Instruction Manual - Gilson Engineering Sales Inc.

Instruction Manual - Gilson Engineering Sales Inc.
5 3 5
5
3
5
1/4 DIN PROCESS CONTROLLER
USER'S MANUAL
M535 V5, © MAY 2002
Table of Contents
Table of Contents
PAGE
CHAPTER 1
INTRODUCTION .............................................................................. 1
535 Modes ........................................................................................ 1
Order Code, Packaging Information .................................................. 2
Where To Go Next ............................................................................ 2
Text formatting in this manual ............................................................ 2
CHAPTER 2
BASIC INTERFACE ......................................................................... 5
Displays ............................................................................................ 5
Icons (Lit) .......................................................................................... 5
Keys .................................................................................................. 6
Basic Operating Procedures ............................................................. 7
Alarm Operation ................................................................................ 8
About This Manual:
Throughout this User’s Manual
information appears along the
margins (NOTE:, CAUTION! and
WARNING!). Please heed these
safety and good practice notices for
the protection of you and your
equipment.
CHAPTER 3
INSTALLATION ............................................................................. 11
Mounting the Controller ................................................................... 11
Wiring ............................................................................................. 12
AC Power Input ...................................................................... 13
Process Variable Input ........................................................... 13
Digital Input(s) ........................................................................ 16
1. Digital Inputs with a Switch or Relay ............................... 16
2. Digital Inputs with an Open Collector .............................. 16
Remote Setpoint Option ......................................................... 16
Output Modules ...................................................................... 17
1. Mechanical Relay Output ............................................... 17
2. Solid State Relay (Triac) Output ..................................... 17
3. DC Logic (SSR Drive) Output ......................................... 18
4. Milliamp Output .............................................................. 18
5. Position Proportioning Output ......................................... 18
Serial Communications ........................................................... 19
Limit Control ........................................................................... 20
CHAPTER 4
HARDWARE SET UP ..................................................................... 21
Hardware Input Types ..................................................................... 21
The Process Variable ...................................................................... 21
The Remote Setpoint ...................................................................... 22
Mechanical Relays .......................................................................... 22
Accessing and changing jumpers .................................................... 23
Adding and Changing output modules ............................................. 24
Special Communications Module .................................................... 26
CHAPTER 5
SOFTWARE CONFIGURATION .................................................... 27
Menus ............................................................................................. 27
Parameters ..................................................................................... 28
Configuration and Operation ........................................................... 29
Where to Go Next ............................................................................ 29
535 User's Manual
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i
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PAGE
CHAPTER 5
CONTROLLER SET UP (cont’d)
Text Formatting in This Manual.......................................................... 29
Software Menus and Parameters ...................................................... 30
CONFIG.................................................................................. 30
PV1 INPUT ............................................................................. 34
PV2 INPUT ............................................................................. 36
CUST. LINR. ........................................................................... 38
CONTROL .............................................................................. 39
ALARMS ................................................................................. 41
REM. SETPT. .......................................................................... 46
RETRANS............................................................................... 47
SELF TUNE ............................................................................ 48
SPECIAL ................................................................................ 50
SECURITY.............................................................................. 51
SER. COMM. .......................................................................... 52
Parameter Value Charts ................................................................... 50
CHAPTER 6
TUNING .......................................................................................... 63
Overview ......................................................................................... 63
TUNING Menu Parameters ............................................................... 64
TUNING Parameter Value Chart ....................................................... 68
Self Tune Messages and Troubleshooting ......................................... 70
CHAPTER 7
APPLICATIONS .............................................................................. 71
A. Control Type ................................................................................ 71
B. Alarms ......................................................................................... 72
C. Duplex Control ............................................................................. 76
Duplex with reverse and direct acting outputs ............................ 77
Duplex with direct and reverse acting outputs ............................ 77
Duplex with 2 reverse acting outputs ......................................... 78
Duplex with a gap between outputs ........................................... 78
Duplex with overlapping outputs and output limits ...................... 79
Duplex with various relative gain settings ................................... 79
Duplex with one ON/OFF output ............................................... 80
Duplex with two ON/OFF outputs .............................................. 80
D. Slidewire Position Proportioning Control ........................................ 81
E. Velocity Position Proportioning Control .......................................... 82
F. Staged Outputs ............................................................................ 83
G. Retransmission ............................................................................ 83
H. Digital Inputs ................................................................................ 84
I. Remote Setpoint .......................................................................... 86
J. Multiple Setpoints ......................................................................... 87
K. Multiple Sets of PID Values ........................................................... 87
L. Powerback .................................................................................. 88
M. Self Tune—Powers POWERTUNE® ............................................ 89
Pretune by Itself ....................................................................... 89
Pretune TYPE 1 and Adaptive Tune .......................................... 91
Pretune TYPE 2 or TYPE 3 and Adaptvie Tune .......................... 91
Adaptive Tune by Itself ............................................................. 92
Self Tune with Multiple Sets of PID ............................................ 94
Self Tune with Time Proportioning Outputs ................................ 94
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535 User's Manual
Table of Contents
PAGE
CHAPTER 7
APPLICATIONS (cont’d)
Self Tune with Control Valves ................................................... 94
N. Ramp-to-Setpoint ......................................................................... 94
O. Input Linearization ........................................................................ 95
Thermocouple and RTD Linearization ....................................... 95
Square Root Linearization ........................................................ 95
Custom Linearization ............................................................... 96
P. Load Line ..................................................................................... 97
Q. Security ....................................................................................... 97
R. Reset Inhibition ............................................................................ 98
S. Process Variable Reading Correction ............................................ 98
T. Serial Communications ................................................................ 99
U. Cascade Control ........................................................................ 100
V. Ratio Control .............................................................................. 103
APPENDIX 1
MENU FLOWCHARTS .................................................................. A-1
APPENDIX 2
PARTS LIST .................................................................................. A-3
APPENDIX 3
TROUBLESHOOTING .................................................................. A-5
APPENDIX 4
CALIBRATION .............................................................................. A-7
Preparation for all Input Calibrations ................................................. A-8
Thermocouple Cold Junction Calibration ........................................... A-9
Analog Milliamp Input Calibration ...................................................... A-9
Milliamp Output Calibration ............................................................ A-10
Reset Menu Data .......................................................................... A-11
Hardware Scan ............................................................................. A-12
Slidewire Test ............................................................................... A-12
Quick Calibration Procedure .......................................................... A-12
APPENDIX 5
SPECIFICATIONS ........................................................................ A-13
APPENDIX 6
GLOSSARY ................................................................................. A-17
APPENDIX 7
ISOLATION BLOCK DIAGRAM ................................................... A-23
535 User's Manual
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iii
Table of Contents
List of Figures
FIGURE
DESCRIPTION
PAGE
Figure 2.1 ....... Operator Interface ............................................................... 5
Figure 2.2 ....... Before and After Acknowledging an Alarm ............................ 8
Figure 3.1 ....... Instrument Panel & Cutout Dimensions ............................... 11
Figure 3.2 ....... Attaching mounting collar ................................................... 11
Figure 3.3 ....... All 535 Terminal Assignments ............................................ 12
Figure 3.4 ....... AC Power Input Terminals ................................................. 13
Figure 3.5 ....... Process Variable Terminals ............................................... 13
Figure 3.6 ....... PV1 and PV2 Wiring for Milliamp, RTD and Voltage Inputs ... 14
Figure 3.7 ....... PV1 and PV2 Wiring for Milliamp Inputs with Internal and
External Power Supply ...................................................... 15
Figure 3.8 ....... Digital input Wiring with a Switch or Relay ............................ 16
Figure 3.9 ....... Digital Input Wiring with an Open Collector .......................... 16
Figure 3.10 ..... Remote Setpoint Terminals ................................................ 16
Figure 3.11 ..... Mechanical Relay Output Wiring ......................................... 17
Figure 3.12 ..... SSR Relay Output Wiring ................................................... 17
Figure 3.13 ..... DC Logic Output Wiring ..................................................... 18
Figure 3.14 ..... Milliamp Output Wiring ....................................................... 18
Figure 3.15 ..... Position Proportioning Output Wiring .................................. 18
Figure 3.16 ..... Serial Communications Terminals ...................................... 19
Figure 3.17 ..... 535 Wiring with Limit Control .............................................. 20
Figure 4.1 ....... Location of Printed Circuit Boards for Hardware
Configuration .................................................................... 21
Figure 4.2 ....... The Microcontroller Circuit Board, the Option Board, and the
Power Supply Board .......................................................... 22
Figure 4.3 ....... Representation of Module .................................................. 25
Figure 4.4 ....... Install Communications Module onto
Microcontroller Board ........................................................ 26
Figure 5.1 ....... Menu Flowchart for Set Up ................................................. 27
Figure 5.2 ....... Independent vs. Dependent Parameters ............................. 28
Figure 5.3 ....... Configuration Flowchart ..................................................... 28
Figure 6.1 ....... Access the Tuning Menu Block .......................................... 63
Figure 7.1 ....... Alarm Examples ................................................................ 75
Figure 7.2 ....... Duplex with reverse and direct acting outputs ...................... 77
Figure 7.3 ....... Duplex with direct and reverse acting outputs ...................... 77
Figure 7.4 ....... Duplex with two reverse acting outputs ............................... 78
Figure 7.5 ....... Duplex with a gap between outputs ..................................... 78
Figure 7.6 ....... Duplex with overlapping outputs and output limits ................ 79
Figure 7.7 ....... Duplex with various relative gain settings ............................ 79
Figure 7.8 ....... Duplex with one ON/OFF output ......................................... 80
Figure 7.9 ....... Duplex with two ON/OFF outputs ....................................... 80
Figure 7.10 ..... Staged Outputs Example ................................................... 83
Figure 7.11 ..... Combinations of Closed Digital Inputs for Each Setpoint (based
on BCD logic) .................................................................... 84
Figure 7.12 ..... Pretune TYPE 1, 2 and 3 with Adaptive Tune ....................... 90
Figure 7.13 ..... Noise Band Calculation Example ........................................ 92
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535 User's Manual
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FIGURE
DESCRIPTION
PAGE
Figure 7.14 ..... Noise Band Values for Temperature Inputs ......................... 93
Figure 7.15 ..... Deadtime and Time Constant ............................................. 93
Figure 7.16 ..... Square Root Linearization Formula .................................... 95
Figure 7.17 ..... 15-point Linearization Curve ............................................... 96
Figure 7.18 ..... Load Line Example ............................................................ 97
Figure 7.19 ..... Heat Exchanger Control Loop for Steam Supply ................ 100
Figure 7.20 ..... Cascade Control of Product Temperature ......................... 101
Figure 7.21 ..... Ratio Control in Mixing Application .................................... 103
Figure A4.1 ..... 535 Rear Terminals for Calibration ........................................ 7
Figure A4.2 ..... Flowchart Calibration Menus ................................................ 7
Figure A4.3 ..... Jumper Locations on the Microcontroller Circuit Board ........... 8
Figure A4.4 ..... Input Calibration Wiring ........................................................ 8
Figure A4.5 ..... Thermocouple/Cold Junction Calibration Wiring .................... 9
Figure A4.6 ..... Analog mA Input Calibration Wiring ..................................... 10
Figure A4.7 ..... Analog mA Input Jumper Positions ..................................... 10
Figure A4.8 ..... Milliamp Output Calibration Wiring ...................................... 11
Figure A4.9 ..... Output Module Menu Cycle ................................................ 11
Figure A4.10 ... Slidewire Test Wiring ......................................................... 12
535 User's Manual
Table of Contents
v
Table of Contents
vi
Table of Contents
535 User's Manual
Introduction
CHAPTER 1
INTRODUCTION
From its surge-resistant power supply to its rugged construction, the 535 process controller is designed to ensure the integrity of your process with maximum reliability — hour after hour, day after day. The isolated inputs and outputs guard against the dangers of electrical interference, the front face meets
NEMA 4X standards for watertight operation and exposure to corrosive environments, and the solid metal housing and sturdy rubber keys enhance durability and ESD protection.
The 535 has been engineered to be the industry’s most user–friendly process
controller. With three digital display areas — two offering up to 9 characters of
true alphanumerics — the 535 effectively eliminates the cryptic messages that
could confuse even the most experienced operator. The bright, crisp display
is vacuum fluorescent, and offers much better readability than any other display technology. Additional operator–friendly features include: custom programmable alarm messages, illuminated keys, and an easy–to–use menu
system.
The 535 is the most accurate instrument in its class. With a sampling rate of
ten times per second, it is ideal for demanding pressure and flow applications.
The 535 also offers a universal process input and modular, field interchangeable outputs that allow more flexibility than ever before. The RS-485 serial
communications interface allows the controller to utilize sophisticated software
routines and high speed hardware to provide exceptionally fast and accurate
transmission of data. The 535 also offers sophisticated control algorithms,
including Moore Industries’ exclusive Adaptive Tune which constantly analyzes your process and makes modifications to the tuning parameters to ensure you’re always under control.
Thank you for selecting the 535
Process Controller — the most
sophisticated instrument in its class.
It will provide you with years of
reliable, trouble-free performance.
Specifications and information subject to change without notice.
535 User’s Manual
Chapter 1
1
Introduction
535 MODES
There are three operating modes for the 535 controller:
OPERATION, the default mode of the controller. When the 535 is operating,
you can change setpoints, select manual control and change output level, acknowledge alarms and monitor conditions.
SET UP, also referred to as configuration. Here you set up the basic functions
of the instrument such as input and output assignments, alarm types and special functions.
TUNING, where you configure control function parameters for Proportional,
Integral and Derivation (PID). Use periodically to optimize the control performance of the instrument.
ORDER CODE, PACKAGING INFORMATION
Compare the product number to the ordering code on page 3 to determine the
outputs and options installed on the 535. The product number is printed on the
label on the top of the controller case.
Included with this 535 are:
• a 535 User’s Manual
• mounting hardware
• 1 sheet of Engineering unit adhesive labels
WHERE TO GO NEXT
•
•
•
To become more familiar with the 535 interface, continue to Chapter 2.
For important hardware installation guidelines, see Chapters 3 and 4.
For a detailed description of all the software menus and parameters of the
535, follow through Chapters 5 and 6. Appendix 1 can be used as a basic
guideline to these parameters.
TEXT FORMATTING IN THIS MANUAL
Feature
KEYS
ICONS
MENUS
PARAMETERS
PARAMETER VALUES
DISPLAY MESSAGES
2
Chapter 1
Format
SET PT
or
DISPLAY
SET PT
DISPLAY
OUT, ALM
CONFIG., TUNING,
CYCLE TM:1, MIN.OUT2
OFF, SETPOINT, LAST OUT.
TOO HOT, OUT%,
535 User’s Manual
Introduction
535 –
Output 1: Control
None
Mechanical Relay (5 amp)
Analog (milliamp)
Solid State Relay (triac) (1 amp)
DC Logic (SSR drive)
0
0
Order
Code
0
1
2
3
4
Output 2: Control, Alarm, or Retransmission
None
Mechanical Relay (5 amp)
Analog (milliamp)
Solid State Relay (triac) (1 amp)
DC Logic (SSR drive)
0
1
2
3
4
Output 3: Control, Alarm, Retransmission, or Loop Power
None
0
Mechanical Relay (5 amp)
1
Analog (milliamp)
2
Solid State Relay (triac) (1 amp)
3
DC Logic (SSR drive)
4
Loop Power
5
Output 4: Alarm, Retransmission, or Loop Power
None
Mechanical Relay (0.5 amp, 24 V)
Analog (milliamp)
Solid State Relay (triac) (0.5 amp, 24 V)
DC Logic (SSR drive)
Loop Power
0
1
2
3
4
5
Options
Enter “0” if not desired
Slidewire Feedback for Position
Proportioning Output
24 VAC/24 VDC Operation
Slidewire and 24 VAC/24 VDC
A
F
G
Remote Setpoint
Profile Controller Option
Remote Setpoint and Profile
B
C
E
Set of Five Digital Inputs
Certification
Five Digital Inputs and
D
H
J
Certification
Serial Communications
Enter “0” if not desired
RS-485 Serial Communications
S
Note 1 :
Capability for position proportioning output is specifed by ordering 535-11xxAxxx00, 535-33xxAxxx00, or 535-44xxAxxx00. Note 2: Capability for
velocity proportioning output is specifed by ordering 535-11xxxxxx00, 535-33xxxxxx00, or 535-44xxxxxx00. Note 3: Up to two outputs may be used for
alarms. Note 4: All outputs are interchangeable modules. Note 5: The mechanical relay and solid state relay modules are derated to 0.5 amp at 24 Vac
when used as the fourth output.
535 User’s Manual
Chapter 1
3
Introduction
4
Chapter 1
535 User’s Manual
Operation
CHAPTER 2
BASIC INTERFACE
535
Displays:
OUT
1 2
ALM
1 2
Icons
1st
2nd
3rd
Figure 2.1
Operator Interface
MANUAL
DISPLAY
ACK
MENU
Location for
identification
label
SET PT
FAST
Keys
DISPLAYS
The display strategy of the 535 Process Controller is the same for all control
modes.
1st Display (five 7-segment digits)
• For the process variable value.
2nd Display (nine 14-segment digits)
• For the setpoint, deviation, output level or valve position (if available)
• In TUNING or SET UP mode, for the parameter name.
• Upon power up, indicates the current setpoint.
3rd Display (nine 14-segment digits)
• For alarm messages, loop name, errors, etc.
• In TUNING or SET UP mode, the value or choice of parameter shown in
the 2nd display.
ICONS (LIT)
OUT
Indicates either 1) relay output is energized; or 2) analog output is
greater than 0%.
ALM1 Indicates the respective alarm (one) is active.
ALM2 Indicates the respective alarm (two) is active.
535 User's Manual
Chapter 2, Controller Operation
OUT
1
OUT
2
OUT
1 2
ALM
1
ALM
2
ALM
1 2
5
Operation
KEYS
FAST
MANUAL
SET PT
DISPLAY
FAST
FAST
+
+
6
+
MANUAL : Press to toggle between manual and automatic control.
When lit, indicates the unit is under manual control.
SET PT : Press to select the active SP.
When lit, indicates that a setpoint other than the primary (e.g., RSP, SP2) is
active.
DISPLAY : Press to toggle through values in the 2nd display for setpoint, ramping setpoint, deviation, PV1, PV2, output and valve position (each, if available).
In Tuning or Set Up mode, press to return controller to Operation mode (display will show current setpoint).
▲
▲ : Press to increase the value or selection of displayed parameter.
▲
FAST+▲
▲ : Press to scroll through values at a faster rate.
▼
▼ : Press to decrease the value or selection of displayed parameter.
▼
FAST+▼
▼ : Press to scroll through values at a faster rate.
ACK
FAST
FAST: Has no independent function. Press to modify the function of another
key (see below).
ACK : Press to acknowledge (an) alarm(s).
When lit, indicates there is an acknowledgeable alarm.
MENU
MENU : In Operation Mode, press to access the Tuning Menu.
In Set Up or Tuning mode, press to advance through a menu’s parameters.
(Use FAST+MENU to advance to the next menu.)
When lit, indicates the controller is in Set Up mode.
MENU
FAST+MENU : Press to access the Set Up menus.
In Set Up mode, press to advance through menus. (Use MENU by itself to
access the parameters of a particular menu.)
Chapter 2, Controller Operation
535 User's Manual
Operation
BASIC OPERATING PROCEDURES
Use the following as a quick guide to key operating functions of the 535.
To select /change a setpoint
NOTE:
See the glossary in Appendix 6 for
explanation of ramping and target
setpoint. Also refer to the applications
in Chapter 7.
1. Use DISPLAY key to toggle display to SetPoint.
2. Use SET PT key to toggle to active setpoint.
Before the newly selected setpoint is made active, there is a two-second
delay to prevent any disruptive bumps. If the setpoint displayed is
ramping, RAMPING will show the 3rd display.
3. To change value, press ▲ or ▼ .
To change from auto to manual control (bumpless transfer)
1. When in automatic control, press the MANUAL key at any time, except while
in the TUNING mode.
2. The MANUAL key will light in red, and the 2nd display will immediately
change to indicate current output level.
To change from manual to auto
1. When in manual control, press MANUAL at any time except while in the
TUNING or SET UP mode.
2. The 2nd display will not change, and the MANUAL key will no longer be lit
once control changes.
To change manual output values
1. Make sure the controller is under manual control.
2. Use the DISPLAY key to toggle 2nd display to output level.
3. Use the ▲ or ▼ key to change the value.
To override security
If a locked operation is attempted, SECURITY appears in the 2nd display for
two seconds).
1. Use the ▲ and ▼ keys to quickly enter the security code, which will show
in the 3rd display. The starting value is 0.
Note: Two seconds of key inactivity will clear the display.
2. If the code is correct, CORRECT appears in the 3rd display. The display
will clear after two seconds, allowing full access.
4. If code is incorrect, INCORRECT appears in the 3rd display. INCORRECT
will disappear after two seconds, and a new security code can then be
entered.
5. The controller will revert back to full security lock after one minute of key
inactivity.
To display control output value
1. Toggle DISPLAY key until the 2nd display shows OUT followed by the output
percentage. This value is the PID output.
• In duplex applications, this value does not directly refer to the output
signal (refer to the Chapter 7 section on Duplex Control for details.)
• For on/off outputs, the output value shown is either ON or OFF.
• For duplex applications with two on/off outputs, the OUT tag is not
shown. In this case, the status of both outputs is shown in the following
manner: 1:ON 2:OFF (1 and 2 are the respective outputs).
535 User's Manual
Chapter 2, Controller Operation
7
Operation
To display the active PID set
1. Press MENU to reach Tuning Mode.
2. In TUNING Mode, press MENU to reach the correct Menu parameter.
3. The active PID set will have an asterisk (*) on both sides of the value.
NOTE:
All alarms are software alarms unless
tied to an output relay in the SET UP
mode. See Chapters 5 and 7 for details
on alarms.
ALARM OPERATION
Alarms may be used in systems to provide warnings of unsafe conditions. All
535 operators must know how the alarms are configured, the consequences
of acknowledging an alarm and how to react to alarm conditions.
Alarm Indication
• lit icons ALM 1 and/or ALM 2
• lit ACK key
• displayed alarm message
Acknowledgable alarms meet the first two of these conditions.
Non-acknowledgable alarms only meet the first condition (only icon is lit).
BEFORE
AFTER
535
OUT
1
ALM
1
535
OUT
1
Figure 2.2
Before and After Acknowledging
an Alarm
NOTE:
Powering down the 535
acknowledges/clears all latched
alarms. When powering up, all
alarms will be reinitialized.
MANUAL
DISPLAY
ACK
MENU
SET PT
▲
MANUAL
DISPLAY
FAST
▼
ACK
MENU
SET PT
▲
FAST
▼
To acknowledge an alarm(s):
1. To acknowledge Alarm 1, press ACK once.
2. To acknowledge Alarm 2, press ACK twice.
3. If both alarms are activated, press ACK once to acknowledge Alarm 1, then
again to acknowledge Alarm 2.
4. The message and alarm icon dissappear.
Latching Alarms
If an alarm is set up to be latching (for details, see Chapter 5) then, in general,
it must be acknowledged in order to clear the alarm and release the relay (if
applicable). A non-latching alarm will clear itself as soon as the process leaves
the alarm condition.
8
Chapter 2, Controller Operation
535 User's Manual
Operation
Limit Sequence
An alarm can be configured to be both latching and non-acknowledgeable. In
this case, the alarm is acknowledgeable only after the process has left the alarm
condition. This is similar to the function of a limit controller.
More on Alarms
For more details on how to set up alarms and for examples of various ways
alarms can be set up, refer to the section on Alarms in Chapter 7.
535 User's Manual
Chapter 2, Controller Operation
9
Operation
10
Chapter 2, Controller Operation
535 User's Manual
Install / Wire
CHAPTER 3
INSTALLATION
MOUNTING THE CONTROLLER
The 535 front face is NEMA 4X rated (waterproof). To obtain a waterproof seal
between the controller and the panel, follow these directions:
1. The 535 fits in a standard 1/4 DIN cutout. Mount the 535 in any panel with
a thickness from .06 in. to .275 in. (1.5 mm to 7.0 mm).
2. Figure 3.1 shows the controller and panel dimensions. The panel cutout
must be precise, and the edges free from burrs and waves.
Figure 3.1
Instrument Panel & Cutout
Dimensions
7.180 (182.37) OVERALL LENGTH
PANEL
1.180 (29.97)
3.770 (95.76)
3.622 (92.00) MIN.
3.653 (92.80) MAX.
MANUAL
DISPLAY
ACK
MENU
SET PT
FAST
FRONT
3.585 (91.06)
3.622 (92.00) MIN.
3.653 (92.80) MAX.
3.770 (95.76)
535
OUT
1 2
ALM
1 2
s
t
BEZEL
GASKET
6.000 (152.40)
CUTOUT
SIDE
3. Place bezel gasket around the controller case (starting at the back of controller). Then, slide the gasket against the back of the bezel.
4. With the bezel gasket in place, insert the 535 into the panel cutout from the
front of the panel.
5. Slide the mounting collar over the back of the case, as shown in Figure 3.2.
The collar clip edges will lock with matching edges on the controller case.
Mounting Clip
Figure 3.2
Attaching mounting collar
Front Panel
Mounting Collar
535 User's Manual
Collar Screws (1 of 4)
Chapter 3
11
Install / Wire
CAUTION!
The enclosure into which the 535
Controller is mounted must be
grounded according to CSA
standard C22.2 No. 0.4.
6. Insert the four mounting collar screws from the rear of the collar. Gradually
tighten the screws (using a Phillips #2 screwdriver) to secure the controller
against the panel.
7. If there is difficulty with any of the mounting requirements, apply a bead of
caulk or silicone sealant behind the panel around the perimeter of the case.
WIRING
WARNING!
Avoid electrical shock. Do not
connect AC power wiring at the
source distribution panel until all
wiring connections are complete.
Powers 535 controllers are thoroughly tested, calibrated and “burned in” at the
factory, so the controller is ready to install. Before beginning, read this chapter
thoroughly and take great care in planning a system. A properly designed system
can help prevent problems such as electrical noise disturbances and dangerous
extreme conditions.
1. For improved electrical noise immunity, install the 535 as far away as
possible from motors, relays and other similar noise generators.
2. Do not run low power (sensor input) lines in the same bundle as AC power
lines. Grouping these lines in the same bundle can create electrical noise
interference.
3. All wiring and fusing should conform to the National Electric Code and to
any locally applicable codes.
4. An excellent resource about good wiring practices is the IEEE Standard
No. 518-1982 and is available from IEEE, Inc., 345 East 47th Street, New
York, NY 10017, (212) 705-7900.
Diagrams on the next three pages serve as guides for wiring different types of
process inputs. The shaded areas on the diagrams show which rear terminals
are used for that type of wiring.
TOP (as viewed from back of controller)
Figure 3.3
All 535 Terminal Assignments
Actual 535 device only has top and
bottom numbers of each column of
terminals marked.
WARNING!
ELECTRIC SHOCK HAZARD!
Terminals 1 and 2 carry live power.
DO NOT touch these terminals when
power is on.
WARNING!
Terminal 9 must be grounded to
avoid potential shock hazard, and
improved noise immunity to your
system.
12
L1
1
9
EARTH
GND
DIN
GND
17
25
not
used
L2/N
2
10 S/W 1
DIN 1
18
26
COMM–
OUT 1–
3
11 S/W 2
DIN 2
19
27
COMM+
OUT 1+
4
12 S/W 3
DIN 3
20
28
PV2–
OUT 2–
5
13 RSP–
DIN 4
21
29
PV2+
OUT 2+
6
14 RSP+
DIN 5
22
30
RTD 3RD
OUT 3–
7
15 OUT 4–
COLD
JUNC–
23
31
PV1–
OUT 3+
8
16 OUT 4+
COLD
JUNC+
24
32
PV1+
Chapter 3
535 User's Manual
Install / Wire
AC Power Input
Terminals 1 and 2 are for power. Terminal 9 is the earth ground.
NOTE:
Use a 0.5 Amp, 250 V, fast-acting fuse in line with your AC power connection. When wiring to a 240 Volt system, an
additional 0.5 Amp, 250V, fast-acting
TOP
fuse is required on L2.
POWER
1
9
2
EARTH/
GROUND
17
25
10
18
26
3
11
19
27
4
12
20
28
5
13
21
29
6
14
22
30
7
15
23
31
8
16
24
32
Figure 3.4
AC Power Input Terminals
CAUTION!
Do not run low power (sensor input)
lines in the same bundle as AC
power lines. Grouping these lines in
the same bundle can create electrical
noise interference.
Screws must be tight to ensure good electrical connection
Process Variable Input
The 535 accommodates the following types of process variable inputs:
• Thermocouple Input
• RTD Input
• Voltage Input
• Milliamp Input with External Power Supply
• Milliamp Input with Internal Power Supply
Each type of input can be wired for PV1 (terminals 31 and 32) or for PV2 (terminals 28 and 29).
Figure 3.5
Process Variable Terminals
1
9
17
25
2
10
18
26
3
11
19
27
4
12
20
28
PV 2–
5
13
21
29
PV 2+
6
14
22
30
RTD 3rd
7
15
23
31
PV 1–
8
16
24
32
PV 1+
535 User's Manual
Chapter 3
13
Install / Wire
NOTE:
Typically, in the U.S., negative leads
are red.
For PV1
For PV2
THERMOCOUPLE INPUT
THERMOCOUPLE INPUT
Figure 3.6
PV1 and PV2 Wiring for Milliamp,
RTD and Voltage Inputs.
