Process Controller Moore Industries 545

5 4 5
5 4 5
1/4 DIN PROCESS CONTROLLER
USER’S MANUAL
M545 V 8, MARCH 2 017

Table of Contents
About This Manual:

Table of Contents Throughout this User’s Manual
information appears along the
PAGE margins, in the form of NOTEs,
CHAPTER 1 CAUTIONs and WARNINGs, usually
INTRODUCTION ............................................................................... 1 in boldface. Please heed these
545 Modes ......................................................................................... 2 safety and good practice notices for
Order Code, Packaging Information ..................................................... 2 the protection of you and your
Where To Go Next .............................................................................. 2 equipment.
Text Formatting in This Manual ............................................................ 2
CHAPTER 2
CONTROLLER OPERATION ............................................................ 5
Displays ............................................................................................. 5
Icons ................................................................................................. 5
Keys .................................................................................................. 6
Basic Operation Procedures ............................................................... 7
Alarm Operation ................................................................................. 8
CHAPTER 3
INSTALLATION AND WIRING ........................................................ 11
Mounting the Controller ..................................................................... 11
Wiring .............................................................................................. 12
AC Power Input ....................................................................... 12
Process Variable Input ............................................................. 13
Digital Input(s) ......................................................................... 16
Remote Setpoint Option ........................................................... 16
Output Modules ....................................................................... 17
Serial Communications ............................................................ 19
CHAPTER 4
HARDWARE CONFIGURATION ..................................................... 21
Hardware Input Types ...................................................................... 21
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
Text Formatting in This Manual .......................................................... 29
Step-by-Step Guide to Set-Up Parameters ......................................... 30
CONFIG.................................................................................. 30
PV INPUT ............................................................................... 35
CUST. LINR. ........................................................................... 37
CONTROL .............................................................................. 38
ALARMS ................................................................................. 41
REM. SETPT. .......................................................................... 45
RETRANS............................................................................... 46
SELF TUNE ............................................................................ 48
SPECIAL ................................................................................ 49
545 User's Manual Table of Contents i

Table of Contents
PAGE
Step-by-Step Guide to Set-Up Parameters (continued)
SECURITY.............................................................................. 51
SER. COMM. .......................................................................... 52
Parameter Value Charts ................................................................... 54
CHAPTER 6
TUNING .......................................................................................... 63
Overview ......................................................................................... 63
TUNING Parameter Guide ................................................................ 64
TUNING Value Chart ........................................................................ 68
Self Tune Messages and Troubleshooting ......................................... 70
CHAPTER 7
APPLICATIONS .............................................................................. 71
A. Control Type ................................................................................ 71
B. Alarms ......................................................................................... 72
C. Duplex Control ............................................................................. 76
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 ............................................................................ 88
J. Multiple Setpoints .......................................................................... 88
K. Multiple Sets of PID Values ........................................................... 89
L. Powerback ................................................................................... 90
M. Self Tune—POWERTUNE® ........................................................................ 90
N. Ramp-to-Setpoint ......................................................................... 96
O. Input Linearization ........................................................................ 97
Thermocouple and RTD Linearization ....................................... 97
Square Root Linearization ........................................................ 97
Custom Linearization ............................................................... 98
P. Load Line ..................................................................................... 98
Q. Security ....................................................................................... 99
R. Reset Inhibition .......................................................................... 100
S. Process Variable Reading Correction .......................................... 100
T. Serial Communications ............................................................... 101
U. Cascade Control ........................................................................ 102
V. Ratio Control .............................................................................. 104
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
ii Table of Contents 545 User's Manual

Table of Contents
PAGE
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
545 User's Manual Table of Contents iii

Table of Contents
List of Figures
FIGURE DESCRIPTION PAGE
2.1 ................. Operator Interface ............................................................... 5
2.2 ................. Before and After Acknowledging an Alarm ............................ 9
3.1 ................. Instrument Panel & Cutout Dimensions ............................... 11
3.2 ................. Attaching Mounting Collar .................................................. 11
3.3 ................. Terminal Assignments ....................................................... 12
3.4 ................. AC Power Input Terminals ................................................. 13
3.5 ................. Process Variable Terminals ............................................... 13
3.6 ................. PV1 and PV2 Wiring for Milliamp, RTD and Voltage Inputs ... 14
3.7 ................. PV1 and PV2 Wiring for Milliamp Inputs
with Internal and External Power Supply ............................. 15
3.8 ................. Digital Input Wiring with a Switch or Relay ........................... 16
3.9 ................. Digital Input Wiring with an Open Collector .......................... 16
3.10 ............... Remote Setpoint Terminals ................................................ 16
3.11 ............... Mechanical Relay Output Wiring ......................................... 17
3.12 ............... SSR Relay Output Wiring ................................................... 17
3.13 ............... DC Logic Output Wiring ..................................................... 18
3.14 ............... Milliamp Output Wiring ....................................................... 18
3.15 ............... Position Proportioning Output Wiring .................................. 18
3.16 ............... Serial Communications Terminals ...................................... 19
4.1 ................. Location of Printed Circuit Boards ....................................... 21
4.2 ................. The Microcontroller Circuit Board, the Option Board,
and the Power Supply Board .............................................. 22
4.3 ................. Representation of Module .................................................. 25
4.4 ................. Install Communications Module .......................................... 26
5.1 ................. Parts of the Menu Block ..................................................... 27
5.2 ................. Independent vs. Dependent Parameters ............................. 28
5.3 ................. Configuration Flowchart ..................................................... 28
6.1 ................. Access the Tuning Menu Block .......................................... 63
7.1 ................. Alarm Examples ................................................................ 75
7.2 ................. Duplex With Reverse and Direct Acting Outputs .................. 77
7.3 ................. Duplex With Direct and Reverse Acting Outputs .................. 77
7.4 ................. Duplex With Two Reverse Acting Outputs ........................... 78
7.5 ................. Duplex With a Gap Between Outputs .................................. 78
7.6 ................. Duplex With Overlapping Outputs and Output Limits ............ 79
7.7 ................. Duplex With Various Relative Gain Settings ........................ 79
7.8 ................. Duplex With One ON/OFF Output ...................................... 80
7.9 ................. Duplex With Two ON/OFF Outputs ..................................... 80
7.10 ............... Staged Outputs Example ................................................... 83
7.11 ............... Combinations of Closed Digital Inputs ................................. 84
7.12 ............... Pretune TYPE 1, 2 and 3 with Adaptive Tune ....................... 93
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
iv Table of Contents 545 User's Manual

Table of Contents
FIGURE DESCRIPTION PAGE

7.18 ............... Load Line Example............................................................ 99
7.19 ............... Cascade Control of Product Temperature -
Functional View............................................................... 102
7.20 ............... Cascade Control of Produce Temperature -
Wiring View ..................................................................... 103
7.21 ............... The Functions of Cascade Control ................................... 103
7.22 ............... Ratio Control in Mixing Application “Wild Stream” -
Wiring View ..................................................................... 104
7.23 ............... Ratio Control in Mixing Application “Controlled Stream” -
Functional View............................................................... 105
7.24 ............... Ratio Control in Mixing Application “Controlled Stream” -
Wiring View ..................................................................... 106
7.25 ............... Feed Forward Control in Mixing Application -
Wiring View ..................................................................... 107
7.26 ............... Feed Forward Control in Mixing Application -
Functional View............................................................... 107
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 ............... Input Calibration Wiring ....................................................... 8
A4.5 ............... Thermocouple/Cold Junction Calibration Wiring ................... 9
A4.6 ............... Analog mA Input Calibration Wiring .................................... 10
A4.7 ............... Analog mA Input Jumper Positions ..................................... 10
A4.8 ............... Milliamp Output Calibration Wiring ..................................... 11
A4.9 ............... Output Module Menu Cycle ............................................... 11
A4.10 ............. Slidewire Test Wiring ......................................................... 12
545 User's Manual Table of Contents v

Table of Contents
vi Table of Contents 545 User's Manual

Introduction
CHAPTER 1
INTRODUCTION
From its surge-resistant power supply to its rugged construction, the 545 Thank you for selecting the dual
process controller is designed to ensure the integrity of your process with loop Process Controller. The 545 is
maximum reliability — hour after hour, day after day. The isolated inputs user-configurable for any of the
and outputs guard against the dangers of electrical interference, the front following functions:
face meets NEMA 4X standards for watertight operation and exposure to • Two independent PID loops
corrosive environments, and the solid metal housing and sturdy rubber keys • Single Station Cascade Control
enhance durability and ESD protection. • Single Station Ratio Control
The 545 has been engineered to be the industry’s most user–friendly • Feed Forward Control
process controller. With three digital display areas — two offering up to 9
characters of true alphanumerics — the 545 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 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. The 545 also offers two universal process inputs and modular, field
interchangeable outputs that allow more flexibility than ever before. With
two independent full feature control loops, the 545 can take the place of two
PID controllers; additionally, preprogrammed functions can be called for
cascade, ratio and feed forward applications.
The 545 uses foreground and background loops that facilitate straight
forward operator interface in any of the dual loop modes. It also offers
sophisticated control algorithms, including heuristic adaptive tuning, split
range and duplex outputs (control), and open or closed loop electric actua-
tor control (velocity control).
Specifications and information subject to change without notice.
545 User's Manual Chapter 1 1

Introduction
545 MODES
There are three operating modes for the 545 controller:
OPERATION, the default mode of the controller. When the 545 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 func-
tions of the instrument such as input and output assignments, alarm types
and special functions
TUNING, where you configure function parameters for Proportional, Integral
and Derivation (PID) control. Use this mode periodically to optimize the
control performance of the instrument.
ORDER CODE, PACKAGING INFORMATION

Comparing the product number to the ordering code on page 3 to determine
the outputs and options installed on the 545. The product number is printed
on the label on the top of the controller case.
Included with the 545 are:
• a 545 User’s Manual
• mounting hardware
• 1 sheet engineering unit adhesive labels
WHERE TO GO NEXT
• To become more familiar with the 545 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 545, follow through Chapter 5 and 6. Appendix 1 can be used as a
guide to these parameters.
TEXT FORMATTING IN THIS MANUAL

Feature Format
KEYS SET PT DISPLAY
or
SET PT DISPLAY
ICONS OUT, ALM

MENUS CONFIG., TUNING,
PARAMETERS CYCLE TM:1, MIN.OUT2
PARAMETER VALUES OFF, SETPOINT, LAST OUT.
DISPLAY MESSAGES TOO HOT, OUT%
2 Chapter 1 545 User's Manual

Introduction
545 – 0 0
Order
Output 1: Control Code
None 0
Mechanical Relay (5 amp) 1
Analog (milliamp) 2
Solid State Relay (triac) (1 amp) 3
DC Logic (SSR drive) 4
Output 2: Control, Alarm, or Retransmission

None 0
Analog (milliamp) 2
Output 3: Control, Alarm, Retransmission, or Loop Power

None 0
Analog (milliamp) 2
Loop Power 5
Output 4: Control, Alarm, Retransmission, or Loop Power

None 0
Mechanical Relay (0.5 amp, 24 V) 1
Analog (milliamp) 2
Solid State Relay (triac) (0.5 amp, 24 V) 3
Loop Power 5
Options
Enter “0” if not desired
Slidewire Feedback for Position
Proportioning Output A
24 VAC/24VDC Operation F
Slidewire and 24 VAC/24VDC G
Remote Setpoint B
Set of Five Digital Inputs D
Certification H
Five Digital Inputs and Certification J
Serial Communications
Enter “0” if not desired
RS-485 Serial Communications S
Note 1: Capability for position proportioning output with slidewire feedback is specifed by ordering 545-11xxAxxx00, 545-33xxAxxx00,
or 545-44xxAxxx00. (Slidewire not required for velocity proportioning.) Note 2: Up to three outputs may be used for alarms. Note 3: All
outputs are interchangeable modules. Note 4: The mechanical relay and solid state relay modules are derated to 0.5 amp at 24 Vac
when used as the fourth output.

Introduction

Basic Interface
CHAPTER 2
CONTROLLER OPERATION
545
Displays:
PV2
OUT
Icons 1 2 1st
ALM
1 2
2nd
3rd
Figure 2.1
Operator Interface
Location for
MANUAL DISPLAY SET PT identification
label
ACK 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)
• For the setpoint, deviation, output value 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)
• Name of current foreground loop
• For alarm messages, errors, etc.
• In TUNING or SET UP mode, for the value or choice of parameter shown in
the 2nd display.
ICONS (LIT)
PV2 Loop 2 is in the foreground (on display); Loop 1 is in the background. PV2
OUT1 For this output, either the relay output is energized or the analog
output is greater than 0%.
OUT2 For this output, either the relay output is energized or the analog OUT OUT OUT
output is greater than 0%. 1 2 1 2
If control output is analog, indicates the output is greater than 0%.
ALM 1 The respective alarm (one) is active.
ALM ALM ALM
ALM 2 The respective alarm (two) is active.
1 2 1 2
ALM An alarm is active but no output is assigned.
Basic Interface
KEYS
FAST: Has no independent function. Press to modify the function of another
FAST
key (see below).
MANUAL: Press to toggle between manual and automatic control.

MANUAL
When lit, indicates the unit is under manual control.
SET PT: Press to select the active setpoint.

SET PT
In SET UP or TUNING mode, press to return controller to OPERATION mode.
When lit, indicates that a setpoint other than the local SP1 is active.
DISPLAY: Press to toggle through values in the 2nd display for setpoint, ramp-
DISPLAY
ing setpoint (if available), deviation, output. background PV, lag (if available)
and valve position (if available).
In SET UP or TUNING mode, press to return controller to OPERATION mode
(with display showing current setpoint).
When lit, Loop 2 is in the foreground.
FAST+DISPLAY: Toggles between the background loop and foreground loop.

FAST + DISPLAY
▲ : Press to increase the value or selection of displayed parameter.

▲
▲ : Press to scroll through values at a faster rate.

FAST+▲
FAST + ▲
▼ : Press to decrease the value or selection of displayed parameter.

▼
▼ : Press to scroll through values at a faster rate.

FAST+▼
FAST + ▼
ACK
ACK: Press to acknowledge (an) alarm(s).
When lit, indicates there is an acknowledgeable alarm.
MENU : In OPERATION Mode, press to access the TUNING mode and menu.
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.
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.)

Basic Interface
BASIC OPERATION PROCEDURES

A Quick Explanation of Dual Loop Operation
Upon power up, Loop 1 is in the foreground (displayed), and Loop 2 is in the
“background” (hidden). Set up changes only affect the foreground loop; to make
changes to the operation of the background loop, it must be brought to the fore-
ground.
The controller helps the user identify the foreground and background loops with
the following:
• When Loop 2 is in foreground DISPLAY key and the PV2 icon are lit
• 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. Those that are specified by the word GLOBAL will
affect both loops (the whole controller).
To switch the foreground and background loops
1. Press FAST+DISPLAY.
To select /change a setpoint
1. Use DISPLAY key to toggle display to Set Point.
2. Use SET PT key to toggle to active setpoint. NOTE:
See the glossary in Appendix 6 for
Before the newly selected setpoint is made active, there is a two-second de- explanation of ramping and target
lay to prevent any disruptive bumps. If the setpoint displayed is ramping, setpoint. Also refer to the section in
RAMPING will show the 3rd display. Chapter 7.
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.

Basic Interface
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 en-
tered.
5. The controller will revert back to full security lock after one minute of key in-
activity.
To display control output value
1. Toggle DISPLAY key until the 2nd display shows OUT followed by the out-
put 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).
To display the active PID set
1. Select the desired foreground loop (hold FAST, press DISPLAY).
2. Press MENU to reach Tuning Mode.
3. In TUNING Mode, press MENU to reach the correct Menu parameter.
4. The active PID set will have an asterisk (*) on both sides of the value.
NOTE:
ALARM OPERATION
All alarms are software alarms unless 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.
more details on alarms.
Alarm Indication
Depending on how the system is configured, the 545 indicates an alarm
condition(s) for the foreground loop by:
• Lit icons ALM 1 and/or ALM 2
• Lit ACK key
• Displayed alarm message
The 545 indicates an alarm condition(s) for the background loop by:
• Showing the (user defined) message for one or both alarms in the third display
(alternate displays for simultaneous alarms).
To acknowledge an alarm(s):
An acknowledgeable alarm has both a lit icon and a lit ACK key.
A non-acknowledgeable alarm has only a lit icon.
Figure 2.2 demonstrates acknowledging an alarm.
1. If the alarm is in the background, bring that loop forward using
FAST+DISPLAY.
2. To acknowledge Alarm 1, press ACK once.
3. To acknowledge Alarm 2, press ACK twice.
4. If both alarms are activated, press ACK once to acknowledge Alarm 1, then
again to acknowledge Alarm 2.
5. The message and alarm icon disappear.

Basic Interface
BEFORE AFTER NOTE:

545 545 Powering down the 545 acknowledges/
clears all latched alarms. When powering
OUT
1
OUT
1
up, all alarms will be reinitialized.
ALM
1
MANUAL DISPLAY SET PT MANUAL DISPLAY SET PT
Figure 2.2
ACK MENU FAST ACK MENU FAST
Before and After Acknowledging an
Alarm
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.
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.

Basic Interface

Installation
CHAPTER 3
INSTALLATION AND WIRING
MOUNTING THE CONTROLLER

The 545 front face is NEMA 4X rated (waterproof). To obtain a waterproof
seal between the controller and the panel, follow these directions:
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).
Figure 3.1
2. Figure 3.1 shows the controller and panel dimensions. The panel cutout Instrument Panel & Cutout
must be precise, and the edges free from burrs and waves. Dimensions
7.180 (182.37) OVERALL LENGTH

PANEL
3.622 (92.00) MIN.
3.770 (95.76) 1.180 (29.97)
3.653 (92.80) MAX.
545
PV2
OUT
3.653 (92.80) MAX.

3.622 (92.00) MIN.
1 2
3.770 (95.76)
ALM
3.585 (91.06)
1 2
MANUAL DISPLAY SET PT
ACK MENU FAST
BEZEL 6.000 (152.40)

GASKET
FRONT SIDE CUTOUT
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 545 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 Collar Screws (1 of 4)

Installation
CAUTION ! 6. Insert the four mounting collar screws from the rear of the collar. Gradu-
The enclosure into which the 545 ally tighten the screws (using a Phillips #2 screwdriver) to secure the
Controller is mounted must be controller against the panel.
grounded. 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.
WARNING!
Avoid electrical shock. Do not WIRING
connect AC power wiring at the
source distribution panel until all Our 545 controllers are thoroughly tested, calibrated and “burned in” at the fac-
wiring connections are complete. tory, so the controller is ready to install. Before beginning, read this chapter thor-
oughly and take great care in planning a system. A properly designed system
can help prevent problems such as electrical noise disturbances and danger-
ous extreme conditions.
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. 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.
AC Power Input
TOP (as viewed from back of controller)

Figure 3.3
Terminal Assignments EARTH DIN
Actual 545 device only has top and
LINE 1 9 GND GND 17 25 (NOT
USED)
bottom numbers of each column of
terminals marked. NEUTRAL 2 10 S/W
CCW
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–
WARNING!
Electric Shock Hazard! Terminals 1
OUT 2– 5 13 RSP– DIN 4 21 29 PV2+
and 2 carry live power. DO NOT touch
these terminals when power is on. OUT 2+ 6 14 RSP+ DIN 5 22 30 RTD 3RD
COLD
OUT 3– 7 15 OUT 4– JUNC– 23 31 PV1–
COLD
WARNING!
OUT 3+ 8 16 OUT 4+ JUNC+ 24 32 PV1+
Terminal 9 must be grounded to avoid

potential shock hazard, and reduced
noise immunity to your system.

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

Use a 0.5 Amp, 250 V, fast-acting fuse in line with your AC power connection.
Process Variable Input
TOP
EARTH/ Figure 3.4

1 9 GROUND
17 25
POWER AC Power Input Terminals
2 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
Screws must be tight to ensure good electrical connection
The 545 accommodates the following types of process variable inputs:

• Thermocouple Input CAUTION!
• RTD Input Do not run low power (sensor input)
lines in the same bundle as AC power
• Voltage Input lines. Grouping these lines in the same
• Milliamp Input with External Power Supply bundle can create electrical noise
• Milliamp Input with Internal Power Supply interference.
Each type of input can be wired for PV1 (terminals 31 and 32) or for PV2 (termi-
nals 28 and 29).
Digital Input(s)
TOP
Figure 3.5
1 9 17 25 Process Variable Terminals
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+
Screws must be tight to ensure good electrical connection

Installation
NOTE: For PV1 For PV2

Typically, in the U.S., negative leads
are red.
THERMOCOUPLE INPUT THERMOCOUPLE INPUT
30
Figure 3.6 – –
PV1 and PV2 Wiring for Milliamp, 31 28
32
+ +
RTD and Voltage Inputs. 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
Third leg 29
of RTD
30 30
31 Third leg of RTD
32
4-WIRE RTD 4-WIRE RTD

Same color Same color
Third leg
of RTD
30 28
31 29
32 30
Third leg Do NOT

Same color of RTD connect
4th leg
DO NOT connect 4th leg
VOLTAGE INPUT VOLTAGE INPUT
31 – – 28 – –
+ Transmitter 29 + + Transmitter
32 +

Installation
For PV1 For PV1
MILLIAMP INPUT MILLIAMP INPUT

Figure 3.7
2-wire transmitter with 2-wire transmitter with PV1 and PV2 Wiring for Milliamp
separate power supply separate power supply
Inputs with Internal and External
Power Supply
– External + – External +
28 Power Supply 31 Power Supply
29 32 – Transmitter +
– Transmitter +

2-wire transmitter with 2-wire transmitter with
loop power supply loop power supply
– – – –
15 2-wire 15 2-wire
+ transmitter + transmitter
16 + +
16
31 – 28 –
32 + 29 +

4-wire transmitter with 4-wire transmitter with NOTE:
loop power supply loop power supply To use loop power, there must be a
15
– – Input power 15
– – Input power
loop power module is installed in the
for transmitter for transmitter 3rd or 4th output socket. Compare the
16 + +
16 + +
– 4-20 mA output – 4-20 mA output
controller product number with the
+ from transmitter + from transmitter order code in Chapter 1 to determine
31 – 28 – if the 545 has a loop power module
32 + 29 + installed. To install a loop power
module, refer to Chapter 4.

Installation
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.
Figure 3.8 1. Digital Inputs with a switch or relay

Digital Input Wiring with a Switch or Wire the switch/relay between terminal 17 and the specific digital input
Relay terminal (Figure 3.8).
DIN DIN DIN DIN DIN

1 9 GND 17 25 GND 17 25 GND 17 25 GND 17 25 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
7 15 23 31
8 16 24 32
Screws must be tight to ensure electrical connection
2. Digital Inputs with an Open Collector

Figure 3.9
Digital Input Wiring with an Open An open collector is also called a transistor. Wire the transistor between
Collector terminal 17 and the specified digital input terminal (Figure 3.9)
DIN DIN DIN DIN DIN

1 9 GND 17 25 GND 17 25 GND 17 25 GND 17 25 GND 17 25
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.
– 13
Source +
–
+
Figure 3.10 14
Remote Setpoint Terminals

Installation
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
DC Logic (SSR Drive) and Analog (Milliamp). option board must be in either mA
To install these modules, plug them into any of the four output sockets on the (milliamp) or V (voltage) position.
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 control-
ler, 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 posi-
tion 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 nor-
mally closed on the power supply circuit board.
• 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

Line Power with Output with Output with Output with Output
Module 1 Module 2 Module 3 Module 4
Figure 3.11
3 3 5 7 15
Load Mechanical Relay Output Wiring
4 4 6 8 16
Recommend use of both MOV and snubber
2. Solid State Relay (Triac) Output

• 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).

