Process & TEMPERATURE Controllers

NOVA PD540 Series

• Thermocouple, RTD, & Process Inputs

• High Accuracy Auto-Tuning PID
• Heating & Cooling Models
• Universal Power Supply 100-240 VAC
• Up to 3 Relays & 2 Analog Outputs
• Digital Input Set Point Selection
• RS-485 Serial Communications Option
• Modbus RTU/ASCII Communications
®

• Free Operating & Data Logging Software

• IP55 & IP65 Fronts
• 1/16, 3/16, 1/8, 1/4 DIN Sizes
• 3 Year Warranty

Precision Digital Corporation www.predig.com

 NOVA PD540 Series process & temperature controllers
Custom Operating Displays Setup Group Menus
The Nova Digital Controller has dual four-digit LEDs and can For easy setup parameter navigation, all parameters are
display commonly used setup parameters defined by the user. grouped by category. To access the group menus, press and
hold the SET/ENT button for 3 seconds. Navigate through the
Operating Display Navigation group menus using the UP or DOWN arrow buttons as shown.
To enter a group menu to access setup parameters, press the
To access additional display information without the need to
SET/ENT button.
enter the setup menus, simply press the SET/ENT button.

Main Operating Display

• PV window displays process variable Button PV Display Group Definition
• SP window displays set point q G.AT Auto-Tuning Group
• Press the SET/ENT button to move to
the next display window
pq G.SP Set Point Group

pq G.PID P.I.D. Group

ENT PwD Password
Percent Output Display
• PV window displays process variable pq G.CTL Control Group
• SP window displays the operating level pq G.IN Input Group
of the control outputs as % of full scale
• Press the SET/ENT button to move pq G.oUT Output Group
to the next display window pq G.ALm Alarm Group

User Defined Display 1

pq G.RET Retransmission Group

• Display any setup parameter pq G.Com* Communications Group*

• Parameters are fully functional, and can *This group menu appears only on models with the serial communications option.
be set through this display
• Set by the user with parameter US1
• Press the SET/ENT button to move to
Menu Password
the next display window To prevent unauthorized changes to key parameters, a user
defined lockout password must be entered to access the
group menus that are not commonly used during operation.
User Defined Display 2 Enter the password at the prompt when navigating the
• Display any setup parameter group menus by pressing the SET/ENT button. The default
• Parameters are fully functional, and password is 0.
can be set through this display
• Set by the user with parameter US2 Easy to Use Menu Structure
• Press the SET/ENT button to return to Each parameter is located in an associated menu group.
the main operating display    ENT 
P uD
~
G.AT G.SP G.PID G.CTL
Easy Setup & Programming SET/ENT

R-S • Hold the SET/ENT button for

All programming of a Nova Digital Controller is done through
SET/ENT 3 seconds to enter the group menu
the front panel. No switches or jumpers are required.
SPSL • Select the menu group using
Front Panel Buttons SET/ENT
the p and q buttons
• Press SET/ENT to access the
• Press the SET/ENT button to confirm an entered value. SP1
parameters in the group
Hold the button for 3 seconds to enter or exit the setup SET/ENT
• Set the value for the parameter,
groups. Press the SET/ENT button to access the next SP2 and press SET/ENT to select
parameter when in a setup group. SET/ENT the next parameter
• Press the Up arrow button to increase numerical values or
D.SLP • Hold the SET/ENT button for
scroll through parameter options and group menus.
SET/ENT 3 seconds to return to the
• Press the Down arrow button to decrease numerical values or operating display
scroll through parameter options and group menus.
• Press the LEFT arrow button to move to the next digit For a complete list of setup parameters, their functions, and
during numerical value programming. setting options, refer to the PD540 Series Instruction Manual.

