Moore 535 PROFILER Manuale utente

M535-PROF V

, © JULY 20

1/4 DIN PROFILE CONTROLLER

USER'S MANUAL

5 3 5 P R O F I L E R

535

PROFILER

535-PROF User's Manual Appendix 7 A-23

Isolation Block Diagram

535-PROF User's Manual Table of Contents i

Table of Contents

TABLE OF CONTENTS

PAGE

CHAPTER1

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

535 Profile Controller Modes .............................................................. 1

Order Code, Packaging Information ................................................... 2

Where to Go Next............................................................................... 2

Text Formatting in this Manual ........................................................... 2

CHAPTER2

BASICINTERFACE .......................................................................... 4

Displays ............................................................................................ 4

Icons (Lit) .......................................................................................... 5

Keys.................................................................................................. 5

Basic Profile Controller Operating Procedures .................................... 7

To Enter the RECIPE SET UP Mode.......................................... 7

To Enter the SET UP Mode ....................................................... 7

To Run a Recipe ........................................................................ 7

To Hold a Recipe ....................................................................... 7

To Abort a Recipe and Switch to Manual Control ........................ 7

To Abort a Recipe and Control to the Idle Setpoint ...................... 7

To Display the Setpoint (SP) while a Recipe Is Running ............. 8

To Display the Recipe Number .................................................. 8

Basic Process Controller Operating Procedures ................................. 8

To Select/Change a Setpoint ..................................................... 8

To Change from Auto to Manual Control (Bumpless Transfer) ..... 8

To Change from Manual to Auto................................................. 8

To Change Manual Output Values ............................................. 8

To Override Security ................................................................. 8

To Display Control Output Value ................................................ 9

To Display the Active PID Set ................................................... 9

Alarm Operation ................................................................................. 9

Alarm Indication ........................................................................ 9

To Acknowledge an Alarm(s) ................................................... 10

Latching Alarms ...................................................................... 10

Limit Sequence ....................................................................... 10

More On Alarms ...................................................................... 10

CHAPTER3

INSTALLATION .............................................................................. 11

Mounting the Controller .................................................................... 11

Wiring .............................................................................................. 12

AC Power Input ....................................................................... 13

Process Variable Input ............................................................ 13

Digital Input(s) ......................................................................... 16

1. Digital Inputs with a Switch or Relay ................................ 16

2. Digital Inputs with an Open Collector ............................... 16

Remote Setpoint Option .......................................................... 16

Output Modules ....................................................................... 17

1. Mechanical Relay Output ................................................ 17

2. Solid State Relay (Triac) Output ...................................... 17

About This Manual:

Throughout this User’s Manual

information appears along the

margins (NOTE: CAUTION! and

WARNING!). Please heed these

safety and good practice notices for

the protection of you and your

equipment.

ii Table of Contents 535-PROF User's Manual

Table of Contents

CHAPTER3

INSTALLATION(CONTINUED)

Output Modules

3. DC Logic (SSR Drive) Output .......................................... 18

4. Milliamp Output .............................................................. 18

5. Position Proportioning Output ......................................... 18

Serial Communications ........................................................... 19

Limit Control ............................................................................ 20

CHAPTER4

HARDWARE SET UP ...................................................................... 21

Hardware Input Types ...................................................................... 21

The Process Variable ....................................................................... 21

The Remote Setpoint ....................................................................... 22

Mechanical Relays .......................................................................... 22

Accessing and Changing Jumpers ................................................... 23

Adding and Changing Output Modules .............................................. 24

Special Communications Module ..................................................... 26

CHAPTER5

SOFTWARECONFIGURATION ...................................................... 27

Menus ............................................................................................. 27

Parameters ...................................................................................... 29

Configuration and Operation ............................................................. 29

Where to Go Next............................................................................. 29

Software Menus and Parameters ..................................................... 31

CONFIG.................................................................................. 31

REC. CONF. ........................................................................... 37

PV1 INPUT ............................................................................. 39

PV2 INPUT ............................................................................. 41

CUST. LINR. ........................................................................... 43

CONTROL .............................................................................. 44

ALARMS................................................................................. 46

REM. SETPT. ......................................................................... 50

RETRANS. ............................................................................. 51

SELF TUNE ............................................................................ 53

SPECIAL ................................................................................ 54

SECURITY ............................................................................. 56

SER. COMM. .......................................................................... 57

RECIPE # ............................................................................... 58

Parameter Value Charts ................................................................... 61