Line Power with Output with Output with Output with Output
3 - 3 5 7 15
-
Load Figure 3.12
4 + + 4 6 8 16 SSR Relay Output Wiring
Recommend use of both MOV and snubber

Installation
3. DC Logic (SSR Drive) Output

• Respective jumper J1, J2 or J3 must be set to normally open for DC
Figure 3.13 Logic output.
DC Logic Output Wiring
• Output 4 is always configured for normally open.
with Output with Output with Output with Output
3 _ _ 3 5 7 15
Load
4 + + 4 6 8 16
4. Milliamp Output
Figure 3.14 • Output 1 is always Control 1.
Milliamp Output Wiring • Respective jumper J1, J2 or J3 must be set to normally open for
Milliamp output.

with Output with Output with Output with Output
_
3 3 5 7 15
Load
4 + 4 6 8 16
5. Position Proportioning Output

Figure 3.15
(with or without Slidewire Feedback)
Position Proportioning Output
Wiring
POSITION
PROPORTIONING
Electric Motor Actuator OUTPUT
CCW CW CCW
Winding Winding 10
Slidewire
Wiper
0–1050 Ohm 11
CW
12
Actuator
Supply
Current
3 4 5 6
COM CCWCOM CW

Installation
• 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 con-
nections 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 RS-232/RS-485 converter (Product #500-485). The communication Figure 3.16
protocol is asynchronous bidirectional half-duplex, hence the leads are Serial Communications Terminals
labelled Comm + and Comm –.
545
Terminals
PC Twisted, shielded Comm – 26 To "Comm –" terminal of

next Moore Industries device
or other host
RS-485 To "Comm +" terminal of

port Comm + 27
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.

Installation

Hardware Configuration
CHAPTER 4
HARDWARE CONFIGURATION
Hardware configuration determines the available outputs as well as the type of
input signal. The 545 controller comes factory set with the following:
• All specified module 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.
Alter the factory configuration of the 545, 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. NOTE:
2. Slide chassis out of the case by pulling firmly on the bezel. Hardware configuration of the
controller is available at the factory;
Consult an application engineer for
FRONT FACE details.
MIC
BO ROCO
ARD NTR
OLL
ER
POW
BOA ER SUP
RD PLY
Figure 4.1
Location of Printed Circuit Boards for
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 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).
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: NOTE:
V Voltage Thermocouple downscale and
upscale burnout offers a choice in
MA Milliamp which direction the controller would
TC ▼ Thermocouple with downscale burnout react in the event of thermocouple
failure. For example, in heat
TC ▲ Thermocouple with upscale burnout applications, typically, it is desirable
RTD RTD to fail upscale (TC ▲) so that the
system does not apply more heat.

NOTE: The Remote Setpoint

Changing the jumpers means moving
the jumper connector. The jumper Figure 4.2 shows the location of the remote setpoint jumper. The factory de-
connector slips over the pins, fault is milliamp. Choose from the following settings:
straddling two rows of pins. The V Remote setpoint with voltage signal (jumper removed)
printed circuit boards are labeled next
to the jumpers. 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 con-
figuration. All relay output are factory set to NO (normally open).
EPROM P1
P2
TB2
V
BATTERY
MA
TC ▼
Figure 4.2 TC ▲
2ND
RTD
(from the top) The Microcontroller
Circuit Board, the Option Board, and 5-Pin Connector V
MA
the Power Supply Board TC ▼
TC ▲
PV1
Female 22-Pin Connector Female 22-Pin Connector
RTD
TB1
Remote Setpoint Jumper
Male 22-Pin Male 22-Pin

Connector Connector
Output 4
4
Male 34-Pin
Connector
Female 34-Pin Connector

NO J1 NC NO J2 NC NO J3 NC
5-Pin Connector
3
Module
Retention
Plate
2
over Outputs 1,2,3
1
Jumpers
NO and NC

Caution!!
ACCESSING AND CHANGING JUMPERS Static discharge can cause damage
Follow these instructions to change jumpers for the Process Variable, Remote to equipment. Always use a wrist
grounding strap when handling
Setpoint and Digital Inputs: electronics to prevent static
Equipment needed: Needle-nose pliers (optional) discharge.
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 2. Be careful not to bend the
pins.
2. 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 1,
please refer to the next section, starting with Step #3.
7. To reassemble the controller, properly orient the chassis with board open-
ing 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.

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).
Equipment needed: Wrist grounding strap
Small flat blade screwdriver
Wire cutters
2. Slide 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 screw-
driver, 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 4. Separate Boards 5. Remove Retention Plate

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 7.
Figure 4.3
Representation of Module
6. Snip Tie Wrap 7. Add/Change Module
9. Replace tie wraps for all the modules (the Retention Plate and Output Mod-
ule 4) with new ones before reassembling the controller.
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.
10. Rejoin the circuit boards by aligning the pins of their connectors, then squeez-
ing 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 open-
ing 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.
properly oriented.

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
Small flat blade screwdriver
1. Before installing the communications module, set up the hardware wiring
for the application. See Chapter 4 for details.
3. Slide the chassis out of the case by pulling firmly on the bezel. Do not detach
the board assembly from the front face of the controller.
4. Orient the Communications Module as shown, and attach it to Connectors
P1 and P2 as shown in Figure 4.4.
Insert module onto connectors
Front of controller
(circuits boards still attached to front face)
P1
Figure 4.4 EPROM
Install Communications Module P2
onto Microcontroller Board
TB2
V
BATTERY REMOTE SP MA
CONFIGURATION TCt
TCs
2ND
RTD
5. 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.
properly oriented.

Software Configuration
CHAPTER 5
SOFTWARE CONFIGURATION
The software configuration menus of the 545 contain user-selected variables that
define the action of the controller. Read through this section before making any Figure 5.1
parameter adjustments to the controller. Parts of the Menu Block
When initially setting up the

controller, cycle through all the
This is a Menu.
parameters in each Menu.
Its name will show in the 2nd display.
Press the MENU+FAST to
advance to the next menu.
press:
MENU/FAST
This is a menu Parameter.
Press MENU to advance to the
CONFIG. The name shows in the 3rd display.
next parameter (this also sets
In this manual, independent parameters
the value for the current
press: appear as white text on black, and
parameter. Use arrow keys to
MENU dependent parameters appear as black
select a value).
INDICATOR
Use the arrows keys to (D) This is a parameter Value.
press: These values appear in the 3rd display,
enter numerical values,
and/or move through the press MENU/FAST replacing the parameter name.
selection group. Go to next Menu Block: In this manual, parameter graphics
indicate the default (factory) setting.
If the default value is dependent on other
variables, (D) is shown.
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
operation; in TUNING mode, there is one. Each set of options is called a menu. manual operation.
When traversing the two modes, the menu names appear in the 2nd display.
Most of the menus are loop dependent, that is, each loop has its own set of
parameters for that menu. Three of the menus are global, that is, one set of
parameters applies to both loops.
CONFIG (Global) Mode selection and input/output hardware assignments
PV INPUT Process variable input options
CUST. LINR. Linearization curve options for PV input.
CONTROL Control options
ALARMS Alarm options
REM. SETPT. (Global) Controller remote setpoint options
RETRANS. (Global) Retransmission output options
SELF TUNE Self tune algorithm options
SPECIAL Special feature options
SECURITY (Global) Security functions NOTE:
SER.COMM. (Global) Serial Communications options (requires comm. board) For information about the Tuning
and menu/mode, refer to Chapter 6. For
more information about set up
TUNING Tuning parameters configuration (see Chapter 6) parameters and 545 applications,
refer to Chapter 7.

TUNE PT. CONTACT 1 PARAMETERS

AUTOMATIC MANUAL Within each menu are parameters for particular control functions. Select val-
ues for each parameter depending on the specific application. Use the MENU
key to access parameters for a particular menu; the parameter name will re-
Figure 5.2 place the menu name in the 2nd display, and the parameter value will show in
Independent vs. Depedent the 3rd display.
Parameters This chapter outlines all the available parameters for the 545. Some parameters
are independent of any special configuration, and others are dependent on
the individual configuration. 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.
Figure 5.3
Configuration Flowchart
ISPLAY op
FAST+D played lo
und loop to dis
backgro for
to move MANUAL
OPERATION
TUNING mode
TUNING
+ or
or for Loop 2 for +
to return to SET UP OPERATION mode for Loop 2
OPERATION mode SET UP mode
for mode
MANUAL TUNING mode
OPERATION SET UP
CONFIG
TUNING
PV INPUT
+ or
+
or for Loop 1 for +
CUST. LINR.
to toggle through
menu blocks
to return to SET UP mode OPERATION mode
CONTROL
for Loop 1 in SET UP mode
OPERATION SET UP mode ALARMS
mode REM. SETPT.
RETRANS.
SELF TUNE
SET UP
SPECIAL
CONFIG
SECURITY
SER. COMM.
PV INPUT LOOP 2
+
CUST. LINR.
to toggle through
menu blocks
CONTROL
in SET UP mode
ALARMS
REM. SETPT.
RETRANS.
SELF TUNE
SPECIAL
SECURITY
SER. COMM.
LOOP 1

CONFIGURATION AND OPERATION

Figure 5.3 shows the relationships among the different modes of the 545 and
the configuration menus:
• Parameter changes can only be made to the loop in the foreground
(Loop 1 upon power up). To bring the background loop into the foreground
to view and make changes, hold down FAST and press DISPLAY.
• SET UP menus can only be accessed from manual control. To transfer the
545 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 auto-
matic 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 Next menu Next parameter Next value Access Tuning Return to Operation Switch Loops
FAST + MENU FAST + MENU MENU ▲ ▼ MENU DISPLAY FAST + DISPLAY
WHERE TO GO NEXT
• 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.
• To mount the controller and configure the wiring of the 545 for inputs and outputs, see Chapter 3.
• To alter the output module and jumper configuration, see Chapter 4.
• For more information about the Tuning function of the 545, see Chapter 6.
• For more information about application for the 545, see Chapter 7.
TEXT FORMATTING IN THIS MANUAL

Feature Format
KEYS SET PT DISPLAY
or
SETPT DISPLAY
ICONS OUT, ALM

MENUS CONFIG., TUNING,
PARAMETERS CYCLE TM:1, MIN.OUT2
PARAMETER VALUES OFF, SETPOINT, LAST OUT.
DISPLAY MESSAGES TOO HOT, OUT%

STEP-BY-STEP GUIDE TO SETUP PARAMETERS
CONFIG. CONFIG.
For configuring the input and output hardware assignments. (GLOBAL)
1. CTRL. TYPE
CTRL. TYPE Defines the fundamental controller setup.
ONE LOOP D ONE LOOP Single PV, Single Control Output
• DUAL LOOP Two PV, with Control Output for each
• RATIO Two loops with Set Points rationed
• CASCADE Two PV with single Control Output
• FFWD.SUM Single loop control, 2nd PV added to or sub-
tracted from output value
• FFWD.MULT Single loop control, 2nd PV multiplies output
value
2. LOOP1 OUT
LOOP1 OUT Defines standard configuration for Loop 1.
STANDARD D STANDARD Standard control output
• DUPLEX Duplex outputs (Refer to Chapter 7)
• STAGED Staged outputs (Refer to Chapter 7)
• POS.PROP. Position proportioning control output
3. LOOP2 OUT
LOOP2 OUT Defines standard configuration for Loop 2.
STANDARD D STANDARD Standard control output
• DUPLEX Duplex outputs (Refer to Chapter 7)
• STAGED Staged outputs (Refer to Chapter 7)
• POS.PROP. Position proportioning control output
• NONE Allows second loop to function as an indicator
4. LINE FREQ
LINE FREQ. Specifies the power source frequency
60 HZ D 60 Hz
• 50 Hz
5. OUTPUT:2
OUTPUT:2 Defines the function of the second output.
OFF D OFF Completely deactivates output
• ALM.RLY:ON
• ALM.RLY:OFF
• RETRANS. Retransmission
• COMM. ONLY Output addressable only through communi-
cations

6. OUTPUT:3
Defines the function of the third output. OUTPUT:3
D OFF Completely deactivates output Off
• ALM.RLY:ON
• ALM.RLY:OFF
cations
7. OUTPUT:4 OUTPUT:4
Defines the function of the fourth output.
D OFF Completely deactivates output
OFF
• ALM.RLY:ON
• ALM.RLY:OFF
cations
8. ANLG. RNG.:1
Defines the output signal for the first output. ANLG.RNG.:1
D 4–20mA
• 0–20mA
4-20mA
• 20-4mA
• 20-0mA
9. ANLG. RNG.:2
Defines the output signal for the second output. ANLG.RNG.:2
D 4–20mA
4-20mA
• 0–20mA
• 20-4mA
• 20-0mA
10. ANLG. RNG.:3
Defines the output signal for the third output. ANLG.RNG.:3
D 4–20mA
• 0–20mA 4-20mA
• 20-4mA
• 20-0mA
11. ANLG. RNG.:4
Defines the output signal for the fourth output. ANLG.RNG.:4
D 4–20mA
4-20mA
• 0–20mA
• 20-4mA
• 20-0mA

12. CONTACT 1
CONTACT 1 Defines the operation of the first digital input, for Loop 1.
L1.MAN D L1. MAN. Trips the controller to manual control
• L1.2ND. SP. Makes the second setpoint active
• L1. 2ND. PID. Makes the second set of PID values active
• L1. ALARM ACK. Acknowledges alarms
• L1. RST. INH. Deactivates the reset term
• L1. D.A./R.A. Switches the control action
• L1. NO. A/T Suspends the adaptive tune function
• L1. LCK. MAN Locks controller in manual control
• UP KEY Remote ▲ function
• DOWN KEY Remote ▼ function
• DISP KEY Toggle between SP DEV or OUT%
• FAST KEY Actives FAST key
• MENU KEY Activates MENU key
• COMM. ONLY Status readable only through communica-
tions
• L1.SP. 1-4 Assigns the first two digital inputs to select
setpoints 1 through 4 via BCD signal
• L1. REM. SP. Makes the remote setpoint active
13. CONTACT 2
CONTACT 2 Defines the operation of the second digital input, for Loop 1.
L1.REM.SP • L1. MAN. Trips the controller to manual control
• DISP KEY Toggles between SP DEV or OUT%
tions
D L1. REM. SP. Makes the remote setpoint active

14. CONTACT 3
Defines the operation of the third digital input, for Loop 1. CONTACT 3
• L1. MAN. Trips the controller to manual control L1.2ND.SP
D L1.2ND. SP. Makes the second setpoint active
tions
15. CONTACT 4
Defines the operation of the fourth digital input, for Loop 2. CONTACT 4
D L2. MAN. Trips the controller to manual control L2.MAN.
• DISP KEY Toggles between SP DEV or OUT%
tions
• L2.SP. 1-4 Assigns DIN 4 and 5 to select setpoints 1
through 4 via BCD signal

16. CONTACT 5
CONTACT 5 Defines the operation of the fifth digital input, for the Loop 2.
L2.REM.SP. • L2. MAN. Trips the controller to manual control
• FAST KEY Activates FAST key
tions
D L2. REM. SP. Makes the remote setpoint active
17. RSP ASSN.
RSP ASSN. Defines the loop that uses the Remote Set Point.
NONE • LOOP 1
D NONE
• LOOP 2
• BOTH
18. SLIDEWIRE
SLIDEWIRE Defines the loop that uses the Slidewire Feedback.
NONE • LOOP 1
• LOOP 2
(D) NONE
19. NAME L1.
NAME L1. A 9-character message associated with Loop 1. The first character of the 3rd
display will be flashing. To enter message, press ▲ and ▼ keys to scroll
LOOP ONE through character set. Press FAST to enter the selection and move to next
digit. Press MENU to advance to next parameter.
D LOOP ONE.

20. NAME L2.

A 9-character message associated with Loop 2. The first character of the 3rd NAME L2.
display will be flashing. To enter message, press ▲ and ▼ keys to scroll
through character set. Press FAST to enter the selection and move to next
LOOP TWO
digit. Press MENU to advance to next parameter.
D LOOP TWO.
PV INPUT PV INPUT
For configuring the process variable (PV) input.
1. PV TYPE
Selects the particular sensor or input range. PV TYPE
T/C RTD Voltage Current (mA) (D)
D J T/C D DIN RTD D 1-5 V D 4-20 mA
• E T/C • JIS RTD • 0-5 V • 0-20 mA
CAUTION!
• K T/C • SAMA RTD • 0-10 mV
Set parameter values in the
• B T/C • 0-30 mV presented order—dependent
• N T/C • 0-60 mV parameters are dynamically related
and changing values of one can alter
• R T/C • 0-100 mV the value of another.
• S T/C • +/-25 mV For example, if SP LO LIM. is set to
• T T/C 0, and the thermocouple type is
changed to B T/C, the SP LO LIM.
• W T/C value will change to 104° (the low
• W5 T/C limit of a type B thermocouple).
• PLAT.II T/C
2. DEG. F/C/K
Selects the temperature unit if using a thermocouple or RTD. DEG. F/C/K
D FAHR. FAHR
• CELSIUS
• KELVIN
3. DECIMAL
Specifies the decimal point position. Decimal
D XXXXX xxxxx
• XXXX.X
• XXX.XX
• XX.XXX
• X.XXXX
4. LINEARIZE
Specifies if the input is to be linearized (automactic for T/C’s and RTD’s). LINEARIZE
D NONE NONE
• SQR. ROOT Square root linearization is activated.
• CUSTOM 15-point custom linearization curve is activated.

5. LOW RANGE
LOW RANGE Specifies the engineering unit value corresponding to the lowest input value,
e.g. 4mA.
(D)
R –9999 to 99999 Maximum is HI RANGE
D Dependent on Input Selection
6. HI RANGE
HI RANGE Specifies the engineering unit value corresponding to the highest input value,
e.g. 20mA.
(D)
R –9999 to 99999 Minimum is LOW RANGE
D Dependent on Input Selection.
7. SP LO LIM.
SP LO LIM. Defines the lowest setpoint value that can be entered from the front panel only.
(D) R –9999 to 99999 Minimum is LOW RANGE, Maximum is SP HI LIM
D Dependent on LOW RANGE
8. SP HI LIM.
Defines the highest setpoint value that can be entered from the front panel
SP HI LIM. only.
(D) R –9999 to 99999 Minimum is SP LO. LIM., Maximum is HI RANGE
D Dependent on HI RANGE
9. SP RAMP
Defines the rate of change for setpoint changes.
R 1 to 99999 units/hour
SP RAMP
D OFF (Deactives the function)
OFF 10. FILTER
Defines the setting for the low pass input filter.
FILTER R 0 to 120 seconds
D 0
0
11. PV OFFSET
Defines the offset to the process variable in engineering units.
PV OFFSET R –9999 to 99999 units

D 0
0
12. PV GAIN
This defines the gain to the process variable.
PV GAIN R 0.100 to 10.000 units
D 1.000
1.000
NOTE
Refer to Chapter 7 for more information
on Offset and Gain.

13.PV RESTOR.
Defines the control mode when a broken process variable signal is restored. PV RESTOR.
D LAST MODE LAST MODE
• MANUAL
• AUTOMATIC
CUST. LINR. CUST. LINR.

Defines a custom linearization curve for the process variable input.Points 1 and 15 are
fixed to the low and high end of the input range, and require only setting a corre-
sponding 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 lineraization table.
1. 1ST. INPUT
Specifies the input signal for to the first point. 1ST.INPUT
D The low end of the appropriate input range (e.g. 4.00mA) (D)
2. 1ST. PV
Specifies the engineering unit value for to the first point. 1ST. PV
R –9999 to 99999
D 0
0
3. XTH. INPUT
Specifies the input signal for to the XTH point (X is 2 to 14) . XTH.INPUT
R Any value greater than the first input (D)
D The low end of the appropriate input range (e.g. 4.00mA)
4. XTH. PV
Specifies the engineering unit value for to the XTH point (X is 2 to 14). XTH. PV
R –9999 to 99999 0
D 0
5. 15TH. INPT.
Specifies the input signal for to the 15th point. 15TH. INPUT
R –9999 to 99999 (D)
D The high end of the appropriate input range (e.g. 20.00mA)
6. 15TH. PV
Specifies the engineering unit value for to the 15th point. 15TH. PV
R –9999 to 99999 Minimum is [XTH-1] INPUT 0
D 0

CONTROL CONTROL
For configuring choices for the control algorithm.
1. ALGORITHM
ALGORITHM Defines the control algorithm used.
PID 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 Selects the variable used to determine the derivative action.
PV D PV “D” term will not react when you change the
setpoint
• DEVIATION “D” term will react when you change the
setpoint
3. ACTION:1
ACTION:1 Defines the action of the first control output.
REVERSE • DIRECT
D REVERSE
4. FIXED LAG
FIXED LAG Defines the fixed amount of lag between control iterations.
0 R 0 to 14400 seconds
D 0 seconds
5. VARBL. LAG
VARBL. LAG Defines the variable amound of lag between control iterations.
D 0 seconds
6. MAX. LAG
MAX. LAG Sets the maximum lag time as a result of PV2 action
D 0 seconds

7. PV BREAK
Defines the manual output level if the process variable input is lost. PV BREAK
Standard Velocity Prop. (D)
R -5 to 105 % D CW
D 0 • CCW
• OUTS.OFF
On/Off Dual On/Off PID On/Off
• ON • 1:ON, 2:ON R (-5 to 105%), 2:ON
D OFF • 1:ON, 2:OFF R (-5 to 105%), 2:OFF
• 1:OFF, 2:ON D 0%, 2:OFF
D 1:OFF, 2:OFF
Feed Forward Loop 1 Feed Forward Loop 2
R -5 to 105% R -100 to 100%
• FEED FWD. D 0%
D 0%
8. LOW OUT.
Defines the lowest output value that can be achieved in automatic control. LOW OUT.
R 0 – 100% Maximum is HIGH OUT 0%
D 0%.
9. HIGH OUT.
Defines the highest output value that can be achieved in automatic control. HIGH OUT.
R 0 – 100% Minimum is LOW OUT 100%
D 100%
10. FF LO LIM.
Defines the low limit for the feed forward output contribution when FF LO LIM.
Loop 2 is in AUTO mode.
-100%
R -100 to 100%
D -100%
11. FF HI LIM.
Defines the high limit for the feed forward output contribution when Loop 2 is in FF HI LIM.
AUTO mode.
100%
R -100 to 100%
D 100%
12. ACTION:2
Defines the action of the second control output. ACTION:2
D DIRECT DIRECT
• REVERSE

13. CCW TIME

CCW TIME Defines the time it takes a motor to fully stroke counterclockwise.
D 60 seconds
14. CW TIME
CW TIME Defines the time it takes a motor to fully stroke clockwise.
D 60 seconds
15. MIN. TIME
MIN. TIME Defines the minimum amount of time the controller must specify for the motor to
be on before it takes action.
0.1
R 0.1 to 10.0 seconds
D 0.1 seconds
16. S/W RANGE
S/W RANGE Specifies the full range resistance of the slide (e.g., 100 ohms)
100 R 0 –1050 Ohms
D 100 Ohms
17. OPEN F/B
OPEN F/B Defines the feedback ohm value corresponding to full open (100% output).
(D) R 0 to S/W RANGE
D Dependent upon S/W RANGE value
18. CLOSE F/B
CLOSE F/B Defines the feedback ohm value corresponding to full close (0% output).
100 R 0 to S/WRANGE
D 100
19. OUT1 STOP
OUT1 STOP Defines the stopping point for control output 1 when staging outputs.
50 R 1 to 100%
D 50%
20. OUT2 STRT.
OUT2 STRT. Defines the starting point for control output 2 when staging outputs.
50 R 0 to 99%
D 50%

