Resources

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, (212) 705-7900.

WARNING!

To avoid electric shock, DO NOT connect AC power wiring at the source distribution panel until all wiring connections are complete.

To avoid shock hazard and reduced noise immunity for your system,

terminal 9 must be grounded.

MOUNTING THE STATION

A. Make the panel cutout

The station fits in a standard 1/4 DIN cutout. You may mount your station in any panel with a thickness from .06 to .275 inches (1.5 mm to 7.0

mm). See Figure 4.1 for dimensions.

If you make a mistake in the panel cutout, you can use a “Goof Plate”

(Repair Part #512-014).

B. Establish a waterproof seal

The station front face (keys, display, and bezel) are NEMA 4X rated

(waterproof).

Figure 4.1

531 Instrument Panel and Cutout

Dimensions

7.180 (182.37) OVERALL LENGTH

1.180 (29.97)

PANEL

PV2

OUT

1 2

ALM

1 2

3.770 (95.76)

3.622 (92.00) MIN.

3.653 (92.80) MAX.

FRONT

531 User's Manual

BEZEL

GASKET

6.000 (152.40)

SIDE

Chapter 4, Mounting and Wiring

CUTOUT

15

Mount/Wire

To obtain a waterproof seal between the station and the panel, make sure:

1.

The panel cutout is precise.

2.

You use a fresh gasket.

3.

The edge of the cutout is free from burrs and “waves”.

4.

The case of the station are centered in the cutout.

If you require a waterproof seal but have difficulty with these requirements, apply a bead of caulk or silicone sealant behind the panel around the perimeter of the case.

Bezel

Housing

Slide gasket on from this end.

MOUNTING BRACKET

(1 EA. SIDE)

Figure 4.2

Mounting Brackets

C. Mount station into panel:

The instrument enclosure mounting must be grounded according to CSA

Standard C22.2 No. 0.4.

You will need a long Phillips screw driver (#2).

1.

Place bezel gasket around the station case (starting at the back of the station). Then, slide the gasket against the back of the bezel.

2.

With the bezel gasket in place, insert the station into the panel cutout from the front of the panel.

3.

From behind the panel, insert the mounting clips (one on each side), as shown in Figure 4.2.

4.

Gradually tighten the mounting bracket screws.

5.

Tighten the screws securely and check bezel gasket to ensure a tight, even seal.

NOTE:

All wiring and fusing should conform to the National Electric Code and to any locally applicable codes.

WIRING THE 531 INPUTS

Figure 4.3 shows the rear terminal configurations for the 531. The actual instrument has only the top and bottom numbers of each column marked. Refer to this diagram for the following input and output wiring instructions.

IMPORTANT!!

When wiring the 531 terminals, DO NOT use alligator clips (they create an open circuit).

16

Chapter 4, Mounting and Wiring 531 User's Manual

Mount/Wire

4–20 mA

Control

Signal

–

I

P

+

LINE

1

AC Power

Optional Local Flag to HOST or Alarm

NEUTRAL

2

OUT 1–

3

OUT 1+

4

CV OUT –

5

NC

6

NC

CV OUT+

Any Final Control Element

7

8

9

EARTH

GND

10

NC

DIN

GND

17

DIN 1

18

11

12

13

NC

14

NC

NC

CV IN+

DIN 2

19

DIN 3

20

DIN 4

21

DIN 5

22

15

16

CV IN–

NC

N/A

23

N/A

24

25

NC

Optional Contact Inputs from HOST (if installed)

26

COMM–

27

COMM+

28

SP IND.–

29

SP. IND+

30

RTD 3rd

31

PV IND.–

32

PV IND.+

RSP from HOST

PV Sensor

4–20 mA Control Signal

HOST

PC, PLC, DCS

A special PC Board covers terminals 5,6,7,8,13,14,15, and 16.

Figure 4.3

531 Rear Terminals

A. AC Power

Terminals 1 and 2 are for power.Terminal 9 is earth ground.

POWER

1

2

9 GROUND

NOTE:

Use a 0.5 Amp, 250 V, fast-acting fuse in line with your AC power connection

(terminal 1).

B. Process Variable

The station accommodates the following types of process variable inputs:

Thermocouple, RTD , Voltage, Milliamp, Voltage and Millivolt.

1.

Thermocouple Input

Use terminals 31 and 32 as shown.

–

31

32

+

T/C Input

531 User's Manual Chapter 4, Mounting and Wiring

17

Mount/Wire

18

RTD INPUT 2-WIRE

Jumper wire

30

31

32

RTD

2.

RTD Input

For 2, 3 or 4 wire RTD, use terminals 30, 31 and 32 as shown.

RTD INPUT 3-WIRE

Same color

Third leg of RTD

30

31

32

RTD INPUT 4-WIRE

Third leg of RTD

30

31

32

Same color

DO NOT connect 4th leg Same color

3.

Voltage Input


4.

Milliamp Input -External Power Supply

Use terminals 31 and 32 with a 2-Wire transmitter.

VOLTAGE INPUT

31

32

–

+

–

+

Transmitter

MILLIAMP INPUT - EXT. POWER

– External +

Power Supply 31

32

– Transmitter +

C. Digital Inputs

1.

With a Switch

Use terminal 17 with the appropriate digital input terminal as shown.

2.

With a Relay (dry contact)

Signal-type relay is recommended. Use terminal 17 with the appropriate digital input terminal as shown.

3.

With an Open Collector (transistor)

11mA typical. 50

Ω

max. resistance. 50

Ω

max. loop resistance. Use terminals 17with the appropriate digital input terminal as shown.

SWITCH / RELAY

17

DIN GND

#

DIN #

OPEN COLLECTOR

17

DIN GND

#

DIN #

DIN 1

18

DIN 2

19

DIN 3

20

DIN 4

21

DIN 5

22


Mount/Wire

D. Remote Setpoint Indicator


28

–

29

+

–

+

Source

WIRING THE 531 OUTPUTS

• Output 1 is available for use as an ALARM or HOST FLAG with installation of a Mechanical Relay, Solid State Relay (Triac) module, or SSR

Drive.

• The 531 is factory configured with an Analog module in Output 2.

• The 531 is factory configured with Mechanical Relays in Outputs 3 and 4.

• The 531 cannot be wired for retransmission.

• A small PC board fits over rear terminals 5 to 8 and 13 to 16.

These instructions explain proper wiring of the 531 for any output module. If you do not know which module(s) have been installed in your station, compare the number on the product label with the Order Code on page 3.

To add or change position of jumper 1 or output module 1, refer to Chapter 3.

A. CV Output

• Use terminals 5 and 8 for CV Output as shown in Figure 4.4.

• Use terminals 14 and 15 for CV Input.

B. Mechanical Relay Output

• Use terminals 3 and 4 as shown in Figure 4.4.

• Jumper J1 can be set to normally open (NO) or normally closed (NC) as desired.

C. Solid State Relay (Triac) Output


• Jumper J1 must be set to normally open (NO).

D. DC Logic (SSR Drive) Output


• Jumper J1 must be set to normally open (NO).

WARNING!

DO NOT make any modifications to the factory setting of output modules 2, 3 and

4; this will place the product in an invalid and undefined state.

Figure 4.4

Output Wiring for the 531

CV OUTPUT

_

5

6

7

8

+

CV

MECHANICAL RELAY

Line Power

SSR (TRIAC)

Line Power

3

4

Load

3

4

-

+

-

Load

+

Recommend use of both MOV and snubber Recommend use of both MOV and snubber

DC LOGIC (SSR DRIVE)

3

4

_

+

_

+

Load

531 User's Manual Chapter 4, Mounting and Wiring

19

Mount/Wire

PC or other host

RS-485 port

531 Terminals

Twisted, shielded

Comm Ð

26

Comm +

27

To "Comm –" terminal of next Powers device

To "Comm +" terminal of next Powers device

The shield needs to be connected continuously but only tied to one ground at the host. Failure to follow these proper wiring practices could result in transmission errors and other communication problems.

Use a 60

Ω

to 100

Ω

terminating resistor connected to the two data terminals of the final device on the line.

Figure 4.5

Serial Communications Terminals

WIRING FOR SERIAL COMMUNICATIONS

You must have this option installed on your 531 in order to use serial communications. Refer to Figure 4.5.

• Use a twisted shielded pair of wires to connect the host and field units.

Belden #9414 foil shield has superior noise rejection characteristics. #8441 braid shield 22-gauge wire has more flexibility.

• The maximum recommended length of the RS 485 line is 4000 ft.

• Termination resistors are required at the host and the last device on the line. Some RS 485 cards/converters already have a terminating resistor.

We recommend using RS-232/RS-485 converter (prod. no. 500-485).


For a step-by-step guide on setting up the software features for your controller, see Chapter 5.

20


Software

CHAPTER 5

SOFTWARE CONFIGURATION

MODE OVERVIEW

Upon power up, as well as during “normal” operation, the 531 is in one of its operating modes - Host, Automatic or Manual.

The 531 also has a set up (configuration) mode that lets you access options for adjusting the operation and display of the station. “Set up” is divided into two groups; one for the first eight menus (as listed below), and another for the OPERATIONS menu by itself.

Figure 5.1 illustrates the relationships among the three operating modes and nine set up menus.

The 8 set up menus can by accessed only when the 531 is in Host or Manual

Mode. The OPERATIONS set up menu can be accessed when the 531 is in

Automatic, Host or Manual Mode.

AUTOMATIC operating mode

HOST or MANUAL operating modes

DISPLAY

or ACK to return to operating modes

MENU +

FAST

for other set up menus

DISPLAY

to return to operating modes

MENU for

Operations set up menu

OPERATIONS

1 set up menu

MENU + FAST

for other set up menus

8 set up menus

CONFIG.

LOCAL OUT.

PV INPUT

CUST. LINR.

RSP INPUT

ALARMS

SECURITY

SER. COMM.

MENU +

FAST

to move from menu to menu

Figure 5.1

Menu Flowchart for Set Up

531 User's Manual Chapter 5, Software Configuration

21

Software

Independent

Parameter

CONFIGURE

UNLOCKED

Dependent

Parameter

RSP TYPE

(D)

Figure 5.2

Independent vs. Dependent

Parameters

MENUS

A menu is a group of configuration control parameters. While in these set up menus, the name of the menu will appear in the 2nd display. The names of the different parameters within that menu group will then replace the menu name in the 2nd display. The values/options for each parameter will then appear in the 3rd display. Figure 5.1 displays the parts of the menu as used by this manual.

The (possible) menus for the 531 are:

•

OPERATIONS To set up special PID control parameters and make adjustments to the transition functions (among operating modes) of the station.

• CONFIG. To configure the input and output hardware assignments.

• LOCAL OUT. To configure the local output control.

• PV INPUT To configure the process variable.

• CUST. LINR To configure the custom linearization curve for the process variable.

• RSP INPUT To configure the remote set point.

• ALARMS To configure alarms.

• SECURITY To configure the security function.

• SER. COMM. To configure serial communications.

SMART MENUS

This chapter outlines, in sequence, all menus, parameters, and selections available for the 531. However, the “smart menu” feature of the station allows only those Menus and Parameters to appear that are relevant to your hardware and software configuration, i.e., parameters which do not apply to your

application will not appear on your station’s display.

• Parameters that apply to all configurations appear in this manual as a white on white box (Figure 5.2, left). These parameters are independent of your configuration.

• Parameters that depend on the configuration of the individual station appear as a black on white box (Figure 5.2, right).

Changing one parameter’s selection (or value) may affect another parameter.

Refer to the section on the PV INPUT menu for an example on how this can affect your low and high range values.

22

Chapter 5, Software Configuration 531 User's Manual

Software

SOFTWARE CONFIGURATION PROCEDURES

On the bottom of each page is a guide to the keypad, to use during your configuration.

To access the 8 set up menus

1.

Hold down the FAST key and press MENU. (see Figure 5.3). The MENU key will illuminate. The first Menu, CONFIG., appears alone in the 2nd display.

2.

Press FAST + MENU to advance to the next menu. The menu name will appear in the 2nd display.

To access the OPERATIONS set up menu

1.

Press MENU. The MENU key will illuminate. OPERATION will appear in the 2nd display.

To advance through parameters and select a parameter value

1.

When you reach your chosen menu, press MENU. The first parameter of this menu appears in the 2nd display, replacing the menu name. The first values/selection for the particular parameter appears in the 3rd display.

2.

Press

▲

or

▼

, with or without the FAST key.

3.

Press MENU to advance to next parameter.

To return to operating mode from configuration

1.

Press the DISPLAY key. The station will return to the operating mode.

MENU

FAST

MENU

Figure 5.3

Keys to Enter and Move through Set

Up Mode

WARNING!!

Scrolling through the choices to make selections will affect the operation of the instrument since changes to parameter selections occur in

"real time" or immediately.

DO NOT MAKE ANY CHANGES DURING ON LINE OPERATION!

Escape to operating mode

DISPLAY

Next parameter

MENU

531 User's Manual

Next menu

FAST

+

MENU

Chapter 5, Software Configuration

Next value

▼ or

▲

23

Software

24

Chapter 5, Software Configuration 531 User's Manual

Software

GUIDE TO SET UP PARAMETERS

Only parameters and selections relevant to your hardware and other software selections will appear on your station.

• Parameter Value

(R)

Parameter Range

(D)

Default Setting

CONFIG.

For configuring the input and output hardware assignments.

1.

LOST HOST

Selects the type of local backup if 531 loses the host CV signal.

•

• MAN. OUT1

MAN. OUT2

• MAN. LAST

(D)

AUTO.LOCAL

Switch to Manual Mode, use preset output MAN. OUT1


Go to Manual Mode using the last known output

Go to Automatic (PID)Mode

• AUTO.TRACK

Go to Automatic (PID)Mode using last PV as the local SP

2.

HOST.RESTR.

Selects the 531 mode upon host CV restoration.

• LOCAL

(D)

HOST MODE

Remain in Manual (or Automatic) Mode

Go to Host Mode

3.

CONTACT 1

•

•

Defines the operation of the 1st digital input.

MAN. LAST Switch to Local Manual Mode, use last output

MAN. OUT1 Switch to Manual Mode, use preset output MAN. OUT1

•

•

•

•

•

•

•

•

•

MAN. OUT2

ALARM ACK.

UP KEY

DOWN KEY

COMM.ONLY

DISP. KEY

MENU KEY

FAST KEY

RST.INHBT.

•

•

• REMOTE SP

LOCAL SP

•

(D)

AUTO.LOCAL

HOST MODE

WATCHDOG


Acknowledge alarms

Remote

▲

key

Remote

▼

key

Make status readable through communications

Remote DISPLAY key

Remote MENU key

Remote FAST key

Inhibits PID reset action

Selects the Remote SP for Automatic Mode

Selects the Local SP for Automatic Mode

Go to Automatic Mode

Go to Host Mode

Monitors the Host device for failure.

CONFIG

LOST HOST

AUTO.LOCAL

HOST.RESTR.

HOST

CONTACT1

AUTO.LOCAL

NOTE:

Refer to Chapter 6 for more on the

Watchdog Monitor.


DISPLAY

Next parameter

MENU

531 User's Manual

Next menu

FAST

+

MENU

Chapter 5, Software Configuration

Next value

▼ or

▲

25

Software

CONFIG

CONTACT 2

MAN.LAST

CONTACT 3

LOCAL SP

4.

CONTACT 2

Defines the operation of the 2nd digital input.

(D)


•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

MAN. OUT1

MAN. OUT2

ALARM ACK.

UP KEY

DOWN KEY

COMM.ONLY

DISP. KEY

MENU KEY

FAST KEY

RST.INHBT.

REMOTE SP

LOCAL SP

AUTO.LOCAL

HOST MODE

WATCHDOG



Acknowledge alarms

Remote

▲

key

Remote

▼

key



Remote MENU key

Remote FAST key



Selects the Local SP for Automatic Mode

Go to Automatic Mode

Go to Host Mode

Monitors the Host device for failure

5.

CONTACT 3

•

•

•

•

•

•

Defines the operation of the 3rd digital input.

MAN. LAST

MAN. OUT1

MAN. OUT2

ALARM ACK.

UP KEY

DOWN KEY

Switch to Local Manual Mode, use last output



Acknowledge alarms

Remote

▲

key

Remote

▼

key

•

•

•

•

• COMM.ONLY

DISP. KEY

MENU KEY

FAST KEY

•

•

• RST.INHBT.

