Hanna Instruments HI510 User manual

INSTRUCTION MANUAL
HI510
Process Controller

All rights are reserved. Reproduction in whole or in part is prohibited without the written consent of the
copyright owner, Hanna Instruments Inc., Woonsocket, Rhode Island, 02895, USA.
Thank you for choosing a Hanna Instruments product.
Please read this instruction manual carefully before using this instrument.
This manual will provide you with the necessary information for correct use of this
instrument, as well as a precise idea of its versatility.
If you need additional technical information, do not hesitate to e‑mail us at
[email protected] or view our contact list at www.hannainst.com.
Dear
Customer,

3
TABLE OF CONTENTS
TABLE OF CONTENTS
1. PRELIMINARY EXAMINATION ............................................................................................... 7
2. SAFETY MEASURES............................................................................................................. 7
3. SPECIFICATIONS................................................................................................................. 8
3.1. CONTROLLER SPECIFICATIONS.................................................................................... 8
3.2. PROBE SPECIFICATIONS ............................................................................................ 9
4. GENERAL DESCRIPTION & INTENDED USE........................................................................... 11
4.1. ADDITIONAL FEATURES ........................................................................................... 12
5. HI510 MODELS & DEDICATED SMART PROBES.................................................................... 14
5.1. CONTROLLER MODELS............................................................................................. 14
5.2. SMART PROBES...................................................................................................... 14
6. FUNCTIONAL & DISPLAY DESCRIPTION ............................................................................... 15
6.1. FRONT PANEL......................................................................................................... 15
6.2. MAIN DISPLAY FUNCTIONS...................................................................................... 16
6.3. KEYPAD DESCRIPTION ............................................................................................. 16
6.4. CONTEXTUAL HELP.................................................................................................. 17
6.5. USB-C PORT........................................................................................................... 17
6.6. OPENING THE ENCLOSURE ..................................................................................... 18
7. INSTALLATION.................................................................................................................. 19
7.1. GENERAL GUIDELINES............................................................................................. 19
7.2. WALL MOUNT (OR SURFACE MOUNT)....................................................................... 19
7.3. PANEL MOUNT........................................................................................................ 22
7.4. PIPE MOUNT .......................................................................................................... 25
8. WIRING THE HI510 PROCESS CONTROLLER ........................................................................ 27
8.1. GENERAL INFORMATION.......................................................................................... 27
8.2. PREPARING CONDUIT OPENINGS.............................................................................. 27
8.3. WIRING THE CONTROLLER ....................................................................................... 29
8.4. Terminal 2 Wiring .................................................................................................. 32
9. DISPLAY DESCRIPTION...................................................................................................... 33
9.1. MAIN DISPLAY........................................................................................................ 33
9.2. ICON DESCRIPTION & FUNCTION.............................................................................. 34

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TABLE OF CONTENTS
10. GENERAL OPERATIONS.................................................................................................... 35
10.1. POWERING THE CONTROLLER................................................................................. 35
11. MENU ........................................................................................................................... 36
11.1. CHANNEL, CAL...................................................................................................... 37
11.2. HOLD MODE......................................................................................................... 55
11.3. OUTPUTS............................................................................................................. 57
11.4. INPUTS................................................................................................................ 62
11.5. CLEANING ............................................................................................................ 63
11.6. MANUAL MODE..................................................................................................... 69
11.7. LOG RECALL.......................................................................................................... 70
11.8. GENERAL.............................................................................................................. 78
12. USE WITH THE HI92500 APPLICATION............................................................................. 86
12.1. HI92500 – HANNA PC SOFTWARE......................................................................... 86
13. CONTROLLER FUNCTIONS & MODES................................................................................. 87
14. CONTROL MODES ........................................................................................................... 89
14.1. CONTROL ALGORITHMS ......................................................................................... 89
15. CLEANING MODE .......................................................................................................... 109
15.1. CLEANING BLOCK INPUTS & OUTPUTS.................................................................. 109
15.2. CLEANING SEQUENCES........................................................................................ 110
15.3. CLEANING ALGORITHMS ...................................................................................... 110
15.4. CLEANING TRIGGERS ........................................................................................... 111
15.5. STOP CLEANING.................................................................................................. 113
15.6. OVERVIEW OF CLEANING TYPES........................................................................... 115
16. HI510 EVENTS MANAGEMENT SYSTEM........................................................................... 116
16.1. ALARMS, WARNINGS, ERRORS............................................................................. 116
17. PROBE CONDITIONING & MAINTENANCE ........................................................................ 123
18. TROUBLESHOOTING GUIDE ........................................................................................... 124
19. BUFFER VALUES AT VARIOUS TEMPERATURES................................................................ 125
20. APPLICATION CONFIGURATION (PROBE, RS485, INPUT & ANALOG WIRING)............................ 126
21. GLOSSARY.................................................................................................................... 127
22. LIST OF FIGURES.......................................................................................................... 128