ALARMS ALARMS
For configuring alarms.
1. ALM. TYPE:1
Defines the type of alarm for alarm 1. ALM. TYPE:1
• HIGH ALRM. OFF
• LOW ALARM
• HIGH/LOW Separate High and Low alarm setpoints in one
alarm
• BAND
• DEVIATION
• MANUAL Causes an alarm when in manual control
• REMOTE SP Causes an alarm when in Remote Setpoint
• RATE Selects a rate-of-change alarm
D OFF Deactivates the first alarm
2. ALM. SRC:1
Selects the source of the value being monitored by a HIGH, LOW or HIGH/LOW ALM. SRC:1
alarm 1.
PV
D PV
• SP
• RAMP SP
• DEVIATION
• OUTPUT
3. ALARM SP:1
Specifies the alarm set point for alarm 1. ALARM SP:1
For HIGH or LOW alarms: (D)
If ALM.SRC.:1=OUTPUT If ALM.SRC.:1=any other type
R 0.0% to 100.0% R LOW RANGE to HI RANGE
D 0.0% D 0
For BAND alarms:
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. HIGH SP:1
If ALM.SRC.:1=OUTPUT If ALM.SRC.:1=any other type (D)
D 0.0% D 0

4B. LOW SP:1

LOW SP:1 Specifies the low alarm setpoint for alarm 1.
(D) If ALM.SRC.:1=OUTPUT If ALM.SRC.:1=any other type
D 0.0% D 0
5. DEADBAND:1
DEADBAND:1 Defines the deadband for alarm 1.
(D) If ALM.SRC.:1=OUTPUT If ALM.SRC.:1=any other type
R 0.1% to 100.0% R 1 to 9999
D 0.2% D 2
6. ALM.:1 OUT.
ALM.:1 OUT. Selects the output number for alarm 1.
NONE D NONE
• 2
• 3
• 4
7. LATCHING:1
LATCHING:1 Defines the latching sequence of alarm 1.
LATCH D LATCH
• NO LATCH
8. ACK.:1
ACK.:1 Defines whether alarm 1 may be acknowledged.
ENABLED D ENABLED This allows the alarm to be acknowledged
• DISABLED This prevents the alarm from being acknowl-
edged while in alarm condition
9. POWER UP:1
POWER UP:1 Defines how alarm 1 will be treated on power up.
NORMAL D NORMAL Alarm depends on process variable
• ALARM Always power up in alarm regardless of PV
• DELAYED Must leave alarm condition and reenter before
activating the alarm
10. MESSAGE:1
MESSAGE:1 A 9- character message associated with alarm 1. The first character of the 3rd
display will be flashing. To enter message, press arrow keys to scroll through
ALARM 1 character set. Press FAST key to enter the selection and move to next digit.
Press MENU key to advance to next parameter.
D ALARM 1

11. ALM. TYPE:2

Defines the type of alarm for alarm 2. ALM. TYPE:2
• HIGH ALRM. OFF
• LOW ALARM
• HIGH/LOW Separate High and Low alarm setpoints in one
alarm
• BAND
• DEVIATION
• MANUAL Causes an alarm when in manual control
• REMOTE SP Causes an alarm when in Remote Setpoint
• RATE Selects a rate-of-change alarm
D OFF Deactivates the first alarm
12. ALM. SRC:2
Selects the source of the value being monitored by a HIGH, LOW or HIGH/LOW ALM.SRC:2
alarm 2.
PV
D PV
• SP
• RAMP SP
• DEVIATION
• OUTPUT
13. ALARM SP:2
Specifies the alarm setpoint for alarm 2. ALARM SP:2
For HIGH or LOW alarms: (D)
If ALM.SRC.:2 = OUTPUT If ALM.SRC.:2 = any other type
D 0.0% D 0
For BAND alarms:
R 1 to 99999
D 0
For DEVIATION or RATE alarms:
R -9999 to 99999
D 0
14A. HIGH SP:2
Specifies the high alarm setpoint for alarm 1. HIGH SP:2
If ALM.SRC.:2 = OUTPUT If ALM.SRC.:2 = any other type
(D)
D 0.0% D 0

14B. LOW SP:2

LOW SP:2 Specifies the low alarm set point for alarm 2.
(D) If ALM.SRC.:2 = OUTPUT If ALM.SRC.:2 = any other type
D 0.0% D 0
15. DEADBAND:2
DEADBAND:2 Defines the deadband for alarm 2.
2 If ALM.SRC.:2 = OUTPUT If ALM.SRC.:2 = any other type
R 0.1% to 100.0% R 1 to 9999
D 0.2% D 2
16. ALM.:2 OUT.
ALM.:2 OUT. Selects the output number for alarm 2.
NONE D NONE
• 2
• 3
• 4
17. LATCHING:2
LATCHING:2 Defines the latching sequence of alarm 2.
LATCH D LATCH
• NO LATCH
18. ACK.:2
ACK.:2 Defines whether alarm 2 may be acknowledged.
ENABLED D ENABLED Allows the alarm to be acknowledged
• DISABLED Prevents alarm acknowledgment while alarm
condition exists.
19. POWER UP:2
POWER UP:2 Defines how alarm 2 will be treated on power up.
NORMAL D NORMAL Alarm depends on process variable
• ALARM Always power up in alarm regardless of PV
• DELAYED Must leave & reenter alarm condition before
activating alarm
20. MESSAGE:2
MESSAGE:2 A 9-character message associated with alarm 2. The first character of the 3rd
ALARM 2 display will be flashing. To enter message, press arrow keys to scroll through
character set. Press FAST key to enter the selection and move to next digit.
Press MENU key to advance to next parameter.
D ALARM 2

21. FAULT
Defines whether either of the alarm relays will trip if a fault condition (lost pro- FAULT
cess variable) is detected.
OFF
Only appears if at least one alarm relay is installed.
D OFF
• ALARM 1
• ALARM 2
22. OUTPUT
Defines whether a rate-of-change alarm will be interpreted as a lost or broken
OUTPUT
process variable (causing a trip to manual output). NO ACTION
• P.V. BREAK
D NO ACTION
23. RATE TIME
Defines the time period over which a rate-of-change alarm condition will be RATE TIME
determined.
5
R 1 to 3600 seconds
D 5 seconds
REM. SETPT. REM. SETPT.

For configuring the remote setpoint. (GLOBAL)
1. TYPE V/mA
Specifies the type of input signal that will be used for remote setpoint. TYPE V/MA
D 1-5/4-20 Volts, mA 1-5/4-20
• 0-5/0-20 Volts, mA
2. RSP:LO RNG.
Specifies the engineering unit value corresponding to the lowest remote RSP:LO RNG.
setpoint input value, e.g. 4mA.
0
R -9999 to 99999
D 0
3. RSP:HI RNG.
Specifies the engineering unit value corresponding to the highest remote RSP:HI RNG.
setpoint input value, e.g. 20mA.
1000
R –9999 to 99999
D 1000
4. TRACKING
Defines whether the local setpoints 1 to 8 will track the remote setpoint. TRACKING
D NO NO
• YES

5. BIAS LOW
BIAS LOW Defines the lowest bias value that may be entered.
-1000 R –9999 to 99999 (Maximum is BIAS HIGH)
D –1000
6. BIAS HIGH
BIAS HIGH Defines the highest bias value that may be entered.
1000 R –9999 to 99999 (Minimum value BIAS LOW)
D 1000
7. RSP FIXED
RSP. FIXED Defines what happens if remote setpoint is lost while it is active and then is re-
stored.
LOCAL
• REMOTE SP Returns to remote setpoint when it is restored
D LOCAL Local SP remains active when remote SP is re-
stored
RETRANS. RETRANS.
For configuring the retransmission output. (GLOBAL)
1. TYPE:2
TYPE:2 Defines what is to be retransmitted for output 2.
PV1 D PV1 Linearized process variable 1
• SP1 Target setpoint 1
• RAMP SP1 Ramping (actual) setpoint 1
• OUT L1 Control output 1
• PV2 Linearized process variable 2
2. LO RANGE:2
LO RANGE:2 Defines the low end of the range of output 2 in engineering units.
(D) R –9999 to 99999
D Dependent upon process variable range
3. HI RANGE:2
HI RANGE:2 Defines the high end of the range of output 2 in engineering units.
(D) R –9999 to 99999
D Dependent on the process variable range

4. TYPE:3
Defines what is to be retransmitted for output 3. TYPE:3
D PV1 Linearized process variable 1 PV1
5. LO RANGE:3
Defines the low end of the range for output 3 in engineering units. LO RANGE:3
R –9999 to 99999 (D)
6. HI RANGE:3
Defines the high end of the range for output 3 in engineering units. HI RANGE:3
R –9999 to 99999 (D)
7. TYPE:4
Defines what is to be retransmitted for output 4. TYPE:4
D PV1 Linearized process variable 1 PV1
8. LO RANGE:4
Defines the low end of the range for output 4 in engineering units. LO RANGE:4
R –9999 to 99999 (D)
9. HI RANGE:4
Defines the high end of the range for output 4 in engineering units. HI RANGE:4
R –9999 to 99999 (D)

SELF TUNE SELF TUNE

For configuring the self tune algorithm.
1. TYPE
TYPE Defines the type of self tuning algorithm that is available.
DISABLED • PRETUNE Allows the operator to initiate Pretune only
• ADAPTIVE Allows the operator to initiate Adaptive Tune
only
• BOTH Allows the operator to initiate both Pretune and
Adaptive Tune
D DISABLED Both Pretune and Adaptive Tune are disabled
2. PRETUNE
PRETUNE Defines the type of pretune algorithm that is available.
TYPE 1 D TYPE 1 Normally used with slower thermal processes
• TYPE 2 Normally used with faster fluid or pressure pro-
cesses
• TYPE 3 Normally used with level control applications.
3. TUNE PT.
TYPE Defines the PV value at which the output with switch off during a TYPE 1
pretune, which helps prevent overshoot.
AUTOMATIC
D AUTOMATIC Controller defines this point
• XXX.X Enter any value within PV RANGE
4. OUT. STEP
OUT. STEP Defines the output step size in absolute percent during TYPE 2 or TYPE 3
pretune.
10.0
R -50.0 to 50.0%
D 10.0%
5. LOW LIMIT
LOW LIMIT Defines the lower limit the process variable can reach during pretune before
aborting.
(D)
R The process variable range
6. HI LIMIT
HI LIMIT Defines the upper limit the process variable can reach during pretune before
aborting.
(D)

7. TIMEOUT
Defines the execution time limit for pretune before aborting. TIMEOUT
R 8 to 1500 minutes 1500
D 1500 minutes
8. MODE
Defines the control mode after pretune is completed. MODE
• MANUAL AUTOMATIC
D AUTOMATIC
9. NOISE BND.
Defines the noise band to be used by the adaptive tuning algorithm, as a per- NOISE BND.
centage of the process variable range. 0.2
R 0.1 to 10%
D 0.2%
10. RESP. TIME
Defines response time to be used by the adaptive tuning algorithm. RESP. TIME
R 10 to 32000 seconds 7200
D 7200 seconds
11. DEAD TIME
Defines the amount of time the process runs before controller responds to an DEAD TIME
output change (POWER BACK feature). 0.1
R 0.1 to 7200.0 seconds
D 0.1 seconds
SPECIAL SPECIAL
For configuring special features.
1. AUTO. TRIP
Defines the condition under which the 545 will automatically trip to automatic AUTO. TRIP
control from manual control upon start up. OFF
D OFF Deactivates this function
• RISING PV Will trip when a rising process variable is within
the specified deviation from the setpoint
• FALLNG. PV 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 trips to automatic. TRIP DEV.
If AUTO.TRIP = RISING PV If AUTO.TRIP = FALLING PV (D)
R -99999 to 0 R 0 to 99999
D 0 D 0

3. DES.OUT.N (N = 1 to 5)
DES.OUT.N Designates the output value the corresponding digital input has placed the con-
troller in manual mode. Choose values based on your process.
(D)
Standard Control On/Off Control Velocity Prop Control
• –5 to 105% • ON • CW
D LAST OUT D OFF • CCW
D OUTS. OFF
4. POWER UP
POWER UP Defines the control mode upon power up.
LAST MODE D LAST MODE Power up in the same mode prior to power down
• MANUAL
• AUTOMATIC
• PRETUNE Will Pretune on every power up (recommended
for TYPE 1 pretune only).
5. PWR. UP:OUT.
Defines the output of the controller if powering up in manual mode. Choose val-
PWR. UP:OUT ues based on your process.
(D) Standard Control On/Off Control Velocity Prop Control
• –5 to 105% • ON • CW
D OUTS. OFF
6. PWR. UP:SP
This defines the setpoint upon power up.
PWR. UP:SP D LAST SP Will power up with the same setpoint (local or re-
LAST SP mote) that was active prior to power down
• LOCAL Will power up using primary local setpoint
• REMOTE Will power up using remote setpoint, if available
7. NO. OF SP
Defines the number of local setpoints (up to 8) to be stored for selection by the
front SET PT key or (up to 4) for selection by BCD (Binary Coded Decimal)
NO. OF SP digital inputs.
1 R 1 to 8 digits
D 1

SECURITY SECURITY
For configuring the security function. (GLOBAL)
1. SEC. CODE
Defines the security code for temporarily unlocking the instrument. SEC. CODE
R –9999 to 99999. 0
D 0
2. SP ADJUST
Defines lockout status for setpoint changes. SP ADJUST
D UNLOCKED UNLOCKED
• LOCKED
3. AUTO./MAN.
Defines lockout status for MANUAL key. AUTO./MAN.
D UNLOCKED UNLOCKED
• LOCKED
4. SP SELECT
Defines lockout status for SET PT key. SP SELECT
D UNLOCKED UNLOCKED
• LOCKED
5. ALARM ACK.
Defines lockout status for ACK key. ALARM ACK.
D UNLOCKED UNLOCKED
• LOCKED
6. TUNING
Defines lockout status for adjusments to tuning parameters. TUNING
D UNLOCKED UNLOCKED
• LOCKED
7. CONFIGURE
Defines lockout status for configuration parameters. CONFIGURE
D UNLOCKED UNLOCKED
• LOCKED

SER. COMM. SER. COMM.

For configuring the serial communications features. (GLOBAL)
1. STATION
STATION Defines the unit’s station address (one address for both loops in dual loop
mode).
1
R 1 to 99
• OFF (Disables the communications function)
D 1
2. BAUD RATE
BAUD RATE Defines the baud rate.
9600 • 1200 BPS
• 2400 BPS
• 4800 BPS
D 9600 BPS
• 19200 BPS
3. CRC
CRC Defines whether CRC (cyclic redundancy check) is being calculated.
YES D YES
• NO
4. SHED TIME
SHED TIME Defines the time interval between communications activity before the control-
ler determines that communications is lost (“sheds”).
OFF
R 1 to 512 seconds
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. SHED OUT.
SHED OUT Defines the output if the unit sheds and trips to manual control. Choose values
based on your process.
(D)
Standard Control On/Off Control Velocity Prop Control
• –5 to 105% • ON • CW
D OUTS. OFF

7. SHED SP
Defines the setpoint status if communications is lost. SHED SP
D LAST SP Continues to use the setpoint that was active LAST SP
prior to communications being lost.
• DESIG. SP Goes to a designated setpoint value if commu-
nications is lost.
8. DESIG. SP
Defines the value of the designated setpoint if communications is lost. DESIG. SP
R The process variable range (D)

PARAMETER VALUE CHARTS

This section of value charts is provided for logging the actual parameters values and selections for the process. It is
recommended that these pages be photocopies so there will always be a master.
CONFIG (Global)
Parameter Description Value
1 CTRL. TYPE Defines fundamental controller Set Up
2 LINE FREQ. Defines the power source frequency
3 LOOP1 OUT Defines standard configuration for Loop 1
4 LOOP2 OUT Defines standard configuration for Loop 2
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 for Loop 1
13 CONTACT 2 Operation of the second digital input for Loop 1
14 CONTACT 3 Operation of the third digital input for Loop 1
15 CONTACT 4 Operation of the fourth digital input for Loop 2
16 CONTACT 5 Operation of the fifth digital input for Loop 2
17 RSP ASSN. 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

PV INPUT
Parameter Description Value Loop 1 Value Loop 2
1 PV TYPE Sensor or range to be used
2 DEG. F/C/K Temperature engineering unit
3 DECIMAL Decimal point position
4 LINEARIZE Type of input linearization
5 LOW RANGE Engineering unit value for lowerst input value
6 HI RANGE Engineering unit value for highest input value
7 SP LO LIM. Lowest setpoint value that can be entered from front panel
8 SP HI LIM. Highest setpoint value that can be entered from front panel
9 SP RAMP Rate of change for setpoint changes
10 FILTER 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

CUST. LINR.
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 2nd INPUT Input signal for the 2nd point (of the 15 point curve)
4 2nd PV Engineering unit value for the 2nd point
5 Xth INPUT Input signal for the Xth (last) point (of the 15 point curve)
6 Xth PV Engineering unit value for the Xth (last 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
31 15th INPUT Input signal for the15th point (of the 15 point curve)

CONTROL
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 FIXED LAG Fixed amount of lag between control iterations
5 VARBL. LAG Variable amount of lag between control iterations
6 MAX. LAG Maximum as result of PV2 action.
7 PV BREAK Output level if the process variable input is lost
8 LOW OUT. Lowest output value in automatic control
9 HIGH OUT. Highest output value in automatic control
10 FF LO LIM. Low limit for feed forward output contribution
when Loop 2 is in automatic control
11 FF HI LIM. High limit for feed forward output contribution
when Loop 2 is in automatic control
12 ACTION:2 Action of the second control output
13 CCW TIME Time for motor to fully stroke in the CCW direction
14 CW TIME TIme for motor to fully stroke in the CW direction
15 MIN. TIME Minimum on-time for the motor before taking action
16 S/W RANGE Full range resistance of the slidewire
17 OPEN F/B Feedback ohm value when the valve is open
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

ALARMS
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
4B 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 1 (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

REM. SETPT. (Global)

1 TYPE V/mA Input signal to be used for remote setpoint
2 RSP: LO RNG. Engineering unit value corresponding to low remote setpoint input value
3 RSP: HI RNG. Engineering unit value corresponding to high remote setpoint input value
4 RSP: LOW Lowest setpoint value to be accepted from the remote setpoint source
5 RSP: HIGH Highest setpoint value to be accepted from the 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 What happens if remote setpoint is lost while active and then restored
RETRANS. (Global)
1 TYPE:2 What is to be retransmitted for output 2
2 LO RANGE:2 Low end of the range of output 2 in engineering units
3 HI RANGE:2 High end of the range of output 2 in engineering units

SELF TUNE
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 Process run time before controller responds to output change
SPECIAL
1 AUTO. TRIP Manual to Auto Control trip method
2 TRIP DEV. Deviation from setpoint at which controller will trip to auto
3 DES. OUT. N Output value for a designated digital input on 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 Number of stored setpoints stored for selection

SECURITY (Global)
1 SEC. CODE Security code for temporarily unlocking the instrument
2 SP ADJUST Lockout status for setpoint changes
3 AUTO./MAN. Lockout status for MANUAL key
4 SP SELECT Lockout status for SETPT key
5 ALARM ACK. Lockout status for ACK key
6 TUNING Lockout status for adjustment of tuning parameters
7 CONFIGURE Lockout status for Set Up Parameters
SER COMM. (Global)

1 STATION The unit’s station address
2 BAUD RATE Baud rate
3 CRC Whether CRC is being calculated
4 SHED TIME Time interval between communications activity 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


Tuning
CHAPTER 6
TUNING
OVERVIEW
The self tune function of the 545 consists of two distinct components — Pretune NOTE:
and Adaptive Tune. In addition, you may choose from three type of Pretune: For more information about Pretune
and Adaptive Tune, refer to section
TYPE 1 - for slow thermal processes. on Tuning applications in Chapter 7.
TYPE 2 - for fast fluid or pressure processes.
TYPE 3 - for level control applications.
• Choose the type of Pretune in the SELF TUNE menu.
• Pretune and Adaptive Tune may be used separately or together. Refer to NOTE:
Chapter 7 for more information. Loop 1 is in the foreground upon
power up. When Loop 2 is in the
• Each control loop has its own set of TUNING parameters. foreground, both the PV2 icon and
On the following pages is the step by step guide to the tuning parameters. DISPLAY key will be lit.
+ FAST
DISPLAY yed loop
und loo p to displa
ackgro
to move b OPERATION
Either Manual or for TUNING mode
Automatic Control
TUNING
or
+ for OPERATION mode
or for Loop 2 +
to return to SET UP mode for Loop 2
OPERATION OPERATION
mode
SET UP mode
Either Manual or for TUNING mode SET UP

Automatic Control …
SELF TUNE
TUNING …
LOOP 2
or
+ for OPERATION mode
or for Loop 1 + Figure 6.1
to return to SET UP mode for Loop 1
OPERATION
Access the Tuning Menu Block
SET UP mode
mode
SET UP
…
SELF TUNE
…
LOOP 1

Tuning
TUNING TUNING
1. ADAPTIVE
ADAPTIVE Activates the self tune algorithm (upon transfer to automatic control).
DISABLED D DISABLED
• ENABLED
2. PRETUNE
PRETUNE Activates the pretune algorithm (if unit is under manual control).
NO To initiate the Pretune cycle, press the ▲ or ▼ . Confirm by pressing ACK
within two seconds.
D NO
3. POWR. BACK
Reduces setpoint overshoot at power up or after setpoint changes.
POWR. BACK D DISABLED
DISABLED • ENABLED
4. PROP. BND.:1
Defines the proportional band for PID set 1.
PROP. BND.:1 R 0.1 to 999.0%
50.0 D 50.0%
5. RESET:1
Defines the integral time for PID set 1.
RESET:1 R 1 to 9999 seconds
20 D 20 seconds
6. RATE:1
Defines the derivative time for PID set 1.
RATE:1 R 0 to 600 seconds
1 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
R 0 to 100%
0 D 0%
8. CYCLE TM.:1
Defines the cycle time for control output 1 when using a time proportioning
CYCLE TM.:1 output.
15.0 R 0.3 to 120.0 seconds
D 15.0 seconds

Tuning
9. CTRL. D.B.
Defines the control deadband when using PID, PI, PD, P or PID On/Off Con- CTRL. D.B.
trol.
15.0
R Any positive value
D 15.0 seconds
10. DEADBAND:1
Defines the dead band for control output 1 when using on/off control. DEADBAND:1
R 1 to 99999 in engineering units 2
D 2
11. P. PROP. D.B.
Defines the dead band setting for a slidewire position proportioning output. P.PROP.D.B.
R 0.5 to 10.0% 2.0
D 2.0%
12A. PID OFST.:1
For duplex applications, defines the offset for the first output. PID OFST.:1
R –50.0% to 50.0% 0
D 0.0%
12B. ON OFST.:1 ON/OFST.:1
For On/Off applications, defines the offset for the first output.
R -9999 to 99999 in engineering units 0
D 0
13A. PID OFST.:2
For duplex applications, defines the offset for the second output.
PID OFST.:2
R –50.0% to 50.0% 0
D 0.0%
13B. ON OFST.:2 ON/OFST.:2
For On/Off applications, defines the offset for the second output.
0
R -9999 to 99999 in engineering units
D 0
14. REL. GAIN:2
Defines the adjustment factor for the second output’s proportional band. It is REL. GAIN:2
multiplied by the effective gain of output 1 to obtain the second output's propor-
tional band. 1.0
R 0.1 to 10.0
D 1.0

