Moore Industries 545 User Manual
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Moore Industries 545 User Manual

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

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

  • Page 2: Table Of Contents

    CAUTIONs and WARNINGs, usually CHAPTER 1 in boldface. Please heed these INTRODUCTION ................1 safety and good practice notices for 545 Modes ..................2 the protection of you and your Order Code, Packaging Information ............. 2 equipment. Where To Go Next ................2 Text Formatting in This Manual ............
  • Page 3 Ratio Control with One Wild Stream ........104 Ratio Control with Combined Discharge Monitoring ....105 W. Feed Forward/Feedback Control ..........107 X. Lag Time ..................108 Fixed Lag ................108 Variable Lag ................109 Table of Contents 545 User's Manual...
  • Page 4 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-23 545 User's Manual Table of Contents...
  • Page 5 7.13 ....Noise Band Calculation Example ........94 7.14 ....Noise Band Values for Temperature Inputs ......95 7.15 ....Deadtime and Time Constant ..........95 7.16 ....Square Root Linearization Formula ........97 7.17 ....15-point Linearization Curve ..........98 Table of Contents 545 User's Manual...

  • Page 6: Figure Description Page

    7.27 ....Fixed and Variable Lag Example - Compound Loop Chlorine Control ........108 A4.1 ....545 Rear Terminals for Calibration ........7 A4.2 ....Flowchart Calibration Menus ..........7 A4.3 ....Jumper Locations on the Microcontroller Circuit Board ..8 A4.4 ....
  • Page 7 Table of Contents Table of Contents 545 User's Manual...

  • Page 8: Chapter 1 Introduction

    The 545 is the most accurate instrument in its class. With a sampling rate of eight times per second, it is ideal for demanding pressure and flow applica- tions.

  • Page 9: 545 Modes

    For important hardware installation guidelines, see Chapters 3 and 4. • For a detailed description of all the software menus and parameters of the 545, follow through Chapter 5 and 6. Appendix 1 can be used as a guide to these parameters. TEXT FORMATTING IN THIS MANUAL...
  • Page 10 Serial Communications Enter “0” if not desired RS-485 Serial Communications : Capability for position proportioning output with slidewire feedback is specifed by ordering 545-11xxAxxx00, 545-33xxAxxx00, Note 1 or 545-44xxAxxx00. (Slidewire not required for velocity proportioning.) Up to three outputs may be used for alarms.
  • Page 11 Introduction Chapter 1 545 User's Manual...

  • Page 12: Controller Operation

    MENU FAST Keys DISPLAYS The display strategy of the 545 Process Controller is the same for all control modes: Dual Loop, Cascade, Ratio and Feed Forward. 1st Display (five 7-segment digits) • For the process variable value. 2nd Display (nine 14-segment digits) •...

  • Page 13: Keys

    When lit, indicates the controller is in SET UP mode. FAST+MENU: Press to access the Set Up menus. FAST MENU In SET UP mode, press to advance through menus. (Use MENU by itself to ac- cess the parameters of a particular menu.) Chapter 2 545 User's Manual...

  • Page 14: Basic Operation Procedures

    The third display will show a message identifying the foreground loop. Use the following as a quick guide to key operating functions of your 545. Most of these procedures will affect whichever loop is in the foreground at the time you execute the procedures.

  • Page 15: Alarm Operation

    Alarms may be used in systems to provide warnings of unsafe conditions. All tied to an output relay in the SET UP 545 operators must know how the alarms are configured, the consequences of mode. See Chapter 5 and Chapter 7 for acknowledging an alarm, and how to react to alarm conditions.

  • Page 16: Before And After Acknowledging An Alarm

    Basic Interface BEFORE AFTER NOTE: Powering down the 545 acknowledges/ clears all latched alarms. When powering up, all alarms will be reinitialized. MANUAL DISPLAY SET PT MANUAL DISPLAY SET PT Figure 2.2 Before and After Acknowledging an MENU FAST MENU...
  • Page 17 Basic Interface Chapter 2 545 User's Manual...

  • Page 18: Installation And Wiring

    1. The 545 fits in a standard 1/4 DIN cutout. Mount the 545 in any panel with a thickness from .06 in. to .275 in. (1.5 mm to 7.0 mm).

  • Page 19: Wiring

    1. For improved electrical noise immunity, install the 545 as far away as pos- sible from motors, relays and other similar noise generators. 2. Do not run low power (sensor input) lines in the same bundle as AC power lines.