CHAPTER6

TUNING .......................................................................................... 71

Overview ......................................................................................... 71

Tuning Parameters .......................................................................... 72

Tuning Value Chart .......................................................................... 76

Self Tune Messages and Troubleshooting ........................................ 78

CHAPTER7

APPLICATIONS .............................................................................. 79

A. Profile Control.............................................................................. 79

Software Configuration ............................................................ 80

Digital Inputs ........................................................................... 84

PAGE

535-PROF User's Manual Table of Contents iii

Table of Contents

CHAPTER7

APPLICATIONS(CONTINUED)

A. Profile Control

Master/Slave Operation ........................................................... 84

HardwareConfiguration ....................................................... 85

B. Control Type ................................................................................ 85

Software Configuration ............................................................ 85

C. Alarms ........................................................................................ 86

Software Configuration ............................................................ 86

D. Duplex Control ............................................................................. 90

HardwareConfiguration ........................................................... 90

Software Configuration ............................................................ 90

Duplex Output State Examples ............................................... 91

Duplex with Reverse and Direct Acting Outputs ................... 91

Duplex with Direct and Reverse Acting Outputs ................... 91

Duplex with 2 Reverse Acting Outputs................................. 92

Duplex with a Gap Between Outputs.................................... 92

Duplex with a Overlapping Outputs and Output Limits .......... 93

Duplex with Various Relative Gain Settings ......................... 93

Duplex with One On/Off Output ........................................... 94

Duplex with Two On/Off Outputs ......................................... 94

E. Slidewire Position Proportioning Control ....................................... 95

HardwareConfiguration ........................................................... 95

Software Configuration ............................................................ 95

F. Velocity Position Proportioning Control ........................................ 96

HardwareConfiguration ........................................................... 96

Software Configuration ............................................................ 96

G. Staged Outputs ........................................................................... 97

HardwareConfiguration ........................................................... 97

Software Configuration ............................................................ 97

H. Retransmission ........................................................................... 97

HardwareConfiguration ........................................................... 97

Software Configuration ............................................................ 97

I. Digital Inputs................................................................................. 98

HardwareConfiguration ........................................................... 98

Software Configuration ............................................................ 98

Basic Operating Procedures .................................................. 100

J. Remote Setpoint ........................................................................ 100

HardwareConfiguration ......................................................... 100

Software Configuration .......................................................... 100

Basic Operating Procedures .................................................. 101

K. Multiple Setpoints ...................................................................... 101

Software Configuration .......................................................... 101

Basic Operating Procedures .................................................. 101

L. Multiple Sets of PID Values ....................................................... 101

Software Configuration .......................................................... 101

Basic Operating Procedures .................................................. 102

Using with Adaptive and Pretune ........................................... 102

M. Powerback ................................................................................ 102

Software Configuration .......................................................... 103

N. Self Tune— Powertune® ........................................................... 103

Pretune ................................................................................. 103

Adaptive Tune ....................................................................... 103

PAGE

iv Table of Contents 535-PROF User's Manual

Table of Contents

CHAPTER7

APPLICATIONS(CONTINUED)

N. Self Tune—Powertune®

Software Configurations ........................................................ 104

Pretune by Itself................................................................ 104

Pretune Type 1 & Adaptive Tune ....................................... 104

Pretune Type 2 or 3 & Adaptive Tune ................................ 106

Adaptive Tune by Itself ..................................................... 106

Self Tuning with Multiple Sets of PID ................................. 108

Self Tune with Time Proportioning Outputs ........................ 108

Self Tune with Control Valves ........................................... 108

O. Ramp-to-Setpoint ...................................................................... 109

Software Configuration .......................................................... 109

P. Input Linearization ..................................................................... 109

Thermocouple and RTD Linearization .................................... 109

Square Root Linearization ...................................................... 109

HardwareConfiguration ..................................................... 110

Software Configuration ...................................................... 110

Custom Linearization ............................................................. 110

Software Configuration ...................................................... 110

Q. Load Line .................................................................................. 111

R. Security .................................................................................... 111

Software Configuration .......................................................... 111

Basic Operating Procedures .................................................. 112

S. Reset Inhibition ......................................................................... 112

Software Configuration .......................................................... 112