Tuning
15. CYCLE TM.:2

CYCLE TM.:2 Defines the cycle time for control output 2 when using a time proportioning
output.
15.0
R 0.3 to 120.0 seconds.
D 15.0 seconds
16. DEADBAND:2
DEADBAND:2 Defines the dead band for control output 2 when using on/off control.
2 R 1 to 99999 in engineering units
D 2
17. RSP RATIO
RSP RATIO Defines the multiplier applied to the remote set point.
R -99.99 to 99.99
1.00
D 1.00
18. RSP BIAS
RSP BIAS Defines the bias (additive term) applied to the remote set point.
(D) R Any value in engineering units (minimum is BIAS LOW; maximum is BIAS HIGH)
D Dependent on the BIAS LOW and BIAS HIGH values
19. FFWD GAIN
FFWD. GAIN Multiplier applied to the feed forward input.
R -99.99 to 99.99
1.00
D 1.00
20. FFWD ZERO
FFWD. ZERO Zero point of the feed forward output contribution.
R -9999 to 99999
0
D 0
21. FF.BRK.GN
FF.BRK.GN Multiplier applied to the feed forward input if PV is broken.
1.00 R -99.99 to 99.99
D 1.00
22. FF.BRK.ZR.
FF.BRK.ZR. Zero point of the feed forward input contribution if PV is broken.
0 R -9999 to 99999
D 0
23. NO. OF PID
NO. OF PID
Defines the number of PID sets that will be stored and available for use.
1 R 1 to 8 For numbers>1, PID TRIP defines tripping between the PID sets
• SP NUMBER Number of PID sets = number of local setpoints (specified in NO.
OF SP). Each PID set has a respective SP NUMBER.
D 1

Tuning
24. PID TRIP

For NO. OF PID > 1, defines the variable used to select the various PID sets. PID TRIP
• PV VALUE PID set selection based on process variable SP VALUE
D SP VALUE PID set selection based on setpoint
• DEV. VALUE PID set selection based on deviation from setpoint
25. TRIP:1
Defines the value that triggers a change to the primary set (#1) of PID values. TRIP:1
R The process variable range (D)
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 param-
eters as they appear for each set of PID. The controller designates the val-
ues for the active PID parameter in the third display with an “*” on either
side.
26. PROP. BND.:X

PROP.BND.:X
Defines the proportional band for PID set X. 50.0
R 0.1 to 999.0%
D 50.0%
27. RESET:X
Defines the integral time for PID set X.
RESET:X
R 1 to 9999 seconds (increments of 1)
D 20 seconds 20
28. RATE:X
Defines the derivative time for PID set X.
RATE:X
R 0 to 600 seconds
D 1 second 1
29. MAN. RST.:X (or LOADLINE:X)
Defines the manual reset (or load line) for PID set X. MAN.RST.:X
R 0 to 100%
0
D 0%
30. TRIP:X
This defines the value that triggers a change to the Xth set of PID values.
TRIP:X
D Dependent on the process variable range (D)

Tuning
TUNING
Parameter Definition Value Loop 1 Value Loop 2
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. CTRL. D.B. Control deadband for PID, PI, PD, P or PID On/Off
10. DEADBAND:1 Defines the dead band for control output 1
11. P. PROP. D.B. Defines the dead band setting for a slidewire output
12A. PID OFST.:1 For duplex applications, defines the offset for the first output
12B. ON OFST.:1 For On/Off applications, defines the offset for the first output
13A. PID OFST.:2 For duplex applications, defines the offset for the 2nd output
13B. ON OFST.:2 For On/Off applications, defines the offset for the 2nd output
14. REL. GAIN:2 Defines the adjustment factor for the output 2 prop. band
15. CYCLE TM.:2 Defines the cycle time for control output 2
16. DEADBAND:2 Defines the dead band for control output 2
17. RSP RATIO Defines the multiplier applied to the remote set point
18. RSP BIAS Defines the bias (additive term) applied to the remote set point
19. FFWD GAIN Adjustment factor for feed forward input
20. FFWD ZERO Zero point of feed forward output contribution
21. FF.BRK.GN Adjustment factor for feed forward input if PV is broken
22. FF.BRK.ZR. Zero point for feed forward output contribution if PV is broken
23. NO. OF PID Defines the number of stored and available PID sets
24. PID TRIP Defines the variable used to select the various PID sets
25. TRIP:1 Defines the value that triggers a change to primary PID set

Tuning
29. MAN. RST.:2 Defines the manual reset (or load line) for PID set 2
30. TRIP:2 Defines the value that triggers a change to the 2nd PID set
35. TRIP:3 Defines the value that triggers a change to the 3rd PID set
40. TRIP:4 This defines the value that triggers a change to the 4th PID set
49. MAN. RST.6 Defines the manual reset (or load line) for PID set 6

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
COMPLETED 1 PRETUNE has generated initial PID and the Dead Time
values.
2, 3 PRETUNE has generated initial PID, Response Time,
Noise Band and the Dead Time values.
ABORTED 1, 2, 3 User has aborted PRETUNE before completion.
LIMIT ERR. 1 The Process Variable went beyond the HI LIMIT or LOW Change the HI LIMIT and LOW LIMIT, or the HIGH OUT
LIMIT. and LOW OUT, and run PRETUNE again.
2, 3 The Process Variable went beyond the HI LIMIT or LOW Change the HI LIMIT and LOW LIMIT, or the OUT.STEP
LIMIT. size, and run PRETUNE again.
1, 2, 3 The initial Process Variable was near or beyond the HI Change the manual output percentage, or the HI LIMIT and
LIMIT or LOW LIMIT. LOW LIMIT, and run PRETUNE again.
TIME OUT 1, 2, 3 TIMEOUT limit was reached before PRETUNE completed. Set a longer TIMEOUT period and/or increase the
OUT.STEP size, and run PRETUNE again.
NOISE ERR. 1, 2, 3 Too much PV noise was detected. Eliminate the noise source (if possible) or increase the
OUT.STEP and run PRETUNE again.
INPUT ERR. 1, 2, 3 PV or Cold Junction break detected during PRETUNE. Check the described conditions and make corrections or
repairs.
1, 2, 3 PV HIGH or PV LOW detected during PRETUNE.
1, 2, 3 SLIDEWIRE break detected during PRETUNE.
1, 2, 3 REMOTE SP break detected during PRETUNE.
OUT. ERROR 1, 2, 3 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.
DATA ERR. 2,3 The PV moved too quickly to be Analyzed. Increase the OUT.STEP size and run PRETUNE again.
ZERO ERR. 2,3 One or more model parameters are calculated to be zero. Increase the OUT.STEP size and run PRETUNE again.
DEV. ERROR 1 The initial PV is too close to the TUNE PT. Move Tune PT. (or the set point if TUNE PT. is automatic)
farther from the process variable and run PRETUNE again.
RETRY 1, 2, 3 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 Potential Problem Corrective Action
RESPONSE Adaptive Tune cannot run if RESPONSE TIME is inaccurate Run TYPE 2 or TYPE 3 Pretune to obtain the correct value,
TIME or enter it manually.
NOISE BAND Adaptive Tune cannot compensate for PV oscillation due to Set NOISE BAND large enough to prevent Adaptive Tune
hysteresis of output device (e.g., a sticky valve). from acting on the oscillation. If oscillation is not acceptable,
consider replacing valve.
PRETUNE Pretune does not develop optimum PID parameters. Wrong Pretune TYPE selected. Refer to Chapter 7, the
Section on Self Tune.

Applications
CHAPTER 7
NOTE:
APPLICATIONS Controller capabilities depend upon
the specified hardware option.
The 545 controller provides a variety of user-programmable control features
and capabilities. The following topics are included in this chapter:
A. Control Type ............................................... 71 I. Remote Setpoint ........................................... 88 Q. Security ...................................................... 99

B. Alarms ......................................................... 72 J. Multiple Setpoints ........................................ 88 R. Reset Inhibition ......................................... 100
C. Duplex Control ............................................ 76 K. Multiple Sets of PID Values ......................... 89 S. Process Variable Reading Correction ........ 100
D. Slidewire Position Proportioning Control ..... 81 L. Powerback .................................................. 90 T. Serial Communications ............................. 101
E. Velocity Position Proportioning Control ....... 82 M. Self Tune— POWERTUNE® ................................... 90 U. Cascade Control ....................................... 102
F. Staged Outputs ........................................... 83 N. Ramp-to-Setpoint ........................................ 96 V. Ratio Control ............................................. 104
G. Retransmission ........................................... 83 O. Input Linearization ...................................... 97 W. Feed Forward/Feedback Control .............. 107
H. Digital Inputs ............................................... 84 P. Load Line .................................................... 98 X. Lag Time ................................................... 108
A. CONTROL TYPE
Each of the control loops in the 545 can be independently configured.
1. Go to the CONTROL menu.
2. For the parameter ALGORITHM, select the type of 545 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 a wide range of setpoints or
load requirements. The integral term works to eliminate offsets.
• PD
Proportional plus derivative control. In addition to proportional con-
trol, it compensates for control errors due to fast load variations.
• PID
Proportional plus integral plus derivative control. In addition to pro-
portional control, it compensates for changes in setpoint, load re-
quirements and process variations.
• PID/ON-OFF
Only available with Duplex control. First output uses the PID algo-
rithm, while second output uses on/off control.

Applications
3. For algorithms using the derivative function (D), choose the conditions for
the derivative term:
Scroll to parameter D. SOURCE
• For derivative action based on error, or deviation from setpoint, choose
DEVIATION
• 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.
The 545 indicates an alarm condition(s) for the foreground loop by:
• Lit icons ALM 1 and/or ALM 2
• Lit ACK key
• Displayed alarm message
The 545 indicates an alarm condition(s) for the background loop by:
• Showing the (user defined) message for one or both alarms in the third dis-
play (alternate displays for simultaneous alarms).
1. Access the ALARM menu.
2. Set values for the following parameters. All possible values are shown.
Remember: there are 2 alarms for each loop (use FAST+DISPLAY to switch
loops).
ALM.TYPE:1 and ALM. TYPE:2
Specifies the type of alarm to implement. Selection includes:
• HIGH ALARM
NOTE: High process variable alarm. Occurs when the process variable ex-
The ability to base alarms on ceeds the alarm setpoint.
parameters other than PV greatly • LOW ALARM
expands the alarm capacity. 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 set-
point. This alarm is dependent on the control setpoint; as the control

Applications
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.
• 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. 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 nega-
tive 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 oc-
curs.
LOW SP:1 and LOW SP:2
For a HIGH/LOW alarm, defines the low setpoint at which an alarm oc-
curs.
DEADBAND:1 and DEADBAND:2
Specifies the range through which the process variable must travel be-
fore 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 .

Applications
Alarm Parameters Reference LATCHING:1 and LATCHING:2

For Alarm 1 A latching (YES) alarm will remain active after leaving the alarm condi-
Parameter Description tion unless it is acknowledged. A non-latching (NO) alarm will return to
ALM. TYPE:1 Type the non-alarm state when leaving the alarm condition without being ac-
ALM. SRC.:1 Source knowledged.
ALARM SP:1 Setpoint ACK.:1 and ACK.:2
HIGH SP:1 High setpoint
For any enabled alarm, enables or disables operator use of the ACK key
LOW SP:1 Low setpoint
to acknowledge an alarm at any time, even if the control process is still
DEADBAND:1 Deadband
in the alarm condition.
ALM.:1 OUT. Output number
LATCHING:1 Latching sequence A latching alarm can always be acknowledged when it is out of the alarm
ACK.:1 Acknowledging condition. When either alarm is available to be acknowledged, the ACK
POWER UP:1 Status on power up key will be illuminated. If both alarms are acknowledgeable, pressing ACK
MESSAGE:1 Message will first acknowledge alarm #1. Pressing ACK a second time will acknowl-
edge alarm #2.
For Alarm 2 POWER UP:1 and POWER UP:2
Parameter Description
For any enabled alarm, selects the alarm condition upon power up.
ALM. TYPE:2 Type
Choices are:
ALM. SRC.:2 Source
• NORMAL
ALARM SP:2 Setpoint
HIGH SP:2 High setpoint Controller will power up in alarm only if it is in alarm condition.
LOW SP:2 Low setpoint • ALARM:
DEADBAND:2 Deadband Controller always powers up in alarm regardless of system’s alarm
ALM.:2 OUT. Output number condition. This is an excellent way to activate an alarm if there has
LATCHING:2 Latching sequence been a power failure.
ACK.:2 Acknowledging • DELAYED
POWER UP:2 Status on power up
Controller will never power up in alarm, regardless of system’s alarm
MESSAGE:2 Message
condition. The system must leave and reenter the alarm condition
before the alarm will activate. This is typically used to avoid alarms
For either alarm
during start up.
(depending on choices)
Parameter Description MESSAGE:1 and MESSAGE:2
FAULT Fault assignment Allows user to specify a nine-character message to be displayed when
OUTPUT Output action for rate the respective alarm is active. If both alarms are active or any other diag-
RATE TIME Time base for rate nostic message is present, the messages will alternate.
FAULT
NOTE:
Each of the two loops has two alarms. Activates an alarm if the process variable signal is lost. Assign this func-
tion to either Alarm 1 or Alarm 2 (not both). This action is in addition the
selected alarm type (additive alarm function).
OUTPUT
For a RATE alarm, selects the output action. Use to obtain early indica-
tion 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.

Applications
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.
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- Figure 7.1
of-change, the shorter the time period, the more sensitive the rate Alarm Examples
alarm.
BAND ALARM HIGH PROCESS VARIABLE ALARM
IN ALARM IN ALARM IN ALARM
CONDITION CONDITION CONDITION
C.SP
DB + A.SP PV
PV A.SP
DB
C.SP
DB TIME
C.SP
- A.SP
TIME RELAY RELAY RELAY
DE-ENERGIZED ENERGIZED DE-ENERGIZED
RELAY RELAY RELAY RELAY
ENERGIZED ICON OFF ICON ON ICON OFF
ENERGIZED DE-ENERGIZED DE-ENERGIZED
ICON OFF ICON ON ICON OFF ICON ON NO ALARM MAY NO ALARM
ACKNOWLEDGE
NO ALARM CANNOT NO ALARM CANNOT
ACKNOWLEDGE ACKNOWLEDGE
PARAMETER SETTINGS:
PARAMETER SETTINGS:
OUTPUT N = ALM.RLY:ON (N = 2 to 4)
OUTPUT N = ALM.RLY:OFF (N = 2 to 4)
ALM. TYPE:1 = HIGH ALRM.
ALM. TYPE:1 = BAND
ALM.:1 OUT. = N (N = 2 to 4)
ALM.:1 OUT. = N (N= 2 to 4)
LATCHING = NO LATCH
LATCHING = NO LATCH
ACK.:1 = ENABLED
ACK.:1 = DISABLED
DEVIATION ALARM POWER UP ALARM
IN ALARM PV
CONDITION
C.SP
A.SP
DB
DB
C.SP
PV + A.SP ALARM
TIME UNIT CONDITION TIME
POWER UP
RELAY RELAY MUST RELAY RELAY
RELAY
DE-ENERGIZED ENERGIZED ACKNOWLEDGE ENERGIZED ENERGIZED
ENERGIZED
TO SHUT OFF
ICON OFF ICON ON ICON AND ICON ON ICON ON ICON ON
DE-ENERGIZE
NO ALARM MAY RELAY MAY CANNOT MAY
ACKNOWLEDGE ACKNOWLEDGE ACKNOWLEDGE ACKNOWLEDGE
PARAMETER SETTINGS: PARAMETER SETTINGS:

OUTPUT N = ALM.RLY:ON (N = 2 to 4) OUTPUT N = ALM.RLY:ON (N = 2 to 4)
ALM. TYPE:1 = DEVIATION ALM. TYPE:1 = HIGH ALM.
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

Applications
NOTE: The duplex output states vary C. DUPLEX CONTROL

depending upon:
1. Control Type (PID, On/Off, etc.) The Duplex control algorithm enables two discrete control outputs for the control
2. Control Action (DA, RA) loop. Duplex control is commonly used for applications that require both heating
3. Output Limits and cooling or when 2 control elements are needed to achieve the desired result.
4. Output Gap or Overlay, and
5. Output 2 Relative Gain and PID% Hardware Configuration
Output. • The controller must have two output modules assigned to the loop (any
Please refer to the output state combination of output modules).
examples in this section to confirm
that the configuration is appropriate
for the process.
1. Go to the CONFIG. menu.
Set LOOP1 OUT or LOOP2 OUT. to DUPLEX.
2. To use different algorithms for each output (PID for the first, and On/Off for
the second):
NOTE: Set manual reset/load line Go to the CONTROL menu.
parameters to 50% when using Duplex Set ALGORITHM to PID:ON/OFF.
control (MAN. RST.:X parameter is in
the TUNING menu.) 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 out-
put 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 Out-
put 2 when using PID control.
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 depen-
dent 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 545 controller actually displays the PID output. To
relate this output to the actual physical output, locate the PID output on the
horizontal axis. Draw a vertical line at that point. At the intersection of this vertical

Applications
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 assume 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 Out 1 Out 2
PID OFST.:2 = 0 100% 100% Figure 7.2
LOW OUT = 0 Duplex with Reverse and Direct
HIGH OUT = 100 Acting Outputs
REL. GAIN = 1.0
Out 1 Out 2
0% 0%
100% 50% 0%
PID OUTPUT
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 Out 1 Out 2
ACTION:2 = REVERSE (Heat) (Cool)
Out 2 Out 1
PID OFST.:1 = 0
PID OFST.:2 = 0 100% 100%
LOW OUT = 0
HIGH OUT = 100 Figure 7.3
REL. GAIN = 1.0 Duplex with Direct and Reverse
Out 1 Out 2 Acting Outputs
0% 0%
100% 50% 0%
PID OUTPUT

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
ACTION:1 = REVERSE
Out 1 Out 2
ACTION:2 = REVERSE (Heat) (Cool)
PID OFST.:1 = 0
PID OFST.:2 = 0 100% 100%
LOW OUT = 0
Figure 7.4 HIGH OUT = 100
Duplex with Two Reverse Acting REL. GAIN = 1.0
Out 1 Out 2
Outputs
0% 0%
100% 50% 0%
PID OUTPUT
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%.
PARAMETER SETTINGS
ACTION:1 = REVERSE
PID OFST.:1 = + VALUE (Heat) (Cool)
PID OFST.:2 = – VALUE 100% 100%
Figure 7.5 LOW OUT = 0
Duplex with a Gap Between HIGH OUT = 100
Outputs REL. GAIN = 1.0
Out 1 Out 2
0% 0%
100% 50% 0%
Offset 1 Offset 2
PID OUTPUT

Applications
Duplex with a 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
(Heat) (Cool)
PID OFST.:1 = – VALUE
PID OFST.:2 = + VALUE 100% 100%
LOW OUT = 10% Figure 7.6
HIGH OUT = 85%
Duplex with Overlapping Outputs
REL. GAIN = 1.0
and Output Limits
Out 1 Out 2
0% 0%
85% 10%
100% 50% 0%
PID OUTPUT
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
Out 1 Out 2
ACTION:2 = DIRECT (Heat) (Cool)
PID OFST.:1 = 0
PID OFST.:2 = 0 100% 100%
LOW OUT = 0 Out 2
HIGH OUT = 100
REL. GAIN ❶ = 2.0 Out 1
REL. GAIN ❷ = 1.0 ❶ 50%
REL. GAIN ❸ = 0.5 ❷ Figure 7.7
❸ Duplex with Various Relative Gain
Settings
0% 0%
100% 50% 25% 0%
PID OUTPUT

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).
PARAMETER SETTINGS
ACTION:1 = REVERSE
Out 1 Out 2
ACTION:2 = DIRECT
(Heat) (Cool)
PID OFST.:1 = 0
ON OFST.:2 = + VALUE 100% ON
Figure 7.8
LOW OUT = 0
Duplex with One ON/OFF Output HIGH OUT = 100
Out 1 Out 2
0% OFF
100% 50% Out 2 Offset 0%
from Setpoint
PID OUTPUT in Engineering Units
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.
PARAMETER SETTINGS
ACTION:1 = REVERSE
(Heat) (Cool)
Figure 7.9 ON OFST.:1 = – VALUE
Duplex with Two ON/OFF Outputs ON OFST.:2 = + VALUE ON ON
Out 1
Out 2
OFF OFF
Low Offset 1 SP Offset 2 High
Range PROCESS VARIABLE Range

Applications
D. SLIDEWIRE POSITION PROPORTIONING CONTROL CAUTION!

The relay in socket 1 drives the
Slidewire position proportioning utilizes a slidewire feedback signal to determine motor counterclockwise and the
the actual position of the actuator being controlled. This option is only relay in output socket 2 drives the
motor clockwise.
available for one of the two control loops.
This is important for:
Hardware Configuration • Wiring the outputs
• Selecting the control ACTION:1
• The controller must have the Slidewire Feedback option installed. Refer to parameter, or
the order code in Chapter 1 for more information. • Determining the normally open or
• The controller must have mechanical relays, solid state relays or DC logic normally closed relays.
modules installed in the two output sockets corresponding to one control loop The configuration choices influence
(1 or 2). the way the position proportioning
algorithm works.
• The Slidewire does NOT have to be wired to the controller in order to set up
position proportioning.
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.
4. Set either LOOP1 OUT or LOOP2 OUT to POS. PROP (position proportion-
ing).
5. Set SLIDEWIRE to LOOP1 or LOOP2.
7. For S/W RANGE, specify the full range resistance of the slidewire from end-
to-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). NOTE: OPEN F/B and CLOSE F/B
values are always reference to the
10. Measure the actual slidewire value at the terminals (10 and 11). CCW end of the Slidewire.
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.
NOTE: P.PROP.D.B. can only be
b. Set P. PROP. D.B. to .5%. configured if the Slidewire Feedback
c. Place controller under Manual control. is wired to the controller.

Applications
d. Change the output percentage and observe if the valve stabilizes at

the new value.
e. If the valve oscillates, increase the P.PROP.D.B. value by 0.5%; re-
peat until oscillation stops.
E.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.
NOTE: Adaptive tuning is not available In automatic control mode, the controller will display “CW” to refer to energizing
with velocity position proportioning
of the clockwise relay, and “CCW” to refer to energizing of the counterclockwise
control.
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.
• 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.
1. Go to CONFIG. menu.
Set LOOP1 OUT or LOOP2 OUT to POS. PROP.
Set SLIDEWIRE to NONE. Alternatively, set SLIDEWIRE to LOOP1 or
LOOP2, whichever does NOT have velocity position proporioning on it.
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.
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.

Applications
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
Output 1 OUT2 STRT. was set to 50%.
Output 2
4 mA
0% 33% 50% 100% PID Output
• The controller must have analog output modules installed in the first two
output sockets.
Set CTRL. TYPE to STAGED.
3. For OUT1 STOP, specify where the first output reaches 100%.
4. For OUT2 START, specify where the second output begins.
G. RETRANSMISSION NOTE:
The retransmission feature may be used to transmit a milliamp signal For an analog output module for
corresponding to any of the following values: PV, SP1, Ramp SP1, Out L1, PV2, retransmission that was not factory-
SP2, Ramp SP2, OUTL2. A common application is to use it to record one of installed, calibrate the output for
maximum accuracy. Refer to
these variables with a recorder. Appendix 4 for details on calibration.
• There must be an analog module installed in output socket 2, 3 or 4.
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).
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 out-
put to define what is being transmitted: the process variable, setpoint, ramping
setpoint or output.
Applications
5. Set parameters LOW RANGE:X and HIGH RANGE:X for the first retrans-
mission 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 the 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 rec-
ommended type, a relay, or and 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 Chapter 5). There are 14 contact types
for the five digital inputs.
• This optional feature is only available if ordered originally from the factory,
Product #545xxxxxxDx00. The five digital inputs share a common ground.
2. Set parameters CONTACT:1 through CONTACT:3 (only those available
NOTE: To take advantage of multiple will shown) by assigning the desired function to each output. Choices are:
setpoints, make sure that the SP
NUMBER parameter in the SPECIAL • L1.SP.1-4
menu is set to a value greater than 1. (CONTACT:1 only) Allows the controller to use the digital inputs 1
and 2 to select a setpoint for Loop 1 (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 re-
mote or 2nd setpoint. To “rearm” this set of digital inputs, the DIN com-
bination must change.
Setpoints DIN 1 DIN 2 DIN 4 DIN 5

Loop 1 SP1 O O
Figure 7.11 Loop 1 SP2 X O
Combinations of Closed Digital Loop 1 SP3 O X
Inputs for Each Setpoint (based on Loop 1 SP4 X X
BCD logic) Loop 2 SP1 O O
X=closed contact Loop 2 SP2 X O
0=open contact Loop 2 SP3 O X
Loop 2 SP4 X X
• 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.

