Moore Industries 555 User Manual

Download

5 5 5

CHLORINATION/DECHLORINATION CONTROLLER USER'S MANUAL

M555 V8, M

ARCH

201

page

TABLE OF CONTENTS............................................................................. i

FIGURE LIST ........................................................................................... iii

CHAPTER 1

GENERAL INFORMATION ............................................................... 1

555 Control Modes ............................................................................ 1

555 Operation ................................................................................... 2

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

Where To Go Next ............................................................................ 2

Text Formatting in This Manual ......................................................... 2

CHAPTER 2

BASIC INTERFACE .......................................................................... 5

Displays ............................................................................................ 5

Icons (Lit) .......................................................................................... 6

Keys .................................................................................................. 6

CHAPTER 3

HARDWARE SET UP ....................................................................... 7

Hardware Input Types ....................................................................... 7

The Process Variable ........................................................................ 7

The Remote Setpoint ........................................................................ 8

Mechanical Relays ............................................................................ 8

Accessing and Changing Jumpers .................................................... 9

Adding and Changing Output Modules ............................................ 10

Special Communications Module .................................................... 12

Contents

About This Manual:

Throughout this User’s Manual information appears along the

margins, in the form of NOTEs, CAUTIONs and WARNINGs, usually in boldface. Please heed these

safety and good practice notices for the protection of you and your equipment.

CHAPTER 4

INSTALLATION .............................................................................. 13

Mounting the Controller ................................................................... 13

Wiring for Input and Outputs ........................................................... 14

AC Power Input ...................................................................... 14

Process Variables .................................................................. 15

Digital Inputs........................................................................... 17

Output Modules ...................................................................... 18

Remote Setpoint ..................................................................... 21

Serial Communications ........................................................... 21

CHAPTER 5

SOFTWARE CONFIGURATION..................................................... 23

Menus ............................................................................................. 23

Parameters ..................................................................................... 24

Configuration and Operation ........................................................... 24

Where to Go Next ........................................................................... 25

Software Menus and Parameters .................................................... 27

CONFIG ................................................................................. 27

CONTROL.............................................................................. 31

FLOW INPT. ........................................................................... 32

CUST.LINR. ........................................................................... 34

RSDL. INPT. .......................................................................... 35

SETPOINT ............................................................................. 36

REM. INPUT .......................................................................... 37

OUTPUT ................................................................................ 38

RETRANS. ............................................................................. 41

ALARMS ................................................................................ 43

555 User's Manual Table of Contents i

Contents

page

POWER-UP ........................................................................... 47

SECURITY ............................................................................. 47

SER. COMM........................................................................... 48

TUNING ................................................................................. 49

Parameter Value Charts.................................................................. 51

CHAPTER 6

APPLICATIONS .............................................................................. 59

A. Flow Pacing Mode ...................................................................... 59

B. Residual Chlorine Loop Mode ..................................................... 61

C. Compound Loop Mode ............................................................... 64

D. Dechlorination Mode ................................................................... 67

E. Alarms ........................................................................................ 70

F. Slidewire Position Proportioning Output ...................................... 74

G. Staged Outputs ........................................................................... 75

H. Retransmission ........................................................................... 75

I. Digital Inputs ............................................................................... 76

J. Remote Input .............................................................................. 78

K. Integral Setting ............................................................................ 79

L. Tuning Tips ................................................................................. 80

M.Input Linearization ...................................................................... 83

N. Security ...................................................................................... 84

O. Process Variable Reading Correction ......................................... 85

P. Serial Communications ............................................................... 86

Q. Lag ............................................................................................. 87

APPENDIX A

ERROR HANDLING ..................................................................... A-1

Troubleshooting ............................................................................ A-1

Error Messages ............................................................................ A-2

APPENDIX B

CALIBRATION .............................................................................. B-1

Analog Input (V and mA) Calibration ............................................. B-1

Milliamp Output Calibration ........................................................... B-3

Reset Menu Data .......................................................................... B-4

Hardware Scan ............................................................................. B-4

Slidewire Test ............................................................................... B-5

Quick Calibration Procedure ......................................................... B-5

APPENDIX C

SPECIFICATIONS ........................................................................ C-1

APPENDIX D

FLOWCHARTS ............................................................................. D-1

Set Up and Tuning Mode Menus and Parameters ........................ D-1

APPENDIX E

GLOSSARY .................................................................................. E-1

APPENDIX F

ISOLATION BLOCK DIAGRAM .................................................... F-1

APPENDIX G

PARTS LIST ................................................................................. G-1

ii Table of Contents 555 User's Manual

Figure.............Title ............................................................................ Page

Figure 1.1 ........ The 555 Chlorination/Dechlorination Controller................. 1

Figure 2.1 ........ 555 Operator Interface ...................................................... 5

Figure 3.1 ........ Accessing the 555 Circuit Boards ..................................... 7

Figure 3.2 ........ The Microcontroller Circuit Board,

The Option Board, and the Power Supply Board ............... 8

Figure 3.3 ........ Output Module ................................................................ 11

Figure 3.4 ........ Install Communications Module onto the

Microcontroller Board ...................................................... 12

Figure 4.1 ........ Controller Dimensions. .................................................... 13

Figure 4.2 ........ Insert Mounting Clips ...................................................... 13

Figure 4.3 ........ 555 Input and Output Wiring Options .............................. 14

Figure 4.4 ........ AC Power Input Wiring .................................................... 15

Figure 4.5 ........ PV Voltage Input Wiring .................................................. 15

Figure 4.6 ........ PV mA Input with External Power Supply Wiring ............. 16

Figure 4.7 ........ PV mA Input with Internal Power Supply and

2-Wire Transmitter Wiring ................................................ 16

Figure 4.8 ........ PV mA Input with Internal Power Supply and

4-Wire Transmitter Wiring ................................................ 17

Figure 4.9 ........ Digital Input Wiring with a Switch or Relay ...................... 17

Figure 4.10 ...... Digital Input Wiring with an Open Collector ..................... 18

Figure 4.11 ...... Mechanical Relay Output Wiring ..................................... 18

Figure 4.12 ...... Solid State Relay Output Wiring ...................................... 19

Figure 4.13 ...... DC Logic Output and Milliamp Output Wiring ..................19

Figure 4.14 ...... Position Proportioning Output

with Slidwire Feedback Terminals ................................... 20

Figure 4.15 ...... Remote Setpoint Terminals ............................................. 21

Figure 4.16 ...... Serial Communications Terminals ................................... 21

Figure 5.1 ........ Menus, Parameters and Values ...................................... 23

Figure 5.2 ........ Independent vs. Dependent Parameters ......................... 24

Figure 5.3 ........ Operation and Configuration Flowchart ...........................24

Figure 6.1 ........ Flow Pacing Control ........................................................ 59

Figure 6.2 ........ Residual Chlorine Loop Control ...................................... 61

Figure 6.3 ........ Compound Loop Control ................................................. 64

Figure 6.4 ........ Dechlorination Control .................................................... 67

Figure 6.5 ........ Alarm Examples .............................................................. 73

Figure 6.6 ........ Residual Control Responses .......................................... 81

Figure 6.7 ........ Square Root Linearization Formula................................. 83

Figure 6.8 ........ Custom Linearization Curve............................................ 84

Figure 6.9 ........ Compound Loop Flow Pacing with Lag Times ................. 87

Figure B.1 ........ Calibration Menu Flowchart .......................................... B-1

Figure B.2 ........ Microcontroller Circuit Board ......................................... B-2

Figure B.3 ........ PV1 & PV2 Calibration Wiring ....................................... B-2

Figure B.4 ........ Milliamp Output Calibration Wiring ................................ B-3

Figure B.5 ........ Output Module Menu Cycle ........................................... B-4

Figure B.6 ........ Slidewire Calibration Wiring .......................................... B-5

Contents

555 User's Manual Table of Contents iii

Contents

iv Table of Contents 555 User's Manual

CHAPTER 1 GENERAL INFORMATION

General Information

Figure 1.1 The 555 Chlorination/Dechlorination Controller

Automatic and accurate control of chlorine in potable and waste water is more important than ever due to health and regulatory concerns. Poor control can lead to failure of biomonitoring tests, leading to an even more costly “Toxicity Reduction Evaluation.” The 555 is a cost effective way to upgrade chlorination and dechlorination processes in an easy to use, rugged 1/4 DIN size package. The 555 can be easily set up to handle flow proportional control, residual control, compound loop control with lag times, and dechlorination with sulfur dioxide.

Designed with the needs of the water and wastewater industry in mind, the 555 offers features that set it apart from the competition. The front panel is NEMA 4X rated for protection from water and corrosion. The vacuum fluorescent display is bright and crisp, offering the best readability in all light conditions. All prompts are displayed in easy to understand terms, with two fully alphanumeric displays. An extra large third display is dedicated to indicating one of the measured variables. When performing Compound Loop Flow Pacing control, the 555 clearly displays both flow rate and residual chlorine level simultaneously. The sturdy rubber keys are large and backlit with excellent tactile feel.

The 555 is designed to quickly integrate with your flow transmitters and residual analyzers through straightforward menu configuration selections.

555 CONTROL MODES

FLOW PACING MODE: control mode for adding chlorine to and/or removing chlorine from the water, based on flow rate with no feedback.

RESIDUAL CHLORINE MODE: control mode for adding chlorine to the water based on residual level as the process variable.

COMPOUND LOOP MODE: control mode for adding chlorine based on a combination of both flow pacing and residual level.

DECHLORINATION MODE: the control output for adding SO2 to the water based on a combination of both flow pacing and residual chlorine level.

555 User's Manual Chapter 1 1

General Information

555 OPERATION

There are 3 operation “modes” for the 555 controller: OPERATING, the default mode of the controller. While the 555 is “operating,”

you can change dosage setpoints, select manual control and change output level, acknowledge alarms and monitor conditions.

SET UP, sometimes referred to as “configuration.” In set up, you configure the basic functions of the instrument such as input and output assignments, alarm types and special functions.

TUNING, where you configure control function parameters for Residual and Compound Loop control. Use the tuning function periodically to optimize the performance of the 555.

Refer to Chapter 5, and Figure 5.3, to view the relationship between these 3 modes.

ORDER CODE, P A CKAGING INFORMATION

Compare the product number on your controller (the label on top of the controller) with the order code on the next page. From this number you can confirm the options on your 555.

In the controller packaging, you should have received:

• one 555 controller

• one 555 User’s Manual

• 555 mounting hardware

• one sheet engineering unit adhesive labels

• one rear terminal label

WHERE TO GO NEXT

• To become more familiar with the 555 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 555, follow through Chapter 5. Appendix D can be used as a basic guideline to these parameters.

TEXT FORMA TTING IN THIS MANU AL

Feature Format KEYS SET PT DISPLAY

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 1 555 User's Manual

ORDER CODE

General Information

OUTPUT 1 — CONTROL

OUTPUT 2 — CONTROL, ALARM, OR RETRANSMISSION

OUTPUT 3 — ALARM, OR RETRANSMISSION

OUTPUT 4 — ALARM, RETRANSMISSION, OR LOOP POWER

None .......................................................... 0

Mechanical relay (5 amp) ........................... 1

Analog (milliamp) ....................................... 2

Solid state relay (triac) (1 amp) ...................3

DC logic (SSR drive) .................................. 4

None .......................................................... 0

Mechanical relay (5 amp) ........................... 1

Analog (milliamp) ....................................... 2

Solid state relay (triac) (1 amp) ...................3

DC logic (SSR drive) .................................. 4

None .......................................................... 0

Mechanical relay (5 amp) .......................... 1

Analog (milliamp) ....................................... 2

Solid state relay (triac) (1 amp) .................. 3

DC logic (SSR drive) ................................. 4

None .......................................................... 0

Mechanical relay (0.5 amp, 24 V) .............. 1

Analog (milliamp) ....................................... 2

Solid state relay (triac) (0.5 amp, 24 V) ..... 3

DC logic (SSR drive) ................................. 4

Loop power................................................ 5

0 0555 -

Optional Inputs

ENTER “0” IF

OPTIONAL

NOT DESIRED

INPUT

Slidewire feedback for position proportioning

output ........................................................ A

Remote setpoint (Standard) ....................... B

Five digital inputs (for vacuum alarm and

stand by mode) .......................................... D

SERIAL COMMUNICATIONS

ENTER

“0” IF

RS-485 serial

communications......................................... S

COMMUNICATIONS

NOT

DESIRED

Note 1: Capability for position proportioning output is specified by ordering 555-11xxAxxx00, 555-33xxAxxx00, or 555-44xxAxxx00. (Slidewire not required for velocity proportioning.) Note 2: Up to two 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.

555 User's Manual Chapter 1 3

General Information

4 Chapter 1 555 User's Manual

CHAPTER 2 BASIC INTERF A CE

Interface

Icons

OUT 1 2 ALM 1 2

555

Displays:

1st

2nd

3rd

MANUAL

ACK

DISPLAY

SET PT

FAST

Keys

DISPLAYS

Refer to Chapter 6 for details on the interface functions for specific modes.

1st Line (five 7-segment digits)

• Always displays a (primary) process variable, with value/units depending on the individual mode.

2nd Line (nine 14-Segment Digits)

• Under “normal” operating conditions, displays process dosage or setpoints, deviations, output values, lags, trim, pace, etc., depending upon the mode.

• When configuring the 555 (in any mode), displays the menu names and subsequent parameter names.

• When using a ramping setpoint that is actively ramping, alternates between the target SP (SP2, RSP) and the ramping setpoint (which causes RAMPING to show in the third display).

• When using the slidewire option, displays the actual valve position.

3rd Line (nine 14-Segment Digits)

• For dual PV modes shows the alternate PV, whether it is flow or residual level. To switch the display positions of the primary and secondary PV,

press FAST + DISPLAY.

• If alarms occur, this line will show alarm messages alternating with any other messages.

• During configuration, this line shows the parameter value in the menu system.

Figure 2.1 555 Operator Interface

555 User's Manual Chapter 2 5

Interface

OUT OUT OUT 1212

ALM ALM ALM 1212

PV2

ICONS (LIT)

OUT1 Indicates the output is at a level greater than 0%, or “activated” (for time

OUT2 Indicates the second output (SO

ALM1 Indicates the respective alarm (one) is active. ALM2 Indicates the respective alarm (one) is active. PV2 Indicates that the flow input (PV2) is in the 1st display.

KEYS

FAST: Has no independent function - press to modify the function of another

key (see below).

MANUAL : Press to toggle between manual and automatic control. When lit,

indicates that the unit is under manual control.

FAST+MANUAL : Press to transfer controller from manual to automatic control

when setting up bumpless transfer dosage values. Refer to Chapter 6 for more information about bumpless transfer and dosage values.

SET PT : Press to select the active SP. When lit, indicates that a setpoint other

than the primary (e.g., RSP, SP2) is active.

DISPLAY

MANUAL

SET PT

proportioning or a digital output).

staging or slidewire output is active.

) of the duplex flow pacing mode,

FAST

DISPLAY

▲

▲ ▼

▼

DISPLAY : Press to step through the values (SP, %OUT, DOSAGE, etc.) to be

shown in the 2nd display.

FAST+DISPLAY : Allows user to switch display positions of the PV1 (residual)

and PV2 (flow) between the 1st and 3rd displays.

▲▲

▲ : Press to advance to previous value or parameter

▲▲

FAST+

▼▼

▼ : Press to advance to next value or parameter

▼▼

FAST+

ACK : Press to acknowledge (an) alarm(s). When lit, indicates that there is an

acknowledgeable alarm.

MENU : Press to access the Tuning Menu, and its parameters. When lit, indicates

that the controller is in Set Up mode (in the configuration menus).

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

parameters of the software menus. When lit, indicates that the controller is in Set Up mode (in the configuration menus).

▲▲

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

▲▲

▼▼

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

▼▼

6 Chapter 2 555 User's Manual

CHAPTER 3 HARDW ARE SET UP

Hardware

The configuration of the hardware in your controller determines the available

outputs as well as the type of input signal. Your 555 controller comes factory

set with the following:

• All the specified modules and options installed. (For more details, refer to the order code in Chapter 1.)

• Process variable, setpoint and/or valve position inputs set to accept a milliamp input

• Relay outputs set to normally open

To alter the factory configuration of your 555, you will need to access the 555 circuit boards, and locate the jumpers and output modules on the circuit boards (see Figure 3.1):

1. With power off, loosen two front screws, and remove them.

2. Slide the chassis out of the case by pulling firmly on the bezel.

MICROCONTROLLER

BOARD

POWER SUPPLY

BOARD

NOTE:

If you would like your controller configured at the factory, please consult an application engineer.

NOTE:

Your hardware configuration will influence the available software options as discussed in Chapter 3.

Figure 3.1 Accessing the 555 Circuit Boards

OPTION BOARD

A detailed view of the circuit boards appears in Figure 3.2. After configuring the hardware, or if you do not need to make any changes, con-

tinue your process set up as needed.

HARDW ARE INPUT TYPES

The Process Variable

The 555 accepts both voltage and milliamp process variable signals. You must set a jumper location to specify the type of input signal. You set the particular range in the software (see Chapter 5 for software menus, or Chapter 6 for applications).

The jumpers for the process variable are located on the Microcontroller Circuit

Board (see Figure 3.2). The factory default is Milliamp. Locations are marked

as follows:

V Voltage MA Milliamp

555 User's Manual Chapter 3 7

NOTE:

Any changes you make to the output modules will render the code on the product label invalid.

Hardware

BATTERY

EPROM

Figure 3.2 (from the top) The Microcontroller Circuit board, The Option Board, and the Power Supply Board

The Remote Setpoint

Figure 3.2 shows the location of the remote setpoint jumper. The factory default is Milliamp. Choose from the following settings:

V Voltage MA Milliamp

Mechanical Relays

There are three output module sockets on the Power Supply Circuit Board, and one output module on the Option Board (see Figure 3.2). 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 de-

termines this configuration. All the relay outputs are factory set to NO

(normally open).

EPROM

Comm Module

TB2

BATTERY

5-Pin Connector

Female 22-Pin ConnectorFemale 22-Pin Connector

MA TC TC

RTD

2ND

PV1

TB1

8 Chapter 3 555 User's Manual

Male 22-Pin

Connector

4-Pin Connector

Output 4

Female 44-Pin Connector

Male 22-Pin

Connector

Male 44-Pin Connector

Module

Retention

Plate

over Outputs 1,2,3

3 2

NO J3 NC

NO J2 NC

NO J1 NC

Jumpers

NO and NC

ACCESSING AND CHANGING JUMPERS

Follow these instructions to change jumpers for the Process Variable, Remote Setpoint and Digital Inputs:

Equipment needed: Needle-nose pliers (optional)

Phillips screwdriver (#2) Wrist grounding strap

1. With power off, loosen two front screws, and remove them.

2. Slide the chassis out of the case by pulling firmly on the bezel.

3. Use Figure 3.2 to help you locate the jumper connector that you intend to change.

4. Using either your fingers or the needle nose pliers, pull straight up on the connector and remove it from its pins, as shown in Photo 4. Be careful not to bend the pins.

Hardware

4. Remove Jumpers

5. Find the new location of the jumper connector (again, refer to Figure 3.2). Carefully place it over the pins, then press connector straight down. Make sure it is seated firmly on the pins.

6. Make any other jumper changes as needed. modules, please refer to the next section, starting with Step #3.

7. To reassemble the controller, properly orient the chassis with board opening on top. Align the circuit boards into the grooves on the top and bottom of the case. Press firmly on the front face assembly until the chassis is all the way into the case.

If you have difficulty sliding the chassis in all the way, make sure you have removed the screws (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.