  • Page 20: Process Variable Input

    Figure 3.4 EARTH/ GROUND AC Power Input Terminals POWER Screws must be tight to ensure good electrical connection The 545 accommodates the following types of process variable inputs: CAUTION! • Thermocouple Input Do not run low power (sensor input) •...

  • Page 21: Pv1 And Pv2 Wiring For Milliamp, Rtd And Voltage Inputs

    4-WIRE RTD Same color Same color Third leg of RTD Third leg Do NOT of RTD connect Same color 4th leg DO NOT connect 4th leg VOLTAGE INPUT VOLTAGE INPUT – – – – Transmitter Transmitter Chapter 3 545 User's Manual...

  • Page 22: Pv1 And Pv2 Wiring For Milliamp Inputs With Internal And External Power Supply

    4-20 mA output – order code in Chapter 1 to determine from transmitter from transmitter – if the 545 has a loop power module – installed. To install a loop power module, refer to Chapter 4 . 545 User's Manual Chapter 3...

  • Page 23: Digital Input(S)

    DIN 5 DIN 5 DIN 5 Screws must be tight to ensure electrical connection Remote Setpoint Option Use terminals 13 and 14 to connect the remote setpoint signal. – – Source Figure 3.10 Remote Setpoint Terminals Chapter 3 545 User's Manual...

  • Page 24: Output Modules

    OUTPUT MODULES NOTE: Refer to Figure 4.2 for location of the The 545 output modules are used for control, alarms and retransmission. The corresponding jumpers. four output module types are: Mechanical Relay, Solid State Relay (Triac), Second input jumper connector on the option board must be in either mA DC Logic (SSR Drive) and Analog (Milliamp).

  • Page 25: Dc Logic Output Wiring

    Module 4 Load 5. Position Proportioning Output Figure 3.15 (with or without Slidewire Feedback) Position Proportioning Output Wiring POSITION PROPORTIONING OUTPUT Electric Motor Actuator Winding Winding Slidewire Wiper 0–1050 Ohm Actuator Supply Current CCW COM Chapter 3 545 User's Manual...

  • Page 26: Serial Communications

    Comm + and Comm – . Terminals To "Comm –" terminal of Comm – Twisted, shielded next Moore Industries device or other host RS-485 To "Comm +" terminal of port Comm +...
  • Page 27 Installation Chapter 3 545 User's Manual...

  • Page 28: Hardware Configuration

    HARDWARE INPUT TYPES The Process Variable The 545 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).

  • Page 29: The Microcontroller Circuit Board, The Option Board And The Power Supply Board

    Female 22-Pin Connector Female 22-Pin Connector Remote Setpoint Jumper Male 22-Pin Male 22-Pin Connector Connector Output 4 Male 34-Pin Connector Female 34-Pin Connector 5-Pin Connector Module Retention Plate over Outputs 1,2,3 Jumpers NO and NC Chapter 4 545 User's Manual...

  • Page 30: Accessing And Changing Jumpers

    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. 545 User's Manual Chapter 4...

  • Page 31: Adding And Changing Output Modules

    Hardware Configuration ADDING AND CHANGING OUTPUT MODULES The 545 has provisions for four output modules. A controller ordered with output module options already has the modules properly installed. Follow these instruc- tions to add modules, change module type(s) or change module location(s).

  • Page 32: Representation Of Module

    Failure to use the tie wraps may result in loosening of the module and even- tual failure. All separately ordered modules should come with a tie wrap. Extra sets of tie wraps are available by ordering Part #545-665. NOTE: For greatest accuracy, calibrate all milliamp modules added for retransmission as per the instructions in Appendix 2.

  • Page 33: Special Communications Module

    Hardware Configuration SPECIAL COMMUNICATIONS MODULE A special communications module is available for the 545; see order code in Chapter 1 for details. Equipment needed: Wrist grounding strap Phillips screwdriver (#2) Small flat blade screwdriver 1. Before installing the communications module, set up the hardware wiring for the application.

  • Page 34: Software Configuration

    MENUS CAUTION! All software changes occur in real time; In SETUP mode, there are 12 sets of options that control different aspects of 545 always perform set up functions under manual operation. operation; in TUNING mode, there is one. Each set of options is called a menu.

