HI 504 Panel-mounted, Microprocessor-based pH/ORP Process Controller Instruction Manual
TABLE OF CONTENTS WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MODEL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . 5 PRELIMINARY EXAMINATION . . . . . . . . . . . . . . . . . . 6 GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . 6 FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . 8 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MECHANICAL DIMENSIONS . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . .
WARRANTY All Hanna Instruments meters are guaranteed for two years (sensors, electrodes and probes for six months) against defects in workmanship and materials when used for their intended purpose and maintained according to instructions. This warranty is limited to repair or replacement free of charge. Damage due to accident, misuse, tampering or lack of prescribed maintenance are not covered. If service is required, contact the dealer from whom you purchased the instrument.
PRELIMINARY EXAMINATION Remove the instrument from the packing material and examine it carefully to make sure that no damage has occurred during shipping. If there is any noticeable damage, notify your Dealer or the nearest Hanna Customer Service Center immediately. Note Save all packing materials until you are sure that the instrument functions correctly. Any damaged or defective items must be returned in their original packing materials together with the supplied accessories.
FUNCTIONAL DESCRIPTION REAR PANEL FRONT PANEL 1. Liquid Crystal Display 2. LCD key enters and exits the event scrolling mode. During pH calibration, alternately displays pH buffer value or current temperature 3. SETUP key enters and exits setup mode 4. CAL DATA key last calibration data viewing (enters and exits) 5. CAL key initiates and exits calibration mode 6. æ key increases the blinking digit/letter by one when selecting a parameter.
SPECIFICATIONS Range -2.00 to 16.00 pH -2000 to 2000 mV -30 to 130.0 ºC Alarm Relay Electromechanical Relay SPDT contact output, 5A - 250 VAC, 5A - 30 VDC (resistive load) Fuse protected: 5A, 250V Quick Blow Fuse Resolution 0.01 pH 1 mV 0.1 ºC above -10 ºC; 1 ºC below Analog Output • 2 independent outputs • 0 - 22 mA (configuring as 0-20 mA or 4-20 mA) Accuracy ±0.02 pH ±2 mV ±0.5 ºC (-9.9 to 130.0 ºC); ±1 ºC (-30 to -10 ºC) Analog Output Resolution 0.1‰ f.s. Analog Output Accuracy ± 2‰ f.s.
INSTALLATION Refer to diagram on page #9 Note Note • Input power: Connect a 3-wire power cable to the terminal strip line (L), earth (PE) and neutral (N) terminal connections. Note Note • Electrode: Connect the pH or ORP electrode to the BNC socket (#1 at page 9).
The pH and ORP calibrations can not be initiated while the process controller is configurated to take measurements from the Digital Transmitter. CALIBRATION MODE The calibration mode allows to calibrate the pH/ORP input, temperature input and 4-20 mA analog outputs. The controller is factory calibrated for all these parameters. Periodical calibration of the instrument is recommended, in particular when greatest accuracy is required and at least biyearly.
• In the second case (pH value not close to the buffer) the meter will remain in the same state until the reading becomes unstable or the calibration mode is quitted. The default buffer set is the one used for last calibration, even if the procedure was not completed. • Once confirmed the set of buffer values, the primary LCD shows the measured pH value, while the secondary LCD displays the first required buffer value. • For the second buffer value it is possible to choose between pH 4.01 and pH 10.
• When the reading becomes stable, if the ORP value is close to the calibration point, the “CFM” indicator starts blinking; otherwise the “WRONG” indicator blinks and the “CAL” is fixed on. • In the first case press CFM to confirm calibration. The meter will proceed showing the scrolling message “Press CFM again to confirm the current buffer or right to escape” (to prevent from confirming the calibration point inadvertently). Pressing again CFM the secondary LCD will display the second calibration point.
• Once visualized the selected output, press the key to choose the range of the analog output (0-20 mA or 4-20 mA); then press the CFM key to confirm the choice. • Once selected and confirmed the range for the analog output, the secondary LCD shows the first point of calibration (1 or 4 mA) and the primary LCD displays the range of the actual calibration. • With the tester check the real current value provided by the instrument at the output port.
is exited (by pressing the CAL key). • When performing the second calibration point, it is possible to choose between two values, 25°C and 50°C. Pressing the æ or key the value on the secondary LCD will switch between the two possibilities. • Once selected the value, immerse the temperature probe in the second beaker as near as possible to the Checktemp and the calibration procedure will be the same as for the first point.