555 User's Manual Chapter 3 9

If you need to alter output

Hardware

ADDING AND CHANGING OUTPUT MODULES

The 555 has provisions for four output modules. A controller ordered with output module options already has the modules properly installed. Follow these instructions to add modules, change module type(s) or change module location(s).

Equipment needed: Wrist grounding strap

Phillips screwdriver (#2) Small flat blade screwdriver Wire cutters

1. With power off, loosen two front screws, and remove them.

2. 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, use your hands, or the flat screwdriver, to carefully pry apart the smaller Option board and the Power Supply board (the one with 3 modules).

5. If you need 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

10 Chapter 3 555 User's Manual

4. Separate Boards

5. Remove Retention Plate

6. If you need 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 3.3 shows a representation of an output module. Inspect your module(s) to make sure that the pins are straight.

8. To install any module, align its pins with the holes in the circuit board, and carefully insert the module in the socket. Press down on the module until it is firmly seated; refer to Photo 8.

Hardware

Figure 3.3 Output Module

6. Snip Tie Wrap

9. Replace tie wraps for all the modules (the Retention Plate and Output Module 4) with new ones before you reassemble.

Failure to use the tie wraps may result in loosening of the module and eventual failure. All separately ordered modules should come with a tie wrap. Extra sets of tie wraps are available by ordering Part #555-665.

10.Rejoin the circuit boards by aligning the pins of their connectors, then squeezing the board(s) together. Make sure that all three printed circuit boards are properly seated against one another; check along side edges for gaps. Make sure the cable assemblies are not pinched.

11.To reattach the board assembly to the front face assembly, align the boards (with the open area on top) into the slots of the font face assembly. The clips should snap into place.

12.To reassemble the controller, properly orient the chassis with board opening on top. Align the circuit boards into the grooves on the top and bottom of the case. Press firmly on the front face assembly until the chassis is all the way into the case.

If you have difficulty sliding the chassis in all the way, make sure you have removed the screws (they can block proper alignment), and that the chassis is properly oriented.

13.Carefully insert and align screws. Tighten them until the bezel is seated

firmly against the gasket. Do not overtighten.

8. Add/Change Module

NOTE: For greatest accuracy,

calibrate all milliamp modules added for retransmission as per the instructions in Appendix B.

SPECIAL COMMUNICA TIONS MODULE

555 User's Manual Chapter 3 11

Hardware

A special communications module is available for the 555; see order code in Chapter 1 for details.

Equipment needed: Wrist grounding strap

Phillips screwdriver (#2) Small flat blade screwdriver

1. Before you install the communications module, set up the hardware wiring for your application. See Chapter 4 for details.

2. With power off, loosen two front screws, and remove them.

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 with the arrow pointing towards the rear

of the 555 unit, and attach it to Connectors P1 and P2 as shown in Figure

3.4.

5. To reassemble the controller, properly orient the chassis with board open-

Insert module onto connectors. Make sure arrow on module points toward rear terminals.

Figure 3.4 Install Communications Module onto Microcontroller Board

Front of controller (circuits boards still attached to front face)

EPROM

TB2

(REMOTE SP

BATTERY

DIGITAL INPUT)

CONFIGURATION

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 you have difficulty sliding the chassis in all the way, make sure you have removed the screws (they can block proper alignment), and that the chassis is properly oriented.

6. Carefully insert and align screws. Tighten them until the bezel is seated firmly

against the gasket. Do not overtighten.

2ND

12 Chapter 3 555 User's Manual

CHAPTER 4 INSTALLA TION

MOUNTING THE CONTROLLER

The front face of the 555 is NEMA 4X rated. To obtain a waterproof seal between the controller and the instrument panel, follow these directions:

1. The 555 fits in a standard 1/4 DIN cutout. You may mount your 555 in any panel with a thickness from 0.06 in. to 0.275 in. (1.5mm to 7.0mm).

2. Figure 4.1 shows controller and panel dimensions. The panel cutout must be precise, and the edges free from burrs and waves.

7.180 (182.37) OVERALL LENGTH

1.180 (29.97)

3.770 (95.76)

PANEL

Installation

Figure 4.1 Controller Dimensions

3.622 (92.00) MIN.

3.653 (92.80) MAX.

OUT 1 2 ALM 1 2

3.770 (95.76)

6.000 (152.40)

SIDE

FRONT

BEZEL GASKET

3. Place a new bezel gasket around the controller case, starting at the back of controller. Then, slide the gasket up against the back of the bezel. To ensure a good seal, always use a fresh gasket.

4. With the bezel gasket in place, insert the 555 into the panel cutout from the front of the panel. The case of the controller must be centered in the cutout.

5. From behind the panel, insert the mounting clips (one on each side), as shown in Figure 4.2.

3.585 (91.06)

CUTOUT

Figure 4.2 Insert Mounting Clips

3.622 (92.00) MIN.

3.653 (92.80) MAX.

MOUNTING BRACKET (1 EA. SIDE)

BEZEL

555 User's Manual Chapter 4 13

Slide gasket on from this end.

HOUSING

Installation

6. Gradually tighten the mounting bracket screws with a long Phillips screw driver (#2). Make sure the screws are secure, and check the bezel gasket for a tight, even seal.

7. If you have difficulty with any of the mounting requirements, apply a bead of caulk or silicone sealant behind the panel around the perimeter of the case.

WIRING FOR INPUT AND OUTPUTS

555 controllers are thoroughly tested, calibrated and “burned in” at the factory, so your controller is ready to install. Before you begin wiring your system, read this section thoroughly and take care in planning your system. A properly designed system can help prevent problems such as electrical noise disturbances and dangerous extreme conditions.

Special Notes:

1. For improved electrical noise immunity, install the 555 as far away as possible from motors, relays and other similar noise generators.

2. Do not run low power (sensor input) lines in the same bundle as AC power lines. Grouping these lines in the same bundle can create electrical noise interference.

3. All wiring and fusing should conform to the National Electric Code and to any locally applicable codes.

4. An excellent resource about good wiring practices is the IEEE Standard No. 518-1982 and is available from IEEE, Inc., 345 East 47th Street, New York, NY 10017, (212) 705-7900.

Rear terminal diagrams on the next pages are guides for wiring the different types of inputs and outputs for the 555. Remember that the installed output modules (Chapter 3) determine which inputs and outputs are available, and your software set up (Chapter 5) will determine how your instrument controls.

Figure 4.3 555 Input and Output Wiring

Digital Inputs Option (if installed)Slidewire Option Input

Options

AC Power

Flow Pacing, Residual, Compound Loop: CL2 valve output (4-20mA or Relay)** Dechlorination: SO2 valve output (4-20mA or Relay)**

Dual Flow Pacing: SO2 valve output (4-20mA or Relay)** Alarm Relay/Retransmission: 2nd staged output (4-20mA)** 2nd slidewire output (relay)**

Alarm Relay/ Retransmission**

** Outputs 1, 2, 3 and 4 must be filled with appropriate modules. See Chapter 3.

LINE

NEUTRAL

OUT 1–

OUT 1+

OUT 2–

OUT 2+

OUT 3–

OUT 3+

Alarm Relay/ Retransmission**

EARTH GND

S/W CCW

S/W2

S/W3

RSP–

RSP+

OUT 4–

OUT 4+

DIN

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

N/A

24 32

Remote Set Point Option Input

N/A

RS485–

RS485+

PV2–

PV2+

N/A

PV1–

PV1+

RS485 Com (if installed)

Flow signal input 4-20mA from transmitter

CL2 signal input 4-20mA from analyzer

14 Chapter 4 555 User's Manual

AC P ower Input

Installation

Terminals 1 and 2 are for POWER. Terminal 9 is earth ground. Use a 0.5 Amp, 250 V fast-acting fuse in line with your AC power connection.

AC LINE

AC NEUTRAL

1 2

7 8

Screws must be tight to ensure electrical connection

EARTH GND

24 32

Process V ariables

Note:

On the actual 555, the only terminals with printed numbers are those shown in Figure 4.4.

Figure 4.4 AC Power Input Wiring

The 555 uses up to two process variables depending on the control mode: PV1 is for Cl

residual level, and PV2 is for flow (rate). Each PV signal can be

either voltage or milliamp input.

1. Voltage Input (Figure 4.5)

• PV1 uses terminals 31 and 32 connected to a transmitter.

• PV2 uses terminals 28 and 29 connected to a transmitter.

1 2 3 4 5 6 7 8

Screws must be tight to ensure electrical connection

9 10 11 12 13 14 15 16

17 18 19 20 21 22 23

25 26 27 28 29 30 31

24 32

PV1–

PV1+

–

Transmitter

1 2 3 4 5 6 7 8

Screws must be tight to ensure electrical connection

9 10 11 12 13 14 15 16

Figure 4.5 PV Voltage Input Wiring

17 18 19 20 21 22 23

25 26 27 28 29 30 31

PV2–

PV2+

24 32

–

Transmitter

555 User's Manual Chapter 4 15

Installation

24 32

Screws must be tight to ensure electrical connection

2-wire

transmitter

–

Input power can come from a loop power module in Output 2 (terminals 5 & 6), Output 3 (terminals 7 & 8), or Output 4 (terminals 15 & 16).

Transmitter output can be connected to PV1 (temrinals 31 & 32) or PV2 (temrinals 28 & 29)

OUT 4–

OUT 4+

OUT 3–

OUT 3+

OUT 2–

OUT 2+

PV1–

PV1+

PV2–

PV2+

Figure 4.6 PV mA Input with External Power Supply Wiring

2. Milliamp Input + External Power Supply (Figure 4.6)

• PV1 Milliamp Input with an external power supply uses terminals 31 and 32 with a 2-wire transmitter.

• PV2 Milliamp Input with an external power supply uses terminals 28 and 29 with a 2-wire transmitter.

Screws must be tight to ensure electrical connection

24 32

Figure 4.7 PV mA Input with Internal Power Supply and 2-wire Transmitter Wiring

PV1–

PV1+

External Power

Supply

–

Transmitter

–

Screws must be tight to ensure electrical connection

24 32

3. Milliamp Input + Internal (loop) Power Supply

If internal loop power is desired, a loop power module must be installed in Output 2, 3 or 4. See Chapter 1 for details on your controller’s installed options. See also Chapter 3 for module installation details.

2-wire Transmitter (Figure 4.7)

• PV1: terminals 31 and 32 with the loop power module output terminals, and a 2-wire transmitter.

• PV2: terminals 28 and 29 with the loop power module output terminals, and a 2-wire transmitter.

PV2–

PV2+

External Power

Supply

–

Transmitter

–

16 Chapter 4 555 User's Manual

4-wire Transmitter (Figure 4.8)

• PV1: terminals 31 and 32 with the loop power module output terminals, and a 4-wire transmitter.

• PV2: terminals 28 and 29 with the loop power module output terminals, and a 4-wire transmitter.

Installation

Input power can come from a loop power module in Output 2 (terminals 5 & 6), Output 3 (terminals 7 & 8), or Output 4 (terminals 15 & 16).

Power for

transmitter

PV2–

PV2+

PV1–

PV1+

4-20mA

output from

transmitter

Transmitter output can be connected to PV1 (temrinals 31 & 32) or PV2 (temrinals 28 & 29)

Input

OUT 2–

OUT 2+

OUT 3–

OUT 3+

OUT 4–

OUT 4+

24 32

Screws must be tight to ensure electrical connection

Digital Inputs

Digital inputs can be activated in three ways: a switch (signal type) - the recommended 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 type, and supplies the appropriate software menu.

1. Digital Inputs with a switch or relay

Wire the switch/relay between terminal 17 and the specific digital input terminal (Figure 4.9).

Figure 4.8 PV mA Input with Internal Power Supply and 4-wire Transmitter Wiring

NOTE:

There are 14 contact types for the up to 5 digital inputs - refer to Chapter 6 for a complete discussion.

1 2 3 4 5 6 7 8

Screws must be tight to ensure electrical connection

DIN

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

17 18 19 20 21 22 23 24 32

9 10 11 12 13 14 15 16

25 26 27 28 29 30 31

555 User's Manual Chapter 4 17

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

DIN

17 18 19 20 21 22 30

25 26 27 28 29

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

DIN

17 18 19 20 21 22 30

25 26 27 28 29

DIN

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

17 18 19 20 21 22 30

25 26 27 28 29

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

DIN

17 18 19 20 21 22 30

25 26 27 28 29

Figure 4.9 Digital Input Wiring with a Switch or Relay

Installation

Figure 4.10 Digital Input Wiring with an Open Collector (transistor)

1 2 3 4 5 6 7 8

Screws must be tight to ensure electrical connection

DIN

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

17 18 19 20 21 22 23 24 32

9 10 11 12 13 14 15 16

25 26 27 28 29 30 31

2. Digital Inputs with an Open Collector

An open collector is also called a transistor. Wire the transistor between terminal 17 and the specific digital input terminal (Figure 4.10)

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

DIN

17 18 19 20 21 22 30

25 26 27 28 29

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

DIN

17 18 19 20 21 22 30

25 26 27 28 29

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

DIN

17 18 19 20 21 22 30

25 26 27 28 29

GND

DIN 1

DIN 2

DIN 3

DIN 4

DIN 5

DIN

17 18 19 20 21 22 30

Output Modules

Output modules are used for control, alarms and retransmission (the wiring is

the same). There are three digital types — Mechanical Relay, Solid State Relay (Triac), DC Logic (SSR Drive) — and one Analog type (Milliamp).

To identify which modules (if any) are installed on your 555, compare the product order code in Chapter 1 against the code on top of your controller. If you want to change the configuration of the modules, refer to Chapter 3.

Wire using the corresponding output terminals (examples show Output 1).

1. Mechanical Relay Output (Figure 4.11)

• Output 1 is always the Control output.

• Output Slots 1 and 2 together will allow for duplex flow pacing mode control (again, only as time-proportioned outputs).

•“Staging” outputs is not allowed.

• Output Slots 2, 3 and/or 4 can be used for alarms (up to two). However, Output 2 is not available for alarms when using “duplex” control (i.e., duplex flow pacing, staging, or slidewire).

25 26 27 28 29

Figure 4.11 Mechanical Relay Output Wiring

18 Chapter 4 555 User's Manual

Output 1 uses terminals 3 & 4 Output 2 uses terminals 5 & 6 Output 3 uses terminals 7 & 4 Output 4 uses terminals 15 & 16

Line Power

Load

Recommend use of both MOV and snubber

OUT 1–

OUT 1+

OUT 2–

OUT 2+

OUT 3–

OUT 3+

OUT 4–

OUT 4+

24 32

Screws must be tight to ensure electrical connection

2. Solid State Relay (Triac) Output (Figure 4.12)

• Output 1 is always the Control output.

• Output Slots 1 and 2 together will allow for duplex flow pacing mode control (again, only as time-proportioned outputs).

•“Staging” outputs is not allowed.

• Output Slots 2, 3 and/or 4 can be used for alarms (up to two); however, Output 2 is not available for alarms when using “duplex” control (i.e., duplex flow pacing, staging, or slidewire).

Output 1 uses terminals 3 & 4 Output 2 uses terminals 5 & 6 Output 3 uses terminals 7 & 4 Output 4 uses terminals 15 & 16

Line Power

–

Load

Recommend use of both MOV and snubber

OUT 1–

OUT 1+

OUT 2–

OUT 2+

Installation

Figure 4.12 Solid State Relay Output Wiring

OUT 3–

OUT 3+

Screws must be tight to ensure electrical connection

OUT 4–

OUT 4+

24 32

3. DC Logic (SSR Drive) Output (Figure 4.13)

• Output 1 is always the Control output.

• Output Slots 1 and 2 together will allow for duplex flow pacing mode control (again, only as time-proportioned outputs).

•“Staging” outputs is not allowed.

• Output Slots 2, 3 and/or 4 can be used for alarms (up to two); however, Output 2 is not available for alarms when using “duplex” control (i.e., duplex flow pacing, staging, or slidewire).

Output 1 uses terminals 3 & 4 Output 2 uses terminals 5 & 6 Output 3 uses terminals 7 & 4 Output 4 uses terminals 15 & 16

–

Load

OUT 1–

OUT 1+

OUT 2–

Figure 4.13 DC Logic Output and Milliamp Output Wiring

OUT 2+

OUT 3–

OUT 3+

Screws must be tight to ensure electrical connection

555 User's Manual Chapter 4 19

OUT 4–

OUT 4+

24 32

Installation

4. Milliamp (analog) Output (Figure 4.13)

• Output 1 is always the Control output.

• Output Slots 1 and 2 together allow for duplex flow pacing mode or output “staging.”

• Output Slots 2, 3 and/or 4 can be used for retransmission (up to two). However, Output 2 is not available when using duplex flow pacing, staging or slidewire control.

5. Loop Power

• Any unused output slot (except for Output 1) may be used to hold a loop power module, when needed to supply voltage for a transducer.

• Output 1 is always the Control output.

• Refer to Figure 4.7 for a diagram of Loop Power.

6. Position Proportioning Output (with Slidewire Feedback)

• Output Slots 1 and 2 with mechanical or solid state relay modules, plus the slidewire option, will allow for electrical control valve actuators (motorized CCW/CW) to operate as the control output (see Figure 4.14).

Figure 4.14 Position Proportioning Output with Slidewire Feedback Terminals

Slidewire Wiper 0–1050

CCW

CCW Winding

CW Winding

ELECTRIC MOTOR

ACTUATOR

Actuator Supply Current

Screws must be tight to ensure electrical connection

COM

CCW

Slidewire Wiper

ELECTRIC

ACTUATOR OUTPUT

20 Chapter 4 555 User's Manual

Remote Setpoint

If you have the remote setpoint option, use terminals 13 and 14 to connect your remote setpoint signal (Figure 4.15).

–

RSP

Source

Installation

Figure 4.15 Remote Setpoint Terminals

Screws must be tight to ensure electrical connection

RSP–

RSP+

24 32

Serial Communications

If you have this option, use terminals 26 and 27 as shown in Figure 4.16. 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

To Comm – terminal of next device

To Comm + terminal of next device

24 32

Screws must be tight to ensure electrical connection

555 User's Manual Chapter 4 21

RS485–

RS485+

Use a 60 to 100 ohm terminating resistor connected to the two data terminals of the final device on the line

Comm –

Twisted, shielded

Comm +

This 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.

Figure 4.16 Serial Communications Terminals

PC or

other

RS-485

port

host

Installation

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. Use a RS-232/RS-485 converter, Part #500-485. The communication protocol is asynchronous bidirectional half-duplex, therefore the leads are labeled Comm + and Comm–.

22 Chapter 4 555 User's Manual

CHAPTER 5 SOFTW ARE CONFIGURATION

The software configuration menus of the 555 contain user-selected variables that define the action of the controller. Read through this section before making any parameter adjustments to your controller.

Software Configuration

Figure 5.1 Menus, Parameters and Values

When initially setting up the

controller, cycle through all the

parameters in each Menu.

Press the MENU+FAST to

advance to the next Menu.

Press MENU to advance to the

next parameter (this also sets the

value for the current parameter.

Use arrow keys to selects a value).

press:

MENU/FAST

CONFIG.

press:

INDICATOR

Use the arrows keys to enter

numerical values, and/or move

through the selection group.

press:

NONE

press MENU/FAST

Go to next Menu Block:

MENUS

In Set Up mode, there are 13 sets of options that control different aspects of 555

operation; in Tuning mode, there is one. Each set of options is called a menu. As

you traverse the two modes, the menu names appear in the 2nd display. CONFIG Mode selection and input/output hardware assignments CONTROL Control options FLOW INPT. Flow data input (PV2) options CUST. LINR. Linearization curve options for PV2 input. RSDL. INPT. Residual Cl2 data input (PV1) options SETPOINT Controller setpoint options REM. INPUT Remote Setpoint input options OUTPUT Output options RETRANS. Retransmission output options ALARMS Alarm options POWER-UP Power Up values configuration SECURITY Security functions SER.COMM. Serial Communications options (requires comm. board) and TUNING Tuning parameters configuration

This is a Menu. Its name will show in the 2nd display.