30
31
32
–
28
+
29
–
+
2-WIRE RTD
2-WIRE RTD
Jumper wire
28
RTD
29
30
30
31
RTD
32
Jumper wire
3-WIRE RTD
3-WIRE RTD
Same color
Same
color
28
RTD
29
Third leg
of RTD
30
30
31
Third leg of RTD
32
4-WIRE RTD
4-WIRE RTD
Same color
Same color
30
Third leg
of RTD
28
31
29
32
30
Same color
Third leg
of RTD
DO NOTconnect 4th leg
VOLTAGE INPUT
31 –
32 +
14
Chapter 3
–
+ Transmitter
Do NOT
connect
4th leg
VOLTAGE INPUT
28 –
29 +
–
+ Transmitter
535 User's Manual
Install / Wire
For PV1
For PV2
MILLIAMP INPUT
MILLIAMP INPUT
2-wire transmitter with
separate power supply
2-wire transmitter with
separate power supply
31
– External
+
Power Supply
28
– External
+
Power Supply
32
– Transmitter +
29
– Transmitter +
MILLIAMP INPUT
MILLIAMP INPUT
2-wire transmitter with
loop power supply
2-wire transmitter with
loop power supply
–
–
15
+
16
+
15
2-wire
transmitter
16
–
–
+
+
31 –
28 –
32 +
29 +
MILLIAMP INPUT
4-wire transmitter with
loop power supply
4-wire transmitter with
loop power supply
–
16 +
–
+
Input power
for transmitter
– 4-20 mA output
+ from transmitter
–
–
16 +
+
15
Input power
for transmitter
– 4-20 mA output
+ from transmitter
31 –
28 –
32 +
29 +
535 User's Manual
NOTE:
To use loop power, there must be a
loop power module installed in the
3rd or 4th output socket. Compare
the controller product number with
the order code in Chapter 1 to
determine if the 535 has a loop
power module installed. To install a
loop power module, refer to
Chapter 4.
2-wire
transmitter
MILLIAMP INPUT
15
Figure 3.7
PV1 and PV2 Wiring for Milliamp
Inputs with Internal and External
Power Supply
Chapter 3
15
Install / Wire
Digital Input(s)
Digital inputs can be activated in three ways: a switch (signal type), closure of
a relay, or an open collector transistor. Digital inputs are only functional when
that option is installed (via hardware) The controller detects the hardware and
supplies the appropriate software menu.
1. Digital Inputs with a switch or relay
Figure 3.8
Digital input Wiring with a Switch or
Relay
Wire the switch/relay between terminal 17 and the specific digital input
terminal (Figure 3.8).
1
9
DIN
GND
17
25
DIN
GND
17
25
DIN
GND
17
25
DIN
GND
17
25
DIN
GND
17
25
2
10
DIN 1
18
26
DIN 1
18
26
DIN 1
18
26
DIN 1
18
26
DIN 1
18
26
3
11
DIN 2
19
27
DIN 2
19
27
DIN 2
19
27
DIN 2
19
27
DIN 2
19
27
4
12
DIN 3
20
28
DIN 3
20
28
DIN 3
20
28
DIN 3
20
28
DIN 3
20
28
5
13
DIN 4
21
29
DIN 4
21
29
DIN 4
21
29
DIN 4
21
29
DIN 4
21
29
6
14
DIN 5
22
30
DIN 5
22
30
DIN 5
22
30
DIN 5
22
30
DIN 5
22
30
7
15
23
31
8
16
24
32
b i h
l
S
i l
i
2. Digital Inputs with an Open Collector
Figure 3.9
Digital Input Wiring with an Open
Collector
An open collector is also called a transistor. Wire the transistor between
terminal 17 and the specified digital input terminal (Figure 3.9)
1
9
DIN
GND
17
25
DIN
GND
17
25
DIN
GND
17
25
DIN
GND
17
25
DIN
GND
17
25
2
10
DIN 1
18
26
DIN 1
18
26
DIN 1
18
26
DIN 1
18
26
DIN 1
18
26
3
11
DIN 2
19
27
DIN 2
19
27
DIN 2
19
27
DIN 2
19
27
DIN 2
19
27
4
12
DIN 3
20
28
DIN 3
20
28
DIN 3
20
28
DIN 3
20
28
DIN 3
20
28
5
13
DIN 4
21
29
DIN 4
21
29
DIN 4
21
29
DIN 4
21
29
DIN 4
21
29
6
14
DIN 5
22
30
DIN 5
22
30
DIN 5
22
30
DIN 5
22
30
DIN 5
22
30
7
15
23
31
8
16
24
32
Screws must be tight to ensure electrical connection
Remote Setpoint Option
Use terminals 13 and 14 to connect the remote setpoint signal (see Figure 3.10).
–
Figure 3.10
Remote Setpoint Terminals
16
–
Source +
Chapter 3
+
13
14
535 User's Manual
Install / Wire
OUTPUT MODULES
The 535 output modules are used for control, alarms and retransmission. The
four output module types are: Mechanical Relay, Solid State Relay (Triac),
DC Logic (SSR Drive) and Analog (Milliamp)
To install these modules, plug them into any of the four output sockets on the
printed circuit boards (refer to Chapter 4). The wiring is the same whether the
modules are used for control, alarm or retransmission.
The diagrams on the next two pages are a guide for properly connecting the
various outputs. To find out which module(s) have been installed in the
controller, compare the product number on the controller label with the section
Order Code in Chapter 1. This section also includes a diagram of how to wire
a position proportioning output, a special application using two mechanical or
two solid state relays.
1. Mechanical Relay Output
•
•
Output 1 is always Control 1.
Outputs 1, 2 and 3 are jumper selectable for normally open and
normally closed on the power supply circuit board.
Output 4 is always configured for normally open and has reduced
voltage and current ratings (see Specifications).
•
NOTE:
Refer to Figure 4.2 for location of the
corresponding jumpers.
Second input jumper connector on the
option board must be in either mA
(milliamp) or V (voltage) position.
Terminals used Terminals used Terminals used Terminals used
with Output
with Output
with Output
with Output
Module 4
Module 3
Module 1
Module 2
Line Power
3
3
5
7
15
4
6
8
16
Load
4
Figure 3.11
Mechanical Relay Output wiring
Recommend use of both MOV and snubber
2. Solid State Relay (Triac) Output
•
•
Output 1 is always Control 1.
Respective jumper J1, J2 or J3 must be set to normally open for SSR
(Triac) output.
Output 4 is always configured for normally open and has reduced
voltage and current ratings (see Specifications).
•
Terminals used Terminals used Terminals used Terminals used
with Output
with Output
with Output
with Output
Module 4
Module 3
Module 1
Module 2
Line Power
3
4
+
-
3
5
7
15
4
6
8
16
Load
+
Figure 3.12
SSR Relay Output Wiring
Recommend use of both MOV and snubber
535 User's Manual
Chapter 3
17
Install / Wire
3. DC Logic (SSR Drive) Output
•
•
•
Output 1 is always Control 1.
Respective jumper J1, J2 or J3 must be set to normally open for DC
Logic output.
Output 4 is always configured for normally open.
Terminals used Terminals used Terminals used Terminals used
with Output
with Output
with Output
with Output
Module 3
Module 4
Module 1
Module 2
Figure 3.13
DC Logic Output Wiring
3
_
_
+
4
3
5
7
15
4
6
8
16
Load
+
4. Milliamp Output
•
•
Output 1 is always Control 1.
Respective jumper J1, J2 or J3 must be set to normally open for
Milliamp output.
Terminals used Terminals used Terminals used Terminals used
with Output
with Output
with Output
with Output
Module 4
Module 3
Module 1
Module 2
Figure 3.14
Milliamp Output Wiring
3
4
_
+
3
5
7
15
4
6
8
16
Load
5. Position Proportioning Output
(with or without Slidewire Feedback)
POSITION
PROPORTIONING
OUTPUT
Electric Motor Actuator
CCW
Winding
CW
Winding
CCW
Slidewire Wiper
0–1050 Ohm
Figure 3.15
Position Proportioning Output
Wiring
CW
11
12
Actuator
Supply
Current
3
COM
18
10
Chapter 3
4
5
CCW COM
6
CW
535 User's Manual
Install / Wire
•
•
•
Mechanical relay or solid state relay modules must be installed in
output sockets 1 and 2.
When using velocity control (no slidewire feedback), there are no
connections at terminals 10, 11 and 12.
Use of the slidewire feedback is optional
Serial Communications
A twisted shielded pair of wires should be used to interconnect the host and
field units. Belden #9414 foil shield or #8441 braid shield 22-gauge wire are
acceptable for most applications. The foil shielded wire has superior noise
rejection characteristics. The braid shielded wire has more flexibility. The
maximum recommended length of the RS 485 line is 4000 feet. 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
our RS-232/RS-485 converter. The communication protocol is asynchronous
bidirectional half-duplex, hence the leads are labelled Comm + and Comm –
.
535
Terminals
PC
or other host
Twisted, shielded
RS-485
port
Comm –
26
Comm +
27
Figure 3.16
Serial Communications Terminals
To "Comm –" terminal of
next Moore Industries device
To "Comm +" terminal of
next Moore Industries device
Use a 60 to 100 Ohm terminating resistor
connected to the two data terminals of
the final device on the line.
CAUTION
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
communications problems.
535 User's Manual
Chapter 3
19
Install / Wire
Limit Control
Temperature applications where abnormally high or low temperature conditions
pose potential hazards for damage to equipment, product and operator. For
such applications, we recommend the use of an FM-approved temperature
limit device in conjunction with the process controller. This wiring example
illustrates a typical application using the 535 Process Controller with a 353 Limit
Controller.
Figure 3.17
535 Wiring with Limit Control
EARTH GROUND
535 PROCESS
CONTROLLER
25
CONTROLLER
AC POWER
17
26
9
18
27
10
19
28
1
11
20
29
2
12
21
30
22
31
23
32
3
L1
L2
4
13
5
14
6
15
7
16
T.C.
INPUT
24
8
0.5 AMP, 250 V,
FAST ACTING
FUSE
FAST ACTING
FUSE
L1
LOAD
POWER
MERCURY
RELAY
FOR CONTROL
L2
+
HIGH LIMIT
MECHANICAL
CONTACTOR
1
20
2
19
3
18
4
17
-
COIL
5
16
6
15
7
14
8
13
9
12
10
11
N.O.
L2
HEAT
LOAD
RELAY/
CONTACTOR
COIL POWER
PROCESS SENSOR
FAST
ACTING
FUSE
T/C INPUT
L1
L2
INDICATOR ON
WHEN LIMIT TRIPS
LIMIT CONTROLLER
AC POWER
L2
L1
OPTIONAL
MOMENTARY SWITCH
MANUAL RESET
FOR LIMIT CONTROL
FUSE
353 LIMIT CONTROLLER
LIMIT SENSOR
20
Chapter 3
535 User's Manual
Hardware Set Up
CHAPTER 4
HARDWARE SET UP
Hardware configuration determines the available outputs as well as the type of
input signal. The 535 controller comes factory set with the following:
• All specified modules and options installed (for details, refer to the Order
Code in Chapter 1).
• Process variable and remote setpoint set to accept a milliamp input.
• Relay outputs set to normally open.
Altering the factory configuration of the 535, requires accessing the circuit
boards, and locating the jumpers and output modules (see Figure 4.1).
1. With the power off, loosen the four front screws, and remove them.
2. Slide chassis out of the case by pulling firmly on the bezel.
NOTE: Hardware configuration of the
controller is available at the factory;
Consult a Moore Industries application
engineer for details.
FRONT FACE
MIC
BO ROCO
ARD
NTR
O
LLE
R
POW
BOA ER SUP
RD
PLY
Figure 4.1
Location of Printed Circuit Boards for
Hardware Configuration
OPTION BOARD
A detailed view of the circuit boards appears in Figure 4.2.
After configuring the hardware, or if no changes are necessary, continue setting up the process as needed.
HARDWARE INPUT TYPES
The Process Variable
The 535 accepts several different types of process variable signals. Set a jumper
location to specify the type of input signal. Set the signal range in the software
(see Chapter 5 for software menus, or Chapter 7 for applications).
The jumpers for the process variable are located on the Microcontroller Circuit
Board (see Figure 4.2). The factory default is Milliamp. Locations are marked
as follows:
V
Voltage
MA
Milliamp
TC ▼
Thermocouple with downscale burnout
TC ▲
Thermocouple with upscale burnout
RTD
RTD
535 User's Manual
Chapter 4
NOTE: Thermocouple downscale
and upscale burnout offers a choice
in which direction the controller
would react in the event of
thermocouple failure. For example,
in heat applications, typically, it is
desirable to fail upscale (TC s) so
that the system does not apply more
heat.
21
Hardware Set Up
NOTE:
Changing the jumpers means
moving the jumper connector. The
jumper connector slips over the pins,
straddling two rows of pins. The
printed circuit boards are labeled
next to the jumpers.
The Remote Setpoint
Figure 4.2 shows the location of the remote setpoint jumper. The factory default is milliamp. Choose from the following settings:
V Remote setpoint with voltage signal (jumper removed)
MA Remote setpoint with milliamp signal (jumper installed)
Mechanical Relays
There are three output module sockets on the Power Supply Circuit Board, and
one output module on the Option Board (see Figure 4.2). The mechanical relay on the Power Supply Board may be configured for either normally open (NO)
or normally closed (NC). A jumper located next to each socket determines this
configuration. All relay outputs are factory set to NO (normally open).
P1
EPROM
P2
V
MA
TC t
TC s
RTD
5-Pin Connector
Female 22-Pin Connector
Female 22-Pin Connector
PV1
Figure 4.2
(from the top) The Microcontroller
Circuit Board, the Option Board, and
the Power Supply Board
2ND
TB2
V
MA
TC t
TC s
RTD
BATTERY
TB1
Remote Setpoint Jumper
Male 22-Pin
Connector
Output 4
4
Male 22-Pin
Connector
Female 34-Pin Connector
5-Pin Connector
Module
Retention
Plate
over Outputs 1,2,3
3
2
1
NO J1 NC NO J2 NC NO J3 NC
Male 34-Pin
Connector
Jumpers
NO and NC
22
Chapter 4
535 User's Manual
Hardware Set Up
ACCESSING AND CHANGING JUMPERS
Follow these instructions to change jumpers for the Process Variable, Remote
Setpoint and Digital Inputs:
Equipment needed:
Needle-nose pliers (optional)
Phillips screwdriver (#2)
Wrist grounding strap
1. With power off, loosen two front screws, and remove them.
2. Side the chassis out of the case by pulling firmly on the bezel.
3. Use Figure 4.2 to locate the jumper connector to change.
4. Using the needle nose pliers (or fingers), pull straight up on the connector
and remove it from its pins, as shown in Photo 4. Be careful not to bend the
pins.
CAUTION!!
Static discharge can cause damage
to equipment. Always use a wrist
grounding strap when handling
electronics to prevent static
discharge.
4. Remove Jumpers
5. Find the new location of the jumper connector (again, refer to Figure 3.2).
Carefully place it over the pins, then press connector straight down. Make
sure it is seated firmly on the pins.
6. Make any other jumper changes as needed. To alter output modules,
please refer to the next section, starting with Step #3.
7. To reassemble the controller, properly orient the chassis with board opening on top. Align the circuit boards into the grooves on the top and bottom
of the case. Press firmly on the front face assembly until the chassis is all
the way into the case.
If it is difficult to slide the chassis in all the way, make sure the screws have
been removed (they can block proper alignment), and that the chassis is
properly oriented.
8. Carefully insert and align screws. Tighten them until the bezel is seated firmly
against the gasket. Do not overtighten.
535 User's Manual
Chapter 4
23
Hardware Set Up
ADDING AND CHANGING OUTPUT MODULES
The 535 has provisions for four output modules. A controller ordered with output
module options already has the modules properly installed. Follow these instructions to add modules, change module type(s) or change module
location(s).
Equipment needed:
Wrist grounding strap
Phillips screwdriver (#2)
Small flat blade screwdriver
Wire cutters
1. With power off, loosen two front screws, and remove them.
2. Side the chassis out of the case by pulling firmly on the bezel.
3. Use a flat screwdriver to carefully pry apart the clips that hold the front face
assembly to the chassis, as in Photo 3. Separate the printed circuit board
assembly from the front face assembly. Use care not to break the clips or
scratch the circuit boards.
4. As shown in Photo 4, carefully pry apart, using hands or a small flat screwdriver, the smaller Option board and the Power Supply board (the one with
3 modules).
5. To change modules 1, 2 or 3:
Output modules 1, 2, and 3 are firmly held in place by a retention plate and
tie wrap. Carefully snip the tie wrap with a wire cutter. To prevent damage
to the surface mount components, ALWAYS snip the tie wrap on TOP of
the Retention Plate, as shown in Photo 5.
Remove the retention plate.
3. Pry Clips
24
4. Separate Boards
Chapter 4
5. Remove Retention Plate
535 User's Manual
Hardware Set Up
6. To change module 4:
Output Module 4 (on the Option board) is also held in place by a tie wrap.
Snip tie wrap to remove module as shown in Photo 6.
7. Figure 4.3 shows a representation of an output module. Inspect the
module(s) to make sure that the pins are straight.
8. To install any module, align its pins with the holes in the circuit board, and
carefully insert the module in the socket. Press down on the module until it
is firmly seated; refer to Photo 8.
Figure 4.3
Representation of Module
6. Snip Tie Wrap
8. Add/Change Module
9. Replace tie wraps for all the modules (the Retention Plate and Output
Module 4) with new ones before reassembling the controller.
Failure to use the tie wraps may result in loosening of the module and eventual failure. All separately ordered modules should come with a tie wrap.
Extra sets of tie wraps are available by ordering Part #535-665.
10.Rejoin the circuit boards by aligning the pins of their connectors, then
squeezing the board(s) together. Make sure that all three printed circuit
boards are properly seated against one another; check along side edges
for gaps. Make sure the cable assemblies are not pinched.
11.To reattach the board assembly to the front face assembly, align the boards
(with the open area on top) into the slots of the font face assembly. The clips
should snap into place.
12.To reassemble the controller, properly orient the chassis with board opening on top. Align the circuit boards into the grooves on the top and bottom
of the case. Press firmly on the front face assembly until the chassis is all
the way into the case.
If it is difficult to slide the chassis in all the way, make sure the screws have
been removed (they can block proper alignment), and that the chassis is
properly oriented.
13.Carefully insert and align screws. Tighten them until the bezel is seated firmly
against the gasket. Do not overtighten.
NOTE: For greatest accuracy, calibrate all milliamp modules added for retransmission as per the instructions in
Appendix 2.
SPECIAL COMMUNICATIONS MODULE
A special communications module is available for the 535; see order code in
Chapter 1 for details.
535 User's Manual
Chapter 4
25
Hardware Set Up
Equipment needed:
1.
2.
3.
4.
5.
Wrist grounding strap
Phillips screwdriver (#2)
Small flat blade screwdriver
Before installing the communications module, set up the hardware wiring
for the application. See Chapter 4 for details.
With power off, loosen two front screws, and remove them.
Slide the chassis out of the case by pulling firmly on the bezel. Do not detach the board assembly form the front face of the controller.
Orient the Communications Module as shown, and attach it to Connectors
P1 and P2 as shown in Figure 4.4.
To reassemble the controller, properly orient the chassis with board opening on top. Align the circuit boards into the grooves on the top and bottom
Insert module onto connectors
Front of controller
(circuits boards still attached to front face)
P1
EPROM
P2
Figure 4.4
Install Communications Module
onto Microcontroller Board
BATTERY
REMOTE SP
CONFIGURATION
V
MA
TCt
TCs
RTD
2ND
TB2
of the case. Press firmly on the front face assembly until the chassis is all
the way into the case.
If it is difficult to slide the chassis in all the way, make sure the screws have
been removed (they can block proper alignment), and that the chassis is
properly oriented.
6. Carefully insert and align screws. Tighten them until the bezel is seated firmly
against the gasket. Do not overtighten.
26
Chapter 4
535 User's Manual
Controller Set Up
CHAPTER 5
SOFTWARE CONFIGURATION
The software configuration menus of the 535 contain user-selected variables
that define the action of the controller. Read through this section before making
any parameter adjustments to the controller.
When initially setting up the
controller, cycle through all the
parameters in each Menu.
Press the MENU+FAST to
advance to the next Menu.
Press MENU to advance to the
next parameter (this also sets the
value for the current parameter.
Use arrow keys to select a value).
Use the arrows keys to enter
numerical values, and/or move
through the selection group.
This is a Menu.
Its name will show in the 2nd display.
press:
MENU/FAST
CONFIG.
press:
MENU
press:
This is a menu Parameter.
The name shows in the 3rd display.
In this manual, independent parameters appear
as white text on black, and dependent
parameters appear as black text on white.
INDICATOR
(D)
press MENU/FAST
Go to next Menu Block:
This is a parameter Value.
These values appear in the 3rd display,
replacing the parameter name.
In this manual, parameter graphics indicate
the default (factory) setting.
If the default value is dependent on other
variables, (D) is shown.
MENUS
In Set Up mode, there are 13 sets of options that control different aspects of 535
operation; in Tuning mode, there is one. Each set of options is called a menu.
When traversing the two modes, the menu names appear in the 2nd display.
CONFIG
Mode selection and input/output hardware assignments
PV1 INPUT 1st process variable input options
PV2 INPUT 2nd process variable input options
CUST. LINR. Linearization curve options for PV1 input.
CONTROL
Control options
ALARMS
Alarm options
REM. SETPT. Controller remote setpoint options
RETRANS.
Retransmission output options
SELF TUNE Self tune algorithm options
SPECIAL
Special feature options
SECURITY
Security functions
SER.COMM. Serial Communications options (requires comm. board)
and
TUNING
Tuning parameters configuration (see Chapter 6)
535 User's Manual
Figure 5.1
Menu Flowchart for Set Up
Chapter 5
CAUTION!
All software changes occur in real time;
always perform set up functions under
manual operation.
NOTE: For information about the
Tuning menu/mode, refer to Chapter 6.
For more information about set up
parameters and 535 applications, refer
to Chapter 7.
27
Controller Set Up
TUNE PT.
CONTACT 1
AUTOMATIC
MANUAL
Figure 5.2
Independent vs. Dependent
Parameters
PARAMETERS
Within each menu are parameters for particular control functions. Select values for each parameter depending on the specific application. Use the MENU
key to access parameters for a particular menu; the parameter name will replace the menu name in the 2nd display, and the parameter value will show in
the 3rd display.
This chapter outlines all the available parameters for the 535. Some parameters
are independent of any special configuration, and others are dependent on
the individual configuration. This manual displays these two types of parameters differently; refer to Figure 5.2. A special feature of the 535, called Smart
Menus, determines the correct parameters to display for the specific configuration, so not all the listed parameters will appear.
MANUAL
OPERATION
for
TUNING mode
TUNING
Figure 5.3
Configuration Flowchart
or
to return to
OPERATION
mode
+
for SET UP
mode
or
for
OPERATION mode
+
for SET UP
mode
SET UP
CONFIG
PV1 INPUT
PV2 INPUT
CUST. LINR.
+
to toggle through
the 12 menu blocks
in SET UP mode
CONTROL
ALARMS
REM. SETPT.
RETRANS.
SELF TUNE
SPECIAL
SECURITY
SER. COMM.
28
Chapter 5
535 User's Manual
Controller Set Up
CONFIGURATION AND OPERATION
Figure 5.3 shows the relationships among the different modes of the 535 and
the configuration menus:
• SET UP menus can only be accessed from manual control. To transfer the
535 from automatic to manual control, press MANUAL.
• To access the SET UP menus, hold down FAST and press MENU. The
MENU key will illuminate; and CONFIG will appear in the 2nd display.
• To access the parameters for a particular menu, press MENU.
• To select a parameter value, use ▲ and ▼ . Press MENU to advance to the
next parameter, or FAST+MENU to advance to the next menu.
• To advance to the next menu, press FAST+MENU.
• TUNING mode (and the TUNING menu) can be accessed from either automatic or manual control. To access the tuning menu, press MENU .
• To return controller to manual control, press DISPLAY or SET PT.
A key to these functions (as shown below) appears at the bottom of every page
in the menu section of this chapter.
Access Set Up
FAST
+
MENU
Return to Operation
DISPLAY
Next menu
FAST
+
MENU
Next parameter
MENU
Next value
▲
▼
Access Tuning
Return to Operation
MENU
DISPLAY
WHERE TO GO NEXT
•
•
•
•
•
•
For information about all the software menus and parameters, continue reading this chapter. Refer to Appendix D for a quick-reference flowchart of all
menus and parameters.
For information about the installed options on the 535, compare the product
label on top of the controller to the order code in Chapter 1.
To mount the controller and configure the wiring of the 535 for inputs and
outputs, see Chapter 3.
To alter the output module and jumper configuration of the controller, see
Chapter 4.
For more information about applications for the 535, see Chapter 6.
For more information about the Tuning function of the 535, see Chapter 7.
535 User's Manual
Chapter 5
29
Controller Set Up
SOFTWARE MENUS AND PARAMETERS
CONFIG.
CONFIG.
CTRL. TYPE
STANDARD
1. CTRL. TYPE
Defines the type of control output(s).
D
•
•
•
LINE FREQ
60 Hz
STANDARD
POS. PROP.
STAGED
DUPLEX
Standard control output, no special algorithms
Position proportioning control output
Staged outputs
Duplex outputs
2. LINE FREQ
Defines the power source frequency.
• 50 HZ
D 60 HZ
3. PV SOURCE
PV SOURCE
PV1
Defines how the PV input is derived from PV1 and PV2.
D
•
•
•
•
•
•
•
NOTE:
PV1 and PV2 can be of different types and
different range.
PV1
1/2:SWITCH
1/2:BACKUP
PV1–PV2
PV1+PV2
AVG. PV
HI SELECT
LO SELECT
Use PV1
Use PV1 until contact/com selects PV2
Use PV2 if PV1 is broken
Use PV1–PV2
Use PV1+PV2
Use the average of PV1 and PV2
Use PV1 or PV2 (whichever is greater)
Use PV1 or PV2 (whichever is less)
4. REM. SETPT.
REM. SETPT.
DISABLED
Selects function of the remote setpoint.
D DISABLED
• ENABLED
5. OUTPUT 2
Defines the function of the second output.
•
•
•
•
D
OUTPUT 2
OFF
Access Set Up
FAST
30
+
MENU
Return to Operation
DISPLAY
ALM.RLY:ON
ALM.RLY:OFF
RETRANS.
COMM. ONLY
OFF
Next menu
FAST
+
MENU
Chapter 5
Next parameter
MENU
Retransmission
Output addressable through communication
Completely deactivates the output
Next value
▲
▼
Access Tuning
Return to Operation
MENU
DISPLAY
535 User's Manual
Controller Set Up
6. OUTPUT 3
OUTPUT 3
OFF
Defines the function of the third output.
7.
•
ALM.RLY:ON
•
ALM.RLY:OFF
•
RETRANS.
Retransmission
•
COMM. ONLY
Output addressable through communications
D OFF
Completely deactivates the output
OUTPUT 4
Defines the function of the fourth output.
•
•
•
•
D
ALM.RLY:ON
ALM.RLY:OFF
RETRANS.
COMM. ONLY
OFF
OUTPUT 4
OFF
Retransmission
Output addressable through communications
Completely deactivates the output
8. ANLG. RNG.:1
Defines the output signal for the first output.
D
•
•
•
ANLG.RNG.:1
4-20 mA
4–20 mA
0–20 mA
20–4 mA
20–0 mA
9. ANLG. RNG.:2
ANLG.RNG.:2
4-20mA
Defines the output signal for the second output.
D
•
•
•
4–20 mA
0–20 mA
20–4 mA
20–0 mA
10. ANLG. RNG.:3
Defines the output signal for the third output.
D
•
•
•
ANLG.RNG.:3
4-20mA
4–20 mA
0–20 mA
20–4 mA
20–0 mA
11. ANLG. RNG.:4
ANLG.RNG.:4
Defines the output signal for the fourth output.
D
•
•
•
4–20 mA
0–20 mA
20–4 mA
20–0 mA
4-20mA
Access Set Up
Return to Operation
+
DISPLAY
FAST
MENU
535 User's Manual
Next menu
FAST
+
MENU
Next parameter
MENU
Next value
▲
Chapter 5
▼
Access Tuning
Return to Operation
MENU
DISPLAY
31
Controller Set Up
CONTACT 1
MANUAL
12. CONTACT 1
Defines the operation of the first digital input.
•
SETPT. 1–8
•
D
•
•
•
•
•
•
•
•
REM. SETPT.
MANUAL
2ND. SETPT.
2ND. PID
ALARM ACK.
RST. INHBT.
D.A./R.A.
STOP A/T
LOCK. MAN.
UP KEY
Assigns the first four digital inputs to select
setpoints 1 through 8 via BCD signal
Makes the remote setpoint active
Trips the controller to manual control
Makes the second setpoint active
Makes the second set of PID values active
Acknowledges alarms
Deactivates the reset term
Switches the control action
Suspends the adaptive tune function
Locks controller in manual control
Remote ▲ function
•
DOWN KEY
Remote ▼ function
•
DISP KEY
Toggle between SP DEV or OUT%
•
FAST KEY
Activates FAST key
•
MENU KEY
Activates MENU key.
•
COMM. ONLY
Status readable only through communications
•
PV2.SWITCH
Switches between PV1 and PV2
13. CONTACT 2
CONTACT 2
Defines the operation of the second digital input.
REM.SETPT.
D
•
•
•
•
•
•
•
•
•
REM. SETPT.
MANUAL
2ND. SETPT.
2ND. PID
ALARM ACK.
RST. INHBT.
D.A./R.A.
STOP A/T
LOCK. MAN.