  • Page 35: Parameters

    This manual displays these two types of param- eters differently; refer to Figure 5.2. A special feature of the 545, called Smart Menus, determines the correct parameters to display for the specific configu- ration, so not all the listed parameters will appear.

  • Page 36: Configuration And Operation

    For information about all the software menus and parameters, continue reading this chapter. Refer to Appendix 1 for a quick-reference flowchart of all menus and parameters. • For information about the installed options on the 545, compare the product label on top of the controller to the order code in Chapter 1. •...

  • Page 37: Step-By-Step Guide To Setup Parameters

    COMM. ONLY Output addressable only through communi- cations Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST DISPLAY FAST MENU FAST MENU DISPLAY Chapter 5 545 User's Manual...
  • Page 38 D 4–20mA 4-20mA • 0–20mA • 20-4mA • 20-0mA Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST FAST MENU FAST MENU DISPLAY DISPLAY 545 User's Manual Chapter 5...
  • Page 39 D L1. REM. SP. Makes the remote setpoint active Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST DISPLAY FAST MENU FAST MENU DISPLAY Chapter 5 545 User's Manual...
  • Page 40 L2. REM. SP. Makes the remote setpoint active Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST FAST MENU FAST MENU DISPLAY DISPLAY 545 User's Manual Chapter 5...
  • Page 41 Press MENU to advance to next parameter. D LOOP ONE. Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST DISPLAY FAST MENU FAST MENU DISPLAY Chapter 5 545 User's Manual...

  • Page 42: Pv Input

    • CUSTOM 15-point custom linearization curve is activated. Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST FAST MENU FAST MENU DISPLAY DISPLAY 545 User's Manual Chapter 5...
  • Page 43 Refer to Chapter 7 for more information on Offset and Gain. Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST DISPLAY FAST MENU FAST MENU DISPLAY Chapter 5 545 User's Manual...

  • Page 44: Cust. Linr

    R –9999 to 99999 Minimum is [XTH-1] INPUT Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST FAST MENU FAST MENU DISPLAY DISPLAY 545 User's Manual Chapter 5...

  • Page 45: Control

    R 0 to 14400 seconds D 0 seconds Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST DISPLAY FAST MENU FAST MENU DISPLAY Chapter 5 545 User's Manual...
  • Page 46 Defines the action of the second control output. DIRECT D DIRECT • REVERSE Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST FAST MENU FAST MENU DISPLAY DISPLAY 545 User's Manual Chapter 5...
  • Page 47 Defines the starting point for control output 2 when staging outputs. R 0 to 99% D 50% Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST DISPLAY FAST MENU FAST MENU DISPLAY Chapter 5 545 User's Manual...

  • Page 48: Alarms

    R LOW RANGE to HI RANGE D 0.0% Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST FAST MENU FAST MENU DISPLAY DISPLAY 545 User's Manual Chapter 5...
  • Page 49 Press MENU key to advance to next parameter. D ALARM 1 Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST DISPLAY FAST MENU FAST MENU DISPLAY Chapter 5 545 User's Manual...
  • Page 50 R LOW RANGE to HI RANGE D 0.0% Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST FAST MENU FAST MENU DISPLAY DISPLAY 545 User's Manual Chapter 5...
  • Page 51 Press MENU key to advance to next parameter. D ALARM 2 Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST DISPLAY FAST MENU FAST MENU DISPLAY Chapter 5 545 User's Manual...

  • Page 52: Rem. Setpt

    Defines whether the local setpoints 1 to 8 will track the remote setpoint. D NO • Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST FAST MENU FAST MENU DISPLAY DISPLAY 545 User's Manual Chapter 5...

  • Page 53: Retrans

    R –9999 to 99999 D Dependent on the process variable range Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST DISPLAY FAST MENU FAST MENU DISPLAY Chapter 5 545 User's Manual...
  • Page 54 R –9999 to 99999 D Dependent on the process variable range Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST FAST MENU FAST MENU DISPLAY DISPLAY 545 User's Manual Chapter 5...

  • Page 55: Self Tune

    R The process variable range D Dependent on the process variable range Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST DISPLAY FAST MENU FAST MENU DISPLAY Chapter 5 545 User's Manual...