This is a Parameter. Its names show in the 3nd display. In this manual, when the appearance of a parameter is dependent upon other hardware/software options, the background is black. When the appearance of a paramter is dependent on those options,the background is white.

This is a Value. The numbers/values that correspond to your particular hardware/software options will show in the 3rd display. The graphics in this chapter show the default (factory)setting.

IMPORTANT!!

All software changes occur in real time; always perform set up functions under Manual operation.

555 User's Manual Chapter 5 23

Software Configuration

PARAMETERS

Independent

Parameter

CONFIGURE

UNLOCKED

Figure 5.2 Independent vs. Dependent Parameters

NOTE:

Changing the value of one parameter may affect the value or status of another.

Dependent

Parameter

RSP TYPE

(D)

MANUAL to switch

between automatic and

manual operating controls

DISPLAY or SET PT

Within each menu are parameters for particular control functions. You select

values for each parameter depending on the specific application. Use the MENU key to access parameters for a particular menu; the parameter name will replace the menu name in the 2nd display, and the parameter value will show in the 3rd display.

This chapter outlines all the available parameters for the 555. Some parameters are independent of any special configuration you apply, and others are depen- dent on the individual configuration. This manual displays these two types of

parameters differently; refer to Figure 5.2. A special feature of the 555, called

Smart Menus, determines the correct parameters to display for your configu-

ration, so not all the listed parameters will appear.

CONFIGURA TION AND OPERATION

Figure 5.3 shows the relationships among the different modes of the 555 and

the configuration menus:

AUTOMATIC control

MANUAL control

DISPLAY or SET PT

to return to manual

operating control

to restore

operating display

FAST + MENU

to access set up menus

to access tuning menu

Figure 5.3 Operation and Configuration Flowchart

13 set up menus

CONFIG.

CONTROL

FLOW INPT.

CUST.LINR.

RSDL. INPT.

SETPOINT

REM. INPUT

OUTPUT

RETRANS.

ALARMS

POWER-UP

SECURITY

SER.COMM.

FAST

to move

from menu

to menu

FAST + MENU

to access set up menus

1 tuning menu

TUNING

24 Chapter 5 555 User's Manual

• Set Up menus can only be accessed from manual control. To transfer the

555 from automatic to manual control, press MANUAL.

• To access the set up menus, press FAST+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 access the parameters for a particular menu, press MENU.

▲▲

• To select a parameter value, use

next parameter, or FAST+MENU to advance to the next menu.

• To return controller to manual control, press DISPLAY or SET PT.

• To transfer the controller from manual to automatic control when setting up

bumpless transfer dosage values, press FAST+MANUAL.

A key to these functions appears at the bottom of every page in the menu section of this chapter.

▼▼

▲ and

▼. Press MENU to advance to the

▲▲

▼▼

WHERE T O GO NEXT

• For information about all the software menus and parameters, continue reading this chapter. Refer to Appendix D for a quick-reference flowchart of all menus and parameters.

• For information about the installed options on your 555, look at the product label on top of the controller, and compare it to the order code in Chapter 1.

• To alter the output module and jumper configuration of your controller, see Chapter 3.

• To mount your controller and configure the wiring of the 555 for inputs and outputs, see Chapter 4.

• To set up the 555 control modes, and other applications, see Chapter 6.

Software Configuration

555 User's Manual Chapter 5 25

Software Configuration

26 Chapter 5 555 User's Manual

SOFTW ARE MENU AND P ARAMETERS

Software Configuration

CONFIG.

1. CTRL. MODE

Selects the main operating mode of the controller.

• FLOW PACE

• RESIDUAL D COMPOUND

• DECHLOR

2. OUT. MODE

Selects the control output mode of the controller.

D STANDARD Fixed value if different modules in slots 1 and

2, slot 2 is empty, or 2 digital outputs with no slidewire option

• STAGED Only available if analog modules in slots 1 and 2.

• SLIDEWIRE Only available if digital modules in slots 1 and 2 and slidewire option installed)

• DUAL OUT. Only available if 2 analog or 2 digital modules in slots 1 and 2 with flow pacing mode

3. LINE FREQ.

Defines the AC line frequency, so that the input sampling rate will be optimized for common mode noise rejection.

D 60 HZ.

• 50 HZ.

CONFIG

CTRL. MODE

COMPOUND

OUT . MODE STANDARD

LINE FREQ.

60 HZ.

4. OUTPUT 2

Selects use for an existing output in slot 2 (not for control or loop power).

D OFF

• ALM.RLY.: ON (digital only)

• ALM.RLY.: OFF (digital only)

• RETRANS. (analog only)

• COMM. ONLY

OUTPUT 2

OFF

5. OUTPUT 3

Selects use for an existing output in slot 3 (not for control or loop power).

D OFF

• ALM.RLY.: ON (digital only)

• ALM.RLY.: OFF (digital only)

• RETRANS. (analog only)

• COMM. ONLY

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

555 User's Manual Chapter 5 27

DISPLAY

FAST MENU

▲▲

▲

▲▲

▼▼

▼

▼▼

OUTPUT 3

OFF

DISPLAY

Software Configuration

6. OUTPUT 4

OUTPUT 4

OFF

7. ANLG.RNG.:1

aNLG.RNG.: 1

4-20 MA

Selects use for an existing output in slot 4 (not for control or loop power).

D OFF

• ALM.RLY.: ON (digital only)

• ALM.RLY.: OFF (digital only)

• RETRANS. (analog only)

• COMM. ONLY

Selects the range of operation for an existing mA output in slot 1.

• 0 – 20mA D 4 – 20mA

ANLG.RNG.: 2

4-20 MA

ANLG.RNG.: 3

4-20 MA

ANLG.RNG.: 4

4-20 MA

CONT A CT 1

MANU A L

8. ANLG.RNG.: 2

Selects the range of operation for an existing mA output in slot 2.

• 0 – 20mA D 4 – 20mA

9. ANLG.RNG.: 3

Selects the range of operation for an existing mA output in slot 3.

• 0 – 20mA D 4 – 20mA

10. ANLG.RNG.: 4

Selects the range of operation for an existing mA output in slot 4.

• 0 – 20mA D 4 – 20mA

11. CONTACT 1

Selects the use for the existing digital input 1.

• REM. INPUT D MANUAL

• 2ND. SETPT.

• 2ND. INT.

• ALARM ACK.

• INT. INHBT.

• LOCK MAN.

• STANDBY

• LO VACUUM

• HI VACUUM

• UP KEY

• DOWN KEY

• DISP. KEY

• MENU KEY

• FAST KEY

• COMM. ONLY

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

28 Chapter 5 555 User's Manual

DISPLAY

FAST MENU

▲

▲▲

▼▼

▼

▼▼

DISPLAY

12. CONTACT 2

Selects the use for the existing digital input 2.

D REM. INPUT

• MANUAL

• 2ND. SETPT.

• 2ND. INT.

• ALARM ACK.

• INT. INHBT.

• LOCK MAN.

• STANDBY

• LO VACUUM

• HI VACUUM

• UP KEY

• DOWN KEY

• DISP. KEY

• MENU KEY

• FAST KEY

• COMM. ONLY

Software Configuration

CONT A CT 2

REM. INPUT

13. CONTACT 3

Selects the use for the existing digital input 3.

• REM. INPUT

• MANUAL

D 2ND. SETPT.

• 2ND. INT.

• ALARM ACK.

• INT. INHBT.

• LOCK MAN.

• STANDBY

• LO VACUUM

• HI VACUUM

• UP KEY

• DOWN KEY

• DISP. KEY

• MENU KEY

• FAST KEY

• COMM. ONLY.

CONT A CT 3

2ND.SETPT.

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

555 User's Manual Chapter 5 29

DISPLAY

FAST MENU

▲▲

▲

▲▲

▼▼

▼

▼▼

DISPLAY

Software Configuration

14. CONTACT 4

CONT A CT 4

2ND. INT .

Selects the use for the existing digital input 4.

• REM. INPUT

• MANUAL

• 2ND. SETPT. D 2ND. INT.

• ALARM ACK

• INT. INHBT.

• LOCK MAN.

• STANDBY

• LO VACUUM

• HI VACUUM

• UP KEY

• DOWN KEY

• DISP. KEY

• MENU KEY

• FAST KEY

• COMM. ONLY

CONT A CT 5

ALARM. A CK.

REMOTE IN.

OFF

15. CONTACT 5

Selects the use for the existing digital input 5.

• REM. INPUT

• MANUAL

• 2ND. SETPT.

• 2ND. INT. D ALARM ACK.

• INT. INHBT.

• LOCK MAN.

• STANDBY

• LO VACUUM

• HI VACUUM

• UP KEY

• DOWN KEY

• DISP. KEY

• MENU KEY

• FAST KEY

• COMM. ONLY

16. REMOTE IN.

Defines the value of the remote setpoint feature.

D OFF

• SETPOINT

• CL2 DOSE

• SO2 DOSE

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

30 Chapter 5 555 User's Manual

DISPLAY

FAST MENU

▲

▲▲

▼▼

▼

▼▼

DISPLAY

Software Configuration

CONTROL

Available only for Residual or Compound Loop Mode.

1. FIXED LAG

Sets the fixed lag term used for computing the total lag.

R 0 to 14400 seconds D0

2. VARBL. LAG

(Compound Loop mode)

Sets the variable lag term used for computing the total lag.

R 0 to 14400 seconds D0

3. MAX. LAG

(Compound Loop mode)

Sets the maximum limit for the total lag calculation.

R 0 to 14400 seconds D 14400

4. MIN. TRIM

(Compound Loop mode)

Sets the minimum amount of correction that can be applied to the current flow pacing output level.

R –100 to 100% D –100%

CONTROL

FIXED LA G

V ARBL. L AG

MAX. LA G

14400

MIN. TRIM

-100%

5. MAX. TRIM

(Compound Loop mode)

Sets the maximum amount of correction that can be applied to the current flow pacing output level.

R –100 to 100% D 100%.

MAX. TRIM

100%

6. FLOW ONLY

(Compound Loop mode)

Determines whether to allow flow pacing only control or remain under automatic control if the residual signal is lost (see RSDL REST. in the RSDL.INPT. menu).

D DISABLED

• ENABLED

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

555 User's Manual Chapter 5 31

DISPLAY

FAST MENU

▲▲

▲

▲▲

▼▼

▼

▼▼

FLO W ONL Y

DISABLED

DISPLAY

Software Configuration

RSDL. ONLY

disabled

FLO W INPT .

PV TYPE

4-20 mA

7. RSDL. ONLY

(Compound Loop mode)

Determines whether to allow residual only control (i.e., remain under auto-

matic control) if the flow signal is lost (see FLOW REST. in the FLOW INPT.

menu).

D DISABLED

• ENABLED

FLO W INPT .

Available only when a flow signal is used (Flow Pacing, Compound Loop or Dechlorination Mode).

1. PV TYPE

Selects the type of PV being used for the flow input.

If jumper is set to volts:

D 1 – 5V

• 0 – 5V

• 0 – 100mV

• 0 – 60mV

• 0 – 30mV

• 0 – 10mV

• ± 25mV If jumper is set to mA:

D 4 – 20mA

• 0 – 20mA

DECIMAL

XXXXX

LINEARIZE

NORMAL

LO W RANGE

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

32 Chapter 5 555 User's Manual

DISPLAY

2. DECIMAL

Selects position of the decimal point in the engineering units display of flow.

D XXXXX

• XXXX.X

• XXX.XX

• XX.XXX

• X.XXXX

3. LINEARIZE

Selects the type of linearization used for the flow input.

D NORMAL

• SQR. ROOT

• CUSTOM

4. LOW RANGE

Sets the value in engineering units corresponding to the low flow input value.

R –9999 to 99999 D0

FAST MENU

▲

▲▲

▼▼

▼

▼▼

DISPLAY

5. HI RANGE

Sets the value in engineering units corresponding to the high flow input value.

R –9999 to 99999 D 1000

6. FILTER

Sets the amount of filtering to be used for the flow input.

R 0 to 120 seconds D0

7. PV OFFSET

Sets a constant offset to be applied to the flow input.

R –9999 to 99999 D0

8. PV GAIN

Sets a constant gain to be applied to the flow input.

R 0.100 to 10.000 D 1.000

9. FLOW BRK.

Defines percentage of (first) output upon switching to Manual control due to a flow signal break signal.

R -5% to 105% D0%

10. FLOW BRK.2

(Dual Flow Pacing mode)

Defines percentage of second output upon switching to Manual control due to a flow signal break signal.

R -5% to 105% D0%

Software Configuration

HI RANGE

1000

FILTER

PV OFFSET

PV GAIN

1.000

FLO W BRK.

FLO W BRK.2

11. FLOW REST.

(Flow Pacing mode, Dechlorination mode, and Compound Loop mode with Residual Only control disabled)

Defines type of control mode after flow signal is restored.

D LAST MODE

• MANUAL

• AUTOMATIC

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

555 User's Manual Chapter 5 33

DISPLAY

FAST MENU

▲▲

▲

▲▲

▼▼

▼

▼▼

FLO W REST.

LAST MODE

DISPLAY

Software Configuration

CUST.LINR.

1ST . INPUT

LO W RANGE

1ST . PV

XTH. INPUT

LO W RANGE

XTH. PV

CUST.LINR.

Available only if a flow signal is used (Flow Pacing, Compound Loop or Dechlorina-

tion mode) with LINEARIZE set to CUSTOM.

Defines a custom linearization curve for the Flow input (PV2). Points 1 and 15 are fixed to the low and high end of the input range (respectively) and only require you to set a corresponding PV value. Points 1 through 14 (the X points) require you to set both the input and the PV.

You do not have to use all 15 points. Whenever the Xth INPUT becomes the high

end of the range, that will be the last point in the linearization table.

Refer to Chapter 6 for more details.

1. 1st. INPUT

Sets the flow input value for Point 1.

R LOW RANGE to HIGH RANGE based on FLOW PV TYPE

D LOW RANGE

2. 1st. PV

Sets the engineering units value for Point 1.

R –9999 to 99999 D0

3. Xth. INPUT

Sets the flow input value for Point X (X = 2 to 14).

R LOW RANGE to HIGH RANGE based on FLOW PV TYPE

D LOW RANGE

4. Xth. PV

Sets the engineering units value for Point X (X = 2 to 14).

R –9999 to 99999 D0

15TH. INPUT

LO W RANGE

15TH. PV

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

34 Chapter 5 555 User's Manual

DISPLAY

FAST MENU

29. 15th. INPUT

Sets the flow input value for Point 15.

R LOW RANGE to HIGH RANGE based on FLOW PV TYPE

D LOW RANGE

30. 15th. PV

Sets the engineering units value for Point 15.

R –9999 to 99999 D0

▲

▲▲

▼▼

▼

▼▼

DISPLAY

Software Configuration

RSDL. INPT.

Available only if a residual chlorine signal is used (Compound Loop or Dechlorination mode).

1. PV TYPE

Selects the type of PV being used for the residual chlorine input.

If jumper set to volts

D 1 – 5V

• 0 – 5V

• 0 – 100mV

• 0 – 60mV

• 0 – 30mV

• 0 – 10mV

• ± 25mV If jumper set to mA:

D 4 – 20mA

• 0 – 20mA

2. DECIMAL

Selects the position of the decimal point in the engineering units display of residual value.

D XXXXX

• XXXX.X

• XXX.XX

• XX.XXX

• X.XXXX

RSDL. INPT.

PV TYPE

4-20 mA

DECIMAL

XXXXX

3. LOW RANGE

Sets the value in engineering units corresponding to the low residual input value.

R –9999 to 99999 D0

LO W RANGE

4. HI RANGE

Sets the value in engineering units corresponding to the high residual input value.

R –9999 to 99999 D 1000

HI RANGE

1000

5. FILTER

Sets the amount of filtering to be used for the residual input.

R 0 to 120 seconds D0

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

555 User's Manual Chapter 5 35

DISPLAY

FAST MENU

▲▲

▲

▲▲

▼▼

▼

▼▼

FILTER

DISPLAY

Software Configuration

PV OFFSET

PV GAIN

1.000

RSDL. BRK.

RSDL. REST .

LAST MODE

SETPOINT

6. PV OFFSET

Sets a constant offset to be applied to the residual input.

R –9999 to 99999 D0

7. PV GAIN

Sets a constant gain to be applied to the residual input.

R 0.100 to 10.000 D 1.000

8. RSDL. BRK.

Defines output percentage upon switching to Manual control due to a break in the residual signal.

R -5% to 105% D0%

9. RSDL. REST.

(Residual mode, Dechlorination mode, and Compound Loop mode with Flowonly control disabled).

Defines control mode upon restoration of residual signal.

D LAST MODE

• MANUAL

• AUTOMATIC

SETPOINT

SP LO W

Available only for Residual or Compound Loop mode.

1. SP LOW

SP HIGH

1000

Sets the value in engineering units corresponding to the lowest SP value allowed.

R –9999 to 99999 D0

2. SP HIGH

Sets the value in engineering units corresponding to the highest SP value allowed.

R –9999 to 99999 D 1000

3. SP RAMP

Turns SP ramping off, or defines the SP ramping rate in engineering units per

SP RAMP

OFF

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

hour (e.g., a value of 3600 translates to 1 SP step increment every second).

R 1 to 99999 D OFF

▲

▲▲

▼▼

▼

▼▼

DISPLAY

36 Chapter 5 555 User's Manual

Software Configuration

REM. INPUT

Availble only if the remote input (REMOTE IN.) is enabled.

1. TYPE V/mA

Selects the type/value for the Remote Input.

D 1 – 5 / 4 – 20 1 – 5 V, 4 – 20mA

• 0 – 5 / 0 – 20 0 – 5V, 0 – 20mA

2. LOW RANGE

Sets the value in engineering units corresponding to the low remote input value.

For SP:

R –9999 to 99999 D0 For Dose:

R 0.0% to 400.0% D 0.0%

3. HI RANGE

Sets the value in engineering units corresponding to the high remote input value.

For SP:

R –9999 to 99999 D 1000 For Dose:

R 0.0% to 400.0% D 100.0%

REM. INPUT

TYPE V/MA

1-5/4-20

LOW RANGE

HI RANGE

1000

4. RATIO

Sets the ratio (a constant gain) applied to the remote input.

R –99.99 to 99.99 D 1.00

5. BIAS

Sets the bias (a constant offset) applied to the remote input.

For SP:

R –9999 to 99999 D0 For Dose:

R –400.0% to 400.0% D 0.0%

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

555 User's Manual Chapter 5 37

DISPLAY

FAST MENU

▲▲

▲

▲▲

▼▼

▼

▼▼

RATIO

1.00

BIAS

DISPLAY

Software Configuration

TRACKING

RESTORE

LOCAL

OUTPUT

MIN. OUT.

MAX. OUT .

100%

6. TRACKING

Determines whether or not to keep the remote input value if the signal is lost. Otherwise, the controller automatically uses a local value.

• YES DNO

7. RESTORE

Defines which value to use once the remote input signal is restored.

D LOCAL

• REMOTE

OUTPUT

1. MIN. OUT.

Selects the lowest value for the output under automatic control (NOTE: The 555 will not limit the output under manual control).

R 0 to 100 % D0%

2. MAX. OUT.

Selects the highest value for the output under automatic control (NOTE: The 555 will not limit the output under manual control).

