Moore Industries 555 User manual

CHLORINATION/DECHLORINATION
CONTROLLER USER'S MANUAL
5 5 5
M555 V 8 , M ARCH 201 7
5 5 5

555 User's Manual Table of Contents i
Contents
page About This Manual:
Throughout this User’s Manual
information appears along the
margins, in the form of NOTEs,
CAUTIONs and WARNINGs, usually
in boldface. Please heed these
safety and good practice notices for
the protection of you and your
equipment.
TABLE OF CONTENTS............................................................................. i
FIGURE LIST ........................................................................................... iii
CHAPTER 1
GENERAL INFORMATION ............................................................... 1
555 Control Modes ............................................................................ 1
555 Operation ................................................................................... 2
Order Code, Packaging Information .................................................. 2
Where To Go Next ............................................................................ 2
Text Formatting in This Manual ......................................................... 2
CHAPTER 2
BASIC INTERFACE .......................................................................... 5
Displays ............................................................................................ 5
Icons (Lit) .......................................................................................... 6
Keys .................................................................................................. 6
CHAPTER 3
HARDWARE SET UP ....................................................................... 7
Hardware Input Types ....................................................................... 7
The Process Variable ........................................................................ 7
The Remote Setpoint ........................................................................ 8
Mechanical Relays ............................................................................ 8
Accessing and Changing Jumpers .................................................... 9
Adding and Changing Output Modules ............................................ 10
Special Communications Module .................................................... 12
CHAPTER 4
INSTALLATION .............................................................................. 13
Mounting the Controller ................................................................... 13
Wiring for Input and Outputs ........................................................... 14
AC Power Input ...................................................................... 14
Process Variables .................................................................. 15
Digital Inputs........................................................................... 17
Output Modules ...................................................................... 18
Remote Setpoint ..................................................................... 21
Serial Communications ........................................................... 21
CHAPTER 5
SOFTWARE CONFIGURATION..................................................... 23
Menus ............................................................................................. 23
Parameters ..................................................................................... 24
Configuration and Operation ........................................................... 24
Where to Go Next ........................................................................... 25
Software Menus and Parameters .................................................... 27
CONFIG ................................................................................. 27
CONTROL.............................................................................. 31
FLOW INPT. ........................................................................... 32
CUST.LINR. ........................................................................... 34
RSDL. INPT. .......................................................................... 35
SETPOINT ............................................................................. 36
REM. INPUT .......................................................................... 37
OUTPUT ................................................................................ 38
RETRANS. ............................................................................. 41
ALARMS ................................................................................ 43

Contents
ii Table of Contents 555 User's Manual
page
POWER-UP ........................................................................... 47
SECURITY ............................................................................. 47
SER. COMM........................................................................... 48
TUNING ................................................................................. 49
Parameter Value Charts.................................................................. 51
CHAPTER 6
APPLICATIONS .............................................................................. 59
A. Flow Pacing Mode ...................................................................... 59
B. Residual Chlorine Loop Mode ..................................................... 61
C. Compound Loop Mode ............................................................... 64
D. Dechlorination Mode ................................................................... 67
E. Alarms ........................................................................................ 70
F. Slidewire Position Proportioning Output ...................................... 74
G. Staged Outputs ........................................................................... 75
H. Retransmission ........................................................................... 75
I. Digital Inputs ............................................................................... 76
J. Remote Input .............................................................................. 78
K. Integral Setting............................................................................ 79
L. Tuning Tips ................................................................................. 80
M.Input Linearization ...................................................................... 83
N. Security ...................................................................................... 84
O. Process Variable Reading Correction ......................................... 85
P. Serial Communications ............................................................... 86
Q. Lag ............................................................................................. 87
APPENDIX A
ERROR HANDLING ..................................................................... A-1
Troubleshooting ............................................................................ A-1
Error Messages ............................................................................ A-2
APPENDIX B
CALIBRATION .............................................................................. B-1
Analog Input (V and mA) Calibration ............................................. B-1
Milliamp Output Calibration ........................................................... B-3
Reset Menu Data .......................................................................... B-4
Hardware Scan ............................................................................. B-4
Slidewire Test ............................................................................... B-5
Quick Calibration Procedure ......................................................... B-5
APPENDIX C
SPECIFICATIONS ........................................................................ C-1
APPENDIX D
FLOWCHARTS ............................................................................. D-1
Set Up and Tuning Mode Menus and Parameters ........................ D-1
APPENDIX E
GLOSSARY .................................................................................. E-1
APPENDIX F
ISOLATION BLOCK DIAGRAM .................................................... F-1
APPENDIX G
PARTS LIST ................................................................................. G-1