UP KEY
•
DOWN KEY
Makes the remote setpoint active
Trips the controller to manual control
Makes the second setpoint active
Makes the second set of PID values active
Acknowledges alarms
Deactivates the reset term
Switches the control action
Suspends the adaptive tune function
Locks controller in manual control
Remote ▲ function
Remote ▼ function
•
DISP KEY
Toggle between SP DEV or OUT%
•
FAST KEY
Activates FAST key
•
MENU KEY
Activates MENU key.
•
COMM. ONLY
Status readable only through communications
•
PV2.SWITCH
Switches between PV1 and PV2
Access Set Up
FAST
32
+
MENU
Return to Operation
DISPLAY
Next menu
FAST
+
MENU
Chapter 5
Next parameter
MENU
Next value
▲
▼
Access Tuning
Return to Operation
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DISPLAY
535 User's Manual
Controller Set Up
14. CONTACT 3
CONTACT 3
2ND. SETPT.
Defines the operation of the third digital input.
•
•
D
•
•
•
•
•
•
•
REM. SETPT.
MANUAL
2ND. SETPT.
2ND. PID
ALARM ACK.
RST. INHBT.
D.A./R.A.
STOP A/T
LOCK. MAN.
UP KEY
•
DOWN KEY
Makes the remote setpoint active
Trips the controller to manual control
Makes the second setpoint active
Makes the second set of PID values active
Acknowledges alarms
Deactivates the reset term
Switches the control action
Suspends the adaptive tune function
Locks controller in manual control
Remote ▲ function
Remote ▼ function
•
DISP KEY
Toggle between SP DEV or OUT%
•
FAST KEY
Activates FAST key
•
MENU KEY
Activates MENU key.
•
COMM. ONLY
Status readable only through communications
•
PV2.SWITCH
Switches between PV1 and PV2
15. CONTACT 4
Defines the operation of the fourth digital input.
CONTACT 4
•
•
•
D
•
•
•
•
•
•
REM. SETPT.
MANUAL
2ND. SETPT.
2ND. PID
ALARM ACK.
RST. INHBT.
D.A./R.A.
STOP A/T
LOCK. MAN.
UP KEY
•
DOWN KEY
Makes the remote setpoint active
Trips the controller to manual control
Makes the second setpoint active
Makes the second set of PID values active
Acknowledges alarms
Deactivates the reset term
Switches the control action
Suspends the adaptive tune function
Locks controller in manual control
Remote ▲ function
Remote ▼ function
•
DISP KEY
Toggle between SP DEV or OUT%
•
FAST KEY
Activates FAST key
•
MENU KEY
Activates MENU key.
•
COMM. ONLY
Status readable only through communications
•
PV2.SWITCH
Switches between PV1 and PV2
Access Set Up
Return to Operation
+
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FAST
MENU
535 User's Manual
Next menu
FAST
+
MENU
Next parameter
MENU
2ND. PID
Next value
▲
Chapter 5
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DISPLAY
33
Controller Set Up
16. CONTACT 5
CONTACT 5
ALARM ACK.
This defines the operation of the fifth digital input.
•
•
•
•
D
•
•
•
•
•
REM. SETPT.
MANUAL
2ND. SETPT.
2ND. PID
ALARM ACK.
RST. INHBT.
D.A./R.A.
STOP A/T
LOCK. MAN.
UP KEY
•
DOWN KEY
Makes the remote setpoint active
Trips the controller to manual control
Makes the second setpoint active
Makes the second set of PID values active
Acknowledges alarms
Deactivates the reset term
Switches the control action
Suspends the adaptive tune function
Locks controller in manual control
Remote ▲ function
Remote ▼ function
•
DISP KEY
Toggle between SP DEV or OUT%
•
FAST KEY
Activates FAST key
•
MENU KEY
Activates MENU key.
•
COMM. ONLY
Status readable only through communications
17. LOOP NAME
A 9-character message associated with the loop. The first character of the 3rd
display will be flashing. To enter message, press ▲ and ▼ 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.
LOOP NAME
LOOP ONE
D LOOP ONE
PV INPUT
PV1 INPUT
1. PV1 TYPE
Specifies the particular sensor range or input range for PV1.
PV1 TYPE
T/C
J T/C
D
•
•
•
•
•
•
•
•
•
•
CAUTION!
Set parameter values in the presented
order—dependent parameters are
dynamically related and changing values
of one can alter the value of another.
For example, if SP LO LIM. is set to 0,
and then thermocouple type is changed
to B T/C, the SP LO LIM. value will
change to 104° (the low limit of a type B
thermocouple).
Access Set Up
FAST
34
+
MENU
Return to Operation
DISPLAY
J T/C
D
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
Next menu
FAST
+
RTD
MENU
Chapter 5
DIN RTD
JIS RTD
SAMA RTD
Next parameter
MENU
VOLTAGE
CURRENT (mA)
D
•
•
•
•
•
•
D 4-20mA
• 0-20mA
Next value
▲
▼
1-5 V
0-5 V
0-10 mV
0-30 mV
0-60 mV
0-100 mV
+/– 25 mV
Access Tuning
Return to Operation
MENU
DISPLAY
535 User's Manual
Controller Set Up
2. DEG. F/C/K
DEG. F/C/K
FAHR
Selects the PV1 temperature units if using a thermocouple or RTD.
D FAHR.
• CELSIUS
• KELVIN
DECIMAL
XXXXX
3. DECIMAL
Specifies the PV1 decimal point position.
D
•
•
•
•
XXXXX
XXXX.X
XXX.XX
XX.XXX
X.XXXX
4. LINEARIZE
LINEARIZE
Specifies if the PV1 input is to be linearized. NOTE: T/C’s and RTD’s are automatically linearized.
D NONE
• SQR. ROOT
• CUSTOM
NONE
Square root linearization is activated.
15-point custom linearization curve is
activated.
LOW RANGE
5. LOW RANGE
Specifies the engineering unit value corresponding to the lowest PV1 input
value, e.g. 4 mA.
(D)
R –9999 to 99999
Max. is HI RANGE
D Dependent on the input selection
6. HI RANGE
HI RANGE
(D)
Specifies the engineering unit value corresponding to the highest PV1 input
value, e.g., 20mA.
R -9999 to 99999
Min. is LOW RANGE
D Dependent on the input selection
SP LO LIM.
(D)
7. SP LO LIM.
Defines the lowest setpoint value that can be entered from the front panel only.
R –9999 to 99999
Max. is SP HI LIM. Min. is LOW RANGE
D Dependent on the LOW RANGE value.
SP HI LIM.
8. SP HI LIM.
(D)
Defines the highest setpoint value that can be entered from the front panel only.
R –9999 to 99999
Min. is SP LO. LIM. Maximum is HI RANGE
D Dependent on HI RANGE
Access Set Up
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+
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FAST
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535 User's Manual
Next menu
FAST
+
MENU
Next parameter
MENU
Next value
▲
Chapter 5
▼
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Return to Operation
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DISPLAY
35
Controller Set Up
SP RAMP
OFF
9. SP RAMP
Defines the rate of change for setpoint changes.
D OFF
Deactivates this function
R 1 to 99999 units per hour
10. FILTER
FILTER
Specifies the setting for the low pass PV1 input filter.
R 0 to 120 seconds
D 0 seconds
0
OFFSET
0
GAIN
1.000
RESTORE
LAST MODE
PV2 INPUT
11. OFFSET
Defines the offset to PV1 in engineering units.
R –9999 to 99999
D 0
12. GAIN
Defines the gain to PV1.
R 0.100 to 10.000
D 1.000
13. RESTORE
Defines the control mode when a broken PV1 signal is restored.
D LAST MODE
• MANUAL
• AUTOMATIC
PV2 INPUT
1. PV2 SETUP
Defines function of PV2
D SAME.AS.PV1
PV2 SETUP
SAME.AS.PV1
Access Set Up
FAST
36
+
MENU
Return to Operation
DISPLAY
•
NOT PV1
Next menu
FAST
+
MENU
Chapter 5
Next parameter
MENU
All PV2 parameters are set to the same values
as PV1 (no further parameters will appear)
Enables user to enter different values for the
following PV2 parameters
Next value
▲
▼
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535 User's Manual
Controller Set Up
2. PV2 TYPE
PV2 TYPE
J/TC
Selects the particular sensor or input range for PV2
T/C
D
•
•
•
•
•
•
•
•
•
•
RTD
J T/C
D
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
DIN RTD
JIS RTD
SAMA RTD
VOLTAGE
CURRENT (mA)
D
•
•
•
•
•
•
D 4-20mA
• 0-20mA
1-5 V
0-5 V
0-10 mV
0-30 mV
0-60 mV
0-100 mV
+/– 25 mV
3. DECIMAL
DECIMAL
Specifies the PV2 decimal point position.
D
•
•
•
•
XXXXX
XXXX.X
XXX.XX
XX.XXX
X.XXXX
XXXXX
4. LINEARIZE
LINEARIZE
Specifies if the PV2 input is to be linearized. Thermocouples and RTD’s are
automatically linearized.
D NONE
• SQR. ROOT
NONE
Square root linearization is activated.
5. LOW RANGE
LOW RANGE
(D)
Specifies the engineering unit value corresponding to the lowest PV2 input
value, e.g. 4 mA.
R –9999 to 99999
Max. is HI RANGE
D Dependent on the input selection
6. HI RANGE
HI RANGE
Specifies the engineering unit value corresponding to the highest PV2 input
value, e.g. 20 mA.
(D)
R -9999 to 99999
Min. is LOW RANGE
D Dependent on the input selection
7. FILTER
FILTER
0
Setting for the low pass PV2 input filter.
R 0 to 120 seconds
D 0 seconds
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+
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MENU
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Chapter 5
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37
Controller Set Up
OFFSET
0
8. OFFSET
Defines the offset to PV2 in engineering units.
R –9999 to 99999
D 0
9. GAIN
Defines the gain for PV2.
GAIN
1.000
R 0.100 to 10.000
D 1.000
10. RESTORE
Defines the control mode when a broken PV2 signal is restored.
RESTORE
LAST MODE
CUST. LINR.
D LAST MODE
• MANUAL
• AUTOMATIC
CUST. LINR.
Defines a custom linearization curve for PV1, if selected. Points 1 and 15 are
fixed to the low and high end of the input range and require only setting a
corresponding PV value. Points 2 through 14 (the Xth points) require setting
both the input and PV values.
It is not necessary to use all 15 points. Whenever the XTH INPUT becomes the
high end of the range, that will be the last point in the linearization table.
1ST. INPUT
1. 1ST. INPUT
Specifies the input signal corresponding to the first point.
(D)
D The low end of the appropriate input range (e.g. 4.00 mA)
2. 1ST. PV
Specifies the engineering unit value corresponding to the first point.
1ST. PV
R –9999 to 99999
D 0
0
3. XTH. INPUT
Specifies the input signal corresponding to the XTH point (X is 2 to 14).
XTH INPUT
(D)
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 unit value corresponding to the XTH point (X is 2 to 14).
XTH PV
0
Access Set Up
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38
+
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Return to Operation
DISPLAY
R –9999 to 99999
D 0
Next menu
FAST
+
MENU
Chapter 5
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MENU
Next value
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535 User's Manual
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5. 15TH. INPT.
15TH INPT.
(D)
Specifies the input signal corresponding to the 15th point.
R –9999 to 99999
Minimum is [XTH-1] INPUT
D The high end of the appropriate input range (e.g. 20.00 mA)
6. 15TH. PV
15TH PV
Specifies the engineering unit value corresponding to the 15th point.
R –9999 to 99999
D 0
0
CONTROL
CONTROL
For configuring the choices for the control algorithm.
1. ALGORITHM
ALGORITHM
PID
Defines the type of control algorithm.
D
•
•
•
•
•
PID
PI
PD
P
ON/OFF
PID:ON/OFF
For Duplex applications using PID for the first output and
on/off for the second output
2. D. SOURCE
D. SOURCE
PV
Selects the variable for the derivative action.
D
•
PV
DEVIATION
Derivative term will not react when setpoint changes
Derivative term will react when setpoint changes
3. ACTION:1
ACTION:1
REVERSE
Defines the action of the first control output.
•
D
DIRECT
REVERSE
4. PV BREAK
Defines the manual output level if the process variable input is lost. Choose
values based on the process type.
Standard Control
On/Off Control
Velocity Prop Control
•
D
•
D
•
•
D
–5 to 105%
0
ON
OFF
PV BREAK
(D)
CW
CCW
OUTS. OFF
5. LOW OUT.
Defines the lowest output value that can be achieved in automatic control.
R
D
0 – 100%
0%
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LOW OUT
Max is HIGH OUT
0
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39
Controller Set Up
HIGH OUT.
100
6. HIGH OUT.
Defines the highest output value that can be achieved in automatic control.
R 0 – 100%
D 100%
Min is LOW OUT
7. ACTION:2
ACTION:2
DIRECT
Defines the action of the second control output.
D DIRECT
• REVERSE
8. P.P. TYPE
P.P. TYPE
Defines the type of position proportioning algorithm. Choose values based on
the process.
(D)
Feedback option installed
Feedback option not installed
D SLIDEWIRE
• VELOCITY
• SLIDEWIRE
D VELOCITY
9. CCW TIME
CCW TIME
Defines the time it takes a motor to fully stroke counter clockwise.
R 1 to 200 seconds
D 60 seconds
60
10. CW TIME
Defines the time it takes a motor to fully stroke clockwise .
CW TIME
R 1 to 200 seconds
D 60 seconds
60
11. MIN. TIME
Defines the minimum amount of time the controller must specify for the motor to
be on before it takes action.
MIN. TIME
0.1
R 0.1 to 10.0 seconds
D 0.1 seconds
12. S/W RANGE
S/W RANGE
100
OPEN F/B
Specifies the full range resistance of the slide (e.g., 100 ohms)
R 0–1050 Ohms
D 100 Ohms
13. OPEN F/B
Defines the feedback ohm value corresponding to full open (100% output).
(D)
Access Set Up
FAST
40
+
MENU
R 0 to S/W RANGE
D Dependent on S/W RANGE value
Return to Operation
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+
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14. CLOSE F/B
CLOSE F/B
100
Defines the feedback ohm value corresponding to full close (0% output).
R 0 to S/W RANGE
D 100 Ohms
15. OUT1 STOP
OUT1 STOP
50
This defines the stopping point for control output 1 when staging outputs.
R 1 to 100%
D 50%
16. OUT2 STRT.
OUT2 STRT.
Defines the starting point for control output 2 when staging outputs.
50
R 0 to 99%
D 50%
ALARMS
ALARMS
1. ALM. TYPE:1
Defines the type of alarm for alarm 1.
•
•
•
HIGH ALRM.
LOW ALARM
HIGH/LOW
•
•
•
•
•
D
BAND
DEVIATION
MANUAL
REMOTE SP
RATE
OFF
ALM. TYPE:1
OFF
Separate High & Low alarm setpoints in one
alarm
Causes an alarm when in manual control
Causes an alarm when in Remote Setpoint
Selects a rate-of-change alarm
Deactivates the first alarm
2. ALM. SRC:1
ALM. SRC:1
Selects the source of the value being monitored by HIGH, LOW or HIGH/LOW
alarm 1.
D
•
•
•
•
•
PV
PV
SP
RAMP SP
DEVIATION
OUTPUT
PV2
Access Set Up
Return to Operation
+
DISPLAY
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Controller Set Up
ALARM SP:1
0.0%
3. ALARM SP:1
Specifies the alarm set point for alarm 1 (except HIGH/LOW)
For HIGH or LOW alarms:
If ALM.SRC.:1 = OUTPUT
R 0.0% to 100.0%
D 0.0%
For BAND alarms:
If ALM.SRC.:1 = any other type
R LOW RANGE to HI RANGE
D 0
R 1 to 99999
D 0
For DEVIATION or RATE alarms:
R -9999 to 99999
D 0
4A. HIGH SP:1
Specifies the high alarm set point for alarm 1 of type HIGH/LOW.
HIGH SP:1
If ALM.SRC.:1 = OUTPUT
R 0.0% to 100.0%
D 0.0%
0.0%
If ALM.SRC.:1 = any other type
R LOW RANGE to HI RANGE
D 0
4B. LOW SP:1
Specifies the low alarm set point for alarm 1 of type HIGH/LOW.
If ALM.SRC.:1 = OUTPUT
R 0.0% to 100.0%
D 0.0%
LOW SP:1
0.0%
If ALM.SRC.:1 = any other type
R LOW RANGE to HI RANGE
D 0
5. DEADBAND:1
Defines the deadband for alarm 1.
DEADBAND:1
2
If ALM.SRC.:1 = OUTPUT
R 0.1% to 100.0%
D 2
If ALM.SRC.:1 = any other type
R 1 to 99999
D 2
6. ALM.:1 OUT.
Selects the output number for alarm 1.
ALM.:1 OUT
NONE
LATCHING:1
NONE
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D
•
•
•
NONE
2
3
4
7. LATCHING:1
Defines the latching sequence of alarm 1.
D LATCH
• NO LATCH
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8. ACK.:1
ACK.:1
ENABLED
Defines whether alarm 1 may be acknowledged.
D ENABLED
• DISABLED
Allows the alarm to be acknowledged
Prevents the alarm from being acknowledged
while in alarm condition
9. POWER UP:1
Defines how alarm 1 will be treated on power up.
D NORMAL
• ALARM
• DELAYED
POWER UP:1
NORMAL
Alarm depends on process variable
Always power up in alarm regardless of PV
Must leave alarm condition and reenter before
activating the alarm
10. MESSAGE:1
MESSAGE:1
A 9-character message associated with alarm 1. To enter message: The first
character of third display will be flashing. Press the ▲ and ▼ keys to scroll
through the character set. Press FAST key to advance to subsequent
characters. Press the MENU to advance to next parameter.
ALARM 1
D ALARM 1.
11. ALM. TYPE:2
ALM. TYPE:2
Defines the type of alarm for alarm 2.
•
•
•
HIGH ALRM.
LOW ALARM
HIGH/LOW
•
•
•
•
•
D
BAND
DEVIATION
MANUAL
REMOTE SP
RATE
OFF
OFF
Separate High & Low alarm setpoints in one
alarm
Causes an alarm when in manual control
Causes an alarm when in Remote Setpoint
Selects a rate-of-change alarm
Deactivates the first alarm
ALM.SRC.:2
PV
12. ALM. SRC:2
Selects the source of the value being monitored by HIGH, LOW or HIGH/LOW
alarm 2.
D
•
•
•
•
•
PV
SP
RAMP SP
DEVIATION
OUTPUT
PV2
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Controller Set Up
ALARM SP:2
(D)
13. ALARM SP:2
Specifies the alarm set point for alarm 2 (except HIGH/LOW)
For HIGH or LOW alarms:
If ALM.SRC.:2 = OUTPUT
R 0.0% to 100.0%
D 0.0%
For BAND alarms:
If ALM.SRC.:2 = any other type
R LOW RANGE to HI RANGE
D 0
R 1 to 99999
D 0
For DEVIATION or RATE alarms:
R -9999 to 99999
D 0
14A. HIGH SP:2
HIGH SP:2
Specifies the high alarm set point for alarm 2 of type HIGH/LOW.
If ALM.SRC.:2 = OUTPUT
R 0.0% to 100.0%
D 0.0%
0.0%
If ALM.SRC.:2 = any other type
R LOW RANGE to HI RANGE
D 0
14B. LOW SP:2
Specifies the low alarm set point for alarm 2 of type HIGH/LOW.
LOW SP:2
0.0%
If ALM.SRC.:2 = OUTPUT
R 0.0% to 100.0%
D 0.0%
If ALM.SRC.:2 = any other type
R LOW RANGE to HI RANGE
D 0
15. DEADBAND:2
Defines the deadband for alarm 2.
If ALM.SRC.:2 = OUTPUT
R 0.1% to 100.0%
D 2
DEADBAND:2
2
If ALM.SRC.:2 = any other type
R 1 to 99999
D 2
16. ALM.:2 OUT.
Selects the output number for alarm 2.
D
•
•
•
ALM.:2 OUT.
NONE
NONE
2
3
4
17. LATCHING:2
Defines the latching sequence of alarm 2.
LATCHING:2
D LATCH
• NO LATCH
LATCH
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18. ACK.:2
ACK.:2
ENABLED
Defines whether alarm 2 may be acknowledged.
D ENABLED
• DISABLED
Allows the alarm to be acknowledged
Prevents the alarm from being acknowledged
while in alarm condition
19. POWER UP:2
POWER UP:2
Defines how alarm 2 will be treated on power up.
D NORMAL
• ALARM
•
Alarm depends on process variable
Always power up in alarm regardless of
process variable
Must leave alarm condition and reenter before
activating the alarm
DELAYED
NORMAL
MESSAGE:2
20. MESSAGE:2
ALARM 2
A 9-character message associated with alarm 2. To enter message: The first
character of third display will be flashing. Press the ▲ and ▼ keys to scroll
through the character set. Press FAST key to advance to subsequent
characters. Press MENU to advance to next parameter.
D ALARM 2.
21. FAULT
FAULT
Defines whether either of the alarm relays will trip if a fault condition (lost
process variable) is detected. Only appears if at least one alarm relay is
installed.
OFF
D OFF
• ALARM 1
• ALARM 2
OUTPUT
NO ACTION
22. OUTPUT
Defines whether a rate-of-change alarm is interpreted as a lost or broken
process variable (causing a trip to manual output).
• P.V. BREAK
D NO ACTION
RATE TIME
5
23. RATE TIME
Defines the time period over which a rate-of-change alarm condition is
determined.
R 1 to 3600 seconds
D 5 seconds
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Controller Set Up
REM. SETPT.
RSP. TYPE
1-5 4-20
RSP:LO RNG.
REM. SETPT.
This menu appears only if parameter REM. SETPT (of the CONFIG. menu) =
ENABLED.
1. TYPE V/mA
Specifies the type of input signal that will be used for remote setpoint.
D 1-5 /4-20
• 0-5/0-20
1–5 volt or 4–20 mA remote setpoint
0–5 volt or 0–20 mA remote setpoint
2. RSP:LO RNG.
0
Specifies the engineering unit value corresponding to the lowest remote
setpoint input value, e.g. 4 mA.
R -9999 to 99999
D 0
RSP:HI RNG.
3. RSP:HI RNG.
Specifies the engineering unit value corresponding to the highest remote
setpoint input value, e.g. 20 mA.
1000
RSP:LOW
(D)
R –9999 to 99999
D 1000
4. RSP: LOW
Defines the lowest setpoint value to be accepted from the remote setpoint
source.
R –9999 to 99999.
D Dependent on RSP:LO.RNG. value.
RSP:HIGH
5. RSP: HIGH
(D)
Defines the highest setpoint value from a remote setpoint source.
TRACKING
NO
R –9999 to 99999
D Dependent on RSP:HI.RNG. value
6. TRACKING
Defines whether the local setpoints 1 to 8 will track the remote setpoint.
D NO
• YES
BIAS LOW
7. BIAS LOW
-1000
Defines the lowest bias value that may be entered.
R –9999 to 99999.
D –1000
BIAS HIGH
1000
8. BIAS HIGH
Defines the highest bias value that may be entered.
R –9999 to 99999.
D 1000
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9. RSP FIXED
RSP: FIXED
LOCAL
Defines what happens if remote setpoint is lost while it is active and then is
restored.
• REMOTE SP
D LOCAL
Returns to remote setpoint when it is restored
Local setpoint remains active when RSP is
restored
RETRANS.
RETRANS.
1. TYPE:2
TYPE:2
Defines what is to be retransmitted for output 2
D PV
• SETPOINT
• RAMP SP
•
PV
This refers to the linearized process variable
This is the target setpoint
This is the ramping, or actual setpoint, when the
setpoint is ramping
This is the control output value
CTRL. OUT
2. LOW RANGE:2
LO RANGE:2
(D)
Defines the low end of the range for output 2 in engineering units. Does not appear
for type CTRL.OUT.
R –9999 to 99999
D Dependent on the process variable range
3. HI RANGE:2
Defines the high end of the range for output 2 in engineering units. Does not
appear for type CTRL.OUT.
HI RANGE:2
(D)
R –9999 to 99999
D Dependent on the process variable range
4. TYPE:3
Defines what is to be retransmitted for output 3
D PV
• SETPOINT
• RAMP SP
•
TYPE:3
PV
This refers to the linearized process variable
This is the target setpoint
This is the ramping, or actual setpoint, when the
setpoint is ramping
This is the control output value
CTRL. OUT
5. LOW RANGE:3
LO RANGE:3
Defines the low end of the range for output 3 in engineering units. Does not appear
for type CTRL.OUT.
(D)
R –9999 to 99999
D Dependent on the process variable range
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Controller Set Up
6.
HI RANGE:3
(D)
R
D
7.
TYPE:4
PV
LO RANGE:4
(D)
HI RANGE:3
Defines the high end of the range for output 3 in engineering units. Does not
appear for type CTRL.OUT.
8.
TYPE:4
Defines what is to be retransmitted for output 4
D
•
•
PV
SETPOINT
RAMP SP
•
CTRL. OUT
HI RANGE:4
(D)
SELF TUNE
1.
2.
3.
TUNE PT.
AUTOMATIC
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TYPE
Defines the type of self tuning algorithm that is available.
•
•
•
PRETUNE
ADAPTIVE
BOTH
D
DISABLED
Allows the operator to initiate Pretune only
Allows the operator to initiate Adaptive Tune only
Allows the operator to initiate both Pretune and
Adaptive Tune
Both Pretune and Adaptive Tune are disabled
PRETUNE
Defines the type of pretune algorithm that is available.
D
•
•
TYPE 1
FAST
–9999 to 99999
Dependent on the process variable range
SELF TUNE
PRETUNE
Return to Operation
–9999 to 99999
Dependent on the process variable range
HI RANGE:4
Defines the high end of the range for output 4 in engineering units. Does not
appear for type CTRL.OUT.
R
D
TYPE
DISABLED
Access Set Up
This refers to the linearized process variable
This is the target setpoint
This is the ramping, or actual setpoint, when the
setpoint is ramping
This is the control output value
LOW RANGE:4
Defines the low end of the range for output 4 in engineering units. Does not appear
for type CTRL.OUT.
R
D
9.
–9999 to 99999
Dependent on the process variable range
TYPE 1
TYPE 2
TYPE 3
Normally used with slower thermal processes
Normally used with faster fluid or pressure processes
Normally used with level control applications
TUNE PT.
Defines the PV value at which the output will switch off during a TYPE 1 pretune.
Helps prevent overshoot.
R Any value in PV input range
D AUTOMATIC (Controller defines this point, low end for Automatic)
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4. OUT. STEP
OUT.STEP
10.0
Defines the output step size in absolute percent during a TYPE 2 or TYPE 3
pretune.
R –50% to 50.0%
D 10.0%
5. LOW LIMIT
LOW LIMIT
Defines the lower most limit the process variable can reach during pretune
before aborting.
(D)
R Any value in the process variable range
D Dependent on the process variable range
6. HI LIMIT
HI LIMIT
Defines the upper most limit the process variable can reach during pretune
before aborting.
(D)
R Any value in the process variable range
D Dependent on the process variable range
7. TIMEOUT
TIMEOUT
1500
This defines the execution time limit for pretune before aborting.
R 8 to 1500 minutes
D 1500 minutes
MODE
8. MODE
Defines the control mode after pretune is completed or aborted.
AUTOMATIC
• MANUAL
D AUTOMATIC
NOISE BND.
0.2
9. NOISE BND.
Defines the noise band to be used by the adaptive tuning algorithm.
R 0.1% to 10% of the process variable range
D 0.2%
10. RESP. TIME
RESP. TIME
Defines response time to be used by the adaptive tuning algorithm.
60
R 10 to 32000 seconds
D 7200 seconds
11. DEAD TIME
Defines the amount of time required for process to begin to respond to an output
change (used by POWERBACK algorithm).
DEAD TIME
0.1
R 0.1 seconds to 7200.0 seconds
D 0.1 seconds
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Controller Set Up
SPECIAL
SPECIAL
1. AUTO. TRIP
Defines the condition under which the 535 will automatically trip to automatic
control from manual control upon start up.
AUTO. TRIP
OFF
D OFF
• RISING PV
•
FALLNG. PV
Deactivates this function
Will trip when a rising process variable is within
the specified deviation from the setpoint
Will trip when a falling process variable is within
the specified deviation from the setpoint
2. TRIP DEV.
Defines the deviation from setpoint at which the controller will trip to automatic.
TRIP DEV.
(D)
For AUTO. TRIP = RISING PV
For AUTO. TRIP = FALLING PV
R -99999 to 0
D 0
R 0 to 99999
D 0
3. DES. OUTPT.
If a digital input is defined to trip the controller to manual mode, this designates
the output value after the trip. LAST OUT means that the output value will be
equal to the last output value while in automatic. Choose values based on the
process.
DES. OUTPT.
(D)
Standard Control
On/Off Control
Velocity Prop Control
• –5 to 105%
D LAST OUT
• ON
D OFF
• CW
• CCW
D OUTS. OFF
4. POWER UP
Defines the control mode upon power up.
POWER UP
D LAST MODE
LAST MODE
•
PRETUNE
•
•
MANUAL
AUTOMATIC
Will power up in the same mode prior to power
down
Will Pretune on every power up.
(Recommended for TYPE 1 pretune only.)
5. PWR. UP:OUT.
PWR.UP:OUT.
(D)
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Defines the output of the controller if powering up in manual mode. “LAST OUT”
means that the output value will be equal to the last output value while in
automatic. Choose values based on the process.
Standard Control
On/Off Control
Velocity Prop Control
• –5 to 105%
D LAST OUT
• ON
D OFF
• CW
• CCW
D OUTS. OFF
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6. PWR. UP:SP
PWR. UP:SP
Defines the setpoint upon power up.