REMOTE SP

•

(D)

LOCAL SP

AUTO.LOCAL

HOST MODE

WATCHDOG



Remote MENU key

Remote FAST key





Go to Host Mode



DISPLAY

26

Next parameter

MENU

Next menu


FAST

+

MENU

Next value

▼

or

▲

531 User's Manual

6.

CONTACT 4

•

Defines the operation of the 4th digital input.


•

•

•

•

•

•

•

•

•

•

•

•

• MAN. OUT1

MAN. OUT2

•

(D)

ALARM ACK.

UP KEY

DOWN KEY

COMM.ONLY

DISP. KEY

MENU KEY

FAST KEY

RST.INHBT.

REMOTE SP

LOCAL SP

AUTO.LOCAL

HOST MODE

WATCHDOG



Acknowledge alarms

Remote

▲

key

Remote

▼

key



Remote MENU key

Remote FAST key





Go to Host Mode


7.

CONTACT 5

•

•

•

•

•

•


MAN. LAST

MAN. OUT1

MAN. OUT2

ALARM ACK.

UP KEY

DOWN KEY

Switch to Local Manual Mode, use last output



Acknowledge alarms

Remote

▲

key

Remote

▼

key

•

•

•

•

• COMM.ONLY

DISP. KEY

MENU KEY

FAST KEY

•

•

•

• RST.INHBT.

REMOTE SP

LOCAL SP

AUTO.LOCAL

(D)

HOST MODE

WATCHDOG



Remote MENU key

Remote FAST key





Go to Host Mode


8.

WATCHDOG

Defines function of the watchdog contact(s) for monitoring the Host.

•

(D)

DISABLED

ENABLED

Software

CONFIG

CONTACT 4

ALARM ACK

CONTACT 5

HOST MODE

WATCHDOG

DISABLED


DISPLAY

Next parameter

MENU

531 User's Manual

Next menu

FAST

+

MENU


Next value

▼ or

▲

27

Software

CONFIG.

LINE FREQ.

60 Hz

OUTPUT 1

OFF

PID ACTION

REVERSE

STN. NAME

BYPASSER

LOCAL OUT.

AUTO.LO.LIM.

0%

AUTO.HI.LIM.

100%

MAN. OUT1

0.0%

MAN. OUT2

100.0%


DISPLAY

9.

LINE FREQ.

Specifies the power source frequency.

(D)

60 Hz

• 50 Hz

10. OUTPUT 1

Defines the function of the 1st output.

(D)

OFF

• ALARM

• COMM.ONLY

Deactivates output

(Digital only)

Output addressable only through communications

11. PID.ACTION

•

Select the PID control action.

DIRECT

(D)

REVERSE

12. STN. NAME

Allows you to enter a nine character message to name the station. To use:

The first character of the 3rd display will be flashing. Use the

▲

and

▼

keys to scroll through characters. Press FAST to enter the selection and move to next digit. Press MENU to advance to next parameter.

(D)

BYPASSER

LOCAL OUT.

To configure the local output control.

1.

AUTO.LO.LIM.

Selects how low the Automatic PID output can be adjusted.

(R)

0% to 100%

(D)

0%

2.

AUTO.HI.LIM.

Selects how high the Automatic PID output can be adjusted.

(R)

0% to 100%

(D)

100%

3.

MAN. OUT1

Selects the Manual Mode preset output #1.

(R)

–5.0% to 105.0%

(D)

0.0%

4 MAN. OUT2

Selects the Manual Mode preset output #2.

(R)

–5.0% to 105.0%

(D)

100.0%

Next parameter

MENU

Next menu

FAST

+

MENU

Next value

▼

or

▲

28


531 User's Manual

Software

LOCAL OUT.

5.

PWR.UP:MODE

Selects the power-up mode for the 531.

•

•

MANUAL

HOST MODE

Manual Mode

Host Mode

(D)

LAST MODE

• AUTO.LOCAL

Automatic Mode (must have a valid PV signal )

6.

MAN. PWR.UP

Determines the output percentage when the 531 powers up in Manual

Mode .

(R)

–0.5% to 105%

(D)

LAST OUT

PV INPUT

For configuring the process variable (PV) input. The whole menu appears only if PV indicator is enabled.

1.

PV TYPE

Selects the particular sensor or input range.

F

OR

T/C I

NPUT

:

(D) J T/C

• E T/C

• K T/C

• B T/C

• N T/C

• R T/C

• S T/C

• T T/C

• W T/C

• W5 T/C

• PLAT.II T/C

F

OR

RTD I

NPUT

:

(D) DIN RTD

• JIS RTD

• SAMA RTD

F

OR

V

OLTAGE

I

NPUT

:

(D) 1-5 V

• 0-5 V

• 0-10 mV

• 0-30 mV

• 0-60 mV

• 0-100 mV

• +/–25 mV

F

OR

C

URRENT

(

M

A)

NPUT

:

(D) 4-20 mA

• 0-20 mA

2.

DEG. F/C/K

Selects the temperature unit if using a thermocouple or RTD.

(D)

FAHR.

• CELSIUS

• KELVIN

3.

DECIMAL

Specifies the decimal point position.

F

OR

V/

M

A I

NPUT

:

(D) XXXXX

• XXXX.X

F

OR

RTD I

NPUT

:

(D) XXXXX

• XXXX.X

• XXX.XX

• XX.XXX

• X.XXXX


DISPLAY

Next parameter

MENU

Next menu

FAST

+

MENU

531 User's Manual


PWR.UP:MODE

LAST MODE

MAN. PWR.UP

LAST OUT

PV INPUT

PV TYPE

(D)

DEG. F/C/K

FAHR.

DECIMAL

XXXXX

Next value

▼ or

▲

29

Software

PV INPUT

LINEARIZE

NONE

LOW RANGE

(D)

HI RANGE

(D)

FILTER

0

PV OFFSET

0

PV GAIN

1.000

PV BREAK

0%

PV.RESTORE

AUTO.LOCAL

4.

LINEARIZE

Specifies how to linearize the input. For V/mA Inputs only (Thermocouple and RTD inputs are automatically linearized).

(D)

NONE Normal linearization (2 point)

•

•

SQR. ROOT

CUSTOM

Square root linearization

15-point custom linearization curve

5.

LOW RANGE

Specifies the engineering unit value corresponding to the lowest input value, e.g. 4 mA. For V/mA input only.

(R)

–9999 to 99999 (Maximum is HI RANGE)

(D)

Dependent upon the input selection

6.

HI RANGE

Specifies the engineering unit value corresponding to the highest input value, e.g. 20 mA. For V/mA input only.

(R)

–9999 to 99999 (Minimum is LOW RANGE)

(D)

Dependent on the input selection

7.

FILTER

Defines the setting in seconds for the low pass input filter.

(R)

0 to 120

(D)

0

8.

PV OFFSET

Defines the offset to the process variable in engineering units.

(R)

–9999 to 99999

(D)

0

9.

PV GAIN

Defines the gain to the process variable. For V/mA input only.

(R)

0.100 to 10.000

(D)

1.000

10. PV BREAK

Determines the manual output value if the PV input is broken (station switches to Manual Mode).

(R)

–5% to 105%

(D)

0%

11. PV.RESTORE

Determines manual output (source) upon PV restoration.

• MAN. LAST Maintain the last output from Manual Mode

(D)

AUTO.LOCAL

Return to Automatic Control (and output)


DISPLAY

30

Next parameter

MENU

Next menu


FAST

+

MENU

Next value

▼

or

▲

531 User's Manual

Software

CUST. LINR.

Defines a custom linearization curve for the process variable input. The curve may be either ever increasing or ever decreasing. However, plateaus or flat spots (adjacent points with the same PV) are allowable.

The curve has 15 points. Points 1 and 15 are fixed to the low and high end of the input range (respectively) and only require you to set a corresponding

PV value. Points 2 through 14 (the X points) require you to set both the input and PV values.

NOTE: Changing the PV TYPE parameter in the PV INPUT menu clears the custom linearization curve and resets the linearization type to NORMAL.

You must again select CUSTOM for the linearization type and reenter your curve, adjusted for the new input type.

1.

1ST. INPUT

Specifies the input signal for to the first point.

(D)

The low end of the appropriate input range (e.g. 4.00 mA)

2.

1ST. PV

Specifies the engineering unit value for to the first point.

(R)

–9999 to 99999

(D)

0

3.

XTH. INPUT

Specifies the input signal for to the XTH point (X is 2 to 14) .

(R)

Any value greater than the first input

(D)

The low end of the appropriate input range (e.g. 4.00 mA)

4.

XTH. PV

Specifies the engineering unit value for to the XTH point (X is 2 to 14).

(R)

–9999 to 99999

(D)

0

You do not have to use all 15 points. Whenever the XTH INPUT becomes the high end of the input range, that will be the last point in the table.

5.

15TH. INPT.

Specifies the input signal for to the 15th point.

(R)

–9999 to 99999

(D)

The high end of the appropriate input range (e.g. 20.00 mA)

6.

15TH. PV

Specifies the engineering unit value for to the 15th point.

(R)

–9999 to 99999

(D)

0

CUST. LINR.

1ST. INPUT

(D)

1ST. PV

0

XTH. INPUT

(D)

XTH. PV

0

15TH. INPT.

(D)

15TH. PV

0


DISPLAY

Next parameter

MENU

531 User's Manual

Next menu

FAST

+

MENU


Next value

▼ or

▲

31

Software

RSP INPUT

RSP TYPE

(D)

RSP LOW

0

RSP HIGH

1000

R

SP OFFSET

0

RSP GAIN

1.000

TRACKING

YES

R

SP.RESTOR.

REMOTE SP

RSP INPUT

For configuring the remote setpoint (if enabled).

1.

RSP TYPE

Specifies type of input signal that will be used for the setpoint indicator.

I

F THE JUMPER IS IN THE M

A

POSITION

(D) 4-20 mA

• 0-20 mA

I

F THE JUMPER IS IN THE

V

POSITION

:

(D) 1-5 V

• 0-5 V

2.

RSP LOW

Specifies the engineering unit value corresponding to the lowest setpoint indicator input value, e.g. 4 mA.

(R)

–9999 to 99999

(D)

0

3.

RSP HIGH

Specifies the engineering unit value corresponding to the highest setpoint indicator input value, e.g. 20 mA.

(R)

–9999 to 99999

(D)

1000

4.

RSP.OFFSET

Defines the offset to the remote setpoint in engineering units.

(R)

–9999 to 99999

(D)

0

5.

RSP GAIN

Defines the gain to the remote setpoint.

(R)

0.100 to 10.000

(D)

1.000

6.

TRACKING

Determines whether or not the local SP will track the remote SP (upon RSP break, or switch to local from remote SP).

(D)

YES

• NO

7.

RSP.RESTOR.

Determines RSP (source) upon RSP input restoration.

• LOCAL SP

(D)

REMOTE SP


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ALARMS

For configuring alarms.

1.

ALM. TYPE:1

•

•

•

This defines the type of alarm for alarm 1.

•

•

•

•

(D)

OFF

• LOCAL

HIGH PV

LOW PV

RATE

BAND

Deactivates the first alarm

Causes an alarm when in local control (Host flag)

High alarm based on the process variable

Low alarm based on the process variable

Selects a rate-of-change alarm

DEVIATION

HIGH CV

LOW CV

High alarm based on the control value

Low alarm based on the control value

2.

ALARM SP:1

Specifies the alarm set point for alarm 1.

F

OR

ALM. TYPE:1 =

RATE HIGH CV

OR

LOW CV A

NY

O

THER

T

YPE

(R) –9999 to 99999 units (R) 0.0–100.0% (R) The PV range

(D) 0 (D) 0.0% (D) Dependent on

LOW RANGE value

3.

DEADBAND:1

Defines the deadband for alarm 1.

F

OR

ALM. TYPE:1 =

HIGH CV

OR

LOW CV

(R) 0.1%–100.0%

(D) 0.2%

A

NY

O

THER

T

YPE

(R) 1 to 9999

(D) 2

4.

RELAY:1

Defines the state of the relay in the alarm condition for alarm 1.

(D)

RELAY ON

• RELAY OFF

5.

LATCHING:1

Defines the latching sequence of alarm 1.

(D)

LATCH

• NO LATCH

6.

ACK.:1

•

Defines whether alarm 1 may be acknowledged.

(D)

ENABLED Allows the alarm to be acknowledged

DISABLED Prevents existing alarm from being acknowledged


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ALARMS

ALM. TYPE:1

OFF

ALARM SP:1

(D)

DEADBAND:1

2

RELAY:1

RELAY ON

LATCHING:1

LATCH

ACK.:1

ENABLED

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33

Software

ALARMS

POWER UP:1

NORMAL

MESSAGE:1

ALARM 1

ALM. TYPE:2

OFF

ALARM SP:2

(D)

DEADBAND:2

2

RELAY:2

RELAY ON

7.

POWER UP:1

Defines how alarm 1 will be treated on power up.

(D)

NORMAL Alarm depends on process variable

•

•

ALARM

DELAYED

Power up in alarm regardless of PV

Must leave alarm condition and reenter before activating the alarm

8.

MESSAGE:1

Allows you to enter a nine character message associated with alarm 1. The first character of the 3rd display will be flashing. To enter message, press arrow keys to scroll through character set. Press FAST to enter the selection and move to next digit. Press MENU to advance to next parameter.

(D)

ALARM 1

9.

ALM. TYPE:2

•

•

•

•

•

•

•

•

This defines the type of alarm for alarm 2.

(D)

OFF Deactivates the first alarm

LOCAL

HIGH PV

LOW PV

RATE

BAND

DEVIATION

HIGH CV

LOW CV

Causes an alarm when in local control (Host flag)

High alarm based on the process variable

Low alarm based on the process variable

Selects a rate-of-change alarm

High alarm based on the control value

Low alarm based on the control value

10. ALARM SP:1


F

OR

ALM. TYPE:2 =

RATE HIGH CV

OR

LOW CV A

NY

O

THER

T

YPE

(R) –9999 to 99999 units (R) 0.0–100.0%

(D) 0 (D) 0.0%

(R)

The PV range

(D)

Dependent on

LOW RANGE value

11. DEADBAND:2


F

OR

ALM. TYPE:2 =

HIGH CV

OR

LOW CV

(R) 0.1%–100.0%

(D) 0.2%

A

NY

O

THER

T

YPE

(R) 1 to 9999

(D) 2

12. RELAY:2

Defines the state of the relay in the alarm condition for alarm 2.

(D)

RELAY ON

• RELAY OFF


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ALARMS

13. LATCHING:2


(D)

LATCH

• NO LATCH

14. ACK.:2


(D)

ENABLED

• DISABLED

Allows the alarm to be acknowledged

Prevents the alarm acknowledgment while alarm condition exists.

15. POWER UP:2

•

•


(D)

NORMAL Alarm depends on process variable

ALARM

DELAYED

Always power up in alarm regardless of process variable

Must leave alarm condition and reenter before activating the alarm

16. MESSAGE:2

Allows you to enter a nine character message associated with alarm 2. The first character of the 3rd display will be flashing. To enter message, press arrow keys to scroll through character set. Press FAST key to enter the selection and move to next digit. Press MENU key to advance to next parameter.

(D)

ALARM 2

17. RATE TIME

Defines the time period (in seconds) over which a rate-of-change alarm condition will be determined.

(R)

1 to 3600

(D)

5

SECURITY

For configuring the security function.

1.

SEC. CODE

Defines security code for temporarily unlocking the station.

(R)

–9999 to 99999

(D)

0

2.

HOST KEY

Defines lockout status of the HOST key (mode changes via the HOST key).

(D)

UNLOCKED

• LOCKED


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L

ATCHING:2

LATCH

ACK.:2

ENABLED

POWER UP:2

NORMAL

MESSAGE:2

ALARM 2

RATE TIME

5

SECURITY

SEC. CODE

0

HOST KEY

UNLOCKED

Next value

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35

Software

SECURITY

MAN. KEY

UNLOCKED

MAN. OUT

UNLOCKED

LOCAL SP

UNLOCKED

ALARM ACK

UNLOCKED

OPERATION

UNLOCKED

CONFIGURE

UNLOCKED

SER. COMM.

STATION

1

3.

MAN. KEY

Defines lockout status of the MANUAL key (mode changes via the

MANUAL key).

(D)

UNLOCKED

• LOCKED

4.

MAN. OUT

Defines lockout status of the changes to the local output (via the

▲

and

▼ keys).

(D)

UNLOCKED

• LOCKED

5.