R 0 to 100% D 100%

3. MIN. OUT2

MIN.OUT2

(Dual Flow Pacing mode)

Selects the lowest value for the second output under automatic control. (NOTE: The 555 will not limit the output under manual control.)

R 0 to 100 % D0%

4. MAX. OUT2

(Dual Flow Pacing mode)

MAX.OUT2

100%

Selects the highest value for the second output under automatic control. (NOTE: The 555 will not limit the output under manual control).

R 0 to 100% D 100%

5. CYCLE TM.:1

Selects the time base for output 1, when time-proportioning a digital output.

CYCLE TM.:1

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

Appears only when a digital output in slot 1 is being used for a control (except when using slidewire).

R 0.3 to 2.0 (by tenths), 3 to 120 seconds (by ones) D 15 seconds

▲

▲▲

▼▼

▼

▼▼

DISPLAY

38 Chapter 5 555 User's Manual

Software Configuration

6. CYCLE TM.:2

Selects the time base for output 2, when time-proportioning a digital output.

Appears only when a digital output in slot 2 is being used for a control (except when using slidewire).

R 0.3 to 2.0 (by tenths), 3 to 120 seconds (by ones) D 15 seconds

7. DIG.IN.1:OUT.

Selects the designated output for an existing manual, locked manual, standby, low vacuum, or high vacuum digital contact 1.

D LAST OUT. R –5 to 105%

8. DIG.IN.2:OUT.

Selects the designated output for an existing manual, locked manual, standby, low vacuum, or high vacuum digital contact 2.

D LAST OUT. R –5 to 105%

9. DIG.IN.3:OUT.

Selects the designated output for an existing manual, locked manual, standby, low vacuum, or high vacuum digital contact 3.

D LAST OUT. R –5 to 105%

FLO W REST .

LAST MODE

DIG.IN.1:OUT.

LAST OUT .

DIG.IN.2:OUT.

LAST OUT .

DIG.IN.3:OUT.

LAST OUT .

10. DIG.IN.4:OUT.

Selects the designated output for an existing manual, locked manual, standby, low vacuum, or high vacuum digital contact 4.

D LAST OUT. R –5 to 105%

DIG.IN.4:OUT.

LAST OUT .

11. DIG.IN.5:OUT.

Selects the designated output for an existing manual, locked manual, standby, low vacuum, or high vacuum digital contact 5.

D LAST OUT. R –5 to 105%

DIG.IN.5:OUT.

LAST OUT .

12. DIG.IN.1:OUT2

(Dual Flow Pacing mode)

For existing properly configured contacts: Selects the designated second output for a manual, locked manual, standby, low vacuum, or high vacuum digital contact 1.

D LAST OUT. R –5 to 105%

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

▲▲

▲

▲▲

▼▼

▼

▼▼

DIG.IN.1:OUT2

LAST OUT .

DISPLAY

555 User's Manual Chapter 5 39

Software Configuration

DIG.IN.2:OUT2

LAST OUT .

DIG.IN.3:OUT2

LAST OUT .

DIG.IN.4:OUT2

LAST OUT .

13. DIG.IN.2:OUT2

(Dual Flow Pacing mode)

For existing properly configured contacts: Selects the designated second output for a manual, locked manual, standby, low vacuum, or high vacuum digital contact 2.

D LAST OUT. R –5 to 105%

14. DIG.IN.3:OUT2

(Dual Flow Pacing mode)

For existing properly configured contacts: Selects the designated second output for a manual, locked manual, standby, low vacuum, or high vacuum digital contact 3.

D LAST OUT. R –5 to 105%

15. DIG.IN.4:OUT2

(Dual Flow Pacing mode)

For existing properly configured contacts: Selects the designated second output for a manual, locked manual, standby, low vacuum, or high vacuum digital contact 4.

D LAST OUT. R –5 to 105%

DIG.IN.5:OUT2

LAST OUT .

STAGE:OUT1

50%

STAGE:OUT2

50%

16. DIG.IN.5:OUT2

(Dual Flow Pacing mode)

For existing properly configured contacts: Selects the designated second output for a manual, locked manual, standby, low vacuum, or high vacuum digital contact 5.

D LAST OUT. R –5 to 105%

17. STAGE:OUT1

When staging outputs, selects the value of the control output value at which output 1 stops (100% for output 1).

R 1 to 100% D 50%

18. STAGE:OUT2

When staging outputs, selects the value of the control output at which output 2 starts (at 0%). 100% control output = 100% on output 2.

R 0 to 99% D 50%

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

40 Chapter 5 555 User's Manual

DISPLAY

FAST MENU

▲

▲▲

▼▼

▼

▼▼

DISPLAY

19. S/W RANGE

Sets the full range resistance of the slidewire being used.

R 1 to 1050 ohms D 1000 ohms

Software Configuration

S/W RANGE

1000

20. S/W OPEN

Sets the slidewire position corresponding to “OPEN” (100% output value).

R 0 to current S/W RANGE value D 1000 ohms

21. S/W CLOSE

Sets the slidewire position corresponding to “CLOSE” (0% output value).

R 0 to current S/W RANGE value D 100 ohms

22. S/W D.BAND

Sets the value percentage of the deadband applied to slidewire control.

R 0.5 to 10.0% (in 0.5% increments) D 2.0 %

23. S/W BREAK

Defines the action to take if the slidewire input is lost (while under automatic control). For ON options, the corresponding relay is turned on (closed) and stays that way throughout the break condition.

D OUTS. OFF same as last out

• OUT1 ON

• OUT2 ON

S/W OPEN

1000

S/W CLOSE

100

S/W D.BAND

2.0%

S/W BREAK

OUTS. OFF

RETRANS.

Requires outputs configured for retransmission. Up to two outputs are allowed for retransmission. Any undefined choices will give “undefined” results (flat line).

RETRANS.

1. RET. TYPE: 2

Selects the type data retransmission for existing retransmission output 2.

D OUT

• FLOW

• RESIDUAL

• CL2 DOSE

• SO2 DOSE

• SETPOINT

• RAMP SP

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

555 User's Manual Chapter 5 41

DISPLAY

FAST MENU

▲▲

▲

▲▲

▼▼

▼

▼▼

RET. TYPE: 2

OUT

DISPLAY

Software Configuration

RET . LO W: 2

RET . HIGH: 2

1000

RET. TYPE: 3

OUT

RET . LO W: 3

2. RET. LOW: 2

Sets the value in engineering units corresponding to the low retransmission output value 2 (except for retransmission of output).

R –9999 to 99999 D0

3. RET. HIGH: 2

Sets the value in engineering units corresponding to the high retransmission output value 2 (except for retransmission of output).

R –9999 to 99999 D 1000

4. RET. TYPE: 3

Selects the type data retransmission for existing retransmission output 3.

D OUT

• FLOW

• RESIDUAL

• CL2 DOSE

• SO2 DOSE

• SETPOINT

• RAMP SP

5. RET. LOW: 3

Sets the value in engineering units corresponding to the low retransmission output value 3 (except for retransmission of output).

R –9999 to 99999 D0

6. RET. HIGH: 3

RET . HIGH: 3

1000

Sets the value in engineering units corresponding to the high retransmission output value 3 (except for retransmission of output).

R –9999 to 99999 D 1000

7. RET. TYPE: 4

RET. TYPE: 4

OUT

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

42 Chapter 5 555 User's Manual

DISPLAY

FAST MENU

Selects the type data retransmission for existing retransmission output 4.

D OUT

• FLOW

• RESIDUAL

• CL2 DOSE

• SO2 DOSE

• SETPOINT

• RAMP SP

▲

▲▲

▼▼

▼

▼▼

DISPLAY

8. RET. LOW: 4

Sets the value in engineering units corresponding to the low retransmission output value 4 (except for retransmission of output).

R –9999 to 99999 D0

9. RET. HIGH: 4

Sets the value in engineering units corresponding to the high retransmission output value 4 (except for retransmission of output).

R –9999 to 99999 D 1000

Software Configuration

RET . LOW: 4

RET . HIGH: 4

1000

ALARMS

Note: All alarms may be assigned to the same output.

1. ALM.TYPE: 1

Selects the type for alarm 1.

D OFF

• HIGH ALRM.

• LOW ALARM

• MANUAL

• VACUUM

• BAND

• DEVIATION

• RATE

2. ALARM SRC: 1

For ALM.TYPE 1 = HIGH ALRM. or LOW ALARM, selects the alarm source.

D FLOW

• RESIDUAL

• CL2 DOSE

• SO2 DOSE

• SETPOINT

• RAMP SP

• DEVIATION

• OUTPUT

ALARMS

ALM.TYPE: 1

OFF

ALARM SRC: 1

FLO W

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

555 User's Manual Chapter 5 43

DISPLAY

FAST MENU

▲▲

▲

▲▲

▼▼

▼

▼▼

DISPLAY

Software Configuration

3. ALARM SP: 1

ALARM SP . 1

4. DEADBAND: 1

DEADBAND: 1

Selects the setpoint for ALM.TYPE 1 = HIGH ALRM., LOW ALARM, BAND,

DEVIATION or RATE.

If ALARM SRC: 1 = FLOW, RESIDUAL, SETPOINT, RAMP or DEVIATION:

R –9999 to 99999 D0

If ALARM SRC: 1 = CL2 DOSE, SO2 DOSE, or OUTPUT:

R 0.0% to 400.0% D0%

Selects the deadband.for ALM.TYPE 1 = HIGH ALRM., LOW ALARM,

BAND, DEVIATION or RATE,

If ALARM SRC: 1 = FLOW, RESIDUAL, SETPOINT, RAMP or DEVIATION:

R –1 to 99999 D2

If ALARM SRC: 1 = CL2 DOSE, SO2 DOSE, or OUTPUT:

R 0.0% to 400.0% D 0.2%

ALM:1OUT.

NONE

LATCHING: 1

LATCH

ACK.: 1

ENABLED

POWER UP: 1

NORMAL

5. ALM.:1 OUT.

For an enabled ALM.TYPE 1, selects the physical output number.

D NONE

• ( of any outputs configured as alarms)

6. LATCHING: 1

For an enabled ALM.TYPE 1, enables or disables alarm latching.

D LATCH

• NO LATCH

7. ACK.: 1

For an enabled ALM.TYPE 1, enables or disables the ACK key.

D ENABLED

• DISABLED

8. POWER UP: 1

For an enabled ALM.TYPE 1, selects condition of the alarm upon power-up.

D NORMAL

• ALARM

• DELAYED

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

44 Chapter 5 555 User's Manual

DISPLAY

FAST MENU

▲

▲▲

▼▼

▼

▼▼

DISPLAY

9. MESSAGE: 1

For enabled ALM.TYPE 1 (except for type VACUUM), a 9-character user-defined message can be shown in the 3rd line display when the alarm is activated.

To use: Select a character with the FAST key (cursor will flash). Use

keys to modify. Selecting all blanks disables the alarm message.

D ALARM 1

10. ALM.TYPE: 2

Selects the type for alarm 2.

D OFF

• HIGH ALRM.

• LOW ALARM

• MANUAL

• VACUUM

• BAND

• DEVIATION

• RATE

▲▲

▲ and

▲▲

Software Configuration

MESSAGE: 1

LAST MODE

▼▼

▼

▼▼

ALM.TYPE: 2

OFF

11. ALARM SRC: 2

For ALM.TYPE 2 = HIGH ALRM. or LOW ALARM, selects the alarm source.

D FLOW

• RESIDUAL

• CL2 DOSE

• SO2 DOSE

• SETPOINT

• RAMP SP

• DEVIATION

• OUTPUT

12. ALARM SP: 2

Selects the setpoint for ALM.TYPE 2 = HIGH ALRM., LOW ALARM, BAND,

DEVIATION or RATE.

If ALARM SRC: 2 = FLOW, RESIDUAL, SETPOINT, RAMP or DEVIATION:

R –9999 to 99999 D0

If ALARM SRC: 2 = CL2 DOSE, SO2 DOSE, or OUTPUT:

R 0.0% to 400.0% D0%

ALARM SRC: 2

FLO W

ALARM SP. 2

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

555 User's Manual Chapter 5 45

DISPLAY

FAST MENU

▲▲

▲

▲▲

▼▼

▼

▼▼

DISPLAY

Software Configuration

13. DEADBAND: 2

DEADBAND: 2

ALM:2 OUT .

NONE

LA TCHING: 2

LATCH

14. ALM.:2 OUT.

15. LATCHING: 2

Selects the deadband for ALM.TYPE 2 = HIGH ALRM., LOW ALARM,

BAND, DEVIATION or RATE.

If ALARM SRC: 2 = FLOW, RESIDUAL, SETPOINT, RAMP or DEVIA-

TION:

R –1 to 99999 D2

If ALARM SRC: 2 = CL2 DOSE, SO2 DOSE, or OUTPUT:

R 0.0% to 400.0% D 0.2%

For an enabled ALM.TYPE 2, selects the physical output number.

D NONE

• ( of any outputs configured as alarms)

For an enabled ALM.TYPE 2, enables or disables alarm latching.

D LATCH

• NO LATCH

A CK.: 2

ENABLED

PO WER UP: 2

NORMAL

MESSAGE: 2

ALARM 2

RATE TIME

16. ACK.: 2

For an enabled ALM.TYPE 2, enables or disables the ACK key.

D ENABLED

• DISABLED

17. POWER UP: 2

For an enabled ALM.TYPE 2, selects the condition of the alarm upon

power-up.

D NORMAL

• ALARM

• DELAYED

18. MESSAGE: 2

For an enabled ALM.TYPE 2 (except for type VACUUM), a 9-character

user-defined message can be shown in the 3rd line display when the alarm is activated.

To use: Select a character with the FAST key (cursor will flash). Use ▼ keys to modify. Selecting all blanks disables the alarm message.

D ALARM 2

19. RATE TIME

Selects the time base for ALM.TYPE = RATE. Rate time combined with

rate alarm SP defines the rate of change (slope) that triggers the alarm.

R 1 to 3600 seconds D5

▲▲

▲ and

▲▲

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

46 Chapter 5 555 User's Manual

DISPLAY

FAST MENU

▲

▲▲

▼▼

▼

▼▼

DISPLAY

Software Configuration

POWER-UP

1. PWR.UP:MODE

Selects the Power-Up mode for the 555.

D LAST MODE

• MANUAL

• AUTOMATIC

2. PWR. UP:OUT.

Selects the power-up value for the output. Used for manual mode power-ups only, or for automatic power-ups when using residual control.

D LAST OUT. R –5.0 to 105.0 %

3. PWR. UP:OUT2

(Dual Flow Pacing Mode)

Selects the power-up value for the second output. Used for manual mode power-ups only.

D LAST OUT. R –5.0 to 105.0 %

4. PWR. UP:SP

Selects the power-up setpoint value source for the 555.

D LAST SP

• LOCAL

• REMOTE

PO WER-UP

PWR.UP:MODE

LAST MODE

PWR. UP:OUT .

LAST OUT .

PWR. UP:OUT2

LAST OUT .

PWR. UP:SP

LAST

SECURITY

1. SEC. CODE

Selects the code number (password) for security.

R –9999 to 99999 D0

SEC. CODE

2. SETPT KEY

Selects lockout status of the SET PT key (SP selection).

• LOCKED D UNLOCKED

SETPT KEY

UNLOCKED

3. SP/DOSAGE

Selects lockout status of the DOSEs).

• LOCKED D UNLOCKED

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

555 User's Manual Chapter 5 47

DISPLAY

▲▲

▲ and

▲▲

▼▼

▼ keys (for modifying local SPs or

▼▼

FAST MENU

▲▲

▲

▲▲

▼▼

▼

▼▼

SP /DOSA GE

UNLOCKED

DISPLAY

Software Configuration

A UTO./MAN.

ALARM ACK.

UNLOCKED

TUNING

UNLOCKED

CONFIGURE

UNLOCKED

SER. COMM.

4. AUTO./MAN.

Selects lockout status of the MANUAL key.

• LOCKED D UNLOCKED

5. ALARM ACK.

Selects lockout status of the ACK key.

• LOCKED D UNLOCKED

6. TUNING

Selects lockout status of the tuning menu.

• LOCKED D UNLOCKED

7. CONFIGURE

Selects lockout status of all the configuration menus.

• LOCKED D UNLOCKED

SER. COMM.

For use with installed communications board (see Chapter 1 to check your controller’s installed options, and Chapter 3 for details on installing the communications module).

1. STATION

STATION

Selects the RS-485 station number for the unit.

• OFF R 1 – 99 D1

2. BAUD RATE

Selects the BAUD rate (in BPS) for the unit.

BA UD RA TE

9600

• 1200

• 2400

• 4800 D 9600

• 19200

3. CRC

CRC

YES

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

Selects whether or not to use the CRC.

D YES

•NO

▲

▲▲

▼▼

▼

▼▼

DISPLAY

48 Chapter 5 555 User's Manual

4. SHED TIME

Defines the time in seconds (from the last communications activity) the controller will wait before determining that communications is lost (“sheds”).

R 1 to 512 D OFF shedding off

5. SHED MODE

If shedding is enabled, selects the state of the controller if communications is lost (“sheds”).

D LAST MODE

• MANUAL

• AUTOMATIC

Software Configuration

SHED TIME

OFF

SHED MODE

LAST MODE

6. SHED OUT.

If shedding is enabled, selects the manual shedding output for the 555.

D LAST OUT. R –5.0 to 105.0 %

7. SHED OUT2

(Dual Flow Pacing Mode only)

If shedding is enabled, selects the second manual shedding output for the 555.

D LAST OUT. R –5.0 to 105.0 %

8. SHED SP

If shedding is enabled, selects the shedding SP for the 555.

D LAST SP

• DESIG. SP

9. DESIG. SP

If shedding is enabled and SHED SP = DESIG. SP, selects the designated

shed SP for the 555.

R LOW RANGE to HI RANGE based on the PV (flow or residual) D0

TUNING

1. CL2 DOSE

Defines the origin of the Cl2 dosage signal. (CL2 DOSE must be selected as the remote input signal for this parameter to appear).

D LOCAL

• REMOTE

SHED OUT .

last out.

SHED OUT2

LAST OUT .

SHED SP

LAST SP

DESIG. SP

TUNING

CL2 DOSE

LOCAL

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

555 User's Manual Chapter 5 49

DISPLAY

FAST MENU

▲▲

▲

▲▲

▼▼

▼

▼▼

DISPLAY

Software Configuration

SO2 DOSE

LOCAL

RSDL. DEV.

INTEGRAL:1

10.0%

TRIPPING

OFF

2. SO2 DOSE

Defines the origin of the SO2 dosage signal. (SO2 DOSE must be selected as the remote input signal for this parameter to appear).

D LOCAL

• REMOTE

3. RSDL. DEV.

(Residual & Compound loop mode)

Determines the deviation from residual setpoint (positive or negative) required before additional integral action will be applied to the output.

R 0 to span of the residual PV input D0

4. INTEGRAL:1

(Residual and Compound loop mode)

Defines Integral value 1.

R 0.0 to 250.0% D 10.0%

5. TRIPPING

(Residual or Compound loop mode)

Determines the type of tripping method to use.

D OFF

• SP NUMBER

• RSDL.PV

• SP VALUE

6. TRIP PT.

(Residual and Compound loop modes)

TRIP PT .

Defines the trip point for Integral value tripping.

R LOW RANGE to HI RANGE Range is the full scale of the residual

input

7. INTEGRAL:2

INTEGRAL:2

10.0%

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

(Residual and Compound loop modes)

Defines Integral value 2.