555 User's Manual Table of Contents iii
Contents
Figure 1.1 ........ The 555 Chlorination/Dechlorination Controller ................. 1
Figure 2.1 ........ 555 Operator Interface ...................................................... 5
Figure 3.1 ........ Accessing the 555 Circuit Boards ..................................... 7
Figure 3.2 ........ The Microcontroller Circuit Board,
The Option Board, and the Power Supply Board ............... 8
Figure 3.3 ........ Output Module ................................................................ 11
Figure 3.4 ........ Install Communications Module onto the
Microcontroller Board ...................................................... 12
Figure 4.1 ........ Controller Dimensions. .................................................... 13
Figure 4.2 ........ Insert Mounting Clips ...................................................... 13
Figure 4.3 ........ 555 Input and Output Wiring Options .............................. 14
Figure 4.4 ........ AC Power Input Wiring .................................................... 15
Figure 4.5 ........ PV Voltage Input Wiring .................................................. 15
Figure 4.6 ........ PV mA Input with External Power Supply Wiring ............. 16
Figure 4.7 ........ PV mA Input with Internal Power Supply and
2-Wire Transmitter Wiring ................................................ 16
Figure 4.8 ........ PV mA Input with Internal Power Supply and
4-Wire Transmitter Wiring ................................................ 17
Figure 4.9 ........ Digital Input Wiring with a Switch or Relay ...................... 17
Figure 4.10 ...... Digital Input Wiring with an Open Collector ..................... 18
Figure 4.11 ...... Mechanical Relay Output Wiring ..................................... 18
Figure 4.12 ...... Solid State Relay Output Wiring ...................................... 19
Figure 4.13 ...... DC Logic Output and Milliamp Output Wiring .................. 19
Figure 4.14 ...... Position Proportioning Output
with Slidwire Feedback Terminals ................................... 20
Figure 4.15 ...... Remote Setpoint Terminals ............................................. 21
Figure 4.16 ...... Serial Communications Terminals ................................... 21
Figure 5.1 ........ Menus, Parameters and Values ...................................... 23
Figure 5.2 ........ Independent vs. Dependent Parameters ......................... 24
Figure 5.3 ........ Operation and Configuration Flowchart ........................... 24
Figure 6.1 ........ Flow Pacing Control ........................................................ 59
Figure 6.2 ........ Residual Chlorine Loop Control ...................................... 61
Figure 6.3 ........ Compound Loop Control ................................................. 64
Figure 6.4 ........ Dechlorination Control .................................................... 67
Figure 6.5 ........ Alarm Examples.............................................................. 73
Figure 6.6 ........ Residual Control Responses .......................................... 81
Figure 6.7 ........ Square Root Linearization Formula ................................. 83
Figure 6.8 ........ Custom Linearization Curve ............................................ 84
Figure 6.9 ........ Compound Loop Flow Pacing with Lag Times ................. 87
Figure B.1 ........ Calibration Menu Flowchart .......................................... B-1
Figure B.2 ........ Microcontroller Circuit Board ......................................... B-2
Figure B.3 ........ PV1 & PV2 Calibration Wiring ....................................... B-2
Figure B.4 ........ Milliamp Output Calibration Wiring ................................ B-3
Figure B.5 ........ Output Module Menu Cycle........................................... B-4
Figure B.6 ........ Slidewire Calibration Wiring .......................................... B-5
Figure.............Title ............................................................................ Page