D LAST SP
•
•
Powers up with the same setpoint (local or
remote) that was active prior to power down
Powers up using primary local setpoint
Powers up using remote setpoint, if available
LOCAL
REMOTE
LAST SP
7. NO. OF SP
NO. OF SP
Defines the number of local setpoints (up to 8) to be stored for selection by BCD
(binary coded decimal), digital inputs, or front SET PT key.
R
1 through 8
D
1
1
SECURITY
SECURITY
For configuring the security function.
SEC. CODE
1. SEC. CODE
0
Defines the security code temporarily unlocking the instrument.
R –9999 to 99999
D 0
2. SP ADJUST
SP ADJUST
UNLOCKED
Defines lockout status setpoint changes.
D UNLOCKED
• LOCKED
3. AUTO./MAN.
AUTO./MAN.
UNLOCKED
Defines lockout status of the MANUAL key.
D UNLOCKED
• LOCKED
4. SP SELECT
SP SELECT
UNLOCKED
Defines lockout status of the SET PT key.
D UNLOCKED
• LOCKED
5. ALARM ACK.
ALARM ACK
UNLOCKED
Defines lockout status of the ACK key.
D UNLOCKED
• LOCKED
6. TUNING
TUNING
Defines lockout status of the tuning parameters.
UNLOCKED
D UNLOCKED
• LOCKED
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Controller Set Up
CONFIGURE
UNLOCKED
SER. COMM.
7. CONFIGURE
Defines lockout status of the configuration parameters.
D UNLOCKED
• LOCKED
SER. COMM.
1. STATION
Defines the unit’s station address.
STATION
R 1 to 99
• OFF
D 1
1
Disables the communications function
2. BAUD RATE
Defines the baud rate.
BAUD RATE
9600
CRC
YES
•
•
•
D
•
1200 BPS
2400 BPS
4800 BPS
9600 BPS
19200 BPS
3. CRC
Defines whether CRC (cyclic redundancy check) is being calculated.
D YES
• NO
SHED TIME
4. SHED TIME
Defines the time interval between communications activity before the controller
determines that communications is lost (“sheds”).
OFF
R 1 to 512 seconds
D OFF
5. SHED MODE
Defines the state of the controller if communications is lost (“sheds”).
D LAST MODE Remain in automatic or manual control (last mode
before losing communications)
SHED MODE
LAST MODE
SHED OUT.
•
•
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Trip to manual control
Trip to automatic control
6. SHED OUT.
Defines the output if the unit sheds and trips to manual control. Choose values
based on the process.
(D)
Access Set Up
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AUTOMATIC
Standard Control
On/Off Control
Velocity Prop Control
• –5 to 105%
D LAST OUT
• ON
D OFF
• CW
• CCW
D OUTS. OFF
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7. SHED SP
SHED SP
LAST SP
Defines the setpoint status if communications is lost.
D LAST SP
•
Continues to use setpoint that was active prior
to losing communications
Goes to a designated setpoint value if
communications is lost.
DESIG. SP
8. DESIG. SP
DESIG. SP
(D)
Defines the value of the designated setpoint if communications is lost.
R Any value in the process variable range
D Dependent on the process variable range
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Controller Set Up
PARAMETER VALUE CHARTS
This section of value charts is provided for logging in the actual parameter
values and selections for the process. It is recommended that these pages
be photocopied so there will always be a master.
CONFIG
Parameter
Description
Values
1. CTRL. TYPE
Defines fundamental controller Set Up
2 LINE FREQ.
Defines the power source frequency
3 PV SOURCE
Defines how PV input is derived from PV1 and PV2
4 REM. SETPT.
Selects function of the remote setpoint
5 OUTPUT 2
Function of the second output
6 OUTPUT 3
Function of the third output
7 OUTPUT 4
Function of the fourth output
8 ANLG.RNG.:1
Output signal for the first output
9 ANLG.RNG.:2
Output signal for the second output
10 ANLG.RNG.:3
Output signal for the third output
11 ANLG.RNG.:4
Output signal for the fourth output
12 CONTACT 1
Operation of the first digital input
13 CONTACT 2
Operation of the second digital input
14 CONTACT 3
Operation of the third digital input
15 CONTACT 4
Operation of the fourth digital input
16 CONTACT 5
Operation of the fifth digital input
17 LOOP NAME
Nine character message associated with control loop
54
Chapter 5
535 User's Manual
Controller Set Up
PV1 INPUT
Parameter
Description
Value
1 PV1 TYPE
PV1 sensor or range to be used
2 DEG. F/C/K
PV1 temperature engineering unit
3 DECIMAL
PV1 decimal point position
4 LINEARIZE
Type of PV1 input linearization
5 LOW RANGE
Engineering unit value for lowest PV1 input value
6 HI RANGE
Engineering unit value for highest PV1 input value
7 SP LO LIM.
Lowest setpoint value that can be entered
8 SP HI LIM.
Highest setpoint value that can be entered
9 SP RAMP
Rate of change for setpoint changes
10 FILTER
Setting for the low pass PV1 input filter (in seconds)
11 OFFSET
Offset to PV1 in engineering units
12 GAIN
Gain to PV1
13 RESTORE
Control mode when a broken PV1 is restored
PV2 INPUT
Parameter
Description
Value
1 PV2 SETUP
Makes PV2 input parameters match PV1, or user definable.
2 PV2 TYPE
PV2 sensor or range to be used
3 DECIMAL
PV2 decimal point position
4 LINEARIZE
Type of PV2 input linearization
5 LOW RANGE
Engineering unit value for lowest PV2 input value
6 HI RANGE
Engineering unit value for highest PV2 input value
7 FILTER
Setting for the low pass PV2 input filter (in seconds)
8 OFFSET
Offset to the PV2 in engineering units
9 GAIN
Gain to PV2
10 RESTORE
Control mode when a broken PV2 is restored
535 User's Manual
Chapter 5
55
Controller Set Up
ALARMS
Parameter
Description
Value
1 ALM. TYPE:1
Type of alarm for alarm 1
2 ALM. SRC.:1
Source of value monitored by HIGH, LOW or HIGH/LOW
alarm 1
3 ALARM SP:1
Alarm setpoint for alarm 1 (except for HIGH/LOW)
4A HIGH SP:1
High alarm setpoint for HIGH/LOW alarm 1
4A LOW SP:1
Low alarm setpoint for HIGH/LOW alarm 1
5 DEADBAND:1
Deadband for alarm 1
6 ALM.:1 OUT.
Output number for alarm 1
7 LATCHING:1
Latching sequence for alarm 1
8 ACK.:1
Whether alarm 1 may be acknowledged
9 POWER UP:1
How alarm 1 will be treated upon power up
10 MESSAGE:1
Nine character message associated with alarm 1
11 ALM. TYPE:2
Type of alarm for alarm 2
12 ALM. SRC.:2
Source of value monitored by HIGH, LOW or HIGH/LOW
alarm 2
13 ALARM SP:2
Alarm setpoint for alarm 2 (except for HIGH/LOW)
14A HIGH SP:2
High alarm setpoint for HIGH/LOW alarm 2
14B LOW SP:2
Low alarm setpoint for HIGH/LOW alarm 2
15 DEADBAND :2
Deadband for alarm 2
16 ALM.:2 OUT.
Output number for alarm 2
17 LATCHING :2
Latching sequence for alarm 2
18 ACK.:2
Whether alarm 2 may be acknowledged
19 POWER UP:2
How alarm 2 will be treated upon power up
20 MESSAGE:2
Nine character message associated with alarm 2
21 FAULT
Alarm relay status if fault condition is detected
22 OUTPUT
Output if the rate-of-change alarm is tripped
23 RATE TIME
Time period over which a rate-of-change alarm is
determined
56
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535 User's Manual
Controller Set Up
CUST. LINR.
Parameter
Description
Value
1 1st INPUT
Input signal for the 1st point (of the 15 point curve)
2 1st PV
Engineering unit value for the 1st point
3 Xth INPUT
Input signal for the Xth Point (of the 15 point curve)
4 Xth PV
Engineering unit value for the Xth point
5 2nd INPUT
Input signal for the 2nd point (of the 15 point curve)
6 2nd PV
Engineering unit value for the 2nd point
7 3rd INPUT
Input signal for the 3rd point (of the 15 point curve)
8 3rd PV
Engineering unit value for the 3rd point
9 4th INPUT
Input signal for the 4th point (of the 15 point curve)
10 4th PV
Engineering unit value for the 4th point
11 5th INPUT
Input signal for the 5th point (of the 15 point curve)
12 5th PV
Engineering unit value for the 5th point
13 6th INPUT
Input signal for the 6th point (of the 15 point curve)
14 6th PV
Engineering unit value for the 6th point
15 7th INPUT
Input signal for the 7th point (of the 15 point curve)
16 7th PV
Engineering unit value for the 7th point
17 8th INPUT
Input signal for the 8th point (of the 15 point curve)
18 8th PV
Engineering unit value for the 8th point
19 9th INPUT
Input signal for the 9th point (of the 15 point curve)
20 9th PV
Engineering unit value for the 9th point
21 10th INPUT
Input signal for the 10th point (of the 15 point curve)
22 10th PV
Engineering unit value for the 10th point
23 11th INPUT
Input signal for the 11th point (of the 15 point curve)
24 11th PV
Engineering unit value for the 11th point
25 12th INPUT
Input signal for the 12th point (of the 15 point curve)
26 12th PV
Engineering unit value for the 12th point
27 13th INPUT
Input signal for the 13th point (of the 15 point curve)
28 13th PV
Engineering unit value for the 13th point
29 14th INPUT
Input signal for the 14th point (of the 15 point curve)
30 14th PV
Engineering unit value for the 14th point
31 15th INPUT
Input signal for the15th point (of the 15 point curve)
32 15th PV
Engineering unit value for the 15th point
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57
Controller Set Up
CONTROL
Parameter
Description
Value
1 ALGORITHM
Control algorithm used
2 D. SOURCE
Variable used to determine the derivative value
3 ACTION:1
Action of the first control output
4 PV BREAK
Output level if the process variable input is lost
5 LOW OUT.
Lowest output value that can be achieved in automatic control
6 HIGH OUT.
Highest output value that can be achieved in automatic control
7 ACTION:2
Action of the second control output
8 P.P. TYPE
Type of position proportioning algorithm
9 CCW TIME
Time it takes a motor to fully stroke in the CCW direction
10 CW TIME
Time it takes a motor to fully stroke in the CW direction
11 MIN. TIME
Minimum time for the motor to be on before taking action
12 S/W RANGE
Full range resistance of the slidewire
13 OPEN F/B
Feedback ohm value when the valve is open
14 CLOSE F/B
Feedback ohm value when the valve is closed
15 OUT1 STOP
Stopping point for control output 1 when staging outputs
16 OUT2 STRT
Starting point for control output 2 when staging outputs
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535 User's Manual
Controller Set Up
ALARMS
Parameter
Description
Value
1 ALM. TYPE:1
Type of alarm for alarm 1
2 ALM. SRC.:1
Source of value being monitored by HIGH or LOW
alarm 1
3 ALARM SP:1
Alarm setpoint alarm 1
4 DEADBAND:1
Dead band for alarm 1
5 ALM.:1 OUT.
Output number for alarm 1
6 LATCHING:1
Latching sequence for alarm 1
7 ACK.:1
Whether alarm 1 may be acknowledged
8 POWER UP:1
How alarm 1 will be treated upon power up
9 MESSAGE:1
Nine character mesage associated with alarm 1
10 ALM. TYPE:2
Type of alarm for alarm 2
11 ALM. SRC.:2
Source of value being monitored by HIGH or LOW
alarm 2
12 ALARM SP:2
Alarm setpoint for alarm 2
13 DEADBAND :2
Dead band for alarm 2
14 ALM.:2 OUT.
Output number for alarm 2
15 LATCHING :2
Latching sequence for alarm 2
16 ACK.:2
Whether alarm 2 may be acknowledged
17 POWER UP:2
How alarm 2 will be treated upon power up
18 MESSAGE:2
Nine character message associated with alarm 2
19 FAULT
Alarm status if a fault condition is detected
20 OUTPUT
Output if the rate-of-change alarm is tripped
21 RATE TIME
Time period over which a rate-of-change will be
determined
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Chapter 5
59
Controller Set Up
REM. SETPT.
Parameter
Description
Values
1 TYPE V/mA
Input signal to be used for remote setpoint
2 RSP: LO RNG.
Eng. unit value for low remote setpoint input value
3 RSP: HI RNG.
Eng. unit value for high remote setpoint input value
4 RSP: LOW
Lowest accepted setpoint value from remote setpoint
source
5 RSP: HIGH
Highest accepted setpoint value from remote setpoint
source
6 TRACKING
Whether the local setpoint will track the remote setpoint
7 BIAS LOW
Lowest bias value that may be entered
8 BIAS HIGH
Highest bias value that may be entered
9 RSP FIXED
Status upon restoration of lost remote setpoint
RETRANS.
Parameter
Description
Values
1 TYPE:2
What is to be retransmitted for retransmission output 2
2 LOW RANGE:2
Low end of range in eng. units for retransmission output 2
3 HI RANGE:2
High end of range in eng. units for retransmission output 2
4 TYPE:3
What is to be retransmitted for retransmission output 3
5 LOW RANGE:3
Low end of range in eng. units for retransmission output 3
6 HI RANGE:3
High end of range in engl units for retransmission output 3
7 TYPE:4
What is to be retransmitted for retransmission output 4
8 LOW RANGE:4
Low end of range in eng. units for retransmission output 4
9 HI RANGE:4
High end of range in eng. units for retransmission output 4
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Chapter 5
535 User's Manual
Controller Set Up
SELF TUNE
Parameter
Description
Value
1 TYPE
Type of self tuning algorithm that is available
2 PRETUNE
Output step size in absolute percent
3 TUNE PT.
TYPE 1: Defines the PV value at which the output
switches off
4 OUT. STEP
TYPE 2 & 3: Defines output step size in absolute percent
5 LOW LIMIT
Lower limit PV can reach during Pretune before aborting
6 HI LIMIT
Upper limit PV can reach during Pretune before aborting
7 TIMEOUT
Execution time limit for Pretune before aborting
8 MODE
Control mode after Pretune is completed or aborted
9 NOISE BND.
Noise band to be used by adaptive tuning algorithm
10 RESP. TIME
Response time to be used by adaptive tune
11 DEAD TIME
Time required to wait before responding to output change
SPECIAL
Parameter
1 AUTO. TRIP
Description
Value
How controller automatically trips to auto control for
manual
2 TRIP DEV.
Deviation from setpoint at which controller will trip to auto
3 DES. OUTPT.
Output value on a trip to manual
4 POWER UP
Control mode upon power up
5 PWR. UP:OUT.
Output of the controller is powering up in manual control
6 PWR. UP: SP
Setpoint upon power up
7 NO. OF SP
#of setpoints stored for selection by digital input or SET
PT key
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61
Controller Set Up
SECURITY
Parameter
Description
Values
1 SEC. CODE
Security code for temporarily unlocking the instrument
2 SP ADJUST
Lockout status for setpoint changes
3 AUTO./MAN.
Lockout status of the MANUAL key
4 SP SELECT
Lockout status of the SET PT key
5 ALARM ACK.
Lockout status of the ACK key
6 TUNING
Lockout status for adjustment of tuning parameters
7 CONFIGURE
Lockout status for Set Up parameters
SER COMM.
Parameter
Description
Values
1 STATION
The unit’s station address
2 BAUD RATE
Baud rate
3 CRC
Whether CRC is being calculated
4 SHED TIME
Time between communications before controller sheds
5 SHED MODE
State of the controller if communications is lost (sheds)
6 SHED OUT.
Output if the unit sheds
7 SHED SP
Setpoint status if communications is lost
8 DESIG. SP
Value of the setpoint if controller sheds
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Tuning
CHAPTER 6
TUNING
OVERVIEW
The self tuning function of the 535 consists of two distinct components —
Pretune and Adaptive Tune. In addition, you may choose from three types
of Pretune:
TYPE 1 - for slow thermal processes.
TYPE 2 - for fast fluid or pressure processes.
TYPE 3 - for level control applications.
You choose the type of Pretune in the SELF TUNE menu.
The Pretune and Adaptive Tune components may be used separately or
together.
On the following pages is the step by step guide to the TUNING menu
parameters.
NOTE:
For more information about Pretune
and Adaptive Tune, refer to the section
on Tuning applications in Chapter 7.
OPERATION
Either Manual or
Automatic Control
for TUNING mode
TUNING
or
for OPERATION mode
+
for SET
UP mode
or
to return to
OPERATION
mode
Figure 6.1
Access the Tuning Menu Block
+
for SET
UP mode
SET UP
…
SELF TUNE
…
Access Set Up
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+
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63
Tuning
TUNING
TUNING
1. ADAPTIVE
Activates the self tune algorithm (upon transfer to automatic control).
ADAPTIVE
D DISABLED
• ENABLED
DISABLED
2. PRETUNE
Activates the pretune algorithm (if unit is under manual control).
To initiate the Pretune cycle, press the ▲ or ▼ . Confirm by pressing ACK
within two seconds.
PRETUNE
NO
D NO
3. POWR. BACK
Reduces setpoint overshoot at power up or after setpoint changes.
POWR. BACK
D DISABLED
• ENABLED
DISABLED
4. PROP. BND.:1
Defines the proportional band for PID set 1.
PROP. BND.:1
R 0.1 to 999.0%
D 50.0%
50.0
5. RESET:1
Defines the integral time for PID set 1.
RESET:1
20
R 1 to 9999 seconds
D 20 seconds
6. RATE:1
Defines the derivative time for PID set 1.
RATE:1
1
R 0 to 600 seconds
D 1 second
7. MAN. RST.:1 (or LOADLINE:1)
Defines the manual reset for PID set 1. If using automatic reset, then this
specifies the load line out value.
MAN. RST.:1
0
R 0 to 100%
D 0%
8. CYCLE TM.:1
Defines the cycle time for control output 1 when using a time proportioning
output.
CYCLE TM.:1
15.0
Access Set Up
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+
DISPLAY
FAST
64
R 0.3 to 120.0 seconds
D 15.0 seconds
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535 User's Manual
Tuning
9. DEADBAND:1
DEADBAND:1
Defines the dead band for control output 1 when using on/off control.
R 1 to 99999 in engineering units
D 2
2
10. P. PROP. D.B.
P.PROP.D.B.
Defines the dead band setting for a slidewire position proportioning output.
2.0
R 0.5 to 10.0%
D 2.0%
11. A. PID OFST.:1
PID OFST.:1
0
For duplex applications, defines the offset for the first output.
R –50.0% to 50.0%
D 0.0%
11B. ON OFST.:1
ON/OFST.:1
For On/Off applications, defines the offset for the first output.
0
R -9999 to 99999 in engineering units
D 0
12A. PID OFST.:2
PID OFST.:2
For duplex applications, defines the offset for the second output.
0
R –50.0% to 50.0%
D 0.0%
ON/OFST.:2
12B. ON OFST.:2
For On/Off applications, defines the offset for the second output.
0
R -9999 to 99999 in engineering units
D 0
13. REL. GAIN:2
REL. GAIN:2
Defines the adjustment factor for the second output’s proportional band. It is
multiplied by the effective gain of output 1 to obtain the second output's proportional band.
1.0
R 0.1 to 10.0
D 1.0
14. CYCLE TM.:2
CYCLE TM.:2
15.0
Defines the cycle time for control output 2 when using a time proportioning
output.
R 0.3 to 120.0 seconds.
D 15.0 seconds
Access Set Up
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Chapter 6
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65
Tuning
DEADBAND:2
2
15. DEADBAND:2
Defines the dead band for control output 2 when using on/off control.
R 1 to 99999 in engineering units
D 2
16. RSP RATIO
Defines the multiplier applied to the remote set point.
RSP RATIO
1.00
R -99.99 to 99.99
D 1.00
17. RSP BIAS
Defines the bias (additive term) applied to the remote set point.
RSP BIAS
R Any value in engineering units (minimum is BIAS LOW; maximum is
BIAS HIGH)
D Dependent on the BIAS LOW and BIAS HIGH values
(D)
18. NO. OF PID
Defines the number of PID sets that will be stored and available for use.
NO. OF PID
R 1 to 8
1
• SP NUMBER
• PV NUMBER
For numbers>1, PID TRIP defines tripping between
the PID sets
Number of PID sets = number of local setpoints
(specified in NO. OF SP). Each PID set has a
respective SP NUMBER.
PID Set = the process variable (PV1 or PV2) used
when PV SOURCE = 1/2: SWITCH or PV SOURCE =
1/2 :BACKUP
D 1
PID TRIP
19. PID TRIP
For NO. OF PID > 1, defines the variable used to select the various PID sets.
SP VALUE
• PV VALUE
D SP VALUE
• DEV. VALUE
TRIP:1
PID set selection based on process variable
PID set selection based on setpoint
PID set selection based on deviation from setpoint
20. TRIP:1
Defines the value that triggers a change to the primary set (#1) of PID values.
(D)
R The process variable range
D Dependent on the process variable range
FOR EACH SET OF PID 2 THROUGH 8, you need to set up the following
group of parameters (X represents the PID set number). Set up the parameters as they appear for each set of PID. The controller designates the
values for the active PID parameter in the third display with an “*” on
either side.
Access Set Up
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+
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66
MENU
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FAST
+
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535 User's Manual
Tuning
21. PROP. BND.:X
PROP.BND.:X
Defines the proportional band for PID set X.
(D)
R 0.1 to 999.0%
D 50.0%
22. RESET:X
RESET:X
Defines the integral time for PID set X.
(D)
R 1 to 9999 seconds (increments of 1)
D 20 seconds
23. RATE:X
RATE:X
1
Defines the derivative time for PID set X.
R 0 to 600 seconds
D 1 seconds
24. MAN. RST.:X (or LOADLINE:X)
MAN.RST.:X
Defines the manual reset (or load line) for PID set X.
0
R 0 to 100%
D 0%
25. TRIP:X
TRIP:X
(D)
This defines the value that triggers a change to the Xth set of PID values.
R The process variable range
D Dependent on the process variable range
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+
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Chapter 6
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67
Tuning
TUNING
Parameter
Definition
Values
1. ADAPTIVE
Activates the self tune algorithm.
2. PRETUNE
Activates the pretune algorithm.
3. POWR. BACK
Reduces setpoint overshoot.
4. PROP. BND.:1
Defines the proportional band for PID set 1.
5. RESET:1
Defines the integral time for PID set 1.
6. RATE:1
Defines the derivative time for PID set 1.
7. MAN. RST.:1
Defines the manual reset for PID set 1.
8. CYCLE TM.:1
Defines the cycle time for control output 1.
9. DEADBAND:1
Defines the dead band for control output 1.
10. P. PROP. D.B.
Defines the dead band setting for a slidewire output.
11A. PID OFST.:1
For duplex applications, defines the offset for the first output.
11B. ON OFST.:1
For On/Off applications, defines the offset for the first output.
12A. PID OFST.:2
For duplex applications, defines the offset for the 2nd output.
12B. ON OFST.:2
For On/Off applications, defines the offset for the 2nd output.
13. REL. GAIN:2
Defines the adjustment factor for the output 2 prop. band.
14. CYCLE TM.:2
Defines the cycle time for control output 2.
15. DEADBAND:2
Defines the dead band for control output 2.
16. RSP RATIO
Defines the multiplier applied to the remote set point.
17. RSP BIAS
Defines the bias (additive term) applied to the remote set point.
18. NO. OF PID
Defines the number of stored and available PID sets.
19. PID TRIP
Defines the variable used to select the various PID sets.
20. TRIP:1
Defines the value that triggers a change to primary PID set.
21. PROP. BND.:2
Defines the proportional band for PID set 2.
22. RESET:2
Defines the integral time for PID set 2.
23. RATE:2
Defines the derivative time for PID set 2.
24. MAN. RST.:2
Defines the manual reset (or load line) for PID set 2.
25. TRIP:2
Defines the value that triggers a change to the 2nd PID set.
26. PROP. BND.:3
Defines the proportional band for PID set 3.
27. RESET:3
Defines the integral time for PID set 3.
28. RATE:3
Defines the derivative time for PID set 3.
29. MAN. RST.:3
Defines the manual reset (or load line) for PID set 3.
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535 User's Manual
Tuning
30. TRIP:3
Defines the value that triggers a change to the 3rd PID set.
31. PROP. BND.:4
Defines the proportional band for PID set 4.
32. RESET:4
Defines the integral time for PID set 4.
33. RATE:4
Defines the derivative time for PID set 4.
34. MAN. RST.:4
Defines the manual reset (or load line) for PID set 4.
35. TRIP:4
This defines the value that triggers a change to the 4th PID set.
36. PROP. BND.:5
Defines the proportional band for PID set 5.
37. RESET:5
Defines the integral time for PID set 5.
38. RATE:5
Defines the derivative time for PID set 5.
39. MAN. RST.:5
Defines the manual reset (or load line) for PID set 5.
40. TRIP:5
This defines the value that triggers a change to the 5th PID set.
41. PROP. BND.:6
Defines the proportional band for PID set 6.
42. RESET:6
Defines the integral time for PID set 6.
43. RATE:6
Defines the derivative time for PID set 6.
44. MAN. RST.6
Defines the manual reset (or load line) for PID set 6.
45. TRIP:6
This defines the value that triggers a change to the 6th PID set.
46. PROP. BND.:7
Defines the proportional band for PID set 7.
47. RESET:7
Defines the integral time for PID set 7.
48. RATE:7
Defines the derivative time for PID set 7.
49. MAN. RST.:7
Defines the manual reset (or load line) for PID set 7.
50. TRIP:7
This defines the value that triggers a change to the 7th PID set.
51. PROP. BND.:8
Defines the proportional band for PID set 8.
52. RESET:8
Defines the integral time for PID set 8.
53. RATE:8
Defines the derivative time for PID set 8.
54. MAN. RST.:8
Defines the manual reset (or load line) for PID set 8.
55. TRIP:8
This defines the value that triggers a change to the 8th PID set.
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Chapter 6
69
Tuning
SELF TUNE MESSAGES AND TROUBLESHOOTING
Refer to Chapter 7 for more information on the Self Tune function of the 535 controller.
When the Pretune function terminates, one of the following messages will appear:
Message Pretune Conclusion/Problem
A
Type A
COMPLETED
1
2, 3
ABORTED
LIMIT ERR.
1, 2, 3
1
2, 3
1, 2, 3
TIME OUT
1, 2, 3
NOISE ERR.
1, 2, 3
INPUT ERR.
1, 2, 3
1, 2, 3
OUT. ERROR
1, 2, 3
1, 2, 3
1, 2, 3
DATA ERR.
ZERO ERR.
DEV. ERROR
2,3
2,3
1
RETRY
1, 2, 3
Corrective Action
A
PRETUNE has generated initial PID and the Dead Time
values.
PRETUNE has generated initial PID, Response Time,
Noise Band and the Dead Time values.
User has aborted PRETUNE before completion.
The Process Variable went beyond the HI LIMIT or LOW
LIMIT.
The Process Variable went beyond the HI LIMIT or LOW
LIMIT.
The initial Process Variable was near or beyond the HI
LIMIT or LOW LIMIT.
TIMEOUT limit was reached before PRETUNE completed.
Change the HI LIMIT and LOW LIMIT, or the HIGH OUT
and LOW OUT, and run PRETUNE again.
Change the HI LIMIT and LOW LIMIT, or the OUT.STEP
size, and run PRETUNE again.
Change the manual output percentage, or the HI LIMIT and
LOW LIMIT, and run PRETUNE again.
Set a longer TIMEOUT period and/or increase the
OUT.STEP size, and run PRETUNE again.
Too much PV noise was detected.
Eliminate the noise source (if possible) or increase the
OUT.STEP and run PRETUNE again.
PV or Cold Junction break detected during PRETUNE. Check the described conditions and make corrections or
repairs.
PV HIGH or PV LOW detected during PRETUNE.
SLIDEWIRE break detected during PRETUNE.
REMOTE SP break detected during PRETUNE.
The initial control output is outside the high and low limits Change the manual output percent and run PRETUNE again.
defined in the Control Menu.
The PV moved too quickly to be Analyzed.
Increase the OUT.STEP size and run PRETUNE again.
One or more model parameters are calculated to be zero. Increase the OUT.STEP size and run PRETUNE again.
Move Tune PT. (or the set point if TUNE PT. is automatic)
The initial PV is too close to the TUNE PT.
farther from the process variable and run PRETUNE again.
The Process Variable went beyond the HI LIMIT or LOW Check if any PID values are generated and if they are
LIMIT
acceptable. If not, eliminate noise sources (if possible) and
run PRETUNE again.
If Pretune and Adaptive Tune do not generate optimal PID values for control, check the following menu entries:
Message
A
Potential Problem
A
Corrective Action
A
RESPONSE
TIME
NOISE BAND
Adaptive Tune cannot run if RESPONSE TIME is inaccurate
PRETUNE
Pretune does not develop optimum PID parameters.
Run TYPE 2 or TYPE 3 Pretune to obtain the correct value,
or enter it manually.
Set NOISE BAND large enough to prevent Adaptive Tune
from acting on the oscillation. If oscillation is not acceptable,
consider replacing valve.
Wrong Pretune TYPE selected. Refer to Chapter 7, the
Section on Self Tune.
70
Adaptive Tune cannot compensate for PV oscillation due to
hysteresis of output device (e.g., a sticky valve).
Chapter 6
535 User's Manual
Applications
CHAPTER 7
APPLICATIONS
NOTE: Controller capabilities depend
upon the specified hardware option.
The 535 controller provides a variety of user-programmable control features
and capabilities. The following topics are included in this chapter:
A.
B.
C.
D.
E.
F.
G.
H.