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TABLE OF CONTENTS
23. ACCESSORIES............................................................................................................... 130
23.1. pH CALIBRATION SOLUTIONS............................................................................... 130
23.2. ORP SOLUTIONS................................................................................................. 130
23.3. ELECTRODE STORAGE SOLUTIONS ........................................................................ 130
23.4. ELECTRODE CLEANING SOLUTIONS ....................................................................... 130
23.5. ELECTRODE HOLDERS.......................................................................................... 131
23.6. FLOW CELL & SADDLE FITTINGS ........................................................................... 133
23.7. MOUNTING KIT ACCESSORIES .............................................................................. 135
CERTIFICATION.................................................................................................................... 138
RECOMMENDATIONS FOR USERS.......................................................................................... 138
WARRANTY ......................................................................................................................... 138

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About this Manual
• This manual contains instructions for installation and operation of the Hanna Instruments HI510
Universal Process Controller.
• This release of the product manual contains information that applies to HI510 Process Controller
operating with HI10X6-Y8ZZ pH & Temperature or HI20X4-Y8ZZ ORP & Temperature series of
smart probes.
• The HI510 Process Controller can be paired up with a family of smart probes that can be ordered
separately. When pairing up the controller with a different probe, probe-specific setup information
as well as calibration and accessories sections need to be updated. This manual covers HI510-0320
& HI510-0540 models as well as HI1006-1805 & HI2004-1805 smart probes.
• Procedures and instructions in the Safety Measures section may require special precautions to
ensure the safety of the personnel performing the operations.

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PRELIMINARY EXAMINATION
1. PRELIMINARY EXAMINATION
Remove the instrument and accessories from the packaging and examine it carefully.
For further assistance, please contact your local Hanna Instruments Office or email us at
[email protected].
Each HI510 Process Controller is delivered in a cardboard box and is supplied with power cable
(3 meters long), a set of cable gland seals, instrument certificate, and instruction manual.
All mounting kits must be ordered separately.
Note: Save all packing material until you are sure that the instrument works correctly. Any
damaged or defective item must be returned in its original packing material with the supplied
accessories.
2. SAFETY MEASURES
General Safety Precautions & Preliminary Installation Recommendations
• Electrical connection, installation, start-up, operation and maintenance must be carried
out by specialized personnel only.
• The specialized personnel must have read and understood the instructions in this
manual and should adhere to them.
• User serviceable connections are all accessible inside the enclosure.
• Do not operate or energize the instrument with the case open.
• Before powering the controller, verify wiring has been done properly.
• Always disconnect the instrument from power when making electrical connections.
• Do not run other cables through the same cable gland with the power cable.
• A clearly marked disconnect switch must be installed in the vicinity of the instrument to
ensure that the electrical circuit is completely de-energized for service or maintenance.
• Do not operate damaged instruments which could pose a danger.
• Damaged instruments should be clearly marked as faulty and replaced.
• If faults cannot be repaired, the instrument must be taken out of service and secured
against unintentional start-up.
Built-in Safety Features
• All electrical connections are enclosed inside IP65 - rated enclosure.
• Galvanic isolation is provided for all inputs and outputs.
• EMC compliant hardware and software design.
Note: If system faults or a power failure occurs, a fault-signaling contact triggers the alarm.
HI510 has been tested for electromagnetic compatibility in industrial use according to radiated
emissions.
SAFETY MEASURES