• When the whole password has been inserted, press CFM to confirm it. SETUP MODE The Setup Mode allows the user to set all needed characteristics of the meter. To enter the mode, press the SETUP key and enter the password when the device is in idle or control mode. If the correct password is not entered, the user can only view the setup parameters (except for passwords) without modifying them (and the device remains in control mode).
Note Otherwise, if a numeric value has to be entered for the item, use the æ or key to change the value of the blinking digit and the key to cycle through the number’s digits. While in the setup mode, if no activity is performed for about 5 minutes after entering the setup mode, the mode is automatically exited and the instrument returns to the previous mode.
Code Valid Values Default Present for ORP Code Valid Values Default Present for ORP C.12 Hysteresis for setpoint 1 (H1) 0.00 to 18.00 pH or (see note 1) 0 to 4000 mV 1 pH or 50 mV yes C.51 Monday hold mode enable “OFF”: Disabled “On”: Enabled “OFF” yes C.13 Deviation for setpoint 1 (D1) 0.50 to 18.00 pH or (see note 1) 25 to 4000 mV 1 pH or 50 mV yes C.52 Tuesday hold mode enable “OFF”: Disabled “On”: Enabled “OFF” yes C.14 Reset time for setpoint 1 0.1 to 999.9 minutes 999.9 min.
Code Valid Values Default 0.05 Hold digital output “OFF”: Disabled “HOLd” “HOLd”: Enabled upon hold mode Present for ORP yes ANALOG OUTPUT #1 (“Out1”) O.10Analog output 1 mode (see notes 6, 21) “rECO”: Recorder “SEt”: Control, setpoint 1 “rECO” yes O.11Analog output 1 type “0-20”: 0-20 mA “4-20”: 4-20 mA 4-20 (6) yes yes O.13Measurement value for -2.00 to 16.00 pH 14.
Code Valid Values Default Present for ORP r.02 Current year 2000 to 2099 (see note 20) from RTC (5) yes SOLUTION COMPENSATION (“SOLC”) r.03 Current time 00:00 to 23:59 (see note 20) from RTC (5) yes CELLULAR/MODEM/PC CONNECTION (“PHOn”) Code Valid Values Default Present for ORP S.00 Solution compensation enable “On”: compensation enabled “OFF”: compensation disabled “OFF” no P.
Code Valid Values Default Present for ORP ERROR CONFIGURATION (“Erro”) 34 Code Valid Values Default Present for ORP TEST (“tESt”) E.00 Alarm for setpoint 1 error configuration 0 to 5 and 24 to 29 (see note 7) 3 yes t.00 Display test “OFF”: To skip without testing “GO”: To start the display test “OFF” yes E.01 Alarm for setpoint 2 error configuration 0 to 5 and 24 to 29 (see note 7) 5 yes t.01 Keyboard test “OFF”: To skip without testing “OFF” “GO”: To start the keyboard test yes E.
if M2 = “PIdL” then D2 R A2 and -2.00 pH or -2000 mV R S2-A2; if M1 = “OOHI” and M2 = “OOLO” then S1-H1S S2+H2; if M1 = “OOLO” and M2 = “OOHI” then S2-H2S S1+H1; if M1 = “PIdH” and M2 = “OOLO” then S1S S2+H2; if M1 = “OOLO” and M2 = “PIdH” then S1+H1R S2; if M1 = “PIdL” and M2 = “OOHI” then S1R S2-H2; if M1 = “OOHI” and M2 = “PIdL” then S1-H1S S2; if M1 = “PIdH” and M2 = “PIdL” then S1S S2; if M1 = “PIdL” and M2 = “PIdH” then S2S S1; were the minimum deviation (DN) is 0.5 pH (pH) or 25 mV (mV).
(8): The hold mode is never enabled by the control timing if the “hold time start” is the same as the “hold time end”. Items “C.41” and “C.42” apply to all days. The hold mode can be enabled all day by using items “C.51” through “C.57”. (9): See the “Temperature compensation” subsection for more details on how the Automatic temperature compensation and Manual temperature compensation work.
or PID) or low (ON/OFF or PID) setpoint respectively. The same is true for Alarm relay delta value for setpoint 2. A small fixed hysteresis (0.2 pH for pH and 30 mV for ORP) must be passed to have the alarm turned off (for a high alarm the alarm is turned off below high alarm - hysteresis, while for a low alarm the alarm is turned off above low alarm + hysteresis). (23): The actual start of a cleaning action depends on how relay 3, relay 4 and the Advanced Cleaning parameters have been configured.