R 0.0 to 250.0% D 10.0%

▲

▲▲

▼▼

▼

▼▼

DISPLAY

50 Chapter 5 555 User's Manual

PARAMETER VALUE CHARTS

Use these charts to record the parameter values of your controller.

Software Configuration

CONFIG.

1. CTRL. MODE Selects the main operating mode of the controller.

2. OUT. MODE Selects the control output mode of the controller.

3. LINE FREQ. Defines the AC line frequency.

4. OUTPUT 2 Selects use for an existing output in slot 2.

5. OUTPUT 3 Selects use for an existing output in slot 3.

6. OUTPUT 4 Selects use for an existing output in slot 4.

7. ANLG.RNG.:1 Selects the range of operation for an existing mA output in slot 1.

8. ANLG.RNG.: 2 Selects the range of operation for an existing mA output in slot 2.

9. ANLG.RNG.: 3 Selects the range of operation for an existing mA output in slot 3.

10. ANLG.RNG.: 4 Selects the range of operation for an existing mA output in slot 4.

11. CONTACT 1 Selects the use for the existing digital input 1.

12. CONTACT 2 Selects the use for the existing digital input 2.

13. CONTACT 3 Selects the use for the existing digital input 3.

14. CONTACT 4 Selects the use for the existing digital input 4.

15. CONTACT 5 Selects the use for the existing digital input 5.

VALUE

16. REMOTE IN. Defines the value of the remote setpoint feature.

CONTROL

1. FIXED LAG Sets the fixed lag term used for computing the total lag.

2. VARBL. LAG Sets the variable lag term used for computing the total lag.

3. MAX. LAG Sets the maximum limit for the total lag calculation.

4. MIN. TRIM Sets minimum correction to the current flow pacing output level.

5. MAX. TRIM Sets maximum correction to the current flow pacing output level.

6. FLOW ONLY Determines whether to allow flow pacing only control.

7. RSDL. ONLY Determines whether to allow residual only control.

555 User's Manual Chapter 5 51

Software Configuration

FLOW INPT.

1. PV TYPE Selects the type of PV being used for the flow input.

2. DECIMAL Selects position of the decimal point of displayed flow.

3. LINEARIZE Selects the type of linearization used for the flow input.

4. LOW RANGE Sets the value of the low flow input value.

5. HI RANGE Sets the value of the high flow input value.

6. FILTER Sets the amount of filtering to be used for the flow input.

7. PV OFFSET Sets a constant offset to be applied to the flow input.

8. PV GAIN Sets a constant gain to be applied to the flow input.

9. FLOW BRK. Defines percentage of 1st output upon switching to Manual.

10. FLOW BRK.2 Defines percentage of 2nd output upon switching to Manual.

11. FLOW REST. Defines type of control mode after flow signal is restored.

VALUE

52 Chapter 5 555 User's Manual

Software Configuration

CUST.LINR.

1. 1st. INPUT Sets the flow input value for Point 1.

2. 1st. PV Sets the engineering units value for Point 1.

3. 2nd. INPUT Sets the flow input value for Point 2.

4. 2nd. PV Sets the engineering units value for Point 2.

5. 3rd. INPUT Sets the flow input value for Point 3.

6. 3rd. PV Sets the engineering units value for Point 3.

7. 4th. INPUT Sets the flow input value for Point 4.

8. 4th. PV Sets the engineering units value for Point 4.

9. 5th. INPUT Sets the flow input value for Point 5.

10. 5th. PV Sets the engineering units value for Point 5.

11. 6th. INPUT Sets the flow input value for Point 6.

12. 6th. PV Sets the engineering units value for Point 6.

13. 7th. INPUT Sets the flow input value for Point 7.

14. 7th. PV Sets the engineering units value for Point 7.

15. 8th. INPUT Sets the flow input value for Point 8.

VALUE

16. 8th. PV Sets the engineering units value for Point 8.

17. 9th. INPUT Sets the flow input value for Point 9.

18. 9th. PV Sets the engineering units value for Point 9.

19. 10th. INPUT Sets the flow input value for Point 10.

20. 10th. PV Sets the engineering units value for Point 10.

21. 11th. INPUT Sets the flow input value for Point 11.

22. 11th. PV Sets the engineering units value for Point 11.

23. 12th. INPUT Sets the flow input value for Point 12.

24. 12th. PV Sets the engineering units value for Point 12.

25. 13th. INPUT Sets the flow input value for Point 13.

26. 13th. PV Sets the engineering units value for Point 13.

27 14th. INPUT Sets the flow input value for Point 14.

28. 14th. PV Sets the engineering units value for Point 14.

29. 15th. INPUT Sets the flow input value for Point 15.

30. 15th. PV Sets the engineering units value for Point 15.

555 User's Manual Chapter 5 53

Software Configuration

RSDL. INPT.

1. PV TYPE Selects the type of PV being used for the residual chlorine input.

2. DECIMAL Selects position of the decimal point for display of residual value.

3. LOW RANGE Sets the value of the low residual input value.

4. HI RANGE Sets the value of the high residual input value.

5. FILTER Sets the amount of filtering to be used for the residual input.

6. PV OFFSET Sets a constant offset to be applied to the residual input.

7. PV GAIN Sets a constant gain to be applied to the residual input.

8. RSDL. BRK. Defines output percentage upon switching to Manual control.

9. RSDL. REST. Defines control mode upon restoration of residual signal.

SETPOINT

1. SP LOW Sets the value of the lowest SP value allowed.

2. SP HIGH Sets the value of the highest SP value allowed.

3. SP RAMP Defines the SP ramping rate in engineering units per hour.

VALUE

REM. INPUT

1. TYPE V/mA Selects the type/value for the remote input.

2. LOW RANGE Sets the value of the low remote input value.

3. HI RANGE Sets the value of the high remote input value.

4. RATIO Sets the ratio (a constant gain) applied to the remote input.

5. BIAS Sets the bias (a constant offset) applied to the remote input.

6. TRACKING Determines status of remote input value if the signal is lost.

7. RESTORE Defines value to use once the remote input signal is restored.

54 Chapter 5 555 User's Manual

Software Configuration

OUTPUT

1. MIN. OUT. Selects lowest value for the output under automatic control.

2. MAX. OUT. Selects highest value for the output under automatic control.

3. MIN. OUT2 Selects lowest value for the 2nd output under automatic control.

4. MAX. OUT2 Selects highest value for the 2nd output under automatic control.

5. CYCLE TM.:1 Selects the time base for output 1.

6. CYCLE TM.:2 Selects the time base for output 2.

7. DIG.IN.1:OUT. Selects the designated output for digital contact 1.

8. DIG.IN.2:OUT. Selects the designated output for digital contact 2.

9. DIG.IN.3:OUT. Selects the designated output for digital contact 3.

10. DIG.IN.4:OUT. Selects the designated output for digital contact 4.

11. DIG.IN.5:OUT. Selects the designated output for digital contact 5.

12. DIG.IN.1:OUT2 Selects the designated second output for digital contact 1.

13. DIG.IN.2:OUT2 Selects the designated second output for digital contact 2.

14. DIG.IN.3:OUT2 Selects the designated second output for digital contact 3.

15. DIG.IN.4:OUT2 Selects the designated second output for digital contact 4.

16. DIG.IN.5:OUT2 Selects the designated second output for digital contact 5.

VALUE

17. STAGE:OUT1 Selects control output value at which output 1 stops.

18. STAGE:OUT2 Selects control output value at which output 2 starts.

19. S/W RANGE Sets the full range resistance of the slidewire being used.

20. S/W OPEN Sets slidewire position corresponding to “OPEN”.

21. S/W CLOSE Sets slidewire position corresponding to “CLOSE”.

22. S/W D.BAND Sets percentage of the deadband applied to slidewire control.

23. S/W BREAK Defines action if the slidewire input is lost.

555 User's Manual Chapter 5 55

Software Configuration

RETRANS.

1. RET. TYPE: 2 Selects data retransmission type for retransmission output 2.

2. RET. LOW: 2 Sets value of the low retransmission output value 2.

3. RET. HIGH: 2 Sets value of the high retransmission output value 2.

4. RET. TYPE: 3 Selects data retransmission type for retransmission output 3.

5. RET. LOW: 3 Sets value of the low retransmission output value 3

6. RET. HIGH: 3 Sets value of the high retransmission output value 3.

7. RET. TYPE: 4 Selects data retransmission type for retransmission output 4.

8. RET. LOW: 4 Sets value of the low retransmission output value 4.

9. RET. HIGH: 4 Sets value of the high retransmission output value 4.

ALARMS

1. ALM.TYPE: 1 Selects the type for alarm 1.

2. ALARM SRC: 1 Selects the alarm source for alarm 1.

3. ALARM SP: 1 Selects the setpoint for alarm 1.

4. DEADBAND: 1 Selects the deadband for alarm 1.

VALUE

5. ALM.:1 OUT. Selects the physical output number for alarm 1.

6. LATCHING: 1 Enables or disables alarm latching for alarm 1.

7. ACK.: 1E Enables or disables the ACK key for alarm 1.

8. POWER UP: 1 Selects condition of the alarm upon power-up for alarm 1.

9. MESSAGE: 1 A 9-character user-defined message for alarm 1.

10. ALM.TYPE: 2 Selects the type for alarm 2.

11. ALARM SRC: 2 Selects the alarm source for alarm 2.

12. ALARM SP: 2 Selects the setpoint for alarm 2.

13. DEADBAND: 2 Selects the deadband for alarm 2.

14. ALM.:2 OUT. Selects the physical output number for alarm 2.

15. LATCHING: 2 Enables or disables alarm latching for alarm 2.

16. ACK.: 2 Enables or disables the ACK key for alarm 2.

17. POWER UP: 2 Selects the condition of the alarm upon power-up for alarm 2.

18. MESSAGE: 2 A 9-character user-defined message for alarm 2.

19. RATE TIME Selects the time base for ALM.TYPE = RATE.

56 Chapter 5 555 User's Manual

Software Configuration

POWER-UP

1. PWR.UP:MODE Selects the power-up mode for the 555.

2. PWR. UP:OUT. Selects the power-up value for the output.

3. PWR. UP:OUT2 Selects the power-up value for the second output.

4. PWR. UP:SP Selects the power-up setpoint value source for the 555.

SECURITY

1. SEC. CODE Selects the code number (password) for security.

2. SETPT KEY Selects lockout status of the SET PT key (SP selection).

3. SP/DOSAGE Selects lockout status of the

4. AUTO./MAN. Selects lockout status of the MANUAL key.

5. ALARM ACK. Selects lockout status of the ACK key.

6. TUNING Selects lockout status of the tuning menu.

7. CONFIGURE Selects lockout status of all the configuration menus.

▲▲

▲ and

▲▲

▼▼

▼ keys.

▼▼

VALUE

SER. COMM.

1. STATION Selects the RS-485 station number for the unit.

2. BAUD RATE Selects the BAUD rate (in BPS) for the unit.

3. CRC Selects whether or not to use the CRC.

4. SHED TIME Defines the time the controller will wait before shedding.

5. SHED MODE Selects the state of the controller if communications is lost.

6. SHED OUT. Selects the manual shedding output for the 555.

7. SHED OUT2 Selects the second manual shedding output for the 555.

8. SHED SP If shedding is enabled, selects the shedding SP for the 555.

9. DESIG. SP Selects the designated shed SP for the 555.

555 User's Manual Chapter 5 57

Software Configuration

TUNING

1. CL2 DOSE Defines the origin of the Cl2 dosage signal.

2. SO2 DOSE Defines the origin of the SO2 dosage signal.

3. RSDL. DEV. Determines the deviation from residual setpoint.

4. INTEGRAL:1 Defines Integral value 1.

5. TRIPPING Determines the type of tripping method to use.

6. TRIP PT. Defines the trip point for Integral value tripping.

7. INTEGRAL:2 Defines Integral value 2.

VALUE

58 Chapter 5 555 User's Manual

CHAPTER 6 APPLICATIONS

The 555 Controller provides a variety of user-programmable control features and capabilities you may wish to implement in your system. These instructions describe controller setup for specific features. Be sure to cross reference:

• Chapter 4 for complete hardware configuration, wiring and mounting

• Chapter 5 for all software menu parameter configuration

• Appendix D for 555 controller calibration (before use)

A. FLOW PA CING MODE

Flow paced control (also called “flow-proportioning”) positions a chlorine (and/ or sulfur dioxide) valve in direct proportion to the water flow rate. This is an open loop control method, with no feedback value on the chlorine residual level (see Figure 6.1). The process variable (PV2) is the control signal, and the user-defined dosage replaces the traditional setpoint. The dosage can be set from 0.0% to 400% (percentage of gas flow per water flow). It increases or decreases the gas feed rate, in order to maintain the desired chlorine residual level after injection. Similarly, a dosage ranging from 0.0% to 400% is also available for dechlorination with SO2.

Chlorination and dechlorination may be accomplished simultaneously based on the same water rate; this is called Dual Flow Pacing Mode.

Applications

Figure 6.1 Flow Pacing Control

Dosage

Setting

Water Flow

Flow

Signal

Flow

Meter

555

Controller

Valve

Control

Signal

Interface

1st line of display

PV2 Flow in engineering units, as scaled by FLOW INPT. Menu.

(PV2 icon will be lit when applicable)

2nd line of display

OUT [desired] valve position 1 (single and dual flow pacing) OUT2 [desired] valve position 2 (dual flow pacing) DOSE Chlorine or sulfur dioxide dosage (single flow pacing) CL2 Chlorine dosage (dual flow pacing) SO2 Sulfur dioxide dosage (dual flow pacing) VMD [actual] valve position (slidewire option only)

Automatic

Chlorine

Ejector

Valve

Water Flow

555 User's Manual Chapter 6 59

Applications

3rd line of display

Blank under “normal” operation. Used for special messages and alarms. Displays parameter values during configuration.

Basic Operating Procedures

Switch from Automatic to Manual Control:

Press the MANUAL key.

Automatic to manual transition is bumpless ( i.e., the control output value will remain unchanged once the controller is switched to manual control).

Other actions can also switch the controller from automatic to manual control: a PV break, the digital inputs, a communications shed, etc. In these cases the output value will be determined by the associated parameter value (i.e., it can change).

Switch from Manual to Automatic Control:

Press the MANUAL key; this transition is not bumpless. For a bumpless Manual to Automatic transition, press FAST+MANUAL to

initialize the dose values.

Access Set Up & Configuration Menus

Press MANUAL to place the controller under Manual Control. Press FAST+MENU to scroll through menus. Press MENU to scroll through parameters for any menu.

Return to Operating Mode from Set Up

Press DISPLAY, then MANUAL.

Change the Controller Output (percentage):

Press MANUAL (places the controller under manual control). The 2nd dis-

play will show OUT%. Use the

▲▲

▲ and

▲▲

Change the Output:

Press DISPLAY until the 2nd display shows OUT (or for dual flow pacing,

OUT2). Use the

▲▲

▲ and

▲▲

▼▼

▼ to adjust the output percentage.

▼▼

Change Dosage:

For flow pacing: Press DISPLAY until the 2nd line of the display shows

DOSE:.

For dual flow pacing: Press DISPLAY until the 2nd line of the display shows

CL2 or SO2.

▲▲

Use the

▼▼

▲ and

▼ keys to modify the dosage setting.

▲▲

▼▼

▼ to adjust the output percentage.

▼▼

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

60 Chapter 6 555 User's Manual

Hardware Configuration

1. Confirm the installed options of your 555 by comparing the product label (on top of the controller) to the order code in Chapter 1. The output type is contingent upon the module (s) installed.

To change output modules or jumpers, refer to Chapter 3.

2. To mount your controller into a panel, refer to Chapter 4.

▲▲

▲

▲▲

▼

▼▼

DISPLAY

3. Inputs: The Milliamp signal from the flow meter must be wired to terminals

28 and 29. BE SURE to match polarity.

Outputs: The primary output to the chlorinator is wired to terminals 3 and

4 (output 1). Match the polarity. For dual flow pacing, wire the SO2 ejector to terminals 5 and 6 (output 2). Match the polarity. Outputs installed and not used for control can be used for alarms or retransmission.

For full wiring instructions, refer to Chapter 4.

Software Configuration

1. Place 555 under manual control. Enter Set Up mode.

2. Go to CONFIG. Menu

3. Set parameter CTRL. MODE = FLOW PACE.

3. For either chlorination or dechlorination only, set parameter OUT. MODE =

STANDARD.

For chlorination and dechlorination together, set parameter OUT. MODE =

DUAL OUT.

4. You must set all relevant parameters in the FLOW INPT. Menu (e.g., pro-

cess variable input range and scaling data).

5. You must set all relevant parameters in the OUTPUT Menu.

6. Continue through the other set up menus to set all other relevant param-

eters. The TUNING Menu will not be used for Flow Pacing mode.

For proper setup and operation, ALL menus/parameters must be reviewed. Refer to Chapter 5 for a complete listing of menus and parameters.

Applications

B. RESIDUAL CHLORINE LOOP MODE

Residual control is a closed loop system that positions a chlorine valve based on a chlorine residual measurement (PV1). With a user-defined residual set point, the 555 increases or decreases the Cl2 gas feed rate based on the deviation from setpoint (refer to Figure 6.2)

For improved residual control, the 555 uses a fixed lag time function. This function compensates for the time the residual analyzer takes to sample and update its output, as well as the lag in transport time between the chlorine ejector and the residual analyzer. This is Integral (I) control. Flow is not measured, nor factored into this control method; however, over time, the integral control algorithm will correct for changes in flow.

Residual Signal

Residual

Setpoint

Water Flow

555

Controller

Valve

Control

Signal

Automatic

Valve

Chlorine

Ejector

Figure 6.2 Residual Chlorine Loop Control

Chlorine Residual Analyzer

Flow

Sample

Residual Sampling

Point

Water Flow

555 User's Manual Chapter 6 61

Applications

Residual control is well suited for applications where the water flow rate is constant, but the oxidation demand varies. The 555 makes residual control easy to use by continuously displaying the chlorine residual and set point (see INTERFACE below).

Interface

1st line of display

PV1 Chlorine residual level in engineering units, as scaled by the

RSDL.INPT. Menu.

2nd line of display

OUT [desired] valve position LAG Current lag countdown value SP Current setpoint SP2 “” RSP “” DEV Deviation from setpoint VMD [actual] valve position (slidewire option only)

3rd line of display

Blank under “normal” operation. Used for special messages & alarms. Displays parameter values during configuration.

Basic Operating Procedures

Switch from Automatic to Manual Control.

Press the MANUAL key.

Automatic to manual transition is bumpless (i.e., the control output value will remain unchanged once the controller is switched to manual control).

Switch from Manual to Automatic Control.

Press the MANUAL key.

Manual to automatic transition is bumpless (i.e., the control output value will remain unchanged once the controller is switched to automatic control).

Access Set Up & Configuration Menus

(First place the controller under Manual Control).

Press FAST + MENU to scroll through menus. Press MENU to scroll through parameters for any menu.

Return to Operating Mode from Set Up

Press DISPLAY, then MANUAL.

Access Tuning Mode/Menu

Press MENU.

62 Chapter 6 555 User's Manual

Return to Operation Mode from Tuning

Press DISPLAY.

Change Active Setpoint and/or Value

Press the SET PT key. Controller will display the next available local or re-

mote setpoint for residual control. Both local setpoints are always available, but the remote setpoint can be turned off.

To change the value, press the

▼▼

▲,

▼, FAST +

▲▲

▼▼

▲▲

▲, or FAST +

▲▲

▼▼

▼. There is a

▼▼

▲▲

two-second delay before the displayed setpoint becomes active. The SET PT Key lights when a setpoint other than the local SP1 is activated. (Range can

be scaled under the RSDL.INPT Menu).