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SPECIFICATIONS
3. SPECIFICATIONS
3.1. CONTROLLER SPECIFICATIONS
Digital probes Smart HI10X6 series –pH & Temperature with RS485 interface
Smart HI20X4 series –ORP & Temperature with RS485 interface
Display Graphic LCD, 128 x 64 pixel B/W with backlight
Digital inputs
2 independent, galvanically isolated inputs (configurable for Hold
& Cleaning functions)
On state: 5 to 24 Vdc, low or high level active
Analog outputs
Analog output accuracy
2 or 4 independent, galvanically isolated outputs
0 –22 mA configurable as:
0 –20 mA; 4 –20 mA
22 mA as alarm signal, configurable option
±0.2% f.s.
Digital communication RS485 serial port - Remote monitoring and control
USB-C port - Retrieve log files and firmware upgrading
Relays
Up to 5 relays (independently configurable for process variables,
Hold & Cleaning functions)
Electromechanical relay SPDT and SPST contact outputs
5A –250 Vac; 5A –30 Vdc (resistive load)
Fuse protected: 5A, 250V slow blow fuse
Alarm relay for all
measurement alarms
Electromechanical relay SPDT contact output
5A –250 Vac; 5A –30 Vdc (resistive load)
Fuse protected: 5A, 250V slow blow fuse
Data logging
Interval log, up to 100 files, maximum 8600 records on each stored
file. When the maximum limit of 100 stored files is reached, the most
recent file will automatically erase the oldest one.
Event log, maximum 100 records. When the maximum limit is
reached, the last record overwrites the oldest one.
Power supply 100 –240 Vac ±10%; 50/60 Hz; 15VA; fuse protected (2A,
250V slow blow fuse)
Power consumption 15VA
Installation category II
Enclosure* Single case ½ DIN, type 4X, IP65 ingress protection
*For a water tight seal, tighten the front four screws on the front casing to 13.3 lbf·in (1.5 N·m,
maximum 2.0 N·m), of torque.

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SPECIFICATIONS
Weight Approximately 1.6 kg (3.5 lb.)
Dimensions
Width 144.0 mm (5.7”)
Height 144.0 mm (5.7”)
Depth 151.3 mm (6.0”)
Environment -20 to 50 ºC (-4 to 122 ºF); maximum 100% RH non-condensing
3.2. PROBE SPECIFICATIONS
HI1006-1805 pH Digital Probe
Range 0.00 to 12.00 pH
Temperature -5.0 to 80.0 ºC / 23 to 176 ºF
Accuracy ±0.02 pH
Temperature compensation Automatic or manual from -5.0 to 80.0 ºC
Body PVDF
Junction PTFE
Sensor Low Temperature (LT) glass sensor
Sensor tip Self-cleaning, flat
Maximum pressure 6 bar
Probe cable length 5 meters
Built-in titanium matching pin, to avoid fluctuating measurements & poor process regulation
3/4” NPT external thread for insertion mounting
Note: See 5.2 SMART PROBES section for all pH probes configurations

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SPECIFICATIONS
HI2004-1805 ORP Digital Probe
Range -2000 to +2000 mV
Temperature -5.0 to 80.0 ºC / 23 to 176 ºF
Accuracy ±2 mV
Body PVDF
Junction PTFE
Sensor Platinum ring
Sensor tip Flat
Maximum pressure 6 bar
Probe cable length 5 meters
3/4” NPT external thread for insertion mounting
Note: See 5.2 SMART PROBES section for all ORP probes configurations
Probe Cabling Color Code
Color Functionality
BROWN + Power
YELLOW A RS485 COM
WHITE B RS485 COM
GREEN – Power
GREEN / YELLOW PROTECTIVE GROUND CONNECTION