Control Type ......................................... 71
Alarms ................................................. 72
Duplex Control ...................................... 76
Slidewire Position Proportioning Control .. 81
Velocity Position Proportioning Control .... 82
Staged Outputs .................................... 83
Retransmission .................................... 83
Digital Inputs ......................................... 84
I.
J.
K.
L.
M.
N.
O.
P.
Remote Setpoint ................................... 86
Multiple Setpoints.................................. 87
Multiple Sets of PID Values .................... 87
Powerback ........................................... 88
Self Tune—POWERTUNE® ................. 89
Ramp-to-Setpoint ................................. 94
Input Linearization ................................. 95
Load Line ............................................. 97
Q.
R.
S.
T.
U.
V.
Security ............................................... 97
Reset Inhibition ..................................... 98
Process Variable Reading Correction ..... 98
Serial Communications ......................... 99
Cascade Control ................................. 100
Ratio Control ...................................... 103
A. CONTROL TYPE
Software Configuration
1. Go to the CONTROL menu.
2. For the parameter ALGORITHM, select the type of 535 control:
• ON-OFF
“Crude” control similar to a household thermostat. Used primarily
on slow, stable processes where moderate deviation (cycling)
around setpoint is tolerable. Only available with SSR, SSR Drive,
and relay outputs.
• P
Proportional only control. Provides much better control than on/off.
Used on processes that are less stable or require tighter control, but
have few load variations and do not require a wide range of setpoints.
• PI
Proportional plus integral control. In addition to proportional control,
it compensates for control errors due to wide range of setpoints or
load requirements. The integral term works to eliminate offsets.
• PD
Proportional plus derivative control. In addition to proportional control, it compensates for control errors due to fast load variations.
• PID
Proportional plus integral plus derivative control. In addition to proportional control, it compensates for changes in setpoint, load requirements and process variations.
• PID/ON-OFF
Only available with Duplex control. First output uses the PID algorithm, while second output uses on/off control.
3. For algorithms using the derivative function (D), choose the conditions for
the derivative term:
535 User's Manual
Chapter 7
71
Applications
Scroll to parameter D. SOURCE
• For derivative action based on error, or deviation from setpoint, choose
DEVIATION
• For derivative action based on process variable changes, choose PV.
B. ALARMS
The 535 controller has two extremely flexible and powerful software alarms.
The number of available outputs limits how alarms are linked to relays. A Global
Alarm feature allows all alarms to be assigned to the same relay.
The 535 indicates an alarm condition by:
• Lighting up the alarm icon(s)
• Displaying a custom message in the 3rd display
• Illuminating the ACK key (if the alarm is acknowledgeable)
Software Configuration
1. Access the ALARM menu.
2. Set values for the following parameters. All possible values are shown.
NOTE: Specifying a variable other
than the setpoint (SP) to HIGH
ALARM and LOW ALARM allows for
greater flexibility in creating alarm and
control strategies.
72
ALM.TYPE:1 and ALM. TYPE:2
Specifies the type of alarm to implement. Selection includes:
• HIGH ALARM
High process variable alarm. Occurs when the process variable exceeds the alarm setpoint.
• LOW ALARM
Low process variable alarm. Occurs when the process variable goes
below the alarm setpoint.
• HIGH/LOW
Combination of high and low alarms. Occurs when the PV exceeds
the individually set high or low setpoint.
• BAND
Creates a band centered around the control setpoint, that is twice
the alarm setpoint. Alarm occurs when the process variable travels
outside of this band. The alarm is dependent on the control setpoint.
As the control setpoint changes, the band adjusts accordingly.
For example, if the control setpoint is 500 and the alarm setpoint is
25, then the band extends from 475 to 525.
• DEVIATION
Similar to the band alarm but creates a band only 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. This alarm is dependent on the control setpoint; as the
control setpoint changes, the alarm point changes.
For example, if the control setpoint is 500 and the alarm setpoint is
+50, then an alarm occurs when the process variable exceeds 550.
In order for an alarm to occur when the process variable drops below 450, select an alarm setpoint of –50.
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535 User's Manual
Applications
•
•
MANUAL
Alarm occurs when the controller is put into manual mode of operation. This may be useful for security purposes or to alert the operator
that 535 is no longer under automatic control.
RATE
Alarm occurs when the process variable changes at a rate greater
than what is specified by the alarm setpoint and time base. This alarm
helps to anticipate problems before the process variable can reach
an undesirable level.
For example, if the alarm setpoint is 10 with a time base of 5 seconds, an alarm occurs whenever a change in process variable greater
than 10 occurs in 5 seconds.
ALM.SRC.:1 and ALM.SRC.:2
For HIGH , LOW or HIGH/LOW alarms, specifies the variable (source)
upon which a selected alarm is based. Selection includes:
• PV
• PV2
• SP
• RAMP SP
• DEVIATION
• OUTPUT
ALARM SP:1 and ALARM SP:2
Defines the point at which an alarm occurs. For a RATE (rate of change)
alarm, it specifies the amount of change (per RATE TIME period) that
must occur before the alarm activates. A negative value specifies a negative rate-of-change. Does not apply to HIGH/LOW alarms.
HIGH SP:1 and HIGH SP:2
For a HIGH/LOW alarm, defines the high setpoint at which an alarm occurs.
LOW SP:1 and LOW SP:2
For a HIGH/LOW alarm, defines the low setpoint at which an alarm occurs.
DEADBAND:1 and DEADBAND:2
Specifies the range through which the process variable must travel before leaving an alarm condition (see alarm examples at the end of this
section). Prevents frequent alarm oscillation or “chattering” if the process variable has stabilized around the alarm point.
ALM.1 OUT and ALM.2 OUT
For any enabled alarm, selects the output number to which the selected
alarm will be assigned. It is possible to assign both alarms to the same
output relay, thus creating a “global” alarm application.
LATCHING:1 and LATCHING:2
A latching (YES) alarm will remain active after leaving the alarm condition unless it is acknowledged. A non-latching (NO) alarm will return to
the non-alarm state when leaving the alarm condition without being acknowledged.
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Alarm Parameters Reference
For Alarm 1
Parameter
Description
ALM. TYPE:1 Type
ALM. SRC.:1 Source
ALARM SP:1 Setpoint
HIGH SP:1
High setpoint
LOW SP:1
Low setpoint
DEADBAND:1 Deadband
ALM.:1 OUT. Output number
LATCHING:1 Latching sequence
ACK.:1
Acknowledging
POWER UP:1 Status on power up
MESSAGE:1 Message
For Alarm 2
Parameter
ALM. TYPE:2
ALM. SRC.:2
ALARM SP:2
HIGH SP:2
LOW SP:2
DEADBAND:2
ALM.:2 OUT.
LATCHING:2
ACK.:2
POWER UP:2
MESSAGE:2
Description
Type
Source
Setpoint
High setpoint
Low setpoint
Deadband
Output number
Latching sequence
Acknowledging
Status on power up
Message
ACK.:1 and ACK.:2
For any enabled alarm, enables or disables operator use of the ACK
key to acknowledge an alarm at any time, even if the control process is
still in the alarm condition.
A latching alarm can always be acknowledged when it is out of the alarm
condition. When either alarm is available to be acknowledged, the ACK
key will be illuminated. If both alarms are acknowledgeable, pressing
ACK will first acknowledge alarm #1. Pressing ACK a second time will
acknowledge alarm #2.
POWER UP:1 and POWER UP:2
For any enabled alarm, selects the alarm condition upon power up.
Choices are:
• NORMAL
Controller will power up in alarm only if it is in alarm condition.
• ALARM:
Controller always powers up in alarm regardless of system’s alarm
condition. This is an excellent way to activate an alarm if there has
been a power failure.
• DELAYED
Controller will never power up in alarm, regardless of system’s alarm
condition. The system must leave and reenter the alarm condition
before the alarm will activate. This is typically used to avoid alarms
during start up.
MESSAGE:1 and MESSAGE:2
For either alarm
(depending on choices)
Parameter
Description
FAULT
Fault assignment
OUTPUT
Output action for rate
RATE TIME
Time base for rate
Allows user to specify a nine-character message to be displayed when
the respective alarm is active. If both alarms are active or any other
diagnostic message is present, the messages will alternate.
FAULT
Activates an alarm if the process variable signal is lost. Assign this function to either Alarm 1 or Alarm 2 (not both). This action is in addition to
the selected alarm type (additive alarm function).
OUTPUT
For a RATE alarm, selects the output action. Use to obtain early indication of a possible break in the process variable signal. Select PV BREAK
to have rate-of-change alarm take the same action as a detection of a
break in the process variable signal (where it trips to manual control at
a predetermined output).
RATE TIME
For RATE alarms, defines the time period over which a discrete 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.
Example
A. 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.
B. 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.
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In example A, the process variable would only have to experience a ten
unit change over a short period of time, while in Example B, it would require a 100 unit change over a ten second period. Example A is much
more sensitive than Example B. In general, for a given rate-of-change,
the shorter the time period, the more sensitive the rate alarm.
BAND ALARM
Figure 7.1
Alarm Examples
HIGH PROCESS VARIABLE ALARM
IN ALARM
CONDITION
IN ALARM
CONDITION
IN ALARM
CONDITION
C.SP
+ A.SP
DB
PV
PV
A.SP
DB
C.SP
DB
TIME
TIME
C.SP
- A.SP
RELAY
DE-ENERGIZED
RELAY
ENERGIZED
RELAY
DE-ENERGIZED
RELAY
ENERGIZED
RELAY
DE-ENERGIZED
RELAY
ENERGIZED
RELAY
DE-ENERGIZED
ICON OFF
ICON ON
ICON OFF
ICON OFF
ICON ON
ICON OFF
ICON ON
NO ALARM
NO ALARM
NO ALARM
CANNOT
ACKNOWLEDGE
NO ALARM
CANNOT
ACKNOWLEDGE
MAY
ACKNOWLEDGE
PARAMETER SETTINGS:
OUTPUT N = ALM.RLY:ON (N = 2 to 4)
ALM. TYPE:1 = HIGH ALRM.
ALM.:1 OUT. = N (N = 2 to 4)
LATCHING = NO LATCH
ACK.:1 = ENABLED
PARAMETER SETTINGS:
OUTPUT N = ALM.RLY:OFF (N = 2 to 4)
ALM. TYPE:1 = BAND
ALM.:1 OUT. = N (N= 2 to 4)
LATCHING = NO LATCH
ACK.:1 = DISABLED
DEVIATION ALARM
POWER UP ALARM
IN ALARM
CONDITION
C.SP
PV
A.SP
DB
DB
C.SP
+ A.SP
PV
TIME
RELAY
DE-ENERGIZED
RELAY
ENERGIZED
ICON OFF
ICON ON
NO ALARM
MAY
ACKNOWLEDGE
MUST
ACKNOWLEDGE
TO SHUT OFF
ICON AND
DE-ENERGIZE
RELAY
PARAMETER SETTINGS:
OUTPUT N = ALM.RLY:ON (N = 2 to 4)
ALM. TYPE:1 = DEVIATION
ALM.:1 OUT. = N (N = 2 to 4)
LATCHING = LATCH
ACK.:1 = ENABLED
ALARM SP:1 = (<0)
535 User's Manual
ALARM
CONDITION
UNIT
POWER UP
TIME
RELAY
ENERGIZED
RELAY
ENERGIZED
RELAY
ENERGIZED
ICON ON
ICON ON
ICON ON
MAY
ACKNOWLEDGE
CANNOT
ACKNOWLEDGE
MAY
ACKNOWLEDGE
PARAMETER SETTINGS:
OUTPUT N = ALM.RLY:ON (N = 2 to 4)
ALM. TYPE:1 = HIGH ALM.
ALM.:1 OUT. = N (N = 2 to 4)
LATCHING:1 = LATCH
ACK.:1 = DISABLED
POWER UP:1 = ALARM
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Applications
NOTE: The duplex output states vary
depending upon:
1. Control Type (PID, On/Off, etc.)
2. Control Action (DA, RA)
3. Output Limits
4. Output Gap or Overlay, and
5. Ouput 2 Relative Gain and PID%
Output.
Please refer to the output state
examples in this section to confirm
that the configuration is appropriate
for the process.
NOTE: Set manual reset/load line
parameters to 50% when using Duplex
control (MAN. RST.:X parameter is in
the TUNING menu.)
C. DUPLEX CONTROL
The Duplex control algorithm enables two discrete control outputs for the control
loop. Duplex control is commonly used for applications that require both heating
and cooling or when 2 control elements are needed to achieve the desired result.
Hardware Configuration
•
The controller must have two output modules assigned to the loop (any
combination of output modules).
Software Configuration
1. Go to the CONFIG. menu.
Set CTRL.TYPE to DUPLEX.
2. To use different algorithms for each output (PID for the first, and On/Off for
the second):
Go to the CONTROL menu.
Set ALGORITHM to PID:ON/OFF.
3. To make the control action for each output independent of the other:
Go to the CONTROL menu.
Set ACTION:1 or ACTION:2 to either DIRECT or REVERSE action based
on the diagrams in the output examples section (Figures 7.2 through 7.8).
4. Go to the TUNING menu.
Set values for PID OFST:1 (or ON OFST:1) and PID OFST:2 (or ON
OFST:2). These parameters allow the user to independently offset the point
at which output 1 and output 2 become active. PID OFSET units are in percent (%) of control output; ON OFST is in engineering units. The settings
can be used to make sure there is a dead band, i.e., no controller output
around setpoint. They can also be used to overlap output 1 and output 2 so
that both are “on” in a small band around setpoint.
5. Set MAN. RESET (manual reset) term to 50%. This causes the PID output
to be 50% when there is zero error. This term is still active as a “load line”
setting when using automatic reset (integral), so set it to 50% whether using
automatic reset or not.
6. REL. GAIN (relative gain) changes the gain of Output 2 relative to Output
1. Note that the relative gain can limit the maximum output available for
Output 2 when using PID control.
7. Go to the CONTROL menu.
Set LOW OUT. and HIGH OUT. to limit the maximum or minimum outputs
from Output 1 and Output 2. The actual limitation on the outputs is dependent on the offset settings, the relative gain setting and the control action.
Duplex Output State Examples
The following Duplex examples represent a variety of ways this function can
be set up. PID control examples show the PID output percentage on the
horizontal axis, and On/Off control examples show the process variable on the
horizontal axis. The vertical axes are the output of each physical output. Most
of these examples use the first output as heating and the second output as
cooling.
When using PID control, the 535 controller actually displays the PID output.
To relate this output to the actual physical output, locate the PID output on the
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horizontal axis. Draw a vertical line at that point. At the intersection of this vertical
line and the respective output line, draw a horizontal line. The physical output
is the value where this horizontal line intersects the respective axis.
The illustrations assumes a manual reset/load line term of 50%. Therefore, at
zero error (process variable equals setpoint) the PID output is 50%.
Duplex with reverse and direct acting outputs
A reverse acting output 1 and a direct acting output 2 with: no offset, no restrictive
outputs limits, and a neutral relative gain with PID control.
PARAMETER SETTINGS
ACTION:1 = REVERSE
ACTION:2 = DIRECT
PID OFST.:1 = 0
PID OFST.:2 = 0
LOW OUT = 0
HIGH OUT = 100
REL. GAIN = 1.0
Out 1
Out 2
100%
100%
Out 1
Figure 7.2
Duplex with Reverse and Direct
Acting Outputs
Out 2
0%
0%
100%
50%
PID OUTPUT
0%
Duplex with direct and reverse acting outputs
A reverse acting output 1 and a direct acting output 2 with: no offset, no restrictive
output limits, and a neutral relative gain with PID control.
PARAMETER SETTINGS
ACTION:1 = DIRECT
ACTION:2 = REVERSE
PID OFST.:1 = 0
PID OFST.:2 = 0
LOW OUT = 0
HIGH OUT = 100
REL. GAIN = 1.0
Out 1
(Heat)
Out 2
Out 2
(Cool)
Out 1
100%
100%
Out 1
Figure 7.3
Duplex with Direct and Reverse
Acting Outputs
Out 2
0%
100%
535 User's Manual
0%
50%
PID OUTPUT
0%
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Applications
Duplex with 2 reverse acting outputs
Two reverse acting outputs with: no offset, no restrictive output limits, and a
neutral relative gain with PID control.
PARAMETER SETTINGS
Figure 7.4
Duplex with Two Reverse Acting
Outputs
ACTION:1 = REVERSE
ACTION:2 = REVERSE
PID OFST.:1 = 0
PID OFST.:2 = 0
LOW OUT = 0
HIGH OUT = 100
REL. GAIN = 1.0
Out 1
(Heat)
Out 2
(Cool)
100%
100%
Out 1
Out 2
0%
0%
100%
50%
PID OUTPUT
0%
Duplex with a gap between outputs
A reverse acting output 1 and a direct acting output 2 react with: a positive offset
for output 1 and a negative offset for output 2 (assume no restrictive output limits
and a neutral relative gain with PID control).
On the graph, a positive offset refers to an offset to the left of 50%; a negative
offset is to the right of 50%.
Figure 7.5
Duplex with a Gap Between Outputs
PARAMETER SETTINGS
ACTION:1 = REVERSE
ACTION:2 = DIRECT
PID OFST.:1 = + VALUE
PID OFST.:2 = – VALUE
LOW OUT = 0
HIGH OUT = 100
REL. GAIN = 1.0
Out 1
(Heat)
Out 2
(Cool)
100%
100%
Out 1
Out 2
0%
0%
100%
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Chapter 7
Offset 1
50%
PID OUTPUT
Offset 2
0%
535 User's Manual
Applications
Duplex with overlapping outputs and output limits
A reverse acting output 1 and a direct acting output 2 with: a negative offset for
output 1, a positive offset for output 2, and restrictive high and low output limits
with PID control.
This combination of offsets results in an overlap where both outputs are active
simultaneously when the PID output is around 50%.
The output limits are applied directly to the PID output. This in turn limits the
actual output values. In this example, the high output maximum limits the
maximum value for output 1, while the low output minimum limits the maximum
value for output 2. The value the actual outputs are limited to depends on offset
settings, control action and relative gain setting with PID control.
PARAMETER SETTINGS
ACTION:1 = REVERSE
ACTION:2 = DIRECT
PID OFST.:1 = – VALUE
PID OFST.:2 = + VALUE
LOW OUT = 10%
HIGH OUT = 85%
REL. GAIN = 1.0
Out 1
(Heat)
Out 2
(Cool)
100%
100%
Out 1
Figure 7.6
Duplex with Overlapping Outputs
and Output Limits
Out 2
0%
0%
100%
85%
10%
50%
PID OUTPUT
0%
Duplex with various relative gain settings
A reverse acting output 1 and a direct acting output 2 with: various relative gain
settings (assume no offset or restrictive outputs) with PID control.
PARAMETER SETTINGS
ACTION:1 = REVERSE
ACTION:2 = DIRECT
PID OFST.:1 = 0
PID OFST.:2 = 0
LOW OUT = 0
HIGH OUT = 100
REL. GAIN ❶ = 2.0
REL. GAIN ❷ = 1.0
REL. GAIN ❸ = 0.5
Out 1
(Heat)
Out 2
(Cool)
100%
100%
Out 2
Out 1
❶
❷
❸
50%
Figure 7.7
Duplex with Various Relative Gain
Settings
0%
0%
100%
535 User's Manual
50%
PID OUTPUT
25%
0%
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Applications
Notice that the relative gain setting does not affect output 1. In this example, a
relative gain setting of 2.0 (curve 1) results in output 2 reaching its maximum
value at a PID output of 25%. A relative gain setting of 1.0 results in output 2
reaching its maximum value at a PID output of 0%. A relative gain setting of 0.5
results in output 2 reaching a maximum of 50% at a PID output of 0%.
Duplex with one ON/OFF output
A reverse acting output 1 and a direct acting, on/off output 2 with a positive offset.
Relative gain does not apply when using duplex with an on/off output. The
deadband setting for output 2 works the same as the deadband in single on/off
control (the deadband effect for output 2 is not illustrated here).
Figure 7.8
Duplex with One ON/OFF Output
PARAMETER SETTINGS
ACTION:1 = REVERSE
ACTION:2 = DIRECT
PID OFST.:1 = 0
ON OFST.:2 = + VALUE
LOW OUT = 0
HIGH OUT = 100
Out 1
(Heat)
Out 2
(Cool)
ON
100%
Out 1
Out 2
0%
OFF
50%
100%
Out 2 Offset 0%
from Setpoint
in Engineering Units
PID OUTPUT
Duplex with two ON/OFF outputs
A reverse acting on/off output 1 and a direct acting on/off output 2 with a negative
offset for output 1 and a positive offset for output 2.
Note that here the horizontal axis is expressed in terms of process variable
rather than PID output.
Figure 7.9
Duplex with Two ON/OFF Outputs
PARAMETER SETTINGS
ACTION:1 = REVERSE
ACTION:2 = DIRECT
ON OFST.:1 = – VALUE
ON OFST.:2 = + VALUE
Out 1
(Heat)
Out 2
(Cool)
ON
ON
Out 1
Out 2
OFF
OFF
Low
Range
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Offset 2
SP
PROCESS VARIABLE
Offset 1
High
Range
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Applications
D. SLIDEWIRE POSITION PROPORTIONING CONTROL
Slidewire position proportioning utilizes a slidewire feedback signal to determine
the actual position of the actuator being controlled.
Hardware Configuration
•
•
•
The controller must have the Slidewire Feedback option installed. Refer to
the order code in Chapter 1 for more information.
The controller must have mechanical relays, solid state relays or DC logic
modules installed in the first two output sockets.
The Slidewire does NOT have to be wired to the controller in order to set up
position proportioning.
CAUTION!
The relay in socket 1 drives the motor
counterclockwise and the relay in
output socket 2 drives the motor
clockwise.
This is important for:
• Wiring the outputs
• Selecting the control ACTION:1
parameter, or
• Determining the normally open or
normally closed relays,
The configuration choices influence
the way the position proportioning
algorithm works.
Software Configuration
1. To configure the controller before wiring the slidewire feedback signal to
the controller, complete these steps:
a. Go to the CONTROL menu.
b. Set a value for PV BREAK.
c. Go to the SPECIAL menu.
d. Set a value for DES. OUTPT.
e. Set a value for PWR.UP:OUT.
f. Go to SER. COMM. menu.
g. Set a value for SHED OUT.
2. Place the controller under manual control.
3. Go to the CONFIG. menu.
4. Set CTRL. TYPE to POS. PROP (position proportioning).
5. Set P.P. TYPE to SLIDEWIRE.
6. Go to the CONTROL menu.
7. For S/W RANGE, specify the full range resistance of the slidewire from endto-end. With a 100 ohm slidewire, this parameter should be set to 100.
8. Scroll to OPEN F/B (Open feedback). Enter the ohm value when the actuator is fully open (0 to 1050 ohms).
9. Scroll to CLOSE F/B (Closed feedback). Enter the ohm value when the actuator is fully closed (0 to 1050 ohms).
10.Measure the actual slidewire value at the terminals (10 and 11).
As an alternative, set up these two parameters dynamically. Before entering Set Up set the manual output at 100%. Enter Set Up and change the
OPEN F/B value until the actuator just reaches its full open position.
Exit Set Up and set the manual output to 0%. Enter configuration and change
the CLOSE F/B value until the actuator just reaches its full closed position.
11.Set the parameter P. PROP. D.B., which is used to eliminate cycling of the
motor. A low deadband setting may result in motor overspin or cycling. A
high deadband will result in reduction of sensitivity. To set:
a. Go to the TUNING menu.
b. Set P. PROP. D.B. to .5%.
c. Place controller under Manual control.
d. Change the output percentage and observe if the valve stabilizes at
the new value.
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Chapter 7
NOTE: OPEN F/B and CLOSE F/B
values are always reference to the
CCW end of the Slidewire.
NOTE: P.PROP.D.B. can only be
configured if the Slidewire Feedback is
wired to the controller.
81
Applications
e. If the valve oscillates, increase the P.PROP.D.B. value by 0.5%; repeat until oscillation stops.
12.Set the parameter S/W BREAK to define the output value for when the slidewire breaks.
E. VELOCITY POSITION PROPORTIONING CONTROL
NOTE: Adaptive tuning is not available
with velocity position proportioning
control.
Velocity position proportioning does not utilize direct feedback. It estimates
the position of the actuator, based on time and the speed of the actuator.
In automatic control mode, the controller will display “CW” to refer to energizing
of the clockwise relay, and “CCW” to refer to energizing of the counterclockwise
relay. A blank display means that both relays are de-energized.
In manual control mode, the display is blank unless an output change is being
made. Use the ▲ and ▼ keys to change the output; the relay is only energized
while the keys are being pressed. The display indicates the percentage change
in valve position in real time. The rate of change is dependent on the values
entered for CCW TIME and CW TIME.
The controller will transfer to manual control due to a lost process variable (PV.
BREAK), a digital input closure (DES.OUTPT.), a power-up sequence
(PWR.UP:OUT.), or lost communications (SHED OUT). In these cases, the
output can be set to: remain at its last value with both relays de-energized (OUTS
OFF); rotate fully counterclockwise (CCW); or rotate fully clockwise (CW). CCW
and CW will energize the respective relay for a period two times that of the CCW
TIME or CW TIME.
Hardware Configuration
•
The controller must have mechanical relay, solid state relay or DC logic
modules installed in the first two output sockets.
Refer to the section on Chapter 1 for more information.
Software Configuration
1. Go to CONFIG. menu.
Set CTRL. TYPE to POS. PROP.
2. Go to the CONTROL menu.
Set P.P. TYPE to VELOCITY.
3. Set CCW TIME to the amount of time (in seconds) it takes for the actuator
to fully rotate in the counterclockwise direction.
Set CW TIME to the amount of time (in seconds) it takes for the actuator to
fully rotate in the clockwise direction.
Loads on the valve may affect the time required, therefore, it is best to measure
these values when the valve is in service. As an alternative, enter the values
specified by the actuator manufacturer and then make adjustments later.
5. Set MIN. TIME to the minimum amount of time the controller must specify
for the motor to be on before it takes any action.
6. Set values for PV. BREAK, DES. OUTPT., PWR.UP:OUT. and SHED OUT.
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F. STAGED OUTPUTS
With staged outputs, one analog output can vary its signal (e.g., 4-20 mA) over
a portion of the PID output range. The second analog output then varies its signal
over another portion of the PID output range. This is an excellent method to
stage two control valves or two pumps using standard control signal ranges.
20 mA
Figure 7.10
Staged Outputs Example
OUT1 STOP was set to 33% and
OUT2 STRT. was set to 50%.
Output 1
Output 2
4 mA
0%
33%
50%
100% PID Output
Hardware Configuration
•
The controller must have analog output modules installed in the first two
output sockets.
Software Configuration
1. Go to the CONFIG. menu.
Set CTRL. TYPE to STAGED.
2. Go to the CONTROL menu.
3. For OUT1 STOP, specify where the first output reaches 100%.
4. For OUT2 START, specify where the second output begins.
G. RETRANSMISSION
The retransmission feature may be used to transmit a milliamp signal
corresponding to the process variable, target setpoint, control output, or actual
setpoint to another device. A common application is to use it to record one of
these variables with a recorder.
NOTE: For an analog output module
for retransmission that was not factoryinstalled, calibrate the output for
maximum accuracy. Refer to
Appendix 4 for details on calibration.
Hardware Configuration
•
There must be an analog module installed in output socket 2, 3 or 4.
Software Configuration
Up to two outputs can be configured for retransmission. The menu will scroll
through the configuration parameters for specified value “X” (2, 3 or 4).
1. Go to the CONFIG. menu.
2. For OUTPUT:2, OUTPUT:3 and OUTPUT:4 parameters, set one or two of
them to RETRANS.
3. Go to the RETRANS. menu.
4. Set the corresponding parameter, TYPE:X, for the first retransmission output to define what is being transmitted: the process variable, setpoint, ramping setpoint or output.
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Applications
5. Set parameters LOW RANGE:X and HIGH RANGE:X for the first retransmission output, to define the range of the transmitted signal in engineering
units. This can be useful in matching the input range of the receiving device.
6. For any other retransmission output, continue to scroll through this menu
and set the TYPE:X, LOW RANGE:X and HIGH RANGE:X for the second
retransmission output.
H. DIGITAL INPUTS
Digital inputs can be activated in three ways: A switch (signal type)—the recommended type, a relay, or an open collector transistor.
Digital inputs are only functional when that option is installed (via hardware).
The controller detects the hardware type, and supplies the appropriate software menus (see the section on parameters in Chatper 5). There are 14 contact types for the up to 5 digital inputs.
Hardware Configuration
•
This optional feature is only available if ordered originally from the factory,
Product #535xxxxxxDx00. The (up to ) five digital inputs share a common
ground.
Software Configuration
NOTE: To take advantage of multiple
setpoints, make sure that the SP
NUMBER parameter in the SPECIAL
menu is set to a value greater than 1.
1. Go to the CONFIG. menu.
2. Set parameters CONTACT:1 through CONTACT:5 (only those available
will shown) by assigning the desired function to each output. Choices are:
• SETPT 1-8
(For CONTACT:1 only) Allows the controller to use the first four digital
inputs to select a setpoint (see Figure 7.11). If the state of these inputs remains constant, the controller will continue to use the selected
setpoint unless overridden. Override the set of digital inputs by selecting a different setpoint (by using SET PT key or through communications), or by using the fifth digital input to select the remote or
2nd setpoint. To “rearm” this set of digital inputs, the DIN combination must change.
Setpoints
SP
SP2
SP3
SP4
SP5
SP6
SP7
SP8
Figure 7.11
Combinations of Closed Digital
Inputs for Each Setpoint (based on
BCD logic)
X=closed contact
0=open contact
DIN 1
DIN 2
DIN 3
DIN 4
X
O
X
O
X
O
X
O
X
X
O
O
X
X
O
O
O
X
X
X
X
O
O
O
O
O
O
O
O
O
O
X
•
REM. SETPT.