View Output

Press DISPLAY until 2nd display shows OUT.

View Lag Component

Press DISPLAY until 2nd display shows LAG.

View Residual Setpoint

Press DISPLAY until 2nd line shows SP, SP2, or RSP.

View deviation between Setpoint and Residual Setpoint

Press DISPLAY until 2nd line shows DEV.

Applications

Hardware Configuration

1. Confirm the installed options of your 555 by comparing the product label (on top of the controller) to the order code in Chapter 1. The output type is contingent upon the module (s) installed.

To change output modules or jumpers, refer to Chapter 3.

2. To mount your controller into a panel, refer to Chapter 4.

3. Inputs: The Milliamp signal from the chlorine analyzer is wired to terminals

31 and 32. Be sure to match polarity.

Outputs: (4-20mA) The primary output to the chlorinator is wired to termi-

nals 3 and 4 (output 1). Match the polarity. Outputs installed and not used for control can be used for alarms or retransmission.

For full wiring instructions, refer to Chapter 4.

Software Configuration

See key below for key references to traverse modes/menus.

1. Place 555 under manual control. Enter Set Up.

2. Go to CONFIG. Menu.

3. Set parameter CTRL. MODE = RESIDUAL.

3. Go to CONTROL Menu.

4. Set the parameter FIXED LAG to the appropriate time.

5. Go to RSDL. INPT. Menu. You must set all relevant parameters in this menu

(e.g., process variable input range and scaling data).

6. Continue through the other set up menus to set all other relevant parameters.

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

555 User's Manual Chapter 6 63

DISPLAY

FAST MENU

▲▲

▲

▲▲

▼▼

▼

▼▼

DISPLAY

Applications

NOTE:

You will not see the FLOW INPT. and FLOW LINR. menus due to the “smart menu” function of the 555.

Figure 6.3 Compound Loop Control

7. Access Tuning Mode (press MENU). Set all relevant parameters in the TUNING Menu.

For proper setup and operation, ALL menus/parameters must be reviewed. Refer to Chapter 5 for a complete listing of menus and parameters.

C. COMPOUND LOOP MODE

Compound loop mode combines both flow pacing and residual chlorine mode. The controller positions a chlorine valve based on chlorine residual measurement (PV1) as well as water flow measurement (PV2). The residual control signal trims (modifies) the valve position signal generated by flow proportioning control.

This mode offers the best of both flow pacing and residual control: fast response to changes in water flow (“flow pacing”) that continuously adjusts the Cl tion rate, and fine tuning (integral control) of the valve position due to changes (as measured at the end of each lag time period).

Compound loop control incorporates both a fixed and variable component into

injec-

Residual

Setpoint

Flow

Meter

Flow

Signal

Residual Signal

555

Controller

Water Flow

Valve

Control

Signal

Automatic

Valve

Chlorine

Ejector

Chlorine Residual Analyzer

Residual Sampling

Point

the time lag period. Fixed lag time (typically) represents the time for the residual analyzer to take a sample and update its output. Variable lag time is the time it takes the water traveling from the Cl2 injector to reach the residual sampling point. This compensates for changes in this transportation time due to varying flow rates.

Compound loop is well suited for applications where water flow rate and oxidation demand vary, or where tight control is required. The 555 makes compound loop mode easy to use by continuously displaying the chlorine residual level, residual setpoint, and the flow rate.

Interface

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

64 Chapter 6 555 User's Manual

1st line of display

PV1 Primary PV: Chlorine residual level PV2 or flow input

▲▲

▲

▲▲

▼▼

▼

▼▼

DISPLAY

2nd line of display

OUT [desired] valve position PACE Current portion of the output due to flow pacing TRIM Current portion of the output due to integral LAG Current lag countdown value SP Current Setpoint SP2 “” RSP “” DEV Deviation from setpoint DOSE Chlorine dosage VMD [actual] valve position (slidewire option only)

3rd line of display

RSDL Secondary PV: Chlorine residual level (PV1) FLOW or flow input (PV2)

To switch the display positions of the primary and secondary

PV, press FAST + DISPLAY.

Also used for special messages and alarms (alternates messages with other queued information). Displays parameter values during configuration.

Applications

Basic Operating Procedures

Switch from Automatic to Manual Control

Press the MANUAL key.

Automatic to Manual transition is bumpless (i.e., the control output value will remain unchanged once the controller is switched to Manual Control).

Other actions can also switch the controller from Automatic to Manual Control: a PV break, the digital inputs, a communications shed, etc. In these cases the output value will be determined by the associated parameter value (i.e., it can change).

Switch from Manual to Automatic Control

Press the MANUAL key; this transition is not bumpless. For a bumpless Manual to Automatic transition, press FAST+MANUAL to

initialize the dose values.

Access Set Up & Configuration Menus

(First place the controller under Manual Control).

Press FAST + MENU to scroll through menus. Press MENU to scroll through parameters for any menu.

Return to Operating Mode from Set Up

Press DISPLAY, then MANUAL.

Access Tuning Mode/Menu

Press MENU.

Return to Operation Mode from Tuning

Press DISPLAY.

View Output

Press DISPLAY until the 2nd display shows OUT.

555 User's Manual Chapter 6 65

Applications

View the Flow Pacing Contribution

Press DISPLAY key until 2nd line shows PACE %.

View Residual Contribution

Press DISPLAY key until 2nd line shows TRIM %.

Change Active/Remote Setpoint

Press the SET PT key. Press the SET PT key once to show SP in the 2nd display. Press the SET PT key again to show SP2, and once more to show RSP.

Controller will display the next available local or remote setpoint for residual control. Both local setpoints are always available, but the remote setpoint can be turned off.

To change the value, press the ▲, ▼, FAST + ▲, or FAST + ▼. There is a two-second delay before the displayed setpoint becomes active. The SET PT

Key lights when a setpoint other than the local SP1 is activated.

Change Residual Set Point

▲▲

Press DISPLAY until 2nd line shows SP. Use the

▲ and

▼▼

▼ keys to modify

▲▲

▼▼

the setting (Range is can be scaled under the RSDL.INPT Menu).

View deviation between setpoint and residual set point

Press DISPLAY until 2nd line shows DEV.

Change Dosage

Press DISPLAY key until 2nd line shows DOSE:. Use the

▲▲

▲ and ▼ keys to

▲▲

modify the dosage setting (Range is 0 to 400%).

Hard ware Configuration

1. Confirm the installed options of your 555 by comparing the product label (on top of the controller) to the order code in Chapter 1. The output type is contingent upon the module (s) installed.

To change output modules or jumpers, refer to Chapter 3. To mount your controller into a panel, refer to Chapter 4.

2. Inputs: The signal from the chlorine analyzer is wired to terminals 31 and

32. The signal from the flow meter or transducer is wired to terminals 28 and

29. Be sure to match polarity.

3. Outputs: (4-20mA) The primary output to the chlorinator is wired to termi-

nals 3 and 4 (output 1). Match the polarity. Outputs installed and not used for control can be used for alarms or retrans-

mission.

4. For full wiring instructions, refer to Chapter 4.

Software Configuration

See key below for key references to traverse modes/menus.

1. Place 555 under manual control. Enter Set Up.

2. Go to CONFIG. Menu.

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

▲

▲▲

▼▼

▼

▼▼

DISPLAY

66 Chapter 6 555 User's Manual

3. Set parameter CTRL. MODE = COMPOUND.

4. Go to CONTROL Menu

5. Set the parameters FIXED LAG and VARBL. LAG.

The controller must record the normalized flow present when the variable lag value is entered (thus calibrating this term of the total lag formula). If you are setting up the 555 at a work bench (not installed at site), provide a signal to the flow input terminals that equals the normalized flow value. If setting up the 555 at the installation site, set the variable lag parameter when the normal flow is present.

To allow for real-time display of flow while entering lag values, use the FAST and DISPLAY keys to toggle between the residual level and flow (PV2 icon

lit) in the upper display line.

6. Go to FLOW. INPT. Menu. You must set all relevant parameters in this menu

(e.g., process variable input range and scaling data).

7. Go to RSDL. INPT Menu. You must set all relevant parameters this menu

(e.g., residual input range and scaling data).

8. Continue through the other set up menus to set all other relevant parameters.

9. Access Tuning Mode (press MENU). Set all relevant parameters in the

TUNING Menu. For proper setup and operation, ALL menus/parameters must be re-

viewed. Refer to Chapter 5 for a complete listing of menus and parameters.

Applications

Note:

In Compound mode, both a residual set point and dosage must be set.

D. DECHLORINA TION MODE

Feedforward dechlorination positions a valve, typically SO2,in direct proportion to the water flow rate and the residual Cl2 level. The user defines the SO dosage value from 0.01% to 400% (percentage of gas flow per water flow). The 555 will increase or decrease the rate of gas release depending upon changes in the residual level or water flow rate.

Ease of use is provided by continuous readout of chlorine residual level, dosage setting and flow rate. Dechlorination is required to maintain the amount of free chlorine within regulatory discharge limits.

Valve Control Signal

Dosage

Setting

Flow

Meter

Flow

Signal

555

Controller

Water Flow

Residual

Signal

Chlorine Residual Analyzer

Residual Sampling

Point

Figure 6.4 Dechlorination Control

Automatic

Valve

Sulfur

Dioxide

Injector

555 User's Manual Chapter 6 67

Applications

Interface

1st line of display

PV1 Primary PV: Chlorine residual level (PV1) PV2 or flow input (PV2)

To allow for real-time display of flow while entering lag values, use FAST+DISPLAY to toggle between the residual level and flow (PV2 icon lit) in the upper display line.

2nd line of display

OUT [desired] valve position DOSE Sulfur dioxide dosage VMD [actual] valve position (slidewire option only)

3rd line of display

RSDL Secondary PV: Chlorine residual level (PV1) FLOW or flow input (PV2).

To switch the display positions of the primary and secondary

PV, press FAST + DISPLAY.

Also used for special messages and alarms (alternates messages with other queued information). Displays parameter values during configuration.

Basic Operating Procedures

Switch from Automatic to Manual Control

Press the MANUAL key.

Automatic to manual transition is bumpless (i.e., the control output value will remain unchanged once the controller is switched to manual control).

Switch from Manual to Automatic Control

Press the MANUAL key; this transition is not bumpless. For a bumpless Manual to Automatic transition, press FAST+MANUAL to

initialize the dose values.

Access Set Up & Configuration Menus

(First place the controller under Manual Control). Press FAST + MENU to

scroll through menus. Press MENU to scroll through parameters for any menu.

Return to Operating Mode from Set Up

Press DISPLAY, then MANUAL.

View Output

Press DISPLAY key until the 2nd display will show OUT.

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

68 Chapter 6 555 User's Manual

▲▲

▲

▲▲

▼▼

▼

▼▼

DISPLAY

Change Dosage

▲▲

Press DISPLAY key until 2nd line shows DOSE:. Use the modify the dosage setting. The input range can be scaled in the FLOW INPT.

Menu.

▲ and

▲▲

▼▼

▼ keys to

▼▼

Hardware Configuration

1. Confirm the installed options of your 555, by comparing the product label (on top of the controller) to the order code in Chapter 1. The output type is contingent upon the module (s) installed.

To change output modules or jumpers, refer to Chapter 3.

2. To mount your controller into a panel, refer to Chapter 4.

3. Inputs: The signal from the chlorine analyzer is wired to terminals 31 and

32. The signal from the flow meter or transducer is wired to terminals 28 and 29. Be sure to match polarity.

Outputs: The primary output to the dechlorinator is wired to terminals 3

and 4 (output 1). Match the polarity. Outputs installed and not used for control can be used for alarms or retransmission.

For full wiring instructions, refer to Chapter 4.

Applications

Software Configuration

See key below for key references to traverse modes/menus.

1. Place 555 under manual control. Enter Set Up.

2. Go to CONFIG. Menu.

3. Set parameter CTRL. MODE = DECHLOR.

4. Go to FLOW. INPT. Menu You must set all relevant parameters in the FLOW. INPT. Menu (e.g., pro-

cess variable input range and scaling data).

5. Go to RSDL. INPT. Menu You must set all relevant parameters in the RSDL. INPT. Menu (e.g., re-

sidual input range and scaling data).

6. Continue through the Menus (except TUNING) to set all other relevant

parameters.

For proper setup and operation, ALL menus/parameters must be reviewed. Refer to Chapter 5 for a complete listing of menus and parameters.

555 User's Manual Chapter 6 69

Applications

E. ALARMS

The 555 controller has two extremely flexible and powerful software alarms. Linking alarms to relays is limited by the number of outputs available. A Global Alarm feature allows both alarms to be assigned to the same relay. This is configured under the output assignment menu selection.

The 555 indicates an alarm condition:

• Lighting up the alarm icon(s)

• Displaying a custom message in the 3rd display

• Illuminating the ACK key if the alarm is acknowledgeable

Parameter s

All possible parameters are listed here. However, once you select an alarm type, only those parameters related to that alarm will appear in your display.

ALM. TYPE: 1 and ALM. TYPE: 2

Specifies the type of alarm to implement. Selection includes:

• OFF Alarm off.

• HIGH ALRM. High alarm. Occurs when the selected alarm source value exceeds

the alarm setpoint.

• LOW ALARM Low alarm. Occurs when the selected alarm source value falls be-

low the alarm setpoint.

• MANUAL Occurs when the controller is put into manual mode of operation. This

may be useful for security purposes or to alert the operator that he is no longer controlling automatically.

• VACUUM Occurs when a low or high vacuum input is detected.

• BAND (Residual and Compound Loop Mode only) Creates a band centered around the control setpoint. The overall size

of the band is twice the alarm setpoint. Alarm is dependent on the control setpoint. As the control setpoint changes, the band changes accordingly.

For example, if your control setpoint is 500 and the alarm setpoint is 25, then the band extends from 475 to 525. An alarm occurs when the process variable travels outside of this band.

• DEVIATION (Residual and Compound Loop Mode only) Similar to the band alarm except it only creates a band on one side of

the control setpoint. Occurs when the process variable deviates from the control setpoint by an amount greater than the alarm setpoint. Alarm is dependent on the control setpoint; as the control setpoint changes, the alarm point changes.

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

70 Chapter 6 555 User's Manual

▲▲

▲

▲▲

▼

▼▼

DISPLAY

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, you would select an alarm setpoint of –50.

• RATE (Residual and Compound Loop Mode only) 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 has a chance to reach an undesirable level.

For example, if you have an alarm setpoint of 10 and 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

Specifies the variable upon which any selected HIGH or LOW alarm will be based (available for each alarm). Selection includes:

• FLOW

• RESIDUAL

• CL2 DOSE

• SO2 DOSE

• SETPOINT

• RAMP SP

• DEVIATION

• OUTPUT.

ALARM SP:1 and ALARM SP:2

For High, Low, Band, Deviation or Rate alarms, specifies the point at which an alarm occurs (for qualifying alarms) in engineering units.

• If the Alarm Source = FLOW, RESIDUAL, SETPOINT, RAMP SP or DEVIATION, the setpoint range is from –9999 to 99999.

• If the Alarm Source = CL2 DOSE, SO2 DOSE, or OUTPUT, the setpoint range is 0.0% to 400.0%.

DEADBAND:1 and DEADBAND:2

For High, Low, Band, Deviation or Rate alarms, specifies the range through which the process variable must travel before leaving an alarm condition (see alarm examples at the end of this section for an illustration). This prevents frequent alarm oscillation or “chattering” if the process variable has stabilized around the alarm point.

• If the Alarm Source = FLOW, RESIDUAL, SETPOINT, RAMP SP or DEVIATION, the setpoint range is from 1 to 99999.

• If the Alarm Source = CL2 DOSE, SO2 DOSE, or OUTPUT, the setpoint range is 0.0% to 400.0%.

ALM:1 OUT and ALM:2 OUT

For any enabled alarm, selects the physical output number to which the selected alarm output will be assigned. It is possible to assign all alarms to the same output relay, thus creating a “global” alarm output.

Applications

555 User's Manual Chapter 6 71

Applications

NOTE:

Powering down the 555 acknowledges (clears) all latched alarms.

LATCHING:1 and LATCHING:2

For any enabled alarm, enables or disables latching. A latching alarm will remain active after leaving the alarm condition unless it is acknowledged. A non-latching alarm will return to the non-alarm state when leaving the alarm condition without being acknowledged.

ACK.:1 and ACK.:2

For any enabled alarm, enables or disables operator use of the ACK key

to acknowledge an alarm at any time, even if the control process is still in the alarm condition.

A latching alarm can always be acknowledged when it is out of the alarm

condition. When either alarm is available to be acknowledged, the ACK

key will be illuminated. If both alarms are acknowledgeable, pressing the

ACK key will first acknowledge alarm #1. Pressing the ACK key a sec-

ond time will acknowledge alarm #2.

POWER UP:1 and POWER UP:2

For any enabled alarm, selects the alarm condition upon power up. Choices are:

• NORMAL Controller will power up in alarm only if it is in an alarm condition.

• ALARM Controller always powers up in alarm regardless of system’s alarm

condition. This is an excellent way to activate an alarm if there has been a power failure.

• DELAYED Controller will never power up in alarm, regardless of system’s alarm

condition. The system must leave and reenter the alarm condition before the alarm will activate. This is typically used to avoid alarms during start up.

MESSAGE:1 and MESSAGE:2

For any enabled alarm except type VACUUM, allows nine-character, user-defined message in the 3rd display, when the respective alarm is active. If both alarms are active or another diagnostic message is present, the messages will alternate.

To use: Select a character with the FAST key (cursor will flash). Use

▼▼

and

▼ keys to modify. Selecting all blanks disables the alarm message.

▼▼

RATE TIME

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. The range is from 1 to 3600 seconds.

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.

▲▲

▲

▲▲

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

72 Chapter 6 555 User's Manual

▲▲

▲

▲▲

▼

▼▼

DISPLAY

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-of-change, the shorter the time period, the more sensitive the rate alarm.

Applications

Alarm Examples

A. BAND ALARM

IN ALARM

CONDITION

C.SP

RELAY ENERGIZED

ICON OFF NO ALARM CANNOT

PARAMETER SETTINGS:

ALM. TYPE:1 = BAND OUTPUT N = ALM.RLY:OFF

RELAY DE-ENERGIZED

ICON ON CANNOT

ACKNOWLEDGE

ALM.:1 OUT.= N LATCHING:1 = DISABLED

(N = output number)

RELAY ENERGIZED

ICON OFF

NO ALARM

IN ALARM

CONDITION

TIME

RELAY DE-ENERGIZED

ICON ON

ACKNOWLEDGE

ACK.:1 = DISABLED

C.SP +

A.SP

C.SP – A.SP

Figure 6.5 Alarm Examples

B. HIGH PROCESS VARIABLE ALARM

IN ALARM

CONDITION

RELAY DE-ENERGIZED

ICON OFF NO ALARM

PARAMETER SETTINGS:

ALM. TYPE:1 = HIGH ALRM. OUTPUT N = ALM.RLY:ON ACK.:1 = ENABLED

RELAY ENERGIZED

ICON ON MAY

ACKNOWLEDGE

(N = output number)

ALM. SRC.:1 - FLOW (or RESIDUAL) ALM.:1 OUT. = N LATCHING:1 = DISABLED

TIME

RELAY DE-ENERGIZED

ICON OFF NO ALARM

A.SP

C. DEVIATION ALARM

IN ALARM

C.SP

CONDITION

RELAY DE-ENERGIZED

ICON OFF NO ALARM

PARAMETER SETTINGS:

ALM. TYPE:1 = DEVIATION OUTPUT N = ALM.RLY:ON

555 User's Manual Chapter 6 73

RELAY ENERGIZED

ICON ON

MAY ACKNOWLEDGE

(N = output number)

ALM.:1 OUT.= N LATCHING:1 = DISABLED

C.SP + A.SP

TIME

MUST ACKNOWLEDGE TO SHUT OFF ICON AND DE-ENERGIZE RELAY

ACK.:1 = ENABLED ALARM SP:1 = (<0)

D. POWER UP ALARM

A.SP

UNIT POWER UP

RELAY ENERGIZED

ICON ON

MAY ACKNOWLEDGE

PARAMETER SETTINGS:

ALM. TYPE:1 = HIGH ALRM. OUTPUT N = ALM.RLY:ON ACK.:1 = DISABLED

ALARM

CONDITION

RELAY ENERGIZED

ICON ON CANNOT

ACKNOWLEDGE

(N = output number)

ALM. SRC.:1 - FLOW (or RESIDUAL) ALM.:1 OUT. = N LATCHING:1 = ENABLED

TIME

RELAY ENERGIZED

ICON ON

MAY ACKNOWLEDGE

Applications

F . SLIDEWIRE POSITION PROPORTIONING OUTPUT

The 555 accommodates electric actuators with slidewire position proportioning feedback. Slidewire position proportioning utilizes a slidewire feedback signal to determine the true position of the actuator being controlled.