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GENERAL DESCRIPTION & INTENDED USE
4. GENERAL DESCRIPTION & INTENDED USE
HI510 is a universal process controller that supports continuous measurement of process parameters
with dedicated digital probes, such as HI1006-1805 for pH & Temperature and HI2004-1805 for ORP
& Temperature.
It can be configured for a wide range of applications requiring monitoring and / or control of process
parameters.
It’s designed to adapt to every user’s unique process control requirements, and thus provides a high
degree of flexibility for all hardware inputs and outputs, and software-defined functions. This includes
from 5V up to 24 Vdc digital inputs, and flexible function assignments for relays regarding process
control, cleaning or Hold mode.
Hanna Instruments dedicated smart probes allow for shared management of settings between
controller and probe, where the controller manages only settings related to the intended application,
as defined by requirements of the industrial process, and the probe manages settings and warnings
related to measurements, including temperature compensation and buffer calibration. Smart technology
enables optimization of probes for specific applications, such as different temperatures or pH ranges.
The controller is intended to use in industrial environments, and as such is suitable for wall-, pipe- and
panel-mounting installations. It has a low profile vulcanized rubber keypad for all operations, blue
LEDs to indicate when relays are energized, multi-color LEDs for detailed inspection of status, and
EMI protected RS485 interface to probe, and remote control and monitoring port. It also provides an
intuitive interface for control setup, relay activation, alarm signaling or hold status, and a help and
diagnostic feature that guides users to identify the problems and suggests possible action(s) to be
taken. Safety features include fuse-protected relays and a hold-to-safe-values mode.
Programming is done through the keypad or the RS485 connection, which requires a PC running the
HI92500 Windows compatible software.

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GENERAL DESCRIPTION & INTENDED USE
MAIN FEATURES
PROCESS INPUT • Smart probes with RS485 connection. Automatic probe recognition
and upload of settings configuration and measurement data
MENUS • Easily navigable main menu and submenus
ANALOG OUTPUTS • Two or four, depending on the controller model, galvanically isolated,
(0-20 or 4-20mA)
ALARM RELAY • Activates on errors and programmable alarm conditions
CONTROL RELAYS • Up to five programmable SPDT contact outputs 5A-250 Vac, 5A-30 Vdc
CLEANING FUNCTION
• Integral water or chemical cleaner control
• Simple or advanced cleaning is configurable to be triggered manually,
triggered at a set time interval, scheduled for a specific day of the
week or triggered by a digital input
• Blowers, water jets, washers (user supplied)
BACKLIT DOT MATRIX
LCD DISPLAY • With virtual key function
ENCLOSURE • Rugged molded housing with hinged front panel
4.1. ADDITIONAL FEATURES
HOLD MODE • Automatic mode for entering calibration, Setup and cleaning cycle
• Can be triggered manually or via an external digital input
?DIAG key ( ) • User help key, opens a guide for diagnosing a problem or
troubleshooting
SECURITY ACCESS CODE • Protected calibration and setup settings
LANGUAGES
• Allows language used for settings and messages to be changed to a
supported one, according to user preferences e.g. Francais, Magyar,
Italiano, Nederland, Portugues, Deutsch, Español
• Default operating language, English
REMOTE CONTROL • HI92500 remote PC-based application, using RS485 connection
• Allows remote access for monitor and control of process parameters
USB-C PORT • USB for exporting (or importing) data with a flash drive