  • Page 56: Special

    D 0.1 seconds SPECIAL SPECIAL For configuring special features. 1. AUTO. TRIP AUTO. TRIP Defines the condition under which the 545 will automatically trip to automatic control from manual control upon start up. D OFF Deactivates this function • RISING PV...
  • Page 57 NO. OF SP digital inputs. R 1 to 8 digits Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST DISPLAY FAST MENU FAST MENU DISPLAY Chapter 5 545 User's Manual...

  • Page 58: Security

    Defines lockout status for configuration parameters. UNLOCKED D UNLOCKED • LOCKED Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST FAST MENU FAST MENU DISPLAY DISPLAY 545 User's Manual Chapter 5...

  • Page 59: Ser. Comm

    D OFF 5. SHED MODE SHED MODE Defines the state of the controller if communications is lost (“sheds”). LAST MODE D LAST MODE The 545 remains in either automatic or manual control • MANUAL Trips to manual control • AUTOMATIC Trips to automatic control 6.
  • Page 60 R The process variable range D Dependent on the process variable range Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST FAST MENU FAST MENU DISPLAY DISPLAY 545 User's Manual Chapter 5...

  • Page 61: Parameter Value Charts

    Defines which loop uses the Remote Set Point 18 SLIDEWIRE Defines which loop uses Slidewire Feedback 19 NAME L1 Allows 9 character message to name Loop 1 20 NAME L2 Allows 9 character message to name Loop 2 Chapter 5 545 User's Manual...
  • Page 62 Setting for the low pass input filter 11 PV OFFSET Offset to the PV in engineering units 12 PV GAIN Gain to the PV 13 PV RESTOR. Control mode when a broken PV is restored 545 User's Manual Chapter 5...
  • Page 63 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 Chapter 5 545 User's Manual...
  • Page 64 18 CLOSE F/B Feedback ohm value when the valve is closed 19 OUT1 STOP Stopping point for control output 1 when staging outputs 20 OUT2 STRT. Starting point for control output 2 when staging outputs 545 User's Manual Chapter 5...
  • Page 65 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 Chapter 5 545 User's Manual...
  • Page 66 What is to be retransmitted for output 4 8 LO RANGE:4 Low end of the range of output 4 in engineering units 9 HI RANGE:4 High end of the range of output 4 in engineering units 545 User's Manual Chapter 5...
  • Page 67 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 Number of stored setpoints stored for selection Chapter 5 545 User's Manual...
  • Page 68 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 545 User's Manual Chapter 5...
  • Page 69 Software Configuration Chapter 5 545 User's Manual...

  • Page 70: Chapter 6 Tuning

    TUNING OVERVIEW NOTE: The self tune function of the 545 consists of two distinct components — Pretune For more information about Pretune and Adaptive Tune. In addition, you may choose from three type of Pretune: and Adaptive Tune, refer to section TYPE 1 - for slow thermal processes.

  • Page 71: Tuning Parameter Guide

    R 0.3 to 120.0 seconds D 15.0 seconds Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST MENU FAST MENU DISPLAY FAST DISPLAY Chapter 6 545 User's Manual...
  • Page 72 R 0.1 to 10.0 D 1.0 Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST MENU FAST MENU DISPLAY FAST DISPLAY 545 User's Manual Chapter 6...
  • Page 73 OF SP). Each PID set has a respective SP NUMBER. Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST MENU FAST MENU DISPLAY FAST DISPLAY Chapter 6 545 User's Manual...
  • Page 74 R The process variable range D Dependent on the process variable range Access Set Up Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops ▲ ▼ MENU MENU FAST MENU FAST MENU DISPLAY FAST DISPLAY 545 User's Manual Chapter 6...

  • Page 75: Tuning Value Chart

    Defines the value that triggers a change to primary PID set 26. PROP. BND.:2 Defines the proportional band for PID set 2 27. RESET:2 Defines the integral time for PID set 2 28. RATE:2 Defines the derivative time for PID set 2 Chapter 6 545 User's Manual...
  • Page 76 Defines the derivative time for PID set 8 59. MAN. RST.:8 Defines the manual reset (or load line) for PID set 8 60. TRIP:8 This defines the value that triggers a change to the 8th PID set 545 User's Manual Chapter 6...

  • Page 77: Self Tune Messages And Troubleshooting

    Tuning SELF TUNE MESSAGES AND TROUBLESHOOTING Refer to Chapter 7 for more information on the Self Tune function of the 545 controller. When the Pretune function terminates, one of the following messages will appear: Message Pretune Conclusion/Problem Corrective Action Type...