Applications
• L1. MAN. NOTE: The second display does not

change when tripping to manual from
Closing input trips the controller to manual. Opening input reverts con- a closed digital input.
troller to automatic. Override by using MANUAL key, a communica-
tions command, or “trip to automatic” function.
• L1. 2ND. SP.
Closing input changes active setpoint to the 2nd local setpoint. Open-
ing input reverts controller to previous setpoint digital input. Override
by selecting a different setpoint via the SET PT key, a communica-
tions command, or other digital inputs.
• L1. 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.
• L1.ALARM ACK.
Closing input acknowledges all active alarms. Opening input “rearms”
the controller. If the digital input remains closed, it does not continue NOTE: Only alarms configured to be
to immediately acknowledge alarms as they become active. acknowledged are affected by this
• L1. RSP. INH. digital input.
Reset Inhibition. Closing input deactivates “I” (integral) term, regard-
less of the PID values being used. Opening input activates “I” term (if
applicable).
• L1. 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). Open-
ing reinstates original action.
• L1. NO A/T
Closing input temporarily disables Adaptive Tuning. Opening input
enables it.
• L1. LCK. MAN
Closing contact places the controller in manual control at the desig-
nated output percentage. All locked manual contacts must be opened
in order to return controller to automatic control.
• UP KEY
Closing the contact mimics the ▲ key. Useful if controller is mounted
behind a window; contact push-buttons can be used to change
setpoint values.
• DOWN KEY
Closing the contact mimics the ▼ key. Useful if controller is mounted
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.

Applications
• MENU KEY
Closing contact mimics the MENU key. In OPERATION Mode, pro-
vides entry to TUNING menu. In SET UP or TUNING Mode, ad-
vances through the menus.
• COMM. ONLY
Makes input status readable through communications (but has no
effect on the controller itself).
3. Set parameters CONTACT:4 and CONTACT:5 (only those available will
be shown) by assigning the desired function to each output. Choices are:
• L2.SP.1-4
(CONTACT:4 only) Allows the controller to use the digital inputs 4
and 5 to select a setpoint for Loop 2 (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 in-
puts by selecting a different setpoint (by using SET PT key or through
communications), or by using the fifth digital input to select the re-
mote or 2nd setpoint. To “rearm” this set of digital inputs, the DIN
combination must change.
• L2.REM.SP.
Closing input changes active setpoint to remote setpoint. Opening
reverts controller to previous setpoint. Override by selecting a dif-
ferent setpoint via the SET PT key, a communications command, or
other digital inputs.
• L2. MAN.
Closing input trips the controller to manual. Opening input reverts
controller to automatic. Override by using MANUAL key, a commu-
nications command, or “trip to automatic” function.
• L2. 2ND. SP.
Closing input changes active setpoint to the 2nd local setpoint. Open-
ing input reverts controller to previous setpoint digital input. Over-
ride by selecting a different setpoint via the SET PT key, a commu-
nications command, or other digital inputs.
• L2. 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 ac-
tive setpoint and changing the active setpoint.
• L2.ALARM ACK.
Closing input acknowledges all active alarms. Opening input “re-
arms” the controller. If the digital input remains closed, it does not
continue to immediately acknowledge alarms as they become ac-
tive.
• 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).

Applications
• L2. 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). Open-
ing reinstates original action.
• L2. NO A/T
Closing input temporarily disables Adaptive Tuning. Opening input
enables it.
• L2. LCK. MAN
Closing contact places the controller in manual control at the desig-
nated output percentage. All locked manual contacts must be opened
in order to return controller to automatic control.
• UP KEY
Closing the contact mimics the ▲ key. Useful if controller is mounted
setpoint values.
• DOWN KEY
Closing the contact mimics the ▼ key. Useful if controller is mounted
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, pro-
vides entry to TUNING menu. In SET UP or TUNING Mode, advances
through the menus.
• COMM. ONLY
Makes input status readable through communications (but has no
effect on the controller itself).
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.

Applications
I. REMOTE SETPOINT
The Remote Setpoint can be assigned to Loop 1, Loop 2, or both. Remote setpoint
limits are the same as setpoint limits.
• This optional feature is available only if ordered originally from the factory,
Product #545-xxxxxBxx00 or #545-xxxxxExx00). Refer to the order code in
Chapter 1.
NOTE: There is a one-second delay
before a closed digital input takes • Before configuring the software, make sure the corresponding jumper is set
action. properly. Refer to Chapter 4 to check or change jumper positions.
1. Go to the REM. SETPT. menu.
2. Set TYPE V/mA to define the input signal range (e.g. 4-20mA).
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.

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 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).
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.

Applications
Set NO. OF PID to SP NUMBER.

For details on multiple sets of PID, refer to the next section in this chapter.

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 seconds setpoint, SP2. A set of two digital
inputs per loop may be used, to select up to 4 setpoints per loop (see the section
in this Chapter in 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 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. These methods are explained in this section.
2. NO.OF PID is the desired number of PID sets to be stored. SP NUMBER
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.

A PID set can be selected in one of four ways.
• 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 545 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
Applications
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 Moore Industries’ 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.
2. Set POWR.BACK parameter to ENABLED.
3. Go to the SELF TUNE menu.
4. The DEAD TIME is the time between initiation of an input change and the
start of an observable response in the process variable. Pretune will
automatically calculate a value for this parameter. However, if Pretune is
not run, or results are poor, value choices are:
R 10 to 3200 seconds
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.
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)
and DEAD TIME will also be calculated.

Applications
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 CAUTION!

Adaptive Tune continuously monitors the process and natural disturbances and Disable Adaptive Tuning before
makes adjustments in the tuning parameters to compensate for these changes. altering process conditions (e.g., for
In order to make accurate calculations, Adaptive Tune needs noise band and shutdown, tank draining, etc.).
response time values. Pretune TYPE 2 and TYPE 3 automatically calculate these Otherwise, the 545 will attempt to
adapt the Tuning parameters to the
values. These values may also be entered or changed manually in the SELF temporary process conditions.
TUNE menu. For Pretune TYPE 1, Noise Band, Response Time and Dead Time Adaptive Tune can be disabled via
parameters must be entered manually. digital input (if applicable—see Digital
Figure 7.12 illustrates the relationship between Pretune and Adaptive Tune Inputs in this chapter), or via menus:
1.Go to the TUNING menu.
2.Go to parameter ADAPTIVE.
Software Configurations 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.
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.
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 period of 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 is AUTOMATIC.
9. If POWERBACK algorithm is being utilized, set a value for DEAD TIME.
10. Place the controller under manual control.

Applications
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

2. Set TYPE to BOTH.
3. Set PRETUNE to TYPE 1.
4. Set a value for TUNE PT.
5. Set NOISE BND parameter.
6. Set the RESP. TIME parameter.
7. Make sure that the process is reasonably stable and place the controller under
manual control.
Set ADAPTIVE to ENABLED. The Adaptive Tuning cycle does not begin
until the controller is under automatic control.
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

2. Set the TYPE parameter to BOTH.
3. Set the PRETUNE parameter to TYPE 2 or TYPE 3.
4. Set the value for OUTSTEP.
5. DO NOT Enter values for NOISE BND, RESP TIME and DEAD TIME. The
Pretune algorithm should calculate these values.
6. Make sure that the process is reasonably stable and place the controller under
manual control.
8. Set parameter ADAPTIVE to ENABLED. The Adaptive Tuning cycle does
not begin until the controller is under automatic control.

Applications
11. When Pretune is complete, the 3rd display will show COMPLETED for two Figure 7.12
seconds and then return to the current menu display. Pretune TYPE 1, 2 and 3 with
The controller will automatically transfer to automatic control upon completion Adaptive Tune
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.
100% High Out Limit TYPE 1 Pretune/Adaptive Control

70%
• A to B is ON/OFF control to determine initial PID values.
50% • B is Pretune completed, so Adaptive PID control beings if ENABLED.
30%
CONTROL Note: Noise Band and Resp. Time must be entered before
OUTPUT 0% Low Out Limit enabling Adaptive TUne)
900
700
500 SP
300
PV 0
➔
➔
PRETUNE ADAPTIVE
A B
TIME
100%
TYPE 2 Pretune/Adaptive Control
70%
• A to B is a 5 second noise band measurement.
50% • B to C is an open loop bump test to determine initial PID values
Out Step
and response time.
30%
CONTROL • C is Pretune completed, so Adaptive PID control begins if ENABLED.
OUTPUT 0%
900
700
500 SP
300
PV 0
➔
➔
➔
NOISE BUMP ADAPTIVE

A B C
TIME
Pretune
100%
TYPE 3 Pretune/Adaptive Control
70%
• A to B is a 5 second noise band measurement.
50% • B to C is an impulse to determine initial PID values and response
Out Step
time.
30%
CONTROL • C is Pretune completed, so Adaptive PID control begins if ENABLED.
OUTPUT 0%
900
700
500 SP
300
PV 0
➔
➔
➔
NOISE BUMP ADAPTIVE

A B C
TIME
Pretune

Applications
NOTE: Adaptive tuning is not Adaptive Tune by Itself

available for velocity position
proportional control. 1. Go to the SELF TUNE menu.
2. Set the TYPE parameter to ADAPTIVE.
4. Set the ADAPTIVE parameter to ENABLED. The Adaptive Tuning cycle does
not begin until the controller is under automatic control.
CAUTION! Poor Pretune Results

If the process conditions are
temporarily changed, (e.g., during If Pretune results are poor, or process conditions do not allow Pretune to run,
process shutdown, draining of a tank, the POWERBACK and Adaptive Tune parameters can be manually configured.
etc.) disable adaptive tuning. Proper setting of the noise band and response time parameters will yield
Otherwise, the controller will attempt excellent adaptive control without running the Pretune function.
to adapt its tuning parameters to the 1. Go to the SELF TUNE menu.
temporary process conditions.
Disable adaptive tuning by: 2. Set NOISE BND.
1. In the TUNING menu, change The noise band is chosen to distinguish between disturbances which affect
ADAPTIVE to DISABLED through the process and process variable “noise.” The controller functions to
the keypad; or compensate for disturbances (i.e., load changes), but it cannot compensate
2. Closing the appropriate digital for process noise. Attempting to do this will result in degraded controller
input (see Digital Input section in performance. The Noise Band is the distance the process deviates from the
this chapter).
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.
752
(407 – 402)
NOISE BAND = X 100 = .5%
PROCESS 409 [ 752 – (–352) ]
408
VARIABLE 407
406
Type T 405
404
Thermocouple
Figure 7.13 403
402
401
Noise Band Calculation Example Range
–328°F TO 752° F 400
–328
0 40 80 120 160 200 240
TIME (SECONDS)
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.

Applications
INPUT TYPE Figure 7.14

B E J K N R/S T W/WSPLATINEL RTD 0.1°RTD Noise Band Values for
0 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 Temperature Inputs
1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1
Peak to Peak Noise °F
2 0.1 0.1 0.1 0.1 0.1 0.1 0.2 0.1 0.1 0.1 0.2
3 0.1 0.2 0.2 0.1 0.1 0.1 0.3 0.1 0.2 0.2 0.3
4 0.1 0.2 0.2 0.1 0.1 0.1 0.4 0.1 0.2 0.2 0.5
5 0.2 0.2 0.2 0.2 0.2 0.2 0.5 0.1 0.2 0.3 0.6
6 0.2 0.3 0.3 0.2 0.2 0.2 0.6 0.1 0.3 0.3 0.7
7 0.2 0.3 0.3 0.2 0.3 0.2 0.6 0.2 0.3 0.4 0.8
8 0.2 0.4 0.4 0.3 0.3 0.3 0.7 0.2 0.4 0.4 0.9
9 0.3 0.4 0.4 0.3 0.3 0.3 0.8 0.2 0.4 0.5 1.0
10 0.3 0.4 0.4 0.3 0.4 0.3 0.9 0.2 0.4 0.5 1.1
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.
3. Set RESP. TIME.
Control Output
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 Dead time of the process plus one Time Constant. The
Dead time 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 Final PV
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). 63% of Final PV
PV
Example
After a stimulus (e.g., valve movement), if it takes 300 seconds for a process DT τ
to reach 63% of its new (expected) value, the response time is 300 seconds.
RT
If the response time is set too short, the process will be unstable and cycle Time ➜
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 a response DT = Dead Time
time that is too long rather than too short. τ = Time Constant
4. Set DEAD TIME. RT = Response Time
Figure 7.15
Self Tuning with Multiple Sets of PID Deadtime and Time Constant
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 lo-
cal 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.
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.

Applications
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.
Self Tune with Cascade Control

1. To pretune Loop 2 with a Type 1 pretune, Loop 1 must be under manual
control. Otherwise, the controller will display the error message PRETUNE
LP1 AUTO.
2. To pretune Loop 1, Loop 2 must be under Automatic Control. Otherwise the
controller will display the error message PRETUNE L2 MANUAL.
N. RAMP-TO-SETPOINT
The 545 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-of-
change 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.
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 545 powers up in automatic control, then the setpoint
will ramp from the process variable value to the setpoint value at the specified
rate.

Applications
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.
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 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. To linearize this signal for use by the 545, the square root of
the signal must be calculated. The 545 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.
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).
Figure 7.16
V low is the low end of the input signal range (e.g. 1 volt or 4 mA). 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 + [ (1000 – 0) (3-1) / (5–1) ] = 1000 .5 = 707
• A voltage or milliamp input must be installed on the controller.
2. Set LINEARIZE to SQR. ROOT.

Applications
Custom Linearization
Custom linearization allows virtually any nonlinear signal to be linearized using
a 15-point straight line approximation curve (see Figure 7.17). Typical
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.
15th
PV VALUE in engineering units

10th
5th
Figure 7.17
15-point Linearization Curve 1st
1st 5th 10th 15th
INPUT VALUE in milliamps or voltage
2. Set the parameter LINEARIZE to CUSTOM.
3. Go to the CUST. LINR. menu.
4. 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
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 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

Applications
adjusted to give the best response when bringing the load to the desired level
from a “cold” start.
100%
Controller Output
LO
LO
LO
AD
AD
AD
Figure 7.18
LIN
LIN
LIN
50% Load Line Example
E2
E8
50
0%
0%
%
0 20% 40% 60% 80% 100%
Process Variable Location (% of Controller Span)
Q. SECURITY
The 545 security system is easily customized to fit a system’s needs.
1. Go to the SECURITY menu.
2. SEC. CODE defines the security password (range from -9999 to 99999). The NOTE: SEC CODE does not appear
unless all functions are unlocked.
rest of the security parameters can be selectively locked out.
3. SP ADJUST prevents the operator from using the ▲ 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.
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 NOTE: Lock out CONFIGURE for full
security. If left unlocked, the operator
unauthorized changes to the configuration parameters. If locked out, the will have access to the security code.
security code is not accessible.

Applications
NOTE: The security function is Basic Operating Procedures

compromised if the security code is left
at zero (0). 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 forgotten, the
security feature can still be overridden.
NOTE: Security does not prevent the • The security override code is 62647 .
operation from the digital inputs or Store this number in a secure place and blacken out the code in this manual
serial communications. 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).
2. Set corresponding parameter(s) CONTACT:1 to CONTACT:5 to RST.
INHBT.
S. PROCESS VARIABLE READING CORRECTION

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.
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 ther-
mocouple 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
NOTE: PV GAIN is only available if
using a linear voltage or current input. 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.

Applications
T. SERIAL COMMUNICATIONS
The serial communications option enables the 545 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 545 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 545. Through communications,
there is access to every Set up, Tuning and Operating parameter. For details
on 545 protocol, contact a Moore Industries’ application engineer.
• This optional features 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.
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.
3. Choose a BAUD RATE from 1200 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 545 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 545 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 shes.
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 545 sheds, set SHED SP to DESIG. SP and then, set the parameter
DESIG. SP to the desired setpoint.

Applications
U. CASCADE CONTROL
In Cascade control, the output of one control loop (outside loop) becomes the
remote setpoint of a second control loop (inside). The 545 performs this cas-
cade control in a single instrument. The Cascade strategy enables better con-
trol of processes with significant lag times by breaking the process into two faster
responding loops.
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 (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. Loop 2’s output comes out of Output 1. Should
Loop 2 require two outputs, (e.g. duplex, staged) the second output would come
out of Output 2.
raw
materials
OUT
RSP
IN
MIXER
INSIDE LOOP
OUT
IN
HEAT
OUTSIDE LOOP
EXCHANGER
steam
pressure
sensor
temperature sensor
• Wire as in Figure 7.20
Figure 7.19 1. For Loop 1
Cascade Control of Product a. In CONFIG. menu, set CTRL. TYPE to CASCADE.
Temperature-Functional View
b. In PV INPUT menu, set the PV TYPE.
If type is V/mA, set LO RANGE and HI RANGE parameters to match the
transmitter range.

Applications
raw
materials
EARTH DIN
USED)
NEUTRAL 2 10 S/W
CCW
DIN 1 18 26 COMM–
MIXER
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+
HEAT
EXCHANGER OUT 2+ 6 14 RSP+ DIN 5 22 30 RTD 3RD
COLD
OUT 3– 7 15 OUT 4– JUNC– 23 31 PV1–
steam OUT 3+ 8 16 OUT 4+

COLD
24 32 PV1+
JUNC+
545 002
pressure
sensor
OUTSIDE LOOP
temperature sensor
INSIDE LOOP
c. Go to the CONTROL menu.

Figure 7.20
If you want an increase in Loop 1 process variable to result in an increase
Cascade Control of Produce
for the Loop 2 setpoint, set ACTION:1 to DIRECT (acting).
Temperature-Wiring View
If you want an increase in Loop 1 process variable to result in a decrease
in Loop 2 setpoint, set ACTION:1 to REVERSE (acting).
d. Use LOW OUT. and HIGH OUT. to limit the Loop 2 RSP values of without
changing the RSP range. Refer to Figure 7.21 for details.
PV2 RANGE = 0-1000 (LOOP 1) LOW OUT = 30

SP LOW LIM = 200 (LOOP 1) HIGH OUT = 70
SP HI LIM = 800
100% 100%
Loop 1 Output (Outside Loop)
Loop 1 Output (Outside Loop)
70%
Figure 7.21
The Functions of Cascade Control
30%
0% 0%
0 200 800 1000 0 200 800 1000
Loop 2 SP (Inside Loop) Loop 2 SP (Inside Loop)
2. For Loop 2
a. In PV INPUT menu, set SP LO LIM. and SP HI LIM. to the portion of range
of Loop 2 setpoint over which you want control.
Example
Your Loop 2 range is 0 to 1000; you want its setpoint span to be 100 to 500.
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.

Applications
Similarly, whenever Loop 1 output is 100%, then Loop 2 SP is at 800. All the
intermediate values follow a linear curve, as shown in Figure 7.21.
Tuning Cascade Control

1. Set the secondary, or inner loop, into Manual, and perform a Pretune on this
loop. Once the Pretune is completed, the inner loop must be in Automatic
mode.
2. Place the primary, or outer loop, into Manual and perform a Pretune on this
loop.
3. Once Pretune is complete, the Cascade Control Loop is completely tuned,
and placing the primary loop into Automatic will allow the system to control
TUNING TIP to the desired Setpoint of the Primary loop. If desired, adaptive tune can be
1.To pretune Loop 2 with a Type 1 enabled for both loops.
pretune, Loop 1 must be under
manual control. Otherwise, the
controller will display the error V. RATIO CONTROL
message PRETUNE LP1 AUTO. Ratio Control is employed in blending applications that require materials to be
2.To pretune Loop 1, Loop 2 must be mixed to a desired ratio. In some applications not only is the ratio being con-
under Automatic Control.
Otherwise the controller will display trolled but also the combined flow or total discharge rate of the mixed materials.
the error message PRETUNE L2
MANUAL. Ratio control with one wild stream
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.
EARTH DIN
USED)
NEUTRAL 2 10 S/W
CCW
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–
Figure 7.22 OUT 2– 5 13 RSP– DIN 4 21 29 PV2+
Ratio Control in Mixing Application OUT 2+ 6 14 RSP+ DIN 5 22 30 RTD 3RD

“Wild Stream”-Wiring View COLD
OUT 3– 7 15 OUT 4– JUNC– 23 31 PV1–
COLD
OUT 3+ 8 16 OUT 4+
JUNC+ 24 32 PV1+
545 002
Flow Sensor
Material A
MIXER Controlled Stream
Material B
Wild Stream Flow Sensor

Applications
• Follow wiring as in Figure 7.22.
• Set the PV jumper (of Loop 1) and the RSP jumpers to “mA” position.
Make sure the software ranges of both inputs match the range of the corre-
sponding transmitter.
1. In the PV INPUT menu, set HI. RANGE and LOW RANGE
2. In the REM. SETPT. menu, set RSP: LO RNG and RSP:HI RNG .
3. In the TUNING menu, RSP RATIO adjusts the ratio between the two streams.
The value of this parameter is multiplied by the remote setpoint signal to
yield the effective remote setpoint NOTE:
In dual stream Ratio Control, enter
Example the ratio and bias values in the
In this example, the remote setpoint signal is the flow rate of Material B. The TUNING menu of Loop 2 under SP
desired amount of B is twice that of A. Therefore, the ratio is 2.0. If the flow of RATIO and SP BIAS
Material B is measured at 50 gallons/minute, the effective remote setpoint value
would be 2 times 50, or 100. The 535 would try to maintain the flow of Material
A at 100. As the flow of Material B changes, the setpoint would change accord-
ingly, always in a 2:1 ratio.
Ratio control with combined discharge monitoring

This process requires not only the same ratio of blending as in example 1, but
also requires the control of the combined discharge rate. In this example, ma-
terial A will always by in the proper ratio to material B even as the flow of B is
controlled to a specific rate. By controlling the flow rate of B, the total discharge
from the mixer (in Figure 7.23) can also be regulated.
Material B (PV1) has the only user defined setpoint in the system. The total flow
setpoint of the system is calculated by the following formula:
Total Flow = PV1 + ((PV2 x Loop2 SP Ratio) + SP Bias)
Secondary Loop
RSP INPUT
OUT
Primary Loop Figure 7.23
IN
Ratio Control in Mixing Application
PV1 RETRANS “Controlled Stream”-Functional View
OUT IN
FLOW
SENSOR
MATERIAL A
MIXER
MATERIAL B
FLOW
SENSOR
• Follow wiring as in Figure 7.24

Applications
EARTH DIN
USED)
NEUTRAL 2 10 S/W
CCW
DIN 1 18 26 COMM–
Figure 7.24
Ratio Control in Mixing Application OUT 1– 3 11 S/W 2 DIN 2 19 27 COMM+
“Controlled Stream”-Wiring View

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
COLD
OUT 3– 7 15 OUT 4– JUNC– 23 31 PV1–
COLD
OUT 3+ 8 16 OUT 4+ JUNC+ 24 32 PV1+
FLOW
SENSOR
MATERIAL A
TUNING TIP:
Put Loop 1 under manual control
MIXER
when tuning Loop 2, in order to hold MATERIAL B
Loop 2 SP at a constant.
FLOW
SENSOR
1. For Loop 1
a. In the CONFIG. menu, set CTRL. TYPE to RATIO.
b. Set all other parameters for a standard control loop.
2. For Loop 2
a. In the PV INPUT menu, set SP LO LIM. and SP HI LIM. to the same value
as those for 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.