Contents
iv Table of Contents 555 User's Manual

555 User's Manual Chapter 1 1
GeneralInformation
CHAPTER 1
GENERAL INFORMATION
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 and
residual analyzers through straightforward menu configuration selections.
555 CONTROL MODES
FLOW PACING MODE: control mode for adding chlorine to and/or removing
chlorine from the water, based on flow rate with no feedback.
RESIDUAL CHLORINE MODE: control mode for adding chlorine to the water
based on residual level as the process variable.
COMPOUND LOOP MODE: control mode for adding chlorine based on a
combination of both flow pacing and residual level.
DECHLORINATION MODE: the control output for adding SO2 to the water
based on a combination of both flow pacing and residual chlorine level.
Figure 1.1
The555 Chlorination/Dechlorination
Controller

GeneralInformation
2Chapter 1 555 User's Manual
555 OPERATION
There are 3 operation “modes” for the 555 controller:
OPERATING, the default mode of the controller. While the 555 is “operating,”
you can change dosage setpoints, select manual control and change output level,
acknowledge alarms and monitor conditions.
SET UP, sometimes referred to as “configuration.” In set up, you configure the
basic functions of the instrument such as input and output assignments, alarm
types and special functions.
TUNING, where you configure control function parameters for Residual and
Compound Loop control. Use the tuning function periodically to optimize the
performance of the 555.
Refer to Chapter 5, and Figure 5.3, to view the relationship between these 3
modes.
ORDER CODE,PACKAGING INFORMATION
Compare the product number 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:
•one 555 controller
•one 555 User’s Manual
•555 mounting hardware
•one sheet engineering unit adhesive labels
•one rear terminal label
WHERETO GO NEXT
•To become more familiar with the 555 interface, continue to Chapter 2.
•For important hardware installation guidelines, see Chapters 3 and 4.
•For a detailed description of all the software menus and parameters of the
555, follow through Chapter 5. Appendix D can be used as a basic guideline
to these parameters.
TEXT FORMATTING INTHIS MANUAL
Feature Format
KEYS SET PT DISPLAY
or
ICONS OUT, ALM
MENUS CONFIG., TUNING,
PARAMETERS CYCLE TM:1, MIN.OUT2
PARAMETER VALUES OFF, SETPOINT, LAST OUT.
DISPLAY MESSAGES TOO HOT, OUT%,
SET PT DISPLAY

555 User's Manual Chapter 1 3
GeneralInformation
ORDER CODE
0 0555 -
OUTPUT 2 —
CONTROL,
ALARM,
OR
RETRANSMISSION
OUTPUT 4 —
ALARM,
RETRANSMISSION,
OR LOOP POWER
None .......................................................... 0
Mechanical relay (5 amp) ........................... 1
Analog (milliamp) ....................................... 2
Solid state relay (triac) (1 amp) ................... 3
DC logic (SSR drive) .................................. 4
None .......................................................... 0
Mechanical relay (5 amp) ........................... 1
Analog (milliamp) ....................................... 2
Solid state relay (triac) (1 amp) ................... 3
DC logic (SSR drive) .................................. 4
None .......................................................... 0
Mechanical relay (5 amp) .......................... 1
Analog (milliamp) ....................................... 2
Solid state relay (triac) (1 amp) .................. 3
DC logic (SSR drive) ................................. 4
None .......................................................... 0
Mechanical relay (0.5 amp, 24 V) .............. 1
Analog (milliamp) ....................................... 2
Solid state relay (triac) (0.5 amp, 24 V) ..... 3
DC logic (SSR drive) ................................. 4
Loop power................................................ 5
Slidewire feedback for
position proportioning
output ........................................................ A
Remote setpoint (Standard) ....................... B
Five digital inputs (for vacuum alarm and
stand by mode) .......................................... D
RS-485 serial
communications......................................... S
SERIAL
COMMUNICATIONS
ENTER “0” IF
COMMUNICATIONS
NOT DESIRED
OptionalInputs
ENTER “0” IF
OPTIONAL
INPUT NOT DESIRED
Note1:Capabilityforpositionproportioningoutputisspecifiedbyordering555-11xxAxxx00,555-33xxAxxx00,
or 555-44xxAxxx00. (Slidewire not required for velocity proportioning.) Note 2: Up to two outputs may be
usedforalarms. Note3: Alloutputsareinterchangeablemodules. Note4: Themechanicalrelayandsolid
state relay modules are derated to 0.5 amp at 24 Vac when used as the fourth output.
OUTPUT 3 —
ALARM,
OR
RETRANSMISSION
OUTPUT 1 —
CONTROL
B