  • Page 78: Applications

    P. Load Line ............ 98 X. Lag Time ........... 108 A. CONTROL TYPE Each of the control loops in the 545 can be independently configured. Software Configuration 1. Go to the CONTROL menu. 2. For the parameter ALGORITHM, select the type of 545 control: •...

  • Page 79: Alarms

    For derivative action based on PV changes, choose PV. B. ALARMS Each loop of the 545 controller has two extremely flexible and powerful software alarms (4 alarms total). 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.
  • Page 80 MANUAL Alarm occurs when the controller is put into manual mode of opera- tion. This may be useful for security purposes or to alert the operator that 545 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.
  • Page 81 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. Chapter 7 545 User's Manual...

  • Page 82: Alarm Examples

    ALM.:1 OUT. = N (N = 2 to 4) ALM.:1 OUT. = N (N = 2 to 4) LATCHING = LATCH LATCHING:1 = LATCH ACK.:1 = ENABLED ACK.:1 = DISABLED ALARM SP:1 = (<0) POWER UP:1 = ALARM 545 User's Manual Chapter 7...

  • Page 83: Duplex Control

    When using PID control, the 545 controller actually displays the PID output. To relate this output to the actual physical output, locate the PID output on the horizontal axis.

  • Page 84: Duplex With Reverse And Direct Acting Outputs

    PID OFST.:1 = 0 100% 100% PID OFST.:2 = 0 LOW OUT = 0 HIGH OUT = 100 Figure 7.3 REL. GAIN = 1.0 Duplex with Direct and Reverse Out 1 Out 2 Acting Outputs 100% PID OUTPUT 545 User's Manual Chapter 7...

  • Page 85: Duplex With Two Reverse Acting Outputs

    PID OFST.:2 = – VALUE 100% 100% LOW OUT = 0 Figure 7.5 HIGH OUT = 100 Duplex with a Gap Between REL. GAIN = 1.0 Outputs Out 1 Out 2 100% Offset 1 Offset 2 PID OUTPUT Chapter 7 545 User's Manual...

  • Page 86: Duplex With Overlapping Outputs And Output Limits

    HIGH OUT = 100 ❶ Out 1 REL. GAIN = 2.0 ❶ ❷ REL. GAIN = 1.0 ❷ ❸ REL. GAIN = 0.5 Figure 7.7 ❸ Duplex with Various Relative Gain Settings 100% PID OUTPUT 545 User's Manual Chapter 7...

  • Page 87: Duplex With One On/Off Output

    ACTION:2 = DIRECT (Heat) (Cool) ON OFST.:1 = – VALUE Figure 7.9 ON OFST.:2 = + VALUE Duplex with Two ON/OFF Outputs Out 1 Out 2 Offset 1 Offset 2 High Range Range PROCESS VARIABLE Chapter 7 545 User's Manual...

  • Page 88: Slidewire Position Proportioning Control

    To set: a. Go to the TUNING menu. NOTE: P.PROP.D.B. can only be b. Set P. PROP. D.B. to .5%. configured if the Slidewire Feedback is wired to the controller. c. Place controller under Manual control. 545 User's Manual Chapter 7...

  • Page 89: Velocity Position Proportioning Control

    4. Set MIN. TIME to the minimum amount of time the controller must specify for the motor to be on before it takes any action. 5. Set values for PV. BREAK, DES. OUTPT., PWR.UP:OUT. and SHED OUT. Chapter 7 545 User's Manual...

  • Page 90: Staged Outputs

    RETRANS. 3. Go to the RETRANS. menu. 4. Set the corresponding parameter, TYPE:X, for the first retransmission out- put to define what is being transmitted: the process variable, setpoint, ramping setpoint or output. 545 User's Manual Chapter 7...

  • Page 91: Digital Inputs

    • L1.REM.SP. Closing input changes active setpoint to remote setpoint. Opening reverts controller to previous setpoint. Override by selecting a differ- ent setpoint via the SET PT key, a communications command, or other digital inputs. Chapter 7 545 User's Manual...
  • Page 92 Setpoint, Deviation % and Output %. • FAST KEY Closing contact mimics the FAST key . Use in conjunction with ▲ ▲ ▲ ▲ ▲ , ▼ ▼ ▼ ▼ ▼ , DISPLAY and MENU keys. 545 User's Manual Chapter 7...
  • Page 93 • L2. RSP. INH. Reset Inhibition. Closing input deactivates “I” (integral) term, regard- less of the PID values being used. Opening input activates “I” term (if applicable). Chapter 7 545 User's Manual...
  • Page 94 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. 545 User's Manual Chapter 7...