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 NOVA PD540 Series process & temperature controllers
Process & Temperature Inputs Input Bias Adjustment
Nova Controllers use a single universal input that accepts process Up to five bias points can be used to provide precise offset
and temperature inputs. adjustments at specific input values. The controller will use the
offset to create a smooth input value curve leading up to the bias
Thermocouple: J, K, T, E, R, B, S, L, N, U, W, Platinel II points.
RTD: Pt100 (0.00385), JPt100 (0.00392)
On/Off Timers
Process: -10 to 20 mV, 0 to 100 mV The start timer delays control output operation from power-
0.4 to 2 V, 1 to 5 V, 0 to 10 V up. The process timer determines how long the control outputs
4 to 20 mA input with a resistor shunt will run after starting. These timers may run up to 99 hours 59
minutes, or be turned off.
VERSATILE OPERATION
Powerful standard and optional features such as universal inputs,
Start Time Process Time
up to three relays and two analog outputs, two digital inputs, and
serial communications make this controller applicable for most u
process or temperature control applications. STOP RUN STOP
POWER

Programmable Relays
ON

All PD540 Series controllers have a standard 3 A Form C (SPDT)

relay. Up to two additional 1 A Form A (SPST) relays. All relays Digital Input Set Point Selection
can be programmed for numerous control or alarm functions. Two digital inputs can be added as an optional feature. Digital
• Time-Proportional PID Control inputs are activated by closing contacts or low logic levels.
• On/Off Control The configuration of the two inputs can select which of the 4
• High/Low Alarms programmable set points to run or turn the control outputs on and
• Set Point Deviation Alarms off while selecting one of two programmable set points.
• Fail-Safe and Standby Alarms
• Alarm Delays and Deadbands
DI Selection Input 1 Input 2 Function
Analog Output Configurations
Up to two analog outputs are available on all PD540
Series controllers. Each analog output can be programmed
independently, and numerous output types are selectable.
• 4-20 mA PID Control
• 4-20 mA Retransmitting
• Time-Proportional PID Voltage Pulse
• Transmitter Loop Power Supply

Auto-Tuning PID Normally open switches (external excitation not required)

A high accuracy auto-tuning function using Fuzzy Logic calculates or open collector transistor
the PID values for your system with the push of a button,
eliminating the need for complex PID calculations and time
consuming setup. After several on/off cycles, the PID values will Serial Communications & Adapters
be setup automatically. Nova controllers with the serial communications option can
be used for data acquisition, master/slave set point control,
Gain Adjustment or Modbus communication (RTU and ASCII). Nova controllers
Adjustments to system control characteristics can be done after transmit via RS-485. The PDA7485 RS-232 to RS-485 and
auto-tuning with the programmable Gain function. Increasing the PDA8485 USB to RS-485 converters are available for use with
Gain will increase accuracy and reduce overshoot. Lowering the the Nova Multi-Monitoring software or other PC applications.
Gain will let the system reach the set point faster.

Gain < 1
Gain = 1

Gain > 1
PDA7485
PV Reactions to SP Change Based on Gain
PDA8485

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 NOVA PD540 Series process & temperature controllers
Sync Master/Slave Set Point Control
PD540 Series Digital Controllers with the serial communications
option can use Sync set point control. By connecting controllers
together using the RS-485 serial communication capability, one
controller can control the set point of an entire string.

Sync Master
Changing the set point of the Sync Master
controller will change the set points on all
Sync Slave controllers.
RS-485

Simultaneously View Up to 30 Nova Controllers

Remotely Control Set Points

Program each of the 4 set points through a detailed operation
screen available for every connected controller. In addition,
control outputs can be set to run or stop, auto tuning enabled,
Slave 1 Slave 2 Slave 3 Slave 4 and automatic or manual control established.