T. Process Variable Reading Correction ......................................... 112

U. Serial Communications .............................................................. 113

HardwareConfiguration ......................................................... 113

Software Configuration .......................................................... 113

V. Cascade Control ........................................................................ 114

HardwareConfiguration ......................................................... 116

Software Configuration .......................................................... 116

Tuning Cascade Control ........................................................ 116

W. Ratio Control............................................................................. 117

HardwareConfiguration ......................................................... 118

Software Configuration .......................................................... 118

PAGE

535-PROF User's Manual Table of Contents v

Table of Contents

APPENDIX 1

MENUFLOWCHARTS ................................................................... A-1

APPENDIX 2

PARTS LIST ..................................................................................A-3

APPENDIX 3

TROUBLESHOOTING ...................................................................A-4

APPENDIX 4

CALIBRATION ...............................................................................A-6

Preparation For All Input Calibrations ..............................................A-7

Thermocouple Cold Junction Calibration ......................................... A-8

Analog Milliamp Input Calibration ....................................................A-8

Milliamp Output Calibration .............................................................A-9

Reset Menu Data .......................................................................... A-10

HardwareScan ..................................................................... A-11

Slidewire Test ............................................................................... A-11

Quick Calibration Procedure .......................................................... A-11

APPENDIX 5

SPECIFICATIONS ....................................................................... A-12

APPENDIX 6

GLOSSARY ................................................................................. A-17

APPENDIX 7

ISOLATION BLOCK DIAGRAM .................................................... A-22

PAGE

vi Table of Contents 535-PROF User's Manual

Table of Contents

LIST OF FIGURES

PAGE

Figure2.1 ....... Operator Interface ................................................................ 4

Figure2.2 ....... Before and After Acknowledging An Alarm ............................. 9

Figure3.1 ....... Instrument Panel & Cutout Dimensions ............................... 11

Figure3.2 ....... Attaching Mounting Collar ................................................... 11

Figure3.3 ....... All535-PROFTerminalAssignments .................................. 12

Figure3.4 ....... ACPowerInputTerminals .................................................. 13

Figure3.5 ....... Process Variable Terminals ................................................ 13

Figure3.6 ....... PV1 and PV2 Wiring for Milliamp, RTD and

Voltage Inputs. .................................................................. 14

Figure3.7 ....... PV1 and PV2 Wiring for Milliamp Inputs with

Internaland External Power Supply ..................................... 15

Figure3.8 ....... Digital Inputs Wiring with A Switch or Relay .......................... 16

Figure3.9 ....... Digital Input Wiring with An Open Collector ........................... 16

Figure 3.10 ...... RemoteSetpoint Terminals ................................................ 16

Figure 3.11 ...... MechanicalRelay Output Wiring ......................................... 17

Figure 3.12 ...... SSRRelay Output Wiring ................................................... 17

Figure 3.13 ...... DCLogicOutput Wiring ...................................................... 18

Figure 3.14 ...... MilliampOutput Wiring ....................................................... 18

Figure 3.15 ...... PositionProportioning OutputWiring ................................... 18

Figure 3.16 ...... SerialCommunications Terminals ...................................... 19

Figure 3.17 ...... 535-PROFWiring with LimitControl ..................................... 20

Figure4.1 ....... Location of Printed Circuit Boards for

HardwareConfiguration ...................................................... 21

Figure4.2 ....... (From the Top) the Microcontroller Circuit Board,

the Option Board, and the Power Supply Board .................... 22

Figure4.3 ....... Representation of Module ................................................... 25

Figure4.4 ....... InstallCommunicationsModule onto

MicrocontrollerBoard ......................................................... 26

Figure5.1 ....... Menu Flowchart for Set Up ................................................. 27

Figure5.2 ....... Configuration Flowchart ...................................................... 28

Figure5.3 ....... Independent vs. DependentParameters .............................. 29

Figure6.1 ....... Access the Tuning Menu Block .......................................... 71

Figure7.1 ....... Contacts for Recipe Selection ............................................. 84

Figure7.2 ....... Alarm Examples ................................................................ 89

Figure7.3 ....... Duplex with Reverse and Direct Acting Outputs ................... 91

Figure7.4 ....... Duplex with Direct and Reverse Acting Outputs ................... 91

Figure7.5 ....... Duplex with Two Reverse Acting Outputs ............................ 92