  • Page 95: Remote Setpoint

    J. MULTIPLE SETPOINTS The 545 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 545 can also store multiple sets of PID parameters (see next section).

  • Page 96: Multiple Sets Of Pid Values

    K. MULTIPLE SETS OF PID VALUES The 545 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.

  • Page 97: Powerback

    D 7200 seconds M. SELF TUNE—POWERTUNE ® The Self Tune function of the 545 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.
  • Page 98 In order to make accurate calculations, Adaptive Tune needs noise band and Otherwise, the 545 will attempt to response time values. Pretune TYPE 2 and TYPE 3 automatically calculate these adapt the Tuning parameters to the values.
  • Page 99 8. Set parameter ADAPTIVE to ENABLED. The Adaptive Tuning cycle does not begin until 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. Chapter 7 545 User's Manual...

  • Page 100: Pretune Type 1, 2 And 3 With Adaptive Tune

    • B to C is an impulse to determine initial PID values and response Out Step time. • C is Pretune completed, so Adaptive PID control begins if ENABLED. CONTROL OUTPUT NOISE BUMP ADAPTIVE TIME Pretune 545 User's Manual Chapter 7...

  • Page 101: Noise Band Calculation Example

    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. Chapter 7 545 User's Manual...

  • Page 102: Noise Band Values For Temperature Inputs

    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. 545 User's Manual Chapter 7...

  • Page 103: Ramp-To-Setpoint

    The ramp-to-setpoint function is triggered by one of three conditions: 1. Upon power up, if the 545 powers up in automatic control, then the setpoint will ramp from the process variable value to the setpoint value at the specified rate.

  • Page 104: Input Linearization

    O. INPUT LINEARIZATION Thermocouple and RTD Linearization For a thermocouple or RTD input, the incoming signal is automatically linearized. The 545 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.

  • Page 105: Custom Linearization

    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 Chapter 7 545 User's Manual...

  • Page 106: Security

    Load Line Example 100% Process Variable Location (% of Controller Span) Q. SECURITY The 545 security system is easily customized to fit a system’s needs. Software Configuration 1. Go to the SECURITY menu. NOTE: SEC CODE does not appear 2. SEC. CODE defines the security password (range from -9999 to 99999). The unless all functions are unlocked.

  • Page 107: Reset Inhibition

    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. Chapter 7 545 User's Manual...

  • Page 108: Serial Communications

    Software Configuration 1. Access the SER. COMM. menu. 2. STATION specifies the unit’s station address. It is the only way one 545 can be distinguished from another. Each 545 on the same RS-485 interface must have a unique station address.

  • Page 109: Cascade Control

    (see Figure 7.19). When the 545 is configured for Cascade, Loop 1 is automatically the primary or outer feedback Loop and Loop 2 is the secondary or inner feedback loop. Loop 1 will not have a physical output, but rather the PID algorithm output is internally fed to Loop 2 as its Setpoint.

  • Page 110: Cascade Control Of Produce Temperature Wiring View

    Remember that the setpoint span of Loop 2 is driven by the PID output of Loop 1 (the outside loop). Therefore you set SP LO LIM at 200 and SP HI LIM at 800. With these parameters, whenever Loop 1 output is 0%, the Loop 2 SP is 200. 545 User's Manual Chapter 7...

  • Page 111: Ratio Control

    Figure 7.22 shows a simple example of a two stream blending application in which one of the streams is wild (uncontrolled). Ratio control for the type of ap- plication where one loop is “wild,” can be accomplished with a 545 configured for one loop.

  • Page 112: Ratio Control With Combined Discharge Monitoring

    Secondary Loop RSP INPUT Figure 7.23 Primary Loop Ratio Control in Mixing Application “Controlled Stream”-Functional View PV1 RETRANS FLOW SENSOR MATERIAL A MIXER MATERIAL B FLOW SENSOR Hardware Configuration • Follow wiring as in Figure 7.24 545 User's Manual Chapter 7...