Nova PC Software
Any Nova Controller with the serial communications option can
be configured to interface with the Nova Multi-Monitoring PC
software. Up to 30 controllers can be monitored and operated,
and each can use independent data logging.
• Easy to Set Up and Use
• Connect up to 30 Nova Controllers
• View PV, SP, and Alarm Status Simultaneously
• Control Set Points
• Log, View, and Save Data in Spreadsheet Files
• Free Download from www.predig.com

Specifications Monitor and Control Common Parameters

System Requirements: Windows® 95\98\ME\2000\XP
Communications: An RS-232 to RS-485 or USB to RS-485 Data Acquisition
converter may be used for communication with a PC and Nova
PV and SP data can be logged independently for each unit. This
Multi-Monitoring Software.
data can be graphed using the Data Viewer for quick and clear
Number of Units: Up to 30 Nova Controllers
analysis. Logged data can be exported into spreadsheet format.
Baud Rate: 9,600 to 19,200 bps
Data Logging: Graph and save data as .hdr format. Each
controller saves graphs independently. Data exportable in
spreadsheet format.
Logging Interval: 1 second to 24 hours

Simultaneous Monitoring
Simultaneously monitor up to 30 Nova Controllers and view
the PV, SP, and alarm status for all connected controllers. The
main view screen also displays the basic model numbers of all
connected units. Any series of Nova Controllers with the serial
communications option may be monitored with this software.

View Logged Data Graphs and Export Data

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 NOVA PD540 Series process & temperature controllers
CONNECTIONS
PD540 & PD541 NO switches (external excitation not required) or open collector transistor
Open circuit voltage:
approximately 5 VDC

Logic levels:
LO = 0 to 0.8 VDC
HI = 4.7 to 28 VDC

4-20 mADC or Voltage Pulse

MAX: 19200bps

Rating: 250 VAC @ 3 A

30 VDC @ 3 A

100 - 240 VAC 50/60 Hz

4-20 mADC or Voltage Pulse Rating: 250 VAC @ 1 A

30 VDC @ 1 A

PD542 & PD543

100 - 240 VAC 50/60 Hz 4-20 mADC or Voltage Pulse

Rating: 250 VAC @ 3 A
30 VDC @ 3 A

Open circuit voltage:

approximately 5 VDC

Logic levels:
20 19 18 17 16 15 14 13 12 11 LO = 0 to 0.8 VDC
HI = 4.7 to 28 VDC

10 9 8 7 6 5 4 3 2 1

NO switches (external excitation not required)

or open collector transistor

MAX: 19200bps Rating: 250 VAC @ 1 A Rating: 250 VAC @ 1 A

30 VDC @ 1 A 30 VDC @ 1 A

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 NOVA PD540 Series process & temperature controllers
PD544 & PD545
NO switches (external excitation not required) or open collector transistor
Open circuit voltage:
approximately 5 VDC

Logic levels:
- LO = 0 to 0.8 VDC
HI = 4.7 to 28 VDC

MAX: 19200bps

Rating: 250 VAC @ 3 A

30 VDC @ 3 A

Rating: 250 VAC @ 1 A

30 VDC @ 1 A

4-20 mADC or Voltage Pulse

Rating: 250 VAC @ 1 A

30 VDC @ 1 A

100 - 240 VAC 50/60 Hz

4-20 mADC or Voltage Pulse

PD546 & PD547

Rating: 250 VAC @ 1 A

30 VDC @ 1 A

Rating: 250 VAC @ 3 A

30 VDC @ 3 A
Rating: 250 VAC @ 1 A
30 VDC @ 1 A

4-20 mADC or Voltage Pulse

MAX: 19200bps

Open circuit voltage:

approximately 5 VDC
100 - 240 VAC 50/60 Hz Logic levels:
LO = 0 to 0.8 VDC
HI = 4.7 to 28 VDC

NO switches (external excitation not required) or open collector transistor

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 NOVA PD540 Series process & temperature controllers
PD548 & PD549

Rating: 250 VAC @ 1 A

30 VDC @ 1 A

Rating: 250 VAC @ 3 A

30 VDC @ 3 A
Rating: 250 VAC @ 1 A
30 VDC @ 1 A

4-20 mADC or Voltage Pulse

MAX: 19200bps

100 - 240 VAC 50/60 Hz

Open circuit voltage:

approximately 5 VDC
Logic levels:
LO = 0 to 0.8 VDC
HI = 4.7 to 28 VDC

NO switches (external excitation not required) or open collector transistor

Model Number Guide

The following guide describes the possible PD540 Series Nova Digital Process & Temperature Controller model numbers.
Refer to the price list for the complete list of models and accessories.