GeneralInformation
4Chapter 1 555 User's Manual

555 User's Manual Chapter 2 5
Interface
Figure 2.1
555 Operator Interface
MANUAL DISPLAY SET PT
FAST
MENU
ACK
555
OUT
1 2
ALM
1 2
Icons 1st
Keys
2nd
3rd
Displays:
CHAPTER 2
BASIC INTERFACE
DISPLAYS
Refer to Chapter 6 for details on the interface functions for specific modes.
1st Line (five 7-segment digits)
• Always displays a (primary) process variable, with value/units depending
on the individual mode.
2nd Line (nine 14-Segment Digits)
• Under “normal” operating conditions, displays process dosage or
setpoints, deviations, output values, lags, trim, pace, etc., depending upon
the mode.
• When configuring the 555 (in any mode), displays the menu names and
subsequent parameter names.
• When using a ramping setpoint that is actively ramping, alternates between
the target SP (SP2, RSP) and the ramping setpoint (which causes
RAMPING to show in the third display).
• When using the slidewire option, displays the actual valve position.
3rd Line (nine 14-Segment Digits)
• For dual PV modes shows the alternate PV, whether it is flow or residual
level. To switch the display positions of the primary and secondary PV,
press FAST + DISPLAY.
• If alarms occur, this line will show alarm messages alternating with any
other messages.
• During configuration, this line shows the parameter value in the menu
system.

Interface
6Chapter 2 555 User's Manual
ICONS (LIT)
OUT1 Indicates the output is at a level greater than 0%, or “activated” (for time
proportioning or a digital output).
OUT2 Indicates the second output (SO2) 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.
SETPT: 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+▲▲
▲▲
▲: Press to scroll through values at a faster rate.
▼▼
▼▼
▼: Press to advance to next value or parameter
FAST+▼▼
▼▼
▼: 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: Press to access the Tuning Menu, and its parameters. When lit, indicates
that the controller is in Set Up mode (in the configuration menus).
FAST+MENU : Press to access the Set Up menus. Use MENU to access the
parameters of the software menus. When lit, indicates that the controller is in
Set Up mode (in the configuration menus).
OUT OUT OUT
1212
ALM ALM ALM
1212
PV2
MANUAL
DISPLAY
▲
▼
DISPLAY
MANUAL
SET PT
DISPLAY
▲
▼
MENU
MENU
+
DISPLAY
FAST
FAST
+
FAST
+
FAST
+
+