Hard ware Configuration

1. You must have the Slidewire Feedback option installed.

2. You must have mechanical relays, solid state relays or DC logic modules installed in the first two output sockets.

Refer to the Order Code in Chapter 1 for more information.

Software Configuration

To configure the software for Slidewire Position Proportioning, make the following menu selections:

1. Place the controller under Manual control.

2. Go to the CONFIG. Menu.

3. Set parameter OUT.MODE to SLIDEWIRE. You must have the slidewire

feedback option installed in order to able to select SLIDEWIRE.

4. Go to the OUTPUT Menu.

5. For parameter S/W RANGE, enter the value of the full range resistance

of the slidewire from end-to-end. If you have a 100 ohm slidewire, then this parameter should be set to 100.

6. Scroll to S/W OPEN (Open feedback). Enter the ohm value when the

actuator is fully open (0 to 1050 ohms).

7. Scroll to S/W CLOSE (Closed feedback). Enter the ohm value when the

actuator is fully closed (0 to 1050 ohms).

8. Measure the actual slidewire value at the terminals (10 and 11). As an alternative, you can set up these two parameters dynamically.

Before entering Set Up set the manual output at 100%. Enter Set Up and

change the S/W OPEN, 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 S/W CLOSE value until the actuator just reaches its full

closed position.

9. Set the parameter S/W D.BAND, 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 find the optimum setting:

a. Set parameter S/W D.BAND to 0.5%.

b. Place the controller under Manual control. c. Change the output percentage and observe if the valve stabilizes

at the new value.

d. If the valve oscillates, increase the S/W D.BAND value by 0.5%;

repeat until oscillation stops.

10.Set the parameter S/W BREAK to define the output value for when the

slidewire breaks.

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

74 Chapter 6 555 User's Manual

▲▲

▲

▲▲

▼

▼▼

DISPLAY

G. STA GED OUTPUTS

With staged outputs, one analog output can vary its signal (e.g. 4—20mA) 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.

Hardware Configuration

•

There must be an analog output modules in each of the first two output sockets.

Software Configuration

1. Go to the CONFIG. Menu.

2. Set the CTRL. MODE parameter to STAGED.

3. Go to the OUTPUT Menu.

4. For the STAGE:OUT1 parameter, specify the output percent where the

first output reaches its maximum.

5. For the STAGE:OUT2. parameter, specify the output percent where the

second output begins (at 0%).

Applications

H. RETRANSMISSION

The retransmission feature may be used to transmit (milliamp) signals to two outputs. You may send any of the following values: OUT, FLOW, RESIDUAL, CL2 DOSE, SO2 DOSE, SETPOINT or RAMP SP. A common application is to use it to send one of these variables to a recorder.

Hardware Configuration

• There must be an analog module installed in output socket 2, 3 or 4.

Software Configuration

1. Go to the CONFIG. Menu.

2. For OUTPUT:2, OUTPUT:3 and OUTPUT:4 parameters, set one or two

of them to RETRANS.

3. Go to the RETRANS. Menu.

4. Set the corresponding parameter RET.TYPE:X for your first retransmis-

sion output. This defines whether you will be transmitting the process variable, setpoint, ramping setpoint or output.

5. For your first retransmission output, set parameters RET.LOW:X and RET.HIGH:X. These parameters allow you to define the range of the

transmitted signal in engineering units. This can be useful in matching the input range of the device to which you are transmitting.

6. For any other retransmission output, continue to scroll through the this

menu and set the RET.TYPE:X, RET.LOW:X and RET.HIGH:X for the

second retransmission output.

555 User's Manual Chapter 6 75

Applications

I. DIGIT AL INPUTS

Digital inputs can be activated in three ways:

• A switch (signal type) — the recommended type

• Closure of a relay

• 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 “smart menus” in Chapter 5). There are 14 contact types for the up to 5 digital inputs.

Hard ware Configuration

• This optional feature is only available if ordered originally from the factory, Product #555xxxxxxDx00. The five digital (contact) inputs share a common ground.

Software Configuration

1. Go to the CONFIG. Menu.

2. Set parameters CONTACT:1 through CONTACT:5 (only those available

will show) by assigning the desired function to each input. Choices are as follows:

• MANUAL Contact closure places the 555 under manual control. Contact can

be overridden by using the MANUAL key. If contact causes a transi-

tion to manual from automatic control, the corresponding designated output action is performed.

• LOCK MAN. Contact closure locks the 555 in manual control. Contact cannot be

overridden with the MANUAL key; attempts cause LOCKED mes-

sage to be displayed. Whether or not the contact caused a transition to manual, the corresponding designated output action is always performed.

• REM. INPUT Contact closure activates use of the remote input (RSP, CL2 DOSE

or SO2 DOSE). Contact can be overridden with the SET PT key (for RSP), or by the LOCAL/REMOTE selection in the TUNING Menu

(for remote doses).

• 2ND. SETPT. Contact closure activates use of the second setpoint, SP2. Contact

can be overridden with SET PT key.

• 2ND. INT. Contact closure activates use of the 2nd integral value.

• ALARM ACK. Contact closure acknowledges any existing, acknowledgeable

alarms.

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

76 Chapter 6 555 User's Manual

▲▲

▲

▲▲

▼

▼▼

DISPLAY

• INT. INHBT (Residual or Compound Loop modes only) Contact closure suspends

integral term calculations. Controller will hold any existing integral contribution at its last value.

• UP KEY, DOWN KEY, DISP. KEY, MENU KEY, FAST KEY Contact closure causes action as if the corresponding key is pressed.

Useful for enclosure mounting or other short length remote control applications where the user can still see the 555 display.

• COMM. ONLY Contact closure allows reading of the state of that contact via RS-

485 communications.

• STANDBY Contact closure:

1. Locks the controller into Manual Control (and any integral “windup”

is prevented);

2. Puts the output at a predefined output or holds the “last” output,

as configured by the corresponding digital input/output entry. Predefined output values range from –5% to 105%.

3. Adds the message STANDBY to the 3rd display queue. Clearing this contact will assert AUTOMATIC control unless this is

prevented by other conditions. Therefore in Compound Mode, the “trim” contribution is automatically zeroed upon leaving “standby” mode, allowing a fresh start from the initial flow paced output.

• LO VACUUM, HI VACUUM Contact closure initially starts a 30 second delay timer. After the 30

seconds:

1. The controller locks into manual control (controller cannot enter

into automatic control);

2. The output goes to a predefined output or holds the “last” output,

as configured by the corresponding DIG.IN.X:OUT. entry. Pre-

defined output values range from –5% to 105%.

3. For a low vacuum contact, NO VACUUM is added to the mes-

sage queue. For a high vacuum contact, NO GAS is added to the message

queue.

4. If configured for a VACUUM alarm, an alarm relay is activated.

The above special message replaces the traditional alarm message.

For Digital Inputs of type MANUAL, LOCKED MANUAL, STANDBY, LO VACUUM or HI VACUUM , continue with step 3.

3. Go to the OUTPUT Menu.

4. Set corresponding designated output parameter(s) DIG.IN.X:OUT, where

X=1,2,3,4 or 5. Values are LAST OUT., or range from –5 to 105%.

5. Set corresponding designated output parameter(s) DIG.IN.X:OUT2, where

X=1,2,3,4 or 5. Values are LAST OUT., or range from –5 to 105%.

Applications

555 User's Manual Chapter 6 77

Applications

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.

J. REMOTE INPUT

This feature can be used for receiving remote input signals.

Hard ware Configuration

• This optional feature is only available if ordered originally from the factory, Product #555-xxxxxBxx00. Before configuring the software make sure that the corresponding jumper is in the proper location (refer to your order code in Chapter 1, and hardware set up in Chapter 3).

Software Configuration

1. Go to the CONFIG. Menu

2. Set the value for the parameter REMOTE IN. Choices are:

• OFF

• SETPOINT

• CL2 DOSE

• SO2 DOSE

3. For REMOTE IN. = SETPOINT, you can enable a ramping to setpoint function, by entering a numeric value for the parameter SP RAMP. This

value defines the maximum rate of change toward setpoint (in engineering units per hour) allowed after power up, a setpoint change or a manual-to-automatic mode transfer. Ramping is only allowed only under automatic control.

• An actively ramping setpoint causes the 2nd display to alternate showing the SP (SP2, RSP) and the ramping setpoint. The 3rd display will show RAMPING.

4. Go to the REM. INPUT. Menu and set its parameters, as follows.

5. Parameter TYP. V/MA defines the input signal range (e.g. 1 - 5 V and 4 -

20mA).

6. Parameters LOW RANGE and HI RANGE define the range of the remote

setpoint in engineering units. The correct range will be dependent on the source of the remote setpoint signal.

7. Parameter RATIO applies constant gain to the output. Range is from –

99.99 to 99.99 with a default of 1.00.

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

78 Chapter 6 555 User's Manual

▲▲

▲

▲▲

▼

▼▼

DISPLAY

8. Parameter BIAS applies a constant offset to the RSP input. For setpoint,

the range is from –9999 to 99999. For dosages, the range is from –

200.0% to 200.0%.

9. Parameter TRACKING determines whether or not the controller will

revert to a local setpoint if the remote setpoint signal is lost (only for remote input = setpoint). This prevents a process upset due to a sudden change in setpoint. Choices are YES and NO.

10.Parameter RESTORE determines to what signal the controller will revert

once the RSP loss is restored. Choices are LOCAL and REMOTE.

Basic Operating Procedures

After configuring the hardware and software, you select the remote input by:

1. Pressing the SET PT key until RSP shows in the 2nd display; or

2. Using a digital input (see Digital Input section in Chapter 5).

K. INTEGRAL SETTING

The 555 uses two integral values to tune its control action. This tuning option is available only for residual and compound loop modes. A

“tripping” parameter determines use of one or both of the values.

Applications

Software Configuration

1. The controller must set for residual or compound loop control in order to use Integral settings.

2. Enter the TUNING Menu, by pressing MENU.

3. Set parameter INTEGRAL:1. Range is from 0.0% to 250.0%.

4. Set parameter TRIPPING. Choices are:

D OFF (default)

• SP NUMBER Enables both integral settings, with the active value determined by

the active local setpoint number. (Changing to RSP will be a “last”, i.e., it does not change the active set.).

• RSDL. PV, SP VALUE Enables both integral settings. Value# 1 is used, unless the

TRIPPING value is greater than or equal to TRIP PT.

(see next step).

5. If using both values, set parameter TRIP PT. This specifies the point for

integral value tripping.

6. If using both values, set parameter INTEGRAL:2. Range is from 0.0% to

250.0%.

555 User's Manual Chapter 6 79

Applications

NOTE:

To change the 555 to automatic mode without initializing the dose values, press the MANUAL key alone.

L. TUNING TIPS

The 555 uses flow-paced and integral calculations to determine output under automatic control. The control algorithm determines the specific control strategy.

Flow Pacing Contr ol

Flow Pacing control calculates the control output percentage based on the PV2 and dose values. The equation is:

OUT = FLOW x DOSE

where FLOW is a percentage of the flow input range, and DOSE is a percentage value.

For duplex flow pacing, the first output becomes a function of FLOW and CL2 dose, and the second control output is a function of FLOW and SO2 dose. The equations are:

OUT = FLOW x CL2 OUT2 = FLOW x SO2

where for both the FLOW is a percentage of the flow input range, and CL2 and SO2 are percentage values.

• The PV2 input parameters must be properly configured for Flow Pacing output calculations.

• The DOSE, CL2 and SO2 values can be manually set with the

▼▼

▼ keys, or through automatic algorithm. For automatic set up of the

▼▼

dosage values:

a. Connect the flow input to the 555. Properly configure the FLOW

INPT Menu parameters. The flow must be stable and at a non-

minimal value (a high flow rate produces a more accurate dose).

b. Adjust the OUT (while under manual control) to the desired value

for the current flow rate. For duplex mode.

c. Hold the FAST key and press MANUAL. This will switch the 555

to automatic mode while initializing the dose values to maintain the current ratio of output contribution to flow rate.

d. For duplex flow pacing, perform a, b, and c for OUT2 as well.

▲▲

▲ and

▲▲

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

80 Chapter 6 555 User's Manual

DISPLAY

FAST MENU

Residual Control

Residual control calculates the control output percentage based on the PV1, setpoint and integral values. At the end of each lag period, the deviation from the residual setpoint is measured and multiplied by the integral value, to determine the amount of output correction to make. The lag compensates for the time it takes the residual to respond to the most recent output change (before another integral adjustment is made). If there is no lag, an integral adjustment is made every 0.1 seconds. The equation is:

OUT =

where INTEGRAL is a percentage value, and SP and RSDL are percent-

ages of the residual input (PV1) range.

(INTEGRAL x [SP - RSDL]

ΣΣ

▲▲

▲

▲▲

▼

▼▼

DISPLAY

• The PV1 input parameters and fixed lag time must be properly configured for residual output calculations.

• The integral value is used to eliminate deviation from setpoint. Control performance should be observed for several lag periods to determine if any integral value adjustments are needed. Control responses may be as follows (refer to Figure 6.6):

a. Overdamped control

If several lag periods elapse before the Residual PV reaches the setpoint, the integral value should increase slightly.

b. Underdamped control

If the residual PV overshoots the setpoint, and then needs several additional lag periods to settle, the integral value should be decreased slightly.

c. Oscillating control

If the control valve alternately opens and closes each lag period, decrease the integral value a large amount.

Note: Configuring a specific value for the PWR.UP:OUT parameter (in the POWER-UP Menu) to load into the output at power-up,

will bring the Residual PV to setpoint more quickly.

Applications

Overdamped Response Underdamped Response Oscillating Response

Residual

01234

Acceptable Response 1 Acceptable Response 2

Residual

01234

Residual

01234

Residual

01234 Lag Times

Residual

01234 Lag Times

SETPOINT

Compound Loop Control

Compound Loop control calculates the control output percentage based on the PV2 flow, dose, setpoint and integral values. This is essentially a combination of Flow Pacing and Residual control: the dose value sets the ratio of chlorine contribution to the flow rate, and integral control is used to eliminate any deviation from setpoint over time.

At the end of each lag period, the deviation from the residual setpoint is measured and multiplied by the integral value, to determine the amount of output correction to make. The lag compensates for the time it takes the

SETPOINT

Figure 6.6 Residual Control Responses

555 User's Manual Chapter 6 81

Applications

residual to respond to the most recent output change (before another integral adjustment is made). If there is no lag, an integral adjustment is made every

0.1 seconds. The equation is:

NOTE:

To change the 555 to automatic mode without initializing the dose values, press the MANUAL key alone.

OUT = (FLOW x DOSE) +

where FLOW is a percentage of the flow input range, DOSE and INTEGRAL are percentage values, and SP and RSDL are percentages of the residual input range.

• The PV1, PV2, fixed and variable lag parameters must be set up properly to enable Compound Loop output calculations.

• The DOSE value can be manually set with the automatic algorithm. For automatic set up of the dosage values:

a. Connect the flow and residual inputs to the 555. Properly configure

the FLOW INPT. Menu and RSDL. INPT. Menu parameters. The flow

must be stable and at a non-minimal value (a high flow rate produces a more accurate dose).

b. Adjust the OUT (while under manual control) to the desired value for

the current flow rate. For duplex mode.

c. Hold the FAST key and press MANUAL. This will switch the 555 to

automatic mode while initializing the dose values to maintain the current ratio of output contribution to flow rate.

• Control performance should be observed for several lag periods to determine if any integral value adjustments are needed. Control responses may be as follows (refer to Figure 6.6):

a. Overdamped control

If several lag periods elapse before the Residual PV reaches the setpoint, the integral value should increase slightly.

b. Underdamped control

If the residual PV overshoots the setpoint, and then needs several additional lag periods to settle, the integral value should be decreased slightly.

c. Oscillating control

If the control valve alternately opens and closes each lag period, decrease the integral value a large amount.

Note: Configuring a specific value for the PWR.UP:OUT parameter (in the POWER-UP Menu) to load into the output at power-up, will

bring the Residual PV to setpoint more quickly.

(INTEGRAL x [SP - RSDL])

ΣΣ

▲▲

▲ and

▲▲

▼▼

▼ keys, or through

▼▼

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

82 Chapter 6 555 User's Manual

DISPLAY

FAST MENU

Dechlorination Control

Dechlorination control calculates the control output percentage based on the PV1, PV2, and the SO2 dose values. The equation is:

OUT = FLOW x RSDL x DOSE

where FLOW is a percentage of the flow input range, RSDL is a percentage of the residual input range, and DOSE is a percentage values.

▲▲

▲

▲▲

▼

▼▼

DISPLAY

• The PV1 and PV2 input parameters must be properly configured for the dechlorination output calculations.

▲▲

• The DOSE values can be manually set with the

▼▼

▲ and

▼ keys, or through

▲▲

▼▼

automatic algorithm. For automatic set up of the dosage values:

a. Connect the flow and residual input to the 555. Properly configure

the FLOW INPT. Menu and RSDL.INPT. Menu parameters. The flow

and residual inputs must be stable and at a non-minimal value (larger values will produce a more accurate dose).

b. Adjust the OUT (while under manual control) to the desired output

value for the current flow rate.

c. Hold the FAST key and press MANUAL. This will switch the 555 to

automatic mode while initializing the dose values to maintain the current ratio of output contribution to flow rate and residual value.

M. INPUT LINEARIZA TION

This function is only available for control modes that use a flow signal, i.e., Flow Pacing, Compound Loop or Dechlorination. Input linearization is useful because many flow transmitters generate a nonlinear signal corresponding to the flow being measured. There are two methods of input linearization: square root and custom.

For square root linearization, the 555 calculates the square root of the signal. For the first 1% of the input span, the input is treated in a linear fashion. Then it is calculated using the formula in Figure 6.7.

Applications

NOTE:

To change the 555 to automatic mode without initializing the dose values, press the MANUAL key by itself.

PV = Low Range + [ (Hi Range – Low Range) (V

Where: Hi Range is the high end of the process variable.

Low Range is the low end of the process variable. V

is the actual voltage or current value of the input.

input

is the high end of the input signal range (e.g. 5 volts or 20 mA).

high

is the low end of the input signal range (e.g. 1 volt or 4 mA).

low

Example: Process variable range is 0 – 1000.