  • Page 113: Ratio Control In Mixing Application "Controlled Stream Wiring View

    Loop 1 LOW OUT and HIGH OUT. b. Set all other parameters for a standard control loop. c. In the TUNING menu (for Loop 2) enter values for SP RATIO and SP BIAS. Chapter 7 545 User's Manual...

  • Page 114: Feed Forward/Feedback Control

    1. In the CONFIG. menu , set CTRL. TYPE to FFWD. SUM or FFWD. MULT. 2. Set up and tune the PID feedback loop (PV1). 3. In the TUNING menu, set the effect of the feed forward input (PV2) on the control output through the following parameters: 545 User's Manual Chapter 7...

  • Page 115: Lag Time

    Fixed Lag (FIXED. LAG) is a constant delay that prevents change in the control output before the results of the previous control value change can be measured. The fixed lag function may be used with the following control types: ONE LOOP, DUAL LOOP, FFWD. SUM and FFWD. MULT. Chapter 7 545 User's Manual...

  • Page 116: Variable Lag

    5. Set the MAX. LAG parameter from 0 to 14400 seconds. This represents the maximum lag time the variable lag feature can achieve. When in the normal operating mode, the lag time will decrease as the PV2 value increases, and will increases as the PV2 value decreases. 545 User's Manual Chapter 7...
  • Page 117 Applications Chapter 7 545 User's Manual...

  • Page 118: Appendix 1

    PWR. UP:SP NO. OF SP SECURITY SEC. CODE SP ADJUST AUTO./MAN. SP SELECT ALARM ACK. TUNING CONFIGURE SHED OUT. SER. COMM. STATION BAUD RATE SHED TIME SHED MODE SHED SP DESIG. SP G DENOTES GLOBAL MENUS 545 User's Manual Appendix 1...
  • Page 119 PROP. BND.:4 RESET:4 RATE:4 MAN. RST.:4 TRIP:4 PROP. BND.:5 RATE:5 MAN. RST.:5 RESET:5 TRIP:5 PROP. BND.:6 RATE:6 MAN. RST.:6 RESET:6 TRIP:6 PROP. BND.:7 RESET:7 RATE:7 MAN. RST.:2 TRIP:7 PROP. BND.:8 RATE:8 MAN. RST.:8 RESET:8 TRIP:8 Appendix 1 545 User's Manual...

  • Page 120: Appendix 2

    Module Retention Kit for Outputs 1-3 ( Includes Retention Plate) 535 664 Module Retention Kit for Output 4: Set of 5 Tie Wraps 535 665 Circuit Board Support (Bezel Insert) 535 075 Engineering unit labels (1 sheet) 535 106 545 User's Manual Appendix 2...
  • Page 121 Parts List Appendix 2 545 User's Manual...

  • Page 122: Appendix 3 Troubleshooting

    Can’t switch to auto control Input sensor signal is not connected or valid See LOST PV message Erratic display Resetting action due to electrical noise on Filter power line. powerline PID values not set properly Retune controller 545 User's Manual Appendix 3...
  • Page 123 This is a fatal error and requires an EPROM or During power up, a discrepancy was found EEPROM change. Call factory for assistance. between the EEPROM's and controller's model numbers. Controller locks up until fixed. Appendix 3 545 User's Manual...

  • Page 124: Appendix 4 Calibration

    Failure to do so may result in small junction Figure A4.1 temperature (0.6°C/1.1°F). 545 Rear Terminals for Calibration Access the parts of the calibration menu as shown in Figure A4.2 . Figure A4.2 CAL. VREF...

  • Page 125: Preparation For All Input Calibrations

    Use the ▲ ▲ ▲ ▲ ▲ and ▼ ▼ ▼ ▼ ▼ (and FAST) keys on the controller until the display on the Terminals 1 and 2 carry live power. DO NOT touch these terminals controller matches the meter reading. when power is on. Appendix 4 545 User's Manual...

  • Page 126: Thermocouple Cold Junction Calibration

    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. 545 User's Manual Appendix 4...

  • Page 127: Milliamp Output Calibration

    • 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 4 545 User's Manual...

  • Page 128: Reset 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 2 seconds. 8. When complete, return jumpers to their original positions. A-11 545 User's Manual Appendix 4...