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GENERAL DESCRIPTION & INTENDED USE
DATA LOGGER & EVENT
LOGGER
• The controller automatically logs the process control information in
an interval log, and various event alarms and errors in an event log
• Logged data can be retrieved and events visualized on the screen, in
Log Recall menu
• Interval logs store up to 8600 records, maximum number is 100.
• Logging interval can be set in the General settings menu
• Thelogged dataincludes: pH(or ORP)andtemperaturemeasurements,
last calibration data, setup configuration, event data, event code, start
date and time, end date and time, previous value, mV value of the
parameter
• Event log can store up to 100 records of events, alarms, errors related
data
• Log files can be uploaded to a USB flash drive via USB-C port
MANUAL MODE
• Used to exercise relays and analog outputs
• Useful for setting up the system, filling up the pump circuit, checking the
cabling wiring, and during general maintenance
• Default option when the industrial application requires manual input
• As a safety feature, a 60-minutes timeout is implemented before relays
turn off and analog outputs return to their previous value before entering
Manual Mode
CALIBRATION
• pH single point process calibration, or calibration up to three-points,
using two buffer sets:
• Hanna Instruments –1.68, 4.01, 7.01, 10.01, 12.45 pH
• NIST –1.68, 4.01, 6.86, 9.18, 12.45 pH
• ORP calibration using a single point process calibration
• Last calibration is stored in the probe and can be visualized in the
Cal Data window
• Calibration reminder can be scheduled (1 to 99 days, Off)
Note: As a safety feature, when in Setup or Calibration mode, without making any changes or
pressing any key, the controller will return to Measure mode and restart control.

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HI510 MODELS & DEDICATED SMART PROBES
5. HI510 MODELS & DEDICATED SMART PROBES
5.1. CONTROLLER MODELS
There are two HI510 models: the HI510-0320 model, with three relays and two analog outputs, and
the HI510-0540 model, with five relays and four analog outputs.
5.2. SMART PROBES
Hanna Instruments smart probes enable accurate and automated collection of data. The pH and ORP
configuration schemes detailed below list all the combination, flat tip, PVDF-body, polymer filled
electrodes with matching pin and operating pressure of up to 6 bar (87 psi).
pH electrodes
HI10
x y—w z
w = 06 PTFE junction
16 Ceramic junction
x = 1 LT (Low Temperature) glass sensor
-5 to 80 ºC (23 to 156 ºF)
0 to 12 pH
3 HT (High Temperature) glass sensor, titanium matching pin
0 to 100 ºC (32 to 212 ºF)
0 to 14 pH
4 HF (Fluoride-resistant) glass sensor*
y = 8 Smart probe, with RS485 connection
z = 5, 10, 15, 25, 50 cable length (meters)
*F-<2g/L, temperature<60 °C, pH>2
ORP electrodes
HI20
x y—w z
w = 04 PTFE junction
14 Ceramic junction
x = 1 Platinum sensor
2 Gold sensor
y = 8 Smart probe, with RS485 connection
z = 5, 10, 15, 25, 50 cable length (meters)

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FUNCTIONAL & DISPLAY DESCRIPTION
6. FUNCTIONAL & DISPLAY DESCRIPTION
6.1. FRONT PANEL
• The front panel includes a graphic display and keypad with tactile feedback.
• The first LCD line displays information regarding controller status, the second LCD line displays
measurement readings, and the third LCD line displays the temperature value or additional
messages.
• Two LEDs, ALARM and STATUS, indicate alarm and status conditions.
• HOLD LED lights up yellow indicating controller HOLD status.
• Depending on the model, up to five additional LEDs light up blue, indicating relay status.
STATUS
HOLD
HELP
MENU
ESC
DIAG
1
2
3
4
6
7
5
8
Alarm & Control relay LEDs
1
2
3Cable glands
Keypad
4
5Hold LED
Graphic Display (LCD)
6USB-C Port
7
8
Status LED
Captive spring loaded screws
Figure 1: Front Panel & Keypad Description