Applications
W. FEED FORWARD/FEEDBACK CONTROL

In feedback control, controller output is based on the difference between pro-
cess variable and setpoint. By contrast, feed forward control generates an out-
put signal based upon the process variable. Feed forward control functions
compensate for system lag times by providing a predictive or anticipative out-
put signal based on a process measurement. Typically a feed forward signal is
used to enhance the performance of a feedback loop.
Example
Below is an alkaline effluent stream with a constantly changing flow rate, into
which an acid is being mixed (Refer to Figures 7.25 and 7.26). The acid valve is
positioned as a result of the flow rate of the stream and the pH of the mix. This
type of control is called Feed Forward/Feed Back. The pH sensor is a closed
(feedback) loop that actually measures the result of the valve’s action. The flow
rate is an open (feed forward) loop, adding, subtracting or multiplying its
output to the pH loop.
SP
Figure 7.25
Feed Forward Control in Mixing
OUTPUT SUM OUTPUT Application-Wiring View
PV1 PID TO VALVE
or +/–
ZERO GAIN
PV2
Feed Forward PV
545
Feed Forward Acid
Controller Tank
Feed Forward
Figure 7.26 Mixing Tank
Input (PV2) (PV1) pH Sensor
Feed Forward Control in Flow Sensor
Mixing Application-
Functional View
Raw Material
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:

Applications
a. FFWD ZERO (Feed forward zero):

This parameter is the PV2 (feed forward) value at which there is 0% con-
tribution to controller output. For example, if you want the feed forward
contribution to be 0% when PV2 is 500, set this parameter to 500.
b. FFWD GAIN (Feed forward gain):
This parameter is the feed forward output contribution multiplier. For ex-
ample, a gain of 1 causes a 1% output addition if PV2 is 1 unit above FFWD
ZERO. A gain of -2 causes a -2% output addition if PV2 is 1 unit about
FFWD ZERO.
c. FFWD HI LIM. and FFWD LO LIM. (Feed forward high limit & low limit):
These parameters are output “clamps” used to limit the amount of feed
forward contribution to control output. For example, if you wanted the feed
forward contribution to never exceed 50%, set FF HI LIM. to 50%. FF LO
LIM. limits the negative contribution to the output. See Figure 7.27 for an
illustration of the use of these parameters.
X. LAG TIME
These functions are for slow processes with long or changing lag times.
Figure 7.27 shows a compound loop flow pacing (feed forward/feed back) water
chlorination control system. The fixed lag time is the time under steady flow it
takes the chlorine to travel from the injector to the residual sampling point. Under
fluctuating flow rates, the travel time between the injector and the sampling point
will vary. When variable lag time is invoked, changes in the flow past the flow
meter automatically increase or decrease the lag time between the injector and
sampling point.
Residual Signal Chlorine

Residual
Figure 7.27 Analyzer
Fixed and Variable Lag Example- Control Valve
Compound Loop Chlorine Control 545
Controller
Valve Control Signal
Flow
Sample
Flow
Chlorine
Signal
Tank
Flow Chlorine Residual

Meter Injector Sampling
Water Flow Water Flow Point
Fixed Lag
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.

Applications
1. In the CONFIG. menu set CTRL.TYPE to : ONE LOOP, DUAL LOOP,
FFWD.SUM or FFWD.MULT.
2. In the CONTROL menu, set the FIXED LAG from 0 to 14400 seconds.
3. Set up all other parameters as needed for your control application.
Remember, changes in the control output will occur only at the end of the FIXED
LAG period.
Variable Lag
Variable lag (VARBL. LAG) can be used in feed forward/feed back control strat-
egies where the feedforward contribution (PV2 input) can vary and thus increase
or decrease the amount of actual process lag time. Variable Lag may be used
with FFWD. SUM and FFWD. MULT control types.
1. In the CONFIG. menu, set CTRL.TYPE to FFWD. SUM or FFWD.MULT.
3. Set FIXED LAG time (if necessary) from 0 to 14400 seconds.
4. Set the VARBL. LAG time from 0 to 14400 seconds. The time set should be
in the middle to high end of the variable range of the PV2 input.
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.

Applications

Menu Flowcharts
SET UP APPENDIX 1 MENU FLOWCHARTS

➤
CONFIG. G CTRL. TYPE LOOP1 OUT LOOP2 OUT OUTPUT: 2 OUTPUT: 3 OUTPUT: 4
ANLG. RNG.:1 ANLG. RNG.:2 ANLG. RNG.:3 ANLG. RNG.:4 CONTACT 1 CONTACT 2
CONTACT 3 CONTACT 4 CONTACT 5 RSP ASSN. SLIDEWIRE NAME L1.
NAME L2
➤
PV INPUT PV TYPE DEG. F/C/K DECIMAL LINEARIZE LOW RANGE HI RANGE
SP LO LIM. SP HI LIM. SP RAMP FILTER PV OFFSET PV GAIN
PV RESTOR.
➤
CUST. LINR. 1ST. INPUT 1ST. PV 2ND. INPUT 2ND. PV 15TH. INPUT* 15TH. PV*
➤
CONTROL ALGORITHM D. SOURCE ACTION: 1 FIXED LAG VARBL. LAG MAX LAG
PV BREAK LOW OUT. HIGH OUT. FF LO LIM. FF HI LIM. ACTION:2
CCW TIME CW TIME MIN. TIME S/W RANGE OPEN F/B CLOSE F/B
OUT1 STOP OUT2 STRT.

➤
ALARMS ALM. TYPE:1 ALM SRC:1 ALARM SP:1 HIGH SP:1 LOW SP:1 DEADBAND:1
ALM.:1 OUT. LATCHING:1 ACK.:1 POWER UP:1 MESSAGE:1 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 FAULT OUTPUT
RATE TIME
➤
REM. SET PT. TYPE V/MA RSP:LO RNG. RSP:HI RNG. TRACKING BIAS LOW BIAS HIGH
RSP FIXED
➤
RETRANS. TYPE:2 LO RANGE:2 HI RANGE:2 TYPE:3 LO RANGE:3 HI RANGE:3
TYPE:4 LO RANGE:4 HI RANGE:4

➤
SELF TUNE TYPE PRETUNE TUNE PT. OUT. STEP LOW LIMIT HI LIMIT
TIMEOUT MODE NOISE BND. RESP. TIME DEAD TIME

➤
SPECIAL AUTO. TRIP TRIP DEV. DES. OUTPT. POWER UP PWR. UP:OUT. PWR. UP:SP
NO. OF SP
➤
SECURITY G SEC. CODE SP ADJUST AUTO./MAN. SP SELECT ALARM ACK. TUNING
CONFIGURE
➤
SER. COMM.G STATION BAUD RATE CRC SHED TIME SHED MODE SHED OUT.
SHED SP DESIG. SP G DENOTES GLOBAL MENUS
545 User's Manual Appendix 1 A-1

Menu Flowcharts
TUNING 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 FFWD GAIN
FFWD ZERO FF.BRK.GN FF.BRK.ZR NO. OF PID PID TRIP TRIP:1

Up to 8 times, depending on NO. OF PID
PROP. BND.:2 RESET:2 RATE:2 MAN. RST.:2 TRIP:2
A-2 Appendix 1 545 User's Manual

Parts List
APPENDIX 2
PARTS LIST
OPERATOR CIRCUIT CIRCUIT BOARDS BEZEL CONTROLLER BODY MOUNTING

INTERFACE BOARD SUPPORT GASKET shown with mounting COLLAR
ASSEMBLY (BEZEL INSERT) collar in place
shown with bezel
insert in place
ITEM PART #
Output Modules
Mechanical Relay Module 535 600
Analog (Milliamp Module) 535 601
Solid State Relay Module 535 602
DC Logic (SSR Drive) Module 535 603
Loop Power Module 535 604
RS-485 Communications Module 535 705
Repair/Replacement Parts
Operator Interface Assembly 545 634
Power Supply Circuit Board 535 730
Microcontroller Circuit Board 535 731
Option Circuit Board w/no Options 535 720
Option Circuit Board w/Set of 5 Digital Contacts 535 721
Option Circuit Board w/Slidewire Feedback 535 722
Option Circuit Board w/set of 5 Digital Contacts & Slidewire Feedback 535 723
EPROM w/no Remote Setpoint Option 545 740
EPROM w/Remote Setpoint Option 545 741
Lithium Battery 093 128
Jumper Kit: Set of All Jumper Connectors 545 660
Gasket Kit: 1 Panel Gasket & 1 Bezel Gasket 535 662
Mounting Kit: Mounting Collar & 4 screws 535 761
Bezel Retention Screw Kit 535 663
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

Parts List

Troubleshooting
APPENDIX 3
TROUBLESHOOTING
SYMPTOM PROBLEM SOLUTION
Display will not light up 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 Input jumper selection improperly set Move jumper to proper location
• Voltage/current 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
Improper/Lost PV reading Defective thermocouple Replace thermocouple
• Thermocouple Input jumper selection improperly set Select Proper input
Wrong TC type selected in software Select proper thermocouple type in
software
Improper wiring Wire properly
Improper/Lost PV reading Defective RTD Replace RTD
• RTD Input jumper selection improperly set Move jumper connector to proper
location
Improper wiring Wire properly
No control output Output wiring and module location do not match Check and correct wiring or module
location
If SSR, SSR Drive of Milliamp output, jumpers J1, Set jumper connector to proper 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 LOST PV message
Erratic display Resetting action due to electrical noise on Filter power line.
powerline
PID values not set properly Retune controller

Troubleshooting
Message When does it occur? What to do:
DEFAULTS Whenever the memory is cleared and all Entering the Set Up mode and changing a
parameters revert to factory default settings. parameter will clear the message. If due to
This may be done by purposely clearing the something other than the user purposely
memory or when the unit is powered up for the clearing the memory, call factory for assis-
first time or if the software version is changed. tance.
LOST CAL. or Indicates that the calibration data has been Problem should never happen. Must correct
ERROR: BAD CAL. DATA lost. Occurs if all the memory has been erased. the situation and recalibrate. Call factory for
assistance.
PV1 UNDER or When the process variable value travels May not need to do anything. May want to
PV1 OVER or slightly outside the boundaries of the instru- check the transmitter accuracy and check to
PV2 UNDER or ment span. Does not apply to thermocouple or see if range of transmitter matches the range of
PV2 OVER or RTD inputs. the controller.
LOST PV1 or When the controller senses a lost process Check wiring and sensor/transmitter.
LOST PV2 variable signal or the input signal travels well
beyond the instrument span.
LOST RSP When the remote setpoint is in use and the Check wiring and remote setpoint source.
controller senses that the signal has been lost
or has traveled well outside the range.
COMM SHED When the communications is lost for longer Check communications wiring, etc. To clear
than the communications shed time. message, must make an auto/manual change.
ERROR: ROM CHECKSUM On power up, a problem with the EPROM is This is a fatal error and requires an EPROM
detected. Controller locks up until fixed. change. Call factory for assistance.
OUT1 CONF or Upon power up, controller senses that the Must power down and install correct module
OUT2 CONF or modules needed for control as determined by combination or reconfigure the controller to
OUT3 CONF or software configuration are not present. match the current module combination.
OUT4 CONF
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.
ERROR: BAD EEPROM During power up, an EEPROM failure is This is a fatal error and requires an EPROM
detected. Controller locks up until fixed. change. Call factory for assistance.
NEEDS CAL. When the controller is powered up with default Enter calibration menu and recalibrate the
calibration data (input and output accuracy controller. Call factory for assistance.
specifications may not be met).
ERROR: BAD MODEL NUM. During power up, a discrepancy was found This is a fatal error and requires an EPROM or
between the EEPROM's and controller's model EEPROM change. Call factory for assistance.
numbers. Controller locks up until fixed.

Calibration
APPENDIX 4 1 9 17 25
CALIBRATION OUT 1-
2
3
10
11
18
19
26
27
4 12 28 PV2–
• To maintain optimum performance, once a year calibrate the analog input, OUT 1+ 20
the cold junction and milliamp output (when used). To achieve published OUT 2- 5 13 21 29 PV2+
accuracy specifications, follow directions carefully and use calibrated instru- OUT 2+ 6 14 22 30
ments of like quality to those suggested. OUT 3- 7 15 OUT 4– – 23 31 PV1–
• If the controller is moved into an alternate case, or the hardware configura- OUT 3+ 8 16 OUT 4+ + 24 32 PV1+
tion is changed, and the thermocouple input is needed, recalibrate the cold
junction for maximum accuracy. 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.
CALIBRATE CAL. VREF Figure A4.2

ANALOG IN PRESS ACK
5.0000 PRESS MENU CAL. 120mV, etc. Flowchart Calibration Menus
PRESS ACK
PRESS MENU
mA CALIB.
Power Down Attach 20mA Attach 20mA COMPLETED
CALIBRATE SET BOTH Move Jumpers PV1=20mA to PV1 PV2=20mA to PV2 If mA calibration values are
PRESS ACK Power Up Press ACK Press ACK OK.
ANA. mA IN JUMPER=mA PRESS ACK PRESS ACK
PRESS MENU mA CALIB.

FAILED
CALIBRATE PV= –150 C
If mA calibration values are
PRESS ACK out of range.
COLD JUNC. PRESS ACK
PRESS ACK
PRESS MENU
CALIBRATE OUTPUT "X"

PRESS ACK PRESS MENU
ANLG. OUT 4 mA OUTPUT X, etc
PRESS ACK
PRESS MENU
RESET
RESET After two
seconds SKIPPED
PRESS ACK PUSH MENU
MENU DATA
TO RESET
PRESS
PRESS MENU
MENU
before two RESET
seconds
HARDWARE COMPLETED
SCAN PRESS ACK DISPLAY ONLY
PRESS MENU
SLIDEWIRE SLIDEWIRE
TEST PRESS ACK ____%
PRESS MENU
PRESS ACK

Calibration
EPROM
Figure A4.3
Jumper Locations on the P1
Microcontroller Circuit Board
P2
Jumper locations for
Analog,Thermocouple
and Milliamp calibration
TB2
CALIBRATION V
JUMPERS— MA
SELECT V TC
TC
2ND
AND TC
RTD
PV INPUT V
JUMPER MA
CONFIGURATION TC
PV1
TC
RTD
Y TB1
PREPARATION for ALL INPUT CALIBRATIONS

Equipment for analog input calibration:
• Precision 5-1/2 or 6-1/2 digit multimeter, e.g., Fluke 8842® or HP3478A®
(a 4-1/2 digit meter will sacrifice accuracy)
• Four small pieces of wire
• Test leads with clips
Figure A4.4
• #2 Phillips screwdriver
Input Calibration Wiring
Additional equipment for thermocouple input:
• Precision thermocouple calibrator, e.g., Micromite II® by Thermo Elec-
17 25 tric Instruments
• Special limits grade, Type T thermocouple wire
18 26 1. Disconnect power to the instrument.
2. Remove chassis from case.
19 27
3. On the Microcontroller Circuit Board, locate jumper locations marked PV1
20 28 and 2nd near the edge connector. Reposition both jumper connectors in the
Hook-up 2nd location onto pins for V and TCs as shown in Figure A4.3.
21 29 wires to 4. Connect hook up wires between terminals 31 and 32 as shown in Figure A4.4,
multimeter and the multimeter.
22 30 Set the meter for DC volts.
PV1–
23 31 5. Reinsert chassis into the case and apply power.
The 2nd and 3rd display should read CALIBRATE ANALOG IN.
24 32 PV1+ 6. Allow the controller to warm up for at least 30 minutes.
7. Press the ACK key to get to the first step/parameter.
The 2nd display should show CAL. VREF; the 3rd display should show a
value close to 5.0000.
WARNING!
8. The multimeter should read a value in the range 4.9750 - 5.0250.
ELECTRIC SHOCK HAZARD!
Terminals 1 and 2 carry live power. Use the ▲ and ▼ (and FAST) keys on the controller until the display on the
DO NOT touch these terminals controller matches the meter reading.
when power is on.

Calibration
9. Press MENU key.

The 2nd display should show CAL. 120mV. The 3rd display should show a
value close to 120.000. Match the controller display to the multimeter value
using the ▲ and ▼ keys.
10. Press MENU three more times. Each time, match the displays of the con-
troller 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 Thermocouple Cold Junction Calibra-
tion.
13. For analog milliamp input, proceed to Analog Milliamp Input Calibration.
14. For milliamp output , 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 posi-
tions (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 mul- 17 25
Type T
timeter also), and are not touching each other. 18 26 thermocouple
2. Turn on power to the unit and let controller warm up for 30 minutes in the wires (floating)
normal horizontal position: while the unit is warming up, the rear face of the 19 27 – red
controller should be vertical, not horizontal. 20 28
3. Press the MENU key until the display indicates CALIBRATE COLD JUNC. + blue
4. Press the ACK key. The display should show PV = -150 C PRESS ACK. 21 29
5. Connect both pairs of T/C wires in parallel—do not daisy chain—to a 22 30 – red
Type T thermocouple calibrator. (Both pairs must be connected or the cali-
bration will not be accurate.) 23 31
+ blue
6. Set the thermocouple calibrator to an output value of -150° C for a Type T 24 32
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. Figure A4.5
Let the controller warm up for 10 minutes, then skip to step 5. Thermocouple/Cold Junction
9. If calibration is complete, power down, then place all the jumpers in their Calibration Wiring
original positions (as specified in Chapter 3).
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 tight-
ened, 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.
Calibration
6. Remove both input jumper connectors from the pins in the 2nd position. Place
17 25 one of the jumpers on the PV1 position mA pins, and place the other jumper
Wires to 20mA
on the 2nd position mA pins as shown in Figure A4.7.
18 26 current (floating) 7. Reinsert the chassis into the case and apply power. The controller should
19 27 display PV1=20mA PRESS ACK to indicate it is ready to calibrate the PV1
PV2–
milliamp input.
20 28 8. Connect a precision 20mA input to the PV1 terminals (31 is PV1-, 32 is PV1+).
PV2+
21 29 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
22 30 yet.
PV1–
23 31 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
24 32 PV1+ PV1 input.
10. If the controller displays PV2=20mA PRESS ACK, PV1 calibration was suc-
cessful. Move on to step 12.
Figure A4.6
Analog mA Input Calibration Wiring 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.
P1
12. Remove the 20mA input from the PV1 terminals, and attach it to the PV2
P2 terminals (see Figure A4.6).
Make sure the terminal connections are fastened tightly and that a 20mA
current is flowing through PV2.
TB2
13. Let the controller warm up for an additional 5 minutes (keep in the normal
BRATION V
PERS— MA horizontal position). Make sure the current is flowing, then press ACK to
LECT V TC
TC calibrate the PV2 input.
2ND
D TCs
RTD 14. If the controller displays mA CALIB. COMPLETED, PV2 calibration was suc-
NPUT V cessful and the analog milliamp calibration procedure has been completed.
MPER MA
GURATION TC
If calibration is complete, power down. Place the jumpers into their original
PV1
TC positions (see Chapter 4).

RTD
15. If the controller briefly displays mA CALIB. FAILED, PV2 calibration was not
TB1 successful. Check the 20mA connections, and return to step #3 to recalibrate
the PV1 and PV2 inputs.
Figure A4.7
Analog mA Input Jumper Positions MILLIAMP OUTPUT CALIBRATION
If the controller uses milliamp outputs, it is usually not necessary to calibrate
them. If the milliamp output are being used for accurate retransmission of data,
it is recommended that each output with an analog module be calibrated annu-
ally 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.

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

and 2nd near the edge connector. Reposition both jumper connectors in the 1 9
2nd location onto pins for V and TCs, as shown in Figure A4.3.
4. Reinsert chassis into the case and apply power. 2 10
5. Allow controller to warm up for at least 30 minutes. OUT 1– 3 11
The 2nd and 3rd displays should read CALIBRATE ANALOG. IN.
(CALIBRATE Menu, ANALOG. IN section). OUT 1+ 4 12
Press MENU three times to reach the CALIBRATE ANLG. OUT Menu.
OUT 2– 5 13
6. Connect hook up wires to the terminals for the corresponding milliamp
output modules. OUT 2+ 6 14
Output 1 uses terminals 3 and 4.
Output 2 uses terminals 5 and 6
OUT 3– 7 15 OUT 4–
Output 3 uses terminals 7 and 8 (shown in Figure A4.8)
– OUT 3+ 8 16 OUT 4+
Output 4 uses terminals 15 and 16.
Attach the test leads from the multimeter to the wires, and then plug the test +
Connect to
leads into the meter. Set the meter for DC milliamp.
multi-meter
7. Press ACK. The 2nd display will read OUTPUT1, OUTPUT2, OUTPUT3 or
OUTPUT4 (depending on the module installation). Figure A4.8
8. Press MENU to scroll to the output to be calibrated (see Figure A4.9). The Milliamp Output Calibration Wiring
3rd display should read 4mA.
The multimeter should read a value close to 4.00.
9. Wait one minute. Use ▲ and ▼ (and FAST) on the controller to change the TO OTHER
meter’s display to exactly 4.00mA. CALIBRATION
MENU OUTPUT "X"
10. Press MENU. The 3rd display should read 20mA. PRESS
4 mA
11. Let this setting stabilize for 5 minutes. Use ▲ and ▼ (and FAST) on the
controller to change the meters display to exactly 20mA. PRESS
12. To calibrate another analog output:

Move the wires and test leads to the new output terminals. OUTPUT "X"
PRESS
Press MENU until the 3rd display shows 4mA for the corresponding output 20 mA
in the 2nd display. Repeat step 9-11. PRESS
13. To complete calibration, press ACK key, disconnect the power and place
the jumper connectors back into their original position.
EACH OUTPUT WILL GO
THROUGH THIS CYCLE
RESET MENU DATA
Figure A4.9
Resets all parameter values back to their factory default values (except for Output Module Menu Cycle
calibration information). Refer to the flowchart in Figure A4.2.
1. Disconnect power to the instrument.
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 2 seconds.
8. When complete, return jumpers to their original positions.

Calibration
HARDWARE SCAN
Use this read-only feature to identify the output hardware and installed options
of the controller.
1. Set the jumpers to V and TC▲ ▲ (see Figure A4.3).
2. Power up the controller
3. Press MENU until HARDWARE SCAN is displayed.
4. Press ACK to initiate the hardware display.
1 9 5. When complete, return jumpers to their original positions.
CCW
2 10
SLIDEWIRE TEST
WIPER
3 11 If the slidewire option is installed, use the following to test its function:
CW 1. Press MENU to scroll to the SLIDEWIRE TEST menu (refer to Figure A4.2)
4 12 2. Attach a 100 ohms to 1000 ohms potentiometer to terminals 10, 11 and 12
as shown in Figure A4.10.
5 13
3. Moving the potentiometer from one end to the other should display from “0%”
6 14 to “100%” on the controller.
4. If the error message OPEN appears, check the connectors and try again.
7 15 6. Press ACK to exit.
8 16 QUICK CALIBRATION PROCEDURE

This procedure may benefit users that have ISO or other standards requiring
Figure A4.10 periodic calibration verification. It enables verification and modification of the
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.
3. Apply power and allow controller to warm up for 30 minutes.
4. Place controller in MANUAL mode then press FAST + MENU to reach the
PV 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 4-20mA 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: Continue 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.