LOCAL SP

Defines lockout status of the changes to the local setpoint (via the

▲

and

▼

keys).

(D)

UNLOCKED

• LOCKED

6.

ALARM ACK.

Defines lockout status of the ACK key (alarm acknowledgment).

(D)

UNLOCKED

• LOCKED

7.

OPERATION

Defines lockout status of the OPERATION menu parameters.

(D)

UNLOCKED

• LOCKED

8.

CONFIGURE

Defines lockout status of the other 8 configuration parameters.

(D)

UNLOCKED

• LOCKED

SER. COMM.

For configuring the serial communications features.

1.

STATION

Defines the unit’s station address.

(R)

1 to 99

• OFF Disables the communications function.

(D)

1


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2.

BAUD RATE

•

Defines the baud rate.

1200 BPS

•

•

2400 BPS

4800 BPS

(D)

9600 BPS

• 19200 BPS

3.

CRC

Defines whether CRC (cyclic redundancy check) is being calculated.

(D)

YES

• NO

OPERATION

For modifications to the transition functions. Use the same PID parameters

as your HOST device.

1.

PROP. BAND

Defines the proportional band for the PID set.

(R)

0.1% to 999.0%

(D)

50.0%

2.

RESET

Defines the integral time for the PID set.

(R)

1 to 9999 seconds/repeat

(D)

30

3.

RATE

Defines the derivative time for the PID set.

(R)

0 to 600 seconds

(D)

1

4.

LOADLINE

Defines the loadline (manual reset) for the PID set.

(R)

0% to 100%

(D)

0%

5.

SP SOURCE

Selects a local or remote setpoint.

(D)

LOCAL SP

• REMOTE SP (only for 2nd input V or mA)

Software

SER. COMM.

BAUD RATE

9600

CRC

YES

OPERATION

PROP. BAND

50.0%

RESET

20

RATE

1

LOADLINE

0%

SP SOURCE

LOCAL SP


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37

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OPERATION

MAN. RAMP

OFF

HOST RAMP

OFF

6.

MAN. RAMP

Determines ramping value for output to a defined Manual output value

(MAN. OUT1, MAN. OUT2 or PV BREAK) upon transfer to Manual Mode.

(R)

0.1% to 999.9% per minute

(D)

OFF

7.

HOST RAMP

Determines ramping value for output to the Host Mode CV value, upon transfer to Host Mode.

(R)

0.1% to 999.9% per minute

(D)

OFF


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PARAMETER VALUE CHARTS

Record the values for the various configuration menu parameters on the charts in this section.

NOTE:

You may want to photocopy these pages instead of entering the values on the master sheets.

CONFIG.

4.

5.

6.

7.

For configuring the input and output hardware assignments.

1.

LOST HOST Selects the type of local backup when host CV breaks.

2.

3.

HOST. RESTR.

CONTACT 1

Selects the 531 mode upon host CV restoration.

Defines the operation of the 1st digital input.

CONTACT 2

CONTACT 3

CONTACT 4

CONTACT 5

Defines the operation of the 2nd digital input.

Defines the operation of the 3rd digital input.



8.

9.

WATCHDOG

LINE FREQ.

10.

OUTPUT 1

11.

PID.ACTION

12.

STN. NAME

Defines function of Host watchdog monitor.

Specifies the power source frequency.

Defines the function of the 1st output.

Select the PID control action.

Specifies a nine character message to name the station.

LOCAL OUT.

4

5.

6.

To configure the local output control.

1.

AUTO.LO.LIM.

Selects low limit for adjusting the Automatic PID output.

2.

3.

AUTO.HI.LIM.

MAN. OUT1

Selects high limit for adjusting the Automatic PID output.

Selects the Manual Mode preset output #1.

MAN. OUT2

PWR.UP:MODE

MAN. PWR.UP

Selects the Manual Mode preset output #2.

Selects the power-up mode for the 531.

Determines output % for in Manual Mode power up.

531 User's Manual


39

Software

PV INPUT

4.

5.

6.

7.

For configuring the process variable (PV) input. The whole menu appears only if PV indicator is enabled.

1.

PV TYPE Selects the particular sensor or input range.

2.

3.

DEG. F/C/K

DECIMAL

Selects the temperature unit for a T/C or RTD.

Specifies the decimal point position.

LINEARIZE

LOW RANGE

HI RANGE

FILTER

Specifies how to linearize the input.

Specifies the lowest input value (engineering units).

Specifies the highest input value (engineering units).

Defines setting in seconds for the low pass input filter.

8.

9.

PV OFFSET

PV GAIN

10.

PV BREAK

11.

PV.RESTORE

Defines offset to the PV in engineering units.

Defines gain to the PV.

Determines the manual output if PV input breaks.

Determines manual output (source) upon PV restoration.

40


531 User's Manual

CUST. LINR.

4.

5.

6.

7.

Defines a custom linearization curve for the process variable input.

1.

1ST. INPUT Specifies the input signal for the 1st point.

2.

3.

1ST. PV

2ND. INPUT

Specifies the engineering unit value for the 1st point.

Specifies the input signal for the 2nd point.

2ND. PV

3RD. INPUT

3RD. PV

4TH. INPUT

Specifies the engineering unit value for the 2nd point.

Specifies the input signal for the 3rd point.

Specifies the engineering unit value for the 3rd point.

Specifies the input signal for the 4th point.

8.

9.

4TH. PV

5TH. INPUT

10.

5TH. PV

11.

6TH. INPUT

12.

6TH. PV

13.

7TH. INPUT

14.

7TH. PV

15.

8TH. INPUT

Specifies the engineering unit value for the 4th point.








16.

8TH. PV

17.

9TH. INPUT

18.

9TH. PV

19.

10TH. INPT.

20.

10TH. PV

21.

11TH. INPT.

22.

11TH. PV

23.

12TH. INPT.

24.

12TH. PV

25.

13TH. INPT.

26.

13TH. PV

27.

14TH. INPT.

28.

14TH. PV

29.

15TH. INPT.

30.

15TH. PV
















531 User's Manual


Software

41

Software

RSP INPUT

4.

5.

6.

7.

For configuring the remote setpoint (if enabled).

1.

RSP TYPE Specifies type of input signal for the remote SP.

2.

3.

RSP LOW

RSP HIGH

Lowest (engineering unit) value for the remote SP.

Highest (engineering unit) value for the remote SP.

RSP.OFFSET

RSP GAIN

TRACKING

RSP.RESTOR.

Defines the offset to the remote SP in engineering units.

Defines the gain to the remote setpoint.

Determines whether or not local SP tracks remote SP.

Determines SP (source) upon RSP input restoration.

ALARMS

4.

5.

6.

7.

For configuring alarms.

1.

ALM. TYPE:1

2.

3.

ALARM SP:1

DEADBAND:1

RELAY:1

LATCHING:1

ACK.:1

POWER UP:1

8.

9.

MESSAGE:1

ALM. TYPE:2

10.

ALARM SP:2

11.

DEADBAND:2

12.

RELAY:2

13.

LATCHING:2

14.

ACK.:2

15.

POWER UP:2

16.

MESSAGE:2

17.

RATE TIME

Defines the type of alarm for alarm 1.



Defines the state of the relay for alarm 1.




A nine character message for alarm 1.

Defines the type of alarm for alarm 2.



Defines the state of the relay for alarm 2.




A nine character message for alarm 2.

Defines the time period for a rate-of-change alarm.

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531 User's Manual

Software

SECURITY

4.

5.

6.

7.

8.

For configuring the security function.

1.

SEC. CODE Security code for temporarily unlocking the station.

2.

3.

HOST KEY

MAN. KEY

Lockout status of the HOST key.

Lockout status of the MANUAL key.

MAN.OUT

LOCAL SP

ALARM ACK.

OPERATION

CONFIGURE

Lockout status of the changes to the local output.

Lockout status of the changes to the local setpoint.

Lockout status of the ACK key.

Lockout status of the OPERATION Menu parameters.

Lockout status of the other 8 configuration parameters.

SER. COMM.

For configuring the serial communications features.

1.

STATION Defines the unit’s station address.

2.

3.

BAUD RATE

CRC

Defines the baud rate.

Defines whether CRC is being calculated.

OPERATION

4.

5.

6.

7.

For modifications to the transition functions. Use the same PID parameters as your HOST device.

1.

PROP. BAND Defines the proportional band for the PID set.

2.

3.

RESET

RATE

Defines the integral time for the PID set.

Defines the derivative time for the PID set.

LOADLINE

SP SOURCE

MAN.RAMP

HOST RAMP

Defines the loadline (manual reset) for the PID set.

Selects a local or remote setpoint.

Determines ramping for output to Manual output value.

Determines ramping for output to the Host Mode CV.

531 User's Manual


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Software

44


531 User's Manual

Applications

CHAPTER 6

531 APPLICATIONS

The 531 has a variety of user-programmable control features and capabilities.

This chapter describes how to apply them.

NOTE:

Available capabilities depend upon the hardware option you specified and ordered.

SECTION .............................................................................................................. PAGE

531 Operation ................................................................................. 45

Alarms ............................................................................................ 46

Digital Inputs ................................................................................... 50

Watchdog Monitor .......................................................................... 51

Process Variable and Setpoint ........................................................ 51

Input Linearization .......................................................................... 53

Ramp to a Control Value ................................................................. 54

Security .......................................................................................... 55

Process Variable Reading Correction ............................................. 56

Serial Communications ................................................................... 56

531 OPERATION

The 531 PID Backup Station provides PID based control backup for critical control loops. It is normally installed between a Host device and final control element.

The Host device may be a PLC, DCS or single loop controller (SLC). The final control element may be a valve actuator, positioning device, power control unit for an electric heating element, pump or other control device. The control signal must always be a 4-20mA proportional signal.

Host Mode (Default Mode)

• The HOST key is lit.

• In Host Mode, the 531 is transparent to the control loop; it passes the control signal from the Host device without any degradation.

• The 531 constantly monitors the CV and uses the last good signal as a potential

CV for the Automatic Mode.

• The 531 can be removed from the case without disrupting the Host signal; it is not a point of failure.

• The 531 switches to Host Mode due to:

Return of the Host signal

Keypad selection

Closure of a digital contact; or

Commands through the RS-485 port.

• Upon return of the Host signal, the 531 can be programmed to

Return control to the Host Mode immediately;

Ramp to the new CV at a predetermined rate; or

Remain in the current mode, where the operator can determine whether or not the Host signal is valid.

• The operator can modify the local SP using the

▲

and

▼

keys.

• The operator can enter all the configuration menus.

NOTE:

In this chapter, the following abbreviations are used:

CV - Control signal

SP - Set point

PV - Process variable


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45

Applications

Automatic Mode

• Neither the HOST nor MANUAL keys are lit.

• The 531 switches to Automatic (PID) Mode due to:

Loss of the Host signal

Keypad selection



• Upon switching to Automatic Mode, the 531 generates a control signal based on PID control.

• The 531 executes a bumpless transfer to the new CV while in PID mode

(no ramping needed).


▲

and

▼

keys.

• The operator can only enter the OPERATION menu (other configuration menus are disabled).

Manual Mode

• The MANUAL key is lit.

• The 531 switches to Manual Mode due to:

Loss of the Host signal and PV input

Keypad selection



• In Manual Mode, the 531 can go to a predetermined output. The 531 can also be set to ramp the last Host signal to the new output.

• The operator can modify the CV signal using the

▲

and

▼

keys.


▲

and

▼ keys.

• The operator can enter all the configuration menus.

NOTE:

Refer to Chapter 4 for information on wiring for alarms.

NOTE:

Refer to “Alarm Operation” in

Chapter 2 for information on operating alarms.


DISPLAY

ALARMS

The 531 has 2 alarms available. It indicates alarm conditions by:

• Lighting up the alarm icon(s).

• Displaying a custom message in the 3rd display

• Illuminating the ACK key if the alarm is acknowledgeable.

Each alarm can be assigned one of 6 different types. Also, by adding an output module, one of the alarms can be tied to a relay output. To assign an alarm:

1.

Press FAST + MENU to toggle to the ALARM menu.

2.

Press MENU to select the first parameter ALM.TYPE:1 and select its type

(choose one of the following) using the

▲

and

▼

keys:

LOCAL

(Host Flag) If tied to a relay output, a local alarm notifies the Host that the 531 has taken over the output in Manual or Automatic mode.

You can choose LOCAL for only one of the alarms. Useful when the

Host performs logging functions for Statistical Process Control

(SPC), or to prevent reset windup.

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531 User's Manual

Applications

HIGH PV

Occurs when the process variable exceeds the alarm setpoint.

LOW PV

Occurs when the process variable goes below the alarm setpoint.

RATE

Use to signal an alarm when the PV changes at a rate greater than that specified by the alarm setpoint and time base. For example, if you have an alarm setpoint of 10 and a time base of 5 seconds, an alarm occurs if the PV changes greater than 10 units in 5 seconds.

BAND

Creates a band twice the size of the alarm setpoint [centered] around the control setpoint. Alarm occurs when the process variable travels outside of this band. For example, if your control setpoint is 500 and the alarm setpoint is 25, the alarm occurs if the PV travels outside of the 475 to 525 range.

Alarm is dependent upon retransmission of the control setpoint. As the control setpoint changes, the band centers itself accordingly.

DEVIATION

Creates a band on one side of the control setpoint. Alarm occurs when the process variable deviates from the control setpoint by an amount greater than the alarm setpoint.

For example, if the control setpoint is 500 and the alarm setpoint is +50

(plus 50), an alarm occurs when the process variable exceeds 550. If your alarm setpoint is –50, the alarm occurs when the process variable drops below 450.

Alarm is dependent upon retransmission of the control setpoint. As the control setpoint changes, the band centers itself accordingly.

HIGH CV

Occurs when the control value exceeds the alarm setpoint.

LOW CV

Occurs when the control value goes below the alarm setpoint.

3.

Press the MENU key to select the second parameter ALM.TYPE:2 and select its type using the s and t keys.

Each alarm type (except a LOCAL alarm) has a number of corresponding parameters that must also be set up in the ALARM menu (steps 4 - 11).

Press the MENU key to select the rest of the parameters in the ALARM Menu, and choose their values with the

▲

and

▼

keys.

4.

ALARM SP:1 and ALARM SP:2

Specifies, in engineering units, the point at which the alarm occurs.

For a rate-of-change alarm, it specifies the amount of change that must occur before the alarm activates. A negative value specifies a negative rate-ofchange.

5.

DEADBAND:1 and DEADBAND:2

Specifies the range through which the PV must travel before leaving an alarm condition (see alarm examples at the end of this section).

NOTE:

The Band and Deviation alarms are not selectable without a PV and a retransmitted SP signal.

NOTE:

The HIGH CV and LOW CV alarms, when selected, operate in both Host and Local modes.

NOTE:

Only those parameters that apply to your particular alarm type will appear as you toggle through the parameters.


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47

Applications

NOTE:

You can specify whether the relay is

Normally Open or Normally Closed when configuring the hardware, with jumper selection only for Output 1.

This prevents frequent alarm oscillation or “chattering” if the process variable has stabilized around the alarm point.

6.

RELAY:1

Specifies whether the relay will be on or off. ON means the relay is energized, while OFF means the relay is de-energized when the station is in the alarm condition.

Most applications require the relay to energize. However, limit applications usually require the relay to de-energize.

7.

LATCHING:1 and LATCHING:2

If the alarm is latching (YES), the alarm remains active after leaving the alarm condition unless acknowledged.

If the alarm is non-latching (NO) the alarm returns to its non-alarm state when leaving the alarm condition without being acknowledged.

8.

ACK.:1 and ACK.:2

ENABLED allows the operator to acknowledge an alarm at any time, even if the control process is still in the alarm condition.

DISABLED prevents the operator from acknowledging an alarm while the process is in the alarm condition.

When either alarm is available to be acknowledged, the ACK key will be illuminated. If both alarms are acknowledgable, press the ACK key once to acknowledge alarm #1, then a second time for alarm #2. A latching alarm can always be acknowledged when it is out of the alarm condition.

9.

POWER UP:1 and POWER UP:2

If you want the controller to always power up in alarm, regardless of the alarm condition, then select ALARM. This is an excellent way to activate an alarm if there has been a power failure.

If you never want the controller to power up in alarm, regardless of alarm condition, select DELAYED. The system must leave and reenter the alarm condition before the alarm will activate. This is typically used to avoid alarms during start up.