P D 5 4 0 - 6 R A - 0 0

Digital Controller

Size - DIN Cutout Options

0, 1 = 1/16 DIN 00 = None
2, 3 = 1/8 DIN (H) Notes: PD540, PD541:
4, 5 = 3/16 DIN 0, 2, 4, 6, 8 = Heating or Cooling
11 = 1 relay & 2 digital inputs
6, 7 = 1/8 DIN (V) 1, 3, 5, 7, 9 = Heating & Cooling
14 = 1 relay & RS-485
8, 9 = 1/4 DIN 31 = 1 analog output & 2 digital inputs
Power 34 = 1 analog output & RS-485
6 = 100-240 VAC PD544, PD545:
Display 04 = RS-485
R = Red LED 51 = 2 relays, 1 analog output & 2 digital inputs
Main Control Outputs 54 = 2 relays, 1 analog output & RS-485
PD540, PD541, PD544, PD545: PD542, PD543, PD546 to PD549:
A = 1 relay & 1 analog output 21 = 2 relays & 2 digital inputs
PD542, PD543, PD546 to PD549: 24 = 2 relays & RS-485
B = 1 relay & 2 analog outputs

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 NOVA PD540 Series process & temperature controllers

Dimensions and Panel Cutouts Units: inches

(44.8 x 44.8)
(mm)

1.76 x 1.76
PD540 & PD541
1/16 DIN (48 x 48) 2.76
(70)

0 )
(45 +0.6
(55.2)

1.77
2.17
1.89
(48)

2.76
(70)
1.89 x N

0 )
(45 +0.6
1.77
(48xN-3 +20 )
1.89 0.43 3.92 1.77
(48) (10.9) (99.6) (45 +0.6
0 )
PD542 & PD543
4.72
1/8 DIN (H) (96 x 48)
(120)

(44.6 x 91.6)
1.76 x 3.61
1.89
(48)

2.76
(70)
0 )
(45 +0.6
1.77
3.78 .45 3.92
(96) (11.4) (99.6) 3.62
PD544 & PD545 (92 +0.6
0 )

3/16 DIN (72 x 72) 3.54

(90)
(67.2 x 67.2)
2.65 x 2.65

0 )
(68 +0.6
2.83

2.68
(72)

3.54
(90)

0 )
(68 +0.6
2.80xN

2.68
(71xN-3 +20 )
2.83 0.45 3.92 2.68
(72) (11.4) (99.6) (68 +0.6
0 )
2.76
PD546 & PD547 (70)
1/8 DIN (V) (48 x 96)
(91.6 x 44.6)

0 )
3.61 x 1.76

(92 +0.6
3.62
(107.5)
4.23
3.78
(96)

(120)
4.72

1.89xN
0 )
(92 +0.6
3.62

1.89 0.45 3.92 (48xN-3+20 )

(48) (11.4) (99.6) 1.77
(45 +0.6
0 )
PD548 & PD549 4.72
1/4 DIN (96 x 96) (120)
(91.6 x 91.6)

0 )
3.61 x 3.61

(92 +0.6
3.62
(107.5)
3.78
(96)

4.23

(120)
4.72

3.78xN
0 )
(92 +0.6
3.62

3.78 0.45 3.92 (96xN-4 +0.2

0 )

(96) (11.4) (99.6)