16
FUNCTIONAL & DISPLAY DESCRIPTION
6.2. MAIN DISPLAY FUNCTIONS
1 5
2 6 9
3 7
104 8
1Title & Status area
2Main reading display area
3Main reading value
4Raw reading area (mV)
5Warning (!) or Alarm (!!) icon, press ?DIAG key ( ) for description
6Displayed parameter alarm status (high or low)
7Temperature Compensation status
8Temperature reading area
9Warning icon
10 Virtual key option
6.3. KEYPAD DESCRIPTION
There are six functional keys and three virtual keys that change function with the display above.
Functional Keys
• The Menu direct key ( ) permits access to calibration and Setup parameters.
• The diagnostic (?DIAG) direct key ( ) is a help and diagnostics key that opens a guide for Setup
or diagnosing a problem or troubleshooting.
• The back functional key ( ) returns the user to previous hierarchical menu level. It also performs
an exit or escape function.
• The directional arrow keys ( ) move the user through the menu and submenu in either
direction. They may be used to increment one position, or to move continuously through a menu or
string of values by holding the key in the depressed position.
Virtual Keys
The three virtual keys ( ) ( ) ( ) perform the functions displayed on the bottom of the
display screen. Virtual keys can be used to set or modify parameters values or to access, export or
delete log files.

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FUNCTIONAL & DISPLAY DESCRIPTION
6.4. CONTEXTUAL HELP
• HI510 offers an interactive contextual help mode that assists the user at any time.
• To access the help screen, press the diagnostic (?DIAG ) key. The instrument will display
additional information related to the current screen. To read all the available information, scroll the
text using the keys.
• To exit help mode, press the back ( ) key and the controller returns to the previous screen.
6.5. USB-C PORT
The USB-C port is located on the right side of the controller. Users can connect a USB flash-drive
(either directly or through an adapter) or a cable, to this port.
Note: The flash drive should not be pulled out of the USB-C port while it is still in operation.
USB
1
USB-C Port
1
2
Venting element
2
Figure 2: USB-C Port & Venting Element

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FUNCTIONAL & DISPLAY DESCRIPTION
6.6. OPENING THE ENCLOSURE
The front panel is hinged at the front of the enclosure for easy access to wiring locations. To open the
enclosure, loosen the four captive screws enough for the springs to push them out.
Selection of mounting location should be such that allows the front panel to swing open fully and that
there is adequate room around the mounting location for wire routing.
CA UTION
Disconnect power supply
prior to cover removal.
No user-serviceable parts
inside. Refer servicing to
qualified service personnel.
STATIC SENSITIVE
DEVICE
Figure 3: HI510 Enclosure Opened
Figure 4: Hinged Front Panel

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INSTALLATION
7. INSTALLATION
7.1. GENERAL GUIDELINES
• HI510 Process Controller is suitable for outdoor use, but installation in direct sunlight or in areas of
extreme temperature is not recommended.
• Based on controller specifications, installation thermal conditions are in the -20 ºC to 50 ºC (-4 to
122 ºF) range.
• The controller should be installed in an area where vibrations and electromagnetic interference are
minimized.
• Unused cable conduit entries must be securely sealed with Type 4X or IP66 conduit plugs, to
maintain the ingress protection rating.
• Easy access to the controller should be available at all times.
• Safety precautions must be observed at all times! See SAFETY MEASURES section for details.
• The versatile HI510 enclosure design supports surface or wall-mount, panel-mount and pipe-
mount installations.
7.2. WALL MOUNT (OR SURFACE MOUNT)
Wall-Mount Support Surface & Inside Depth Dimensions
• at least 208 mm (8.2 “) wall support surface, if the mounting plate is mounted horizontally.
• at least 108 mm (4.3 “) wall support surface, if the mounting plate is mounted vertically.
170mm 6.7”
208mm 8.2”
34mm 1.3”
85mm 3.3”
160mm 6.3”
Figure 5: Wall-Mount Panel, Slots Dimensions

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INSTALLATION
83mm 3.3”
Ø0.244”
Ø6.2mm
34mm 1.3”
85mm 3.3”
108mm 4.3”
12mm 0.5”
83mm 3.3”
170mm 6.7”
208mm 8.2”
Ø0.335”
Ø8.5mm
Figure 6: Wall-Mount Panel Thickness, Mounting Bolts & Slots Dimensions
The minimum depth required by HI510 fastened to a 12 mm (0.5 “) mounting plate is 163 mm
(6.4”).
163mm 6.4”
Figure 7: HI510 Controller Fastened to Wall-Mount Panel