  • Page 129: Hardware Scan

    Slidewire Test Wiring PV input without entering the “Factory Configuration” mode. 1. Power down the 545 controller and place the input jumpers in the desired position (see Figure A4.3 and Figure A4.7). 2. Replace the process variable (PV1 or PV2) input signal with a suitable milliamp calibration device.

  • Page 130: Appendix 5 Specifications

    CONTROLLER ARCHITECTURE where the source of feed forward contribution may fluctuate. Feed The 545 Controller hardware can be configured as follows: forward contribution automatically modifies the length of the lag time. Inputs: Two universal process variable inputs are standard. Available...
  • Page 131 100 ohms Pt. (DIN) –328 to 1562 –200 to 850 modules which can be configured to suit your particular application. –328.0 to 545.0 –200.0 to 285.0 The modules may be ordered factory-installed, or they may be 100 ohms Pt. (JIS) –328 to 1202...
  • Page 132 May be installed in the field. ALARMS DIGITAL DISPLAYS The 545 controller has two software alarms per loop for a total of four alarms. High and low alarms may be sourced to the PV, SP, Upper display: five-digit, seven-segment. Used exclusively for RAMP SP, DEVIATION and OUTPUT.
  • Page 133 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. A-16 Appendix 5 545 User's Manual...

  • Page 134: Appendix 6 Glossary

    A component of the 545 baud rate: Any of the standard trans- external conditions. self tune function which continuously...
  • Page 135 A terminal used on the representation of the control action to between heating and cooling functions; 545 to ensure, by means of a special be performed. the range through which an input can connection, the grounding (earthing) of be varied without initiating observable part of the controller.
  • Page 136 A function noise band: A measurement of the the 545 uses to linearize a non-linear ® amount of random process “noise” POWERBACK : Propriertary algorithm...
  • Page 137 A method by which the 545 controller initiates an output relay (mechanical): An electrome- setpoint, actual: The desired value of value change, monitors the manner of a controlled variable that the controller...
  • Page 138 (e.g., a thermocouple converts a temperature difference into millivolts). A-21 545 User's Manual Appendix 6...
  • Page 139 Glossary A-22 Appendix 6 545 User's Manual...

  • Page 140: Isolation Block Diagram

    4. Milliamp, Loop Power and SSR Drive modules in output positions 1, 2, 3 and 4 are not isolated from each other. SSR Driver Milliamp Module Mechanical Relay Loop Power SSR Output A-23 545 User's Manual Appendix 7...
  • Page 141 Isolation Block Diagram A-24 Appendix 7 545 User's Manual...
  • Page 142 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.
  • Page 143 Installation 500 SERIES Form M500 V7 Process Controllers 5 0 0 Hardware Installation and Modification Manual for Electronic Products Series 531, 532, 535, 545, 555 Model 2 Installation Guide 500 Series M500 V 7, APRIL 2016...
  • Page 144 Installation INTRODUCTION This technical brochure provides hardware installation and modification instructions for our controllers: Series 531, 532, 535, 545, and 555. Use these instructions with the following kits: EPROM Kits Display Assembly Kits 531-632 ....531 Display Assembly Kit 531-740 ....531 EPROM Kit 532-632 ....
  • Page 145 Installation INSTRUCTIONS one of the larger two boards from the Option Board (Photo 4). Be careful not to bend the connector pins. Separate the other board in the To Disassemble the Unit same manner. For any hardware modifications, disassemble the unit. Figure 2 (opposite page) shows the Microcontroller 1.
  • Page 146 Installation NOTE: Front of Unit Back of Unit If you replace the EPROM chip, you must align the notch facing the front (toward Operator Interface) (toward rear terminals) of the unit. EPROM BATTERY 5-Pin Connector Female 22-Pin Connector Female 22-Pin Connector NOTE: The 5- and 22-Pin connnectors on the boards are all keyed so they...
  • Page 147 Installation To Change the EPROM 8. Replace tie wraps for the Retention Plate and for Output Module 4 with new ones. 13. The EPROM is located on the Microcontroller Failure to use these devices may result in a Circuit board (Figure 2). It has a white label that loosening of the module and eventual list the part number and software revision level.
  • Page 148 500 Series Process Controllers 531, 532, 535, 545, 555 April 2016 You can order replacement directly fro Moore Industries Purpose using this part number 800-867-52 or an equivalent This supplement is to address the updated Micro CR2450 3V Coin Cell Lithium Battery.
  • Page 149 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.

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