3.62
(92 +0.6
0 )
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 NOVA PD540 Series process & temperature controllers
SPECIFICATIONS Process Inputs
Inputs: Field selectable: 0.4 to 2.0 V, 1 to 5 V, 0 to 10 V,
Except where noted all specifications apply to operation at +25°C.
-10 to 20 mV, 0 to 100 mV. 4-20 mA input requires 100 Ω resistor connected
General across input terminals (order P/N: PDX-RES1).
Accuracy: ±0.1% FS ±1 count
Display: Dual 4 digits, red LED, -1999 to 9999
Decimal Point: Up to 3 decimals: 9.999, 99.99, 999.9, or 9999
DIN PV Display SP Display Weight Calibration: All inputs are calibrated at the factory
Sizes Inch (mm) Inch (mm) oz (g) Scale Range: User programmable over entire range
1/16 0.45 (11.3) 0.37 (9.5) 7.0 (198) Transmitter Supply: 14 to 18 VDC @ 20 mA; available at terminals OUT2 or
OUT3, instead of retransmitting analog output; selection through front panel.
3/16 0.55 (14.0) 0.47 (12.0) 11.4 (324)
1/8 (H) 0.78 (19.8) 0.45 (11.5) 10.8 (306) Relays
Ratings: 1 Form C (SPDT) standard; rated 3 A @ 30 VDC or
1/8 (V) 0.54 (13.6) 0.41 (10.5) 10.7 (304) 3 A @ 250 VAC resistive load. 1 or 2 Form A (SPST) optional; rated
1/4 0.81 (20.5) 0.43 (11.0) 13.7 (389) 1 A @ 30 VDC or 1 A @ 250 VAC resistive load.
Relay Operation: Time proportional PID control, on/off control, forward or
Front Panel: Panel gasket provided. reverse (fail-safe) alarm, or run status
1/16 & 1/8 DIN: IP65, 3/16 & 1/4 DIN: IP55 Cycle Time: 1 to 300 seconds; time proportional PID control only
Programming Methods: Four front panel buttons and Modbus On/Off Hysteresis: For standard models, 0-10.0% of sensor range for
Number of Set Points: Four programmable set points independent high and low hysteresis limit. For heating & cooling models,
Noise Filter: Programmable 1 to 120 seconds or off 0-10.0% of sensor range full hysteresis band.
Display Update Rate: 4/second High/Low Alarm: User may program any alarm for absolute high or low
Password: Restricts modification of programmed settings. trigger values.
Non-Volatile Memory: Settings stored for a minimum of 10 years. Deviation Alarm: User may program any relay for high, low, or high/low range
Power: 100-240 VAC, 50/60 Hz, 10 W set point deviation alarm.
Required Fuse: UL Recognized, 1 A, 250 V, slow-blow Alarm Deadband: 0-100% FS, user selectable
Isolation: 2300 V input/output-to-power line; 4 kV relay output-to-input/ Alarm Delay: 0 to 99 minutes and 59 seconds
output/power line. Reverse Operation (Fail-Safe): Programmable, independent for each alarm.
Operating Temperature: 10 to 50°C Relay coils are energized in non-alarm condition. In case of power failure,
Storage Temperature: -40 to 85°C relays will go to alarm state.
Relative Humidity: 20 to 90% non-condensing Forward Operation: Relay coils are energized in alarm condition. In case of
Enclosure: 1/16, 3/16, 1/8(H), 1/8(V), 1/4 DIN; impact-resistant plastic; power failure, relays will go to non-alarm state.
color: black Auto Alarm Initialization: Normal and standby operation independent for
Approvals: UL & C-UL Recognized, CE Compliant each alarm. Normal alarms will reflect the state of the input to the controller at
UL File Number: E244207; Process Control Equipment all times. Standby alarms will not trigger if the change to alarm state is a result
Warranty: 3 years parts & labor of power up cycle, set point change, or alarm configuration change.
Extended Warranty: 1 or 2 years, refer to Price List for details. Run Status: Relays will energize when PID outputs are running.
Temperature Inputs Analog Outputs
Inputs: Factory calibrated, field selectable: J, K, T, E, B, R, S, L, U, N, W, Scaling Range: Retransmitting 4-20 mA outputs can be scaled for any
Platinel II thermocouples, and 100 Ω platinum RTD (0.00385 or 0.00392 curve) display range.
Cold Junction Reference: Automatic or off Accuracy: ±0.1% FS
Offset Adjustment: Four programmable input bias zones Availability: 1/16 & 3/16 DIN: 1 standard, 1 optional
Sensor Break: Up or down scale, user selectable; display reads S.OPN; 1/8 & 1/4 DIN: 2 standard
alarm relays will follow the up or down scale selection. Output Operation: 4-20 mA PID control, time proportional voltage pulse PID
control, or 4-20 mA retransmitting
Type Range (ºC) Range (ºF) Accuracy* Ratings: Continuous 4-20 mA PID or retransmitting: 600 Ω max
K1 -200 to 1370 -300 to 2500 Time Proportional PID: 15 VDC pulse high, less than 0.1 VDC pulse low;
600 Ω minimum, current limited at 30 mA
K2 -199.9 to 999.9 0 to 2300
>0ºC: ±0.1% FS ±1 count Cycle Time: 1 to 300 seconds; time proportional PID control only
J -199.9 to 999.9 -300 to 2300 <0ºC: ±0.2% FS ±1 count Power: Internally powered 4-20 mA output
Isolation: 500 V input-to-output
T -199.9 to 400.0 -300 to 750
Output Loop Resistance: 600 Ω max
E -199.9 to 999.9 -300 to 1800
Digital Inputs
Thermocouple