If you want the system to power up in alarm only if it is in an alarm condition, select

NORMAL.

10. MESSAGE:1 and MESSAGE:2

Allows you to enter a nine character message to display when the respective alarm is active. The first character of the 3rd display will be flashing. Use

▲ and

▼

keys to scroll through character set for each character. Press FAST to enter the selection and move to the next digit. Press MENU to advance to next parameter.

11. RATE TIME

Defines the time period over which a specific change in process variable must occur for the rate alarm to be activated. The amount of change is defined by the alarm setpoint. The rate-of-change is defined as the amount of change divided by the time period. In general, for a given rate-of-change, the shorter the time period, the more sensitive the rate alarm.


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Applications

Examples:

1.

If the alarm setpoint is set to 10 and the time base is set to 1 second, the rate of change is 10 units per second. The process variable would only have to experience a ten unit change over a short period of time.

2.

If the alarm setpoint is set to 100 and the time base set to 10, the rate of change is also 10 units per second. The PV would require a 100 unit change over a ten second period.

Notice that Example 1 is more sensitive than Example 2.

Alarm Examples

A.SP = Alarm Setpoint C.SP = Control Setpoint DB = Deadband PV = Process Variable

A. BAND ALARM EXAMPLE

Figure 6.1

Alarm Examples

B. HIGH PROCESS VARIABLE ALARM EXAMPLE

DB

IN ALARM

CONDITION

IN ALARM

CONDITION

C.SP + A.SP

IN ALARM

CONDITION

PV

PV

A.SP

DB

C.SP

DB

TIME

RELAY

ENERGIZED

ICON OFF

NO ALARM

RELAY

DE-ENERGIZED

ICON ON

CANNOT

ACKNOWLEDGE

RELAY

ENERGIZED

ICON OFF

NO ALARM

RELAY

DE-ENERGIZED

ICON ON

CANNOT

ACKNOWLEDGE

C.SP – A.SP

PARAMETER SETTINGS:

ALM. TYPE:1 = BAND

RELAY:1 = RELAY OFF

LATCHING = NO LATCH

ACK.:1 = DISABLED

C. DEVIATION ALARM EXAMPLE

C.SP

IN ALARM

CONDITION

TIME

RELAY

DE-ENERGIZED

ICON OFF

NO ALARM

RELAY

ENERGIZED

ICON ON

MAY

ACKNOWLEDGE

RELAY

DE-ENERGIZED

ICON OFF

NO ALARM


ALM. TYPE:1 = HIGH ALRM.

RELAY:1 = RELAY ON

LATCHING = NO LATCH

ACK.:1 = ENABLED

D. POWER UP ALARM EXAMPLE

PV

A.SP

DB

DB

RELAY

DE-ENERGIZED

ICON OFF

NO ALARM

C.SP + A.SP

PV

TIME

RELAY

ENERGIZED

ICON ON

MAY

ACKNOWLEDGE

MUST

ACKNOWLEDGE

TO SHUT OFF

ICON AND

DE-ENERGIZE RELAY


ALM. TYPE:1 = DEVIATION


LATCHING:1 = LATCH

ACK.1 = ENABLED

ALARM SP:1 = ( < 0)

UNIT

POWER UP

ALARM

CONDITION

TIME

RELAY

ENERGIZED

ICON ON

MAY

ACKNOWLEDGE

RELAY

ENERGIZED

ICON ON

RELAY

ENERGIZED

ICON ON

CANNOT

ACKNOWLEDGE

MAY

ACKNOWLEDGE


ALM. TYPE:1 = HIGH ALM.


LATCHING:1 = LATCH

ACK.:1 = DISABLED

POWER UP:1 = ALARM


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NOTE:

To verify your hardware configuration, check your product label on top of the 531, and compare it to the order code in Chapter 1.

DIGITAL INPUTS

This optional feature is only available if ordered originally from the factory. For a set of 5 digital inputs can be ordered, order Product #531 -xxxxxxDx00.

If more than one digital input is closed, then the last one closed generally has priority over the others.

A closed digital input may be overridden by: another digital input, a keyboard operation, or an automatic function. A closed digital input that was overridden must be opened, in order to be “re-armed”.

If one digital input is closed and selects LOCAL, and then REMOTE is keyboard selected, the keyboard selection takes precedence.

1.

Press FAST + MENU to toggle to the CONFIG. menu

2.

Press MENU to access first parameter, CONTACT:1. Use

▲

and

▼

to toggle to the desired function (choose one of the following):

MAN. LAST

Contact closure switches the station to Manual Mode using the last output value.

MAN. OUT1

Contact closure switches the station to Manual Mode using the MAN.OUT1

value.

MAN. OUT2

Contact closure switches the station to Manual Mode using the MAN.OUT2

value.

ALARM ACK.

Contact closure acknowledges all active alarms. The digital input must be opened before it is “re-armed.” If the input remains closed, it will not continue to immediately acknowledge alarms as they become active.

UP KEY and DOWN KEY

Contact closure mimics the

▲ and

▼ keys. If the station is mounted behind a window, this digital input allows you to use momentary contact push button to change the station’s output.

COMM. ONLY

Contact closure renders digital input status readable through communications. It will have no effect on the functions of the station itself.

DISP. KEY

Contact closure mimics the DISPLAY key.

MENU KEY

Contact closure mimics the FAST key.

FAST KEY

Contact closure mimics the FAST key.

RST. INHBT.

Contact closure inhibits local PID reset action.

REMOTE SP

Contact closure selects the remote setpoint for use in Automatic Mode.


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LOCAL SP

Contact closure selects the local setpoint for use in Automatic Mode.

AUTO.LOCAL

Contact closure switches the station to Automatic Mode.

HOST MODE

Contact closure switches the station to Host Mode.

WATCHDOG

Contact closure activates the watchdog monitor.

2.

Press MENU to access contact parameters, CONTACT:2, CONTACT:3,

CONTACT:4, and CONTACT:5. Use the

▲

and

▼ keys to toggle to the desired function for these as well.

WATCHDOG MONITOR

This feature is only available with the factory installed five digital inputs.

The 531 normally uses the presence of the CV for determining Host failure. In some cases, however, a Host can “lock up” or “hang up,” leaving its mA control output frozen at a constant value.

To protect against this type of Host failure, one of the Host relay outputs may be programmed to provide a pulse, or “watchdog,” output. A 531 digital input can be set to monitor this pulse. If the pulse state does not change (toggle) in a 0.4 to 2.5

second period, then the 531 will record the Host’s CV signal as unreliable, and appropriately report a lost CV as Host failure.

To configure a digital input as a watchdog monitor:

1.

Press FAST + MENU to toggle to the CONFIG. menu.

2.

Press MENU to access parameter CONTACT:1 (or 2, 3, 4 or 5). Use the

▲ or

▼ key to select the value WATCHDOG.

3.

Press MENU to access parameter WATCHDOG. To activate the watchdog monitor, set this value to ENABLED.

PROCESS VARIABLE AND SETPOINT

The 531 can be set up to display the process variable and a retransmitted setpoint.

The process variable can be a direct input of a thermocouple, RTD, mA or voltage signal. Milliamp and voltage signal can be displayed as 0–100% or scaled in

Engineering units. Custom linearization is also available.

Select the Process Variable Display Range

1.

Press the FAST + MENU keys to toggle to the PV INPUT menu. Press MENU to access the following parameters. Use the

▲

and

▼

keys to assign values.

2.

PV TYPE

Defines the range of the input signal (T/C, RTD, mA or voltage signal). The type of signal is governed by the hardware jumper selections (see Chapter 3).


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3.

DEG. F/C/K

Selects the units for temperature display (appears only for T/C and RTD input types).

4.

DECIMAL

Sets the position of the decimal point (appears only for V/mA and RTD input types).

5.

LINEARIZE

Selects the type of PV linearization being used (appears only for V/mA input types).

6.

LOW RANGE

Sets the value in engineering units corresponding to the low PV input value

(appears only for v/mA input types).

7.

HI RANGE

Sets the value in engineering units corresponding to the high PV input value

(appears only for V/mA inputs types).

8.

FILTER

Sets the amount of PV filtering to be used.

9.

PV OFFSET

Sets a constant offset to be applied to the PV input.

10. PV GAIN

Sets a constant gain to be applied to the PV input (appears only for V/mA input types).

11. PV BREAK

Sets the manual output value if the PV input is broken while running local

PID.

12. PV. RESTORE

Sets the mode upon restoration of the PV input.

Set Point Display Range

The 531 can be set up to display a retransmitted setpoint from the Host device.

1.

Press FAST + MENU to toggle to the RSP INPUT Menu . Press MENU to access the following parameters, and use

▲

and

▼

to assign values.

2.

RSP TYPE

Defines the input signal range: 0-20mA or 4-20mA (or 0-5V or 1-5V).

3.

RSP LOW and RSP HIGH

Define the range of the set point in engineering units. The correct range will be dependent on the source of the set point signal.

4.

RSP.OFFSET

Define the offset of the remote set point in engineering units.

5.

RSP GAIN

Define the gain to the remote set point in engineering units.

6.

TRACKING

Determines if the Local SP will track the Remote SP upon RSP break or transfer to the local SP value.


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7.

RSP.RESTOR.

Define the setpoint (source) upon remote set point signal restoration from break.

INPUT LINEARIZATION

Thermocouple and RTD Linearization

When you select a thermocouple or RTD input, the station automatically linearizes the incoming signal. The station uses internal lookup tables to provide an accurate reading of the temperature being sensed.

Square Root Linearization

Many flow transmitters generate a nonlinear signal corresponding to the flow being measured. The station must have the square root of this signal in order to use it.

The station has the capability to perform this function for itself.

To utilize this feature, you must have a voltage or milliamp input.

1.

Press FAST + MENU to toggle to the PV INPUT Menu .

2.

Press MENU to access the LINEARIZE parameters, and use the

▲

and

▼ to assign value SQR. ROOT.

For the first 1% of the input span, the input is treated in a linear fashion. After that, the input is a value calculated using the formula shown in Figure 6.2.

PV = Low Range +

[

(Hi Range – Low Range) (V input

- V low

/ (V high

– V low

)

]

Where

: Hi Range is the high end of the process variable.

Low Range is the low end of the process variable.

V

input

is the actual voltage or current value of the input.

V high

V low

is the high end of the input signal range (e.g. 5 volts or 20 mA).

is the low end of the input signal range (e.g. 1 volt or 4 mA).

Example

: Process variable range is 0 – 1000.

Input signal range is 1–5 volts

Input signal is 3 volts.

Therefore, the PV will be—

PV = 0 +

[

(1000 – 0) (3-1) / (5–1)

]

= 1000 .5 = 707

Custom Linearization

Custom linearization allows you to take virtually any nonlinear signal and linearize it using a 15-point straight line approximation curve. Typical applications are linearizing signals from nonlinear transducers, or controlling volume based on level readings for irregularly-shaped vessels. To define the function, you must enter data point pairs—the engineering units corresponding to a particular voltage or current input.

1.

Press FAST + MENU to toggle to the INPUT Menu .

2.

Press MENU to access the LINEARIZE parameters, and use the

▲

and

▼ keys to assign value CUSTOM.

3.

Press FAST + MENU to toggle to the CUST.LINR. Menu

4.

The parameter 1ST.INPUT is fixed at the low end of the mA or Voltage input range.

Figure 6.2

Square Root Linearization Formula


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53

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5.

For parameter 1ST.PV, define the corresponding process variable value in engineering units.

6.

For the 2ND.INPUT though XTH.INPUT (X being your last data point number), define the milliamp or voltage input of the corresponding data point.

7.

For the 2ND.PV through the XTH.PV (X being your last data point number), define the milliamp or voltage input of the corresponding data point.

Once the various points are defined, the station interpolates the values between the points using a straight line relationship between the points.

15th

PV

Figure 6.3

Custom Linearization Curve

PV VALUE

(IN ENGINEERING

UNITS)

10th

PV

5th

PV

NOTE:

The resulting linearization curve must be either ever-increasing or everdecreasing.

1st

PV

1st

Input

5th

Input

10th

Input

INPUT VALUE

(IN MILLIAMPS OR VOLTAGE)

15th

Input

IMPORTANT!!

If you make any modifications to a set curve, you must re-enter all points in

order, from 1 to X. Record the data in the Set Up Charts in Chapter 5.

RAMP TO A CONTROL VALUE

The “ramp to control value” function is useful for all other transitions where the rate-of-change of the control value must be limited, or under any circumstances where there is likely to be a significant difference between control values at the mode transition time.

Under normal operating conditions, the 531 passes the Host signal to the final control element without modification, and stores the current CV value with each cycle of the CPU. Upon loss of the Host signal (or switching out of Host Mode), the 531:

• Switches to Automatic Mode (LOST HOST = AUTO.LOCAL), automatically initiating a bumpless transfer from the last known good CV to the new PIDderived CV;

• Switches to Manual Mode using the last known good value from the Host

(LOST HOST = MAN.LAST); or

• Switches to Manual Mode using one of two preset outputs (LOST HOST =

MAN.OUT1 or MAN.OUT2).


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A preset output value may be considerably different from the Host CV, so the transfer may not be bumpless. The ramp to control value function allows the operator to select the ramping time for the output value change, thus smoothing the transition.

1.

Press the MENU key to access the OPERATIONS Menu .

2.

MAN. RAMP selects the ramping percentage (rate) for gradually changing output to the predefined Manual output value (when switching out of Host

Mode).

The choices are OFF, or 0.1% to 999.9% per minute. 0.1% per minute is equal to 6.0% per hour, and 999.9% per minute is equal to 16.7% per second.

3.

HOST.RAMP selects the ramping percentage for gradually changing output to the Host CV (when returning to Host Mode).

The choices are OFF, or 0.1% to 999.9% per minute. 0.1% per minute is equal to 6.0% per hour, and 999.9% per minute is equal to 16.7% per second.

SECURITY

The security function contains parameters that allow the user to lock out the selective functions of the station. Security only locks out the keypad commands

— digital inputs and serial communications are not affected.

1.

Press the FAST + MENU keys to toggle to the SECURITY Menu . Press MENU to access each of the following parameters, and the

▲

and

▼

keys to set their values.

2.

SEC. CODE

Define the security code using the

▲ and

▼

keys. This parameter does not appear unless all functions are unlocked. The security function is compromised if the security code is left at zero (0).

3.

HOST KEY

Selects lockout status of the HOST key.

4.

MAN. KEY

Selects whether the MANUAL key should be LOCKED or UNLOCKED to prevent the operator from placing the 531 in Manual Mode. Transfer to Manual

Mode is then accomplished by loss of Host signal, digital contact closure or

Serial Communications.

5.

MAN. OUT

Selects whether changes to the output (via the

▲

and

▼

keys) in Manual Mode should be LOCKED or UNLOCKED.

6.

LOCAL SP

Selects whether changes to the setpoint (via the

▲

and

▼

keys) in any operating mode should be LOCKED or UNLOCKED.

7.

ALARM ACK.


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NOTE:

Be sure to set the SEC. CODE before

locking any other feature. The station will not display this parameter if any others have been LOCKED. You would have to unlock all other parameters in order to view the SEC. CODE again.

Selects whether the ACK key should be LOCKED or UNLOCKED for acknowledging alarms.

8.

OPERATION

Selects whether access to the OPERATIONS configuration menu should be LOCKED or UNLOCKED.

9.

CONFIGURE

Selects whether changes to the other configuration parameters should be

LOCKED or UNLOCKED. You must set CONFIGURE to LOCKED if you want full security. If not, the operator has access to the security code. LOCKED does allow access to the menus, but prevents changes to the parameters.

Whenever a locked function is attempted, the operator has the opportunity to enter a security code to override the lock. If the correct code is entered, the operator has full access. The security feature reactivates after one minute of keypad inactivity.

The operator also can enter the SECURITY OVERRIDE CODE, which, if entered correctly, resets the whole station to its default settings. The security override code is

62647

. Store this in a secure place.

Refer to Chapter 2 for details on the Security Override function.

PROCESS VARIABLE READING CORRECTION

Under certain extraneous conditions — such as an aging thermocouple, out of calibration transmitter, lead wire resistance — the station may display values other than the actual process value. To compensate for these conditions, you can set offset and gain values for the process variable.

1.

Press FAST + MENU to toggle to the PV INPUT menu. Press MENU to access each of the following parameters, and the

▲

and

▼

keys to set values for them.

2.