Specifications
SELF TUNING OF PID VALUES—AVAILABLE FOR EACH LOOP

APPENDIX 5 POWERTUNE® On–demand “pretune”: This is an open loop
SPECIFICATIONS 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.
ACCURACY
Three pretune types are available: TYPE 1 for slow thermal
TYPICAL MAXIMUM
processes; TYPE 2 for fast fluid or pressure applicaitons; and TYPE
LINEAR (Voltage) ± 0.025% of full scale ± 0.100% of full scale
3 for level control applications.
(Current) ± 0.050% of full scale ± 0.150% of full scale
RTD 1° ± 0.050% of span ± 0.150% of span Adaptive tune: Our exclusive POWERTUNE® adaptive tuning
0.1° ± 0.095% of span ± 0.225% of span algorithm automatically adjusts the PID values whenever a process
THERMOCOUPLE upset occurs. Preliminary information may be entered manually or
J, K, N, E (> 0°C) ± 0.060% of span ± 0.150% of span automatically calculated by our pretune algorithm.
J, K, N, E (< 0°C) ± 0.150% of span ± 0.375% of span OVERSHOOT PROTECTION
T (> 0°C) ± 0.100% of span ± 0.250% of span POWERBACK is proprietary, user-invoked, setpoint overshoot
T (< 0°C) ± 0.250% of span ± 0.625% of span protection algorithm. When invoked, POWERBACK reduces or
R, S (> 500°C) ± 0.150% of span ± 0.375% of span eliminates setpoint overshoot at power up or after setpoint
R, S (< 500°C) ± 0.375% of span ± 0.925% of span changes. POWERBACK monitors the process variable to make
B (>500°C) ± 0.150% of span ± 0.375% of span predictive adjustments to the control parameters, a feature that
B (<500°C) ± 0.500% of span ± 1.000% of span helps eliminate overshoot of setpoint.
W, W5 & Platinel II ± 0.125% of span ± 0.325% of span
ISOLATION
Accuracy specifications are at reference conditions (25°C—Still Inputs and outputs are grouped into the following blocks:
Air) and only apply for NIST ranges. PV1 Thermocouple Cold Block 1A: process variable input 1
Junction accuracy is 0.02°/degree from reference conditions. PV2 Block 1B: process variable input 2
Thermocouple Cold Junction Accuracy is 0.10°/degree from Block 2: outputs 1, 2, and 4
reference conditions. Display accuracy is ± 1 digit. Cold Junction Block 3: communications, set of five digital inputs, output 3 (Earth Ground)
accuracy is 0.02°/degree. Detailed accuracy information is Block 4: remote setpoint
available upon request.
Each block is electrically isolated from the other blocks to withstand a
CONTROL ALGORITHM HIPOT potential of 500 Vac for 1 minute or 600 Vac for 1 second,
PID, P with manual reset, PI, PD with manual reset, and On-Off are with the exception of blocks 1 and 4, which are isolated to withstand
selectable from the front panel. Duplex outputs each use the same a HIPOT potential of 50 volts peak for 1 minute between each other.
algorithm, except On-Off may be used with PID. The control output Inputs and outputs are not isolated from other inputs and outputs
may be configured for cascade, ratio and feed forward applications. within the same block. Blocks 1A & 1B are ground loop isolated from
Fixed lag capability is available for PID loops with a constant delay. each other to 10V peak to peak.
Variable lag capability is available when using the feed forward mode 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
TUNING PARAMETERS options include 1 remote setpoint, 1 slidewire feedback and 5 digital
Proportional Band: 0.1 to 999% of input range inputs.
Integral: 1 to 39999seconds/repeat Outputs: 4 outputs are available. See Ordering Information.
Derivative: 0 to 600 seconds RS-485 Communications: Available as an option with any configura-
Manual Reset/Load Line: 0 to 100% output tion.
Cycle Time: 0.3 to 120 seconds PROCESS VARIABLE INPUTS—2 AVAILABLE

On-Off Deadband: up to 15% of input range (in eng. units) 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.
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). (continued on next page)
Specifications and Information Subject to Change Without Notice.

Specifications
THERMOCOUPLES RANGE °F RANGE °C INPUT FILTER

B 104 to 3301 40 to 1816 Single pole lowpass digital filter with selectable time constant from 0
E –454 to 1832 –270 to 1000 to 120 seconds.
J –346 to 1832 –210 to 1000
K –418 to 2500 –250 to 1371 CALIBRATION
N –328 to 2372 –200 to 1300 The controller comes fully calibrated from the factory and continu-
R 32 to 3182 0 to 1750 ously calibrates itself for component aging due to temperature and
S 32 to 3182 0 to 1750 time, except for the reference voltage. Field calibration can be easily
T –328 to 752 –200 to 400 performed with a precision multimeter and thermocouple simulator.
W 32 to 4172 0 to 2300 Process variable offset and gain factors are provided to correct for
W5 32 to 4172 0 to 2300 sensor errors.
Platinel II –148 to 2550 –100 to 1399
OUTPUT MODULES
RTDS RANGE °F RANGE °C The controller can have a total of four control outputs, alarm outputs
100 ohms Pt. (DIN) –328 to 1562 –200 to 850 and/or loop power modules installed. There are five types of output
–328.0 to 545.0 –200.0 to 285.0 modules which can be configured to suit your particular application.
100 ohms Pt. (JIS) –328 to 1202 –200 to 650 The modules may be ordered factory-installed, or they may be
–328.0 to 545.0 –200.0 to 285.0 installed in the field.
100 ohms Pt. (SAMA) –328 to 1202 –200 to 650 Analog module: Either 0–20mA or 4–20mA (front panel selectable)
–328.0 to 545.0 –200.0 to 285.0 into a load up to 1000 ohms. Accuracy ± 5µA @ 25°C.
Mechanical relay module: SPDT electromechanical relay.
TRANSMITTER SIGNALS INPUT RANGE Resistive load rated at 5 amps at 120/240 VAC. Normally open or
Milliamps DC 4 to 20 normally closed selection is made by jumper. Output 4 is rated at
0 to 20 0.5 amps at 24 VAC and is always normally open.
Voltage DC 1 to 5 Solid state relay (triac) module: Resistive load rated at 1 amp at
0 to 5 120/240 VAC. Output 4 is rated at 0.5 amps at 24 VAC. These
Millivolts DC 0 to 10 outputs are normally open.
0 to 30 DC logic (SSR drive) module: “ON” voltage is 17 Vdc (nominal).
0 to 60 “OFF” voltage is less than 0.5 Vdc. (Current limited to 40mA.)
0 to 100 Loop power supply module: Current is limited to 25mA @ 24V
–25 to 25 (nominally loading).
LINEARIZATION CONTROL OUTPUTS
Thermocouple and RTD inputs are automatically linearized. Up to two output modules per loop may be designated for control.
Transmitter inputs may be linearized with a square root function
Any combination of output modules, with the exception of the
or user-defineable
15-point straight line linearization function. loop power supply module, may be used.
Duplex control is available if output modules are installed in the
INPUT IMPEDANCE first and second output sockets for either loop.
Current Input: 250 ohms Thermocouples: 10 Mohms Position proportioning control with feedback is available if
Voltage Input: 1 Mohms RTDs: 10 Mohms mechanical or solid state relay modules are installed in the first
two output sockets, and the slidewire feedback option is installed.
UPDATE RATE The feedback option may be added in the field. Slidewire
Input is sampled and output updated 8 times per second. Display feedback range is 0 to 1050 ohms (Slidewire SP available for
is updated five times per second. either loop 1 or loop 2—one loop only).
TRANSMITTER LOOP POWER “Velocity” position proportioning control is available by installing
Isolated 24 Vdc (nominally loaded) loop power supply is available mechanical or solid state relay modules in the first two output
if a loop power module is installed in an output socket. Capacity sockets. A special algorithm controls an electric actuator without
is 25 mA. the slidewire feedback signal.
Staged (split range) outputs are available if analog modules are
INPUT SIGNAL FAILURE PROTECTION
installed in the first and second output sockets. This algorithm
When input is lost, output is commanded to a predetermined
will allow the output range to be split between the two outputs.
output (-5 to 105%). Thermocouple burnout is selectable for
upscale or downscale.
Specifications
RETRANSMISSION OUTPUT SERIAL COMMUNICATIONS

Based on available outputs (any socket not used for control), Isolated serial communications is available using an RS-485
up to two different variables can be simultaneously pro- interface. Baud rates of up to 19,200 are selectable. The protocol
grammed for retransmission. Each precise, 16-bit resolution supports CRC data checking. If communications is lost, a time-
output may be scaled for any range. Variable selection out feature will command the controller to a particular control
includes: PV1, SP1, RAMP SP1, LOOP1OUT, PV2, SP2, mode and specific setpoint or output if desired. Outputs 2–4 and
RAMP SP2 and LOOP2OUT. digital inputs can act as “host-controlled” I/O independent of the
controller’s function. May be installed in the field.
ALARMS
The 545 controller has two software alarms per loop for a total of DIGITAL DISPLAYS
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. If an alarm is tripped, the displaying the process variable value. Height is 15 mm (0.6 in.).
alarm message will show, the ACK key will illuminate (if 2nd display: nine-character, 14-segment alphanumeric. Used for
acknowledgeable) and the ALM icon will light. If the alarm is tied displaying setpoint, deviation, output value, slidewire position
to the first available non-control output, the “1” below the ALM (actual valve position) and configuration information. Height is 6
icon will light. Similarly, if the alarm is tied to the second non- mm (0.25 in.).
control output, the “2” below the ALM will light. The availability of 3rd display: nine-character, 14-segment alphanumeric. Used for
outputs determines how many alarms can be tied to relays. indicating which loop is displayed and for displaying alarm
Global Alarm feature allows one or more of the internal software messages and configuration information. Height is 6 mm
alarms to be tied to the same single, physical output. The (0.25 in.). All displays are vacuum fluorescent. Color is blue-
acknowledge key is active for alarms associated with either loop. green.
The order in which alarms are acknowledged is: loop1 alarm1,
loop1 alarm 2, loop2 alarm 1, loop2 alarm2. STATUS INDICATORS
There are two types of indicators: icons and illuminated keys.
DIGITAL INPUTS
ALM 1 and ALM 2 icons: alarm 1 and alarm 2 status.
A set of five external digital inputs activated by dry contacts (or open
collector transistors) are available. Each can be configured to OUT 1 and OUT 2 icons: control output 1 and control output 2
perform one of the following functions: status.
• Select remote setpoint • Select either direct or reverse PV2 icon illuminated: 2nd loop is on display.
• Select manual control control action DISPLAY key illuminated: 2nd loop is on display.
• Select second local setpoint • Disable adaptive tuning MAN key illuminated: controller is in manual control mode.
• Select a second set of • Addressable through serial ACK key illuminated: alarm may be acknowledged.
PID values communications only
SET PT key illuminated: setpoint other than primary local
• Acknowledge alarms • Inhibit the reset term setpoint is active.
• Simulate front panel keys • Lock controller in manual MENU key illuminated: controller is in configuration mode.
mode
DIMENSIONS
In addition, if the set of five digital inputs is installed, two can be Meets 1/4 DIN designation as specified in DIN standard number 43
designated to select one of four local setpoints per loop (and 700. See diagram for details.
associated PID set, if desired) via a binary coded decimal (BCD)
input. MOUNTING
Panel-mounted. See diagram for details.
SETPOINT SELECTION
A remote setpoint input is available for one of the two loops. Signal is WIRING CONNECTIONS
0–20/4–20 mADC or 0–5/1–5 VDC (jumper selectable). Signal may 31 screw terminals in the rear of the instrument.
be rationed and biased. Eight local setpoints per loop 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 (continued on next page)
the input signal is lost.

Specifications
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 pro-
vided 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
(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.

Glossary
alarm, rate-of-change: A type of alarm configuration: Also called Set Up. The
APPENDIX 6 set up to occur when there is an selection of hardware devices and
excessive change in the process software routines that function together.
GLOSSARY variable (PV) value.
contact: In hardware, a set of conduc-
adaptive control: Control in which automatic controller: A device or tors that can be brought into contact by
automatic means are used to change combination of devices which measures electromechanical action and thereby
the type or influence (or both) of control the value of a variable, quantity, or produce switching. In software, a
parameters in such a way as to improve condition and operates to correct or limit symbolic set of points whose open or
the performance of the control system. its deviation from the setpoint. closed condition depends on the logic
status assigned to them by internal or
adaptive tune: A component of the 545 baud rate: Any of the standard trans- external conditions.
self tune function which continuously mission rates for sending or receiving
monitors the process and natural binary coded data. control action: The slope of the output
disturbances and makes adjustments in of the instrument in reference to the
the tuning parameters to compensate or bias: A reference level. A numeric value input, e.g., direct output increases on
improve the performance of the control in a digital system or a voltage or current rise of input. Typical cooling response or
system. in an analog system. reverse output decreases on rise of
input (typical heating response).
alarm: A condition, generated by a binary coded decimal (BCD): A
controller, indicating that the process notation in which the individual decimal control action, derivative (rate) (D):
has exceeded or fallen below the set or digits are represented by a group of The part of the control algorithm that
limit point. binary bits, e.g., in the 8-4-2-1 coded reacts to rate of change of the process
decimal notation each decimal digit is variable.
alarm, band: A type of alarm set up represented by four binary bits.
where a band is created around the control action, integral (reset) (I): The
control setpoint. bezel: The flat portion surrounding the part of the control algorithm that reacts
face of the controller, which holds the to offset between setpoint and process
alarm, deviation: An alarm similar to a keys and display. variable.
band alarm except it only creates a band
on one side of the alarm setpoint. bump: A sudden increase in the output control action, proportional (P):
power initiated by the controller in order Control action in which there is a
alarm, fault: An indication that becomes to determine the system response continuous linear relation between the
active upon loss of process variable. during a self tune procedure. output and the input.
Fault alarm operates in addition to other
alarm assignments. calibration: The act of adjustment or control action, proportional plus
verification of the controller unit by derivative (PD): A control algorithm that
alarm, global : The single physical comparison of the unit’s reading and provides proportional control with the
output to which one or more internal standards of known accuracy and addition of derivative action to compen-
software alarms are tied. stability. sate for rapid changes in process
variable.
alarm, high process variable: A type of cascade control: Control in which the
alarm that is set up to occur when the output of one (controller or) loop is the control action, proportional plus
process variable goes above the alarm setpoint for another (controller or) loop. integral (PI): A control algorithm that
setpoint. provides proportional control with the
closed loop: Control system that has a addition of integral action to compensate
alarm, low process variable: A type of sensing device for process variable for offsets between setpoint and process
alarm that is set up to occur when the feedback. variable.
process variable goes below the alarm
setpoint. cold junction: Point of connection control action, proportional plus
between thermocouple metals and the integral plus derivative (PID): A control
alarm, manual: A type of alarm set up electronic instrument. algorithm that provides proportional
to occur when the controller is put into control with both integral and derivative
manual mode of operation. cold junction compensation: Elec- action.
tronic means used to compensate for
alarm, power up: A type of alarm that the effect of temperature at the cold control, adaptive: (see adaptive
determines alarm condition on power up junction. control)
of the controller.

Glossary
control algorithm: A mathematical dead band: A temperature band earth ground: 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.
control, cascade: (see cascade change in output.
control) engineering unit: Terms of data
dead time: The interval of time be- measurement such as degrees Celsius,
control output: The end product which tween initiation of an input change or pounds, grams, etc.
is at some desired value that is the stimulus and the start of the resulting
result of having been processed or observable response. error: The difference between the
manipulated. actual and the true value, often ex-
default settings: Parameters selec- pressed as a percentage of either span
control mode, automatic: A user tions that have been made at the or full scale.
selected method of operation where the factory.
controller determines the control output. feedback: Process signal used in
derivative: Anticipatory action that control as a measure of response to
control mode, manual: A user senses the rate of change of tempera- control action; the part of a closed-loop
selected method of operation where the ture, and compensates to minimize system which automatically brings back
operator determines the control output. overshoot and undershoot. Also “rate.” information about the condition under
control.
control parameters: User defined derivative action: (See control action,
values that specify how the process is derivative) feed forward control: Control in which
to be controlled. the output of the control loop is ad-
deviation: The difference between the justed based on the process variable
controlled variable: A process variable value of the controlled variable and the and a second variable that is rationed
which is to be controlled at some value at which it is being controlled. and biased.
desired value by means of manipulating
another process variable. digital input: Used in this manual to final control element: Component of a
indicate the status of a dry contact; also control system, such as a valve or
CRC (cyclic redundancy check): An called “gate”. contractor, which directly regulates that
error checking technique in which a flow of energy or material to the
checking number is generated by taking display, 1st: The top, largest display of process.
the remainder after dividing all the bits controller face that is used to display
in a block (in serial form) by a predeter- the process variable value. FM: Factory Mutual Research Corpora-
mined binary number. tion; an organization which sets safety
display, 2nd: The middle display of the standards.
CSA: Acronym for Canadian Standards controller face used to indicate:
Association. Operation Mode — setpoint, deviation gain: The ratio of the change in output
or output.; Tuning and Set Up Mode — to the change in input which caused it.
cycle time: The time necessary to parameter or parameter menu.
complete a full ON-through-OFF period hunting: Oscillation or fluctuation of
in a time proportioning control system. display, 3rd: The bottom display of the process temperature between setpoint
controller face that is used to indicate: and process variable.
cycling (oscillation): A periodic Operation Mode — alarm or error
change in the factor under control message; Tuning of Set up Mode — the hysteresis: In ON/OFF control, the
usually resulting in signal excursions value or choice of the parameter. process variable change necessary to
above and below the control point. change the output from full ON to full
disturbance: An undesired change that OFF.
DIN: Deutsche Industrial Norms, a takes place in a process that tends to
German agency that sets standard for affect adversely the value of a con- icons: Indicators on the face of the
engineering units and dimensions. trolled variable. controller.
damping: The decrease in amplitude of duplex control: Control method where input: Process variable information
an oscillation due to the dissipation of the temperature of the end product is being supplied to the instrument.
energy. maintained by controlling two final
elements using two of the 545 outputs. integral: Control action that automati-
damped, 1/4 amplitude: The loss of cally eliminates offset, or “droop”,
one-quarter of the amount of amplitude duty cycle: Percentage of “load ON between setpoint and actual process
with every oscillation. time” relative to total cycle time. temperature. Also “reset.”

Glossary
internal voltage reference: A precision load: The demand for input to a offset: The difference between the
voltage source within the 545 controller, process. setpoint and the actual process
used to establish internal calibration. variable; or adjustment to actual input
loop: A signal path. temperature and to the temperature
isolation: Electrical separation of values the controller uses for display
sensor from high voltage circuitry. Ioop power: An internal 24-volt current and control.
Allows for application of grounded or limited power supply used to power 2 or
ungrounded sensing element. 4 wire transmitter on the input of the ON/OFF control: Control of a process
controller. variable about a setpoint by turning the
JIS: Japanese Industrial Standards. output full ON below setpoint and full
Also Japanese Industrial Standards low pass input filter: A method to OFF above setpoint.
Committee (JISC). Establishes stan- block fast acting signals (typically
dards on equipment and components. noise), while allowing slow acting open loop: Control system with no
signals (actual process variable) to sensory feedback.
jumper: A wire that connects or pass.
bypasses a portion of a circuit on the optimization: The act of controlling a
printed circuit board. manipulated variable: A quantity or process at its maximum possible level
condition which is varied so as to of performance, usually as expressed in
jumper connectors: The connecting change the value of the controlled economic terms.
device that straddles a jumper to variable. (see also control output)
connect or bypass a portion of a circuit output: Action in response to difference
on a printed circuit board. measuring element: An element which between setpoint and process variable.
converts any system activity or condi-
lag, fixed: a consistant, constant delay tion into a form or language that the output modules: Plug in devices that
in detection of a control variable controller can understand. provide power handling to enable
change. process control. These modules are
mechanical relay: (see relay) either binary (on/off) such as a relay, or
lag, variable : A fluctuating delay in the analog (continuously variable) for
detection of a control value change menu: Groups of parameters arranged current loop control.
(usually the feed forward contribution in the software.
source). overshoot: Condition where tempera-
microcontroller: A large scale inte- ture exceeds setpoint due to initial
linearity: The nearness with which the grated circuit that has all the functions power up or process changes.
plot of a signal or other variable plotted of a computer, including memory and
against a prescribed linear scale input/output systems. P control: Proportioning control.
approximates a straight line.
NEMA 4X: A National Electrical PD control: Proportioning control with
linearization: A function the 545 uses Manufacturers Association standard for rate action.
to automatically linearize a non-linear specifying a product’s resistance to
signal, either from thermocouple or water and corrosion. PI control: Proportioning control with
RTD temperature sensors, through the auto-reset.
use of look up tables. The relationship normally open: A switched output (i.e,
that exists between two variables when relay, etc.) whose unpowered state has PID control: Proportioning control with
the ratio of the value of one variable to no connection. auto-reset and rate.
the corresponding value of the other is
constant over an entire range of normally closed: A switched output parameter(s): A user-defined variable
possibilities. (i.e., relay) whose unpowered state that specifies how a particular function
provides connection. in the 545 will operate.
linearization, custom: User-definable
linearization. noise: An unwanted component of a position proportioning: A type of
signal or variable. control output that utilizes two relays to
linearization, square root: A function control an electric motorized actuator.
the 545 uses to linearize a non-linear noise band: A measurement of the
signal corresponding to the flow being amount of random process “noise” POWERBACK®: Propriertary algorithm
measured by flow transmitters. affecting the measurement of the which monitors the PV to make
process variable. predicitve adjustments to control
load line out: A start up output value parameters in order to reduce or
which is to bring initial output closer to eliminate setpoint overshoot at power
actual steady state output. up or after setpoint changes.

Glossary
POWERTUNE®: Moore Industries' ratio: The value obtained by dividing serial communications: The sending
exclusive self tuning function. Consists one number by another used to or receiving of binary coded data to a
of an on-demand pretune which determine proportions. supervisory device such as a personal
calculates PID values or provides computer or programmable logic
preliminary PID values and process ratio control: Control in which the controller.
information for the second tuning setpoint of one loop is a ratio of the
function. Second tuning function is an process variable of another loop or set up: Also called configuration,
adaptive tuning algorithm that automati- sensor output. selection of hardware devices and
cally adjusts PID values whenever a software routines that function together.
process upset or setpoint change regulate: The act of maintaining a
occurs. controlled variable at or near its setpoint: An input variable which sets
setpoint in the face of load distur- the desired value of a controlled
pretune algorithm: A method by which bances. variable.
the 545 controller initiates an output
value change, monitors the manner of relay (mechanical): An electrome- setpoint, actual: The desired value of
the corresponding process variable chanical device that completes or a controlled variable that the controller
change, and then determines the interrupts a circuit by physically moving is currently acting upon.
appropriate PID control parameters. electrical contacts into contact with
each other. setpoint, deviation from: The number
primary loop: The outer loop in a of units difference between the current
cascade system. relay (solid state): A solid state process variable and the setpoint.
switching device which completes or
process:The equipment for which interrupts a circuit electrically with no setpoint, ramping: A setpoint which is
supply and demand must be balanced, moving parts. determined by the ramp function of the
the system under control excluding the controller where over time, the control-
equipment that does the control. reset: Control action that automatically ler variable reaches a desired value.
eliminates offset, or “droop”, between
process variable: In the treatment of setpoint and actual process tempera- setpoint, target: The end point of the
material, any characteristic or measur- ture. Also “integral” ramp function.
able attribute whose value changes
with changes in prevailing conditions. reset term: (see reset) sheds: In serial communications, when
Common variables are level, pressure the signal is lost.
and temperature. relative gain: An open-loop gain
determined with all other manipulated slidewire position proportioning: An
proportional band: The change input variables constant, divided by the same output algorithm that utilizes a slidewire
required to produce a full range change gain determined with all other controlled feedback signal to determine the actual
in the output due to proportional control variables constant. position of the actuator being con-
action. The area around the setpoint trolled.
where proportional control occurs. retransmission: a feature on the 545
which allows the transmission of a solid state relay: (see relay, solid
RTD: Resistance Temperature Detec- milliamp signal corresponding to the state)
tor. Resistive sensing device displaying process variable, target setpoint or
resistance versus temperature charac- actual setpoint to another devices, stability: The desirable condition in
teristics. Displays positive temperature typically a chart recorder. which input and output are in balance
coefficient. and will remain so unless subject to an
SSR drive: A D.C. on/off signal output external stimulus.
ramping: (see setpoint, ramping) for controlling a solid state relay.
staged outputs: The set up of two
rate: Anticipatory action that senses the sample interval: The time interval analog outputs, where one analog
rate of change of temperature and between measurements or observa- output varies its signal over a portion of
compensates to minimize overshoot. tions of a variable. the PID output range, and the second
Also “derivative.” analog output then varies its signal over
secondary loop: The inner loop of a the remainder of the PID output range.
rate action: The derivative function of a cascade system.
controller. static discharge: Undesirable current
self tune: A method of automatically resulting from the discharge of electro-
rate time: The time interval over which calculating and inserting optimum PID static energy.
the system temperature is sampled for parameters by testing system response
the derivative function. and timing.