Input signal range is 1–5 volts Input signal is 3 volts. Therefore, the PV will be—

PV = 0 +

[(1000 – 0) (3-1) / (5–1) ] = 1000 .5 = 707

input

- V

low

/ (V

high

– V

low

) ]

Custom linearization allows you to take virtually any nonlinear signal and linearize it with a 15-point straight line approximation curve (see Figure 6.8). Typical applications are nonlinear transducer signals, or volume control based on level readings for irregularly-shaped vessels. To define the function, you must enter data point pairs — an engineering unit value, and the corresponding voltage or current input.

Once the points are defined, the values between the points are interpolated with straight line relationships. This function is limited by the fact that the resulting curve must be either ever-increasing or ever-decreasing.

Figure 6.7 Square Root Linearization Formula

555 User's Manual Chapter 6 83

Applications

Figure 6.8 Custom Linearization Curve

15th PV

10th PV

5th PV

1st PV

FLOW PV VALUE (In engineering units)

Input 1 Input 5 Input 10 Input 15

FLOW INPUT VALUE (in milliamps or volts)

Hard ware Configuration

• You must have a voltage or milliamp input.

Software Configuration

For square root linearization:

1. Go to the FLOW INPT. Menu.

2. Set parameter LINEARIZE to SQR. ROOT.

For custom linearization

1. Go to the FLOW INPT. Menu.

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 param-

eters define the corresponding process variable value in engineering units.

5. Enter values for any other XTH.INPUT and XTH.PV data point, up to

15TH.INPUT and 15TH.PV. You do not have 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.

N. SECURITY

The 555 security system is flexible and easy to customize to suit your needs.

Software Configuration

1. Go to the SECURITY Menu.

2. SEC. CODE defines the security code “password” (range from –9999 to

99999). The rest of the parameters are the various functions that can be selectively locked out.

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

84 Chapter 6 555 User's Manual

▲▲

▲

▲▲

▼

▼▼

DISPLAY

3. SETPT KEY prevents the operator from changing the setpoint via the SET PT key.

4. SP/DOSAGE prevents the operator from changing the setpoint or

▲▲

dosage value via the

5. AUTO./MAN. locks out the MANUAL key preventing the operator from

transferring from automatic to manual control or vice versa.

6. ALARM ACK. locks out the ACK key, preventing an operator from

acknowledging any alarms.

7. TUNING locks out modification to the parameters in the TUNING Menu,

preventing unauthorized changes to the tuning parameters or the activation/deactivation of the self tuning algorithm.

8. CONFIGURE allows access to the configuration menus, but prevents

any unauthorized changes to the configuration parameters. If locked out, the security code is not accessible.

▲ and

▲▲

▼▼

▼ keys.

▼▼

Basic Operating Procedures

The security feature can be overridden. When a locked function is attempted, the operator will have the opportunity to enter the security code. If the correct security code is entered, the operator has full access. The security feature is reactivated after one minute of keypad inactivity.

Applications

• The security override code is 62647. Store this number in a secure

place and blacken out the code in this manual to limit access.

O. PROCESS VARIABLE READING CORRECTION

Conditions extraneous to the controller — such as an out of calibration transmitter or residual analyzer — can cause the display to indicate a value other than the actual process value. To help compensate for such condi-

tions, the 555 offers the PV OFFSET and PV GAIN parameters as a conve-

nience. This section provides instructions on how to use these temporary corrections; however, we do recommend that you investigate and correct the actual inaccuracy problem(s).

By using a combination of both offset and gain factors, you should be able to compensate for most sensor or transmitter inaccuracies.

Software Configuration

For Flow Pacing, Compound Loop and Dechlorination:

1. Go to the FLOW INPT. Menu.

2. Parameter PV OFFSET sets a value (in engineering units) to be added to

or subtracted from the flow input. Range is from –9999 to 99999. For example, if your flow transmitter always reads 3 m/s too high, you

could set PV OFFSET parameter to -3 m/s to compensate.

3. Parameter PV GAIN sets a constant gain (multiplier) to be applied to the

flow input. Range is from 0.100 to 10.000. The formula is as follows:

adjusted PV= [(current PV reading – PV low end) x PV GAIN] + PV low end

For example, if your process variable range is 50 to 650 and the process

variable reading is 472, a PV GAIN of 0.995 would yield an adjusted

process variable equal to [(472 - 50) x 0.995] + 50 = 470.

555 User's Manual Chapter 6 85

Applications

For Residual, Compound Loop and Dechlorination:

1. Go to the RSDL. INPT. Menu.

2. Parameter PV OFFSET sets a value (in engineering units) to be added to or

subtracted from the flow input. Range is from –9999 to 99999.

3. Parameter PV GAIN sets a constant gain (multiplier) to be applied to the flow

input. Range is from 0.100 to 10.000.

P. SERIAL COMMUNICA TIONS

The serial communications option enables the 555 to communicate with a supervisory device, such as a personal computer or programmable logic controller.

The communications standard 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 555 uses a proprietary protocol which provides extremely fast and accurate responses to any command. Cyclic redundancy checking (CRC) virtually ensures the integrity of any data read by the 555. Through serial communications, you have access to every set up, tuning and operating parameter for all modes. For details on this protocol, contact an application engineer.

Hard ware Configuration

• You must have this option installed in your 555. The circuitry for communications is contained on a modular circuit board that plugs into the Microcontroller Circuit Board. Refer to the order code in Chapter 1 for details.

Software Configuration

1. Go to the SER. COMM. Menu. Set the following parameter values:

2. STATION specifies the unit’s station address. Each 555 on the same RS-

485 interface must have a unique station address. Range is from 1 to 99.

3. Choose a BAUD RATE from 1200 to 19200. In general, select the highest

baud rate. However, every instrument on the RS-485 interface must be set to the same baud rate.

4. CRC enables or disables the cyclic redundancy checking feature. If the host

supports it, we recommend activating the CRC.

5. When the 555 senses that communications is lost, it can go to a predeter-

mined state (called “shedding”). SHED TIME allows you to choose the length

of time that communications can be interrupted before the controller sheds. Since the 555 is a stand-alone controller, it does not depend on communications to operate. Therefore, if you do not want to use the shedding fea-

ture, set SHED TIME to OFF.

6. SHED MODE determines the power-up mode for the 555 if and when it sheds.

Options are:

• LAST MODE

• MANUAL

• AUTOMATIC

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

86 Chapter 6 555 User's Manual

▲▲

▲

▲▲

▼

▼▼

DISPLAY

7. SHED OUT selects the value of the shedding output for the 555 if and when

it sheds. Options are :

• LAST MODE

• values range from –5.0% to 105.0%.

8. For Dual Flow Pacing Mode, SHED OUT2 selects the second value of the

shedding output if and when the 555 sheds. Options are:

• LAST MODE

• values range from –5.0% to 105.0%.

9. SHED SP selects the shedding setpoint for the 555 if and when it sheds.

Options are:

• LAST SP

• DESIG. SP

10. DESIG. SP selects the value of the enabled designated shed setpoint for

the 555 if and when it sheds. Values range from –9999 to 99999.

Q. LAG

The 555 has lag functions that compensate for the time it takes for a change in output to reach a sampling point, whether this time be fixed or variable (depending on the process). Figure 6.9 shows a compound loop flow pacing water chlorination control system.

For Residual Control: Fixed lag time is the interval under steady flow it takes the chlorine to travel from the ejector to the residual sampling point. The FIXED LAG parameter supplies the process with a constant delay time that prevents

a change in the control output before the results of the previous control value change can be measured.

555

Controller

Residual Signal

Control Valve

Valve Control Signal

Chlorine Residual Analyzer

Residual Signal

Applications

Figure 6.9 Compound Loop Flow Pacing with Lag times

Flow Signal

Flow

Meter

Water Flow

For Compound Loop Control: If the flow rate fluctuates, the travel time between the ejector and sampling point varies. With the VARBL. LAG parameter,

changes in flow automatically increase or decrease the total lag time variable. Compound loop control can be configured to use both the fixed and variable lag functions because both flow input and residual levels are measured. The total lag is determined by proportioning the variable lag to the current flow and adding it to the fixed lag term. In the normal operation, the lag time decreases as the PV2 value increases, and increases as the PV2 value decreases.

555 User's Manual Chapter 6 87

Chlorine

Ejector

Chlorine Tank

Water Flow

Residual

Sampling

Point

Applications

NOTE:

The controller normalized flow present when the variable lag value is entered (thus calibrating this term of the total lag formula).

must record the

Software Configuration

For Residual Control

1. Go to the CONTROL Menu.

2. Set the FIXED LAG from 0 to 14400 seconds.

Remember, changes in the control output will occur only at the end of the

FIXED LAG period.

3. Set Up all other parameters as needed for your control application.

For Compound Loop Control

1. Go to the CONTROL Menu.

2. Set FIXED LAG term (if necessary) of the total lag calculation. Values range

from 0 to 14400 seconds.

3. Set the VARBL. LAG term of the total lag calculation. Values range from 0

to 14400 seconds. If configuring the 555 at a work bench (not installed at site), provide a signal

to the flow input terminals that equals the normalized flow value. If configuring the 555 at the installation site, set the variable lag parameter

when the normal flow is present.

4. Set the MAX. LAG parameter from 0 to 14400 seconds. This represents the

maximum value for the total lag calculation.

Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation

FAST MENU

DISPLAY

FAST MENU

88 Chapter 6 555 User's Manual

▲▲

▲

▲▲

▼

▼▼

DISPLAY

APPENDIX A ERROR HANDLING

TROUBLESHOOTING

If you are having mechanical difficulties with your controller, check this troubleshooting list. Any of these problems may or may not include error messages in the display(s). The second part of this appendix addresses those messages directly. Use both sections to help decipher and amend problems with your controller. In some instances, you may have to call the factory for assistance.

Display will not light up

• Defective power source, improper wiring. Check power source and wiring.

• Blown in-line fuse. Replace fuse and check wiring.

• Case not inserted properly/screws not tight. Remove unit from case and remove bezel screws. Replace unit into case. Carefully reinsert screws and tighten.

Improper or Lost PV Reading (see PV BREAK in error messages)

• Input jumper not placed properly. Move jumper to proper location.

• Input range not set properly/transmitter signal out of controller range. Select proper range in the software.

• Polarity of input signal is reversed. Check and correct sensor wiring.

• Improper controller wiring. Check and correct wiring.

• Loop power module missing. Install module.

• Defective PV transmitter. Replace transmitter.

No control output

• Output wiring and module location do not match (see OUTPUT CON-

FLICT under ERROR MESSAGES).

• (For SSR, SSR Drive and mA outputs). The jumper J1, J2 and J3 are not placed properly. Move jumpers to proper locations.

• Software configuration does not match hardware. Reconfigure software.

• Tuning values not set properly. Reset these values.

Cannot switch to automatic control

• Input sensor is not connected or valid (see PV BREAK under ERROR MESSAGES).

Erratic display

• Resetting action due to electrical noise on the power line. Filter the power line.

• Tuning values not set properly. Reset these values.

Error Handling

555 User's Manual Appendix A A-1

Error Handling

ERROR MESSA GES

Error messages will appear in the third line of the controller, and will alternate with any other displayed messages designated for that line. Look for the error message for your particular controller mode.

OUT1 CONF, OUT2 CONF, OUT3 CONF, OUT4 CONF

(Output Conflict)

All modes

“Output conflict” is a mismatch of actual output modules to their configured usage (there is an individual message for each output at fault.

TO FIX: Power down and install the correct module combination or reconfigure software to match current module configuration. Press ACK before reconfiguring.

LOST FLOW

(Lost Process Variable 2)

Flow Pacing

Loss of the PV2 input causes the controller to switch to manual control. The output value will be changed to a predefined output value defined by

the FLOW BRK. parameter. TO FIX: Check wiring and/or sensor transmitter.

Restoring the PV input puts the controller into the state specified by the

FLOW REST. parameter (AUTOMATIC, MANUAL or LAST MODE).

Compound Loop

Loss of the PV2 input causes the controller to either go to residual only

control (as defined by the RSDL.ONLY parameter), or to manual mode at a predefined output value specified by the FLOW BRK. parameter. The FLOW BRK. value is also used after PV2 breaks, when the control-

ler is already in flow mode due to a previous PV1 break.

TO FIX: Check wiring and/or sensor transmitter.

Restoring the PV2 input puts the controller into the state specified by the

FLOW REST. parameter (AUTOMATIC, MANUAL or LAST MODE).

Dechlorination

Loss of the PV2 input causes the controller to revert to manual control at

a predefined output value specified by the FLOW BRK. parameter. TO FIX: Check wiring and/or sensor transmitter.

Restoring the PV2 input puts the controller into the state specified by the

FLOW REST. parameter (AUTOMATIC, MANUAL or LAST MODE).

LOST RSDL.

(Lost Process Variable 1)

Residual

Loss of the PV1 (residual) input will result in the controller going to manual mode. The output will be changed to a predefined value specified by the

RSDL. BRK. parameter will specify that output value. TO FIX: Check wiring and/or sensor transmitter. Restoring PV1 puts the

controller into the state specified by the RSDL REST. parameter

(AUTOMATIC, MANUAL or LAST MODE).

A-2 Appendix A 555 User's Manual

Compound Loop

Loss of the PV1 (residual) input causes the controller to either go to flowonly control (as defined by the FLOW ONLY parameter), or to manual control, at a predefined value specified by the RSDL. BRK. parameter. In flow-only control, the residual control signal (trim) is reset to zero. The RSDL. BRK. value is also used after PV1 breaks, when the controller is already in residual mode due to a previous PV2 break.

TO FIX: Check wiring and/or sensor transmitter. Restoring PV1 puts the controller into the state specified by the RSDL REST. parameter (AUTOMATIC, MANUAL or LAST MODE).

Dechlorination

Loss of the PV1 (residual) input causes the controller to revert to manual control at a predefined value specified by the RSDL. BRK. parameter.

TO FIX: Check wiring and/or sensor transmitter. Restoring PV1 puts the controller into the state specified by the RSDL REST. parameter (AUTOMATIC, MANUAL or LAST MODE).

LOST REM.

(Remote Setpoint Break, Remote Dose Break)

Residual, Compound Loop

A remote setpoint break causes the controller to use local setpoint #1. The SET PT key will no longer be illuminated in this case. The TRACK- ING parameter can be set to cause the local setpoint to “track” the value of the last remote upon remote setpoint break. Then the value of local setpoint #1 will be overwritten with the last valid remote setpoint value.

TO FIX: Check wiring and remote setpoint source. Restoring the remote setpoint causes the controller to use the setpoint

specified by the RESTORE parameter (LOCAL or REMOTE).

Flow Pacing, Compound, Dechlorination

A remote dose break causes the controller to use a local dose value. The TRACKING parameter can be configured to cause the local dose to “track” the value of the last remote upon remote dose break. Then the value of the local dose will be overwritten with the last valid remote dose value.

TO FIX: Check wiring and remote dose source. Restoring the remote dose causes the controller to use the dose speci-

fied by the RESTORE parameter (LOCAL or REMOTE).

LOST F/B

(Slidewire Break)

Flow Pacing, Residual, Compound Loop

If the 555 loses its slidewire signal in automatic, it can be set to open both output relays, close output 1 or close output 2, regardless of the previous output state. This selection is made with the S/W BREAK entry. The controller is also placed under Manual control. From there,

▲▲

the manual control of the actuator). In slidewire mode, Output 1 is wired to the CCW motor and Output 2 is wired to the CW motor.

TO FIX: Check slidewire wiring.

▼▼

▲ and

▼ keys are used to control Outputs 1 and 2 respectively, (for

▲▲

▼▼

Error Handling

555 User's Manual Appendix A A-3

Error Handling

LOST CAL

(Lost Calibration Data)

All modes

The calibration data has been lost due to a total wipe out of the memory. This problem should not happen.

TO FIX: The controller will need to be recalibrated; call the factory for assistance.

DEFAULTS

(Factory Default)

All modes

Controller memory has been cleared and all parameters have been restored to their factory default settings. Occurs intentionally when unit is powered up for the first time and when the software version has been changed. Else, call the factory.

TO FIX: Enter the Set Up mode to clear the message. Call the factory if

memory has not been intentionally cleared.

FLOW OVER, FLOW:UNDER

(Process Variable 2 Boundary Error)

Flow Pacing, Compound Loop, Dechlorination

The process variable (PV2) has travelled outside the boundaries of the instrument span.

TO FIX: Check the transmitter accuracy and if the range of the transmitter

matches the range of the controller.

RSDL. OVER, RSDL.:UNDER

(Process Variable 1 Boundary Error)

Residual, Compound Loop, Dechlorination

The process variable (PV1) has travelled outside the boundaries of the instrument span.

TO FIX: Check the transmitter accuracy and if the range of the transmitter

matches the range of the controller.

ROM ERROR

(ROM Error)

All modes

A problem with the ROM has been detected upon instrument power-up. This is a fatal error, and the controller will lock until fixed.

TO FIX: The instrument requires an EPROM change; call the factory for

assistance.

Shedding - Communications Loss (no message)

The 555 has the standard error checking common to all PPC products, parity checking, and an optional CRC algorithm. These checks occur automatically and if they fail, the errant communications packet is ignored. No messages are shown to the user via the front display, but the lack of response would be noted by the host.

TO FIX: Check communications wiring. To clear the message, you must

make an auto/manual change.

A-4 Appendix A 555 User's Manual

Flow Pacing, Residual, Dechlorination

The SHED TIME parameter defines the amount of time between RS-485

communication packets (in seconds) before lost communications will be detected. Then the controller will go to the mode specified by the

SHED MODE parameter.

Compound Loop

The SHED TIME parameter defines the amount of time between RS-485

communication packets (in seconds) before lost communications will be detected. Then the controller will go to the mode specified by the

SHED MODE (AUTOMATIC, MANUAL or LAST MODE) and SHED SP

(LAST SP or DESIG. SP) parameters. For the corresponding choices, the

DESIG.SP parameter defines which local setpoint to use.

Error Handling

555 User's Manual Appendix A A-5

Error Handling

A-6 Appendix A 555 User's Manual

APPENDIX B CALIBRATION

To maintain optimum performance, once a year calibrate the analog input(s) and milliamp output(s). To achieve published accuracy specifications, follow directions carefully and use calibrated instruments like those suggested.

Access these parts of the calibration menu as shown in Figure B.1.

Calibration

CALIBRATE

ANLG. IN

PRESS MENU

CALIBRATE

ANLG. OUT

PRESS MENU

RESET

MENU DATA

PRESS MENU

HARDWARE

SCAN

PRESS MENU

S/W

TEST

PRESS MENU

PRESS ACK

CAL VREF

5.0000

OUTPUT "X"

0 mA

PUSH MENU

TO RESET

DISPLAY ONLY

____%

PRESS ACK

S/W

PRESS MENU

After two

seconds

PRESS

before two

seconds

CAL. 120mV, etc.

PRESS ACK

OUTPUT X, etc

PRESS ACK

RESET

SKIPPED

RESET

COMPLETED

Figure B.1 Calibration Menu Flowchart

ANALOG INPUT (V AND mA) CALIBRA TION

You should calibrate each set of PV terminals used for analog input (especially for applications requiring use of both process variables).

Equipment: Precision 5-1/2 or 6-1/2 digit multimeter, such as a

Fluke 8842® or Hewlett Packard HP3478A Two small pieces of wire Test leads with clips #2 Phillips screwdriver

1. Disconnect power to the instrument.

2. Remove chassis from case.

3. On the Microcontroller Circuit Board, locate jumpers at locations PV1 and 2nd marked on the edge of the board (see Figure B.2) Reposition the jumpers at 2nd location onto pins for V and TC

555 User's Manual Appendix B B-1

▲▲

▲.

▲▲

Moore Industries 555 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual