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1. RETRANS VALUE 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 Selects data retransmission type for retransmission output 3 5 RET LOW 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 5 ALM 1 OUT Selects the physical output number for alarm 1 6 LATCHING 1 Enables or disables alarm latching for alarm 1 de 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. ALARMS VALUE ALM TYPE 1 Selects the type for alarm 1 ALARM SRC 1 Selects the alarm source for alarm 1 3 ALARM SP 1 Selects the setpoint for alarm 1 except for HIGH LOW 4A HIGH SP 1 Selects the high setpoint for HIGH LOW alarm 1 4B LOW SP 1 Selects the low setpoint for HIGH LOW alarm 1 5 DEADBAND 1 Selects the deadband for alarm 1 6 ALM 1 OUT Selects the physical output number for alarm 1 T LATCHING 1 Enables or disables alarm latching for alarm 1 8 ACK 1 Enables or disables the ACK key for alarm 1 9 POWER UP 1 Selects condition of the alarm upon power up for alarm 1 10 MESSAGE 1 A 9 character user defined message for alarm 1 11 ALM TYPE 2 Selects the type for alarm 2 12 ALARM SRC 2 Selects the alarm source for alarm 2 1 ALARM SP 2 Selects the setpoint for alarm 2 except for HIGH LOW 13B HIGH SP 2 Selects the high setpoint for HIGH LOW alarm 2 14 LOW SP 2 Selects the low setpoint for HIGH LOW alarm 2 15 DEADBAND 2 Selects the deadband for alarm 2 16 ALM 2 OUT Selects the physical output number for alarm 2 17 LATCHING 2 Enables or disables alarm latching for alarm 2 18 ACK 2 Enables or disables the ACK key for alarm 2 19 POWER UP 2 Selects the condition of the alarm upon power up for alarm 2 20 MESSAGE 2 A 9 character user defined message for alarm 2 21 RATE TIME Selects the time base for ALM TYPE RATE 10 555
3. Chapter 6 Page 64 Add this note NOTE For more information on Fixed or Variable Lag refer to the Lag section on page 87 Chapter 6 Page 67 Add this note NOTE When modifying VARBL LAG one of the following messages appears for 3 5 seconds CALIBRATE FORFLOW indicating that variable lag can be calibrated FLOW PV IS BROKEN f PV is actually broken fix and try again Chapter 6 Page 70 71 Addendum Inthe Parameters section addthe following bullet points and new parameters ALM TYPE 1 and ALM TYPE 2 e REMOTEIN Remote Input Occurs when remote inputis usedto perform function assignedin REMOTE IN parameter e HIGH LOW Combination of High and Low alarms Occurs when the process vari able exceeds the individually set high and low alarm setpoints Remove the RATE value and insert RSDL RATE Alarm is based on residual PV 1 input e FLOWRATE Alarm is based on flow PV2 input HIGH SP 1 and HIGH SP 2 For High Low alarms specifies the high end setpoint at which an alarm occurs for qualifying alarms in engineering units e Ifthe Alarm Source CL2DOSE SO2 DOSE or OUTPUT the range is from 0 0 to 400 0 e Ifthe Alarm Source any othertype the range is from 9999 to 99999 LOW SP 1 and LOW SP 2 For High Low alarms specifies the low end setpoint at which an alarm occurs for qualifying alarms in engineering units e fthe Alarm Source CL2DOSE SO2 DOSE or
4. NOJ1NC NOJ2NC NOJ3 NC 4 500 Series Installation Guide Installation 8 Replace tie wraps for the Retention Plate and for Output Module 4 with new ones Failure to use these devices may result in a loosening of the module and eventual failure If you ordered a module separately it should have come with a tie wrap An extra set of tie wraps is available by order ing Part 535 665 Note For greatest accuracy milliamp modules added for retransmission must be calibrated per instructions in Operator s Manual To Change the Option Board 9 See Photos 3 and 4 Replace the existing Option board with the NEW one Note When adding Option board for 5 digital inputs associated screw terminal in the rear terminal block must be installed See information on page 1 for ordering a Screw Kit To Change the Power Supply or Microcontroller CPU Board 10 For the Microcontroller Board disconnect the 5 pin female connector that wires it to the Display Assembly Reattach the connector to the new board You can only orient the connector one way For the Power Supply Board disconnect the 5 pin female connector that wires it to the Display Assembly Reattach the connector to the new board You can only orient the connector one way To Change the Display Assembly 11 Disconnect the 5 pin female connector that wires the Microcontroller Board to the Display Assembly Disconnect the 5 pin female connector that wires
5. 555 User s Manual Chapter 6 61 Applications 62 Residual control is well suited for applications where the water flow rate is con stant but the oxidation demand varies The 555 makes residual control easy to use by continuously displaying the chlorine residual and set point see INTER FACE 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 i RSP DEV Deviation from setpoint VMD actual valve position slidewire option only 3rd line of display Blank under normal operation Used for special messages amp alarms Displays parameter values during configuration Basic Operating Procedures Switch from Automatic to Manual Control Press the MANUAL key Automaticto 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 con trol 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 Manualto automatic transition is bumpless i e the control output value will remain unchanged once the controller is sw
6. a v Lew 32 Chapter 5 555 User s Manual Software Configuration Configuration 5 RANGE Sets the value in engineering units corresponding to the high flow input value 9999 to 99999 D 1000 6 FILTER Sets the amount of filtering to be used for the flow input FILTER R Oto 120 seconds 7 PV OFFSET Sets a constant offset to be applied to the flow input R 9999 to 99999 PV OFFSET 8 PV GAIN Sets a constant gain to be applied to the flow input 0 100 to 10 000 PV GAIN D 1 000 9 FLOW BRK Defines percentage of first output upon switching to Manual control due toa flow signal break signal 5 to 105 FLOW 0 10 FLOW BRK 2 076 Dual Flow Pacing mode HI RANGE Defines percentage of second output upon switchingto Manual control due to aflow signal break signal FLOW BRK 2 5 to 105 D 0 11 FLOW REST Flow Pacing mode Dechlorination mode and Compound Loop mode with Residual Only control disabled FLOW REST Defines type of control mode after flow signal is restored LAST MODE D LASTMODE MANUAL AUTOMATIC Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Eeo ew Ee Dev a we 555 User s Manual Chapter 5 33 Software Configuration CUST LINR CUST LINR Available only ifa flow signalis used Flow Pacing Compound Loop or Dechlorina tion mode with LINEARIZ
7. Operation and Configuration Flowchart 24 Figure 6 1 Flow Pacing Control tee ertet eben tines 59 Figure 6 2 Residual Chlorine Loop Control 61 Figure 6 3 Compound Loop 64 Figure 6 4 Dechlorination Control sseseeee 67 Figure 6 5 AlarmiExamlples hai 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 amp PV2 Calibration Wiring B 2 Figure B 4 Milliamp Output Calibration Wiring B 3 Figure B 5 Output Module Menu B 4 Figure B 6 Slidewire Calibration Wiring B 5 555 User s Manual Table of Contents iii Table of Contents 555 User s Ma
8. 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 con trol 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 abumpless Manual to Automatic transition press FAST MANUAL to initialize the dose values Access Set Up amp 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 A and V to adjust the output percentage Change the Output Press DISPLAY until the 2nd display shows OUT orfor dual flow pacing OUT2 Use the A and V to adjust the output percentag
9. D ENABLED ENABLED e DISABLED 8 POWER UP 1 POWER UP 1 Foran enabled ALM TYPE 1 selects condition of the alarm upon power up D NORMAL NORMAL ery DELAYED Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Returnto Operation eme wes a 44 Chapter 5 555 User s Manual Software Configuration Configuration 9 MESSAGE 1 up MESSAGE 1 Forenabled ALM TYPE 1 exceptfortype VACUUM a 9 character user de fined message can be shown in the 3rd line display when the alarm is acti LAST MODE To use Select a character with the FAST key cursor will flash Use A and V keys to modify Selecting all blanks disables the alarm message D ALARM 1 10 ALM TYPE 2 Selects the type for alarm 2 ALM TYPE 2 D OFF e HIGHALRM LOWALARM MANUAL VACUUM BAND DEVIATION RATE 11 ALARM SRC 2 For ALM TYPE 2 HIGH ALRM or LOW ALARM selects the alarm source ALARM SRC 2 e RESIDUAL CL2DOSE SO2DOSE e SETPOINT RAMPSP DEVIATION OUTPUT 12 ALARM SP 2 Selects the setpoint for ALM TYPE 2 HIGH ALRM LOW ALARM BAND ALARM SP 2 DEVIATION or RATE 0 lf ALARM SRC 2 FLOW RESIDUAL SETPOINT RAMP or DEVIATION R 9999 to 99999 D 0 lf ALARM SRC 2 CL2 DOSE SO2 DOSE or OUTPUT R 0 0 to 400 0 D 0 Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Op
10. Conforms to the following safety standard EN 61010 1 2001 Supplemental Information CE option requires CE KIT PN 535 765 Date Fred Adt Robert Stockham Quality Assurance Director Moore Industries International Inc European Contact Your Local Moore Industries Sales and Service Office The Interface Solution Experts www miinet com United States info miinet com Belgium info mooreind be China sales mooreind sh cn MOOR Tel 818 894 7111 FAX 818 891 2816 Tel 03 448 10 18 FAX 03 440 17 97 Tel 86 21 62481120 FAX 86 21 62490635 IND USTRIES Australia sales mooreind com au The Netherlands sales mooreind nl United Kingdom sales mooreind com Tel 02 8536 7200 FAX 02 9525 7296 Tel 0 344 617971 FAX 0 344 615920 Tel 01293 514488 FAX 01293 536852 RETURN PROCEDURES To return equipment to Moore Industries for repair follow these four steps 1 Call Moore Industries and request a Returned Material Authorization RMA number Warranty Repair If you are unsure if your unit is still under warranty we can use the unit s serial number to verify the warranty status for you over the phone Be sure to include the RMA number on all documentation Non Warranty Repair If your unit is out of warranty be prepared to give us a Purchase Order number when you call In most cases we will be able to quote you the repair costs at that time The repair price you are quoted will
11. 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 A and V keysto modify Selecting all blanks disables the alarm message RATE TIME Defines the time period over which a discrete change in process vari able 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 Ifthe alarm setpoint is setto 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 ew Ca 72 6 555 User s Manual Applications _ B Ifthe alarm setpointis set to 100 and the time base setto 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 re quire 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 t
12. m connected bibe o ground at the host Failure to follow these proper wiring practices data terminals ofthe could result in transmission errors and other communications final device on the line problems Figure 4 16 Serial Communications Terminals Screws must be tight to ensure electrical connection 555 User s Manual Chapter 4 21 installation maximum recommended length of the RS 485 line is 4000 feet Termina tion 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 Software Configuration Configuration CHAPTER 5 SOFTWARE 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 Figure 5 1 parameter adjustments to your controller 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 This is a Menu Its name will show in the 2nd display This is a Parameter press Its names show in the 3nd display MENU FAST In this manual when the appearance of a parameter is dependent upon other hardware so
13. 11 Hardware Figure 3 4 Install Communications Module onto Microcontroller Board 12 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 Slidethechassis out of the case by pulling firmly on the bezel Do not detach the board assembly from the front face of the controller 4 Orientthe 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 Toreassemble the controller properly orient the chassis with board open Insert module onto connectors Make sure arrow on module points toward rear terminals q Front of controller circuits boards still attached to front face REMOTE SP OR DIGITAL INPUT CONFIGURATION BATTERY ing ontop 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 chas sis is properly oriented 6
14. 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 Configuration TUNING VALUE E CL2 DOSE Defines the origin of the Cl dosage signal 2 SO2 DOSE Defines the origin of the SO dosage signal 9 RSDL DEV Determines the deviation from residual setpoint 4 INTEGRAL 1 Defines Integral value 1 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 58 Chapter 5 555 User s Manual Applications _ 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 de scribe controller setup for specific features Be sure to cross reference Chapter 4 for complete hardware configuration wiring and mounting Chapter 5for all software menu parameter configuration Appendix D for 555 controller calibration before use A FLOW PACING MODE Flow paced contr
15. D ALARM ACK INT INHBT LOCKMAN STANDBY e LOVACUUM e HIVACUUM UPKEY DOWNKEY DISP KEY MENUKEY e FASTKEY COMM ONLY 16 REMOTE IN Defines the value of the remote setpoint feature D OFF CL2DOSE SO2DOSE CONTACT 5 Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Returnto Operation Er now v Dew 30 Chapter 5 555 User s Manual Software Configuration Configuration Sets the variable lag term used for computing the total lag R Oto 14400 seconds 3 MAX LAG Compound Loop mode MAX LAG Sets the maximum limit for the total lag calculation R Oto 14400 seconds D 14400 4 MIN TRIM Compound Loop mode CONTROL CONTROL Available only for Residual or Compound Loop Mode 1 FIXEDLAG FIXED LAG Sets the fixed lag term used for computing the total lag a R Oto 14400 seconds D 0 2 VARBL LAG Compound Loop mode VARBL LAG Sets the minimum amount of correction that can be applied to the current flow MIN TRIM pacing output level 100 R 10010 100 2 D 100 5 MAX TRIM Compound Loop mode MAX TRIM Sets the maximum amountof correction that can be applied tothe current flow pacing output level 100 to 100 D 100 6 FLOW ONLY Compound Loop mode Determines whether to allow flow pacing only control or remain under FLOW ONLY automatic control if the residual signal is lost see
16. SER COMM Serial Communications options requires comm board and TUNING Tuning parameters configuration 555 User s Manual Chapter 5 23 Software Configuration Configuration PARAMETERS Independent Dependent Within each menu are parameters for particular control functions You select Parameter Parameter values for each parameter depending on the specific application Use the MENU key to access parameters for a particular menu the parameter name will re CONFIGURE pt place the menu name in the 2nd display and the parameter value will show in UNLOCKED D the 3rd display This chapter outlines allthe available parameters forthe 555 Some parameters fs e E are independent of any special configuration you apply and others are depen Papier 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 NOTE ration so not all the listed parameters will appear Changing the value of one parameter may affect the value or status of another CONFIGURATION AND OPERATION Figure 5 3 shows the relationships among the different modes of the 555 and the configuration menus MANUAL to switch AUTOMATIC control between automatic and manual operating controls MANUAL control DISPLAY or SET PT DISPLAY or SET PT to restore
17. e RETRANS analog only COMM ONLY 5 OUTPUT3 Selects use for an existing output in slot 3 not for control or loop power D OFF e ALM RLY ON digital only e ALM RLY OFF digital only e RETRANS COMM ONLY analog only Access Set Up Return to Operation Next menu Next parameter Next value CONFIG CTRL MODE COMPOUND OUT MODE STANDARD LINE FREQ OUTPUT 2 OUTPUT 3 Access Tuning Return to Operation Eeo Ee Dev 555 User s Manual Chapter 5 27 Software Configuration Configuration OUTPUT 4 E nde for an existin g output in slot 4 not for control or loop power e ALM RLY ON digital only e ALM RLY OFF digital only e RETRANS analog only e COMM ONLY 7 ANLG RNG 1 Selects the range of operation for an existing mA output in slot 1 4 20mA 8 ANLG RNG 2 NLG RNG 1 ANLG RNG 2 Selects the range of operation for an existing mA output in slot 2 4 20 9 ANLG RNG 3 ANLG RNG 3 Selects the range of operation for an existing mA output in slot 3 4 20 10 ANLG RNG 4 ANLG RNG 4 Selects the range of operation for an existing mA output in slot 4 4 20 11 CONTACT 1 CONTACT 1 Selects the use for the existing digital input 1 MANUAL REM INPUT D MANUAL e 2ND SETPT e 2ND INT e ALARMACK INT INHBT e LOCKMAN STANDBY LOVACUUM e HIVACUUM UPKEY e DOWNKEY e DISP KEY e MENU KEY e
18. ecc ODE S ENSE 49 Parameter Value 51 CHAPTER 6 APPLIGATIONS eroe has trc esser 59 A Flow PacingiMOdge e rere ena ror 59 B Residual Chlorine Loop Mode 61 C Compound Loop Mode tie Lt erede anes 64 D Dechlorination Mode 67 XX c D 70 F Slidewire Position Proportioning 74 G StaG Sd OUT OUTS Em 75 Fi REMWANSMISSION Ene e 75 OUTS etuer ot reete tnnt bentes exis 76 Ji Remote Inputs s c rode oie Dee toin e 78 IK Integral re 79 80 Milnput LING anZation uoce rper ete ree iue 83 MSIE 84 Process Variable Reading Correction 85 P Serial Communications sssssssseeen 86 E A 87 APPENDIX ERROR HANDLING heii A 1 Troubleshooting 1 Eror Messages 2 APPENDIX B e Wine B 1 Analog Input V and mA Calibration B 1 Milliamp Output Calibration ee B 3 Reset Monu Data it
19. Carefully insertand align screws Tighten them until the bezel is seated firmly against the gasket Do not overtighten Chapter 3 555 User s Manual Installation CHAPTER 4 INSTALLATION MOUNTING THE CONTROLLER The front face of the 555 is NEMA 4X rated To obtain a waterproof seal be tween 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 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 Figure 4 1 7 180 182 37 OVERALL LENGTH Controller Dimensions 1 180 29 97 PANEL 3 622 92 00 MIN __ 3 653 92 80 Max FARRERES 5 ae E oo S T o oo T zz 9 S 6 000 152 40 _ FRONT SIDE CUTOUT 3 Place anewbezel gasket around the controller case starting atthe back of controller Then slide the gasket up against the back of the bezel To en sure a good seal always use a fresh gasket 4 With the bezel gasketin 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 Figure 4 2 Insert Mounting
20. For any enabled alarm enables or disables latching A latching alarm will remain active after leaving the alarm condition unless it is acknowl edged Anon latching alarm will return to the non alarm state when leav ing the alarm condition without being acknowledged ACK 1 and ACK 2 Forany enabledalarm enables or disables operator use ofthe ACK key to acknowledge an alarm at any time even if the control process is still NOTE in the alarm condition Poweringdownthe 555 acknowledges f clears all latched alarms Alatching alarm can always be acknowledged when itis 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 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 itis 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 upin 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
21. OUTPUT N ALM RLY ON 1 DISABLED ALARM SP 1 lt 0 555 User s Manual Chapter 6 73 Applications F SLIDEWIRE POSITION PROPORTIONING OUTPUT The 555 accommodates electric actuators with slidewire position proportion ing feedback Slidewire position proportioning utilizes a slidewire feedback signal to determine the true position of the actuator being controlled Hardware 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 Setparameter OUT MODE to SLIDEWIRE You must have the slidewire feedback option installed in order to able to select SLIDEWIRE 4 Goto 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 Scrollto S W CLOSE Closed feedback Enter the ohm value when the actuator is fully closed 0 to 1050 ohms 8 Measure the actual slidewire va
22. 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 A and V keys are used to control Outputs 1 and 2 respectively for 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 555 User s Manual Appendix A REM LASI Pye A 3 Error Handling EFPIAMES FLUW LIVER FLUWLUNUER EIS RUM ERRLIR A 4 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 as sistance DEFAULTS Factory Default All modes Controllermem
23. ence in the number of units between the current process variable and the setpoint setpoint ramping A setpoint which is determined by the ramp function of the controller where over time the controller variable reaches a desired value setpoint target The end point of the ramp function set up Also called configuration selection of hardware devices and software routines that function together sheds In serial communications when the signal is lost slidewire position proportioning An output algorithm that utilizes a slidewire feedback signal to determine the actual position of the actuator being controller solid state relay see relay solid state SSR drive A DC on off signal output for controlling a solid state relay E 3 7 stability The desirable condition in tuning Adjusting control parameters for which input and output are in balance meximum efficiency and will remain so unless subject to an variable A level quantity or other external stimulus condition which is subject to change staged outputs The set up of two This may be regulated or simply mea analog outputs where one analog output sured varies its signal over a portion of the PID output range and the second analog output then varies its signal over the remainder of the PID output range static discharge Undesirable current resulting from the discharge of electro static energy station address The unique identif
24. flow pacing chlorine control Control method that positions a chlorine or sulfur dioxide valve in direct proportion to the water flow rate gain The ratio of the change in output to the change in input which caused it hysteresis In ON OFF control the process variable change necessary to change the output from full ON to full OFF icons Indicators on the face of the controller input Process variable information being supplied to the instrument integral Control action that autornati cally eliminates offset or droop between setpoint and actual process temperature Also reset internal voltage reference A precision voltage source within the 555 controller used to establish internal calibration isolation Electrical separation of sensor from high voltage circuitry Allows for application of grounded or ungrounded sensing element offset Adjustment to actual input temperature and to the temperature values the controller uses for display and control jumper A wire that connects or bypasses a portion of a circuit on the printed circuit board Appendix E jumper connectors The connecting device that straddles a jumper to connect or bypass a portion of a circuit on a printed circuit board lag fixed a consistant constant delay in detection of a control variable change lag variable A fluctuating delay in the detection of a control value change usually the feed forward contribution Sou
25. 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 oftimethatcommunications can be interrupted before the controller sheds Since the 555 is a stand alone controller it does not depend on communi cations to operate Therefore if you do not want to use the shedding fea ture set SHED TIMEto OFF 6 SHED MODE determines the power up mode for the 555 if andwhenit sheds Options are e LAST MODE MANUAL AUTOMATIC Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Returnto Operation ew Ca ww 86 Chapter 6 555 User s Manual Applications _ 7 SHED OUT selects the value of the shedding output for the 555 if and when it sheds Options are e 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 e LAST MODE e 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 e LAST SP e 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
26. the Power Supply Board to the Display Assembly 12 Attach the new Display Assembly to the boards at the appropriate connectors CAUTION Static discharge will cause damage to equip ment Always ground yourself with a wrist grounding strap when handling electronics to prevent static discharge CAUTION Do not scratch the boards or bend the pins of the connectors Installation Guide To Change the EPROM 13 The EPROM is located on the Microcontroller Circuit board Figure 2 It has a white label that list the part number and software revision level Use an I C Extractor to carefully remove the EPROM If you do not have an I C extractor gently use a small flat blade screwdriver to pry up the EPROM DO Not bend the EPROM legs 14 Carefully insert the new EPROM To position correctly match the notched end of the EPROM to the markings on the board The notched end will face towards the display Make sure all pins are in the socket To Reassemble the Unit 15 See Figure 2 Align the connector pins on the Option Board with the connector sockets on the Microcontroller and Power Supply boards Squeeze them together making certain all three are properly seated against one another Check along the side edges for gaps Make sure the conector is properly aligned Also check that the cable assemblies are not pinched 16 See Figure 2 Align the board assembly with the front face assembly with the Option board at the bo
27. 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 Tomount 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 Software Configuration See key below for key references to traverse modes menus 1 Place 555 under manual control Enter Set Up 2 Goto CONFIG Menu 3 Set parameter CTRL MODE DECHLOR 4 Goto FLOW INPT Menu You mustset all relevant parameters in the FLOW INPT Menu e g pro cess variable input range and scaling data 5 Goto 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 re viewed Referto Chapter 5 for acomplete listing of menus and parameters 555 User s Manual Chapter 6 69 Applications E ALARMS The 555 controller has two extremely flexible
28. 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 RATETIME Selects the time base for ALM TYPE RATE 56 Chapter 5 555 User s Manual Software Configuration Configuration POWER UP VALUE 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 and W keys 4 AUTO MAN Selects lockout status of the MANUAL key ALARM 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 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
29. 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 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 SW 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 24 OUT RATE Defines max rate of change of control output Addendum 555 EET CNN 1 Chapter 5 Page 56
30. JUMPER mA Power Up PRESS ACK Press ACK PRESS ACK Press ACK mA CALIB COMPLETED If mA calibration values are d mA CALIB 77 FAILED PV 150 If mA calibration values are PRESS ACK PRESS ACK out of range _________ PRESS ACK Figure B 1 OUTPUT X Calibration Flowchart PRESS RESET SKIPPED After two 77 PRESS PUSH MENU seconds TO RESET RESET PRESS MENU before two seconds COMPLETED PRESS ACK DISPLAY ONLY SLIDEWIRE PRESS ACK gt PRESS ACK eee we sew Dii d diee 555 15 Figure 2 Microntroller Circuit Board PV1 PV1 Figure B 3 Input Calibration Wiring 16 Locations for the jumpers L for Analog Thermocouple ores Tt and Milliamp calibration d 4 TB2 CALIBRATION 4 JUMPERS SELECT V ANDTCs amp PV1 INPUT JUMPER CONFIGURATION 00000000000 PREPARATION for all input Calibration Equipment for analog input calibration e Precision 5 1 2 or 6 1 2 digit multimeter e g Fluke 88429 or HP3478A9 a 4 1 2 digit meter will sacrifice accuracy e Four small pieces of wire e Testleads with clips e 2 Phillips screwdriver 1 Disconnect power to the instrument 2 Remove chassis from case 3 Onthe Microcontroller Circuit Board locate jumper locations marked PV1 and 2nd near the edge connector Reposition both jumper connectors in the 2nd loca
31. OUTPUT the range is from 0 0 to 400 0 e Alarm Source any other type the range is from 9999 to 99999 555 11 EET CNN 1 Chapter 6 Page 71 Chapter 6 Page 74 Add this note NOTE ALOW FLOW alarm will automatcially cause a FLOW PV break When the alarmis cleared the PV Flow will no longer be considered broken ifthe flow signal is valid Insert the following correction to Software Configuration step 3 3 Set parameter OUT MODE to SLIDEWIRE You must have the slidewire feedback option installed in order to be able to select SLIDEWIRE Chapter 6 Page 76 77 Under Digital Inputs in the Software Configuration section add the following items to the list of choices e NOFLOW Contact closure causes the corresponding PV inputto be considered broken Opening the contact allows the PV input to be restored if the signal is valid e NORSDL Contact closure causes the corresponding PV inputto be considered broken Opening the contact allows the PV input to be restored if the signal is valid Insert the following as additional information to the STANDBY section regard ing trimfunction while in Command Loop Mode When configured for Compound Mode the unit falls to flow only or residual only mode However before the transition trim is held at the last output value Since the trim value is an offset holding at the last output value would create a growing error as flow decreased As aresult under t
32. RSDL REST in the RSDL INPT menu DISABLED D DISABLED ENABLED Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Ems ww mw a v we 555 User s Manual Chapter 5 31 Software Configuration Configuration 7 RSDL ONLY RSDL ONLY Compound Loop mode disabled 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 FLOW INPT FLOW INPT PVTYPE Available only when a flow signal is used Flow Pacing Compound Loop or Dechlorination Mode 420m 1 pv TYPE Selects the type of PV being used for the flow input If jumper is setto volts D 1 5V e 0 5V 0 100mV 0 60mV 0 30mV e 0 10mV e 25mV If jumper is setto mA D 4 20mA 0 20mA DECIMAL 2 DECIMAL Selects position of the decimal point in the engineering units display of flow XXXXX NONU XXXX X e XXX XX XX XXX e X XXXX LINEARIZE 3 LINEARIZE NORMAL Selects the type of linearization used forthe flow input D NORMAL e SQR ROOT CUSTOM LOW RANGE 4 LOW RANGE 0 Sets the value in engineering units corresponding to the low flow input value R 9999to 99999 Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Eesi
33. SETPOINT SP LOW SP HIGH SP RAMP _ REM INPUT RESTORE OUTPUT MIN OUT MAX OUT MIN OUT2 MAX OUT2 CYCLE TM 1 CYCLE TM 2 DIG IN 1 OUT DIG IN 2 OUT DIG IN 3 OUT DIG IN 4 OUT DIG IN 5 OUT DIG IN 1 OUT2 DIG IN 2 0UT2 DIG IN 3 OUT2 DIG IN 4 OUT2 7 DIG IN 5 OUT2 STAGE OUT1 STAGE OUT2 S W RANGE S W OPEN S W CLOSE S W D BAND S W BREAK RETRANS RET TYPE 2 RET LOW 2 RET HIGH 2 RET TYPE 3 RET LOW 3 RET HIGH 3 RET TYPE 4 RET LOW 4 RET HIGH 4 4 ALARMS ALM TYPE 1 ALARM SRC 1 ALARM SP 1 DEADBAND 1 ALM 1 OUT LATCHING 1 POWER UP 1 MESSAGE 1 ALM TYPE 2 ALARM SRC 2 ALARM SP 2 DEADBAND 2 ALM 2 OUT LATCHING 2 POWER UP 2 MESSAGE 2 RATE TIME 4 C POWER UP 1 ul SECURITY SEC CODE SETPT KEY SP DOSAGE AUTO MAN ALARM ACK TUNING CONFIGURE I COMM SHED OUT TUNING MODE TUNING CL2 DOSE SO2 DOSE RSDL DEV INTEGRAL 1 TRIPPING TRIP PT INTEGRAL 2 555 User s Manual Appendix D D 1 555 User s Manual EEE eee APPENDIX E GLOSSARY accuracy Conformity to an indicated standard or true value expressed as a percentage of span or full scale deviation from the value automatic controller A device or combination of devices which measures the value of a variable quantity or condition and operates to correct or limit its deviation from the setpoint alarm A condition
34. User s Manual Chapter 6 87 Applications Software Configuration For Residual Control 1 Goto 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 Goto the CONTROL Menu 2 Set FIXED LAG term if necessary of the total lag calculation Values range from 0 to 14400 seconds 3 Setthe VARBL LAG term of the total lag calculation Values range from 0 to 14400 seconds NOTE If configuring the 555 at a work bench not installed at site provide a signal The controller must record the to the flow input terminals that equals the normalized flow value normalized flow present when the If configuring the 555 at the installation site set the variable lag parameter variable lag value is entered thus calibrating this term of the total lag when the normal flow is present formula 4 Setthe 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 pe Ee D v ww 88 Chapter 6 555 User s Manual Error Handling _ Handling APPENDIX A ERROR HANDLING TROUBLESHOOTING Ifyou are having mechanical difficulties with your controller check t
35. amp 1 Analog sss 2 Solid State Relay triac 1 amp 3 DC Logic SSR drive 4 Output 2 Control Alarm or Retransmission NONG 0 Mechanical Relay 5 amp 1 Analog milliamp ss 2 Solid State Relay triac 1 amp 3 DC Logic SSR 4 Output 3 Control Alarm Retransmission or Loop Power NONG iiaaaaaiaaneieieieiiiiisereeeiensiriri sirean 0 Mechanical Relay 5 1 Analog 2 Solid State Relay triac 1 3 DC Logic SSR 4 Loop Power 5 Output 4 Control Alarm Retransmission or Loop Power None eese odes ertet ete 0 Mechanical Relay 0 5 amp 24 V 1 Analog milliamp sss 2 Solid State Relay triac 0 5 amp 24 V 3 DC Logic SSR 4 Loop Power eee 5 Options Enter 0 if not desired Slidewire Feedback for Position Proportioning Output A 24VAC 24VDC F Slidewire and 2AVAC 24VDC s G Remote Input B Set of Five Digital Inputs D _ sss H Five Digital Inputs and Certification J Serial Communica
36. 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 SO to the water based on a combination of both flow pacing and residual chlorine level 555 User s Manual Chapter 1 1 General Information 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 outputlevel 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 ofthe 555 Refer to Chapter 5 and Figure 5 3 to view the relationship between these 3 modes ORDER CODE PACKAGING INFORMATION Compare the product num
37. and W keys 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 activa tion 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 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 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 cor
38. and W 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 FLOWINPT Menu and RSDL INPT Menu parameters The flow andresidualinputs mustbe stable and at a non minimal value larger values will produce a more accurate dose b Adjustthe 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 LINEARIZATION This function is only available for control modes that use a flow signal i e Flow Pacing Compound Loop or Dechlorination Inputlinearization 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 PV Low Range Hi Range Low Range Jv input V low high V low Where Hi Range is the high end of the process variable Low Range is the low end of the process variable V input is the actual voltage or current value of the input V high is the hig
39. any other type R LOW RANGE to HIGH RANGE DO Chapter 5 Page 51 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 8 INT ACTION Determines how integral action modifies the output Chapter 5 Page 54 SETPOINT il SPLOW Sets the lowest allowed SP value 2 SP HIGH Sets the highest allowed SP value 3 SP RAMP Defines SP ramping rate in engineering units hour 4 NO OF SP Sets number of local setpoints 8 555 Addendum Chapter 5 Page 55 OUTPUT VALUE 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
40. any selected HIGH or LOW alarm will be based available for each alarm Selection includes FLOW e RESIDUAL CL2DOSE SO2DOSE e SETPOINT e 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 Ifthe Alarm Source FLOW RESIDUAL SETPOINT RAMP SP or DEVIATION the setpoint range is from 9999 to 99999 fthe 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 musttravel before leaving an alarm condition see alarm examples at the end of this section for an illustra tion This prevents frequent alarm oscillation or chattering if the pro cess variable has stabilized around the alarm point e Ifthe Alarm Source FLOW RESIDUAL SETPOINT RAMP SP or DEVIATION the setpoint range is from 1 to 99999 Ifthe 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 555 User s Manual Chapter 6 71 Applications LATCHING 1 and LATCHING 2
41. block Groups of parameters arranged in the software microcontroller A large scale inte grated circuit that has all the functions of a computer including memory and input output systems NEMA 4x A National Electrical Manufacturers Association standard for specifying a product s resistance to water and corrosion normally open A switched output i e relay etc whose unpowered state has no connection normally closed A switched output i e relay whose unpowered state provides connection noise An unwanted component of a signal or variable noise band A measurement of the amount of random process noise affecting the measurement of the process variable offset The difference between the setpoint and actual process variable open loop Control system with no sensory feedback optimization The act of controlling process at its maximum possible level of performance usually as expressed in economic terms output modules Plug in devices that provide power handling to enable process control These modules are either binary on off such as a relay or analog continuously variable for current loop control output Action in response to the difference between setpoint and process variable overshoot Condition where tempera ture exceeds setpoint due to initial power up or process changes parameter s A user defined variable that specifies how a particular function in the 555 will oper
42. 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 Software Configuration 1 The controller must set for residual or compound loop control in order to use Integral settings 2 Enterthe TUNING Menu by pressing MENU 3 Setparameter INTEGRAL 1 Range is from 0 096 to 250 096 4 Setparameter TRIPPING Choices are D OFF default SPNUMBER 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 e 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 lfusing both values set parameter TRIP PT This specifies the point for integral value tripping 6 Ifusing both values set parameter INTEGRAL 2 Range is from 0 0 to 25
43. generated by a controller indicating that the process has exceeded or fallen below the set or limit point alarm band A type of alarm set up where a band is created around the control setpoint alarm deviation An alarm similar toa band alarm except it only creates a band on one side of the alarm setpoint alarm fault An indication that becomes active upon loss of process variable Fault alarm operates in addition to other alarm assignments alarm global The single physical output to which one or more internal software alarms are tied alarm low process variable A type of alarm that is set up to occur when the process variable goes below the alarm setpoint alarm high process variable A type of alarm that is set up to occur when the process variable goes above the alarm setpoint alarm manual A type of alarm set up to occur when the controller is put into manual mode of operation alarm power up A type of alarm that determines alarm condition on power up of the controller alarm rate of change A type of alarm set up to occur when there is an excessive change in the process variable PV value bias A reference level A numeric value in a digital system or a voltage or current in an analog system 555 User s Manual baud rate Any of the standard trans mission rates for sending or receiving binary coded data bezel The flat portion surrounding the face of the controller which holds the
44. go to residual only control as defined by the RSDL ONLY parameter or to manual mode ata 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 ofthe 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 Appendix A 555 User s Manual Error Handling _ Compound Loop Loss of the PV1 residual input causes the controller to either go to flow only control as defined by the FLOW ONLY parameter or to manual control ata predefined value speci
45. 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 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 Configuration FLOW INPT VALUE 1 PV 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 Set
46. keys and display bump A sudden increase in the output power initiated by the controller in order to determine the system response during a self tune procedure binary coded decimal BCD A notation in which the individual decimal digits are represented by a group of binary bits e g in the 8 4 2 1 coded decimal notation each decimal digit is represented by four binary bits calibration Adjustment or verification of acontroller unit by comparison of the unit s reading to standards of known accuracy and stability chlorine CI Chemical oxidant used to disinfect water Chlorine oxidizes organic material and reduces bacteria 98 99 chlorination The controlled addition of chlorine to disinfect water closed loop Control system that has a sensing device for process variable feedback compound loop chlorine control Control method that positions a chlorine valve based on chlorine residual measurement and water flow measure ment configuration Also called set up selection of hardware devices and software routines that function together contact In hardware a set of conduc tors that can be brought into contact by electromechanical action and thereby produce switching In software a symbolic set of points whose open or closed condition depends on the logic status assigned to them by internal or external conditions control action The slope of the output of the instrument in reference to the input e
47. mooreind be Tel 03 448 10 18 FAX 03 440 17 97 The Netherlands sales 9 mooreind nl Tel 0 344 617971 FAX 0 344 615920 Specifications and Information subject to change without notice 500 SERIES Form M500 V6 Process Controllers Hardware Installation and Modification Manual for Electronic Products Series 531 532 535 545 555 Model 2 il moore INDUSTRIES M500 V6 JUNE 2005 Installation INTRODUCTION This technical brochure provides hardware installation and modification instructions for our controllers Series 531 532 535 545 and 555 Use these instructions with the following kits Display Assembly Kits 5812682 531 Display Assembly Kit 532 692 532 Display Assembly Kit 535 632 535 Display Assembly Kit 545 634 545 Display Assembly Kit 555 632 555 Display Assembly Kit Output and Communications Module Kits 532 600 531 532 Analog Module Kit 535 600 Mechanical Relay Module Kit 535 601 Milliamp Module Kit 535 602 SSR Module Kit 535 603 SSR Drive Module Kit 535 604 Loop Power Module Kit 535 705 RS 485 Communications Module Kit Power Supply Kit 535 790 usns 90 to 250VAC Power Supply Kit 585 782 uus 24VAC NDC Power Supply Kit Mounting Kit 535 761 Mounting Kit Miscellaneous Kits 532 100 531 532 Bypas
48. of signal from either the flow transducer or the chlorine analyzer default to preset control output b Loss of the flow signal revert to residual control c Loss of the chlorine residual signal revert to flow proportioning control INPUT FILTER Single pole lowpass digital filter with selectable time constant from 0 to 120 seconds CALIBRATION Appendix C C 1 Specifications Continuous calibration compensates for component aging due to temperature and time except for the reference voltage Reference calibration can be easily performed in the field with only a precision multimeter Process variable offset and gain factors are provided to correct for sensor errors OUTPUT MODULES Up to four output modules may be installed There are five types of output modules which can be mixed and matched to suit your particular application The modules may be ordered factory installed or they may be installed in the field Analog module Either 0 20mA or 4 20mA front panel selectable into a load up to 1000 ohms Mechanical relay module SPDT electromechanical relay Resistive load rated at 5 amps at 120 240 VAC Normally open or normally closed selection is made by jumper Output 4 is rated at 0 5 amps at 24 VAC and is always normally open Solid state relay triac module Resistive load rated at 1 amp at 120 240 VAC Output 4 is rated at 0 5 amps at 24 VAC DC logic SSR drive module ON voltage is 17 Vdc nominal O
49. 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 If you need to alter output modules please refer to the next section starting with Step 3 7 Toreassemble the controller properly orient the chassis with board open ing on top Align the circuit boards into the grooves on the top and bottom of the case Press firmly on the front face assembly until the chassis is all the way into the case If 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 chas sis is properly oriented 8 Carefully insertand align screws Tighten them until the bezel is seated firmly against the gasket Do not overtighten 555 User s Manual Chapter 3 9 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 aflat screwdriver to carefully pry apart the clips that hold the front face assembly to the chass
50. power module in Figure 4 8 Output 2 terminals 5 amp 6 PV mA Input with Internal Power Output 3 terminals 7 amp 8 or P T Output 4 terminals 15 amp 16 SUPPly and 4 wire Transmitter Wiring Input Power for transmitter 4 20 output from x transmitter Transmitter output can be connected to PV1 temrinals 31 amp 32 or PV2 temrinals 28 amp 29 Screws must be tight to ensure electrical connection Digital Inputs NOTE Digital inputs can be activated in three ways a switch signaltype therecom There are 14 contact types for the up mended type closure of a relay or an open collector transistor to 5 digital inputs refer to Chapter 6 Digital inputs are only functional when that option is installed via hardware fora complete discussion Thecontroller detects the hardwaretype 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 P a Figure 4 9 Digital Input Wiring with a Switch or Relay Screws must be tight to ensure electrical connection 555 User s Manual Chapter 4 17 installation Figure 4 10 2 Digital Inputs with an Open Collector Digital Input Wiring with an Open Co
51. return equipment to Moore Industries for repair follow these four steps 1 Call Moore Industries and request a Returned Material Authorization RMA number Warranty Repair If you are unsure if your unit is still under warranty we can use the unit s serial number to verify the warranty status for you over the phone Be sure to include the RMA number on all documentation Non Warranty Repair If your unit is out of warranty be prepared to give us a Purchase Order number when you call In most cases we will be able to quote you the repair costs at that time The repair price you are quoted will be a Not To Exceed price which means that the actual repair costs may be less than the quote Be sure to include the RMA number on all documentation Provide us with the following documentation a Anote listing the symptoms that indicate the unit needs repair b Complete shipping information for return of the equipment after repair c The name and phone number of the person to contact if questions arise at the factory Use sufficient packing material and carefully pack the equipment in a sturdy shipping container 4 Shipthe equipment to the Moore Industries location nearest you The returned equipment will be inspected and tested at the factory A Moore Industries repre sentative will contact the person designated on your documentation if more information is needed The repaired equipment or its replacement will be
52. returned to you in accordance with the shipping instructions furnished in your documentation WARRANTY DISCLAIMER THE COMPANY MAKES NO EXPRESS IMPLIED OR STATUTORY WARRANTIES INCLUDING ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO ANY GOODS OR SERVICES SOLD BY THE COMPANY THE COMPANY DISCLAIMS ALL WARRANTIES ARISING FROM ANY COURSE OF DEALING OR TRADE USAGE AND ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY ACKNOWLEDGES THAT THERE ARE NO WARRANTIES IMPLIED BY CUSTOM OR USAGE IN THE TRADE OF THE BUYER AND OF THE COMPANY AND THAT ANY PRIOR DEALINGS OF THE BUYER WITH THE COMPANY DO NOT IMPLY THAT THE COMPANY WARRANTS THE GOODS OR SERVICES IN ANY WAY ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY AGREES WITH THE COMPANY THAT THE SOLE AND EXCLUSIVE REMEDIES FOR BREACH OF ANY WARRANTY CONCERNING THE GOODS OR SERVICES SHALL BE FOR THE COMPANY AT ITS OPTION TO REPAIR OR REPLACE THE GOODS OR SERVICES OR REFUND THE PURCHASE PRICE THE COMPANY SHALL IN NO EVENT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES EVEN IF THE COMPANY FAILS IN ANY ATTEMPT TO REMEDY DEFECTS IN THE GOODS OR SERVICES BUT IN SUCH CASE THE BUYER SHALL BE ENTITLED TO NO MORE THAN A REFUND OF ALL MONIES PAID TO THE COMPANY BY THE BUYER FOR PURCHASE OF THE GOODS OR SERVICES ANY CAUSE OF ACTION FOR BREACH OF ANY WARRANTY BY THE COMPANY SHALL BE BARRED UNLESS THE COMPANY RECEIVES FROM THE BUYER A WRITTEN NOTICE OF THE A
53. s Manual Appendix B Figure B 4 Milliamp Output Calibration Wiring B 3 TO OTHER CALIBRATION MENU Ma PRESS ACK OUTPUT X 4mA PRESS MENU OUTPUT X PRESS MENU EACH OUTPUT WILL GO THROUGH THIS CYCLE Figure B 5 Output Module Menu Cycle B 4 Attach the test leads from the multimeter to the wires and then plug the test leads into the meter Set the meter for DC milliamps 6 Press the ACK key The 2nd display will read OUTPUT 1 OUTPUT2 OUTPUTS or OUTPUTA depending on module installation 7 Press MENU key until you see the output you wish to calibrate in the 2nd display and 4 mA in the 3rd display see Figure B 5 The meter should read a value close to 4 00mA 8 Wait one minute Use the and V and FAST keys on the 555 to change the meter s display to exactly 4 00mA 9 Press MENU The 2nd display will still be for your specified module and the 3rd display should read 20mA 10 Wait one minute Use the and V and FAST keys on the 555 to change to meter s display to exactly 20mA 11 To calibrate another analog output Move your wires and test leads to the new output terminals Press MENU until the 3rd display shows 4mA for the corresponding output in the 2nd display Repeat steps 8 9 and 10 and 11 12 To complete calibration press and disconnect the power Remove the controller from its case and place the jumpers in their correct opera
54. several lag periods to deter mine 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 forthe 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 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 ofthe flow input range RSDL is a percentage of the residual input range and DOSE is a percentage values NOTE Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation rm ew Ca 82 Chapter 6 555 User s Manual Applications _ The PV1 and PV2 input parameters must be properly configured for the dechlorination output calculations e TheDOSE values can be manually set with the
55. solid state switching device which completes or interrupts a circuit electrically with no moving parts reset Control action that automatically eliminates offset or droop between setpoint and actual process tempera ture Also integral reset term see reset residual chlorine control Control method that positions a chlorine valve based on chlorine residual measure ment Appendix E relative gain An open loop gain determined with all other manipulated variables constant divided by the same gain determined with all other controlled variables constant retransmission a feature on the 555 which allows the transmission of a milliamp signal corresponding to the process variable target setpoint or actual setpoint to other devices typically a chart recorder sample interval The time interval between measurements or observa tions of a variable secondary loop The inner loop of a cascade system self tune A method of automatically calculating and inserting optimum PID parameters by testing system response and timing serial communications The sending or receiving of binary coded data to a supervisory device such as a personal computer or programmable logic controller setpoint An input variable which sets the desired value of a controlled variable setpoint actual The desired value of a controlled variable that the controller is currently acting upon setpoint deviation from The differ
56. standby low vacuum or high vacuum digital contact 3 D LAST OUT LAST OUT 5to105 10 DIG IN 4 OUT Selects the designated output for an existing manual locked manual DIG IN 4 OUT standby low vacuum or high vacuum digital contact 4 D LASTOUT LAST OUT 510105 11 DIG IN 5 OUT Selects the designated output for an existing manual locked manual DIG IN 5 OUT standby low vacuum or high vacuum digital contact 5 D LASTOUT LAST OUT 510105 12 DIG IN 1 OUT2 Dual Flow Pacing mode For existing properly configured contacts Selects the designated second DIG IN 1 OUT output for a manual locked manual standby low vacuum or high vacuum Tar digital contact 1 LAST OUT D LASTOUT 510105 Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Ew Dev Ca few 555 User s Manual Chapter 5 39 Software Configuration Configuration 13 DIG IN 2 OUT2 Dual Flow Pacing mode DIG IN 2 OUT LAST OUT For existing properly configured contacts Selects the designated second output for a manual locked manual standby low vacuum or high vacuum digital contact 2 LAST OUT 5to105 14 DIG IN 3 OUT2 Dual Flow Pacing mode DIG IN 3 OUT For existing properly configured contacts Selects the designated second LAST OUT output for a manual locked manual standby low vacuum or high vac
57. switch to automatic control Input sensor is not connected or valid see PV BREAK under ERROR MESSAGES Erratic display Resettingaction dueto electrical noise onthe power line Filterthe power line Tuning values not set properly Reset these values 555 User s Manual Appendix A A 1 Error Handling LILI T EINE LUST FLUW LES A 2 ERROR MESSAGES 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 config ured 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
58. the input range of the device to which you are transmitting 6 Forany other retransmission output continue to scroll through the this menu and setthe RET TYPE X RET LOW X and RET HIGH X for the secondretransmission output 555 User s Manual Chapter 6 75 Applications DIGITAL INPUTS Digital inputs can be activated in three ways Aswitch signal type the recommended type Closure of arelay e 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 Hardware 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 Goto 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 usingthe MANUAL key If contact causes atransi tionto manual from automatic control the corresponding designated output action is performed LOCKMAN Contact closure locks the 555 in manual control Contact cannot be overridden with the MANUAL key attempts cau
59. to the output to be calibrated The 3rd display should read 4 mA refer to Figure B 7 The multimeter should read a value close to 4 00 9 Wait one minute Use A and V and FAST on the controller to change the meter s display to exactly 4 00mA 10 Press MENU The 3rd display should read 20mA 11 Letthis setting stabilize for 5 minutes Use and V and FAST onthe con troller to change the meters display to exactly 20mA 12 To calibrate another analog output Move the wires and test leads to the new output terminals Press MENU until the 3rd display shows 4mA for the corresponding output in the 2nd display Repeat step 8 11 13 To complete calibration press ACK key disconnect the power and place the jumper connectors back into their original position 555 Addendum RESET MENU DATA This function resets all parameter values back to their factory default values except for calibration information Refer to the flowchart in Figure B 1 os 7 8 1 Disconnect power to the instrument 2 3 Onthe Microcontroller Circuit Board set jumpers at the 2nd PV location to Remove chassis from case V and TCA see Figure B 3 Press MENU key until the display shows RESET MENU DATA Press the ACK key Press MENU key within two seconds to reset the menu data If successful RESET COMPLETED will appear in the display If failed RESET SKIPPED will appear instead Totry again press ACK key and then
60. windup is prevented 2 Putsthe output at a predefined output or holds the last output as configured bythe corresponding digital input output entry Pre defined output values range from 5 to 105 3 Addsthe 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 LOVACUUM HI VACUUM Contact closure initially starts a 30 second delay timer After the 30 seconds 1 Thecontroller locks into manual control controller cannot enter into automatic control 2 Theoutput 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 Foralow 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 mes sage For Digital Inputs of type MANUAL LOCKED MANUAL STANDBY LO VACUUM or HI VACUUM continue with step 3 3 Gotothe OUTPUT Menu 4 Setcorresponding 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 Setcorresponding designated output p
61. 0 096 555 User s Manual Chapter 6 79 Applications L TUNINGTIPS The 555 uses flow paced and integral calculations to determine output under automatic control The control algorithm determines the specific control strategy Flow Pacing Control 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 percent age 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 and WV 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 Adjustthe 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 NOTE to automatic mode while initializing the dose values to maintain the T
62. 55 Option Board Kit Slidewire Feedback and RSP 545 727 535 545 555 Option Board Kit Digital Inputs Slidewire Feedback and RSP HOW TO USE THIS MANUAL A CAUTION Static discharge will cause damage to equipment Always ground yourself with a wrist grounding strap when handling electronics to prevent static discharge B Before removing or inserting any hardware on the controller copy down all configuration parameters Also replacing the battery EPROM or MCU Board will erase parameter settings and they will need to be reset C Forall hardware adjustments perform steps 1 2 and 3 D Follow the guide and complete any additional steps as required by your particular application E Complete your hardware adjustments with steps 15 16 17 18 19 amp 20 EQUIPMENT To make any hardware changes to the units you will need the following equipment e Wrist grounding strap Phillips screwdriver 2 e Small flat blade screwdriver Wire cutters e C Extractor if changing the EPROM 2 500 Series Installation Guide Installation INSTRUCTIONS one of the larger two boards from the Option Board Photo 4 Be careful not to bend the To Disassemble the Unit connector pins Separate the other board in the same manner Figure 2 opposite page shows the Microcontroller Board Option Board and Power Supply Board For any hardware modifications disassemble the unit 1 With power off loosen four cap
63. AL 120mV etc PRESS ACK Figure 1 Calibration Menu Flowchart PRESS ACK PRESS MENU CAHBR TE ANLG OUT PRESS ACK PRESS MENU rm mmeumemcmnIee ti Sim SSR RSIS meme aes Sie RESET RESET After two SKIPPED SKIPPED d MENU DATA PUSH MENU seconds TO RESET PRESS MENU PRESS MENU before two HARDWARE SCAN seconds DISPLAY ONLY arida PRESS eS eevee eet tee PRESS ACK COMPLETED PRESS ACK PRESS MENU ANALOG INPUT V AND mA CALIBRATION 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 88429 or Hewlett Packard HP3478A9 Two small pieces of wire Test leads with clips 2 Phillips screwdriver 1 Disconnect power to the instrument 2 Remove chassis from case 3 Onthe Microcontroller Circuit Board locate jumpers at locations PV1 and 2nd marked on the edge of the board see Figure B 2 Reposition the jump ers at 2nd location onto pins for Vand TCA 555 User s Manual Appendix B B 1 Calibration Figure B 2 Comm Module Microcontroller Circuit Board 000000 For PV1 residual calibration For PV2 flow calibration 4 Connect the hook up wire to 4 Connect the hook up wire to terminals 31 and 32 as shown in terminals 28 and 29 as shown in
64. AUTOMATIC 6 SHED OUT SHED OUT If shedding is enabled selects the manual shedding output for the 555 D LASTOUT dastout R 5 0to 105 0 7 SHED OUT2 Dual Flow Pacing Mode only SHED OUT2 If shedding is enabled selects the second manual shedding outputfor the 555 LAST OUT D LAST OUT R 5 0to 105 0 8 SHEDSP SHED SP If shedding is enabled selects the shedding SP for the 555 D LASTSP LAST SP e DESIG SP 9 DESIG SP If shedding is enabled and SHED SP DESIG SP selects the designated DESIG SP shed SP for the 555 R LOW RANGE to HI RANGE based on the PV flow or residual 1 CL2DOSE Defines the origin of the Clo dosage signal CL2 DOSE must be selected as the remote input signal for this parameter to appear CL2 DOSE D LOCAL REMOTE LOCAL Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Eeo Ee ev v 555 User s Manual Chapter 5 49 Software Configuration Configuration SO2 DOSE RSDL DEV 4 INTEGRAL 1 10 0 5 TRIPPING 6 TRIP PT 7 INTEGRAL 2 10 0 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 RSDL DEV Residual amp Compound loop mode Determines the deviation from residual setpoint positive or negative required before additional integral action will be appl
65. Accessing and Changing 9 Adding and Changing Output 10 Special Communications Module sse 12 CHAPTER 4 INSTALLATION icta etre tette 13 Mounting the Controller ssseeeeenn 13 Wiring for Input and Outputs sss 14 AG Power Input re Cete tana 14 Process Variables ic eee tente ertet 15 Digital Inputs zc tree reae rtu tee rette p eet 17 Output Modules sess 18 Remote Setpolhl en Lnd 21 Serial Communications sse 21 CHAPTER 5 SOFTWARE CONFIGURATION essen 23 Mfr EE 23 zlii 24 Configuration and Operation sssssseeeee 24 Where to Go Next ssssssssssssssseeenee nennen nennt nennt 25 Software Menus and Parameters 27 eene 27 CONTROL tektites es 31 abeam 32 CUS TEIN R e 34 ats Ue SIN PM PS ERE DN 35 SETPOINT x 1 28 223r III iei DIU 36 REM ANPUT iiie ritur ettet eere ea pseudo nier a bee 37 QUI PUT 38 RETRANS i der rre ei 41 ALARMS p tistics i a N E 43 555 User s Manual Table of Contents i POWER UP ee eee ee 47 SECURITY EE 47 SER COMM ae 48
66. Clips Slide gasket on from this end MOUNTING BRACKET 1 EA SIDE HOUSING BEZEL 555 User s Manual Chapter 4 13 Installation Figure 4 3 555 Input and Output Wiring Options NEUTRAL 2 Flow Pacing Residual Compound Loop CL2 valve output 4 20mA or Relay Dechlorination SO valve output 4 20mA or Relay Dual Flow Pacing SO valve output 4 20mA or Relay Alarm Relay Retransmission 2nd staged output 4 20mA 2nd slidewire output relay Alarm Relay Retransmission lt Outputs 1 2 3 and 4 must be filled with appropriate modules See Chapter 3 14 OUT 1 P dE UT 2 UT 2 UT 3 UT 3 L Alarm Relay Retransmission 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 Ifyou 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 atthe 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 de signed system can help prevent problems such as electrical noise disturbances and dangerous extreme conditions Special
67. Conforms to the following safety standard EN 61010 1 2001 Supplemental Information CE option requires CE KIT PN 535 766 Date Fred Adt Robert Stockham Quality Assurance Director Moore Industries International Inc European Contact Your Local Moore Industries Sales and Service Office The Interface Solution Experts www miinet com United States info miinet com Belgium info mooreind be China sales mooreind sh cn MOOR Tel 818 894 7111 FAX 818 891 2816 Tel 03 448 10 18 FAX 03 440 17 97 Tel 86 21 62481120 FAX 86 21 62490635 IND USTRIES Australia sales mooreind com au The Netherlands sales mooreind nl United Kingdom sales mooreind com Tel 02 8536 7200 FAX 02 9525 7296 Tel 0 344 617971 FAX 0 344 615920 Tel 01293 514488 FAX 01293 536852 Declaration of Conformity C 4 EMC Directive 89 336 EEC Manufacturer s Name Moore Industries International Inc Manufacturer s Address 16650 Schoenborn Street North Hills CA 91343 6196 USA Declares that the product s Product Name 500 Series MODEL 1 INPUT OUTPUT POWER OPTIONS HOUSING Model Number s 500 Series T Universal Power H or J x Supply Indicates any input output option and housing as stated on the product data sheet Indicates CE Compliant Conforms to the following EMC specifications EN61326 1 1998 Electromagnetic Compatibility requirements for electrical equipment for control use
68. DARD Forchlorination and dechlorinationtogether 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 re viewed Referto Chapter 5fora complete listing of menus and parameters B RESIDUAL CHLORINE LOOP MODE Residual control is a closed loop system that positions a chlorine valve based on achlorine residual measurement PV1 With a user defined residual set point the 555 increases or decreases the Cl gas feed rate based on the devia tion from setpoint refer to Figure 6 2 Forimproved residual control the 555 uses a fixed lag time function This func tion compensates for the time the residual analyzer takes to sample and up date 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 overtime theintegralcontrolalgo Figure 6 2 rithm will correct for changes in flow Residual Chlorine Loop Control Residual Signal Automatic Chlorine Residual Analyzer Residual Setpoint Water Flow Water Flow
69. E COMPANY MAKES NO EXPRESS IMPLIED OR STATUTORY WARRANTIES INCLUDING ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO ANY GOODS OR SERVICES SOLD BY THE COMPANY THE COMPANY DISCLAIMS ALL WARRANTIES ARISING FROM ANY COURSE OF DEALING OR TRADE USAGE AND ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY ACKNOWLEDGES THAT THERE ARE NO WARRANTIES IMPLIED BY CUSTOM OR USAGE IN THE TRADE OF THE BUYER AND OF THE COMPANY AND THAT ANY PRIOR DEALINGS OF THE BUYER WITH THE COMPANY DO NOT IMPLY THAT THE COMPANY WARRANTS THE GOODS OR SERVICES IN ANY WAY ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY AGREES WITH THE COMPANY THAT THE SOLE AND EXCLUSIVE REMEDIES FOR BREACH OF ANY WARRANTY CONCERNING THE GOODS OR SERVICES SHALL BE FOR THE COMPANY AT ITS OPTION TO REPAIR OR REPLACE THE GOODS OR SERVICES OR REFUND THE PURCHASE PRICE THE COMPANY SHALL IN NO EVENT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES EVEN IF THE COMPANY FAILS IN ANY ATTEMPT TO REMEDY DEFECTS IN THE GOODS OR SERVICES BUT IN SUCH CASE THE BUYER SHALL BE ENTITLED TO NO MORE THAN A REFUND OF ALL MONIES PAID TO THE COMPANY BY THE BUYER FOR PURCHASE OF THE GOODS OR SERVICES ANY CAUSE OF ACTION FOR BREACH OF ANY WARRANTY BY THE COMPANY SHALL BE BARRED UNLESS THE COMPANY RECEIVES FROM THE BUYER A WRITTEN NOTICE OF THE ALLEGED DEFECT OR BREACH WITHIN TEN DAYS FROM THE EARLIEST DATE ON WHICH THE BUYER COULD REASONABLY HAVE DISCOVERED THE AL
70. E 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 1ST INPUT Refer to Chapter 6 for more details 1 1st INPUT LOW RANGE Sets the flow input value for Point 1 LOW RANGE to HIGH RANGE based on FLOW PV TYPE D LOWRANGE 2 1st PV Sets the engineering units value for Point 1 9999 to 99999 XTH INPUT dp 3 Xth INPUT LOW RANGE Sets the flow input value for Point X X 2 to 14 R LOW RANGE to HIGH RANGE based on FLOW PV TYPE D LOWRANGE XTH PV 4 Xth PV 0 Sets the engineering units value for Point X X 2 to 14 9999to 99999 DO 15TH INPUT 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 15TH PV Sets the engineering units value for Point 15 0 Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Ere now v 34 Chapter 5 555 User s Manual Software Configuration Configuration RSDL INPT RSDL INPT Available
71. ER WITH THE COMPANY DO NOT IM PLY THAT THE COMPANY WARRANTS THE GOODS OR SERVICES IN ANY WAY ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY AGREES WITH THE COMPANY THAT THE SOLE AND EXCLUSIVE REMEDIES FOR BREACH OF ANY WARRANTY CONCERNING THE GOODS OR SERVICES SHALL BE FOR THE COMPANY AT ITS OPTION TO REPAIR OR REPLACE THE GOODS OR SERVICES OR REFUND THE PURCHASE PRICE THE COMPANY SHALL IN NO EVENT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES EVEN IF THE COMPANY FAILS IN ANY ATTEMPT TO REMEDY DEFECTS IN THE GOODS OR SERVICES BUT IN SUCH CASE THE BUYER SHALL BE ENTITLED TO NO MORE THAN A REFUND OF ALL MONIES PAID TO THE COMPANY BY THE BUYER FOR PURCHASE OF THE GOODS OR SERVICES ANY CAUSE OF ACTION FOR BREACH OF ANY WARRANTY BY THE COMPANY SHALL BE BARRED UNLESS THE COMPANY RECEIVES FROM THE BUYER A WRITTEN NOTICE OF THE ALLEGED DEFECT OR BREACH WITHIN TEN DAYS FROM THE EARLIEST DATE ON WHICH THE BUYER COULD REASONABLY HAVE DISCOVERED THE ALLEGED DE FECT OR BREACH AND NO ACTION FOR THE BREACH OF ANY WAR RANTY SHALL BE COMMENCED BY THE BUYER ANY LATER THAN TWELVE MONTHS FROM THE EARLIEST DATE ON WHICH THE BUYER COULD REASONABLY HAVE DISCOVERED THE ALLEGED DEFECT OR BREACH RETURN POLICY For a period of thirty six 36 months from the date of shipment and under normal conditions of use and service Moore Industries The Company will atits option replace repair or refund the purchase price for any of its manu factured p
72. ERNATE RESIDUAL SP amp DOSAGE SETTING A remote input is available Signal is 0 20 4 20 mADC 0 5 1 5 VDC jumper selectable Signal may be ratioed and biased Two local setpoints may be stored in memory selectable via SET PT key or digital contact s SERIAL COMMUNICATIONS Isolated serial communications is available using an RS 485 interface Baud rates of up to 19 200 are selectable The protocol supports CRC data checking If communications is lost a time out feature will command the controller to a particular control mode and specific setpoint or output if desired Outputs 2 4 and digital inputs can act as host controlled I O independent of the controller s function May be installed in the field DIGITAL DISPLAYS Upper display five digit seven segment 15mm 0 6 in height Indicates flow rate when flow pacing residual in residual mode and either in compound or dechlorination modes 2nd display nine character 14 segment alphanumeric 6mm 0 25 in height Indicates dosage setting or output when flow pacing and dechlorinating residual SP output or valve position for residual and compound control configuration information 3rd display nine character 14 segment alphanumeric 6mm 0 25 in height Indicates second input in compound and dechlorination modes Also displays alarm messages first priority and configuration information All displays are vacuum fluorescent Color is blue green STATUS INDICATORS There are tw
73. FASTKEY COMM ONLY Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Eesi v Dew 28 Chapter 5 555 User s Manual Software Configuration Configuration 12 CONTACT 2 Selects the use for the existing digital input 2 REM INPUT REM INPUT e MANUAL 2ND SETPT 2ND INT e ALARM ACK e INT INHBT LOCKMAN STANDBY e LOVACUUM e HIVACUUM e UPKEY DOWNKEY DISP KEY e MENU KEY e FASTKEY e COMM ONLY 13 CONTACT Selects the use for the existing digital input 3 CONTACT 3 REM INPUT 2ND SETPT MANUAL D 2ND SETPT e 2ND INT e ALARMACK INT INHBT e LOCKMAN STANDBY LOVACUUM e HIVACUUM e UPKEY e DOWNKEY e DISP KEY e MENU KEY e FASTKEY e COMM ONLY CONTACT 2 Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Eeo Ee ev we 555 User s Manual Chapter 5 29 Software Configuration Configuration 14 CONTACT 4 CONTACT 4 Selects the use for the existing digital input 4 OND INT REM INPUT MANUAL e 2ND SETPT D 2ND INT e ALARM ACK INT INHBT LOCKMAN STANDBY LOVACUUM e HIVACUUM UPKEY DOWNKEY e DISP KEY e MENUKEY e FASTKEY e COMM ONLY 15 CONTACT 5 Selects the use for the existing digital input 5 ALARM ACK REM INPUT MANUAL e 2ND SETPT 2ND INT
74. FF voltage is less than 0 5 Vdc Loop power supply module Current is limited to 25mA RETRANSMISSION OUTPUT A retransmission output is available if an analog output module is installed in any output socket not used for control The precise 16 bit retransmission output may be scaled for any range The transmitted signal can be process variable setpoint or control output value ALARMS Alarms are completely flexible Up to two software alarms are available High and low alarms may be sourced to the following variables flow rate chlorine residual dosage setting residual setpoint rate of change deviation output manual mode high vacuum low vacuum Alarm latching is selectable Up to two alarm outputs are available if an associated mechanical solid state relay or DC logic module is installed in any output Socket not used for control An alarm output may be configured as a global alarm allowing activation by multiple software alarms DIGITAL INPUTS set of five inputs for external dry contacts or open collector transistors are available Each can be configured to perform one of the following functions Select remote setpoint or dosage Lock in manual mode Select manual control Low vacuum alarm input Select second local setpoint High vacuum alarm input Select a second set of PID values Standby mode Acknowledge alarms Simulate front panel keys Inhibit the integral term C 2 Appendix C ALT
75. Figure B 3 left The hook up wire Figure B 3 right The hook up connects to the multi meter Set wire connects to the multi meter the meter for DC volts Make Set the meter for DC volts Make sure the screws are tight sure the screws are tight Figure B 3 left PV1 Calibration Wiring right PV2 Calibration Wiring hook up wires to multi meter hook up wires to multi meter 5 Reinsert chassis into the case secure the front panel screws and apply power The 2nd and 3rd displays should read CALIBRATE and ANLG IN to show you are in the CALIBRATE Menu ANLG IN section 6 Allowthe controller and meter to warm up for at least 45 minutes 7 Press the ACK key to getto the first step The 2nd display should show CAL VREF while the 3rd display should show a value close to 5 0000 8 The multimeter should show a value between 4 9750 and 5 0250 Use the and V keys and FAST on the 555 to match the value in the 3rd display to the meter s reading 9 Press MENU The 2nd display should read CAL 120mV and the 3rd display should now read a value close to 120mV B 2 Appendix B 555 User s Manual Calibration 10 Repeat the sequence of steps 7 8 and 9 four more times Each time you should match the displays of the controller and your meter Press ACK when done 11 If you will be calibrating milliamp outputs power down then up again Wait at least 5 minutes then continue to M
76. ITEM PART NO Output Modules 16 Option circuit board w remote setpoint amp 1 Mechanical relay module 535 600 slidewire feedback 545 626 2 Analog milliamp module 535 601 17 Option circuit board w remote setpoint 3 Triac SSR module 535 602 5 digital contacts amp slidewire feedback 545 627 4 DC logic SSR drive module 535 603 18 EPROM 555 644 5 Loop power module 535 604 19 Lithium battery 093 044 6 RS 485 communications module 535 605 20 Jumper kit set of all jumper connectors 545 660 Repair Parts 21 Gasket Kit Includes 1 panel gasket 7 Operator interface assembly 555 632 1 bezel gasket 535 662 8 Power supply circuit board 535 630 22 Mounting Kit Includes mounting brackets 2 9 Microcontroller circuit board 555 633 screws 2 amp rear terminal label 555 661 10 Option circuit board no options 535 620 23 Bezel retention screw kit 535 663 11 Option circuit board w set of 5 digital contacts 535 621 24 Module retention kit for outputs 1 3 12 Option circuit board w slidewire feedback 535 622 includes retention plate 535 664 13 Option circuit board w set of 5 digital contacts 25 Module retention kit for output 4 amp slidewire feedback 535 623 Includes Set of five tie wraps 535 665 14 Option circuit board w remote setpoint 545 624 26 Terminal Block 545 031A 15 Option circuit board w remote setpoint amp 5 digital contacts 545 625 555 User s Manual Appendix G G 1 555 User s Manual RETURN PROCEDURES To
77. LEGED DEFECT OR BREACH AND NO ACTION FOR THE BREACH OF ANY WARRANTY SHALL BE COMMENCED BY THE BUYER ANY LATER THAN TWELVE MONTHS FROM THE EARLIEST DATE ON WHICH THE BUYER COULD REASONABLY HAVE DISCOVERED THE ALLEGED DEFECT OR BREACH RETURN POLICY For a period of thirty six 36 months from the date of shipment and under normal conditions of use and service Moore Industries The Company will at its option replace repair or refund the purchase price for any of its manufactured products found upon return to the Company transportation charges prepaid and otherwise in accordance with the return procedures established by The Company to be defective in material or workmanship This policy extends to the original Buyer only and not to Buyer s customers or the users of Buyer s products unless Buyer is an engineering contractor in which case the policy shall extend to Buyer s immediate customer only This policy shall not apply if the product has been subject to alteration misuse accident neglect or improper application installation or operation THE COMPANY SHALL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES WORLDWIDE www miinet com China sales mooreind sh cn Tel 86 21 62491499 FAX 86 21 62490635 United Kingdom sales mooreind com Tel 01293 514488 FAX 01293 536852 es LU MOORE INDUSTRIES Tol 02 859 7200 PG 02 0925 208 2006 Moore Industries International Inc Belgium info 9
78. LLEGED DEFECT OR BREACH WITHIN TEN DAYS FROM THE EARLIEST DATE ON WHICH THE BUYER COULD REASONABLY HAVE DISCOVERED THE ALLEGED DEFECT OR BREACH AND NO ACTION FOR THE BREACH OF ANY WARRANTY SHALL BE COMMENCED BY THE BUYER ANY LATER THAN TWELVE MONTHS FROM THE EARLIEST DATE ON WHICH THE BUYER COULD REASONABLY HAVE DISCOVERED THE ALLEGED DEFECT OR BREACH RETURN POLICY For a period of thirty six 36 months from the date of shipment and under normal conditions of use and service Moore Industries The Company will at its option replace repair or refund the purchase price for any of its manufactured products found upon return to the Company transportation charges prepaid and otherwise in accordance with the return procedures established by The Company to be defective in material or workmanship This policy extends to the original Buyer only and not to Buyer s customers or the users of Buyer s products unless Buyer is an engineering contractor in which case the policy shall extend to Buyer s immediate customer only This policy shall not apply if the product has been subject to alteration misuse accident neglect or improper application installation or operation THE COMPANY SHALL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES WORLDWIDE www miinet com China sales mooreind sh cn Tel 86 21 62491499 FAX 86 21 62490635 United Kingdom sales mooreind com Tel 01293 514488 FAX 01293 536852 LU MO
79. MENU to pedi pecan operating display 3 FAST MENU tuning menu to access set up menus 13 set up menus 1 tuning menu Figure 5 3 CONFIG TUNING Operation and Configuration Flowchart FAST CONTROL CONTROL MENU FAST MENU FLOW INPT to move to access from menu set up menus to menu RETRANS POWER UP SECURITY SER COMM 24 Chapter 5 555 User s Manual Software Configuration Configuration 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 and V Press MENU to advance to the 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 Akey to these functions appears atthe bottom of every page inthe menu section of this chapter WHERE TO GO NEXT Forinformation about allthe software menus and parameters continue reading this chapter Refer to Appendix D fora quick reference flowchart of all menus and parameters For infor
80. NG CONFIGURE J STATION BAUD RATE SHED TIME SHED MODE SHED OUT SHED OUT 2 SHED SP DESIG SP 555 21 Appendix F Page F 1 The Isolation Block Diagram has been modified PV1 Input Output 1 i Multiplexer CPU ISO Ground Referenced PV2 Input Output 2 ISO Ground 9 Referenced o RSP Input Output 3 ISO Ground Referenced Slidewire Input Output 4 V ISO Ground Referenced Vd Digital Th 3 Inputs 1 5 RS485 Serial Communications Interface ZEN be l Isolated output ground 1 Each ofthe three ground circuits are isolated from each other to withstand a potential of 500 volts for 1 minute or 600 volts for 1 second 2 RSP Slidewire and the PV inputs are isolated to withstand 50 volts peak between each other for 1 minute 3 PV1 and PV2 have isolation to 10 volts P P or continuous be tween each other 4 Milliamp Loop Power and SSR Drive modules in output posi tions 1 2 3 and 4 are not isolated from each other 5r db Earth referenced ground ali Internal ground 2 Sm Milliamp Module Mechanical Relay SSR Driver Loop Power SSR Output 22 555 Addendum Appendix G Page G 1 With the modifications to the case and addition of the mounting collar the parts drawings have been modified Also note the new part numbers OPERATOR CIRCUIT BEZEL CIRCUIT BOARDS CONTROLLER BODY MO
81. Notes 1 Forimproved electrical noise immunity install the 555 as far away as pos sible from motors relays and other similar noise generators Do not run low power sensor input lines inthe same bundle as AC power lines Grouping these lines in the same bundle can create electrical noise interference All wiring and fusing should conform to the National Electric Code and to any locally applicable codes Anexcellent resource about good wiring practices isthe IEEE Standard No 518 1982 andis 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 7 2 Slidewire Option Input Digital Inputs Option if installed DIN 47 GND g DIN 1 18 E d n2 19 A on 3 20 EH RS485 RS485 Com if installed RS485 PV2 Flow signal input 4 20mA from transmitter 421 g Pv2 DIN5 22 Ico N A N A 23 e in CL signal input 4 20mA from analyzer N A 24 g PV1 Remote Set Point Option Input Chapter 4 555 User s Manual Installation AC Power Input Terminals 1 and 2 are for POWER Terminal 9 is earth ground Use a 0 5 No
82. ORE INDUSTRIES 2006 Moore Industries International Inc Belgium info 9 mooreind be Tel 03 448 10 18 FAX 03 440 17 97 The Netherlands sales 9 mooreind nl Tel 0 344 617971 FAX 0 344 615920 Specifications and Information subject to change without notice 3 ana peur EE EE 1 4 DIN PROCESS CONTROLLER Addendum to the User s Manual L moore INDUSTRIES WORLDWIDE M555 V6A6 OCTOBER 2006 The555controller has been upgraded with anew microprocessor a new case r ju and modifications to the front panels to improve its NEMA 4X capability In sert the information in this addendum where appropriate in your M555 V1 manual Cover The 500 series controller body has been modified to a 1 piece design with a new face plate 4 screws instead of 2 securing it to the body engem qmm rz ES Chapter 1 Page 1 Figure 1 1 This drawing shows a basic detail of the new faceplate Please refer to this also drawing for any detail of the controller face Chapter 2 Page 5 Figure 2 1 Chapter 4 Page 13 Figure 4 1 Appendix C Page C 3 Specifications and information subject to change without notice Addendum 555 1 55 e 7 7 Chapter 1 Page 3 New Order Code 555 B ollo Order Output 1 Control Code NONO 0 Mechanical Relay 5
83. Output Wiring Options 14 Figure 4 4 AC Power Input Wiring esee 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 sseseeeeeeeee 16 Figure 4 8 PV mA Input with Internal Power Supply and 4 Wire Transmitter Wiring eeeeneeee 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
84. Power Supply Transmitter Screws must be tight to ensure electrical connection Screws must be tight to ensure electrical connection 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 yourcontroller s installed options See also Chapter 3 for module installation details 2 wire Transmitter Figure 4 7 e PV1 terminals 31 and 32 with the loop power module output termi nals and a 2 wire transmitter Figure 4 7 e PV2 terminals 28 and 29 with the loop power module output termi PV mA Input with Internal Power nals and a 2 wire transmitter Supply and 2 wire Transmitter Wiring Input power can come from a loop power module in Output 2 terminals 5 amp 6 Output 3 terminals 7 amp 8 or Output 4 terminals 15 amp 16 2 wire transmitter Transmitter output can be connected to PV1 temrinals 31 amp 32 or PV2 temrinals 28 amp 29 Screws must be tight to ensure electrical connection 16 Chapter 4 555 User s Manual Installation 4 wire Transmitter Figure 4 8 e PV1 terminals 31 and 32 with the loop power module output termi nals and a 4 wire transmitter e PV2 terminals 28 and 29 with the loop power module output termi nals and a 4 wire transmitter Input power can come from loop
85. RE ERE Rid mg Mechanicaltoray 1 Analog milliamp 2 RETRANSMISSION Solid state relay triac 1 amp 3 DC logic SSR drive 4 OUTPUT 3 Bones oe odio militnm terti bein EA 0 ALARM Mechanical relay 5 1 OR Analog milliamp ee 2 RETRANSMISSION Solid state relay triac 1 3 DC logic SSR drive 4 OUTPUT 4 NoNo raae o ALARM Mechanical relay 0 5 amp 24 V 1 RETRANSMISSION Analog milliamp 2 OR LOOP POWER Solid state relay triac 0 5 amp 24 V 3 DC logic SSR drive 4 Loop POWO 5 Optional Inputs Slidewire feedback for ENTER O IF position proportioning u OPTIONAL E A E INPUT NOT DESIRED _ Remote setpoint Standard B Five digital inputs for vacuum alarm and standby mode diede needs D SERIAL RS 485 serial o COMMUNICATIONS communications eeeee S ENTER 0 IF COMMUNICATIONS NOT DESIRED Note 1 Capability for position proportioning output is specified by ordering 555 1 1xxAxxx00 555 33xxAxxx00 or 555 44xxAxxx00 Slidewire not required for velocity proportioning Note 2 Up to two outputs may be used for alarm
86. REQ OUTPUT2 OUTPUT 3 OUTPUT 4 ANLG RNG 3j ANLG RNG 4 CONTACT 1 CONTACT 2 CONTACT 3 CONTACT 4 CONTACT 5 REMOTE IN FIXED LAG VARBL LAG MAX LAG MIN TRIM MAX TRIM FLOW ONLY RSDL ONLY INT ACTION r PV TYPE DECIMAL LINEARIZE LOW RANGE HI RANGE FILTER PV OFFSET PV GAIN FLOW BRK FLOW BRK 2 FLOW REST eS E 1ST INPUT 1ST PV 2ND INPUT 2ND PV 15TH INPUT r PV TYPE DECIMAL LOW RANGE HI RANGE FILTER PV OFFSET PV GAIN RSDL BRK RSDL REST 5 SP LOW SP HIGH SP RAMP NO OF SP V MA LOW RANGE HI RANGE RATIO BIAS TRACKING RESTORE MIN OUT MAX OUT MIN OUT2 MAX OUT2 CYCLE TM 1 CYCLE TM 2 DIG IN 1 OUT H DIG IN 2 OUT DIG IN 3 OUT DIG IN 4 OUT DIG IN 5 OUT DIG IN 1 OUT2 DIG IN 5 OUT2 STAGE OUT1 STAGE OUT2 DIG IN 2 OUT2 DIG IN 3 OUT2 S W RANGE S W OPEN S W CLOSE S W D BAND S W BREAK OUT RATE DIG IN 4 OUT2 r REILIYPE 2 RET LOW 2 RET HIGH 2 RET TYPE 3 RET LOW 3 RET HIGH 3 RET TYPE 4 RET LOW 4 RET HIGH 4 ALM TYPE 1 ALARM SRC 1 ALARM SP 1 HIGH SP 1 LOW SP 1 DEADBAND 1 ALM 1 OUT LATCHING 1 POWER UP 1 MESSAGE 1 ALM TYPE 2 ALARM SRC 2 ALARM SP 2 HIGH SP 2 LOW SP 2 DEADBAND 2 ALM 2 OUT LATCHING 2 POWER UP 2 MESSAGE 2 RATE TIME PWR UP MODE_ PWR UP OUT PWR UP SP J r SEC CODE SETPT KEY SP DOSAGE AUTO MAN ALARM ACK TUNI
87. REST Residual mode Dechlorination mode and Compound Loop mode with Flow RSDL REST only control disabled LAST MODE Defines control mode upon restoration of residual signal D LASTMODE MANUAL AUTOMATIC SETPOINT SP LOW Available only for Residual or Compound Loop mode 1 SPLOW Sets the value in engineering units corresponding to the lowest SP value al lowed 9999 to 99999 SP HIGH 2 SP HIGH Sets the value in engineering units corresponding to the highest SP value al lowed 9999 to 99999 D 1000 3 SP RAMP Turns SP ramping off or defines the SP ramping rate in engineering units per SP RAMP hour e g a value of 3600 translates to 1 SP step increment every second 11099999 D OFF PV OFFSET SETPOINT Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Returnto Operation mw eme ww v ww 36 Chapter 5 555 User s Manual Software Configuration Configuration REM INPUT REM INPUT Availble only if the remote input REMOTE IN is enabled 1 TYPE V mA Selects the type value for the Remote Input TYPEV MA D 1 5 4 20 1 5V 4 20mA e 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 ds to 99999 LOW RANGE For Dose R 0 0 to 400 0 D 0 0 3 RANGE Sets the value in engineering units corresponding to the hig
88. 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 f 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 REM INPUT T 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 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
89. UNTING INTERFACE BOARD SUPPORT GASKET shown with mounting COLLAR ASSEMBLY BEZEL INSERT collar in place shown with bezel insert in place ITEM PART NO ITEM PART NO Output Modules Repair Parts 1 Mechanical relay module 535 600 7 Operatorinterface assembly 545 634 2 Analog milliamp module 535 601 8 Power supply circuit board 535 730 3 Triac SSR module 535 602 9 Microcontroller circuit board 535 731 4 DClogic SSR drive module 535 603 10 Option circuit board no options 535 720 5 Loop power module 535 604 11 Option circuit board w set of 5 digital contacts 535 721 6 RS 485communications module 535705 12 Option circuit board w slidewire feedback 535 722 13 Option circuit board w set of 5 digital contacts amp slidewire feedback 535 723 14EPROM 555 740 15 Lithium battery 093128 16 Jumper kit set of all jumper connectors 545660 17 Gasket Kit Includes 1 panel gasket 1 bezel gasket 535 662 18Mounting Kit mounting collar and 4 screws 535 761 19 Bezel retention screw kit 535 663 20 Module retention kit for outputs 1 3 includes retention plate 535 664 21 Module retention kit for output 4 Includes Set of five tie wraps 535 665 22 Engineering labels 1 sheet 535 106 23 Circuit Board Support bezel insert 535 075 Addendum 555 23 RETURN PROCEDURES To return equipment to Moore Industries for repair follow these four steps 1 Call Moore Industries and request a Return
90. UT2 Selects the highest value for the second output under automatic control NOTE The 555 will not limitthe output under manual control D 10096 5 CYCLE TM 1 Selects the time base for output 1 when time proportioning a digital output CYCLETM 1 Appears only when a digital outputin slot 1 is being used for a control except o0 when using slidewire 0 3 to 2 0 by tenths 3 to 120 seconds by ones D 15seconds Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Returnto Operation eme wes a 38 Chapter 5 555 User s Manual Software Configuration Configuration 6 CYCLE TM 2 Mere FLOW REST 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 LAST MODE when using slidewire R 0 3 to 2 0 by tenths 3 to 120 seconds by ones D 15seconds 7 DIG IN 1 OUT Selects the designated output for an existing manual locked manual DIG IN 1 0UT standby low vacuum or high vacuum digital contact 1 D LAST OUT LAST OUT 5to 105 8 DIG IN 2 OUT Selects the designated output for an existing manual locked manual DIG IN 2 OUT standby low vacuum or high vacuum digital contact 2 LASTOUT D LASTOUT LAST OUT 510105 9 DIG IN 3 OUT Selects the designated output for an existing manual locked manual DIG IN 3 OUT
91. ailure 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 assem bly 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 SPECIAL COMMUNICATIONS MODULE 555 User s Manual Chapter 3 Hardware Figure 3 3 Output Module NOTE For greatest accuracy calibrate all milliamp modules added for retransmission as per the instructions in Appendix B
92. al Control Press the MANUAL key Automaticto manualtransition 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 con trol 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 amp 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 AccessTuning Returnto Operation few eme um A v 68 Chapter 6 555 User s Manual Applications _ Change Dosage Press DISPLAY key until 2nd line shows DOSE Use the and V keys to modify the dosage setting The input range can be scaled inthe FLOW INPT Menu Hardware Configuration 1 Confirm the installed options of your 555 by comparing the product label ontop of the controller
93. 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 Parameters All possible parameters are listed here However once you selectan alarmtype only those parameters related to that alarm will appear in your display ALM TYPE 1 ALM TYPE 2 Specifies the type of alarm to implement Selection includes OFF Alarm off HIGHALRM High alarm Occurs when the selected alarm source value exceeds the alarm setpoint LOWALARM Low alarm Occurs when the selected alarm source value falls be low the alarm setpoint MANUAL Occurs when the controller is putinto 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
94. 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 e DEVIATION Residual and Compound Loop Mode only Similarto the band alarm exceptit only creates a band on one side of thecontrol setpoint Occurs whenthe 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 ew ew Ca 70 Chapter 6 555 User s Manual Applications _ 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 arate greater than what is specified by the alarm setpoint and time base This alarm helps to anticipate problems be fore the process variable has achanceto 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
95. arameter s DIG IN X OUT2 where X 1 2 3 4 or 5 Values are LAST OUT or range from 5 to 105 555 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 Hardware Configuration This optional feature is only available if ordered originally from the fac tory 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 Setthe value for the parameter REMOTE IN Choices are OFF SETPOINT e CL2DOSE SO2DOSE 3 For REMOTEIN SETPOINT you can enable a ramping to setpoin
96. at will be connected to a 20 milliamp input current Make sure terminal screws are securely tightened but do not connect the wires yet leave inputs floating 2 Turnon power to the unit 3 Press MENU until the display indicates CALIBRATE ANA mA IN and press ACK If the display shows PV1 20mA PRESS ACK move ahead to step 8 4 Thecontroller will display SET BOTH JUMPER mA 5 Power down the controller and remove chassis from the case 6 Remove both input jumper connectors from the pins in the 2nd position Place one of the jumpers onthe PV1 position mA pins and place the other jumper on the 2nd position mA pins see Figure B 5 7 Reinsertthe chassis into the case and apply power The controller should display PV1 20mA PRESS ACK to indicate it is ready to calibrate the PV 1 milliamp input 8 Connecta precision 20mA inputtothe PV1 terminals 31 is PV1 3215 PV1 Make sure the terminal connections are fastened tightly and that a 20mA current is flowing through PV1 DO NOT connect the 20mA current to PV2 yet 9 Letthecontroller warm upforatleast 10 minutes keep in normal horizontal position Make sure the currentis flowing then press ACK to calibrate the PV1 input 10 Ifthe controller displays PV2 20mA PRESS ACK PV1 calibration was suc cessful Move on to step 12 11 Ifthe controller displays mA CALIB FAILED PV1 calibration was not suc cessful Check the 20mA connections and return to step 3 to recalibrate the PV1
97. ate position proportioning Type of control output that utilizes two relays to control an electric motorized actuator primary loop The outer loop in a cascade system 555 User s Manual process The equipment for which supply and demand must be balanced the system under control excluding the equipment that does the control process variable In the treatment of material any characteristic or measur able attribute whose value adjusts with changes in prevailing conditions Common variables are level pressure and temperature proportional band The change input required to produce a full range change in the output due to proportional control action The area around the setpoint where proportional control occurs proportional control Control action in which there is a continuous linear relation between the output and the input load The demand for input to a process ramping see setpoint ramping ratio The value obtained by dividing one number by another used to determine proportions ratio control Control in which the setpoint of one loop is a ratio of the process variable of another loop or sensor output regulate The act of maintaining controlled variable at or near its setpoint in the face of load disturbances relay mechanical An electrome chanical device that completes or interrupts a circuit by physically moving electrical contacts into contact with each other relay solid state A
98. automatic control 5 CYCLE TM 1 Selects the time base for output 1 6 CYCLE TM 2 Selects the time base for output 2 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 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 Configuration
99. be a Not To Exceed price which means that the actual repair costs may be less than the quote Be sure to include the RMA number on all documentation Provide us with the following documentation a Anote listing the symptoms that indicate the unit needs repair b Complete shipping information for return of the equipment after repair The and phone number of the person to contact if questions arise at the factory Use sufficient packing material and carefully pack the equipment in a sturdy shipping container 4 Ship the equipment to the Moore Industries location nearest you The returned equipment will be inspected and tested at the factory A Moore Industries representative will contact the person designated on your documentation if more information is needed The repaired equipment or its replacement will be returned to you in accordance with the shipping instructions furnished in your documentation WARRANTY DISCLAIMER THE COMPANY MAKES NO EXPRESS IMPLIED OR STATUTORY WARRAN TIES INCLUDING ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE WITH RESPECT TO ANY GOODS OR SER VICES SOLD BY THE COMPANY THE COMPANY DISCLAIMS ALL WARRAN TIES ARISING FROM ANY COURSE OF DEALING OR TRADE USAGE AND ANY BUYER OF GOODS OR SERVICES FROM THE COMPANY ACKNOWL EDGES THAT THERE ARE NO WARRANTIES IMPLIED BY CUSTOM OR USAGE IN THE TRADE OF THE BUYER AND OF THE COMPANY AND THAT ANY PRIOR DEALINGS OF THE BUY
100. ber on your controller the label on top of the control ler 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 555 controller one 555 User s Manual 555 mounting hardware one sheet engineering unit adhesive labels one rear terminal label WHERE TO GO NEXT Tobecome more familiar with the 555 interface continue to Chapter 2 For important hardware installation guidelines see Chapters and 4 For a detailed description of all the software menus and parameters of the 555 follow through Chapter 5 Appendix D can be usedas abasic guideline to these parameters TEXT FORMATTING IN THIS MANUAL Feature Format KEYS SETPT 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 2 Chapter 1 555 User s Manual General Information Information ORDER CODE 555 B 00 OUTPUT 1 None NR 0 CONTROL Mechanical relay 5 1 Analog milliamp 2 Solid state relay triac 1 amp 3 DC logic SSR drive 4 OUTPUT 2 BIOS oen abies aoi di B E
101. ch the circuit board board in place To The Microcontroller Board and Power Supply Board remove the module remain attached to the Operator Interface Assem snip the tie wrap bly by wired connectors Photo 6 7 Inspect each module before installation to make sure the pins are straight Align 22 the pins with the Photo 6 socket holes and Snip Tie Wrap on Mod 4 carefully insert the module Press down on the module to seat it firmly on the board 4 The Microcontroller and Power Supply board are attached to either side of the Option board by male female pin connectors Use a gentle rocking motion and carefully apply pressure in a uniform direction to separate Photo 4 Separate Boards Installation Guide 500 Series 3 Installation NOTE Front of Unit Back of Unit If you replace the EPROM chip you toward Operator Interface toward rear terminals must align the notch facing the front of the unit BATTERY 5 Pin Connector o Female 22 Pin Connector NOTE The 5 and 22 Pin connnectors on the boards are all keyed so they will only align one correct way Male 22 Pin Remote Setpoint Jumper Male 22 Pin Connector Connector Output 4 4 Male 12 Pin Male 22 Pin Connector Connector Figure 2 12 Pin Female 56 22 Pin Female Microntroller Board Connector Connector Option Board and Power Supply Board 5 Pin Connector Module Retention Plate over Outputs 1 2 3
102. change output modules or jumpers refer to Chapter 3 2 To mount your controller into a panel refer to Chapter 4 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 Place 555 under manual control Enter Set Up Go to CONFIG Menu Set parameter CTRL MODE RESIDUAL Go to CONTROL Menu Set the parameter FIXED LAG to the appropriate time Goto RSDL INPT Menu You mustsetall 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 IAN Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Erpe fee 555 User s Manual Chapter 6 63 Applications 7 Access Tuning Mode press MENU Set all relevant parameters in the TUNING Menu For proper setup and operation ALL menus parameters must be re NOTE viewed Referto Chapter 5fora complete listing of menus and parameters You will not see the FLOW INPT and FLOW LINR menus du
103. d place the input jumpers in the desired position see Figure B 2 and Figure B 5 Replace the process variable PV 1 or PV2 input signal with a suitable cali bration device Apply power and allow controller to warm up for 30 minutes Place controller in Manual mode press MENU and FAST together to reach the FLOW INPT or RSDL INPUT menu Adjust the calibration device to an output signal equal to the 0 range value for the particular input sensor for example 4mA for a 4 20 mA input Verify value indicated in the 1st display is equal to the 0 range value for the particular input sensor If incorrect use the and V keys to scroll to the correct value Press MENU until the PV GAIN parameter appears in the 2nd display Adjust the calibration device to an output signal equal to the 100 range value for the particular sensor Verify that the value shown in the 1st display is equal to 100 of the range value for the particular input sensor If the value is not correct use the and W keys to scroll to the correct value Repeat steps 4 through 9 to verify all values Press DISPLAY to return to the Operation mode Addendum Appendix D D 1 SET UP MODE CONFIG CONTROL FLOW INPT FLOW LINR RSDL INPT SETPOINT REM INPUT OUTPUT RETRANS ALARMS POWER UP SECURITY SER COMM Addendum The Set Up Menus have been updated r CTRL MODE OUT MODE ANLG RNG 1 LINE F
104. e 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 A and V keys to modify the dosage setting 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 outputtype 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 Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Returnto Operation Ems eme Emu a v 60 Chapter 6 555 User s Manual Applications _ 3 Inputs The Milliamp signal from the flow meter mustbe 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 SO 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 Goto CONFIG Menu 3 Setparameter CTRL MODE FLOW PACE 3 Foreither chlorination or dechlorination only set parameter OUT MODE STAN
105. e typically SOo in direct propor tion to the water flow rate and the residual Cl level The user defines the 502 dosage value from 0 01 to 400 percentage of gas flow per water flow The 555 willincrease 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 dos age setting and flow rate Dechlorination is required to maintain the amount of free chlorine within regulatory discharge limits B Figure 6 4 Dechlorination Control Dosage Setting Automatic Valve 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 orflow input PV2 To switch the display positions of the primary and secondary PV press FAST DISPLAY Also used for special messages and alarms alternates mes sages with other queued information Displays parameter values during configuration Basic Operating Procedures Switch from Automatic to Manu
106. e 1st and 3rd displays A Press to advance to previous value or parameter FAST 4A Press to scroll through values at a faster rate Press to advance to next value or parameter FAST V Press to scroll through values at a faster rate ACK Press to acknowledge an alarm s When lit indicates that there is an acknowledgeable alarm MENU Pressto access the Tuning Menu andits 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 Chapter 2 555 User s Manual Hardware CHAPTER 3 HARDWARE SET UP 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 Allthe 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 pulli
107. e 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 amp 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 A V FAST A or FAST V Thereisa 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 R
108. e to the smart menu function of the 555 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 measure ment PV1 as well as water flow measurement PV2 The residual control signaltrims modifies the valve position signal generated by flow proportion ing 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 injec tion rate andfine tuning integral control ofthe valve position due to changes as measured at the end of each lag time period Figure 6 3 Compound loop control incorporates both a fixed and variable component into Compound Loop Control Residual Signal Residual __ __ Setpoint Automatic Valve Flow Water Flow Meter _ gt 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 Cl 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 oxida tion demand vary or where tight control is required The 555 makes compound loop mode easy to use by continuously displaying the chlorine residua
109. ed No mes sages 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 Appendix A 555 User s Manual Error Handling _ Handling 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 Forthe corresponding choices the DESIG SP parameter defines which local setpoint to use 555 User s Manual Appendix A A 5 Error Handling Handling Appendix A 555 User s Manual Calibration 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 CALIBRATE CAL VREF 5 0000 ANLG IN PRESS ACK PRESS MENU C
110. ed Material Authorization RMA number Warranty Repair If you are unsure if your unit is still under warranty we can use the unit s serial number to verify the warranty status for you over the phone Be sure to include the RMA number on all documentation Non Warranty Repair If your unit is out of warranty be prepared to give us a Purchase Order number when you call In most cases we will be able to quote you the repair costs at that time The repair price you are quoted will be a Not To Exceed price which means that the actual repair costs may be less than the quote Be sure to include the RMA number on all documentation Provide us with the following documentation a Anote listing the symptoms that indicate the unit needs repair b Complete shipping information for return of the equipment after repair c The name and phone number of the person to contact if questions arise at the factory Use sufficient packing material and carefully pack the equipment in a sturdy shipping container 4 Shipthe equipment to the Moore Industries location nearest you The returned equipment will be inspected and tested at the factory A Moore Industries repre sentative will contact the person designated on your documentation if more information is needed The repaired equipment or its replacement will be returned to you in accordance with the shipping instructions furnished in your documentation WARRANTY DISCLAIMER TH
111. eration Ems ww Dev Ca Lew 555 User s Manual Chapter 5 45 Software Configuration Configuration 13 DEADBAND 2 DEADBAND 2 Selects the deadband for ALM TYPE 2 HIGH ALRM LOW ALARM L5 BAND DEVIATION or RATE If ALARM SRC 2 FLOW RESIDUAL SETPOINT RAMP or DEVIA TION R 1t099999 2 If ALARM SRC 2 CL2 DOSE SO2 DOSE or OUTPUT 0 0 to 400 0 D 0 2 ALM 2 OUT 14 ALM 2 OUT For an enabled ALM TYPE 2 selects the physical output number D NONE e ofany outputs configured as alarms LATCHING 2 15 LATCHING 2 LATCH For an enabled ALM TYPE 2 enables or disables alarm latching D LATCH e NOLATCH ACK 2 16 ACK 2 For an enabled ALM TYPE 2 enables or disables the ACK key ENABLED D ENABLED e DISABLED 17 POWER UP 2 POWER UP 2 Foran enabled ALM TYPE 2 selects the condition of the alarm upon D NORMAL ALARM DELAYED MESSAGE 2 18 MESSAGE 2 For an enabled ALM TYPE 2 except for type VACUUM a 9 character ALARM 2 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 and keys to modify Selecting all blanks disables the alarm message D ALARM2 RATE TIME 19 RATE TIME F5 3 Selects the time base for ALM TYPE RATE Rate time combined with rate alarm SP defines the rate of change slope that triggers the ala
112. erdamped 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 param eter in the POWER UP Menu to load into the output at power up will bring the Residual PV to setpoint more quickly Overdamped Response Underdamped Response Oscillating Response SETPOINT 2 Bu 2 A e o o a ey c c c v gp v 0 1 2 3 4 012 3 4 0 1 2 3 4 _ Lag Times Acceptable Response 1 Acceptable Response 2 Figure 6 6 SETPOINT Residual Control Responses 2 2 n n o o c c v v 0 1 2 3 4 0 1 2 3 4 Lag Times 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 combi nation 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 integra
113. esidual Set Point Press DISPLAY until 2nd line shows SP Use the A and W 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 A and W keys to modify the dosage setting Range is 0 to 400 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 con tingent 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 Goto CONFIG Menu Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Returnto Operation Eme few reu
114. fied 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 PV 1 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
115. for retransmission of output D 1000 4 RET TYPE 3 Selects the type data retransmission for existing retransmission output 3 RET TYPE 3 D OUT e RESIDUAL CL2DOSE SO2DOSE SETPOINT RAMPSP 5 RET LOW 3 RET LOW OW 3 Sets the value in engineering units corresponding to the low retransmission a 3 output value 3 except for retransmission of output 9999to 99999 6 RET HIGH 3 RET HIGH 3 Sets the value in engineering units corresponding to the high retransmission 100 output value 3 except for retransmission of output R 9999 to 99999 D 1000 7 RET TYPE 4 Selects the type data retransmission for existing retransmission output 4 RET TYPE 4 b ur e RESIDUAL CL2DOSE SO2DOSE SETPOINT e RAMP SP Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Eesi a Lew 42 Chapter 5 555 User s Manual Software Configuration Configuration 8 RET LOW 4 Sets the value in engineering units corresponding to the low retransmission output value 4 except for retransmission of output 9999 to 99999 9 HIGH 4 Sets the value in engineering units corresponding to the high retransmission RET HIGH 4 output value 4 except for retransmission of output R 9999to 99999 D 1000 ALARMS ALARMS Note All alarms may be assigned to the same output 1 ALM TYPE 1 Selects the type fo
116. ftware options the background is black When the appearance of a paramter is dependent 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 on those options the background is white Use the arrows keys to enter TT y numerical values and or move Eus P This is a Value through the selection group press MENU FAST The numbers values that correspond to Go to next Menu Block your particular hardware software options will show in the 3rd display The graphics in this chapter show the default factory setting MENUS IMPORTANT In Set Up mode there 13 sets of options that control different aspects of 555 All software changes occur in realtime operation in Tuning mode there is one Each set of optionsis called amenu As always perform set up functions under you traverse the two modes the menu names appear in the 2nd display Manual operation 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 Cl data input PV 1 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
117. g direct output increases on rise of input Typical cooling response or reverse output decreases on rise of input typical heating response Appendix E control action integral reset I The part of the control algorithm that reacts to offset between setpoint and process variable control action proportional P Control action in which there is a continuous linear relation between the output and the input control algorithm A mathematical representation of the control action to be performed control output The end product which is at some desired value that is the result of having been processed or manipulated control mode automatic A user selected method of operation where the controller determines the control output control mode manual A user selected method of operation where the operator determines the control output control parameters User defined values that specify how the process is to be controlled controlled variable A process variable which is to be controlled at some desired value by means of manipulating another process variable CRC cyclic redundancy check An error checking technique in which a checking number is generated by taking the remainder after dividing all the bits in a block in serial form by a predeter mined binary number CSA Acronym for Canadian Standards Association cycle time The time necessary to complete a full ON through OFF period in a time proporti
118. h SSR triac or DC logic Chapter 5 Page 28 Two new options have been added to each ANLG RNG parameter RNG 1 e 20 4 e 20 0mA 8 2 e 20 4 e 20 0 9 ANLG RNG 3 e 20 4mA e 20 0mA 10 ANLG RNG 4 e 20 4mA e 20 0mA Chapter 5 Pages 29 31 Addendum Two new options have been added to each CONTACT parameter 11 CONTACT 1 e NOFLOW e NORSDL 12 CONTACT2 e NOFLOW NORSDL 13 CONTACT3 e NOFLOW e NORSDL 14 CONTACT 4 NOFLOW e NORSDL 555 5 5 7 15 5 e NOFLOW NORSDL Chapter 5 Page 32 In the CONTROL Menu a new parameter has been added at the end of the menu 8 INT ACTION Residual or Compound Loop Defines how integral action modifies the outputto bring the residual PV toward SP for residual or compound loop mode D REVERSE Cl dosing e DIRECT SO dosing Chapter 5 Page 36 In the SETPOINT Menu a new parameter has been added 4 NO OFSP Defines the number of local setpoints to be stored for selection by digital inputs orthe SET PT key R 1102 D 1 Chapter 5 Pages 41 In the OUTPUT Menu new parameter has been added at the end of the menu 24 OUT RATE Defines the maximum allowable rate of change ofthe control output during automatic control D 10 00 per second R 0 01 to 100 0 per second Chapter 5 Pages 43 46 In the ALARMS Menu the alarm types options have been c
119. h end of the input signal range e g 5 volts or 20 mA joy is the low end of the input signal range e g 1 volt or 4 mA 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 f 3 1 5 1 1000 5 707 Custom linearization allows you to take virtually any nonlinear signal and lin earize itwith a 15 pointstraightline approximation curve see Figure 6 8 Typi cal 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 volt age or current input Oncethe points are defined the values betweenthe 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 555 User s Manual Chapter 6 NOTE Tochange the 555 to automatic mode without initializing the dose values press the MANUAL key by itself Figure 6 7 Square Root Linearization Formula 83 Applications Figure 6 8 Custom Linearization Curve 15th PV 10th PV 5th PV 2 o 2 a lt gt gt a Input 1 Input 5 Input 10 Input 15 FLOW INPUT VALUE in milliamps or volts Hardware Configuration You mu
120. h remote input value apn HI RANGE R 9999 to 99999 D 1000 For Dose R 0 0 to 400 0 D 100 0 4 RATIO Sets the ratio a constant gain applied to the remote input RATIO R 99 99 to 99 99 D 1 00 5 BIAS Sets the bias a constant offset applied to the remote input For SP 9999to 99999 E BIAS For Dose 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 Lew Ca v few 555 User s Manual Chapter 5 37 Software Configuration Configuration 6 TRACKING TRACKING Determines whether or not to keep the remote input value if the signal is lost NO Otherwise the controller automatically uses a local value YES D NO RESTORE 7 RESTORE Defines which value to use once the remote input signal is restored 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 0 100 0 2 OUT Selects the highest value for the output under automatic control NOTE The 555 will not limit the output under manual control R Oto 100 D 10096 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 limitthe output under manual control R 0 100 0 4 OUT2 Dual Flow Pacing mode MAX O
121. hanged and two new setpoint parameters have been added for each alarm 1 ALM 1 D OFF e HIGHALRM e LOWALARM e REMOTEIN Alarm activates when remote input is being used e HIGH LOW Alarm has separate High and Low alarm setpoints MANUAL e VACUUM BAND e DEVIATION RSDL RATE Rate alarm based on residual PV1 input e FLOWRATE Rate alarm based on the flow PV2 input 555 Addendum 4 HIGHSP 1 Selects the high setpoint for ALM TYPE 1 HIGH LOW lf ALARM SRC 1 OUTPUT 0 096to 100 0 DO lf ALARM SRC 1 any other type R LOW RANGE to HIGH RANGE D 0 5 LOWSP 1 Selects the low setpoint for ALM TYPE 1 HIGH LOW lf ALARM SRC 1 OUTPUT 0 0 to 100 0 D 0 lf ALARM SRC 1 any other type R LOW RANGE to HIGH RANGE D 0 12 ALM TYPE 2 D OFF e HIGHALRM e LOWALARM e REMOTEIN Alarm activates when remote input is being used e HIGH LOW Alarm has separate High and Low alarm setpoints e MANUAL e VACUUM e BAND e DEVIATION e RSDL RATE Rate alarm based on residual PV1 input e FLOWRATE Rate alarm based on the flow PV2 input 13 HIGH SP 2 Selects the high setpoint for ALM TYPE 2 HIGH LOW If ALARM SRC 2 OUTPUT 0 0 to 100 0 DO If ALARM SRC 2 any other type R LOW RANGE to HIGH RANGE DO Addendum 555 if 5 7 14 LOW SP 2 Selects the low setpoint for ALM TYPE 2 HIGH LOW lf ALARM SRC 2 OUTPUT 0 0 to 100 0 DO If ALARM SRC 2
122. he following to test the function refer to Figure B 1 flowchart for details Figure B 6 1 Disconnect power to the instrument Slidewire Calibration Wiring 2 Remove chassis from case 3 Onthe Microcontroller Circuit Board locate jumpers at locations PV1 and 2nd marked on the edge of the board see Figure B 2 Reposition the jump ers at 2nd onto pins for V and TCA 4 Press MENU until the 2nd and 3rd displays show S W TEST 5 Attacha 100 ohmsto 1000 ohms potentiometerto terminal 10 11 and 12as shownin Figure B 6 6 By movingthe potentiometer from one endto the other you should be able to display from 096 to 100 on the controller 7 Ifthe error message OPEN appears check the connections and try again 8 Press ACK to exit QUICK CALIBRATION PROCEDURE This procedure is for the benefit of users that have ISO or other standards that require periodic calibration verification The procedure enables verification and modification of the volt or mA process variable input you are using without en teringthe Factory Configuration mode Therefore you do notneedto perform the jumper change as specified in steps 1 2 and 3 in the beginning of this ap pendix 1 Power down the 555 controller 2 Replace the process variable PV input signal with a suitable calibration device 3 Apply power and allow controller to warm up for 30 minutes Place controller under Manual control 5 Go to the FLOW INPT or RSDL INPT menu Scroll to
123. he more sensitive the rate alarm Alarm Examples Figure 6 5 Alarm Examples A BAND ALARM B HIGH PROCESS VARIABLE ALARM IN ALARM IN ALARM CONDITION i CONDITION E 5 A SP RELAY RELAY RELAY RELAY RELAY RELAY RELAY DE ENERGIZED ENERGIZED DE ENERGIZED ENERGIZED DE ENERGIZED ENERGIZED DE ENERGIZED ICON OFF ICON ON ICON OFF ICON OFF ICON ON ICON OFF ICON ON NO ALARM MAY NO ALARM NO ALARM CANNOT NO ALARM CANNOT ACKNOWLEDGE ACKNOWLEDGE ACKNOWLEDGE PARAMETER SETTINGS N output number PARAMETER SETTINGS N output number ALM 1 HIGH ALRM ALM SRC 1 FLOW or RESIDUAL ALM TYPE 1 BAND ALM 1 OUT N ACK 1 DISABLED Wc OUTPUT N ALM RLY ON ALM 1 OUT OUTPUT N ALM RLY OFF LATCHING 1 DISABLED ACK 1 ENABLED LATCHING 1 DISABLED C DEVIATION ALARM D POWER UP ALARM IN ALARM CONDITION C SP A SP CONDITION RELAY RELAY ENERGIZED ENERGIZED ENERGIZED ICON ON ICON ON ICON ON DE ENERGIZED ENERGIZED ACKNOWLEDGE TO SHUT OFF ICON OFF ICON ON ICON AND DE ENERGIZE RELAY NO ALARM MAY ACKNOWLEDGE MAY CANNOT MAY ACKNOWLEDGE ACKNOWLEDGE ACKNOWLEDGE PARAMETER SETTINGS N output number PARAMETER SETTINGS N output number ALM TYPE 1 HIGH ALRM ALM SRC 1 FLOW or RESIDUAL OUTPUT N ALM RLY ON ALM 1 OUT N ACK 1 DISABLED LATCHING 1 ENABLED ALM 1 DEVIATION ALM 1 OUT N ACK 1 ENABLED
124. his condition the trim value now resets to zero Chapter 6 Page 79 12 Add this new section after Integral Setting INTEGRAL ACTION Integral Action describes how the trim integral modifies the output to bring the residual process variable toward set point See Figure 6 6 Typically this value willbe REVERSE for chlorine dosing applications and DIRECT for sulfur diox ide dosing Software Configuration 1 Thecontroller must set for residual or compound loop control in order to use the INT ACTION parameter 2 Place the controller in Manual mode 3 Press FAST MENU to access the CONFIG menu 555 Addendum 4 Set parameter CTRL MODE Choices RESIDUAL COMPOUND 5 Advance to the CONTROL menu 6 Setparameter INT ACTION Choices are e REVERSE DIRECT 7 Setupall other parameters as needed for the application Chapter 6 Page 79 Figure 6 6 This new drawing illustrates Integral Action INT ACTION REVERSE Cl dosing INT ACTION DIRECT SO dosing Cle Cl PV a eee See 7 SP Santa sie nS PV gt time gt time time Output Increased Output Decreased Output Decreased Output Increased Chapter 6 Page 88 Addendum In the section on Lag insert this discussion before the Software Configuration Additional Notes On Fixed and Variable Lag Variable lag timing the amount of time assigned to each lag count as described on page 65 will adj
125. his trouble shooting 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 wir ing e Blown in line fuse Replace fuse and check wiring Casenotinserted properly screws nottight Remove unitfrom 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 Looppower 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
126. i cte de E Do B 4 Hardware Scan B 4 Ie marre E B 5 Quick Calibration Procedure B 5 APPENDIX C SPECIFIGATIOINS aerea C 1 APPENDIX D g s lenilgcs ES 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 LIS T 2i rettet tei t i ai G 1 Table of Contents 555 User s Manual Figure Huic 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 eee ee 11 Figure 3 4 Install Communications Module onto the Microcontroller Board 12 Figure 4 1 Controller Dimensions ieanniannn siiin 13 Figure 4 2 Insert Mounting Clips seee 13 Figure 4 3 555 Input and
127. ical control valve actua tors motorized CCW CW to operate as the control output see Fig ure 4 14 CW Slidewire Wiper 0 1050 Figure 4 14 Position Proportioning Output with Slidewire Feedback Terminals ACTUATOR OUTPUT Slidewire Wiper ELECTRIC CCW Winding CW Winding ELECTRIC MOTOR ACTUATOR Screws must be tight to ensure electrical connection 20 Chapter 4 555 User s Manual Installation Remote Setpoint If you have the remote setpoint option use terminals 13 and 14 to connect your remote setpoint signal Figure 4 15 Figure 4 15 Remote Setpoint Terminals RSP Source Screws must be tight to ensure electrical connection 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 49414 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 Comm Twisted shielded To Comm terminal of next device Comm terminal of next device Use a 60 to 100 ohm This shield needs to be connected continuously but only tied to one terminating resistor
128. ied to the output R Otospan of the residual PV input INTEGRAL 1 Residual and Compound loop mode Defines Integral value 1 0 0to 250 095 D 10 0 TRIPPING Residual or Compound loop mode Determines the type of tripping method to use D OFF SPNUMBER e RSDL PV SPVALUE TRIP PT Residual and Compound loop modes Defines the trip point for Integral value tripping R LOW RANGE to HI RANGE Range is the full scale of the residual input INTEGRAL 2 Residual and Compound loop modes Defines Integral value 2 0 0to 250 0 D 10 0 Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Returnto Operation eme eo 50 Chapter 5 555 User s Manual Software Configuration Configuration PARAMETER VALUE CHARTS Use these charts to record the parameter values of your controller CONFIG VALUE 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
129. ier assigned to a device for communica tions sulfur dioxide SO Chemical reducing agent used to eliminate chlorine from a water effluent time proportioning control A control algorithm that expresses output power 0 10096 as a function of percent ON versus percent OFF within a preset cycle time time proportioning output A controller output assigned by software to facilitate time proportional control typically a relay SSR or SSR Drive output tracking A function that defines whether the local setpoint will track the remote setpoint When the controller is trans ferred to a local setpoint that local setpoint value will match the remote process value when the transfer occurs transducer A device that converts information of one physical form to another physical type in its output e 9 a thermocouple converts a temperature difference into millivolts transmitter 2 wire A device used to transmit data via a 2 wire current loop A two wire transmitter is loop powered transmitter 4 wire A device used to transmit data via a current loop or a DC voltage A 4 wire transmitter uses 2 wires for data and 2 wires for power triac Solid state switching device used to switch alternating current signals on and off Triac circuits are sometimes referred to as solid state relays SSR trip point Value which determines when that set of tuning values becomes active E 4 Appendix E 555 User s Manual Isolati
130. illiamp Output Calibration step 5 When you are finished calibrating power down and return the jumpers in their correct operating positions MILLIAMP OUTPUT CALIBRATION If your controller uses milliamp outputs then it is usually not necessary to cali brate them If you are using milliamp outputs for accurate retransmission of data you should calibrate each output whenever an analog moduleis installed Once a year recalibrate to maintain optimal performance 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 Onthe Microcontroller Circuit Board locate jumpers at locations PV1 and 2nd marked on the edge of the board see Figure B 2 Reposition the jump ers at 2nd location onto pins for Vand TCA 4 Reinsert chassis into the case and apply power The 2nd and 3rd displays should read CALIBRATE and ANLG IN Press the MENU key twice The displays should read CALIBRATE and ANLG OUT 5 Connect the hook up wires to the terminals for the corresponding milliamp output modules see Figure B 4 Output 1 uses terminals 3 and 4 Output 2 uses terminals 5 and 6 Output 3 uses terminals 7 and 8 Output 4 uses terminals 15 and 16 hook up wires to multi meter for each output 555 User
131. in outputto reach asampling point whether this time be fixed or variable depending onthe process Figure 6 9 shows a compound loop flow pacing water chlorina tion 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 Chlorine Residual Residual Signal Analyzer Control Valve 555 Controller 7 L TTT gt 6 9 Valve Control Signal dL Fl ith Residual ompouna Loop row Pacing wit Signal Lag times Flow Signal Chlorine Tank gt Chlorine D Water Flow Ejector Water Flow psi For Compound Loop Control If the flow rate fluctuates the travel time be tween 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 add ing itto the fixedlagterm Inthe normal operation the lag time decreases as the PV2 value increases and increases as the PV2 value decreases 555
132. input 12 Remove the 20mA input from the PV1 terminals and attach it to the PV2 terminals see Figure B 4 Make sure the terminal connections are fastened tightly and that a 20mA current is flowing through PV2 13 Let the controller warm up for an additional 5 minutes keep in the normal horizontal position Make sure the current is flowing then press ACK to calibrate the PV2 input 14 If the controller briefly displays mA CALIB COMPLETED PV2 calibration was successful andthe analog milliamp calibration procedure has been com pleted Place the jumpers back into their original positions see Chapter 4 15 Ifthe controller briefly displays mA CALIB FAILED PV2 calibration was not successful Check the 20mA connections and return to step 3 to recali brate the PV1 and PV2 inputs Addendum 555 PV2 PV2 PV1 PV1 Figure B 4 Analog mA Input Calibration Wiring Figure B 5 Analog mA Input Jumpers hook up OUT 1 T3 wires to mult meter Figure B 6 Milliamp Output Calibration Wiring TO OTHER CALIBRATION MENU PRESS OUTPUT X 4mA PRESS MENU OUTPUT X PRESS MENU PRESS ACK EACH OUTPUT WILL GO THROUGH THIS CYCLE Figure B 7 Output Module Menu Cycle 18 MILLIAMP OUTPUT CALIBRATION If the controller uses milliamp outputs it is usually not necessary to calibrate them If the milliamp output are being used for accura
133. is 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 or3 Output modules 1 2 and 3 are firmly held in place by a retention plate andtie wrap Carefully snip the tie wrap with a wire cutter To prevent damage to the surface mount components ALWAYS snip the tie wrap on TOP of the Retention Plate as shown in Photo 5 Remove the retention plate 3 Pry Clips 4 Separate Boards 5 Remove Retention Plate 10 Chapter 3 555 User s Manual 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 Toinstall 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 itis firmly seated refer to Photo 8 d F 6 Snip Tie Wrap 8 Add Change Module 9 Replace tie wraps for all the modules the Retention Plate and Output Module 4 with new ones before you reassemble F
134. itched to automatic control Access Set Up amp 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 Chapter 6 555 User s Manual Applications _ 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 A V FAST A or FAST V Thereisa 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 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 con tingent upon the module s installed To
135. l 1 control loop based on chlorine residual sensor input with a fixed lag time calculation capability available Compound loop Feedforward feedback control loop Flow based feedforward loop control signal is modified by the feedback residual control loop Fixed and variable lag time capability can be used to delay output change based on flow rate Dechlorination Feedforward control loop where the dosage setting 0 196 to 20096 is applied to a combined signal of the flow rate x chlorine residual TUNING PARAMETERS Proportional Band 0 1 to 99996 of input range Integral 1 to 9999 seconds repeat Manual Reset Load Line 0 to 10096 output Cycle Time 0 3 to 120 seconds Control Deadband in engineering units Dosage 0 to 400 Integral only 0 250 Two sets of PI values may be stored in memory and selected automatically based on setpoint value process variable value or the corresponding local setpoint SP1 SP2 Fixed Lag 0 to 14 400 seconds Variable Lag 0 to 14 400 seconds ISOLATION Inputs and outputs are grouped into the following blocks Block 1 Chlorine and Flow sensor Block 2 outputs 1 2 and 4 Block 3 communications set of five digital inputs output 3 Block 4 remote setpoint Each block is electrically isolated from the other blocks to withstand a HIPOT potential of 500 Vac for 1 minute or 600 Vac for 1 second with the exception of blocks 1 and 4 which are isolated to withstand a HIPOT potential of 50 volts
136. l level residual setpoint and the flow rate Interface 1st line of display PV1 Primary PV Chlorine residual level PV2 or flow input Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Returnto Operation ew ww 64 Chapter 6 555 User s Manual Applications _ 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 a 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 orflow input PV2 To switch the display positions of the primary and secondary PV press FAST DISPLAY Also used for special messages and alarms alternates mes sages 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 Other actions can also switch the controller from Automatic to Manual Con trol a PV break the digital inputs a communications shed etc In these cases the output value will be determined by th
137. l value to determine the amount of output correction to make The lag compensates for the time it takes the 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 OUT FLOW x DOSE gt INTEGRAL x SP RSDL 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 ThePV1 PV2 fixed and variable lag parameters must be set up properly to enable Compound Loop output calculations e The DOSE value can be manually set with the and V keys or through automatic algorithm For automatic set up of the dosage values a Connectthe flow and residual inputs to the 555 Properly configure the FLOW INPT Menu and RSDL INPT Menu parameters The flow mustbe stable and atanon minimal value a high flow rate produces a more accurate dose Tochange the 555 to automatic mode b Adjustthe OUT while under manual control to the desired value for without initializing the dose values the current flow rate For duplex mode press the MANUAL key alone 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 e Control performance should be observed for
138. llector transistor An open collector is also called a transistor Wire the transistor between terminal 17 and the specific digital input terminal Figure 4 10 elelee 1 2 3 4 5 6 7 8 apaga Screws must be tight to ensure electrical connection Output Modules Output modules are used for control alarms and retransmission the wiring is the same There are three digitaltypes 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 prod uct 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 e Output 1 is always the Control output e 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 e Output Slots 2 and or 4 can be used for alarms up to two How ever Output 2 is not available for alarms when using duplex con trol i e duplex flow pacing staging or slidewire Output 1 uses terminals 3 amp 4 Output 2 uses termina
139. ls 5 amp 6 Output 3 uses terminals 7 amp 4 Figure 4 11 Output 4 uses terminals 15 amp 16 Mechanical Relay Output Line Power Wiring Load Recommend use of both MOV and snubber OUT 2 Screws must be tight to ensure electrical connection 18 Chapter 4 555 User s Manual Installation 2 Solid State Relay Triac Output Figure 4 12 e Output 1 is always the Control output e 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 e Output Slots 2 and or 4 can be used for alarms up to two how ever Output 2 is not available for alarms when using duplex con trol i e duplex flow pacing staging or slidewire Output 1 uses terminals 3 amp 4 Output 2 uses terminals 5 amp 6 Output 3 uses terminals 7 amp 4 Output 4 uses terminals 15 amp 16 Line Power Fi 412 igure 4 OUT 1 RE Load 5 Solid State Relay Output Wiring OUT 1 f4 A Recommend use of 5 g 3 both MOV and snubber Screws must be tight to ensure electrical connection 3 DC Logic SSR Drive Output Figure 4 13 e Output 1 is always the Control output e Output Slots 1 and 2 together will allow for duplex flow pacing mode control again o
140. lue 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 096 Enter configuration and change the S W CLOSE value until the actuator just reaches its full closed position 9 Setthe 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 Setparameter S W D BAND to 0 5 b Placethe controller under Manual control c Change the output percentage and observe if the valve stabilizes atthe new value d Ifthe valve oscillates increase the S W D BAND value by 0 596 repeat until oscillation stops 10 Setthe 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 ew ew Ca ww 74 Chapter 6 555 User s Manual Applications _ G STAGED 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 t
141. m A v 66 Chapter 6 555 User s Manual Applications _ 3 Set parameter CTRL MODE COMPOUND Go to CONTROL Menu 5 Setthe 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 notinstalled 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 Toallow for real time display offlow while enteringlag values usethe FAST Note and DISPLAY keys to toggle between the residuallevelandflow PV2icon Compound mode both a residual set lit in the upper display line point and dosage must be set 6 GotoFLOW INPT Menu You mustsetallrelevant parameters inthis menu e g process variable input range and scaling data 7 Goto 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 param eters 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 Referto Chapter 5fora complete listing of menus and parameters D DECHLORINATION MODE Feedforward dechlorination positions a valv
142. mation 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 6 555 User s Manual Chapter 5 25 Software Configuration Configuration 26 Chapter 5 555 User s Manual Software Configuration Configuration SOFTWARE MENU AND PARAMETERS CONFIG 1 CTRL MODE Selects the main operating mode of the controller e FLOW PACE e RESIDUAL D COMPOUND e 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 e STAGED Only available if analog modules in slots 1 and 2 e SLIDEWIRE Only available if digital modules in slots 1 and 2 and slidewire option installed DUALOUT 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 thatthe input sampling rate will be opti mized for common mode noise rejection D 60HZ 50HZ 4 OUTPUT2 Selects use for an existing output in slot 2 not for control or loop power D OFF e ALM RLY ON digital only e ALM RLY OFF digital only
143. module sockets on the Power Supply Circuit Board and one output module on the Option Board see Figure 3 2 The mechani cal relay on the Power Supply Board may be configured for either normally open NO or normally closed NC A jumper located nextto each socket de termines this configuration All the relay outputs are factory set to NO normally open gt 900000 Comm Module Male 22 Pin Connector i Male 44 Pin Connector Male 22 Pin Connector Female 44 Pin Connector o 4 Pin Connector Retention Plate over Outputs 1 2 3 NO J1 NC NO J2 NC NO J3 NC Jumpers NOandNC 555 User s Manual 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 4 Remove Jumpers 5 Find the new location of the jumper connector again refer to Figure 3 2 Carefully
144. n Configuration 4 AUTO MAN AUTO MAN Selects lockout status of the MANUAL key D UNLOCKED 5 ALARM ACK ALARM ACK Selects lockout status of the ACK key UNLOCKED LOCKED D UNLOCKED 6 TUNING TUNING Selects lockout status of the tuning menu UNLOCKED LOCKED D UNLOCKED 7 CONFIGURE CONFIGURE Selects lockout status of all the configuration menus UNLOCKED LOCKED D UNLOCKED SER COMM 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 communi cations module 1 STATION STATION Selects the RS 485 station number for the unit OFF D 1 2 BAUDRATE Selects the BAUD rate in BPS for the unit BAUD RATE 1200 2400 D 9600 19200 3 CRC CRC Selects whether or not to use the CRC YES D YES NO Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Returnto Operation Eesi a v 48 Chapter 5 555 User s Manual Software Configuration Configuration 4 SHED TIME Defines the time in seconds from the last communications activity the con troller will wait before determining that communications is lost sheds O R 110512 shedding off 5 SHED MODE If shedding is enabled selects the state of the controller if communications is 5 lost sheds D LAST MODE LAST MODE MANUAL
145. ng It is highly recommended that a solid state triac or DC logic output module be used mechanical relays have a limited number of operational cycles Software Configuration 1 Gotothe CONFIG Menu 2 Setthe appropriate OUTPUT parameter to WATCHDOG 3 Setupall other parameters as needed for your application The following section replaces Appendix B of the 555 manual 14 555 Addendum APPENDIX B CALIBRATION To maintain optimum performance once a year calibrate the analog input the cold junction and milliamp output when used To achieve published accuracy specifications follow directions carefully and use calibrated in struments of like quality to those suggested Ifthe controlleris moved into an alternate case or the hardware configura tion is changed and the thermocouple input is needed recalibrate the cold junction for maximum accuracy Failure to do so may result in small junc tion temperature 0 6 C 1 1 F Access the parts of the calibration menu as shown in Figure B 1 CALIBRATE ANALOG IN it CALIBRATE ANA mA IN PRESS MENU CALIBRATE COLD JUNC CALIBRATE ANLG OUT RESET MENU DATA PRESS MENU HARDWARE SCAN SLIDEWIRE TEST PRESS Addendum PRESS MENU PRESSMENU PRESSMENU CAL VREF PRESS ACK 5 0000 PRESS MENU PRESS P Di Al h Al h A SET BOTH wmoveJumgers PVi 20mA PV2 20mA PRESS ACK
146. ng firmly on the bezel 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 HARDWARE 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 setthe particular range in the software see Chapter 5 for software menus or Chapter 6 for ap plications The jumpers for the process variable are located on the Microcontroller Circuit Board see Figure 3 2 Thefactory default is Milliamp Locations are marked as follows V Voltage MA Milliamp 555 User s Manual Chapter 3 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 NOTE Any changes you make to the output modules will render the code on the product label invalid Hardware Figure 3 2 from the top The Microcontroller Circuit board The Option Board and the Power Supply Board Chapter 3 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
147. nications option enables the 555 to communicate with a su pervisory device such as apersonal computer or programmable logic control ler The communications standard is RS 485 which provides a multi drop system that communicates at ahigh 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 accu rate responses to any command Cyclic redundancy checking CRC virtually ensures the integrity of any data read by the 555 Through serial communica tions you have access to every set up tuning and operating parameter for all modes For details on this protocol contact an application engineer Hardware Configuration e You must have this option installed in your 555 The circuitry for communi cations is contained on a modular circuit board that plugs into the Microcontroller Circuit Board Refer to the order code in Chapter 1 for de tails Software Configuration 1 Gotothe SER COMM Menu Setthe 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
148. ning Menu andits 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 555 3 7 7 Chapter 3 Page 7 Figure 3 1 This drawing has been modified due to the new controller body OPTION BOARD Chapter 3 Page 8 Figure 3 2 The Microcontroller Board has been modified EPROM BATTERY PV2 Jumper Location PV1 Jumper Location ASS Y 535 607 Chapter 4 Page 13 Figure 4 2 Mounting Collar Collar screw 1 of 4 555 Addendum Chapter 4 Page 13 2c Slide the mounting collar over the back of the case The collar clip edges will lock with matching edges on the controller case 2d Insertthe fourmountingcollarscrews from the rear ofthe collar Gradually tighten the screws to secure the controller against the panel Chapter 5 Pages 27 28 In the CONFIG Menu a new option has been added to each OUTPUT parameter 4 OUTPUT 2 WATCHDOG 5 OUTPUT3 e WATCHDOG 6 OUTPUT 4 e WATCHDOG digital only use with SSR triac or DC logic digital only use with SSR triac or DC logic digital only use wit
149. nly as time proportioned outputs e Staging outputs is not allowed e Output Slots 2 and or 4 can be used for alarms up to two how ever Output 2 is not available for alarms when using duplex con trol i e duplex flow pacing staging or slidewire Output 1 uses terminals 3 amp 4 Figure 4 13 Output 2 uses terminals 5 amp 6 ayie Output 3 uses terminals 7 amp 4 DC Logic Output and Milliamp Output 4 uses terminals 15 amp 16 Output Wiring OUT 1 Load OUT 1 OUT 3 36 ours Screws must be tight to ensure electrical connection 555 User s Manual Chapter 4 19 installation 4 Milliamp analog Output Figure 4 13 e Output 1 is always the Control output e Output Slots 1 and 2 together allow for duplex flow pacing mode or output staging e Output Slots 2 3 and or 4 can be used for retransmission upto two However Output 2 is not available when using duplex flow pacing staging or slidewire control 5 Loop Power e Any unused output slot except for Output 1 may be used to hold a loop power module when neededto supply voltage for a transducer e 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 e Output Slots 1 and 2 with mechanical or solid state relay modules plus the slidewire option will allow for electr
150. nual General Information Information CHAPTER 1 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 fluores cent 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
151. o change the 555 to automatic mode current ratio of output contribution to flow rate without initializing the dose values press the MANUAL key alone d For duplex flow pacing perform a b and c for OUT2 as well 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 INTEGRAL x SP RSDL where INTEGRAL is a percentage value and SP and RSDL are percent ages of the residual input PV1 range Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation ew Dew Ca 80 Chapter 6 555 User s Manual Applications _ The PV1 input parameters and fixed lag time must be properly config ured 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 Ov
152. o 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 Setthe CTRL MODE parameter to STAGED 3 Goto the OUTPUT Menu 4 Forthe STAGE OUT1 parameter specify the output percent where the first output reaches its maximum 5 Forthe STAGE OUT2 parameter specify the output percent where the second output begins at 0 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 RE SIDUAL CL2 DOSE SO2 DOSE SETPOINT or RAMP SP Acommon 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 Gotothe CONFIG Menu 2 For OUTPUT 2 OUTPUT 3 and OUTPUT 4 parameters set one or two ofthem to RETRANS 3 Gotothe RETRANS Menu 4 Setthe 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
153. o types of indicators icons and illuminated keys ALM 1 and ALM 2 icons alarm 1 and alarm 2 status OUT 1 and OUT 2 icons control output 1 and control output 2 status PV2 icon flow is indicated in upper display MAN key illuminated controller is in manual control mode ACK key illuminated alarm may be acknowledged SET PT key illuminated setpoint other than the primary local setpoint is active MENU key illuminated controller is in the configuration mode DIMENSIONS Meets 1 4 DIN designation as specified in DIN standard number 43 700 See dimensional diagram below for details MOUNTING Panel mounted See diagram for details WIRING CONNECTIONS 29 screw terminals in the rear of the instrument POWER CONSUMPTION 15 VA at 120 VAC 60Hz typical 555 User s Manual Specifications _ WEIGHT Approximately 1 kg 2 2 165 AMBIENT TEMPERATURE Operative Limits 0 to 50 C 32 to 122 Storage Limits 40 to 70 C 40 to 158 F RELATIVE HUMIDITY 10 to 90 non condensing VOLTAGE AND FREQUENCY Universal power supply 90 to 250 VAC 48 to 62Hz NOISE IMMUNITY Common mode rejection process input gt 120 dB Normal mode rejection process input gt 80 dB AC line is double filtered and transient protected Snubbers are provided for each relay output CONSTRUCTION Case extruded non perforated black anodized aluminum with ABS plastic sleeve Bezel black plastic ABS Chassis assembly plug in t
154. ol 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 de fined dosage replaces the traditional setpoint The dosage can be set from 0 0 to 400 percentage of gas flow per water flow Itincreases or decreases the gas feed rate in order to maintain the desired chlorine residual level after injec tion Similarly adosage ranging from 0 0 to 400 is also available for dechlo rination with 50 Chlorination and dechlorination may be accomplished simultaneously based Figure 6 1 on the same water rate this is called Dual Flow Pacing Mode Flow Pacing Control Dosage _ _ Setting Automatic Valve Valve Control Water Flow Chlorine Water Flow Ejector 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 502 Sulfur dioxide dosage dual flow pacing VMD actual valve position slidewire option only 555 User s Manual Chapter 6 59
155. on Block Diagram Block Diagram APPENDIX F ISOLATION BLOCK DIAGRAM PV1 Ic cs Input utput 1 Multiplexer CPU ISO Ground e Referenced _ o PV2 Input Output 2 ISO Ground He Referenced 6 I RSP Input Output3 Earth Ground po Referenced o Mee JE Slidewire Input Out 4 ISO Ground Referenced y E Digital gt Ik Inputs 1 5 RS485 Serial Communications Interface L Line l Isolated output ground 1 Earth referenced ground L Internal ground Output Modules may be in any position Milliamp Module Mechanical Relay SSR Driver Loop Power SSR Output 1 Each ofthe three ground circuits are isolated from each other to withstand a potential of 500 volts for 1 minute or 600 volts for 1 second 2 RSP Slidewire andthe PV inputs are isolated to withstand 50 volts peak between each other for 1 minute 9 id and PV2 have isolation to 10 volts P P or continuous between each other 4 Milliamp Loop Power and SSR Drive modules in output positions 1 2 and 4 are isolated from each other 555 User s Manual Appendix F F 1 Isolation Block Diagram Block Diagram Appendix F 555 User s Manual APPENDIX G PARTS LIST CIRCUIT BOARD SUPPORT MOUNTING BRACKET 7 OPERATOR INTERFACE ASSEMBLY CIRCUIT BOARDS ITEM PART NO
156. oning control system cycling oscillation A periodic change in the factor under control usually resulting in signal excursions above and below the control point dead band A temperature band between heating and cooling functions the range through which an input can be varied without initiating observable change in output dead time The interval of time between initiation of an input change or stimulus and the start of the resulting observable response E 1 _ Ciossary 7 dechlorination The controlled use of a reducing agent to reduce or eliminate the chlorine residual from water effluent Sulfer Dioxide SO is commonly used for this purpose default settings Parameter selections that have been made at the factory derivative Anticipatory action that senses the rate of change of tempera ture and compensates to minimize overshoot and undershoot Also rate derivative action See control action derivative deviation The difference between the value of the controlled variable and the value at which it is being controlled digital input Used in this manual to indicate the status of a dry contact also called gate DIN Deutsche Industrial Norms a German agency that sets standard for engineering units and dimensions display 1st The top largest display of controller face that is used to display the process variable value display 2nd The middle display of the controller face used
157. only if a residual chlorine signal is used Compound Loop or Dechlorina tion mode 1 PVTYPE Selects the type of PV being used for the residual chlorine input PVTYPE If jumper setto volts e 0 5V e 0 100mV 0 60mV 0 30mV e 0 10mV e 25mV If jumper setto mA D 4 20mA e 0 20mA 2 DECIMAL Selects the position of the decimal point in the engineering units display of re sidual value DECIMAL XXXXX XXXX X e XXXXX XX XXX e 3 LOW RANGE Sets the value in engineering units corresponding to the low residual input LOW RANGE value 9999 to 99999 4 Sets the value in engineering units corresponding to the high residual input HI RANGE value R 9999 to 99999 D 1000 5 FILTER Sets the amount of filtering to be used for the residual input FILTER R Oto 120 seconds D 0 Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Ee Dev a 555 User s Manual Chapter 5 35 Software Configuration Configuration 6 PV OFFSET Sets a constant offset to be applied to the residual input 9999 to 99999 0 7 PV GAIN PV GAIN Sets a constant gain to be applied to the residual input 0 100 to 10 000 D 1 000 8 RSDL BRK Defines output percentage upon switching to Manual control due to a break in RSDL BRK the residual signal 5 to 105 0 0 9 RSDL
158. ory hasbeen cleared and all parameters have been restored to their factory default settings Occurs intentionally when unit is powered up forthe 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 Aproblem 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 commonto all PPC products parity checking and an optional CRC algorithm These checks occur automati cally and if they fail the errant communications packet is ignor
159. peak for 1 minute between each other Inputs and outputs are not isolated from other inputs and outputs within the same block 555 User s Manual PROCESS VARIABLE INPUTS Two universal inputs are available TRANSMITTER ANALYZER SIGNALS INPUT RANGE Milliamps DC 4 to 20 0 to 20 Voltage DC 1105 0105 Millivolts DC 01010 01030 01060 0 to 100 25 to 25 LINEARIZATION The flow transmitter inputs from Venturi tubes Parshall flumes Palmer Bowlus flumes and others may be linearized using a square root function or a custom user definable 15 point straight line linearization function The residual signal input is linear INPUT IMPEDANCE Current Input 250 ohms Voltage Input 1 Mohms UPDATE RATE Input is sampled every 125msec Output is updated every 100msec Display is updated five times per second TRANSMITTER LOOP POWER Isolated 24 Vdc nominal loop power supply is available if a loop power module is installed in an output socket not used for control Capacity is 25mA max INPUT SIGNAL FAILURE PROTECTION Preprogrammed fault handling appropriate for selected control strategy is standard Flow proportional chlorine control Loss of the flow transducer signal will cause the control output to go to a user defined value Residual chlorine control Loss of the chlorine analyzer signal will cause the control output to go to a user defined value Compound loop chlorine control Any of the following default conditions may be chosen a Loss
160. press MENU key within two seconds When complete return jumpers to their original positions HARDWARE SCAN Use this read only feature to identify the output hardware and installed options of the controller 1 amp Set the jumpers to V and TCA on the Microcontroller Circuit Board see Figure B 2 Power up the controller Press MENU until HARDWARE SCAN is displayed Press ACK to initiate the hardware display When complete return jumpers to their original positions SLIDEWIRE TEST If the slidewire option is installed use the following to test its function 1 Press MENU to scroll to the SLIDEWIRE TEST menu refer to Menu Flow chart in Figure B 1 2 Attach a 100 ohms to 1000 ohms potentiometer to terminals 10 11 and 12 as shown in Figure B 8 Press ACK 3 Moving the potentiometer from one end to the other should display from 0 to 100 on the controller 4 Ifthe error message OPEN appears check the connectors and try again 6 Press ACK to exit Addendum 555 Figure B 8 Slidewire Test 5 7 20 QUICK CALIBRATION PROCEDURE This procedure is for the benefit of users that have ISO or other standards that req uire periodic calibration verification It enables verification and modification ofthe process variable input without entering the Factory Configuration mode 1 2 10 11 555 Power down the 555 controller an
161. r alarm 1 D OFF e HIGHALRM LOWALARM MANUAL VACUUM BAND DEVIATION RATE 2 ALARM SRC 1 For ALM TYPE 1 HIGH ALRM or LOW ALARM selects the alarm source ALARM SRC 1 D FLOW RESIDUAL CL2DOSE SO2DOSE SETPOINT RAMPSP DEVIATION OUTPUT RET LOW 4 ALM TYPE 1 Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Returnto Operation mw we 555 User s Manual Chapter 5 43 Software Configuration Configuration 3 ALARM SP 1 ALARM SP 1 Selects the setpoint for ALM TYPE 1 HIGH ALRM LOW ALARM BAND 07 DEVIATION I ALARMSRC 1 FLOW RESIDUAL SETPOINT RAMP or DEVIATION 9999to 99999 If ALARM SRC 1 2 DOSE 502 DOSE or OUTPUT 0 0 to 400 0 D 0 4 DEADBAND 1 Selects the deadband for ALM TYPE 1 HIGH ALRM LOW ALARM BAND DEVIATION or RATE DEADBAND 1 lf ALARM SRC 1 FLOW RESIDUAL SETPOINT RAMP or DEVIATION D R 199999 D 2 If ALARM SRC 1 CL2 DOSE SO2 DOSE or OUTPUT 0 0 to 400 0 D 0 2 5 ALM 1 OUT ALM 10UT For an enabled ALM TYPE 1 selects the physical output number e of any outputs configured as alarms 6 LATCHING 1 LATCHING 1 For an enabled ALM TYPE 1 enables or disables alarm latching LATCH D LATCH e NOLATCH 7T 1 1 For an enabled ALM TYPE 1 enables or disables the ACK key
162. rce linearity The nearness with which the plot of a signal or other variable plotted against a prescribed linear scale approximates a straight line linearization A function the 555 uses to automatically linearize a non linear signal either from thermocouple or RTD temperature sensors through the use of look up tables The relationship that exists between two variables when the ratio of the value of one variable to the corresponding value of the other is constant over an entire range of possibilities linearization custom User definable linearization linearization square root A function the 555 uses to linearize a non linear signal corresponding to the flow being measured by flow transmitters load The demand for input to a process loop A signal path loop power An internal 24 volt current limited power supply used to power 2 or 4 wire transmitters on the input of the controller low pass input filter A method to block fast acting signals typically noise while allowing slow acting signals actual process variable to pass manipulated variable A quantity or condition which is varied so as to change the value of the controlled variable see also control output measuring element An element which converts any system activity or condi tion into a form or language that the controller can understand mechanical relay see relay menu see menu block 555 User s Manual EEE eee menu
163. re position corresponding to CLOSE 0 output value S W CLOSE Otocurrent S W RANGE value D 1000ohms 22 S W D BAND Setsthe value percentage of the deadband applied to slidewire control S W D BAND 0 5to 10 0 in 0 5 increments 2 0 D 2 0 23 S W BREAK Defines the action to take if the slidewire input is lost while under automatic S W BREAK control For ON options the corresponding relay is turned on closed and stays that way throughout the break condition OUTS OFF D OUTS OFF same as last out e OUT1 ON OUT2ON RETRANS RETRANS Requires outputs configured for retransmission Up to two outputs are allowed for retransmission Any undefined choices will give undefined results flat line 1 RET TYPE 2 Selects the type data retransmission for existing retransmission output 2 2 OUT e RESIDUAL CL2DOSE SO2DOSE e SETPOINT e RAMP SP Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Dev Ca Lew 555 User s Manual Chapter 5 41 Software Configuration Configuration 2 RET LOW 2 RET LOW 2 V Sets the value in engineering units corresponding to the low retransmission Le output value 2 except for retransmission of output 9999 to 99999 3 RET HIGH 2 RET HIGH Setsthe value in engineering units corresponding to the high retransmission output value 2 except
164. rections 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 Goto 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 PVz 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 aconstant gain multiplier to be applied to the flow input Range is from 0 100 to 10 000 P SERIAL COMMUNICATIONS The serial commu
165. ring units value for Point 7 15 8th INPUT Sets the flow input value for Point 8 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 Configuration RSDL INPT VALUE 1 PV 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
166. rm R 1 to 3600 seconds D 5 Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation Eesi v Lew 46 Chapter 5 555 User s Manual Software Configuration Configuration POWER UP POWER UP 1 PWR UP MODE Selects the Power Up mode for the 555 PWR UP MODE D LASTMODE MANUAL LAST MODE AUTOMATIC 2 PWR UP OUT Selects the power up value forthe output Usedfor manual mode power ups PWR UP OUT only or for automatic power ups when using residual control D LASTOUT LAST OUT 5 0t0 105 0 3 PWR UP OUT2 Dual Flow Pacing Mode PWR UP OUT2 Selects the power up value for the second output Used for manual mode LAST OUT power ups only D LAST OUT R 5 0to 105 0 4 PWR UP SP Selects the power up setpoint value source for the 555 PWR UP SP D LAST SP LOCAL e REMOTE SECURITY 1 SEC CODE Selects the code number password for security 9999 to 99999 D 0 2 SETPTKEY Selects lockout status of the SET PT key SP selection SETPT KEY LOCKED D UNLOCKED UNLOCKED 3 SP DOSAGE Selects lockout status of the A and W keys for modifying local SPs or SP DOSAGE DOSES LOCKED UNLOCKED D UNLOCKED Access Set Up Return to Operation Next menu Next parameter Next value Access Tuning Return to Operation ew a we 555 User s Manual Chapter 5 47 Software Configuratio
167. roducts found upon return to the Company transportation charges prepaid and otherwise in accordance with the return procedures established by The Company to be defective in material or workmanship This policy extends to the original Buyer only and not to Buyer s customers or the users of Buyer s products unless Buyer is an engineering contractor in which case the policy shall extend to Buyer s immediate customer only This policy shall not apply if the product has been subject to alteration misuse accident ne glect or improper application installation or operation THE COMPANY SHALL IN NO EVENT BE LIABLE FOR ANY INCIDENTAL OR CONSE QUENTIAL DAMAGES WORLDWIDE www miinet com China sales mooreind sh cn Tel 86 21 62491499 FAX 86 21 62490635 United Kingdom sales mooreind com Tel 01293 514488 FAX 01293 536852 Belgium info mooreind be Tel 03 448 10 18 FAX 03 440 17 97 The Netherlands sales mooreind nl Tel 0 344 617971 FAX 0 344 615920 United States info miinet com MO ORE Tel 818 894 7111 FAX 818 891 2816 INDUSTRIES rei 02 8535 7200 rix 02 9525 725 2006 Moore Industries International Inc Specifications and Information subject to change without notice
168. s 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 Information 4 Chapter 1 555 User s Manual CHAPTER 2 BASIC INTERFACE Figure 2 1 555 Operator Interface Keys DISPLAYS Refer to Chapter 6 for details on the interface functions for specific modes 1st Line five 7 segment digits Alwaysdisplays a primary process variable with value units depending onthe 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 Whenusingaramping setpointthatis 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 Fordual 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 configura
169. s Board Kit 535 188 Rear Terminal Upgrade Kit 535 660 531 532 535 545 555 Jumper Kit 535 662 Gasket Kit 1 Panel Gasket 1 Bezel Gasket 535 763 Bezel Retention Screw Kit 535 664 Module Retention Kit Retention Plate and Tie Wrap 535 665 Module Retention Tie Wrap Kit 093 128 Lithium Battery Universal Kit can be used with all 500 Series Controllers EPROM Kits 531 740 531 EPROM Kit 532 740 532 EPROM Kit 535 74 535 EPROM kit RSP 585 775 535 Profiler EPROM Kit No RSP 585 770 535 Profiler EPROM Kit RSP 535 740 535 EPROM Kit No RSP 545 740 545 EPROM Kit No RSP 545 741 545 EPROM kit RSP 555 740 555 EPROM kit Microcontroller MCU Board Kits 585 7315 MCU Board Kit 545 738 MCU Board Kit with CE Option Option Board Kits b8b 720 inane 531 532 535 545 Option Board Kit No Options 585 721 531 532 535 545 Option Board Kit Digital Inputs 585 722 5 535 545 Option Board Kit Slidewire Feedback 585 729 535 545 Option Board Kit Digital Inputs and Slidewire Feedback 545 724 531 532 535 545 555 RSP 545 725 iis 531 532 535 545 555 Option Board Kit Digital Inputs and RSP 545 726 535 545 5
170. s 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 52 Chapter 5 555 User s Manual Software Configuration Configuration CUST LINR VALUE 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 enginee
171. se LOCKED mes sage to be displayed Whether or not the contact caused atransition to manual the corresponding designated output action is always per formed REM INPUT Contact closure activates use of the remote input RSP CL2 DOSE or SO2 DOSE Contactcan be overridden with the SET PT key for RSP or by the LOCAL REMOTE selection in the TUNING Menu for remote doses e 2ND SETPT Contact closure activates use of the second setpoint SP2 Contact can be overridden with SET PT key e 2ND INT Contact closure activates use of the 2nd integral value e 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 Ee ew Ee D v ww 76 Chapter 6 555 User s Manual Applications _ INT INHBT Residual or Compound Loop modes only Contact closure suspends integral term calculations Controller will hold any existing integral con tribution at its last value UPKEY 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 Locksthecontroller into Manual Control and any integral
172. st have a voltage or milliamp input Software Configuration For square root linearization 1 Goto the FLOW INPT Menu 2 Set parameter LINEARIZE to SQR ROOT For custom linearization Go to the FLOW INPT Menu Set the parameter LINEARIZE to CUSTOM Go to the CUST LINR Menu 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 Goto the SECURITY Menu gt O 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 Emp ee Dew Ca v ww 84 Chapter 6 555 User s Manual Applications _ 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 A
173. t function by entering a numeric value for the parameter SP RAMP This value defines the maximum rate of change toward setpoint in engineer ing 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 Anactively ramping setpoint causes the 2nd display to alternate showing the SP SP2 RSP and the ramping setpoint The 3rd display will show RAMPING 4 Gotothe 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 AccessTuning Returnto Operation ew Dew Ca v 78 Chapter 6 555 User s Manual Applications _ 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
174. te Amp 250 V fast acting fuse in line with your AC power connection On the actual 555 the only terminals with printed numbers are those shown in Figure 4 4 AC LINE g 9 EM Figure 4 4 B AC Power Input Wiring AC NEUTRAL Screws must be tight to ensure electrical connection Process Variables 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 e PV1 uses terminals 31 and 32 connected to a transmitter Figure 4 5 PV2usesterminals 28 and 29 connected to a transmitter PV Voltage Input Wiring Q _ 9A PVI Transmitter PVi Screws must be tight to ensure electrical connection Screws must be tight to ensure electrical connection 555 User s Manual Chapter 4 15 installation 2 Milliamp Input External Power Supply Figure 4 6 PV1 Milliamp Inputwith an external power supply uses terminals 31 Figure 4 6 and 32 with a 2 wire transmitter PV mA Input with External Power e PVa2MIlliamp Input with an external power supply uses terminals 28 Supply Wiring and 29 with a 2 wire transmitter External Power Supply Transmitter PV1 External
175. te retransmission of data itis recommended that each output with an analog module be calibrated annu ally to maintain optimal performance Equipment needed Precision 5 1 2 digit multimeter e g Fluke 88429 or HP3478A 4 1 2 digit meters sacrifice accuracy e Two small pieces of wire for every milliamp output Testleads with banana clips e 2 Phillips screwdriver 1 Disconnect power to the instrument 2 Remove chassis from case 3 the Microcontroller Circuit Board locate jumper locations marked PV1 and 2nd near the edge connector Reposition both jumper connectors in the 2nd location onto pins for V and TCA as shown in Figure B 2 4 Reinsert chassis into the case and apply power 5 Allow controller to warm up for at least 30 minutes The 2nd and 3rd displays should read CALIBRATE ANALOG IN CALI BRATE Menu ANALOG IN section Press MENU three times to reach the CALIBRATE ANLG OUT Menu 6 Connecthook up wires to the terminals for the corresponding milliamp out put modules Refer to Figure B 6 Output 1 uses terminals 3 and 4 Output 2 uses terminals 5 and 6 Output 3 uses terminals 7 and 8 shown Output 4 uses terminals 15 and 16 Attach the test leads from the multimeter to the wires and then plug the test leads into the meter Set the meter for DC milliamp 7 Press ACK The 2nd display will read OUTPUT1 OUTPUT2 OUTPUTS or OUTPUT4 depending on the module installation 8 Press MENU to scroll
176. the PV OFFSET parameter 5 Adjustyourcalibration device to an output signal equal to the 0 range value for your particular input sensor 4mA for a 4 20mA input 6 Verify thatthe value indicated inthe 1stdisplay is equal to the 0 range value for your particular input sensor If the value is incorrect use the and V keys on the 555 to scroll to the correct value 7 Scrollto the PV GAIN parameter 8 Adjust your calibration device to an output signal equal to the 10096 range value for your particular sensor 9 Verify value indicated in the 1stdisplay is equal to the 100 range value for your particular input sensor If incorrect use the A and W keys to scroll to the correct value 10 Repeat steps 3 through 8 to verify all values 11 Return to the Operating mode gt A 555 User s Manual Appendix B B 5 Calibration Appendix B 555 User s Manual Specifications _ APPENDIX C SPECIFICATIONS ACCURACY TYPICAL 0 025 of full scale 0 050 of full scale MAXIMUM 0 100 of full scale 0 150 of full scale Linear Voltage Current Display accuracy is 1 digit These accuracy specifications are at reference conditions 25 C Detailed accuracy information is available upon request CONTROL MODES Flow pacing The controller output is based on a selected chlorine and or sulfur dioxide dosage 0 400956 which is proportional to a given flow rate Residual control Integra
177. ting positions RESET MENU DATA This function resets all parameter values back to their factory defaults except for calibration information Refer to Figure B 1 flowchart for details 1 Disconnect power to the instrument 2 Remove chassis from case 3 Onthe Microcontroller Circuit Board locate jumpers at locations PV1 and 2nd marked onthe edge of the board see Figure B 2 Reposition the jump ers at 2nd onto pins for V and TCA 4 Press MENU until the 2nd and 3rd displays show RESET MENU DATA Press ACK 6 You have two seconds to press MENU to accomplish the reset If successful the 2nd and 3rd displays will read RESET COMPLETED If you failed to press MENU in time RESET SKIPPED will appear 7 Totry again press ACK You again have 2 seconds to initiate the reset HARDWARE SCAN This procedure identifies the installed outputs and options ofthe controller Re ferto Figure B 1 flowchart for details 1 Disconnect power to the instrument 2 Remove chassis from case 3 Onthe Microcontroller Circuit Board locate jumpers at locations PV1 and 2nd marked on the edge of the board see Figure B 2 Reposition the jump ers at 2nd location onto pins for V and TCA 4 Press MENU until the 2nd and 3rd displays show HARDWARE SCAN 5 Press ACK to begin a read only display of your output hardware and installed options e Appendix B 555 User s Manual Calibration SLIDEWIRE TEST If you have the slidewire option use t
178. tion this line shows the parameter value in the menu system 555 User s Manual Chapter 2 5 nterface 7 DISPLAY A MERE EL LIS FAST FAST H H o FAST DISPLAY MANUAL MANUAL SET PT DISPLAY DISPLAY ICONS LIT OUT1 Indicates the outputis at alevel greater than 0 or activated fortime proportioning or a digital output OUT2 Indicates the second output SO of the duplex flow pacing mode staging or slidewire output is active 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 Press to step through the values SP OUT DOSAGE etc tobe shown in the 2nd display FAST DISPLAY Allows user to switch display positions of the PV1 residual and PV2 flow between th
179. tion onto pins for V and TCA as shown in Figure B 2 4 Attachthe PV1 hook up wires to terminals 31 and 32 as shownin Figure B 3 and the multimeter DO NOT connect the PV2 terminals Set the meter for DC volts 5 Reinsert chassis into the case and apply power The 2nd and 3rd display should read CALIBRATE ANALOG IN 6 Allow the controller to warm up for at least 30 minutes 7 Press the ACK key to get to the first step parameter The 2nd display should show CAL VREF the 3rd display should show a value close to 5 0000 8 For PV1 the multimeter should read a value in the range 4 9750 5 0250 Use the A and V and FAST keys on the controller until the display on the controller matches the meter reading 9 Press MENU key The 2nd display should show CAL 120mV The 3rd display should show a value close to 120mV 10 Press MENU three more times Each time match the displays of the con troller and the multimeter Press ACK when done 13 Foranalog milliamp input proceed to the Analog mA Input Calibration 14 For milliamp output power down the controller then power up again Pro ceedto the Milliamp Output Calibration step 5 555 Addendum 15 lfcalibration is complete power down and return the jumpers back in their original positions as specified in Chapter 4 ANALOG mA INPUT CALIBRATION 1 Attach pieces of wire to terminals 28 29 31 and 32 as shown in Figure B 4 and replace them with pieces of wire th
180. tions Enter 0 if not desired RS 485 Serial Communications S 2 555 Addendum Chapter 2 Page 6 FAST FAST FAST FAST FAST Addendum FAST MANUAL MANUAL SET PT DISPLAY DISPLAY HE WERE The key functions have been corrected 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 Press to select the active SP When lit indicates that a setpoint other than the primary e g RSP SP2 is active 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 4A Press to scroll through values at a faster rate Press to advance to next value or parameter FAST Y Press to scroll through values at a faster rate ACK Press to acknowledge alarm s When lit indicates that there is an acknowledgeable alarm MENU Press to access the Tu
181. tive front screws with a Phillips screwdriver Remove the four screws p To Add or Change Output Modules The 500 Series units have provisions for four output modules The units come factory configured with specified modules installed in appropriate locations You can make field modifications by properly remov ing and or adding the modules into the appropriate Sockets Three of the output sockets are located on the Power Supply Circuit Board A fourth output socket is located on the Option Board refer to Figure 2 5 Aretention plate and tie wrap hold Output modules 1 2 and 3 on the Power Supply board firmly in place To remove the retention plate snip the tie wrap with wire cutters Photo 5 OPTION BOARD Figure 1 Location of Printed Circuit Boards for Hardware Configuration 2 Slide the chassis out of the case by pulling on front face plate assembly at the bezel see Figure 1 3 Locate the retention clips holding the front face assembly to the rest of the chassis Pry apart these retention clips gently with a screwdriver to separate the printed circuit board group from the front face assembly Photo 3 Photo 5 Remove Retention Plate CAUTION Always snip the tie wrap on top of the Retention Plate as shown in photo 5 to prevent damage to the surface mount components 6 Adisposable tie wrap Take care not to Photo 3 Pry Clips holds Output module break the clips or 4 on the Option scrat
182. to indicate Operation Mode setpoint deviation or output Tuning and Set Up Mode parameter or parameter menu display 3rd The bottom display of the controller face that is used to indicate Operation Mode alarm or error message Tuning of Set up Mode the value or choice of the parameter disturbance An undesired change that takes place in a process that tends to affect adversely the value of a controlled variable dosage The percentage of gas flow to water flow duty cycle Percentage of load ON time relative to total cycle time earth ground A terminal used on the 555 to ensure by means of a special connection the grounding earthing of part of the controller engineering unit Terms of data measurement such as degrees Celsius pounds grams etc E 2 error The difference between the actual and the true value often ex pressed as a percentage of either span or full scale feedback Process signal used in control as a measure of response to control action the part of a closed loop system which automatically brings back information about the condition under control feed forward control Control in which the output of the control loop is adjusted based on the process variable and a second variable that is ratioed and biased final control element Component of a control system such as a valve or contractor which directly regulates that flow of energy or material to the process
183. ttom see Figure 1 Reinstall the retention clips Align the boards into the slots of the front face assembly and the clips will snap into place 17 When you are ready to reassemble the unit align the boards in the chassis with the case s top and bottom grooves Press firmly to slide the chassis into the case If you have difficulty check that you have properly oriented the chassis and there are no screws interfering with the case 18 Carefully insert and align screws Tighten them until the bezel is seated firmly against the gasket DO NOT OVERTIGHTEN 19 If may be necessary to re configure the software features of your controller or station Please refer to your User s Manual 20 To maintain NEMA 4X Rating you may need new mounting gaskets order part 535 662 Refer to your user s manual 500 Series 5 Declaration of Conformity C 4 EMC Directive 89 336 EEC Manufacturer s Name Moore Industries International Inc Manufacturer s Address 16650 Schoenborn Street North Hills CA 91343 6196 USA Declares that the product s Product Name 500 Series MODEL INPUT OUTPUT POWER OPTIONS HOUSING Model Number s 500 Series T 24 Vdc Hor J E Indicates any input output option and housing as stated on the product data sheet Indicates CE Compliant Conforms to the following EMC specifications EN61326 1 1998 Electromagnetic Compatibility requirements for electrical equipment for control use
184. u M NE im m NE CHLORINATION DECHLORINATION CONTROLLER USER S MANUAL L moore INDUSTRIES WORLDWIDE M555 V6 OCTOBER 2006 TABLE OF CONTENTS wi cecccesccisccceceesccceseeceetecestesenntccesstieesseteesseeeeeecceineette i About This Manual FIGURE Users vania information appears along the CHAPTER 1 margins in the form of NOTEs GENERAL INFORMATION sess nnns 1 CAUTIONs and WARNINGS usually 555 Control Modes sssssssssssssses eene 1 in boldface Please heed these 555 Operation 2 safety and good practice notices for Order Code Packaging E EE 2 the protection of you and your Where TO Go NeXt Ae eee 2 equipment Text Formatting in This Manual eee 2 CHAPTER 2 BASIGUNIIEBFAGE teuer ex tanien 5 BIETET 5 eed Bi ee 6 sete E 6 CHAPTER 3 HARDWARE SET UP 0 ccccccceeeeeeeeeeeeeeeeeeeeaeeeseeeeessaeeeeeneeeeeaeees 7 Hardware Input Typs 7 The Process Variable 7 The Remote Setpoiht 2 5 12 2 eed cnet I aos tb 8 Mechanical Relays 8
185. ust automatically to account for flow changes during lag periods This will enable trim integral adjustments to be timed more accurately when variable lagis used The defaulttime per lag countis 1 second but as flow increases or decreases the time per count can vary from 0 1 to 10 0 seconds For example if the flow rate doubles during a lag period the amount of time per lag count will decrease from 1 0 seconds to 0 5 seconds If residual only control is used with compound loop mode resulting from a flow input break a LOW FLOW alarm or a NO FLOW digital contact the lag time loaded at the beginning of the new lag period will be equal to the most recent lag count used before residual only control was initiated This causes trim inte gral output adjustments to be timed according to the flow rate that was used before the flow signal broke When using fixed and or variable lag the residual PV will be averaged over an additional 1 16 of the total lag time before the output trim is adjusted This will make the calculations more robust 555 13 Se Chapter 6 Page 88 Add the following new section after the discussion on lag R WATCHDOG FEATURE The Watchdog features pulses a digital output relay or solid state relay mod ule to provide an output with a 2 second period 1 second per on off state This selection is available for the OUTPUT parameters in the CONFIG menu This pulse can be used to tell a HOST device that the 555 is worki
186. uum digital contact 3 D LAST OUT R 5to105 15 DIG IN 4 OUT2 Dual Flow Pacing mode DIG IN 4 OUT aud ld Mus For existing properly configured contacts Selects the designated second LAST OUT output for a manual locked manual standby low vacuum or high vacuum digital contact 4 D LASTOUT 510105 16 DIG IN 5 OUT2 DIG IN 5 OUT Dual Flow Pacing mode For existing properly configured contacts Selects the designated second LAST OUT output for a manual locked manual standby low vacuum or high vacuum digital contact 5 D LAST OUT 5to 105 17 STAGE OUT1 STAGE OUT1 When staging outputs selects the value of the control output value at which S output 1 stops 100 for output 1 50 1to100 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 STAGE OUT2 P OB Access Set Up Return to Operation Next menu Next parameter Next value AccessTuning Returnto Operation Er now pee Dew 40 Chapter 5 555 User s Manual Software Configuration Configuration 19 S W RANGE Sets the full range resistance of the slidewire being used S W RANGE 1 1050 ohms D 1000 ohms 20 S W OPEN S W OPEN Sets the slidewire position corresponding to OPEN 100 output value Otocurrent S W RANGE value D 1000 ohms 21 S W CLOSE Sets the slidewi
187. ype Keys silicone rubber with diffusion printed graphics NEMA rating front panel conforms to NEMA 4X when instrument is properly installed AGENCY APPROVALS Gu 84603 Up Re C Available as an option MEMORY RETENTION Lithium battery maintains all programming for approximately ten years Heavy Industrial SECURITY There are two levels of access restricted and full A configurable code is used to enter the full access level Functions not available in the restricted level are configurable DIMENSIONS Il 7 180 182 37 OVERALL LENGTH 1 180 29 97 PANEL 3 622 92 00 MIN 3 770 95 78 3 653 92 80 MANUAL pisPLAY SET PT Vv ACK FAST 3 770 95 76 GASKET FRONT 555 User s Manual XV 08 26 99 NIIN 00 26 229 3 585 91 06 gt mor E 6 000 152 40 HE SIDE CUTOUT Appendix C C 3 Specifications _ Appendix C 555 User s Manual lt APPENDIX FLOWCHARTS SET UP SET UP AND TUNING MODE MENUS AND PARAMETERS MODE CONFIG LINE FREQ ANLG RNG 4 PV OFFSET PV GAIN FLOW BRK FLOW BRK 2 FLOW REST FLOW LINR 1ST INPUT 1ST PV 2ND INPUT 2ND PV 15TH INPUT 15TH PV RSDL INPT PV GAN

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