555 User's Manual Chapter 3 7
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. Your555controllercomesfactory
set with the following:
• All the specified modules and options installed. (For more details, refer to
the order code in Chapter 1.)
• Process variable, setpoint and/or valve position inputs set to accept a
milliamp input
• Relay outputs set to normally open
To alter the factory configuration of your 555, you will need to access the 555
circuit boards, and locate the jumpers and output modules on the circuit boards
(see Figure 3.1):
1. With power off, loosen two front screws, and remove them.
2. Slide the chassis out of the case by pulling firmly on the bezel.
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 INPUTTYPES
The Process Variable
The 555 accepts both voltage and milliamp process variable signals. You must
set a jumper location to specify the type of input signal. You set the particular
range in the software (see Chapter 5 for software menus, or Chapter 6 for ap-
plications).
The jumpers for the process variable are located on the Microcontroller Circuit
Board (see Figure 3.2). ThefactorydefaultisMilliamp. Locations are marked
as follows:
VVoltage
MA Milliamp
Figure 3.1
Accessing the 555 Circuit Boards
NOTE:
If you would like your controller
configured at the factory, please
consult an application engineer.
NOTE:
Any changes you make to the output
modules will render the code on the
product label invalid.
MICROCONTROLLER
BOARD
POWER SUPPLY
BOARD
OPTION
BOARD
NOTE:
Your hardware configuration will
influence the available software
options as discussed in Chapter 3.

Hardware
8Chapter 3 555 User's Manual
TheRemoteSetpoint
Figure 3.2 shows the location of the remote setpoint jumper. Thefactorydefault
isMilliamp.Choose from the following settings:
VVoltage
MA Milliamp
Mechanical Relays
There are three output module sockets on the Power Supply Circuit Board,
and one output module on the Option Board (see Figure 3.2). The mechani-
cal relay on the Power Supply Board may be configured for either normally
open (NO) or normally closed (NC). A jumper located next to each socket de-
termines this configuration. All the relay outputs are factory set to NO
(normallyopen).
Female 44-Pin Connector
NO J1 NC NO J2 NC NO J3 NC
Module
Retention
Plate
over Outputs 1,2,3
Jumpers
NO and NC
1
2
3
4-Pin Connector
Male 22-Pin
Connector Male 22-Pin
Connector
Male 44-Pin
Connector
4
Output 4
5-Pin Connector V
MA
TC
RTD
TC
TB1
PV1 2ND
TB2
V
MA
Female 22-Pin ConnectorFemale 22-Pin Connector
Comm Module
BATTERY
BATTERY
EPROM
EPROM
Figure 3.2
(from the top) The Microcontroller
Circuit board, The Option Board,
and the Power Supply Board

555 User's Manual Chapter 3 9
Hardware
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.
5. Find the new location of the jumper connector (again, refer to Figure 3.2).
Carefully place it over the pins, then press connector straight down. Make
sure it is seated firmly on the pins.
6. Make any other jumper changes as needed. If you need to alter output
modules, please refer to the next section, starting with Step #3.
7. To reassemble 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 insert and align screws. Tighten them until the bezel is seated firmly
against the gasket. Do not overtighten.
4. Remove Jumpers

Hardware
10 Chapter 3 555 User's Manual
ADDING AND CHANGING OUTPUT MODULES
The 555 has provisions for four output modules. A controller ordered with
output module options already has the modules properly installed. Follow
these instructions to add modules, change module type(s) or change module
location(s).
Equipment needed: Wrist grounding strap
Phillips screwdriver (#2)
Small flat blade screwdriver
Wire cutters
1. With power off, loosen two front screws, and remove them.
2. Slide the chassis out of the case by pulling firmly on the bezel.
3. Use a flat screwdriver to carefully pry apart the clips that hold the front
face assembly to the chassis, as in Photo 3. Separate the printed circuit
board assembly from the front face assembly. Use care not to break the
clips or scratch the circuit boards.
4. As shown in Photo 4, use your hands, or the flat screwdriver, to carefully
pry apart the smaller Option board and the Power Supply board (the one
with 3 modules).
5. If you need to change modules 1, 2 or 3:
Output modules 1, 2, and 3 are firmly held in place by a retention plate
and tie wrap. Carefully snip the tie wrap with a wire cutter. To prevent
damage to the surface mount components, ALWAYS snip the tie wrap on
TOP of the Retention Plate, as shown in Photo 5.
Remove the retention plate.
3. Pry Clips 4. Separate Boards 5. Remove Retention Plate