Closing input changes active setpoint to remote setpoint. Opening
reverts controller to previous setpoint. Override by selecting a different setpoint via the SET PT key, a communications command, or
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•
•
•
•
•
•
•
•
•
•
•
•
other digital inputs.
MANUAL
Closing input trips the controller to manual. Opening input reverts
controller to automatic. Override by using MANUAL key, a communications command, or “trip to automatic” function.
2ND. SETPT.
Closing input changes active setpoint to the 2nd local setpoint. Opening input reverts controller to previous setpoint digital input. Override by selecting a different setpoint via the SET PT key, a communications command, or other digital inputs.
2ND. PID
Closing input changes active set of PID values to 2nd set. Opening
input bases active set of PID on rules defined in PID TRIP and TRIP:1
to TRIP:8. Override input only by directly linking PID set to the active setpoint and changing the active setpoint.
ALARM ACK.
Closing input acknowledges all active alarms. Opening input “rearms” the controller. If the digital input remains closed, it does not
continue to immediately acknowledge alarms as they become active.
RST. INHBT.
Reset Inhibition. Closing input deactivates “I” (integral) term, regardless of the PID values being used. Opening input activates “I” term
(if applicable).
D.A./R.A.
Direct Acting/Reverse Acting. Closing input reverses action of the
first control output (from direct to reverse, or reverse to direct). Opening reinstates original action.
STOP A/T
Closing input temporarily disables Adaptive Tuning. Opening input
enables it.
LOCK. MAN.
Closing contact places the controller in manual control at the designated output percentage. All locked manual contacts must be opened
in order to return controller to automatic control.
UP KEY / DOWN KEY
Closing the contact mimics the designated ▲ or ▼ key. Useful if controller is mounted behind a window; contact push-buttons can be
used to change setpoint values.
DISP. KEY
Closing contact mimics the DISPLAY key; scroll through display of
the Setpoint, Deviation % and Output%.
FAST KEY
Closing contact mimics the FAST key . Use in conjunction with ▲ ,
▼ , DISPLAY and MENU keys.
MENU KEY
Closing contact mimics the MENU key. In OPERATION Mode, provides entry to TUNING menu. In SET UP or TUNING Mode, ad-
535 User's Manual
Chapter 7
NOTE: The second display does not
change when tripping to manual from
a closed digital input.
NOTE: Only alarms configured to be
acknowledged are affected by this
digital input.
85
Applications
•
•
NOTE: There is a one-second delay
before a closed digital input takes
action.
vances through the menus.
COMM. ONLY
Makes input status readable through communications (but has no
effect on the controller itself).
PV2.SWITCH
(only applicable for PV SOURCE = 1/2:SWITCH). Closing contact
causes the 535 to use PV2 as the PV input (instead of PV1).
Basic Operating Procedures
1. If more than one digital input closes and their actions conflict, the last digital
input that closed has priority.
For example, if one digital input closes and selects 2nd setpoint, and
then another digital input closes and selects a remote setpoint, the remote setpoint takes precedence.
2. Any digital input can be overridden by: another digital input, a keyboard
operation, or an automatic function. If a closed digital input is overridden,
then it must be opened in order to be rearmed.
For example, if one digital input closes and selects the 2nd setpoint, and
then a different setpoint is selected through the keyboard, the keyboard
selection takes precedence.
I. REMOTE SETPOINT
Remote setpoint limits are the same as setpoint limits.
Hardware Configuration
•
•
The optional feature is available only if ordered originally from the factory,
Product #535-xxxxxBxx00 or #535-xxxxxExx00). Refer to the order code
in Chapter 1.
Before configuring the software, make sure the corresponding jumper is
set properly. Refer to Chapter 4 to check or change jumper positions.
Software Configuration
1. Go to the REM. SETPT. menu.
2. RSP TYPE defines the input signal range (e.g. 4-20 mA).
3. RSP:LO. RNG. and RSP: HI RNG. define the range of the remote setpoint
in engineering units. The correct range will be dependent on the source of
the remote setpoint signal.
4. RSP:LOW and RSP:HIGH set limits on the remote setpoint value in
engineering units.
5. TRACKING determines whether or not the controller will revert to a local
setpoint if the remote setpoint signal is lost. This prevents a process upset
due to a sudden change in setpoint.
6. BIAS LOW and BIAS HIGH set limits on an operator entered bias value.
7. RSP FIXED determines the signal to which the controller will revert when
a lost RSP is restored (fixed). Options are to stay in local or automatically
return to remote setpoint.
8. To bias or ratio the remote setpoint value:
a. Go to the TUNING menu.
b. Set RSP BIAS and RSP RATIO values.
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Basic Operating Procedures
After configuring the hardware and software, select the remote input by:
• pressing the SET PT key until RSP shows in the display
• using a digital input
J. MULTIPLE SETPOINTS
The 535 can store up to eight local setpoints and use a remote setpoint. One
application of this feature is configuring the controller to restrict operators to
discrete setpoint choices. The 535 can also store multiple sets of PID
parameters (see next section).
Software Configuration
1. Go to the SPECIAL menu.
2. Set NO. OF SP to the number of local setpoints desired.
3. Use the SET PT key to scroll to each local setpoint and set it to the desired
value with the ▲ or ▼ keys.
4. To link the PID sets to the corresponding local setpoint:
Go to the TUNING menu.
Set NO. OF PID to SP NUMBER.
For details on multiple sets of PID, refer to the next section in this chapter.
Basic Operating Procedures
To select a set point, toggle the SET PT key to scroll through the setpoints. The
displayed setpoint becomes active after two second of key inactivity.
The digital inputs can also be used to select the active setpoints. A single digital
input may be used for selecting the second setpoint, SP2. A set of four digital
inputs may be used, to select up to 8 setpoints (see the section in this Chapter
on Digital Inputs).
The SET PT key is lit when a setpoint other than the primary local setpoint is
active.
K. MULTIPLE SETS OF PID VALUES
The 535 has the ability to store up to eight sets of PID values. This can be a
valuable feature for operating the controller under conditions which require
different tuning parameters for optimal control. There are various methods of
selecting which set should be active. These methods are explained in this
section.
Software Configuration
1. Go to the TUNING menu.
2. NO.OF PID is the desired number of PID sets to be stored. SP VALUE
automatically sets this value equal to the number of stored local setpoints
(each PID set will be active when its respective local setpoint is active).
3. PID TRIP determines which variable selects the various PID sets: process
variable, setpoint or deviation from setpoint.
4. TRIP:X defines the point (in the PV range) at which that set of PID values
become active.
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Basic Operating Procedures
A PID set can be selected in one of four ways.
• For NO. OF PID = PV NUMBER, the PID set (1 or 2) is selected when
PV1 or PV2 is used.
• For NO. OF PID = SP NUMBER, the active set of PID values is the same
as the active setpoint. For example, if SP3 is active, then PID set #3 will
be active.
• When using PID trip values, a PID set becomes active when the variable
exceeds its trip point.
For example, if PID TRIP = SETPOINT, and TRIP:2 = 500, the second
set of PID values becomes active when the setpoint exceeds 500, and
remains active until the setpoint drops below 500 or exceeds the next
highest trip point. The PID set with the lowest trip point is also active when
the trip variable is less than the trip value. (The user can set the lowest
trip point = the low end of the process variable range, but this is not
required.)
• A digital input can be set to trip to the second set of PID upon closure,
which overrides a selection based on trip points.
Using with Adaptive and Pretune
The 535 can be programmed to automatically set the PID values using the
Pretune and Adaptive Tuning functions. For both functions, the tuned set of
PID is that which is active upon initiation of the tuning function.
The controller cannot trip to other PID sets (based on trip point or the digital
input contact) until Adaptive Tuning is disabled. However, if the PID set is tied
to the corresponding local setpoint, the active PID set values will change with
the local setpoint.
Each PID set has 5 parameters that control its function—proportional band,
reset, rate, manual reset (or loadline), and trip point. For each set (2 thru 8),
these values have to be manually set.
1. Press MENU to access the TUNING menu.
2. Set values for parameters 1 thru 20 (these include the first PID set)
3. Press MENU to access these parameters for each additional PID set
(2 through 8): PROP. BND, RESET, RATE, MAN. RST. and TRIP.
L. POWERBACK
POWERBACK is a proprietary algorithm which, when invoked by the user,
reduces or eliminates setpoint overshoot at power up or after setpoint changes.
Powerback monitors the process variable to make predictive adjustments to
control parameters, which in turn helps to eliminate overshoot of the Setpoint.
Software Configuration
1.
2.
3.
4.
88
Go to the TUNING menu.
Set POWR.BACK parameter to ENABLED.
Go to the SELF TUNE menu.
For DEAD TIME, set the value (time) that the controller should wait before invoking
an output change. This value is typically the dead time of the process. Or, let Pretune
calculate the dead time, then complete just steps 1 and 2 above.
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535 User's Manual
Applications
M. SELF TUNE—POWERTUNE®
The Self Tune function of the 535 consists of two distinct components, Pretune
and Adaptive Tune. These components may be used independently or in
conjunction with one another. For best results, we recommend using them
together.
Pretune
This algorithm has three versions. Choose the type that most closely matches
the process to optimize the calculation of the PID parameters. The three Pretune
types are:
• TYPE 1 Normally used for slow thermal processes
• TYPE 2 Normally used for fast fluid or pressure processes
• TYPE 3 Normally used for level control applications
Pretune is an on-demand function. Upon initiation, there is a five second period
during which the controller monitors the activity of the process variable. Then
the control output is manipulated and the response of the process variable is
monitored. From this information, the initial Proportional Band, Reset and Rate
(P, I and D values) and dead time are calculated. When using TYPE 2 or TYPE
3 Pretune, the Noise Band (NOISE BND.) and Response Time (RESP. TIME)
will also be calculated.
In order to run this algorithm, the process must fulfill these requirements:
• The process must be stable with the output in the manual mode;
• For tuning a non-integrating process, the process must be able to reach
a stabilization point after a manual step change; and
• The process should not be subject to load changes while Pretune
operates.
If these conditions are not fulfilled, set the Adaptive Tune to run by itself.
Adaptive Tune
Adaptive Tune continuously monitors the process and natural disturbances and
makes adjustments in the tuning parameters to compensate for these changes.
In order to make accurate calculations, Adaptive Tune needs noise band and
response time values. Pretune TYPE 2 and TYPE 3 automatically calculate
these values. These values may also be entered or changed manually in the
SELF TUNE menu. For Pretune TYPE 1, Noise Band and Response Time
parameters must be entered manually.
Figure 7.12 illustrates the relationship between Pretune and Adaptive Tune
Software Configurations
CAUTION!
Disable Adative Tuning before altering
process conditions (e.g., for shutdown,
tank draining, etc.). Otherwise, the 535
will attempt to adapt the Tuning
parameters to the temporary process
conditions.
Adaptive Tune can be disabled via
digital input (if applicable—see Digital
Inputs in this chapter), or via menus:
1.Go to the TUNING menu.
2.Go to parameter ADAPTIVE.
Change the value to DISABLED.
Pretune by Itself
1. Go to the SELF TUNE menu (press MENU+FAST)
2. Set the TYPE parameter to PRETUNE.
3. Set the PRETUNE type to the one that best matches the process (see above
section).
4. The next parameter, TUNE PT., appears only for TYPE 1 pretune. This
parameter sets the PV point at which the output will switch off. In thermal
processes, this will help prevent overshoot. The default is AUTOMATIC.
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Applications
5. Set the value for OUT STEP. This parameter defines the size of bump to be
used. The resulting disturbance must change the process variable by an
amount that significantly exceeds the peak-to-peak process noise, but does
not travel beyond the “normal” process variable range.
6. The next two parameters, LOW LIMIT and HI LIMIT, set the process variable
boundaries. If these boundaries are exceeded during the Pretune, the
pretune cycle will abort and return to manual control at the output level prior
to the initiation of pretune.
Figure 7.12
Pretune TYPE 1, 2 and
3 with Adaptive Tune
100%
High Out Limit
TYPE 1 Pretune/Adaptive Control
70%
• A to B is ON/OFF control to determine initial PID values.
• B is Pretune completed, so Adaptive PID control beings if ENABLED.
50%
30%
CONTROL
OUTPUT 0%
Note: Noise Band and Resp. Time must be entered before
enabling Adaptive TUne)
Low Out Limit
900
700
500
SP
0
➔
PV
PRETUNE
A
➔
300
ADAPTIVE
B
TIME
100%
TYPE 2 Pretune/Adaptive Control
70%
50%
• A to B is a 5 second noise band measurement.
• B to C is an open loop bump test to determine initial PID values
and response time.
• C is Pretune completed, so Adaptive PID control begins if ENABLED.
Out Step
30%
CONTROL
OUTPUT 0%
900
700
500
SP
NOISE
A
BUMP
➔
0
➔
PV
➔
300
ADAPTIVE
C
B
TIME
Pretune
100%
TYPE 3 Pretune/Adaptive Control
70%
50%
• A to B is a 5 second noise band measurement.
• B to C is an impulse to determine initial PID values and response
time.
• C is Pretune completed, so Adaptive PID control begins if ENABLED.
Out Step
30%
CONTROL
OUTPUT 0%
900
700
500
SP
300
A
BUMP
B
Pretune
90
Chapter 7
➔
NOISE
➔
0
➔
PV
ADAPTIVE
C
TIME
535 User's Manual
Applications
7. The next parameter, TIMEOUT, defines the maximum time in minutes within
which pretune must complete its calculations before it is aborted.
The first time a pretune is performed, set TIMEOUT to its maximum value.
Make note of the length of the pretune cycle. Then, adjust TIMEOUT to a
value about twice the pretune time.
The purpose of this parameter is to prevent a Pretune cycle from continuing
for an excessive time if a problem develops. The value has no impact on
the PID values being calculated.
8. Next is MODE. This defines what mode the controller will enter when pretune
is completed. Select MANUAL if there will be a need to review PID
parameters before attempting to control with them; the default AUTOMATIC.
9. RESP. TIME defines the amount of damping for the process. The choices
include FAST (results in approximately 20% overshoot), MEDIUM (results
in approximately 10% overshoot), and SLOW (<1%).
10.Place the controller under manual control.
11.Access the TUNING menu (press MENU).
Set the first parameter, ADAPTIVE, to DISABLED.
12.Activate the next parameter, PRETUNE.
13.Press ACK to begin Pretuning.
The 3rd display will show the message EXECUTING.
14.When Pretune is complete, the 3rd display will show COMPLETED for two
seconds and then return to the current menu display.
Pretune TYPE 1 & Adaptive Tune
1.
2.
3.
4.
5.
6.
7.
Go to the SELF TUNE menu.
Set TYPE to BOTH.
Set PRETUNE to TYPE 1.
Set a value for OUTSTEP.
Set NOISE BND parameter.
Set the RESP. TIME parameter.
Make sure that the process is reasonably stable and place the controller
under manual control.
8. Press MENU to access the TUNING menu.
Set ADAPTIVE to ENABLED. The Adaptive Tuning cycle does not begin
the controller is under automatic control.
9. Activate the next parameter, PRETUNE.
10.Press ACK to begin Pretuning.
The 3rd display will show the message EXECUTING.
11.When Pretune is complete, the 3rd display will show COMPLETED for two
seconds and then return to the current menu display.
The controller will automatically transfer to automatic control upon completion
of Pretune if set to do so, or upon manual transfer.
Figure 7.12 illustrates the operation of Pretune TYPE 1 with Adaptive Tune.
Pretune TYPE 2 or 3 & Adaptive Tune
1. Go to the SELF TUNE menu.
2. Set the TYPE parameter to BOTH.
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Applications
NOTE: Adaptive tuning is not
available for velocity position
proportional control.
CAUTION!
If the process conditions are
temporarily changed, (e.g., during
process shutdown, draining of a tank,
etc.) disable adaptive tuning.
Otherwise, the controller will attempt to
adapt its tuning parameters to the
temporary process conditions.
Disable adaptive tuning by:
1. In the TUNING menu, change
ADAPTIVE to DISABLED through
the keypad; or
2. Closing the appropriate digital input
(see Digital Input section in this
chapter).
3. Set the PRETUNE parameter to TYPE 2 or TYPE 3.
4. DO NOT Enter values for NOISE BND and RESP TIME. The Pretune
algorithm will calculate these values.
2. Make sure that the process is reasonably stable and place the controller
under manual control.
3. Press MENU to access the TUNING menu.
4. Set parameter ADAPTIVE to ENABLED. The Adaptive Tuning cycle does
not begin. The controller is under automatic control.
4. Activate the next parameter, PRETUNE.
5. Press ACK to begin Pretuning.
The 3rd display will show the message EXECUTING.
6. When Pretune is complete, the 3rd display will show COMPLETED for two
seconds and then return to the current menu display.
The controller will automatically transfer to automatic control upon completion
of Pretune if set to do so, or upon manual transfer.
Figure 7.12 illustrates the operation of Pretunes TYPE 2 and TYPE 3 with
Adaptive Tune.
Adaptive Tune by Itself
1.
2.
3.
4.
Go to the SELF TUNE menu.
Set the TYPE parameter to ADAPTIVE.
Press MENU to access the TUNING menu.
Set the ADAPTIVE parameter to ENABLED. The Adaptive Tuning cycle
does not begin. The controller is under automatic control.
If Pretune results are poor or process conditions do not allow Pretune to run,
the Adaptive Tune parameters can be manually configured. Proper setting of
the noise band and response time parameters will yield excellent adaptive
control without running the Pretune function.
1. Go to the SELF TUNE menu.
2. Set NOISE BND.
The noise band is chosen to distinguish between disturbances which affect
the process and process variable “noise.” The controller functions to
compensate for disturbances (i.e., load changes), but it cannot compensate
752
(407 – 402)
NOISE BAND =
PROCESS
VARIABLE
Figure 7.13
Noise Band Calculation Example
409
408
407
406
405
Type T
404
Thermocouple
403
402
401
Range
–328°F TO 752° F 400
[ 752 – (–352) ]
X 100 =
.5%
–328
0
40
80
120
TIME
92
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160
200
240
(SECONDS)
535 User's Manual
Applications
for process noise. Attempting to do this will result in degraded controller
performance. The Noise Band is the distance the process deviates from
the setpoint due to noise in percentage of full scale.
Figure 7.13 shows a typical process variable response in a steady-state
situation. In this example, the process noise is within a band of about 0.5%
of full scale.
A noise band that is too small will result in tuning parameter values based
on noise rather than the effects of load (and setpoint) changes. If the noise
band is set too small, then Adaptive Tune will attempt to retune the controller
too often. This may result in the controller tuning cycling between desirable
system tuning and overly sluggish tuning. While the result may be better
than that achieved with a non-adaptive controller, this frequent retuning is
not desirable.
If the noise band is set too large, the process variable will remain within the
noise band, and the controller will not retune itself. With too large a noise
band, important disturbances will be ignored, and the controller will be
indifferent to sluggish and oscillatory behavior.
Noise band settings are generally between 0.1% and 1.0%, with most
common settings of 0.2% or 0.3%. Figure 7.14 shows the conversion of
peak-to-peak noise to an appropriate noise band for each T/C type & RTD.
E
J
K
N
R/S
T
W/WS PLATINEL
RTD
0.1°RTD
0
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
0.1
2
0.1
0.1
0.1
0.1
0.1
0.1
0.2
0.1
0.1
0.1
0.1
3
0.2
0.1
0.2
0.2
0.1
0.1
0.1
4
0.1
0.2
0.2
0.1
0.1
0.1
0.3
0.1
0.2
0.2
0.3
0.4
0.1
0.2
0.2
5
0.2
0.2
0.2
0.2
0.2
0.5
0.2
0.5
0.1
0.2
0.3
6
0.2
0.3
0.3
0.2
0.6
0.2
0.2
0.6
0.1
0.3
0.3
7
0.2
0.3
0.3
0.7
0.2
0.3
0.2
0.6
0.2
0.3
0.4
8
0.2
0.4
0.8
0.4
0.3
0.3
0.3
0.7
0.2
0.4
0.4
9
0.3
0.9
0.4
0.4
0.3
0.3
0.3
0.8
0.2
0.4
0.5
10
0.3
1.0
0.4
0.4
0.3
0.4
0.3
0.9
0.2
0.4
0.5
1.1
3. Set RESP. TIME.
The response time is the most critical value in Adaptive Tuning. Response
time represents the time lag from a change in valve position (controller
output) to a specific amount of change in process variable. Specifically,
Response Time is equal to the Deadtime of the process plus one Time
Constant. The Deadtime is the time between initiation of an input change
and the start of an observable response in the process variable. The Time
Constant is the interval of time between the start of that observable response
and the point where the process variable reaches 63% of its final value. (See
Figure 7.15).
Example
After a stimulus (e.g., valve movement), if it takes 300 seconds for a process
to reach 63% of its new (expected) value, the response time is 300 seconds.
If the response time is set too short, the process will be unstable and cycle
535 User's Manual
Chapter 7
Control Output
B
Figure 7.14
Noise Band Values for
Temperature Inputs
Final PV
63% of Final PV
PV
Peak to Peak Noise °F
INPUT TYPE
τ
DT
Time ➜
DT =
τ =
RT =
RT
Dead Time
Time Constant
Response Time
Figure 7.15
Deadtime and Time Constant
93
Applications
around the setpoint. If the Response Time is set too long, response to an
off-setpoint condition will be sluggish. It is generally better to use too long
a response time than too short.
Self Tuning with Multiple Sets of PID
For both Pretune and Adaptive Tune, the tuned set of PID is that which is active upon initiation of the tuning function.
The controller cannot trip to other PID sets (based on trip point or the digital
input contact) until Adaptive Tuning is disabled. However, if the PID set is tied
to the corresponding local setpoint, the active PID set values will change with
the local setpoint.
Each PID set has 5 parameters that control its function—proportional band,
reset, rate, manual reset (or loadline), and trip point. For each set (2 thru 8),
these values have to be manually set.
1. Press MENU to access the TUNING menu.
2. Set values for parameters 1 thru 20 (these include the first PID set).
3. Press MENU to access these parameters for each additional PID set (2
through 8): PROP. BND, RESET, RATE, MAN. RST. and TRIP.
Self Tune with Time Proportioning Outputs
When using either the Pretune or the Adaptive Tune with a time proportioning
output, use as short of a cycle time as possible within the constraint of
maintaining a reasonable life on relays, contacts or heating elements.
Self Tune with Control Valves
In many systems utilizing a control valve, the point at which the control valve
begins to stroke does not coincide with 0% output, and the point at which it
completes its stroke doesn’t coincide with 100%. The parameters LOW OUT
and HIGH OUT in the CONTROL menu specify the limits on the output. Set
these limits to correspond with the starting and stopping point of the valve’s
stroke. This prevents a form of “windup” and thus provides the adaptive control
algorithm with the most accurate information.
For example, in manual the control output was slowly increased and it was noted
that the control valve started to stroke at 18% and at 91% it completed its stroke.
In this case LOW OUT should be set at 18% and HIGH OUT at 91%.
Note that when output limits are used, the full output range from -5 to 105% is
available in manual control.
N. RAMP-TO-SETPOINT
The 535 contains a ramp-to-setpoint function that may be used at the user’s
discretion. This function is especially useful in processes where the rate-ofchange of the setpoint must be limited.
When the ramping function is activated, the controller internally establishes a
series of setpoints between the original setpoint and the new target setpoint.
These interim setpoints are referred to as the actual setpoint . Either setpoint
may be viewed by the user. When the setpoint is ramping, RAMPING will be
shown in the 3rd display when the actual (ramping) setpoint is displayed.
94
Chapter 7
535 User's Manual
Applications
When the target setpoint is being shown, RAMPING will not appear. Pressing
the DISPLAY key will scroll the 2nd display as follows:
• From the target setpoint to the actual (ramping) setpoint;
• To the deviation from setpoint;
• To the output level; and
• Back to the target setpoint.
Note that when ramping, the deviation indication is with respect to the target
setpoint.
The ramp-to-setpoint function is triggered by one of three conditions:
1. Upon power up, if the 535 powers up in automatic control, then the setpoint
will ramp from the process variable value to the setpoint value at the specified
rate.
2. On a transfer from manual to automatic control the setpoint will ramp from
the process variable value to the setpoint value at the specified rate.
3. On any setpoint change, the setpoint will ramp from the current setpoint to
the new target setpoint. When triggered, the display will automatically change
to indicate the ramping setpoint.
Software Configuration
1. Go to the PV INPUT menu.
2. Set the SP RAMP parameter to the desired rate of change.
O. INPUT LINEARIZATION
Thermocouple and RTD Linearization
For a thermocouple or RTD input, the incoming signal is automatically linearized.
The 535 has lookup tables that it uses 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. To linearize this signal for use by the 535, the square root of
PV = Low Range + [ (Hi Range – Low Range)
(V input - V low / (V high – V low) ]
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 is the high end of the input signal range (e.g. 5 volts or 20 mA).
V low is the low end of the input signal range (e.g. 1 volt or 4 mA).
Figure 7.16
Square Root Linearization Formula
Example:
PV range is 0 – 1000.
Input signal range is 1–5 volts.
Input signal is 3 volts.
Therefore
PV = 0 +
535 User's Manual
[ (1000 – 0)
(3-1) / (5–1) ] = 1000 .5 = 707
Chapter 7
95
Applications
the signal must be calculated. The 535 has the capability to perform this square
root linearization.
For the first 1% of the input span, the input is treated in a linear fashion. Then
it is a calculated value, using the formula in Figure 7.16.
Hardware Configuration
•
A voltage or milliamp input must be installed on the controller.
Software Configuration
1. Go to the PV INPUT menu.
2. Set LINEARIZE to SQR. ROOT.
Custom Linearization
PV VALUE in engineering units
Custom linearization allows virtually any nonlinear signal to be linearized using
a 15-point straight line approximation curve (see Figure 7.17). Typical
Figure 7.17
15-point Linearization Curve
15th
10th
5th
1st
1st
5th
10th
15th
INPUT VALUE in milliamps or voltage
applications are linearizing signals from nonlinear transducers, or controlling
volume based on level readings for irregularly-shaped vessels. To define the
function, enter data point pairs—the engineering units corresponding to a
particular voltage or current input.
Software Configuration
1.
2.
3.
4.
Go to the PV INPUT menu.
Set the parameter LINEARIZE to CUSTOM.
Go to the CUST. LINR. menu.
Enter values for the 1ST INPUT and 1ST PV data points. All the input
parameters define the actual milliamp or voltage input. All the PV parameters
define the corresponding process variable value in engineering units.
It is not necessary 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.
Once the various points are defined, the values between the points are
96
Chapter 7
535 User's Manual
Applications
interpolated using a straight line relationship between the points. The only
limitation is that the resulting linearization curve must be either ever-increasing
or ever-decreasing.
P. LOAD LINE
Load line is a manual reset superimposed on the automatic reset action.
Adjusting the MAN. RST. tuning constant shifts the controller proportional band
Figure 7.18
Load Line Example
0%
E8
40%
LIN
20%
0%
0
AD
LO
%
20
E5
E
50%
LIN
LIN
AD
LO
AD
LO
Controller Output
100%
60%
80%
100%
Process Variable Location (% of Controller Span)
with respect to the setpoint.
When used with a proportional only or proportional/derivative control algorithm,
the MAN. RST. parameter (located in the TUNING menu) is in effect “manual
reset”.
However, when the automatic reset term is present, the reset action gradually
shifts the proportional band to eliminate offset between the setpoint and the
process. In this case, load line provides an initial shift at which the reset action
begins. Load line is adjusted by observing the percent output required to control
the process and then adjusting the load line to that value. This minimizes the
effect of momentary power outages and transients. Load line may also be
adjusted to give the best response when bringing the load to the desired level
from a “cold” start.
Q. SECURITY
The 535 security system is easily customized to fit a system’s needs.
Software Configuration
1. Go to the SECURITY menu.
2. SEC. CODE defines the security password (range from -9999 to 99999).
The rest of the security parameters can be selectively locked out.
3. SP ADJUST prevents the operator from using the ▲ and ▼ and keys to
change the setpoint value. It does not prevent the operator from changing
setpoints via the SET PT key.
4. AUTO./MAN. locks out the MANUAL key preventing the operator from
transferring between automatic control and manual control.
535 User's Manual
Chapter 7
NOTE: SEC CODE does not appear
unless all functions are unlocked.
97
Applications
NOTE: Lock out CONFIGURE for full
security. If left unlocked, the operator
will have access to the security code.
NOTE: The security function is
compromised if the security code is left
at zero (0).
NOTE: Security does not prevent the
operation from the digital inputs or
serial communications.
5. SP SELECT locks out the SET PT key. This prevents the operator from
changing among the various local setpoints or changing to remote setpoint.
It does not prevent the operator from changing the setpoint value via the ▲
and ▼ keys.
6. ALARM ACK. locks out the ACK key, preventing an operator from
acknowledging any alarms.
7. TUNING locks out modification to the parameters in the TUNING menu,
preventing unauthorized changes to the tuning parameters or the activation/
deactivation of the self tuning algorithm.
8. CONFIGURE allows access to the configuration menus, but prevents any
unauthorized changes to the configuration parameters. If locked out, the
security code is not accessible.
Basic Operating Procedures
The security feature can be overridden. When a locked function is attempted, the
operator will have the opportunity to enter the security code. If the correct security
code is entered, the operator has full access. The security feature is
reactivated after one minute of keypad inactivity. If the security code is forgtton,
the security feature can still be overridden.
• The security override code is
62647 .
Store this number in a secure place and blacken out the code in this manual
to limit access.
