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.