555 User's Manual Chapter 3 11
Hardware
6. If you need to change module 4:
Output Module 4 (on the Option board) is also held in place by a tie wrap.
Snip tie wrap to remove module as shown in Photo 6.
7. Figure 3.3 shows a representation of an output module. Inspect your
module(s) to make sure that the pins are straight.
8. To install any module, align its pins with the holes in the circuit board, and
carefully insert the module in the socket. Press down on the module until
it is firmly seated; refer to Photo 8.
9. Replace tie wraps for all the modules (the Retention Plate and Output
Module 4) with new ones before you reassemble.
Failure to use the tie wraps may result in loosening of the module and
eventual failure. All separately ordered modules should come with a tie
wrap. Extra sets of tie wraps are available by ordering Part #555-665.
10.Rejoin the circuit boards by aligning the pins of their connectors, then
squeezing the board(s) together. Make sure that all three printed circuit
boards are properly seated against one another; check along side edges
for gaps. Make sure the cable assemblies are not pinched.
11.To reattach the board assembly to the front face assembly, align the
boards (with the open area on top) into the slots of the font face 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
6. Snip Tie Wrap 8.Add/ChangeModule
Figure 3.3
Output Module
NOTE: For greatest accuracy,
calibrate all milliamp modules added
for retransmission as per the
instructions in Appendix B.

Hardware
12 Chapter 3 555 User's Manual
A special communications module is available for the 555; see order code in
Chapter 1 for details.
Equipment needed: Wrist grounding strap
Phillips screwdriver (#2)
Small flat blade screwdriver
1. Before you install the communications module, set up the hardware wiring
for your application. See Chapter 4 for details.
2. With power off, loosen two front screws, and remove them.
3. Slide the chassis out of the case by pulling firmly on the bezel. Do not detach
the board assembly from the front face of the controller.
4. Orient the Communications Module with the arrow pointing towards the rear
of the 555 unit, and attach it to Connectors P1 and P2 as shown in Figure
3.4.
5. To reassemble the controller, properly orient the chassis with board open-
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.
6. Carefully insert and align screws. Tighten them until the bezel is seated firmly
against the gasket. Do not overtighten.
Figure 3.4
Install Communications Module onto
MicrocontrollerBoard
V
MA
2ND
(REMOTE SP
OR
DIGITAL INPUT)
CONFIGURATION
TC
TB2
EPROM
BATTERY
P1
P2
Insert module onto connectors.
Make sure arrow on module
points toward rear terminals.
Front of controller
(circuits boards still attached to front face)

555 User's Manual Chapter 4 13
Installation
MOUNTING BRACKET
(1 EA. SIDE)
CHAPTER 4
INSTALLATION
MOUNTINGTHE 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 in any
panel with a thickness from 0.06 in. to 0.275 in. (1.5mm to 7.0mm).
2. Figure 4.1 shows controller and panel dimensions. The panel cutout must
be precise, and the edges free from burrs and waves.
3. Place a new bezel gasket around the controller case, starting at the back of
controller. Then, slide the gasket up against the back of the bezel. To en-
sure a good seal, always use a fresh gasket.
4. With the bezel gasket in place, insert the 555 into the panel cutout from the
front of the panel. The case of the controller must be centered in the cutout.
5. From behind the panel, insert the mounting clips (one on each side), as
shown in Figure 4.2.
BEZEL HOUSING
Figure 4.2
Insert Mounting Clips
3.770 (95.76)
3.770 (95.76)
1.180 (29.97)
6.000 (152.40)
7.180 (182.37) OVERALL LENGTH
3.585 (91.06)
PANEL
SIDE
BEZEL
GASKET
3.622 (92.00) MIN.
3.653 (92.80) MAX.
3.622 (92.00) MIN. 3.653 (92.80) MAX.
CUTOUT
FRONT
OUT
1 2
ALM
1 2
Slide
gasket on
from this
end.
Figure 4.1
ControllerDimensions