PV OFFSET

This either adds or subtracts a set value from the process variable reading in engineering units. For example, if your thermocouple was always reading

3° too high, you could set the PV OFFSET parameter to –3 to compensate.

3.

PV GAIN

Multiplies the deviation from the low end of the process variable range by the gain factor and then adds it to the value of the low end of the range to arrive at the adjusted process variable value.

For example, if your process variable range is 50 to 650 and the process variable reading is 472, a PV GAIN of 0.995 would yield an adjusted process variable equal to [(472 – 50) x. 995] + 50 = 470.

By using a combination of both offset and gain factors, you should be able to compensate for just about any inaccuracy in your sensor or transmitter.

SERIAL COMMUNICATIONS

Serial communications is an optional feature. It enables the station to communicate


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with a supervisory device, such as a personal computer or programmable logic controller. The circuitry for communications is contained on a modular circuit board that plugs into the Microcontroller Circuit Board.

The station uses communications standard RS-485, which provides a multi-drop system that communicates at a high rate over long distances. Typical limitations are 32 stations per pair of wires over a distance up to 4000 feet.

The station uses a proprietary protocol which provides an extremely fast and accurate response to any command. A Cyclic Redundancy Checksum (CRC) can be enabled to ensure the integrity of any data read by the controller. Through communications, you have access to every set up and operating parameter in the station.

1.

Press the FAST + MENU keys to toggle to the SER.COMM. Menu. Press

MENU to access each of the following parameters, and use the

▲

and

▼

keys to set values for them.

2.

STATION

Specifies the unit’s station address. It is the only way one controller can be distinguished from another. Each controller on the same RS-485 interface must have a unique station address.

3.

BAUD RATE

Choose a baud rate from 1200 to 19,200. In general, you want to select the highest baud rate. However, every station on the RS-485 interface must be set to the same baud rate.

4.

CRC

Indicates if you are going to take advantage of the Cyclic Redundancy

Checksum feature. If your host program supports it, we highly recommend that you activate it.

NOTE:

The Process Variable Reading

Correction feature is provided only as a convenience. The condition

causing the erroneous reading should be corrected!

NOTE:

PV GAIN is only available if using a linear voltage or current input.

NOTE:

For details on the station communications protocol, contact one of our application engineers.


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Flowcharts

Host Mode

APPENDIX A

MODE, MENU & PARAMETER FLOWCHART

PRESS HOST (TOGGLE)

PRESS HOST

PRESS MANUAL

PRESS MANUAL

(TOGGLE)

OPERATING MODES

Manual Mode

Automatic Mode

SET UP MODES

PRESS

DISPLAY or

ACK

PRESS

MENU

PRESS MENU to traverse parameters for a given menu

RESET PROP. BAND

HOST RAMP

RATE LOADLINE SP SOURCE MAN.RAMP

PRESS

FAST

+

MENU

OPERATION

PRESS

FAST

+

MENU

CONFIG.

PRESS

FAST+MENU to traverse menus

LOCAL OUT.

PV INPUT

LOST HOST

CONTACT 5

HOST. RESTR.

WATCHDOG

CONTACT 1

LINE FREQ.

CONTACT 2

OUTPUT 1

CONTACT 3

PID ACTION

CONTACT 4

STN. NAME

AUTO.LO.LIM.

AUTO.HI.LIM.

MAN.OUT 1

PV TYPE

FILTER

DEG. F/C/K

PV OFFSET

DECIMAL

PV GAIN

MAN.OUT 2 PWR.UP:MODE MAN. PWR.UP

LINEARIZE

PV BREAK

LOW RANGE

RESTORE

CUST. LINR.

1ST.INPT

1ST.PV

2ND.INPT

2ND P.

15TH.INPT

15TH.PV

RSP INPUT

RSP TYPE

RSP. RESTOR.

RSP LOW RSP HIGH RSP.OFFSET

RSP GAIN TRACKING

ALARMS

ALM. TYPE:1

POWER UP:1

LATCHING:2

ALARM SP:1

MESSAGE:1

ACK:2

DEADBAND:1

ALM. TYPE:2

POWER UP:2

RELAY:1

ALARM SP:2

MESSAGE:2

LATCHING:1

DEADBAND:2

RATE TIME

ACK:1

RELAY:2

SECURITY

SEC. CODE

OPERATION

HOST KEY

CONFIGURE

MAN. KEY

STATION BAUD RATE CRC

MAN. OUT LOCAL SP ALARM ACK.

SER. COMM.

531 User's Manual

Appendix A

A-1

Flowcharts

A-2

Appendix A

531 User's Manual

Parts List

APPENDIX B

PARTS LIST*

CIRCUIT

BOARD SUPPORT

(BEZEL INSERT)

MOUNTING BRACKET

GASKET

OPERATOR

INTERFACE ASSEMBLY

TERMINAL BLOCK*

*Terminal Circuit

Board Not Shown

CIRCUIT BOARDS

4

5

1

2

6

7

OUTPUT MODULES

Mechanical relay module

531 Analog (mA) module

Solid State Relay (triac) module

DC Logic (solid state relay drive) module

Loop Power Module

RS-485 serial communications board

* For a complete list of related options and repair kits for the 531, refer to

M500.

531 User's Manual

Part #

535 600

532 600

535 602

535 603

535 604

535 605

8

REPAIR PARTS

Operator interface assembly 531

10 Power supply circuit board

11 Microcontroller circuit board 531

13 Option circuit board

14 Option circuit board w/5 digital inputs 531

18 EPROM 531

20 Lithium battery

21 Jumper kit (set of all jumper connectors)

22 Gasket kit (w/panel and bezel gaskets )

23 Mounting kit

(including mounting brackets and screws)

24 Bezel retention screw kit

25 Module retention kit

(w/retention plate & tie wrap for outputs 1-3)

26 Module retention tie wrap kit

(set of 5 tie wraps)

27 Terminal block

28 Circuit board support/Bezel insert

29 Sheet of engineering unit labels

30 531 Bypass board

31 Goof plate

Part #

531 632

535 630

531 631

535 620

531 621

531 640

093 044

535 660

535 662

532 661

535 663

535 664

535 665

535031A

535 025

535 106

531 100

512 014

Appendix B

B-1

Parts List

B-2

Appendix B 531 User's Manual

Troubleshooting

Message

DEFAULTS

NEEDS CAL.

LOST CAL

ERROR:ROM

CHECKSUM

OUT1 CONF.

OUT2 CONF.

OUT3 CONF.

OUT4 CONF.

LOST CJC

APPENDIX C

TROUBLESHOOTING

When does it occur?

Whenever the memory is cleared and all parameters revert to factory default settings. This may be done by purposely clearing the memory, when the unit is powered up for the first time, or if the software version is changed.

Changing any Set Up parameter will clear the message. If due to something other than the user purposely clearing the memory, call factory for assistance.

What to do:

Indicates that calibration values are at factory defaults (as when a battery is replaced).

Indicates that the calibration data has been lost. Occurs when the memory is wiped clean.

Recalibrate the unit.

Problem should never occur. Must correct the problem, then recalibrate. Call factory for assistance.

On power up, a problem with the ROM is detected. This is a fatal error and requires an EPROM change. Controller locks up until fixed.

Call factory for assistance.

Upon power up, controller senses that the modules needed for control as determined by software configuration are not present.

Sensor not reading properly.

Must power down and install correct module combination or reconfigure the controller to match the current module combination.


531 User's Manual

Appendix C

C-1

Troubleshooting

SYMPTOM

Display will not light up

Improper/Lost PV reading

• Voltage/current


• Thermocouple


• RTD

No control output

Can't switch to Host control

Erratic display

PROBLEM

SOLUTION

Defective power source

Improper wiring

Blown in-line fuse

Unit not inserted in case properly; or, screws have not been tightened

Check power source and wiring.

Correct wiring.

Check wiring, replace fuse.

Remove unit from case (and remove bezel screws), then reinsert unit and properly tighten screws.

Move jumper to proper location.

Select proper range.

Input jumper selection improperly set

Input range improperly selected in software

Reverse polarity

If station powered up, improperly wired

If internal supply for transmitter not installed.

Defective transmitter

Defective thermocouple


Wrong TC type selected in software

Improper wiring

Defective RTD


Improper wiring

Output module not installed

Output wiring and module location do not match

If SSR, SSR Drive or Milliamp output, jumpers J1, J2 and J3 are not set properly

Software configuration does not match hardware (OUTx CONF. message)

Host CV signal is not connected or valid

Resetting action due to electrical noise on powerline

Check and correct sensor wiring.

Check and correct wiring.

Install module.

Replace transmitter.

Replace thermocouple.


Select proper thermocouple type in software.

Wire properly.

Replace RTD.


Wire properly.

Install proper output modules.

Check and correct wiring or module location .

Move jumper to proper location

(N.O.).

Reconfigure software to match hardware. See OUTx CONF. message.

Check wiring. Check that Host is supplying a valid CV signal.

Filter power line.

C-2

Appendix C

531 User's Manual

Calibration

APPENDIX D

CALIBRATION

This section provides information on performing calibration for the following:

• RTD and VmA Input Calibration

• Thermocouple Cold Junction Compensation

• Milliamp Output (Standard on 531).

Access these parts of the calibration menu as shown in Figure D.1.

REGARDING CALIBRATION

To maintain optimum performance, once a year calibrate the analog input, cold junction (when a thermocouple is used) and mA Output (when used). To achieve published accuracy specifications, follow directions carefully and use calibrated instruments of like quality to those suggested. Also, if you move a station chassis into an alternate case or change its hardware configuration, and you choose to use thermocouple input, you may want to recalibrate the cold junction for optimal accuracy. Failure to do so may result in small junction temperature (not more than 0.6°C/1.1°F).

CALIBRATE

ANLG. IN

PRESS ACK

CAL VREF

5.0000

PRESS MENU

CAL. 120mV, etc.

PRESS ACK

PRESS MENU

CALIBRATE

COLD JUNC.

PV = –150 C

PRESS ACK

PRESS ACK

PRESS ACK

PRESS MENU

CALIBRATE

ANLG. OUT

PRESS MENU

PRESS ACK

OUTPUT "X"

0 mA

PRESS MENU

OUTPUT X, etc

PRESS ACK

RESET

SKIPPED

RESET

MENU DATA

PRESS MENU

HARDWARE

SCAN

PRESS ACK

PUSH MENU

TO RESET

After two seconds

PRESS

MENU before two seconds

PRESS ACK

DISPLAY ONLY

PRESS MENU

PRESS ACK

RESET

COMPLETED

ATTENTION!

The 531 comes from the factory with one milliamp output module installed in position (output) 2 and relays in position (outputs) 3 and 4. These must not be

modified. You may install a mechanical relay, solid state relay or DC logic module in position (output) 1 for alarm functions.

531 User's Manual

Appendix D

Figure D.1

Flowchart to Access Parts of

Calibration Menu Block

NOTE:

RESET, HARDWARE SCAN and S/W

TEST are functions in the CALIBRATE menu; these functions are covered later in this Appendix.

D-1

Calibration

ERY

CALIBRATION

JUMPERS—

SELECT V

AND TCs

PV INPUT

JUMPER

CONFIGURATION

V

MA

TB2

TCs

V

MA

TCs

TCt

RTD

TB1

Locations for the jumpers for Analog, Thermocouple and Milliamp calibration

Figure D.2

Microcontroller Circuit Board

ASS'Y

Warning! Electric Shock Hazard!

Terminals 1 and 2 carry live power. Do

not touch these terminals when AC power is on.

–

23

+

24

31

32

– hook up wire to multi-meter

+ hook up wire to multi-meter

Input Calibration

Equipment needed for analog input calibration:

• Precision 5-1/2 or 6-1/2 digit multimeter, such as a Fluke 8842

®

or

HP3478A

®

(a 4-1/2 digit meter will sacrifice accuracy)

• Two small pieces of wire

• Test leads with clips

• #2 Phillips screwdriver

Additional equipment needed if using thermocouple input:

• Precision thermocouple calibrator, such as a Micromite II

®

by Thermo

Electric Instruments

• Special limits grade, Type T thermocouple wire

1. Disconnect power to the instrument.

2. Remove chassis from case.

3. On the Microcontroller Circuit Board find jumper locations marked PV1 and

2nd near the edge connector. As shown in Figure D.2, reposition both jumper connectors in the 2nd location onto pins for V and TCs.

4. Connect the hook up wire to terminals 31 and 32 as shown in Figure D.3.

The hook up wire connects to the multimeter. Set the meter for DC volts.

5. Reinsert chassis into the case and apply power. The 2nd and 3rd displays should read “CALIBRATE ANLG. IN.” to show you are in the Calibrate Menu,

ANLG. IN section.

6. Allow the controller to warm up for at least 30 minutes.

7. Press the ACK key to get to the first step/parameter. The 2nd display should show CAL. VREF; the 3rd display should show a value close to 5.0000.

8. The multimeter should read a value between 4.9750 and 5.0250. Press s and t keys on the controller until the display on the controller matches the meter reading (the FAST key is active if you want to scroll through the numbers more quickly).

9. Press MENU key. The 2nd display should show “CAL. 120mV” and the 3rd display should show a value close to 120.000.

Figure D.3

Calibration Wiring

D-2

Appendix D

531 User's Manual

Calibration

10. Repeat the sequence of steps 7, 8, and 9 four more times. Each time, you should match the displays of the controller and the multimeter. Press ACK when done. The 2nd display should show CALIBRATE; the 3rd display should show COLD JUNC.

11. Turn off power to the unit.

12. If you are using thermocouple, proceed to the Thermocouple Cold Junction

Calibration Procedure.

13. For Milliamp output calibration, proceed to the Milliamp Output Calibration

Procedure, where steps 1–4 can be skipped and only 10 minutes of warm up is required before proceeding to step 5.

If calibration is complete, place all the jumpers back in their original positions (as specified in Chapter 4).

NOTE:

In the United States, the standard negative thermocouple lead is red.

NOTE:

Do not stand the station on its front or back ends; this will disrupt accurate temperature readings.

Thermocouple Cold Junction Calibration

1. Add the T/C wires to terminals 31 and 32 as shown in Figure D.3a. The hook up wire connects to the multimeter. As was set for input calibration, set the meter for DC volts. Make sure the T/C wires are not connected to anything and are not touching each other.

2. Turn on power to the unit and let controller warm up for 30 minutes in the normal horizontal position: while the unit is warming up, the rear face of the controller should be vertical, not horizontal.

3. Press the MENU key until the display indicates “CALIBRATE COLD JUNC.”

4. Press the ACK key. The display should show “BASE VOLT 50.000” .

5. Connect T-Type thermocouple –150°C thermocouple calibrator to thermocouple wires on PV terminals.

6. Disconnect the hook up wires from the PV rear terminals (31 and 32) to the multimeter. Connect the thermocouple wires to the thermocouple calibrator instrument. Connect the meter test leads to the small hoops on terminals 23– and 24+ (see Figure D.4).

7. The 2nd display should show BASE VOLT. and the 3rd display should show a value close to 50.000.

8. Press s and t keys to match the controller display with the multimeter's display. Be sure that the multimeter's value is not drifting; wait until it is stable before pressing s and t keys to adjust controller display (the FAST key is active if you want to scroll through the numbers more quickly). When the value displayed on the controller matches the value on the meter, press the

MENU key.

9. Disconnect the meter leads from terminals 23 and 24, and press the ACK key.

10. Test the thermocouple input to see if it is within ±1°F.

11. If you will be calibrating the milliamp output, move on to the Millamp Output

Calibration, #5, where steps 1–4 can be skipped and only 10 minutes of warm up is required before proceeding to step 5.

If calibration is complete, power down, then place all the jumpers in their original positions (as specified in Chapter 4).

–

23

+

24

– hook up wire to multi-meter

31

–

32

+ red blue

T/C

(floating)

Figure D.3a


+ hook up wire to multi-meter move the meter test lead to 23

– small hoop)

–

23

31 – red

+ blue

T/C wire to

T/C calibrator

+

24

32

+ move the meter test lead to 24

(connect to small hoop)

Figure D.4

Thermocouple & Cold Junction


531 User's Manual

Appendix D

D-3

Calibration

NOTE:

If your multi-meter display does not register a response, check that the jumpers J1, J2 and J3 (on the Power

Supply Board) are positioned as

Normally Open (NO).

1

2

3

–

hook-up

OUT 2– wires to multimeter

+

OUT 2+

4

5

6

7

8

Figure D.5

Milliamp Calibration Wiring

9

10

11

12

13

14

15

16

MILLIAMP OUTPUT CALIBRATION

Once a year, calibrate the mA output to maintain optimal performance.