>400ºC: ±0.15% FS ±1 count

B 0 to 1800 32 to 3300 Configuration: Two contacts, two operating modes
<400ºC: ±5% FS ±1 count
Contacts: Normally open switches (external excitation not required) or
R 0 to 1700 32 to 3100
±0.15% FS ±1 count open collector transistor
S 0 to 1700 32 to 3100 Open Circuit Voltage: Approximately 5 VDC
L -199.9 to 900.0 -300 to 1600 Logic Levels: LO = 0 to 0.8 VDC, HI = 4.7 to 28 VDC
>0ºC: ±0.1% FS ±1 count
<0ºC: ±0.2% FS ±1 count
Operation Modes: Mode 1: Control output run or stop, selection of
U -199.9 to 400.0 -300 to 750 set point 1 or 2. Mode 2: Selection of set points 1 to 4.
>0ºC: ±0.1% FS ±1 count
N -200 to 1300 -300 to 2400
<0ºC: ±0.25% FS ±1 count Serial Communications
W 0 to 2300 32 to 4200 ±0.2% FS ±1 count Compatibility: EIA-485
Protocol: PC, Modbus (ASCII, RTU), Sync (Master/Slave SP Control)
Platinel II 0 to 1390 32 to 2500 ±0.1% FS ±1 count Address: 1 to 99 (Max 31 units connected)
PtA -199.9 to 850.0 -300 to 1560 Baud Rate: 600 to 19,200 bps
±0.1% FS ±1 count Transmit Time Delay: 0 to 100 ms
PtB -199.9 to 500.0 -199.9 to 999.9
Data: 7 or 8 bit, automatic when using Modbus protocol
RTD

PtC -19.99 to 99.99 -4.0 to 212.0 ±0.2% FS ±1 count Stop Bit: 1 or 2

JPtA -199.9 to 500.0 -199.9 to 999.9 Parity: None, even, or odd
±0.1% FS ±1 count
JPtB -150.0 to 150.0 -199.9 to 300.0
LDS540_D 12/15

Precision Digital Corporation

233 South Street • Hopkinton MA 01748 USA • Tel (800) 343-1001 • Fax (508) 655-8990 www.predig.com