Installation
14 Chapter 4 555 User's Manual
6. Gradually tighten the mounting bracket screws with a long Phillips screw
driver (#2). Make sure the screws are secure, and check the bezel gasket
for a tight, even seal.
7. If you have difficulty with any of the mounting requirements, apply a bead of
caulk or silicone sealant behind the panel around the perimeter of the case.
WIRING FOR INPUT AND OUTPUTS
555 controllers are thoroughly tested, calibrated and “burned in” at the factory,
so your controller is ready to install. Before you begin wiring your system, read
this section thoroughly and take care in planning your system. A properly de-
signed system can help prevent problems such as electrical noise disturbances
and dangerous extreme conditions.
Special Notes:
1. For improved electrical noise immunity, install the 555 as far away as pos-
sible from motors, relays and other similar noise generators.
2. Do not run low power (sensor input) lines in the same bundle as AC power
lines. Grouping these lines in the same bundle can create electrical noise
interference.
3. All wiring and fusing should conform to the National Electric Code and to
any locally applicable codes.
4. An excellent resource about good wiring practices is the IEEE Standard No.
518-1982 and is available from IEEE, Inc., 345 East 47th Street, New York,
NY 10017, [phone].
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.
1
2
3
4
5
6
7
816
15
14
13
12
11
10
917
18
19
20
21
22
23
24 32
31
30
29
28
27
26
25
LINE
NEUTRAL
OUT 1–
OUT 1+
OUT 2–
OUT 2+
OUT 3–
OUT 3+
EARTH
GND
S/W
CCW
S/W2
S/W3
RSP–
RSP+
OUT 4–
OUT 4+
DIN
GND
DIN 1
DIN 2
DIN 3
DIN 4
DIN 5
RS485–
RS485+
PV2–
PV2+
N/A
PV1–
PV1+
N/A
N/A
N/A
AC Power
Dual Flow Pacing:
SO2 valve output (4-20mA or Relay)**
Alarm Relay/Retransmission:
2nd staged output (4-20mA)**
2nd slidewire output (relay)**
Digital Inputs Option (if installed)Slidewire Option Input
Remote Set Point Option Input
RS485 Com
(if installed)
Flow Pacing, Residual, Compound Loop:
CL2 valve output (4-20mA or Relay)**
Dechlorination:
SO2 valve output (4-20mA or Relay)**
Alarm Relay/ Retransmission**
Alarm Relay/ Retransmission**
Flow signal input
4-20mA from transmitter
CL2 signal input
4-20mA from analyzer
** Outputs 1, 2, 3 and 4 must be filled
with appropriate modules. See Chapter 3.
Figure 4.3
555 Input and Output Wiring
Options

555 User's Manual Chapter 4 15
Installation
AC Power Input
Terminals 1 and 2 are for POWER. Terminal 9 is earth ground. Use a 0.5
Amp, 250 V fast-acting fuse in line with your AC power connection.
ProcessVariables
The 555 uses up to two process variables depending on the control mode:
PV1 is for Cl2 residual level, and PV2 is for flow (rate). Each PV signal can be
either voltage or milliamp input.
1. Voltage Input (Figure 4.5)
•PV1 uses terminals 31 and 32 connected to a transmitter.
•PV2 uses terminals 28 and 29 connected to a transmitter.
Transmitter
1
2
3
4
5
6
7
816
15
14
13
12
11
10
917
18
19
20
21
22
23
24 32
31
30
29
28
27
26
25
PV1–
PV1+
–
+
Screws must be tight to ensure electrical connection
1
2
3
4
5
6
7
816
15
14
13
12
11
10
917
18
19
20
21
22
23
24 32
31
30
29
28
27
26
25
Screws must be tight to ensure electrical connection
Transmitter
PV2–
PV2+
–
+
1
2
7
816
917
24 32
31
25
AC LINE
AC NEUTRAL
EARTH
GND
Screws must be tight to ensure electrical connection
Figure 4.4
AC Power Input Wiring
Figure 4.5
PV Voltage Input Wiring
Note:
On the actual 555, the only
terminals with printed numbers are
those shown in Figure 4.4.