Additionally, you should calibrate an output when a new mA module is installed.

The 531 local output should be calibrated at terminals 5 and 6 (OUT2– and

OUT2+). The bypass circuitry PC board does not have to be removed to perform the calibration.

Equipment:

• Precision 5-1/2 or 6-1/2 digit multimeter, such as a Fluke 8842

®

or

Hewlett Packard HP3478A

®

• Two small pieces of wire for each milliamp output

• Test leads with clip ends


1.

Disconnect power to the instrument.

2.

Remove chassis from case.

3.

Locate jumpers marked PV 1 and 2nd near the edge connector of the

Microcontroller Board (refer to Figure D.2). Relocate both jumper connectors so that one is positioned on the pins marked V of the 2nd jumper and the other on the pins marked TC

▲

of the 2nd jumper.

4.

Connect the small pieces of wire to the terminals assigned to the milliamp output(s) you are calibrating. Figure D.5 shows the hook up wires applied to OUT2+ and OUT2–. Hook up wires need to be applied to all terminals that have corresponding milliamp output modules in their output sockets. Attach the test leads from the multimeter to the wires, and then plug the test leads into the meter. Set the meter for DC milliamps.

5.

Reinsert chassis into the case and apply power. The 2nd display should read CALIBRATE while the 3rd display reads ANLG. IN. Press MENU twice to get to the ANLG. OUT Menu.

6.

Press ACK. The 2nd display will read OUTPUT 2.

7.

The 3rd display should read 4 mA. Your meter should read a value close to 4.00 mA. Wait one minute. Then press and

▼

key on the station until the meter’s display reads 4.00 mA. You may press FAST with

▲

and

▼ key to change the value at a faster rate.

8.

Press MENU. The 3rd display should read 20 mA. Let this setting stabilize for one minute. Repeat the procedure from Step 7.

9.

To complete calibration, press ACK, and disconnect the power. Remove the station from its case, and place the jumpers in their correct operating positions (as specified in Chapter 4).

You must press the ACK key at the end of any calibration procedure to return to the calibration menu before powering down.

D-4

RESET MENU DATA

Refer to Figure D.1. This function resets all parameter values back to their factory defaults (except for calibration information). Once inside this Menu

Block:

1.

Press MENU until the display shows RESET MENU DATA.

2.

Press ACK.

Appendix D

531 User's Manual

Calibration

3.

The display will prompt you to press MENU to reset the menu data. You have two seconds to press MENU to accomplish the reset. If successful,

RESET COMPLETED will appear in the display.

4.

If you failed to press MENU in time, RESET SKIPPED will appear.

5.

To try again, press ACK , and then press MENU within two seconds.

HARDWARE SCAN

Refer to Figure D.1. This procedure identifies the internal parts of the station.

Should you need to determine the hardware inside your station, press ACK to enter this read-only menu. The station will display the types of output hardware and installed options.

The information displayed should match the information on the product label on top of the controller. You can compare this information to the Order Code on page 2. However, any hardware modifications will render the order code on the product label invalid.

NOTE:

Calibration data will remain intact through the Reset Menu Data function.

QUICK CALIBRATION PROCEDURE

This procedure is for the benefit of users that have ISO or other standards that require periodic calibration verification. The procedure enables verification and modification of the volt or mA process variable input you are using without entering the “Factory Configuration” mode. Therefore you do not need to perform any jumper change.

1. Power down the 531.

2. Replace the process variable (PV) input signal with a suitable calibration device.

3. Apply power and allow controller to warm up for 30 minutes.

4. Place controller under Manual control.

5. Go to the PV INPUT. Scroll to the PV OFFSET parameter.

5. Adjust your calibration device to an output signal equal to the 0% range value for your particular input sensor (4mA for a 4-20 mA input).

6. Verify that the value indicated in the 1st display is equal to the 0% range value for your particular input sensor. If the value is incorrect, use the

▲

and

▼

keys to scroll to the correct value.

7. Scroll to the PV GAIN parameter.

8. Adjust your calibration device to an output signal equal to the 100% range value for your particular sensor.

9. Verify value indicated in the 1st display is equal to the 100% range value for your particular input sensor. If incorrect, use the

▲

and

▼


10. Repeat steps 3 through 8 to verify all values.

11. Return to the operating mode.

531 User's Manual

Appendix D

D-5

Calibration

D-6

Appendix D

531 User's Manual

Specifications

APPENDIX E

SPECIFICATIONS

ACCURACY

TYPICAL

LINEAR

(Voltage)

(Current)

RTD

1°

0.1°

± 0.025% full scale


± 0.050% of span

± 0.095% of span

THERMOCOUPLE

J, K, N, E (> 0°C) ± 0.060% of span

J, K, N, E (< 0°C) ± 0.150% of span

T (> 0°C) ± 0.100% of span

T (< 0°C)

R, S (> 500°C)

R, S (< 500°C)

B (>500°C)

± 0.250% of span

± 0.150% of span

± 0.375% of span

± 0.150% of span

B (<500°C) ± 0.500% of span

W, W5 & Platinel II ± 0.125% of span

MAXIMUM



± 0.150% of span

± 0.225% of span

± 0.150% of span

± 0.375% of span

± 0.250% of span

± 0.625% of span

± 0.375% of span

± 0.925% of span

± 0.375% of span

± 1.000% of span

± 0.325% of span

Display accuracy is ± 1 digit. These accuracy specifcations are at reference conditions (25°C) and only apply for NIST ranges. Detailed accuracy information is available upon request.

CONTROL ALGORITHM

PID, P with manual reset, PI, and PD with manual reset.

TUNING PARAMETERS

Proportional Band: 0.1 to 999% of input range

Integral: 1 to 9999 seconds/repeat

Derivative: 0-600 seconds

Manual Reset: 0-100% output

ISOLATION

Inputs and outputs are grouped into the following blocks:

Block 1 — process variable indication

Block 2 — outputs 1, 2, and 4

Block 3 — communications, set of 5 digital inputs, output 3

Block 4 — setpoint and indicator

Each block is electrically isolated from the other blocks to withstand a

HIPOT potential of 500 Vac for 1 minute or 600 Vac for 1 second, with the exception of blocks 1 and 4, which are isolated to withstand a HIPOT potential of 50 volts peak for 1 minute between each other. Inputs and outputs are not isolated from other inputs and outputs within the same block.

PROCESS VARIABLE INPUTS

Universal input type. Any input type may be selected in the field. Selection of input type (thermocouple, RTD, voltage or current) via jumper. Selection of particular sensor or range is via front panel.


531 User's Manual

E

J

K

THERMOCOUPLES RANGE °F

B 104 to 3301

– 454 to 1832

–346 to 1832

– 418 to 2500

S

T

N

R

W

W5

Platinel II

–328 to 2372

32 to 3182

32 to 3182

–328 to 752

32 to 4172

32 to 4172

–148 to 2550

RTD'S

100

W

Pt. (DIN)

RANGE °F

–328 to 1562

–328.0 to 545.0

–328 to 1202 100

W

Pt. (JIS)

–328.0 to 545.0

100

W

Pt. (SAMA) –328 to 1202

–328.0 to 545.0

TRANSMITTER SIGNALSINPUT RANGE

Milliamps DC 4 to 20

Voltage DC

0 to 20

1 to 5

Millivolts DC

0 to 5

0 to 10

0 to 30

0 to 60

0 to 100

–25 to 25

RANGE °C

40 to 1816

–270 to 1000

–210 to 1000

–250 to 1371

–200 to 1300

0 to 1750

0 to 1750

–200 to 400

0 to 2300

0 to 2300

–100 to 1399

RANGE °C

–200 to 850

–200.0 to 285.0

–200 to 650

–200.0 to 285.0

–200 to 650

–200.0 to 285.0

LINEARIZATION

Thermocouple and RTD inputs are automatically linearized. Transmitter inputs may be linearized with a square root function or user-defineable 15point straight line linearization function.

TRANSITION TIME

CV signal is restored 250 msec. after the HOST signal break is detected.

CV signal is considered lost when it falls below 3.2 mA.

INPUT IMPEDANCE

Current Input: 250

W

Voltage Input: 1 M

W

Thermocouples: 10 M

W

RTDs: 10 M

W

UPDATE RATE

Input is sampled and output updated 5 times per second. Display is updated 5 times per second. Passage of the HOST signal through the 531 is continuous.

INPUT FILTER

Single pole lowpass digital filter with selectable time constant from

0 to 120 seconds.

Appendix E

(Continued on following page)

E-1

Specifications

CALIBRATION

The station comes fully calibrated from the factory and continuously calibrates itself for component aging due to temperature and time, except for reference voltage. Field calibration can be performed easily with a precision multimeter and thermocouple simulator. Process variable offset and gain factors are provided to correct for sensor errors.

OUTPUT MODULES

One analog output (CV), 4–20 mA into a load up to 1000

W

. Also available is an additional mechanical relay module that can be tied to an alarm.

CONTROL OUTPUTS

4–20 mA into a load up to 1000

W

.

ALARMS

The 531 has two powerful software alarms. The 531 provides a LOCAL alarm that indicates when the 531 is in LOCAL mode. When tied to an available output, the HOST device can be flagged as to the change in status. Alternately, a PV High, PV Low, PV Rate, SP Band or SP Deviation alarm may be configured. A 9-character custom alarm message is available for each alarm.

DIGITAL INPUTS

A set of five external dry contacts or open collector driven transistor inputs are available. Each can be configured to perform one of the following functions:

• Select LOCAL control with LAST-OUT or 1 of 2 preset values

• Acknowledge alarms

• Addressable through serial communications only

• s/t Key Emulation

• HOST "watchdog" timer input

SERIAL COMMUNICATIONS

Isolated serial communications is available using an RS-485 interface.

Baud rates of up to 19,200 are selectable. The protocol supports CRC data checking.

DIGITAL DISPLAYS

Displayed information depends upon chosen options.

Upper display: five-digit, seven-segment. Used exclusively to display PV.

Height is 15 mm (0.6 in.).

2nd display: nine-character, 14-segment alphanumeric. Selectable SP or

CV indication. During set up, displays configuration information. Height is 6 mm (0.25 in.).

3rd display: nine-character, 14-segment alphanumeric. When no alarm messages are queued, indicates a user-selectable "station" name. During set up, displays configuration information. Height is 6 mm (0.25 in.).

All displays are vacuum flourescent. Color is blue-green.

STATUS INDICATORS

ALM 1 icon illuminated: alarm status

HOST key illuminated: CV signal from HOST is present

MANUAL key illuminated: 531 is in LOCAL MANUAL mode

ACK key illuminated: alarm is acknowledgable

MENU key illuminated: 531 is in configuration mode

DIMENSIONS

Meets 1/4 DIN designation as specified in DIN standard number

43 700. See diagram on page 5 for details.

MOUNTING

Panel-mounted. See diagram in Chapter 4 for details.

WIRING CONNECTIONS

30 screw terminals in the rear of the instrument.

POWER CONSUMPTION

15 VA at 120 VAC, 60 Hz (typical).

WEIGHT

Approximately 1 kg (2.2 lbs.).

AMBIENT TEMPERATURE

Operative Limits: 0 to 50°C (32 to 122°F).

Storage Limits: – 40 to 70°C (– 40 to 158°F).

RELATIVE HUMIDITY

10 to 90%, non-condensing.

VOLTAGE AND FREQUENCY

Universal power supply: 90 to 250 VAC, 48 to 62 Hz.

NOISE IMMUNITY

Common mode rejection (process input): >120 dB.

Normal mode rejection (process input): >80 dB.

AC line is double filtered and transient protected. Internal snubbers are provided for each relay output.

CONSTRUCTION

Case: extruded, non-perforated black anodized aluminum with ABS plastic sleeve.

Bezel: black plastic ABS.

Chassis assembly: plug-in type.

Keys: silicone rubber with diffusion printed graphics.

NEMA rating: front panel conforms to NEMA 4X when instrument is properly installed.

AGENCY APPROVALS

R

LR 84603

(Heavy Industrial)

(Available as an option)

MEMORY RETENTION

Lithium battery maintains all programming for approximately ten years.

SECURITY

There are two levels of access: restricted and full. A configurable code is used to enter the full access level. Functions not available in the restricted level are configurable.

E-2

Appendix E

531 User's Manual

RETURN PROCEDURES

To return equipment to Moore Industries for repair, follow these four steps:

1. Call Moore 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 number on all documentation.

Non-Warranty Repair –

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 “Not To Exceed” price, which means that the actual repair costs may be less than the quote. Be sure to include the RMA number on all documentation.

2.

Provide us with the following documentation: a) A note listing the symptoms that indicate the unit needs repair b) Complete shipping information for return of the equipment after repair 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 the shipping instructions furnished in your documentation.

WARRANTY DISCLAIMER

THE COMPANY MAKES NO EXPRESS, IMPLIED OR STATUTORY WARRAN-

TIES (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS

FOR A PARTICULAR PURPOSE) WITH RESPECT TO ANY GOODS OR SER-

VICES SOLD BY THE COMPANY. THE COMPANY DISCLAIMS ALL WARRAN-

TIES ARISING FROM ANY COURSE OF DEALING OR TRADE USAGE, AND

ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY ACKNOWL-

EDGES THAT THERE ARE NO WARRANTIES IMPLIED BY CUSTOM OR

USAGE IN THE TRADE OF THE BUYER AND OF THE COMPANY, AND THAT

ANY PRIOR DEALINGS OF THE BUYER WITH THE COMPANY DO NOT IM-

PLY THAT THE COMPANY WARRANTS THE GOODS OR SERVICES IN ANY

WAY.

ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY AGREES

WITH THE COMPANY THAT THE SOLE AND EXCLUSIVE REMEDIES FOR

BREACH OF ANY WARRANTY CONCERNING THE GOODS OR SERVICES

SHALL BE FOR THE COMPANY, AT ITS OPTION, TO REPAIR OR REPLACE

THE GOODS OR SERVICES OR REFUND THE PURCHASE PRICE. THE

COMPANY SHALL IN NO EVENT BE LIABLE FOR ANY CONSEQUENTIAL OR

INCIDENTAL DAMAGES EVEN IF THE COMPANY FAILS IN ANY ATTEMPT

TO REMEDY DEFECTS IN THE GOODS OR SERVICES , BUT IN SUCH CASE

THE BUYER SHALL BE ENTITLED TO NO MORE THAN A REFUND OF ALL

MONIES PAID TO THE COMPANY BY THE BUYER FOR PURCHASE OF THE

GOODS OR SERVICES.

ANY CAUSE OF ACTION FOR BREACH OF ANY WARRANTY BY THE

COMPANY SHALL BE BARRED UNLESS THE COMPANY RECEIVES

FROM THE BUYER A WRITTEN NOTICE OF THE ALLEGED DEFECT OR

BREACH WITHIN TEN DAYS FROM THE EARLIEST DATE ON WHICH THE

BUYER COULD REASONABLY HAVE DISCOVERED THE ALLEGED DE-

FECT OR BREACH, AND NO ACTION FOR THE BREACH OF ANY WAR-

RANTY SHALL BE COMMENCED BY THE BUYER ANY LATER THAN

TWELVE MONTHS FROM THE EARLIEST DATE ON WHICH THE BUYER

COULD REASONABLY HAVE DISCOVERED THE ALLEGED DEFECT OR

BREACH.

RETURN POLICY

For a period of thirty-six (36) months from the date of shipment, and under normal conditions of use and service, Moore Industries ("The Company") will at its option replace, repair or refund the purchase price for any of its manufactured products found, upon return to the Company (transportation charges prepaid and otherwise in accordance with the return procedures established by The Company), to be defective in material or workmanship. This policy extends to the original Buyer only and not to Buyer's customers or the users of Buyer's products, unless Buyer is an engineering contractor in which case the policy shall extend to Buyer's immediate customer only. This policy shall not apply if the product has been subject to alteration, misuse, accident, neglect or improper application, installation, or operation. THE COMPANY

SHALL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSE-

QUENTIAL DAMAGES.

United States • [email protected]

Tel: (818) 894-7111 • FAX: (818) 891-2816

Australia • [email protected]

Tel: (02) 8536-7200 • FAX: (02) 9525-7296

Belgium • [email protected]

Tel: 03/448.10.18 • FAX: 03/440.17.97

The Netherlands • [email protected]

Tel: (0)344-617971 • FAX: (0)344-615920

China • [email protected]

Tel: 86-21-62491499 • FAX: 86-21-62490635

United Kingdom • [email protected]

Tel: 01293 514488 • FAX: 01293 536852

© 2007 Moore Industries-International, Inc.

