Moore Industries 555 User Manual
5 5 5
5 5 5
CHLORINATION/DECHLORINATION
CONTROLLER USER'S MANUAL
M555 V8, M
ARCH
201
7
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
or
SET PT DISPLAY
ICONS OUT, ALM
MENUS CONFIG., TUNING,
PARAMETERS CYCLE TM:1, MIN.OUT2
PARAMETER VALUES OFF, SETPOINT, LAST OUT.
DISPLAY MESSAGES TOO HOT, OUT%,
2 Chapter 1 555 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
B
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
MENU
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
DISPLAY
MANUAL
MANUAL
+
SET PT
proportioning or a digital output).
2
staging or slidewire output is active.
) of the duplex flow pacing mode,
FAST
FAST
FAST
FAST
DISPLAY
DISPLAY
+
+
+
+
▲
▲
▼
▼
MENU
MENU
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
V
MA
V
MA
TC
TC
RTD
2ND
PV1
TB1
8 Chapter 3 555 User's Manual
Male 22-Pin
Connector
4-Pin Connector
Output 4
4
Female 44-Pin Connector
Male 22-Pin
Connector
Male 44-Pin
Connector
Module
Retention
Plate
over Outputs 1,2,3
3
2
1
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
P2
P1
TB2
(REMOTE SP
BATTERY
OR
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.
V
MA
TC
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+
1
2
3
4
5
6
7
8
Alarm Relay/ Retransmission**
9
10
11
12
13
14
15
16
EARTH
GND
S/W
CCW
S/W2
S/W3
RSP–
RSP+
OUT 4–
OUT 4+
DIN
17
GND
DIN 1
18
DIN 2
19
DIN 3
20
DIN 4
21
DIN 5
22
N/A
23
N/A
24 32
Remote Set Point Option Input
25
26
27
28
29
30
31
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
9
16
EARTH
GND
17
25
31
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
2
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
1
2
3
4
5
6
7
8
16
15
14
13
12
11
10
9
17
18
19
20
21
22
23
24 32
31
30
29
28
27
26
25
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.
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
Figure 4.7
PV mA Input with Internal Power
Supply and 2-wire Transmitter
Wiring
PV1–
PV1+
External Power
Supply
–
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
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.
25
26
27
28
29
30
31
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).
Ð
Power for
transmitter
+
PV2–
PV2+
PV1–
PV1+
Ð
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+
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
OUT 4–
OUT 4+
17
18
19
20
21
22
23
25
26
27
28
29
30
31
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+
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
OUT 4–
OUT 4+
17
18
19
20
21
22
23
25
26
27
28
29
30
31
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+
1
2
3
4
5
6
9
10
11
12
13
14
17
18
19
20
21
22
25
26
27
28
29
30
Installation
Figure 4.12
Solid State Relay Output Wiring
OUT 3–
7
OUT 3+
8
Screws must be tight to ensure electrical connection
15
16
OUT 4–
OUT 4+
23
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–
1
2
3
4
5
9
10
11
12
13
17
18
19
20
21
31
25
26
27
28
29
Figure 4.13
DC Logic Output and Milliamp
Output Wiring
OUT 2+
6
OUT 3–
7
OUT 3+
8
Screws must be tight to ensure electrical connection
555 User's Manual Chapter 4 19
14
15
16
OUT 4–
OUT 4+
22
23
30
31
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
CW
Slidewire Wiper 0–1050
CCW
1
2
CCW
3
CCW
Winding
CW
Winding
ELECTRIC MOTOR
ACTUATOR
Actuator Supply Current
Screws must be tight to ensure electrical connection
COM
CW
COM
4
5
6
7
8
9
10
11
12
13
14
15
16
CCW
Slidewire Wiper
CW
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).
1
2
9
10
17
18
25
26
–
RSP
Source
+
Installation
Figure 4.15
Remote Setpoint Terminals
3
4
5
6
7
8
Screws must be tight to ensure electrical connection
11
12
13
14
15
16
RSP–
RSP+
19
20
21
22
23
27
28
29
30
31
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
17
18
To Comm – terminal
of next device
To Comm + terminal
of next device
19
20
21
22
23
24 32
Screws must be tight to ensure electrical connection
555 User's Manual Chapter 4 21
25
26
27
28
29
30
31
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:
MENU
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
MENU
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
+
MENU
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
Loading...