R. RESET INHIBITION
Reset Inhibition is useful in some systems either at the start-up of a process or
when a sustained offset of process variable from setpoint exists. In conditions
like these, the continuous error signal may cause the process temperature to
greatly overshoot setpoint. Any of the digital inputs may be set up so that the
contact closure disables the reset action (sets it to zero).
Software Configuration
1. Go to the CONFIG. menu.
2. Set corresponding parameter(s) CONTACT:1 to CONTACT:5 to RST.
INHBT.
S. PROCESS VARIABLE READING CORRECTION
NOTE: PV GAIN is only available if
using a linear voltage or current input.
98
Conditions extraneous to the controller, an aging thermocouple, out of
calibration transmitter, lead wire resistance, etc.—can cause the display to
indicate a value other than the actual process value. The PV OFFSET and PV
GAIN parameters can be used to compensate for these extraneous conditions.
NOTE: This feature is provided as a convenience only. Correcting the cause
of the erroneous reading is recommended.
1. Go to the PV INPUT menu.
2. Set PV OFFSET. This parameter either adds or subtracts a set value from
the process variable reading in engineering units. For example, if the thermocouple was always reading 3° too high, the parameter could be set to “–
3” to compensate.
3. Set PV GAIN. This 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
Chapter 7
535 User's Manual
Applications
of the range to arrive at the adjusted process variable value.
For example, if the process variable range is 50 to 650 and the process
variable reading is 472, a PV GAIN of .995 would yield an adjusted process
variable equal to [(472 – 50) x .995] + 50 = 470.
With a combination of both offset and gain factors, just about any inaccuracy
in the sensor or transmitter can be compensated.
T. SERIAL COMMUNICATIONS
The serial communications option enables the 535 to communicate with a
supervisory device, such as a personal computer or programmable logic
controller.
The communications standard utilized is RS-485 which provides a multi-drop
system that communicates at a high rate over long distances. Typical limitations
are 32 instruments per pair of wires over a distance up to 4000 feet.
The 535 uses a proprietary protocol which provides an extremely fast and
accurate response to any command. Cyclic redundancy checking (CRC)
virtually ensures the integrity of any data read by the 535. Through
communications, there is access to every Set up, Tuning and Operating
parameter. For details on the 535 protocol, contact a Moore Industries
application engineer.
Hardware Configuration
•
This optional feature is only available if ordered originally from the factory.
The circuitry for communications is contained on a modular circuit board
that plugs into the Microcontroller Circuit Board, Refer to the order code in
Chapter 1 for details.
Software Configuration
1. Access the SER. COMM. menu.
2. STATION specifies the unit’s station address. It is the only way one 535
can be distinguished from another. Each 535 on the same RS-485 interface
must have a unique station address.
3. Choose a BAUD RATE from 1,200 to 19,200. In general, select the highest
value. However, every instrument on the RS-485 interface must be set to
the same baud rate.
4. CRC indicates the cyclic redundancy checking feature. If the host supports
it, activating this option is recommended.
5. When the 535 senses that communications is lost, it can go to a
predetermined state (called “shedding”). The SHED TIME parameter sets
the length of time that communications can be interrupted before the
controller sheds. Since the 535 is a stand-alone controller, it does not depend
on communications to operate. Therefore, if the “shed” feature is not needed,
set it to OFF.
6. SHED MODE designates the mode to which the controller goes after it
sheds. Setting this to MANUAL brings up the following parameters.
7. Use SHED OUT to specify an output level if the unit sheds and trips to manual
control.
8. To specify a control setpoint (in case the host is supervising the setpoint) if
the 535 sheds, Set SHED SP to DESIG. SP and then, set the parameter
535 User's Manual
Chapter 7
99
Applications
DESIG. SP to the desired setpoint.
U. CASCADE CONTROL
While a single 535 Controller is effective in maintaining many control systems,
others require more sophisticated control schemes. Figure 7.19, shows a
sample control set up with a 535 controller. Cascade control is often used to
control a process more precisely. In cascade control, a second variable is
monitored in addition to the primary controlled variable. This second variable
is one that more quickly reflects any changes in the process environment.
Cascade control involves installing one feedback loop within another, as in
Figure 7.20. This second loop, based on steam pressure, is called the inner or
secondary feedback loop. The outer or primary feedback loop is based on the
temperature of the liquid in the heat exchanger. However, instead of directly
positioning the steam valve, the output of the primary 535 controller is now used
to adjust the setpoint of the secondary 535 controller, which then positions the
valve.
Cascade Control is typically used for the following:
• A slow responding process with a significant lag time
• A process requiring more advanced or tighter control
• A process where two PID control loops need to interact to achieve optimum
control. Cascade control is commonly implemented in temperature control
applications where the main control variable is affected by another
variable, i.e., pressure.
Example
In Figure 7.19 we have a 535 set up to control a heat exchanger. In a PIDequipped heat exchanger, pressure in the steam shell more quickly reflects
fluctuations in the steam supply than does the process liquid’s temperature.
535
OUT
1 2
ALM
1 2
raw
materials
MIXER
MANUAL
DISPLAY
SET PT
ACK
MENU
FAST
Figure 7.19
Heat Exchanger Control Loop for
Steam Supply
HEAT
EXCHANGER
steam
temperature sensor
100
Chapter 7
535 User's Manual
Applications
Why? In this example, with PID control, the average temperature of the liquid
in the heat exchanger is 80°, but can vary by as much as five degrees because
the steam supply itself is not constant. Fluctuations in the pressure of the steam
supply cause fluctuations in the temperature of the steam within the heat
exchanger. So, the process liquid’s temperature begins to rise, but it takes
several minutes for the increased heat from the steam to travel through the
process liquid to reach the temperature sensor. By the time the sensor registers
the higher value and calls for a decrease in steam, the process liquid near the
walls is already at an even higher temperature. Although the steam supply is
reduced, the process liquid’s temperature continues to rise for a period of time.
This delay in the transfer of heat prevents the 535 controller from controlling
the temperature more precisely.
The solution to the problem is illustrated in Figure 7.20. Have the PID controller
position the steam valve, but add a sensor by means of another 535 controller
1
9
17
25
1
9
17
25
2
10
18
26
2
10
18
26
OUT 1–
3
11
19
27
OUT 1–
3
11
19
27
OUT 1+
4
12
20
28
OUT 1+
4
12
20
28
5
13
21
29
5
13
21
29
22
30
RTD 3RD
RSP–
6
14
22
30
6
14
7
15
23
31
PV 1–
7
15
23
31
PV 1–
8
16
24
32
PV 1+
8
16
24
32
PV 1+
UNIT 1
RSP+
UNIT 2
raw
materials
MIXER
Figure 7.20
Cascade Control of Product
Temperature
HEAT
EXCHANGER
steam
pressure sensor
temperature sensor
that will monitor the steam pressure. The pressure control system now creates
a second feedback control loop, which “cascades” from the first.
Hardware Configuration
•
Configure Unit 1 for a 4-20mA output (analog module for control).
535 User's Manual
Chapter 7
101
Applications
•
Configure Unit 2 for the optional Remote Setpoint (see Chapter 4).
Software Configuration
1. For Unit #1
a. In CONFIG. menu, set CTRL. TYPE to STANDARD.
b. In PV INPUT menu, set the PV TYPE parameter.
If type is V/mA, set LOW RANGE and HI RANGE parameters to
match the transmitter range.
2. For Unit #2
a. Set the RSP input jumper in the mA position on the Microcontroller
Circuit Board (see Chapter 4).
b. Go to the REM. SETPT menu.
c. Set RSP:LO. RNG. to 0. Set RSP:HI.RNG. to 100. This will set the
range of the remote setpoint to 0 TO 100 (to correspond to the 0% to
100% output range of Unit #1).
d. Wire the control output of Unit #1 to the remote setpoint input of Unit
#2 as shown in Figure 7.20.
e. When in operation, Unit #2 must be under remote setpoint control.
Tuning Cascade Control
1. The secondary loop is controlled by Unit #2, which does most of the work
in controlling the process. Put the secondary loop/Unit #2 under Manual
control, and perform a Pretune on it. Once that Pretune is completed, put
the Unit #2 under Automatic control.
2. The primary loop is controlled by Unit #1, which controls disturbances or
load changes in the process. Now place the primary loop/Unit #1 into Manual
and perform a Pretune on this loop. Once this Pretune is complete, the Cascade Control Loop is completely tuned. Place Unit #1 into Automatic control to allow the system to control to the desired Setpoint of the Primary loop.
102
Chapter 7
535 User's Manual
Applications
V. RATIO CONTROL
Ratio Control is employed in mixing applications that require the materials to
be mixed to a desired ratio.
For example: A given process requires Material A to be blended with Material
B in a 2:1 ratio. Material B is uncontrolled or wild. Flow sensors/transmitters
are used to measure the flow rate of each stream. The flow signal for Material
A is wired to the process variable input, and the flow signal for Material B is
wired to the remote setpoint input of the 535.
For this example, as shown in Figure 7.21, we would set RSP RATIO to 2.0. If
the flow of Material B is measured at 50 gallons/minute, the effective remote
setpoint value would be 2 times 50, or 100. The 535 controller would try to
maintain the flow of Material A at 100. As the flow of Material B changes, the
setpoint would change accordingly, always in a 2:1 ratio.
AC+
1
9
EARTH GND
17
25
AC–
2
10
18
26
OUT 1–
3
11
19
27
OUT 1+
4
12
20
28
5
13
RSP–
21
29
6
14
RSP+
22
30
7
15
23
31
PV 1–
8
16
24
32
PV 1+
BOTTOM (As
Figure 7.21
Ratio Control in Mixing Applicatoin
viewed from rear)
flow
sensor
MATERIAL A
CONTROLLED STREAM
MIXER
MATERIAL B
WILD STREAM
flow
sensor
Hardware Configuration
•
•
Set the process variable jumper and remote setpoint jumper to mA. Make
sure that both inputs are set up to accept the corresponding signal from the
flow transmitters.
Wire as in Figure 7.21.
Software Configuration
1. Make sure that the range of both inputs matches the range of the
corresponding transmitter:
535 User's Manual
Chapter 7
103
Applications
a. Go to the PV INPUT menu.
b. Set the HI. RANGE and LOW RANGE parameters.
c. Go to the REM. SETPT. menu.
d. Set the RSP:HI RNG. and RSP:LO RNG. parameters.
2. Adjust the ratio between the two streams:
a. Go to the TUNING menu.
b. Set the RSP RATIO parameter. The value of this parameter will be
multiplied by the remote setpoint signal to yield the effective remote
setpoint.
104
Chapter 7
535 User's Manual
Menu Flowcharts
APPENDIX 1
MENU FLOWCHARTS
SET UP
CONFIG.
CTRL. TYPE
LINE FREQ.
PV SOURCE
REM. SETPT.
OUTPUT 2
OUTPUT 3
OUTPUT 4
ANLG. RNG.:2
ANLG. RNG.:1
ANLG. RNG.:3
ANLG.RNG.: 4
CONTACT 1
CONTACT 2
CONTACT 3
CONTACT 4
CONTACT 5
LOOP NAME
PV1 TYPE
DEG. F/C/K
DECIMAL
LINEARIZE
LOW RANGE
SP LO LIM.
SP HI LIM.
SP RAMP
FILTER
PV2 SETUP
PV2 TYPE
DECIMAL
LINEARIZE
FILTER
OFFSET
CUST. LINR.
1ST. INPUT
1ST. PV
XTH. INPUT
CONTROL
ALGORITHM
D. SOURCE
ACTION:2
PV1 INPUT
OFFSET
HI RANGE
GAIN
RESTORE
PV2 INPUT
ALARMS
REM. SET PT.
RETRANS.
SELF TUNE
SPECIAL
LOW RANGE
HI RANGE
XTH. PV
15TH. INPUT*
15TH. PV*
ACTION: 1
PV BREAK
LOW OUT.
HIGH OUT.
P.P. TYPE
CCW TIME
CW TIME
MIN. TIME
S/W RANGE
OPEN F/B
CLOSE F/B
OUT1STOP
OUT2STRT.
ALM. TYPE:1
ALM.SRC.:1
ALARM SP:1
HIGH SP:1
LOW SP:1
DEADBAND:1
ALM.:1 OUT.
LATCHING:1
MESSAGE:1
ALM. TYPE:2
ALM.SRC.:2
ALARM SP:2
HIGH SP:2
LOW SP:2
LATCHING:2
DEADBAND:2
ALM.:2 OUT.
LATCHING:2
ACK.:2
POWER UP:2
MESSAGE:2
FAULT
OUTPUT
RATE TIME
TYPE V/MA
RSP:LO RNG.
BIAS LOW
BIAS HIGH
RSP FIXED
TYPE:2
LOW RANGE:2
HI RANGE:2
TYPE:4
LOW RANGE:4
HI RANGE:4
TYPE
PRETUNE
RESTORE
GAIN
POWER UP:1
ACK.:1
RSP:HI RNG.
RSP:LOW
RSP:HIGH
TRACKING
TYPE:X
LOW RANGE:3
HI RANGE:3
TUNE PT.
OUT. STEP
LOW LIMIT
HI LIMIT
TIMEOUT
MODE
NOISE BND.
RESP. TIME
DEAD TIME
AUTO. TRIP
TRIP DEV.
DES. OUTPT.
POWER UP
PWR. UP:OUT.
PWR. UP:SP
SP ADJUST
AUTO./MAN.
SP SELECT
ALARM ACK.
TUNING
STATION
BAUD RATE
CRC
SHED TIME
SHED MODE
SHED SP
DESIG. SP
NO. OF SP
SECURITY
SEC. CODE
CONFIGURE
SER. COMM.
535 User's Manual
Appendix 1
SHED OUT.
A-1
Menu Flowcharts
Up to 8 times, depending on NO. OF PID
TUNING
A-2
ADAPTIVE
PRETUNE
POWR. BACK
PROP BND,:1
RESET:1
RATE:1
MAN. RST.:1
CYCLE TM.:1
DEADBAND:1
P. PROP.D.B.
PID OFST.:1
PID OFST.:2
REL. GAIN:2
CYCLE TM.:2
DEADBAND:2
RSP RATIO
RSP BIAS
NO. OF PID
PID TRIP
TRIP:1
PROP. BND.:2
RESET:2
RATE:2
MAN. RST.:2
TRIP:2
PROP. BND.:3
RESET:3
RATE:2
MAN. RST.:3
TRIP:3
PROP. BND.:4
RESET:4
RATE:4
MAN. RST.:4
TRIP:4
PROP. BND.:5
RESET:5
RATE:5
MAN. RST.:5
TRIP:5
PROP. BND.:6
RESET:6
RATE:6
MAN. RST.:6
TRIP:6
PROP. BND.:7
RESET:7
RATE:7
MAN. RST.:2
TRIP:7
PROP. BND.:8
RESET:8
RATE:8
MAN. RST.:8
TRIP:8
Appendix 1
535 User's Manual
Parts List
APPENDIX 2
PARTS LIST
OPERATOR
INTERFACE
ASSEMBLY
shown with bezel
insert in place
CIRCUIT
BOARD SUPPORT
(BEZEL INSERT)
CIRCUIT BOARDS
BEZEL
GASKET
ITEM
CONTROLLER BODY
shown with mounting
collar in place
MOUNTING
COLLAR
PART #
Output Modules
Mechanical Relay Module
Analog (milliamp Module)
535 600
535 601
Solid State Relay Module
DC Logic (SSR Drive) Module
535 602
535 603
Loop Power Module
RS-485 Communications Module
535 604
535 705
Repair/Replacement Parts
Operator Interface Assembly
535 632
Power Supply Circuit Board
Microcontroller Circuit Board
535 730
535 731
Option Circuit Board w/no Options
Option Circuit Board w/Set of 5 Digital Contacts
535 720
535 721
Option Circuit Board w/Slidewire Feedback
Option Circuit Board w/set of 5 Digital Contacts & Slidewire Feedback
535 722
535 723
EPROM without Remote Setpoint Option
EPROM with Remote Setpoint Option
535 740
535 741
Lithium Battery
Jumper Kit: Set of All Jumper Connectors
093 044
535 660
Gasket Kit: 1 Panel Gasket & 1 Bezel Gasket
Mounting Kit: Mounting Collar & 4 screws
535 662
535 761
Bezel Retention Screw Kit
Module Retention Kit for Outputs 1-3 ( Includes Retention Plate)
535 663
535 664
Module Retention Kit for Output 4: Set of 5 Tie Wraps
Circuit Board Support (Bezel Insert)
535 665
535 075
Engineering unit labels (1 sheet)
535 106
535 User's Manual
Appendix 2
A-3
Parts List
A-4
Appendix 2
535 User's Manual
Troubleshooting
APPENDIX 3
TROUBLESHOOTING
SYMPTOM
Display will not light up
PROBLEM
SOLUTION
Defective power source
Check power source and wiring
Improper wiring
Correct wiring
Blown in-line fuse
Check wiring, replace fuse
Unit not inserted in case properly; or, screws
Remove unit from case (and remove
have not been tightened.
bezel screws), then reinsert unit and
properly tighten screws.
Improper/Lost PV reading
• Voltage/current
Improper/Lost PV reading
• Thermocouple
Input jumper selection improperly set
Move jumper to proper location
Input range improperly selected in software
Select proper range
Reverse polarity
Check and correct sensor wiring
If controller powered, improperly wired
Check and correct wiring
Loop power module not installed
Install module
Defective transmitter
Replace transmitter
Transmitter signal out of range
Select proper range in software
Defective thermocouple
Replace thermocouple
Input jumper selection improperly set
Select Proper input
Wrong TC type selected in software
Select proper thermocouple type in
software
Improper/Lost PV reading
• RTD
Improper wiring
Wire properly
Defective RTD
Replace RTD
Input jumper selection improperly set
Move jumper connector to proper
location
No control output
Improper wiring
Wire properly
Output wiring and module location do not match
Check and correct wiring or module
If SSR, SSR Drive of Milliamp output, jumpers J1,
Set jumper connector to proper location
location
J2 and J3 are not set properly
Software configuration does not match hardware
Reconfigure software to match hardware
PID values not set properly
Set PID values properly
Can’t switch to auto control
Input sensor signal is not connected or valid
See PV LOST message
Erratic display
Resetting action due to electrical noise on
Filter power line.
powerline
PID values not set properly
535 User's Manual
Retune controller
Appendix 3
A-5
Troubleshooting
Message
When does it occur?
What to do:
DEFAULTS
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.
Entering the Set Up mode and changing a parameter
will clear the message. If due to something other than
the user purposely clearing the memory, call factory
for assistance.
LOST CAL. or
ERROR: BAD CAL. DATA
Indicates that the calibration data has been lost.
Occurs if all the memory has been erased.
Problem should never happen. Must correct the
situation and recalibrate. Call factory for assistance.
PV1 UNDER or
PV1 OVER or
PV2 UNDER or
PV2 OVER or
When the process variable value travels slightly
outside the boundaries of the instrument span.
Does not apply to thermocouple or RTD inputs.
May not need to do anything. May want to check the
transmitter accuracy and check to see if range of
transmitter matches the range of the controller.
When the controller senses a lost process
variable signal or the input signal travels well
beyond the instrument span.
Check wiring and sensor/transmitter.
LOST RSP
When the remote setpoint is in use and the
controller senses that the signal has been lost or
has traveled well outside the range.
Check wiring and remote setpoint source.
COMM SHED
When the communications is lost for longer than
the communications shed time.
Check communications wiring, etc. To clear message,
must make an auto/manual change.
On power up a problem with the EPROM is
detected. Controller locks up until fixed.
This is a fatal error and requires an EPROM change.
Call factory for assistance.
Upon power up, controller senses that the
modules needed for control as determined by
software configuration are not present.
Must power down and install correct module
combination or must reconfigure the controller to
match the current module combination.
LOST F/B
The slidewire feedback is sensed as lost.
Check the slidewire wiring.
LOST CJC
The cold junction is sensed as lost.
Call factory for assistance.
During power up an EEPROM failure is
detected. Controller locks up until fixed.
This is a fatal error and requires and EPROM change.
Call factory for assistance.
NEEDS CAL.
When the controller is powered up with default
calibration data (input and output accuracy
specifications may not be met).
Enter calibration menu and recalibrate the controller.
Call factory for assistance.
ERROR: BAD MODEL NUM.
During power up, a discrepancy was found
between the EEPROM's and controller's model
numbers. Controller locks up until fixed.
This is a fatal error and requires an EPROM or
EEPROM change. Call factory for assistance.
CAL.ERROR
SEE.MANUAL
During cold junction calibration, a discrepancy
was found between the controller type and the
case type.
Install the 535 chassis into the actual case with which
it was shipped, then run calibration again. If you
experience further problems, call factory for
assistance.
LOST PV1 or
LOST PV2
ERROR: ROM CHECKSUM
OUT1 CONF or
OUT2 CONF
ERROR: BAD EEPROM
A-6
Appendix 3
535 User's Manual
Calibration
APPENDIX 4
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).
Access the parts of the calibration menu as shown in Figure A4.2.
ANALOG IN
PRESS ACK
5.0000
PRESS MENU
9
17
25
10
18
26
OUT 1-
3
11
19
27
OUT 1+
4
12
20
28
PV2–
OUT 2-
5
13
21
29
PV2+
OUT 2+
6
14
22
30
OUT 3-
7
15
OUT 4–
–
23
31
PV1–
OUT 3+
8
16
OUT 4+
+
24
32
PV1+
Figure A4.1
535 Rear Terminals for Calibration
Figure A4.2
Flowchart Calibration Menus
CAL. VREF
CALIBRATE
1
2
CAL. 120mV, etc.
PRESS ACK
PRESS MENU
mA CALIB.
SET BOTH
CALIBRATE
ANA. mA IN
PRESS ACK
JUMPER=mA
Power Down
Move Jumpers
Power Up
PV1=20mA
PRESS ACK
Attach 20mA
to PV1
Press ACK
PV2=20mA
PRESS ACK
Attach 20mA
to PV2
Press ACK
COMPLETED
If mA calibration values are
OK.
mA CALIB.
PRESS MENU
FAILED
PV= –150 C
CALIBRATE
COLD JUNC.
PRESS ACK
PRESS ACK
PRESS ACK
PRESS MENU
OUTPUT "X"
CALIBRATE
ANLG. OUT
If mA calibration values are
out of range.
PRESS ACK
4 mA
PRESS MENU
OUTPUT X, etc
PRESS ACK
PRESS MENU
RESET
RESET
MENU DATA
PRESS ACK
PUSH MENU
SKIPPED
TO RESET
PRESS
MENU
before two
seconds
PRESS MENU
HARDWARE
SCAN
After two
seconds
RESET
COMPLETED
PRESS ACK
DISPLAY ONLY
PRESS MENU
SLIDEWIRE
TEST
SLIDEWIRE
PRESS ACK
____%
PRESS MENU
PRESS ACK
535 User's Manual
Appendix 4
A-7
Calibration
EPROM
Figure A4.3
Jumper Locations on the
Microcontroller Circuit Board
P1
P2
V
MA
TC▼
TC▲
RTD
PV INPUT
JUMPER
CONFIGURATION
V
MA
TC▼
TC▲
RTD
S'Y
PV1
CALIBRATION
JUMPERS—
SELECT V
AND TC▲
2ND
TB2
Jumper locations for
Analog,Thermocouple
and Milliamp calibration
TB1
Preparation for all Input Calibrations
Equipment for analog input calibration:
•
•
•
•
Additional equipment for thermocouple input:
Figure A4.4
Input Calibration Wiring
17
25
18
26
19
27
20
28
21
29
22
30
31
24
32
Precision thermocouple calibrator, e.g., Micromite II® by Thermo Electric
Instruments
• Special limits grade, Type T thermocouple wire
Disconnect power to the instrument.
Remove chassis from case.
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 A4.3.
Connect hook up wires between terminals 31 and 32 and the multimeter as
shown in Figure A4.4.
Set the meter for DC volts.
Reinsert chassis into the case and apply power.
The 2nd and 3rd display should read CALIBRATE ANALOG IN.
Allow the controller to warm up for at least 30 minutes.
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.
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.
•
1.
2.
3.
4.
Hook-up
wires to
multimeter
5.
PV1–
23
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
#2 Phillips screwdriver
PV1+
6.
7.
WARNING!
ELECTRIC SHOCK HAZARD!
Terminals 1 and 2 carry live power. DO
NOT touch these terminals when power
is on.
8.
A-8
Appendix 4
535 User's Manual
Calibration
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.
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 28, 29, 31 and 32 as shown in
Figure A4.5. 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).
17
25
18
26
19
27
20
28
21
29
22
30
23
31
24
32
Type T
thermocouple
wires (floating)
– red
+ blue
– red
+ blue
Figure A4.5
Thermocouple/Cold Junction
Calibration Wiring
ANALOG MILLIAMP INPUT CALIBRATION
1. Remove the thermocouple wires (if present) from terminals 28, 29, 31 and 32.
Replace them with pieces of wire that will be connected to a 20 milliamp input
current (see Figure A4.6). 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 PV1=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.
535 User's Manual
Appendix 4
A-9
Calibration
17
25
18
26
19
27
20
28
21
29
22
30
23
31
24
32
Wires to 20mA
current (floating)
PV2–
PV2+
PV1–
PV1+
Figure A4.6
Analog mA Input Calibration Wiring
P1
P2
PUT
PER
RATION
V
MA
TCt
TCs
RTD
PV1
V
MA
TCt
TCs
RTD
2ND
TB2
RATION
ERS—
ECT V
TCs
TB1
Figure A4.7
Analog mA Input Jumper Positions
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 A4.7.
7. Reinsert the chassis into the case and apply power. The controller should display PV1=20mA PRESS ACK to indicate it is ready to calibrate the PV1 milliamp input.
8. Connect a precision 20mA input to the PV1 terminals (31 is PV1-, 32 is PV1+).
Make sure the terminal connections are fastened tightly and that a 20mA current is flowing through PV1. Do not connect the 20mA current to PV2 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 PV1
input.
10. If the controller briefly displays PV2=20mA INPUT, PV1 calibration was successful. Move on to step 12.
11. If the controller briefly displays mA CALIB. FAILED, PV1 calibration was not
successful.
Check the 20mA connections, and return to step #3 to recalibrate the PV1 input.
12. Remove the 20mA input from the PV1 terminals, and attach it to the PV2 terminals (see Figure A4.6).
Make sure the terminal connections are fastened tightly and that a 20mA current is flowing through PV2.
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 PV2 input.
14. If the controller briefle displays mA CALIB. COMPLETED, PV2 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, PV2 calibration was not
successful. Check the 20mA connections, and return to step #3 to recalibrate
the PV1 and PV2 inputs.
MILLIAMP OUTPUT CALIBRATION
If the controller uses milliamp outputs, it is usually not necessary to calibrate them.
If the milliamp outputs are being used for accurate retransmission of data, it is recommended that each output with an analog module be calibrated annually to
maintain optimal performance.
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 banana clips
• #2 Phillips screwdriver
1. Disconnect power to the instrument.
2. Remove chassis from case.
•
A-10
Appendix 4
535 User's Manual
Calibration
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 A4.3.
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.
(CALIBRATE Menu, ANALOG. IN section).
Press MENU three times to reach the CALIBRATE ANLG. OUT Menu.
6. Connect hook up wires to the terminals for the corresponding milliamp output
modules.
Output 1 uses terminals 3 and 4.
Output 2 uses terminals 5 and 6
Output 3 uses terminals 7 and 8 (shown in Figure A4.8)
Output 4 uses terminals 15 and 16.
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 OUTPUT1, OUTPUT2, OUTPUT3 or
OUTPUT4 (depending on the module installation).
8. Press MENU to scroll to the output to be calibrated (see Figure A4.9). 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 calibrate another analog output:
Move the wires and test leads to the new output terminals.
Press MENU until the 3rd display shows 4mA for the corresponding output in
the 2nd display. Repeat step 9-11.
13. To complete calibration, press ACK key, disconnect the power and place the
jumper connectors back into their original position.
1
9
2
10
OUT 1–
3
11
OUT 1+
4
12
OUT 2–
5
13
OUT 2+
6
14
OUT 3–
7
15
8
16
– OUT 3+
OUT 4–
OUT 4+
+
Connect to
multi-meter
Figure A4.8
Milliamp Output Calibration Wiring
TO OTHER
CALIBRATION
MENU
OUTPUT "X"
4 mA
PRESS ACK
PRESS MENU
OUTPUT "X"
20 mA
PRESS ACK
PRESS MENU
EACH OUTPUT WILL GO
THROUGH THIS CYCLE
Figure A4.9
Output Module Menu Cycle
RESET MENU DATA
Resets all parameter values back to their factory default values (except for calibration information). Refer to the flowchart in Figure A4.2.
1. Disconnect power to the instrument.
2. Remove chassis from case.
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.
535 User's Manual
Appendix 4
A-11
Calibration
HARDWARE SCAN
Use this read-only feature to identify the output hardware and installed options of
the controller.
▲ (see Figure A4.3).
1. Set the jumpers to V and TC▲
2. Power up the controller.
3. Press MENU until HARDWARE SCAN is displayed.
4. Press ACK to initiate the hardware display.
5. When complete, return jumpers to their original positions.
1
9
2
10
3
11
WIPER
4
12
CW
5
13
6
14
7
15
8
16
CCW
SLIDEWIRE TEST
If the slidewire option is installed, use the following to test its function:
1. Press MENU to scroll to the SLIDEWIRE TEST menu (refer to Figure A4.2)
2. Attach a 100 to 1000 ohms potentiometer to terminals 10, 11 and 12 as shown
in Figure A4.10.
3. Moving the potentiometer from one end to the other should display from “0%”
to “100%” on the controller.
4. If the error message OPEN appears, check the connectors and try again.
5. Press ACK to exit.
QUICK CALIBRATION PROCEDURE
Figure A4.10
Slidewire Test Wiring
This procedure may benefit users that have ISO or other standards requiring
periodic calibration verification. It enables verification and modification of the PV
input without entering the “Factory Configuration” mode.
1. Power down the 545 controller and place the input jumpers in the desired
position (refer to Figure A4.2 and Figure A4.7).
2. Replace the process variable (PV1 or PV2) input signal with a suitable milliamp calibration device.
3. Apply power and allow controller to warm up for 30 minutes.
4. Place controller in manual mode. Then press MENU and FAST together to
reach the PV1 INPUT or PV2 INPUT menu.
5. Press MENU until the OFFSET parameter appears in the 2nd display.
6. 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).
7. Verify value indicated in the 1st display is equal to the 0% range value for the
particular input sensor. If incorrect use the ▲ and ▼ keys to scroll to the correct value.
8. For linear voltage or mA input: Press MENU until the PV GAIN parameter appears in the 2nd display.
For thermocouple or RTD input: go to step 9.
9. Adjust the calibration device to an output signal equal to the 100% range value
for the particular sensor.
10. 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
▼ keys to scroll to the correct value.
11. Repeat steps 4 through 10 to verify all values.
12. Press DISPLAY to return to the Operation mode.
A-12
Appendix 4
535 User's Manual
Specifications
APPENDIX 5
SPECIFICATIONS
ACCURACY
TYPICAL
MAXIMUM
LINEAR (Voltage)
(Current)
± 0.025% of full scale ± 0.100% of full scale
± 0.050% of full scale ± 0.150% of full scale
RTD
± 0.050% of span
± 0.095% of span
1.0°
0.1°
± 0.150% of span
± 0.225% of span
THERMOCOUPLE
J, K, N, E (> 0°C)
± 0.060% of span
± 0.150% of span
J, K, N, E (< 0°C)
± 0.150% of span
± 0.375% of span
T (> 0°C)
± 0.100% of span
± 0.250% of span
T (< 0°C)
± 0.250% of span
± 0.625% of span
R, S (> 500°C)
± 0.150% of span
± 0.375% of span
R, S (< 500°C)
± 0.375% of span
± 0.925% of span
B (> 500°C)
± 0.150% of span
± 0.375% of span
B (< 500°C)
± 0.500% of span
± 1.000% of span
W, W5 & Platinel II ± 0.125% of span
± 0.325% of span
Display accuracy is ± 1 digit. These accuracy specifications 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, PD with manual reset, and On-Off
are selectable from the front panel. Duplex outputs each use the
same algorithm, except On-Off may be used with PID. The PID
algorithm used is non-interacting.
TUNING PARAMETERS
Proportional Band: 0.1 to 999% of input range
Integral: 1 to 9999 seconds/repeat
Derivative: 0 to 600 seconds
Manual Reset/Load Line: 0 to 100% output
Cycle Time: 0.3 to 120 seconds
On-Off Deadband: up to 15% of input range (in eng. units)
Up to eight sets of PID values may be stored in memory and
selected automatically, based on setpoint value, process variable
value, or the corresponding local setpoint (SP1–SP8).
SELF TUNING OF PID VALUES
POWERTUNE® On-demand “pretune”: This is an open loop
algorithm that may be used on its own to calculate PID variables, or
it can be used to provide preliminary PID values, as well as process
identification information to be used by the adaptive tune.
Three pretune types are available: TYPE 1 for slow thermal
processes; TYPE 2 for fast fluid or pressure applications; and TYPE
3 for level control applications.
Adaptive tune: Our exclusive POWERTUNE® adaptive tuning
algorithm automatically adjusts the PID values whenever a process
upset occurs. Preliminary information may be input manually or
automatically calculated by our pretune algorithm.
OVERSHOOT PROTECTION
POWERBACK is Powers’ proprietary, user-invoked, setpoint
overshoot protection algorithm. When invoked, POWERBACK
reduces or eliminates setpoint overshoot at power up or after
setpoint changes. POWERBACK monitors the process variable
to make predictive adjustments to the control parameters, a
feature that helps eliminate overshoot of setpoint.
ISOLATION
Inputs and outputs are grouped into the following blocks:
Block 1:
process variable
Block 2 :
outputs 1, 2, and 4
Block 3:
communications, set of five digital inputs, output 3
(Earth Ground)
Block 4:
remote setpoint
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.
CONTROLLER ARCHITECTURE
The 535 Controller hardware can be configured as follows:
Inputs: One universal process variable input is standard. Available
options include: remote setpoint, slidewire feedback and 5 digital
inputs.
Outputs: Four outputs are available. See Ordering Information.
RS-485 Communications: Available as option with any configuration.
PROCESS VARIABLE INPUTS - 2 PROCESS VARIABLES
AVAILABLE
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.
THERMOCOUPLES
B
E
J
K
N
R
S
T
W
W5
Platinel II
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
(Continued on following page)
Specifications and information subject to change without notice.
535 User's Manual
RANGE °F
104 to 3301
–454 to 1832
–346 to 1832
–418 to 2500
–328 to 2372
32 to 3182
32 to 3182
–328 to 752
32 to 4172
32 to 4172
–148 to 2550
Appendix 5
A-13
Specifications
RTDs
100 Pt. (DIN)
100 Pt. (JIS)
100 Pt. (SAMA)
RANGE °F
–328 to 1562
–328.0 to 545.0
–328 to 1202
–328.0 to 545.0
–328 to 1202
–328.0 to 545.0
TRANSMITTER SIGNALS
Milliamps DC
Voltage DC
Millivolts DC
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
INPUT RANGE
4 to 20
0 to 20
1 to 5
0 to 5
0 to 10
0 to 30
0 to 60
0 to 100
–25 to 25
LINEARIZATION
Thermocouple and RTD inputs are automatically linearized.
Transmitter inputs may be linearized with a square root function or
user-definable 15-point straight line linearization function.
INPUT IMPEDANCE
Current Input: 250 ohms
Voltage Input: 1 Mohms
Thermocouples: 10 Mohms
RTDs: 10 Mohms
UPDATE RATE
Input is sampled and output updated 10 times per second. Display is
updated five times per second.
TRANSMITTER LOOP POWER
Isolated 24 Vdc (nominal) loop power supply is available if a loop power
module is installed in an output socket not used for control. Capacity is 25
mA.
INPUT SIGNAL FAILURE PROTECTION
When input is lost, output is commanded to a predetermined output
(–5 to 105%). Thermocouple burnout is selectable for upscale or
downscale.
INPUT FILTER
Single pole lowpass digital filter with selectable time constant from
0 to 120 seconds.
CALIBRATION
Comes fully calibrated from the factory and continuously calibrates
itself for component aging due to temperature and time, except for
the reference voltage. Field calibration can be easily performed in
the field with a precision multimeter and thermocouple simulator.
Process variable offset and gain factors are provided to correct for
sensor errors.
OUTPUT MODULES
The controller can have a total of four control outputs, alarm outputs
and/or loop power modules installed. There are five types of output
modules which can be configured to suit your particular application.
The modules may be ordered factory-installed, or they may be
installed in the field.
Mechanical relay module: SPDT electromechanical relay.
Resistive load rated at 5 amps at 120/240 VAC. Normally open or
normally closed selection is made by jumper. Output 4 is rated at
0.5 amps at 24 VAC and is always normally open.
Solid state relay (triac) module: Resistive load rated at 1 amp at
120/240 VAC. Output 4 is rated at 0.5 amps at 24 VAC. These
outputs are normally open.
DC logic (SSR drive) module: “ON” voltage is 17 Vdc (nominal).
“OFF” voltage is less than 0.5 Vdc. (Current limited to 40mA.)
Loop power supply module: Current is limited to 25 mA @ 24V
(nominally loading).
CONTROL OUTPUTS
Up to two output modules may be designated for control. Any
combination of output modules, with the exception of the loop
power supply module, may be used.
Duplex control is available if output modules are installed in the
first and second output sockets.
Position proportioning control with feedback is available if
mechanical or solid state relay modules are installed in the first two
output sockets, and the slidewire feedback option is installed.
Slidewire feedback range is 0 to 1050 ohms.
“Velocity” position proportioning control is available by
installing mechanical or solid state relay modules in the first two
output sockets. A special algorithm controls an electric actuator
without the slidewire feedback signal.
Staged (split range) outputs are available if analog modules are
installed in the first and second output sockets. This algorithm will
allow the output range to be split between the two outputs.
RETRANSMISSION OUTPUT
Based on available outputs (any socket not used for control), up to
two different variables can be simultaneously programmed for
retransmission. Each precise, 16-bit resolution output may be
scaled for any range. Variable selection includes: PV, SP, RAMP
SP, and OUTPUT.
ALARMS
The 535 controller has two software alarms. High and low
alarms may be sourced to the PV, SP, RAMP SP, DEVIATION
and OUTPUT. If an alarm is tripped, the alarm message will
show, the ACK key will illuminate (if acknowledgeable) and the
ALM icon will light. If the alarm is tied to the first available noncontrol output, the “1” below the ALM icon will light. Similarly, if
the alarm is tied to the second non-control output, the “2” below
the ALM will light. The availability of outputs determines how
many alarms can be tied to relays.
Up to two alarm outputs are available if an associated mechanical,
solid state relay or DC logic module is installed in any output socket
not used for control.
Global Alarm feature allows one or more of the internal software
alarms to be tied to the same single, physical output. The
acknowledge key is active for alarms associated with either loop.
Analog module: Either 0–20 mA or 4–20 mA (front panel selectable) into a load up to 1000. Accuracy ± 5µA @ 25°C.
A-14
Appendix 5
535 User's Manual
Specifications
DIGITAL INPUTS
A set of five external dry contacts or open collector transistor driven
inputs are available. Each can be configured to perform one of the
following functions:
• Select remote setpoint
• Select manual control
•Select either direct or reverse
control action
• Select second local setpoint
•Disable adaptive tuning
• Select a second set of
PID values
•Addressable through serial
communications only
• Acknowledge alarms
•Inhibit the reset term
• Simulate ▲ and ▼ keys
•Lock controller in manual mode
• Simulate DISPLAY, FAST
and MENU keys
•Select PV1 or PV2
In addition, if the set of five digital inputs is installed, four may be
designated to select one of eight local setpoints (and associated PID
set, if desired) via a binary coded decimal (BCD) input.
SETPOINT SELECTION
A remote setpoint input is available. Signal is 0–20/4–20 mADC or
0–5/1–5 VDC (jumper selectable). Signal may be ratioed and biased.
Eight local setpoints may be stored in memory.
Setpoint selection is made via SET PT key or digital contact(s).
FAULT OUTPUT
One of the alarm outputs may be designated to also energize if
the input signal is lost.
SERIAL COMMUNICATIONS
Isolated serial communications is available using an RS-485
interface. Baud rates of up to 19,600 are selectable. The protocol
supports CRC data checking. If communications is lost, a time-out
feature will command the controller to a particular control mode
and specific setpoint or output if desired. Outputs 2–4 and digital
inputs can act as “host-controlled” I/O independent of the
controller’s function. The PV may be sourced via this interface.
May be installed in the field.
DIGITAL DISPLAYS
Upper display: five-digit, seven-segment. Used exclusively for
displaying the process variable value. Height is 15 mm (0.6 in.).
2nd display: nine-character, 14-segment alphanumeric. Used for
displaying setpoint, deviation, output value, slidewire position
(actual valve position) and configuration information. Height is
6mm (0.25 in.).
3rd display: nine-character, 14-segment alphanumeric. Used for
indicating which loop is displayed and for displaying alarm
messages and configuration information.
Height is 6mm (0.25 in.).
All displays are vacuum fluorescent. Color is blue-green.
STATUS INDICATORS
There are two types of indicators: icons and illuminated keys.
ALM 1 and ALM 2 icons: alarm 1 and alarm 2 status.
OUT 1 and OUT 2 icons: control output 1 and control output 2 status.
MAN key illuminated: controller is in manual control mode.
ACK key illuminated: alarm may be acknowledged.
SET PT key illuminated: setpoint other than primary local setpoint is
active.
MENU key illuminated: controller is in configuration mode.
535 User's Manual
DIMENSIONS
Meets 1/4 DIN designation as specified in DIN standard number
43 700.
See diagram for details.
MOUNTING
Panel-mounted.
WIRING CONNECTIONS
29 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. 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.
(Continued on following page)
Appendix 5
A-15
Specifications
A-16
Appendix 5
535 User's Manual
Glossary
APPENDIX 6
GLOSSARY
alarm, manual: A type of alarm set
up to occur when the controller is
put into manual mode of operation.
adaptive control: Control in which
automatic means are used to
change the type or influence (or
both) of control parameters in such
a way as to improve the
performance of the control system.
alarm, power up: A type of alarm
that determines alarm condition on
power up of the controller.
adaptive tune: A component of the
535 self tune function which
continuously monitors the process
and natural disturbances and makes
adjustments in the tuning
parameters to compensate for or
improve the performance of the
control system.
alarm: A condition, generated by a
controller, indicating that the process
has exceeded or fallen below the set
or limit point.
alarm, band: A type of alarm set up
where a band is created around the
control setpoint.
alarm, deviation: An alarm similar
to a band alarm except it only
creates a band on one side of the
alarm setpoint.
alarm, fault: An indication that
becomes active upon loss of
process variable. Fault alarm
operates in addition to other alarm
assignments.
alarm, global: The single physical
output to which one or more internal
software alarms are tied.
alarm, high process variable: A
type of alarm that is set up to occur
when the process variable goes
above the alarm setpoint.
alarm, low process variable: A
type of alarm that is set up to occur
when the process variable goes
below the alarm setpoint.
535 User's Manual
alarm, rate-of-change: A type of
alarm set up to occur when there is
an excessive change in the process
variable (PV) value.
baud rate: Any of the standard
transmission rates for sending or
receiving binary coded data.
bezel: The flat portion surrounding
the face of the controller, which
holds the keys and display.
bump: A sudden increase in the
output power initiated by the
controller in order to determine the
system response during a self tune
procedure.
binary coded decimal (BCD): A
notation in which the individual
decimal digits are represented by a
group of binary bits, e.g., in the 8-42-1 coded decimal notation each
decimal digit is represented by four
binary bits.
calibration: The act of adjustment
or verification of the controller unit by
comparison of the unit’s reading and
standards of known accuracy and
stability.
cascade control: Control in which
the output of one controller is the
setpoint for another controller.
closed loop: Control system that
has a sensing device for process
variable feedback.
cold junction: Point of connection
between thermocouple metals and
the electronic instrument.
Appendix 6
configuration: Also called “set up,”
selection of hardware devices and
software routines that function
together.
cold junction compensation:
Electronic means used to
compensate for the effect of
temperature at the cold junction.
contact: In hardware, a set of
conductors that can be brought into
contact by electromechanical action
and thereby produce switching. In
software, a symbolic set of points
whose open or closed condition
depends on the logic status
assigned to them by internal or
external conditions.
control action: The slope of the
output of the instrument in reference
to the input, e.g., direct output
increases on rise of input. Typical
cooling response or reverse output
decreases on rise of input (typical
heating response).
control action, derivative (rate)
(D): The part of the control algorithm
that reacts to rate of change of the
process variable.
control action, integral (reset) (I):
The part of the control algorithm that
reacts to offset between setpoint
and process variable.
control action, proportional (P):
Control action in which there is a
continuous linear relation between
the output and the input.
control action, proportional plus
derivative (PD): A control algorithm
that provides proportional control
with the addition of derivative action
to compensate for rapid changes in
process variable.
A-17
Glossary
control action, proportional plus
integral (PI): A control algorithm
that provides proportional control
with the addition of integral action
to compensate for offsets between
setpoint and process variable.
control action, proportional plus
integral plus derivative (PID): A
control algorithm that provides
proportional control with both
integral and derivative action.
control, adaptive: (see adaptive
control)
control algorithm: A
mathematical representation of the
control action to be performed.
control, cascade: (see cascade
control)
control output: The end product
which is at some desired value
that is the result of having been
processed or manipulated.
control mode, automatic: A user
selected method of operation
where the controller determines
the control output.
control mode, manual: A user
selected method of operation
where the operator determines the
control output.
control parameters: User defined
values that specify how the
process is to be controlled.
controlled variable: A process
variable which is to be controlled
at some desired value by means
of manipulating another process
variable.
CRC (cyclic redundancy check):
An error checking technique in
which a checking number is
generated by taking the remainder
after dividing all the bits in a block
A-18
(in serial form) by a predetermined
binary number.
CSA: Acronym for Canadian
Standards Association.
cycle time: The time necessary to
complete a full ON-through-OFF
period in a time proportioning
control system.
damping: The decrease in
amplitude of an oscillation due to
the dissipation of energy.
damped, 1/4 amplitude: The loss
of one-quarter of the amount of
amplitude with every oscillation.
dead band: A temperature band
between heating and cooling
functions; the range through which
an input can be varied without
initiating observable change in
output.
dead time: The interval of time
between initiation of an input
change or stimulus and the start of
the resulting observable response.
default settings: Parameters
selections that have been made at
the factory.
derivative: Anticipatory action that
senses the rate of change of
temperature, and compensates to
minimize overshoot and
undershoot. Also “rate.”
derivative action: (See control
action, derivative)
deviation: The difference between
the value of the controlled variable
and the value at which it is being
controlled.
digital input: Used in this manual
to indicate the status of a dry
contact; also called “gate”.
Appendix 6
DIN: Deutsche Industrial Norms, a
German agency that sets standard
for engineering units and
dimensions.
display, 1st: The top, largest
display of controller face that is
used to display the process
variable value.
display, 2nd: The middle display
of the controller face used to
indicate: in OPERATION Mode the setpoint, deviation or output; in
TUNING or SET UP Mode - the
parameter or parameter menu.
display, 3rd: The bottom display
of the controller face that is used
to indicate: in OPERATION Mode the setpoint, deviation or output; in
TUNING or SET UP Mode - the
parameter or parameter menu.
disturbance: An undesired
change that takes place in a
process that tends to affect
adversely the value of a controlled
variable.
duty cycle: Percentage of “load
ON time” relative to total cycle
time.
earth ground: A terminal used on
the 535 to ensure, by means of a
special connection, the grounding
(earthing) of part of the controller.
engineering unit: Terms of data
measurement such as degrees
Celsius, pounds, grams, etc.
feedback: Process signal used in
control as a measure of response
to control action; the part of a
closed-loop system which
automatically brings back
information about the condition
under control.
535 User's Manual
Glossary
FM: Factory Mutual Research
Corporation; an organization
which sets safety standards.
jumper: A wire that connects or
bypasses a portion of a circuit on the
printed circuit board.
mechanical relay: (see relay)
gain: The ratio of the change in
output to the change in input which
caused it.
jumper connectors: The
connecting device that straddles a
jumper to connect or bypass a
portion of a circuit on a printed circuit
board.
menu block: Groups of parameters
arranged in the software.
heat/cool control: Control method
where the temperature of the end
product is maintained by controlling
two final elements using two of the
535 outputs.
hysteresis: In ON/OFF control, the
temperature change necessary to
change the output from full ON to
full OFF.
hunting: Oscillation or fluctuation
of process temperature between
setpoint and process variable.
icons: Indicators on the face of the
controller.
input: Process variable information
being supplied to the instrument.
integral: Control action that
automatically eliminates offset, or
“droop”, between setpoint and actual
process temperature. Also “reset.”
internal voltage reference: A
precision voltage source within the
535 controller, used to establish
internal calibration.
isolation: Electrical separation of
sensor from high voltage circuitry.
Allows for application of grounded or
ungrounded sensing element.
linearization: A function the 535
uses to automatically linearize a nonlinear signal, either from
thermocouple or RTD temperature
sensors, through the use of look up
tables. The relationship that exists
between two variables when the
ratio of the value of one variable to
the corresponding value of the other
is constant over an entire range of
possibilities.
linearization, custom: Userdefinable linearization.
linearization, square root: A
function the 535 uses to linearize a
non-linear signal corresponding to
the flow being measured by flow
transmitters.
load line out: A start up output value
which is to bring initial output closer
to actual steady state output.
Ioop power: An internal 24-volt
current limited power supply used to
power 2 or 4 wire transmitter on the
input of the controller.
load: The demand for input to a
process.
offset: Adjustment to actual input
temperature and to the temperature
values the controller uses tor display
and control.
low pass input filter: A method to
block fast acting signals (typically
noise), while allowing slow acting
signals (actual process variable) to
pass.
JIS: Japanese Industrial Standards.
Also Japanese Industrial Standards
Committee (JISC). Establishes
standards on equipment and
components.
manipulated variable: A quantity or
condition which is varied so as to
change the value of the controlled
variable. (see also control output)
535 User's Manual
Appendix 6
menu: (see menu block)
microcontroller: A large scale
integrated circuit that has all the
functions of a computer, including
memory and input/output systems.
NEMA 4X: A National Electrical
Manufacturers Association standard
for specifying a product’s resistance
to water and corrosion.
normally open: A switched output
(i.e, relay, etc.) whose unpowered
state has no connection.
normally closed: A switched output
(i.e., relay) whose unpowered state
provides connection.
noise: An unwanted component of a
signal or variable.
noise band: A measurement of the
amount of random process “noise”
affecting the measurement of the
process variable.
offset: The difference in
temperature between the setpoint
and the actual process temperature.
ON/OFF control: Control of
temperature about a setpoint by
turning the output full ON below
setpoint and full OFF above setpoint
in the heat mode.
open loop: Control system with no
sensory feedback.
optimization: The act of controlling
a process at its maximum possible
level of performance, usually as
expressed in economic terms.
output modules: Plug in devices
that provide power handling to
enable process control. These
A-19
Glossary
modules are either binary (on/off)
such as a relay, or analog
(continuously variable) for current
loop control.
output: Action in response to
difference between setpoint and
process variable.
overshoot: Condition where
temperature exceeds setpoint due to
initial power up or process changes.
P control: Proportioning control.
parameter(s): A user-defined
variable that specifies how a
particular function in the 535 will
operate.
PD control: Proportioning control
with rate action.
pretune algorithm: A method by
which the 535 controller initiates an
output value change, monitors the
manner of the corresponding
process variable change, and then
determines the appropriate PID
control parameters.
primary loop: The outer loop in a
cascade system.
process variable: In the treatment
of material, any characteristic or
measurable attribute whose value
changes with changes in prevailing
conditions. Common variables are
level, pressure and temperature.
proportional band: The change in
input required to produce a full
range change in output due to
proportional control action.
PI control: Proportioning control
with auto-reset.
ramping: (see setpoint, ramping)
PID control: Proportioning control
with auto-reset and rate.
rate: Anticipatory action that senses
the rate of change of temperature
and compensates to minimize
overshoot. Also “derivative.”
position proportioning: A type of
control output that utilizes two relays
to control an electric motorized
actuator.
POWERBACK®: Powers
proprietary algorithm which monitors
the PV to make predictive
judgements to control parameters in
order to reduce or eliminate
overshoot at powerup or after
setpoint changes.
POWERTUNE®: The Powers
exclusive special self-tuning
function. Consists of an on-demand
pretune that calculates PID values
or provide preliminary PID values
and process information for the
second tuning function. Second
tuning function is an adaptive tuning
algorithm that automatically adjusts
PID values whenever a process
upset or setpoint change occurs.
A-20
rate action: The derivative function
of a controller.
rate time: The time interval over
which the system temperature is
sampled for the derivative function.
regulate: The act of maintaining a
controlled variable at or near its
setpoint in the face of load
disturbances.
relay (mechanical): An
electromechanical device that
completes or interrupts a circuit by
physically moving electrical contacts
into contact with each other.
relay (solid state): A solid state
switching device which completes or
interrupts a circuit electrically with no
moving parts.
Appendix 6
reset: Control action that
automatically eliminates offset, or
“droop,” between setpoint and actual
process temperature. Also “integral.”
reset term: (see reset)
RTD: Resistance Temperature
Detector. Resistive sensing device
displaying resistance versus
temperature characteristics.
Displays positive temperature
coefficient.
relative gain: An open-loop gain
determined with all other
manipulated variables constant,
divided by the same gain
determined with all other controlled
variables constant.
retransmission: a feature on the
535 which allows the transmission of
a milliamp signal corresponding to
the process variable, target setpoint
or actual setpoint to another device,
typically a chart recorder.
sample interval: The time interval
between measurements or
observations of a variable.
secondary loop: The inner loop of
a cascade system.
self tune: A method of automatically
calculating and inserting optimum
PID parameters by testing system
response and timing.
serial communications: The
sending or receiving of binary coded
data to a supervisory device such as
a personal computer of
programmable logic controller.
setpoint: An input variable which
sets the desired value of a controlled
variable.
setpoint, actual: The desired value
of a controlled variable that the
controller is currently acting upon.
535 User's Manual
Glossary
setpoint, deviation from: The
difference of the number of units
between the current process variable
and the setpoint.
setpoint, ramping: A setpoint which
is determined by the ramp function of
the controller where over time the
controller variable reaches a desired
value.
setpoint, target: The end point of the
ramp function.
set up: Also called configuration,
selection of hardware devices and
software routines that function
together.
sheds: In serial communications,
when the signal is lost.
slidewire position proportioning:
An output algorithm that utilizes a
slidewire feedback signal to
determine the actual position of the
actuator being controller.
solid state relay: (see relay, solid
state)
SSR drive: A D.C. on/off signal
output for controlling a solid state
relay.
staged outputs: The set up of two
analog outputs, where one analog
output varies its signal over a portion
of the PID output range, and the
second analog output then varies its
signal over the remainder of the PID
output range.
static discharge: Undesirable
current resulting from the discharge
of electrostatic energy.
station address: The unique
identifier assigned to a device for
communications.
535 User's Manual
thermocouple: Temperature
sensing device that is constructed of
two dissimilar metals wherein a
measurable, predictable voltage is
generated corresponding to
temperature.
thermocouple break protection:
Fail-safe operation that assures
desired output upon an open
thermocouple condition.
▲ ):
thermocouple upscale burnout (▲
Jumper position that determines
whether, when a thermocouple fails,
its output is replaced by a millivoltage
which will match the thermocouple’s
maximum value. The jumper
connector should be placed in the TC
▲ position.
▼ ):
thermocouple downscale burnout (▼
Jumper position that determines
whether, when a thermocouple fails,
its output is replaced be a millivoltage
which will match the thermocouple’s
minimum value. The jumper
connector should be placed in the TC
▼ position.
three mode control: (See control
action PID)
setpoint, that local setpoint value will
match the remote process value
when the transfer occurs.
transmitter (2-wire): A device used
to transmit data via a two wire current
loop. A two-wire transmitter is loop
powered.
transmitter (4-wire): A device used
to transmit data via a current loop or
a DC voltage. A 4-wire transmitter
uses 2 wires for data and 2 wires for
power.
triac: Solid state switching device
used to switch alternating current
signals on and off. Triac circuits are
sometimes referred to as solid state
relays (SSR).
trip point: Value which determines
when that set of PID values becomes
active.
velocity position proportioning:
This is a control technique where
valve position is determined by
calculating the amount of time it takes
to open/close a valve by moving the
valve for a portion of that time.
time proportioning control: A
control algorithm that expresses
output power (0–100%) as a function
of percent ON versus percent OFF
within a preset cycle time.
windup: Saturation of the integral
mode of a controller developing
during times when control cannot be
achieved, which causes the
controlled variable to overshoot its
setpoint when the obstacle to control
is removed.
time proportioning output: A
controller output assigned by
software to facilitate time proportional
control (typically a relay, SSR, or
SSR Drive output).
wild stream: In mixing applications
that require materials to be mixed to
a desired ratio, this is the one part of
the material that is uncontrolled.
tracking: A function that defines
whether the local setpoint will track
the remote setpoint. When the
controller is transferred to a local
Appendix 6
A-21
Glossary
A-22
Appendix 6
535 User's Manual
Isolation Block Diagram
APPENDIX 7
ISOLATION BLOCK DIAGRAM
PV1
Input
CPU
Multiplexer
PV2
Input
Output 1
ISO Ground
Referenced
Output 2
ISO Ground
Referenced
RSP
Input
Output 3
ISO Ground
Referenced
Power
Supply
Slidewire
Input
Output 4
ISO Ground
Referenced
+V
+Vd
Digital
Inputs 1-5
RS485 Serial
Communications
Interface
ISO
Line
+Ve
L
N
G
E
E
Isolated output ground
E
Earth referenced ground
Internal ground
1. Each of the three ground circuits are isolated from each other to
withstand a potential of 500 volts for 1 minute, or 600 volts for 1
second.
2. RSP, Slidewire and the PV inputs are isolated to withstand 50
volts peak between each other for 1 minute.
3. Milliamp, Loop Power and SSR Drive modules in output
positions 1, 2, and 4 are not isolated from each other.
+V
Milliamp Module
535 User's Manual
Mechanical Relay
SSR Driver
+V
Loop Power
Appendix 7
SSR Output
A-23
Isolation Block Diagram
A-24
Appendix 7
535 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 WARRANTIES (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS
FOR A PARTICULAR PURPOSE) WITH RESPECT TO ANY GOODS OR SERVICES SOLD BY THE COMPANY. THE COMPANY DISCLAIMS ALL WARRANTIES ARISING FROM ANY COURSE OF DEALING OR TRADE USAGE, AND
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ANY PRIOR DEALINGS OF THE BUYER WITH THE COMPANY DO NOT IMPLY 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 DEFECT OR BREACH, AND NO ACTION FOR THE BREACH OF ANY WARRANTY 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 CONSEQUENTIAL DAMAGES.
The Interface Solution Experts • www.miinet.com
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: 86-21-68406724 • FAX: 86-21-50623585
United Kingdom • [email protected]
Tel: 01293 514488 • FAX: 01293 536852
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