Specifications and Information subject to change without notice.

5 3 1

5 3 1

1/4 DIN PID BACKUP STATION

ADDENDUM TO THE USER'S MANUAL

M531 V5A5, © MAY 2002

The 531 controller has been upgraded with a new microprocessor, new case, and modifications to the front panels to improve its NEMA 4x capability. Insert the information in this addendum where appropriate in your M531 V5 manual.

Cover

531

The 500 series controller body has been modified to a 1-piece design, with a new face plate (4 screws instead of 2 securing it to the body).

Chapter 1, Page 1, Figure 1.1

also




This drawing shows a basic detail of the new faceplate. Please refer to this drawing for any detail of the controller face.

531


Addendum

MANUAL DISPLAY

HOST MENU

ACK

FAST

▲

▼

531

1

531

Chapter 1, Page 2

New Order Code for 531.

531 –

Output 1: Alarm

None

Mechanical Relay

Solid State Relay (triac) (1 amp)

DC Logic (SSR drive)

Options

Enter “0” if not desired

24 VAC/24VDC Operation

Order Code

0

1

3

4

Set of Five Digital Inputs

Certification

Five Digital Inputs and Certification

F

D

H

J

Serial Communications

Enter “0” if not desired

RS-485 Serial Communications S

Base instrument contains universal PV input, remote setpoint input, and

4–20 mA CV

(control) output with internal hard-wired bypass relays.

2 1 1 B 0 0

2

531 Addendum

531


This drawing has been modified (due to the new controller body).

MICROCONTROLLER

BOARD

POWER SUPPLY

BOARD



OPTION BOARD

The Microcontroller Board has been modified.

BATTERY

EPROM

Remote SP

Configuration

PV1

Jumper Location

P1

P2

TB2

V

MA

TCt

TCs

RTD

V

MA

TCt

TCs

RTD

TB1

ASS'Y 535-607

A mounting collar replaces the old mounting brackets.

Collar Clip (1 of 2)

Addendum

Front panel

Mounting Collar

531

Collar screw (1 of 4)

3

Chapter 5, Page 33

4

531



2c. Slide the mounting collar over the back of the case. The collar clip edges will lock with matching edges on the controller case.

2d. Insert the four mounting collar screws from the rear of the collar.

Gradually tighten the screws to secure the controller against the panel.

In the CONFIG Menu, add the following new parameter after HOST

RESTR.

3.

CV RANGE

Selects the CV output signal.

(D) 4-20mA

• 20-4mA

All following parameters are renumbered accordingly.

In the ALARMS Menu: two new alarm types have been added, the respective alarm setpoint parameters have been modified, and four new setpoint parameters (2 per alarm) have been added.

1.

ALM. TYPE:1

(D) OFF

•

•

•

LOCAL

HIGH PV

LOW PV

•

•

•

•

•

•

•

RATE

BAND

DEVIATION

HIGH CV

LOW CV

HI/LO CV

HI/LO PV

Separate High and Low CV setpoints

Separate High and Low PV setpoints

2.

ALARM SP:1


For RATE alarms:

(R) -9999 to 99999

(D) 0

For HIGH CV or LOW CV alarms:

(R) 0.0 to 100.0%

(D) 0.0%

For any other type (except HI/LO CV or HI/LO PV)

(R) The PV range

(D) Dependent on LOW RANGE value

3.

HIGH SP:1

Specifies the high alarm set point for HI/LO CV or HI/LO PV alarm 1.

For HI/LO CV alarms:

(R) 0.0% to 100.0%

(D) 0.0%

For HI/LO PV alarms:

(R) LOW RANGE to HI RANGE

(D) 0

531 Addendum

Addendum

531

4.

LOW SP:1

Specifies the low alarm set point for HI/LO CV or HI/LO PV alarm 1.


(R) 0.0% to 100.0%

(D) 0.0%



(D) 0

11. ALM. TYPE:2

(D) OFF

•

•

•

•

•

•

•

•

•

•

LOCAL

HIGH PV

LOW PV

RATE

BAND

DEVIATION

HIGH CV

LOW CV

HI/LO CV

HI/LO PV

Separate High and Low CV setpoints

Separate High and Low PV setpoints

12. ALARM SP:2


For RATE alarms:

(R) -9999 to 99999

(D) 0

For HIGH CV or LOW CV alarms:

(R) 0.0 to 100.0%

(D) 0.0%

For any other type (except HI/LO CV or HI/LO PV)

(R) The PV range

(D) Dependent on LOW RANGE value

13. HIGH SP:2

Specifies the high alarm set point for HI/LO CV or HI/LO PV alarm 2.


(R) 0.0% to 100.0%

(D) 0.0%



(D) 0

14. LOW SP:2

Specifies the low alarm set point for HI/LO CV or HI/LO PV alarm 2.


(R) 0.0% to 100.0%

(D) 0.0%



(D) 0

531

5

531


These parameter set up charts reflect the changes in the set up menus.

CONFIG

Parameter

1

LOST HOST

2

HOST. RESTR.

3

CV RANGE

4

CONTACT 1

5

CONTACT 2

6

CONTACT 3

7

CONTACT 4

8

CONTACT 5

9

WATCHDOG

10 LINE FREQ.

11 OUTPUT 1

12 PID ACTION

13 STN. NAME

Description

Defines fundamental controller Set Up

Defines the power source frequency

Specifies the CV output signal

Operation of the first digital input

Operation of the second digital input

Operation of the third digital input

Operation of the fourth digital input

Operation of the fifth digital input

Defines function of Host watchdog monitor

Specifies the power source frequency

Defines the function of the 1st output

Selects the PID control action

Specifies a 9-character message to name the station

Values

6

531

Addendum

531


ALARMS

Parameter

1

ALM. TYPE:1

2

ALARM SP:1

3

HIGH SP:1

4

LOW SP:1

5

DEADBAND:1

6

RELAY:1

7

LATCHING:1

8

ACK.:1

9

POWER UP:1

10 MESSAGE:1

11 ALM. TYPE:2

12 ALARM SP:2

13 HIGH SP:2

14 LOW SP:2

15 DEADBAND:2

16 RELAY:2

17 LATCHING:2

18 ACK.:2

19 POWER UP:2

20 MESSAGE:2

21 RATE TIME

Description

Type of alarm for alarm 1

Alarm setpoint alarm 1

High alarm setpoint for HI/LO CV or HI/LO PV alarm 1

Low alarm setpoint for HI/LO CV or HI/LO PV alarm 1

Dead band for alarm 1

State of the relay for alarm 1

Latching sequence for alarm 1

Whether alarm 1 may be acknowledged

How alarm 1 will be treated upon power up

Nine character message associated with alarm 1

Type of alarm for alarm 2

Alarm setpoint alarm 2

High alarm setpoint for HI/LO CV or HI/LO PV alarm 2

Low alarm setpoint for HI/LO CV or HI/LO PV alarm 2

Dead band for alarm 2

State of the relay for alarm 2

Latching sequence for alarm 2

Whether alarm 2 may be acknowledged

How alarm 2 will be treated upon power up

Nine character message associated with alarm 2

Time period over which a rate-of-change is determined

Value

Chapter 6, Page 46-47

After LOW CV, insert these two new alarm types:

HI/LO CV

Combination of high and low CV alarms. Occurs when the PV exceeds the individually set high or low CV setpoint.

HI/LO PV

Combination of high and low PV alarms. Occurs when the PV exceeds the individually set high or low setpoint.

Addendum

531

7

531

Appendix A, Page A-1

Host Mode

PRESS MANUAL

Manual Mode

The Menu Flowchart has been modified accordingly:

PRESS MANUAL

(TOGGLE)

OPERATING MODES

Automatic Mode

PRESS HOST (TOGGLE)

SET UP MODES

PRESS

DISPLAY or

ACK

PRESS

FAST

+

MENU

OPERATION

PRESS

FAST

+

MENU

CONFIG.

PRESS

FAST+MENU to traverse menus

PRESS

MENU

PRESS MENU to traverse parameters for a given menu

PROP. BAND RESET RATE

HOST RAMP

LOST HOST

CONTACT 4

STN. NAME

HOST. RESTR.

CONTACT 5

CV RANGE

WATCHDOG

LOADLINE SP SOURCE

CONTACT 1

LINE FREQ.

CONTACT 2

OUTPUT 1

MAN.RAMP

CONTACT 3

PID ACTION

LOCAL OUT.

PV INPUT

CUST. LINR.

AUTO.LO.LIM.

AUTO.HI.LIM.

MAN.OUT 1 MAN.OUT 2 PWR.UP:MODE MAN. PWR.UP

PV TYPE

FILTER

DEG. F/C/K

PV OFFSET

DECIMAL

PV GAIN

LINEARIZE

PV BREAK

LOW RANGE

RESTORE

1ST.INPT

1ST.PV

2ND.INPT

2ND P.

15TH.INPT

15TH.PV

RSP INPUT RSP TYPE

RSP. RESTOR.

RSP LOW RSP HIGH RSP.OFFSET

RSP GAIN TRACKING

ALARMS ALM. TYPE:1

LATCHING:1

HIGH SP:2

POWER UP:2

ALARM SP:1

ACK:1

LOW SP:2

MESSAGE:2

HIGH SP:1

POWER UP:1

DEADBAND:2

RATE TIME

LOW SP:1

MESSAGE:1

RELAY:2

DEADBAND:1

ALM. TYPE:2

LATCHING:2

RELAY:1

ALARM SP:2

ACK:2

SECURITY

SER. COMM.

SEC. CODE

OPERATION

HOST KEY

CONFIGURE

MAN. KEY MAN. OUT LOCAL SP ALARM ACK.

STATION BAUD RATE CRC

8

531

Addendum

Appendix B, Page B-1

531

With the modifications to the case and addition of the mounting collar, the parts drawings have been modified. Also, note the new part numbers.

OPERATOR

INTERFACE

ASSEMBLY shown with bezel insert in place

CIRCUIT

BOARD SUPPORT

(BEZEL INSERT)

CIRCUIT BOARDS BEZEL

GASKET

CONTROLLER BODY shown with mounting collar in place

ITEM

Output Modules

Mechanical Relay Module

Analog (Milliamp Module)

Solid State Relay Module

DC Logic (SSR Drive) Module

Loop Power Module

RS-485 Communications Module

Repair/Replacement Parts

Operator Interface Assembly

Power Supply Circuit Board

Microcontroller Circuit Board

Option Circuit Board w/no Options

Option Circuit Board w/Set of 5 Digital Contacts

EPROM 531

Lithium Battery

Jumper Kit: Set of All Jumper Connectors

Gasket Kit: 1 Panel Gasket & 1 Bezel Gasket

Mounting Kit: Mounting Collar & 4 screws

Bezel Retention Screw Kit

Module Retention Kit for Outputs 1-3 ( Includes Retention Plate)

Module Retention Kit for Output 4: Set of 5 Tie Wraps

Circuit Board Support (Bezel Insert)

Engineering unit labels (1 sheet)

531 Bypass board

MOUNTING

COLLAR

PART #

535 600

535 601

535 602

535 603

535 604

535 705

531 632

535 730

535 731

535 720

535 721

531 740

093 044

535 660

535 662

535 761

535 663

535 664

535 665

535 075

535 106

532 100

Addendum 531

9

531

Appendix C, Page C-1

Message

DEFAULTS

LOST CAL. or

ERROR: BAD CAL. DATA

ERROR: ROM CHECKSUM

OUT1 CONF or

OUT2 CONF or

OUT3 CONF or

OUT4 CONF

LOST CJC

ERROR: BAD EEPROM

NEEDS CAL.

ERROR: BAD MODEL NUM.

Changes and additions to the troubleshooting error messages:

When does it occur?

Whenever the memory is cleared and all parameters revert to factory default settings. This may be done by purposely clearing the memory or when the unit is powered up for the first time or if the software version is changed.

Indicates that the calibration data has been lost. Occurs when there is a total loss of memory.

On power up, a problem with the

EPROM is detected. Controller locks up until fixed.

Upon power up, controller senses that the modules needed for control as determined by software configuration are not present.

The cold junction is sensed as lost.

During power up an EEPROM failure is detected. Controller locks up until fixed.

When the controller is powered up with default calibration data (input and output accuracy specifications may be met).

During power up, a discrepancy was found between the EEPROM's and controller's model numbers. Controller locks up until fixed.

What to do:

Changing any Set Up parameter will clear the message. If due to something other than the user purposely clearing the memory, call factory for assistance.

Problem should never happen. Must correct the situation and recalibrate. Call factory for assistance.


Must power down and install correct module combination or must reconfigure the controller to match the current module combination.


This is a fatal error and requires and

EEPROM change. Call factory for assistance.

Enter calibration menu and recalibrate the controller. Call factory for assistance.

This is a fatal error and requires an

EPROM or EEPROM change. Call factory for assistance.

10

The following pages replace Appendix D of the 531 manual.

531

Addendum

531

APPENDIX D

CALIBRATION

• To maintain optimum performance, once a year calibrate the analog input, the cold junction and milliamp output (when used). To achieve published accuracy specifications, follow directions carefully and use calibrated instruments of like quality to those suggested.

• If the controller is moved into an alternate case, or the hardware configuration is changed, and the thermocouple input is needed, recalibrate the cold junction for maximum accuracy. Failure to do so may result in small junction temperature (0.6°C/1.1°F).

CALIBRATE

ANALOG IN

PRESS ACK

CAL VREF

5.0000

PRESS MENU CAL. 120mV, etc.

PRESS ACK

PRESS MENU

CALIBRATE

ANA. mA IN

PRESS ACK

SET BOTH

JUMPER=mA

Power Down

Move Jumpers

Power Up

PV=20mA

PRESS ACK

Attach 20mA to PV

Press ACK

SP=20mA

PRESS ACK

Attach 20mA to SP

Press ACK

CALIBRATE

COLD JUNC.

PRESS ACK

PV= –150 C

PRESS ACK

PRESS ACK mA CALIB.

COMPLETED

If mA calibration values are

OK.

mA CALIB.

FAILED

If mA calibration values are out of range.

CALIBRATE

ANLG. OUT

PRESS ACK

OUTPUT "X"

4 mA

PRESS MENU

OUTPUT X, etc

PRESS ACK

RESET

SKIPPED

RESET

MENU DATA

PRESS MENU

HARDWARE

SCAN

PRESS ACK

PUSH MENU

TO RESET

After two seconds

PRESS

MENU before two seconds

PRESS ACK

DISPLAY ONLY

PRESS MENU

PRESS ACK

RESET

COMPLETED

Access the parts of the calibration menu as shown in

Figure D.1

.

ATTENTION!

The 531 comes from the factory with one milliamp output module installed in position (output) 2 and relays in position (outputs) 3 and 4. These must not be

modified. You may install a mechanical relay, solid state relay or DC logic module in position (output) 1 for alarm functions.

Addendum

531

11

531

Figure D.2

Microcontroller Circuit Board

WARNING! Electric Shock Hazard!

Terminals 1 and 2 carry live power.

Do not touch these terminals when

AC power is on.

Figure D.3

Input Calibration

12

31

32

PV–

PV+

BATTERY

CALIBRATION

JUMPERS—

SELECT V

AND TCs

PV INPUT

JUMPER

CONFIGURATION

P1

P2

V

MA

TCt

TCs

RTD

TB2

V

MA

TCt

TCs

RTD

TB1

Jumper locations for

Analog,Thermocouple and Milliamp calibration

ASS'Y

PREPARATION FOR ALL INPUT CALIBRATIONS

Equipment for analog input calibration:

• Precision 5-1/2 or 6-1/2 digit multimeter, e.g., Fluke 8842

®

or HP3478A

®

(a 4-1/2 digit meter will sacrifice accuracy)

• Four small pieces of wire

• Test leads with clips


Additional equipment for thermocouple input:

• Precision thermocouple calibrator, e.g., Micromite II

®

by Thermo Electric

Instruments

• Special limits grade, Type T thermocouple wire



3. On the Microcontroller Circuit Board, locate jumper locations marked PV1 and

2nd near the edge connector. Reposition both jumper connectors in the 2nd location onto pins for V and TC

▲

as shown in Figure D.2.