Glossary
station address: The unique identifier transmitter (2-wire): A device used to

assigned to a device for communica- transmit data via a two wire current
tions. loop. A two-wire transmitter is loop
powered.
thermocouple: Temperature sensing
device that is constructed of two transmitter (4-wire): A device used to
dissimilar metals wherein a measur- transmit data via a current loop or a DC
able, predictable voltage is generated voltage. A 4-wire transmitter uses 2
corresponding to temperature. wires for data and 2 wires for power.
thermocouple break protection: Fail- triac: Solid state switching device used
safe operation that assures desired to switch alternating current signals on
output upon an open thermocouple and off. Triac circuits are sometimes
condition. referred to as solid state relays (SSR).
thermocouple upscale burnout (▲): trip point: Value which determines

Jumper position that determines when that set of PID values becomes
whether, when a thermocouple fails, its active.
output is replaced by a millivoltage
which will match the thermocouple’s velocity position proportioning: This
maximum value. The jumper connector is a control technique where valve
should be placed in the TC ▲ position. position is determined by calculating
the amount of time it takes to open/
thermocouple downscale burnout close a valve by moving the valve for a
▼ ): Jumper position that determines
(▼ portion of that time.
whether, when a thermocouple fails, its
output is replaced be a millivoltage windup: Saturation of the integral mode
which will match the thermocouple’s of a controller developing during times
minimum value. The jumper connector when control cannot be achieved,
should be placed in the TC ▼ position. which causes the controlled variable to
overshoot its setpoint when the
three mode control: (See control obstacle to control is removed.
action PID)
wild stream: In mixing applications that
time proportioning control: A control require materials to be mixed to a
algorithm that expresses output power desired ratio, this is the one part of the
(0–100%) as a function of percent ON material that is uncontrolled.
versus percent OFF within a preset
cycle time.
time proportioning output: A control-

ler output assigned by software to
facilitate time proportional control
(typically a relay, SSR, or SSR Drive
output).
tracking: A function that defines

whether the local setpoint will track the
remote setpoint. When the controller is
transferred to a local setpoint, that
local setpoint value will match the
remote process value when the
transfer occurs.
transducer:A device which converts

information of one physical form to
another physical type in its output (e.g.,
a thermocouple converts a temperature
difference into millivolts).

Glossary

Isolation Block Diagram
APPENDIX 7
ISOLATION BLOCK DIAGRAM
PV1
Input Output 1
Multiplexer CPU ISO Ground
Referenced
PV2
Input Output 2
ISO Ground
Referenced
RSP
Input Output 3
ISO Ground
Referenced
Power
Slidewire
Input Supply
Output 4
+V ISO Ground
Referenced
+Vd
Digital
Inputs 1-5
RS485 Serial
Communications
ISO
Interface
L +Ve
Line N
G
E
E
Isolated output 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
Earth referenced ground second.
E
2. RSP, Slidewire and the PV inputs are isolated to withstand 50 volts
Internal ground peak between each other for 1 minute.
3. PV1 and PV2 have isolation to 10 volts P-P or continuous between
each other.
4. Milliamp, Loop Power and SSR Drive modules in output
positions 1, 2, 3 and 4 are not isolated from each other.
+V +V
Milliamp Module Mechanical Relay SSR Driver Loop Power SSR Output

Isolation Block Diagram

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 ANY CAUSE OF ACTION FOR BREACH OF ANY WARRANTY BY THE
THE COMPANY MAKES NO EXPRESS, IMPLIED OR STATUTORY WARRAN- COMPANY SHALL BE BARRED UNLESS THE COMPANY RECEIVES
TIES (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FROM THE BUYER A WRITTEN NOTICE OF THE ALLEGED DEFECT OR
FOR A PARTICULAR PURPOSE) WITH RESPECT TO ANY GOODS OR SER- BREACH WITHIN TEN DAYS FROM THE EARLIEST DATE ON WHICH THE
VICES SOLD BY THE COMPANY. THE COMPANY DISCLAIMS ALL WARRAN- BUYER COULD REASONABLY HAVE DISCOVERED THE ALLEGED DE-
TIES ARISING FROM ANY COURSE OF DEALING OR TRADE USAGE, AND FECT OR BREACH, AND NO ACTION FOR THE BREACH OF ANY WAR-
ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY ACKNOWL- RANTY SHALL BE COMMENCED BY THE BUYER ANY LATER THAN
EDGES THAT THERE ARE NO WARRANTIES IMPLIED BY CUSTOM OR TWELVE MONTHS FROM THE EARLIEST DATE ON WHICH THE BUYER
USAGE IN THE TRADE OF THE BUYER AND OF THE COMPANY, AND THAT COULD REASONABLY HAVE DISCOVERED THE ALLEGED DEFECT OR
ANY PRIOR DEALINGS OF THE BUYER WITH THE COMPANY DO NOT IM- BREACH.
PLY THAT THE COMPANY WARRANTS THE GOODS OR SERVICES IN ANY
WAY. RETURN POLICY
ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY AGREES For a period of thirty-six (36) months from the date of shipment, and under
WITH THE COMPANY THAT THE SOLE AND EXCLUSIVE REMEDIES FOR normal conditions of use and service, Moore Industries ("The Company") will
BREACH OF ANY WARRANTY CONCERNING THE GOODS OR SERVICES at its option replace, repair or refund the purchase price for any of its manu-
SHALL BE FOR THE COMPANY, AT ITS OPTION, TO REPAIR OR REPLACE factured products found, upon return to the Company (transportation charges
THE GOODS OR SERVICES OR REFUND THE PURCHASE PRICE. THE prepaid and otherwise in accordance with the return procedures established
COMPANY SHALL IN NO EVENT BE LIABLE FOR ANY CONSEQUENTIAL OR by The Company), to be defective in material or workmanship. This policy
INCIDENTAL DAMAGES EVEN IF THE COMPANY FAILS IN ANY ATTEMPT extends to the original Buyer only and not to Buyer's customers or the users
TO REMEDY DEFECTS IN THE GOODS OR SERVICES , BUT IN SUCH CASE of Buyer's products, unless Buyer is an engineering contractor in which case
THE BUYER SHALL BE ENTITLED TO NO MORE THAN A REFUND OF ALL the policy shall extend to Buyer's immediate customer only. This policy shall
MONIES PAID TO THE COMPANY BY THE BUYER FOR PURCHASE OF THE not apply if the product has been subject to alteration, misuse, accident, ne-
GOODS OR SERVICES. glect or improper application, installation, or operation. THE COMPANY
SHALL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSE-
QUENTIAL DAMAGES.
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© 2006 Moore Industries-International, Inc. Specifications and Information subject to change without notice.
Installation
Form M500 V7
500 SERIES
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 1

M500 V 7, APRIL 2016
Installation
INTRODUCTION
This technical brochure provides hardware installation and modification instructions for our controllers:
Series 531, 532, 535, 545, and 555. Use these instructions with the following kits:
Display Assembly Kits EPROM Kits

531-632 ............... 531 Display Assembly Kit 531-740 ................ 531 EPROM Kit
532-632 ............... 532 Display Assembly Kit 532-740 ............... 532 EPROM Kit
535-632 ............... 535 Display Assembly Kit 535-741 ................ 535 EPROM Kit (RSP)
545-634 ............... 545 Display Assembly Kit 535-775 ............... 535 Profiler EPROM Kit (No RSP)
555-632 ............... 555 Display Assembly Kit 535-776 ............... 535 Profiler EPROM Kit (RSP)
Output and Communications Module Kits 535-740 ................ 535 EPROM Kit (No RSP)
532-600 ............... 531, 532 Analog Module Kit 545-740 ................ 545 EPROM Kit (No RSP)
535-600* .............. Mechanical Relay Module Kit 545-741 ................ 545 EPROM Kit (RSP)
535-601* .............. Milliamp Module Kit 555-740 ................ 555 EPROM Kit
535-602* .............. SSR Module Kit Microcontroller (MCU) Board Kits
535-603* .............. SSR Drive Module Kit 535-731 ............... MCU Board Kit
535-604* .............. Loop Power Module Kit 545-733 ............... MCU Board Kit with CE Option
535-705* .............. RS-485 Communications Module Kit Option Board Kits
Power Supply Kit 535-720 ............... 531, 532, 535, 545 Option Board Kit
535-730* .............. 90 to 250VAC Power Supply Kit (No Options)
535-732 ............... 24VAC/VDC Power Supply Kit 535-721 ............... 531, 532, 535, 545 Option Board Kit
Mounting Kit (Digital Inputs)
535-761* .............. Mounting Kit 535-722 ............... 535, 545 Option Board Kit
(Slidewire Feedback)
Miscellaneous Kits 535-723 ............... 535, 545 Option Board Kit
532-100 ............... 531, 532 Bypass Board Kit (Digital Inputs and Slidewire Feedback)
535-188* .............. Rear Terminal Upgrade Kit 545-724 ............... 531, 532, 535, 545, 555 Option Board Kit
535-660 ............... 531, 532, 535, 545, 555 Jumper Kit (RSP)
535-662* .............. Gasket Kit 545-725 ............... 531, 532, 535, 545, 555 Option Board Kit
(1 Panel Gasket, 1 Bezel Gasket) (Digital Inputs and RSP)
535-763* .............. Bezel Retention Screw Kit 545-726 ............... 535, 545, 555 Option Board Kit
535-664* .............. Module Retention Kit (Slidewire Feedback and RSP)
(Retention Plate and Tie Wrap) 545-727 ............... 535, 545, 555 Option Board Kit
535-665* .............. Module Retention Tie Wrap Kit (Digital Inputs, Slidewire Feedback,
093-128* .............. Lithium Battery and RSP)
* Universal Kit (can be used with all 500 Series Controllers)
HOW TO USE THIS MANUAL:

A. CAUTION: Static discharge will cause damage to equipment. Always ground yourself with a wrist grounding
strap when handling electronics to prevent static discharge.
B. Before removing or inserting any hardware on the controller, copy down all configuration parameters. Also,
replacing the battery, EPROM or MCU Board will erase parameter settings and they will need to be reset.
C. For all hardware adjustments, perform steps 1, 2 and 3.
D. Follow the guide and complete any additional steps as required by your particular application.
E. Complete your hardware adjustments with steps 15, 16, 17, 18, 19 & 20.
EQUIPMENT
To make any hardware changes to the units, you will need the following equipment:
• Wrist grounding strap • Phillips screwdriver (#2)
• Small flat blade screwdriver • Wire cutters
• I.C. Extractor (if changing the EPROM)
2 500 Series Installation Guide

Installation
INSTRUCTIONS one of the larger two boards from the Option
Board (Photo 4). Be careful not to bend the
To Disassemble the Unit connector pins. Separate the other board in the
same manner.
For any hardware modifications, disassemble the unit.
Figure 2 (opposite page) shows the Microcontroller
1. With power off, loosen four captive front screws with
Board, Option Board and Power Supply Board.
a Phillips screwdriver. Remove the four screws.
To Add or Change Output Modules
The 500 Series units have provisions for four output
modules. The units come factory configured with
specified modules installed in appropriate locations.
You can make field modifications by properly remov-
ing and/or adding the modules into the appropriate
sockets.
Three of the output sockets are located on the Power
Supply Circuit Board. A fourth output socket is
located on the Option Board (refer to Figure 2).
5. A retention plate
and tie wrap hold
Figure 1
Output modules 1, 2,
Location of Printed Circuit Boards for Hardware
and 3 (on the Power
Configuration
Supply board) firmly
2. Slide the chassis out of the case by pulling on front in place. To remove
face plate assembly at the bezel (see Figure 1). the retention plate,
snip the tie wrap
3. Locate the retention with wire cutters
clips holding the front (Photo 5).
face assembly to the
rest of the chassis.
Pry apart these Photo 5.
retention clips gently Remove Retention Plate
with a screwdriver to
separate the printed CAUTION: Always snip the tie wrap on top of the
circuit board group Retention Plate, as shown in photo 5, to prevent
from the front face damage to the surface mount components.
assembly (Photo 3). 6. A disposable tie wrap
Take care not to Photo 3. Pry Clips holds Output module
break the clips or 4 (on the Option
scratch the circuit board. board) in place. To
The Microcontroller Board and Power Supply Board remove the module,
remain attached to the Operator Interface Assem- snip the tie wrap
bly by wired connectors. (Photo 6).
4. The Microcontroller 7. Inspect each module

and Power Supply before installation to
board are attached make sure the pins
to either side of the are straight. Align
Option board by the pins with the Photo 6.
male/female pin socket holes and Snip Tie Wrap on Mod. 4
connectors. Use a carefully insert the
gentle rocking motion module. Press down on the module to seat it
and carefully apply firmly on the board.
pressure in a uniform
direction to separate
Photo 4. Separate Boards

Installation
NOTE:
Front of Unit Back of Unit If you replace the EPROM chip, you
(toward Operator Interface) (toward rear terminals) must align the notch facing the front
of the unit.
EPROM
TB2
V
BATTERY MA
TC
TC
2ND
RTD
V
5-Pin Connector
MA
TC
PV1
TC
Female 22-Pin Connector Female 22-Pin Connector RTD
NOTE:
TB1 The 5- and 22-Pin connnectors on
the boards are all keyed so they
will only align one correct way.
Male 22-Pin Remote Setpoint Jumper Male 22-Pin

Connector Connector
Output 4
Male 12-Pin Male 22-Pin

Connector Connector
Figure 2
12-Pin Female 22-Pin Female Microntroller Board,
Connector Connector Option Board, and
Power Supply Board
NO J3 NC
5-Pin Connector
NO J1 NC NO J2 NC
Module
Retention
Plate
over Outputs 1,2,3
Jumpers
NO and NC
4 500 Series Installation Guide

Installation
8. Replace tie wraps for the Retention Plate and for To Change the EPROM
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.
failure. If you ordered a module separately, Use an I.C. Extractor to carefully remove the
it should have come with a tie wrap. An EPROM. If you do not have an I.C. extractor,
extra set of tie wraps is available by order- gently use a small flat blade screwdriver to pry up
ing Part #535-665. the EPROM. DO Not bend the EPROM legs.
Note: For greatest accuracy, milliamp
modules added for retransmission must be 14. Carefully insert the new EPROM. To position
calibrated per instructions in Operator's correctly, match the notched end of the EPROM to
Manual. the markings on the board. The notched end will
face towards the display. Make sure all pins are in
To Change the Option Board the socket.
9. (See Photos 3 and 4) Replace the existing Option
To Reassemble the Unit
board with the NEW one.
Note: When adding Option board for 5 15. (See Figure 2) Align the connector pins on the
digital inputs, associated screw terminal in Option Board with the connector sockets on the
the rear terminal block must be installed. Microcontroller and Power Supply boards.
(See information on page 1 for ordering a Squeeze them together, making certain all three
Screw Kit.) are properly seated against one another. Check
along the side edges for gaps. Make sure the
To Change the Power Supply or conector is properly aligned. Also, check that the
Microcontroller (CPU) Board cable assemblies are not pinched.
10. For the Microcontroller Board, disconnect the 5-pin 16. (See Figure 2) Align the board assembly with the
female connector that wires it to the Display front face assembly, with the Option board at the
Assembly. Reattach the connector to the new bottom (see Figure 1). Reinstall the retention
board. You can only orient the connector one way. clips. Align the boards into the slots of the front
For the Power Supply Board, disconnect the 5-pin face assembly and the clips will snap into place.
female connector that wires it to the Display
Assembly. Reattach the connector to the new 17. When you are ready to reassemble the unit, align
board. You can only orient the connector one way. the boards in the chassis with the case's top and
bottom grooves. Press firmly to slide the chassis
To Change the Display Assembly into the case. If you have difficulty, check that you
11. Disconnect the 5-pin female connector that wires have properly oriented the chassis, and there are
the Microcontroller Board to the Display Assembly. no screws interfering with the case.
Disconnect the 5-pin female connector that wires
the Power Supply Board to the Display Assembly. 18. Carefully insert and align screws. Tighten them
until the bezel is seated firmly against the gasket.
12. Attach the new Display Assembly to the boards at DO NOT OVERTIGHTEN.
the appropriate connectors.
19. If may be necessary to re-configure the software
CAUTION features of your controller or station. Please refer
Static discharge will cause damage to equip- to your User’s Manual.
ment. Always ground yourself with a wrist
20. To maintain NEMA 4X Rating, you may need new
grounding strap when handling electronics
mounting gaskets, order part #535-662. Refer to
to prevent static discharge.
your user’s manual.
CAUTION
Do not scratch the boards or bend the pins of the
connectors.

User’s Manual Supplement
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.
Controller Board with removable Lithium Battery. Older
models required to be serviced by Moore Industries
to replace Lithium Battery which was soldered directly
on the board, this is an inconvenience and has been
resolved with a Micro Controller Board that has a
replaceable Lithium Battery slot.
To replace battery in your 500 Series unit follow

previous instructions found in M500 V6. Use a flat head
screwdriver to release battery and replace.
Figure 1. Removable Lithium Battery
EPROM
BATTERY
INSERT FLAT
HEAD SCREWDRIVER
TIP HERE TO
RELEASE BATTERY
5-Pin Connector
Female 22-Pin Connector Female 22-Pin Connector
The Interface Solution Experts www.miinet.com

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 ANY CAUSE OF ACTION FOR BREACH OF ANY WARRANTY BY THE
THE COMPANY MAKES NO EXPRESS, IMPLIED OR STATUTORY WARRAN- COMPANY SHALL BE BARRED UNLESS THE COMPANY RECEIVES
TIES (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FROM THE BUYER A WRITTEN NOTICE OF THE ALLEGED DEFECT OR
FOR A PARTICULAR PURPOSE) WITH RESPECT TO ANY GOODS OR SER- BREACH WITHIN TEN DAYS FROM THE EARLIEST DATE ON WHICH THE
VICES SOLD BY THE COMPANY. THE COMPANY DISCLAIMS ALL WARRAN- BUYER COULD REASONABLY HAVE DISCOVERED THE ALLEGED DE-
TIES ARISING FROM ANY COURSE OF DEALING OR TRADE USAGE, AND FECT OR BREACH, AND NO ACTION FOR THE BREACH OF ANY WAR-
ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY ACKNOWL- RANTY SHALL BE COMMENCED BY THE BUYER ANY LATER THAN
EDGES THAT THERE ARE NO WARRANTIES IMPLIED BY CUSTOM OR TWELVE MONTHS FROM THE EARLIEST DATE ON WHICH THE BUYER
USAGE IN THE TRADE OF THE BUYER AND OF THE COMPANY, AND THAT COULD REASONABLY HAVE DISCOVERED THE ALLEGED DEFECT OR
ANY PRIOR DEALINGS OF THE BUYER WITH THE COMPANY DO NOT IM- BREACH.
PLY THAT THE COMPANY WARRANTS THE GOODS OR SERVICES IN ANY
WAY. RETURN POLICY
ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY AGREES For a period of thirty-six (36) months from the date of shipment, and under
WITH THE COMPANY THAT THE SOLE AND EXCLUSIVE REMEDIES FOR normal conditions of use and service, Moore Industries ("The Company") will
BREACH OF ANY WARRANTY CONCERNING THE GOODS OR SERVICES at its option replace, repair or refund the purchase price for any of its manu-
SHALL BE FOR THE COMPANY, AT ITS OPTION, TO REPAIR OR REPLACE factured products found, upon return to the Company (transportation charges
THE GOODS OR SERVICES OR REFUND THE PURCHASE PRICE. THE prepaid and otherwise in accordance with the return procedures established
COMPANY SHALL IN NO EVENT BE LIABLE FOR ANY CONSEQUENTIAL OR by The Company), to be defective in material or workmanship. This policy
INCIDENTAL DAMAGES EVEN IF THE COMPANY FAILS IN ANY ATTEMPT extends to the original Buyer only and not to Buyer's customers or the users
TO REMEDY DEFECTS IN THE GOODS OR SERVICES , BUT IN SUCH CASE of Buyer's products, unless Buyer is an engineering contractor in which case
THE BUYER SHALL BE ENTITLED TO NO MORE THAN A REFUND OF ALL the policy shall extend to Buyer's immediate customer only. This policy shall
MONIES PAID TO THE COMPANY BY THE BUYER FOR PURCHASE OF THE not apply if the product has been subject to alteration, misuse, accident, ne-
GOODS OR SERVICES. glect or improper application, installation, or operation. THE COMPANY
SHALL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSE-
QUENTIAL DAMAGES.
United States • info@miinet.com Belgium • info@mooreind.be China • sales@mooreind.sh.cn

Tel: (818) 894-7111 • FAX: (818) 891-2816 Tel: 03/448.10.18 • FAX: 03/440.17.97 Tel: 86-21-62491499 • FAX: 86-21-62490635
Australia • sales@mooreind.com.au The Netherlands • sales@mooreind.nl United Kingdom • sales@mooreind.com
Tel: (02) 8536-7200 • FAX: (02) 9525-7296 Tel: (0)344-617971 • FAX: (0)344-615920 Tel: 01293 514488 • FAX: 01293 536852
© 2006 Moore Industries-International, Inc. Specifications and Information subject to change without notice.

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5 4 5

M545 V 8, MARCH 2 017

About This Manual:

545 User's Manual Table of Contents i

ii Table of Contents 545 User's Manual

545 User's Manual Table of Contents iii

iv Table of Contents 545 User's Manual

FIGURE DESCRIPTION PAGE

545 User's Manual Table of Contents v

vi Table of Contents 545 User's Manual

Specifications and information subject to change without notice.

545 User's Manual Chapter 1 1

ORDER CODE, PACKAGING INFORMATION

TEXT FORMATTING IN THIS MANUAL

ICONS OUT, ALM

2 Chapter 1 545 User's Manual

Output 2: Control, Alarm, or Retransmission

Output 3: Control, Alarm, Retransmission, or Loop Power

Output 4: Control, Alarm, Retransmission, or Loop Power

545 User's Manual Chapter 1 3

4 Chapter 1 545 User's Manual

MANUAL: Press to toggle between manual and automatic control.

SET PT: Press to select the active setpoint.

FAST+DISPLAY: Toggles between the background loop and foreground loop.

▲ : Press to increase the value or selection of displayed parameter.

▲ : Press to scroll through values at a faster rate.

▼ : Press to decrease the value or selection of displayed parameter.

▼ : Press to scroll through values at a faster rate.

FAST+MENU: Press to access the Set Up menus.

6 Chapter 2 545 User's Manual

BASIC OPERATION PROCEDURES

545 User's Manual Chapter 2 7

4. If code is incorrect, INCORRECT appears in the 3rd display. INCORRECT

8 Chapter 2 545 User's Manual

BEFORE AFTER NOTE:

MANUAL DISPLAY SET PT MANUAL DISPLAY SET PT

545 User's Manual Chapter 2 9

10 Chapter 2 545 User's Manual

MOUNTING THE CONTROLLER

7.180 (182.37) OVERALL LENGTH

3.653 (92.80) MAX.

MANUAL DISPLAY SET PT

ACK MENU FAST

BEZEL 6.000 (152.40)

Mounting Collar Collar Screws (1 of 4)

545 User's Manual Chapter 3 11

TOP (as viewed from back of controller)

OUT 1– 3 11 S/W 2 DIN 2 19 27 COMM+

OUT 1+ 4 12 S/W 3 DIN 3 20 28 PV2–

Terminal 9 must be grounded to avoid

12 Chapter 3 545 User's Manual

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

Process Variable Input

EARTH/ Figure 3.4

Screws must be tight to ensure good electrical connection

The 545 accommodates the following types of process variable inputs:

Screws must be tight to ensure good electrical connection

545 User's Manual Chapter 3 13