Figure7.6 ....... Duplex with A Gap Between Outputs ................................... 92

Figure7.7 ....... Duplex with Overlapping Outputs and Output Limits ............. 93

Figure7.8 ....... Duplex with Various Relative Gain Settings .......................... 93

Figure7.9 ....... Duplex with One On/Off Output ........................................... 94

535-PROF User's Manual Table of Contents vii

Table of Contents

Figure 7.10 ...... Duplex with Two On/Off Outputs ......................................... 94

Figure 7.11 ...... StagedOutputs Example ................................................... 97

Figure 7.12 ...... Combinations of Closed Digital Inputs for

Each Setpoint (Based on BCD Logic) .................................. 98

Figure 7.13 ...... Pretune Type 1, Type 2 and Type 3 with

AdaptiveTune ................................................................. 105

Figure 7.14 ...... NoiseBand Calculation Example ...................................... 107

Figure 7.15 ...... Noise Band Values for Temperature Inputs ........................ 107

Figure 7.16 ...... Deadtimeand Time Constant ........................................... 108

Figure 7.17 ...... SquareRootLinearization Formula .................................... 110

Figure 7.18 ...... 15-pointLinearizationCurve .............................................. 110

Figure 7.19 ...... LoadLine Example .......................................................... 111

Figure 7.20 ...... HeatExchanger Control Loop for Steam Supply ................. 114

Figure 7.21 ...... CascadeControl of Product Temperature .......................... 115

Figure 7.22 ...... RatioControlInMixingApplicatoin .................................... 117

FigureA4.1 ..... 535 Rear Terminals forCalibration ...................................... A-6

FigureA4.2 ..... Flowchart Calibration Menus .............................................. A-6

FigureA4.3 ..... Jumper Locations on the Microcontroller Circuit Board ......... A-7

FigureA4.4 ..... Input CalibrationWiring ...................................................... A-7

FigureA4.5 ..... Thermocouple/Cold Junction CalibrationWiring .................. A-8

FigureA4.6 ..... Analog mA Input Calibration Wiring .................................... A-9

FigureA4.7 ..... Analog mA Input Jumper Positions .................................... A-9

FigureA4.8 ..... MilliampOutput Calibration Wiring .................................... A-10

FigureA4.9 ..... OutputModuleMenu Cycle ............................................. A-10

FigureA4.10 ... Slidewire Test Wiring ...................................................... A-11

535-PROF User’s Manual Chapter 1 1

Introduction

CHAPTER 1

INTRODUCTION

Thank you for selecting the 535 Profile

Controller — the most sophisticated

instrument in its class. It will provide

you with years of reliable, trouble-free

performance.

From its surge-resistant power supply to its rugged construction, the 535 Profile

Controller is designed to ensure the integrity of your process with maximum reli-

ability — hour after hour, day after day. The isolated inputs and outputs guard

against the dangers of electrical interference, the front face meets NEMA 4X stan-

dards for watertight operation and exposure to corrosive environments, and the

solid metal housing and sturdy rubber keys enhance durability and ESD protec-

tion.

The 535 Profile Controller has been engineered to be the industry’s most user–

friendly process controller. With three digital display areas — two offering up to 9

charactersof true alphanumerics — thecontroller effectively eliminates the cryptic

messages that could confuse even the most experienced operator. The bright,

crisp display is vacuum fluorescent, and offers much better readability than any

other display technology. Additional operator–friendly features include: custom

programmable alarm messages, illuminated keys, and an easy–to–use menu

system.

The 535 Profile Controller is the most accurate instrument in its class. With a sam-

pling rate of ten times per second, it is ideal for demanding pressure and flow ap-

plications. The controller also offers a universal process input and modular, field

interchangeable outputs that allow more flexibility than ever before. The RS-485

serial communications interface allows the controller to utilize sophisticated soft-

ware routines and high speed hardware to provide exceptionally fast and accu-

rate transmission of data. The 535 Profile Controller also offers sophisticated

controlalgorithms, including exclusive AdaptiveTune whichconstantly analyzes

your process and makes modifications to the tuning parameters to ensure you’re

always under control.

535 PROFILE CONTROLLER MODES

There are four operating modes for the 535 profile controller:

OPERATION, the default mode of the controller. When the 535-PROF is oper-

ating, you can run recipes, change setpoints, select manual control and change

output level, acknowledge alarms and monitor conditions.

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