4. Connect hook up wires between terminals 31 and 32 as shown in Figure D.3, and the multimeter.

Set the meter for DC volts.

5. Reinsert chassis into the case and apply power.

The 2nd and 3rd display should read CALIBRATE ANALOG IN.

6. Allow the controller to warm up for at least 30 minutes.

7. Press the ACK key to get to the first step/parameter.

The 2nd display should show CAL. VREF; the 3rd display should show a value close to 5.0000.

8. The multimeter should read a value in the range 4.9750 - 5.0250.

Use the

▲

and

▼

(and FAST) keys on the controller until the display on the controller matches the meter reading.

9. Press MENU key.

The 2nd display should show CAL. 120mV. The 3rd display should show a value close to 120.000. Match controller display to multimeter value using

▲

and

▼

keys.

531

Addendum

531

10. Press MENU four more times. Each time, match the displays of the controller and the multimeter. Press ACK when done.

The 2nd display should show CALIBRATE; the 3rd display should show ANA.

mA IN.

11. Turn off power to the unit.

12. For thermocouple input, proceed to the Thermocouple Cold Junction Calibration.

13. For milliamp input , proceed to Analog Milliamp Input Calibration.

14. For milliamp output calibration, let the controller warm up for 10 minutes, then skip to step 5 of Milliamp Output Calibration.

15. If calibration is complete, place all the jumpers back in their original positions

(as specified in Chapter 3).

THERMOCOUPLE COLD JUNCTION CALIBRATION

1. Connect the two pairs of T/C wire to terminals 31 and 32 as shown in Figure D.4.

Make sure the T/C wires are floating (disconnect from the multimeter also), and are not touching each other.

2. Turn on power to the unit and let controller warm up for 30 minutes in the normal horizontal position: while the unit is warming up, the rear face of the controller should be vertical, not horizontal.

3. Press the MENU key until the display indicates CALIBRATE COLD JUNC.

4. Press the ACK key. The display should show PV = -150 C PRESS ACK.

5. Connect both pairs of T/C wires in parallel—do not daisy chain—to a Type T thermocouple calibrator. (Both pairs must be connected or the calibration will not be accurate.)

6. Set the thermocouple calibrator to an output value of -150° C for a Type T thermocouple and allow the calibrator to stabilize for a few minutes.

7. Press ACK to initiate calibration of the cold junction.

8. For milliamp output calibration, proceed to Milliamp Output Calibration. Let the controller warm up for 10 minutes, then skip to step 5.

9. If calibration is complete, power down, then place all the jumpers in their original positions (as specified in Chapter 3).

Figure D.4

Thermocouple Cold Junction


17

18

19

20

21

22

23

24

25

26

27

28

29

30

Type T thermocouple wire (floating)

– red

31

+ blue

32

ANALOG MILLIAMP INPUT CALIBRATION

1. Remove the thermocouple wires (if present) from terminals 31 and 32. Replace them with pieces of wire that will be connected to a 20 milliamp input current

(see Figure D.5). Make sure terminal screws are securely tightened, but do not connect the wires yet (leave inputs floating).

2. Turn on power to the unit.

3. Press MENU until the display indicates CALIBRATE ANA. mA IN, then press ACK.

If the display shows PV=20mA PRESS ACK, move ahead to step #8.

4. The controller will display SET BOTH JUMPER=mA.

5. Power down the controller and remove chassis from the case.

Figure D.5

Analog mA Input Calibration

17

18

19

20

21

22

23

24

25

26

Wires to 20mA current (floating)

27

28

SP–

29

SP+

30

31

PV–

32

PV+

Addendum

531

13

531

Figure D.6

Analog mA Input Jumper Position

RATION

ERS—

ECT V

TCs

PUT

PER

RATION

P1

P2

V

MA

TCt

TCs

RTD

TB2

V

MA

TCt

TCs

RTD

TB1

6. Remove both input jumper connectors from the pins in the 2nd position. Place one of the jumpers on the PV1 position mA pins, and place the other jumper on the 2nd position mA pins, as shown in Figure D.6.

7. Reinsert the chassis into the case and apply power. The controller should display PV=20mA PRESS ACK to indicate it is ready to calibrate the PV milliamp input.

8. Connect a precision 20mA input to the PV terminals (31 is PV-, 32 is PV+). Make sure the terminal connections are fastened tightly and that a 20mA current is flowing through PV. Do not connect the 20mA current to SP yet.

9. Let the controller warm up for at least 10 minutes (keep in normal horizontal position). Make sure the current is flowing, then press ACK to calibrate the PV input.

10. If the controller briefly displays SP=20mA PRESS ACK, PV calibration was successful. Move on to step 12.

11. If the controller briefly displays mA CALIB. FAILED, PV calibration was not successful.

Check the 20mA connections, and return to step #3 to recalibrate the PV input.

12. Remove the 20mA input from the PV terminals, and attach it to the SP terminals

(see Figure D.5).

Make sure the terminal connections are fastened tightly and that a 20mA current is flowing through SP terminals.

13. Let the controller warm up for an additional 5 minutes (keep in the normal horizontal position). Make sure the current is flowing, then press ACK to calibrate the SP input.

14. If the controller briefly displays mA CALIB. COMPLETED, SP calibration was successful and the analog milliamp calibration procedure has been completed.

If calibration is complete, power down. Place the jumpers into their original positions (see Chapter 4).

15. If the controller briefly displays mA CALIB. FAILED, SP calibration was not successful. Check the 20mA connections, and return to step #3 to recalibrate the

PV and SP inputs.

MILLIAMP OUTPUT CALIBRATION

Once a year, calibrate the milliamp output to maintain optimal performance.

Additionally, calibrate an output whenever a new milliamp module is installed.

The 531 local output should be calibrated at terminals 5 and 6 (OUT2– and

OUT2+). The bypass circuitry need not be removed to perform this calibration.

Equipment needed:

• Precision 5-1/2 digit multimeter, e.g., Fluke 8842

®

or HP3478A

®

( 4-1/2 digit meters sacrifice accuracy)

• Two small pieces of wire for every milliamp output

• Test leads with clips ends




14

531

Addendum

531

3. On the Microcontroller Circuit Board locate jumper locations marked PV1 and

2nd near the edge connector. Reposition both jumper connectors in the 2nd location onto pins for V and TC

▲

, as shown in Figure D.2

4. Reinsert chassis into the case and apply power.

5. Allow controller to warm up for at least 30 minutes.

The 2nd and 3rd displays should read CALIBRATE ANALOG. IN. (CALI-

BRATE Menu, ANALOG. IN section).

Press MENU three times to reach the CALIBRATE ANLG. OUT Menu.

6. Connect hook up wires to the terminals for Output 2 (refer to Figure D.7).

Attach the test leads from the multimeter to the wires, and then plug the test leads into the meter. Set the meter for DC milliamp.

7. Press ACK. The 2nd display will read OUTPUT2.

8. The 3rd display should read 4 mA.

The multimeter should read a value close to 4.00.

9. Wait one minute. Use

▲

and

▼

(and FAST) on the controller to change the meter’s display to exactly 4.00 mA.

10. Press MENU. The 3rd display should read 20 mA.

11. Let this setting stabilize for 5 minutes. Use

▲

and

▼

(and FAST) on the controller to change the meter’s display to exactly 20mA.

12. To complete calibration, press ACK key, disconnect the power and place the jumper connectors back into their original position (refer to Chapter 3).

Figure D.7

Milliamp Calibration Wiring

Hook up wires to multimeter

–

OUT 2–

OUT 2+

+

4

5

6

7

8

RESET MENU DATA

This function resets all parameter values back to their factory default values

(except for calibration information). Refer to the flowchart tin Figure D.1.



3. On the Microcontroller Circuit Board, set jumpers at the 2nd PV location to

V and TC

▲

.

4. Press MENU key until the display shows RESET MENU DATA.

5. Press the ACK key.

6. Press MENU key within two seconds to reset the menu data.

If successful, RESET COMPLETED will appear in the display.

If failed, RESET SKIPPED will appear instead.

7. To try again, press ACK key, and then press MENU key within two seconds.

8. When complete, return jumpers to their original positions.

HARDWARE SCAN

Use this read-only feature to identify the output hardware and installed options of the controller.

1. Set the jumpers to V and TC

▲

on the Microcontroller Circuit Board (see Fig-

ure D.2).

2. Power up the controller

3. Press MENU until HARDWARE SCAN is displayed.

Addendum

531

15

531

4. Press ACK to initiate the hardware display.

5. When complete, return jumpers to their original positions (as in Chapter 3).

QUICK CALIBRATION PROCEDURE For mA or V inputs

This procedure is for the benefit of users that have ISO or other standards that require periodic calibration verification. It enables verification and modification of the process variable input without entering the “Factory Configuration” mode.

1. Power down the 531 controller and place the input jumpers in the desired position (refer to Figure D.2 and Figure D.6).

2. Replace the process variable (PV) input signal with a suitable calibration device.

3. Apply power and allow controller to warm up for 30 minutes.

4. Place controller in manual mode. Go to the PV INPUT menu, PV OFFSET parameter.

5. Adjust the calibration device to an output signal equal to the 0% range value for the particular input sensor (for example, 4mA for a 4-20 mA input).

6. Verify value indicated in the 1st display is equal to the 0% range value for the particular input sensor. If incorrect, use the

▲

and

▼


7. For a linear voltage or mA input: Press MENU to scroll to the PV GAIN parameter.

For other inputs: go to step #8.

8. Adjust the calibration device to an output signal equal to the 100% range value for the particular sensor.

9. Verify that the value shown in the 1st display is equal to 100% of the range value for the particular input sensor. If the value is not correct, use the

▲

and

▼


10. Repeat steps 4 through 8 to verify all values.

11. Press DISPLAY to return to the Operation mode.

16

531

Addendum

531

Appendix F, Page F-1 This section has been added: Appendix F, Isolation Block Diagram

PV

Input

RSP

Input

CV

Input

Slidewire

Input

Multiplexer

Power

Supply

+V

CPU

Output 1

ISO Ground

Referenced

Output 2

ISO Ground

Referenced

Output 3

ISO Ground

Referenced

Output 4

ISO Ground

Referenced

Digital

Inputs 1-5

Line

L

N

G

ISO

+Vd

+Ve

RS485 Serial

Communications

Interface

E

Isolated Output Ground

E

Earth Referenced Ground

Internal Ground

E

1. Each of the three ground circuits are isolated from each other to withstand a potential of 500 volts for 1 minutes, or 600 volts for

1 second.

2. CV, RSP, Slidewire and the PV & SP inputs are isolated to withstand 50 volts peak between each other for 1 minute.

3. Milliamp, Loop Power and SSR Drive modules in output position 1, 2, 3 and 4 are not isolated from each other.

4. Inputs are not isolated from the analog output due to the failsafe pass-through circuit.

+V

+V

Milliamp Module

Addendum

Mechanical Relay

SSR Driver

Loop Power

531

SSR Output

17

RETURN PROCEDURES



Warranty Repair –





2.


3.


4.



WARRANTY DISCLAIMER











WAY.











GOODS OR SERVICES.










BREACH.

RETURN POLICY



QUENTIAL DAMAGES.


Tel: (818) 894-7111 • FAX: (818) 891-2816


Tel: (02) 8536-7200 • FAX: (02) 9525-7296


Tel: 03/448.10.18 • FAX: 03/440.17.97


Tel: (0)344-617971 • FAX: (0)344-615920


Tel: 86-21-62491499 • FAX: 86-21-62490635


Tel: 01293 514488 • FAX: 01293 536852



500 SERIES

Process Controllers

Installation

Form M500 V6

5 0 0

Hardware Installation and Modification

Manual

for Electronic Products

Series 531, 532,

535, 545, 555

Model 2

Installation Guide

M500 V6, JUNE 2005

500 Series

1

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:

Display Assembly Kits

531-632 ............... 531 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

EPROM Kits

531-740 ................ 531 EPROM Kit

532-740 ............... 532 EPROM Kit

535-741 ................ 535 EPROM Kit (RSP)

535-775 ............... 535 Profiler EPROM Kit (No RSP)

535-776 ............... 535 Profiler EPROM Kit (RSP)

535-740 ................ 535 EPROM Kit (No RSP)

545-740 ................ 545 EPROM Kit (No RSP)

545-741 ................ 545 EPROM Kit (RSP)

555-740 ................ 555 EPROM Kit

Microcontroller (MCU) Board Kits

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)

* Universal Kit (can be used with all 500 Series Controllers)

HOW TO USE THIS 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)

2

500 Series Installation Guide

Installation

INSTRUCTIONS

To Disassemble the Unit

For any hardware modifications, disassemble the unit.

1.

With power off, loosen four captive front screws with a Phillips screwdriver. Remove the four screws.

one of 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.

Figure 2 (opposite page) shows the Microcontroller

Board, Option Board and Power Supply Board.

Figure 1

Location of Printed Circuit Boards for Hardware

Configuration

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 removing 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).

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 Photo 3. Pry Clips break the clips or scratch the circuit board.

The Microcontroller Board and Power Supply Board remain attached to the Operator Interface Assembly by wired connectors.

Photo 5.

Remove Retention Plate

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.

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).

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

Photo 4. Separate Boards

7.

Inspect each module before installation to make sure the pins are straight. Align the pins with the socket holes and

Photo 6.

Snip Tie Wrap on Mod. 4

carefully insert the module. Press down on the module to seat it firmly on the board.

Installation Guide 500 Series

3

4

Installation

Front of Unit Back of Unit

(toward Operator Interface) (toward rear terminals)

NOTE:

If you replace the EPROM chip, you must align the notch facing the front of the unit.

EPROM

BATTERY

5-Pin Connector



V

MA

TC

TC

RTD

TB2

V

MA

TC

TC

RTD

TB1

NOTE:

The 5- and 22-Pin connnectors on the boards are all keyed so they will only align one correct way.

Male 22-Pin

Connector

Remote Setpoint Jumper

Output 4

Male 22-Pin

Connector

Male 12-Pin

Connector

Male 22-Pin

Connector

12-Pin Female

Connector

5-Pin Connector

22-Pin Female

Connector

Module

Retention

Plate over Outputs 1,2,3

Figure 2

Microntroller Board,

Option Board, and

Power Supply Board

Jumpers

NO and NC

500 Series Installation Guide

Installation

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 ordering 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.

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.

CAUTION

Static discharge will cause damage to equipment. Always ground yourself with a wrist grounding strap when handling electronics to prevent static discharge.

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.

CAUTION

Do not scratch the boards or bend the pins of the connectors.

Installation Guide 500 Series

5

Declaration of Conformity

EMC Directive 89/336/EEC

Manufacturer’s Name:

Moore Industries-International, Inc.

Manufacturer’s Address: 16650 Schoenborn Street

North

USA

Declares that the product(s):

Product Name: 500 Series

MODEL / INPUT / OUTPUT / POWER / OPTIONS / HOUSING

Model Number(s): 500 Series * * 24 Vdc ** H or J *

*Indicates any input, output, option and housing as stated on the product data sheet.

**Indicates CE Compliant.

Conforms to the following EMC specifications:

EN61326-1, 1998, Electromagnetic Compatibility requirements for electrical equipment for control use.

Conforms to the following safety standard:

EN 61010-1, 2001

Supplemental Information:

CE option requires CE KIT PN 535-766.

Janurary 9, 2003

______________________________ _____________________________________

Date Fred Adt Robert Stockham

Quality Assurance Director Moore Industries-International, Inc.

European Contact: Your Local Moore Industries Sales and Service Office

Declaration of Conformity

EMC Directive 89/336/EEC

Manufacturer’s Name:

Moore Industries-International, Inc.

Manufacturer’s Address: 16650 Schoenborn Street

North

USA

Declares that the product(s):

Product Name: 500 Series

MODEL / INPUT / OUTPUT / POWER / OPTIONS / HOUSING

Model Number(s): 500 Series * * Universal Power ** H or J *

Supply

*Indicates any input, output, option and housing as stated on the product data sheet.

**Indicates CE Compliant.

Conforms to the following EMC specifications:

EN61326-1, 1998, Electromagnetic Compatibility requirements for electrical equipment for control use.

Conforms to the following safety standard:

EN 61010-1, 2001

Supplemental Information:

CE option requires CE KIT PN 535-765.

August 15, 2005

______________________________ _____________________________________

Date Fred Adt Robert Stockham

Quality Assurance Director Moore Industries-International, Inc.

European Contact: Your Local Moore Industries Sales and Service Office

RETURN PROCEDURES



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