CONTROL MODE The control mode is the normal operational mode for this meter.
The following graph describes the pH process controller behavior. Similar graph may apply to the mV controller. sure falls below setpoint value minus hysteresis. Such a behavior is suitable to control an acid dosing pump. ON t0 Setpoint 14 A relay enabled as a low setpoint, is energized when the pH value is below the setpoint and is de-energized when the pH value is above the sum of setpoint and the hysteresis. This operational mode may be used to control an alkaline dosing pump.
PID TRANSFER FUNCTION The transfer function of a PID control is as follows: Kp + Ki/s + s Kd = Kp(1 + 1/(s Ti) +s Td) with Ti = Kp/Ki, Td = Kd/Kp, where the first term represents the proportional action, the second is the integrative action and the third is the derivative action. Proportional action can be set by means of the Proportional Band (PB). Proportional Band is expressed in percentage of the input range and is related to Kp according to the following: Kp = 100/PB.
pH or mV value. Read the system time delay Tx on the time axis. 4. The deviation, Ti and Td can be calculated from the following: • Deviation = Tx * max. slope (pH or mV) • Ti = Tx / 0.4 (minutes) • Td = Tx * 0.4 (minutes). 5. Set the above parameters and restart the system with the controller in the loop. If the response has too much overshoot or is oscillating, then the system can be fine-tuned slightly increasing or decreasing the PID parameters one at a time.
and the external alarm circuit. Note In order to have the Fail Safe feature activated, an external power supply has to be connected to the alarm device. CONTROL THROUGH ANALOG OUTPUT Instead of configuring relays, it is possible to have an output signal (selectable among 0-20 mA and 4-20 mA) proportional to the PID action at the analog output terminals.
• Hold mode end delay (set by item C.70): if the device was controlling when the cleaning action started, then the hold mode end delay must expire before restarting control. Advanced cleaning actions are performed in the following order: • Pre-rinsing time: the device enters hold mode and relay 3 is energized. If the device is in normal measurement mode, the “PrE-rinSinG” message scrolls on the LCD. • Detergent washing time: relay 4 is energized (and relay 3 continues to be energized).
IDLE MODE HOLD MODE During idle mode the device performs only measurements but it does not activate relays in order to control the process or let out a control signal to the analog output. In a normal situation the alarm relay is energized (no alarm condition) and the green LED is ON, the red LED is also fixed ON to warn users the device is not controlling the process, the yellow LEDs are OFF.
ANALOG OUTPUT All the alarm signals (red LED, alarm relay, fault currents) are suspended while in hold mode (the correspondent error events are not closed), unless the hold mode is being triggered by one or more errors and no other trigger source (different from an error) is active. The analog output follows these rules: • if it is configured for control (i.e. setup item O.10 or O.20 set to “SEt”), its value is set to the minimum (e.g.
PC COMMUNICATION CONNECTIONS The connections for the 6-pin RS485 terminal provided are as follows: RS485 standard is a digital transmission method that allows long lines connections. Its current-loop system makes this standard suitable for data transmission in noisy environments.
Line conditions, pull-up and pull-down resistors should be connected as shown. The Fail-Safe resistors are connected only to one unit in the line, and their value depends on the application and characteristic impedance of the connection cable. The GND pin of the interface connector and all the interface signals are optoisolated from the ground of the instrument, the electrode and the temperature sensor. Before connecting the meter to the computer, consult the computer manual.
Command Parameter Following are examples for setup item format: Remarks NNEVN not available Requests new events (always available) NNAER not available Requests active errors (always available) NNCLS not available To start advanced cleaning (always available) NNCLP not available To abort cleaning (always available) NNHLD not available To enter/exit the hold mode (always available; pwd required) NNKDS null Same as LCD key NNKCD null Same as CAL DATA key NNKUP null Same as æ key NN
4) “NN”, CAN (char 0x18) if the process controller can not answer to the request (e.g. the current process model does not support the request, the given general password is wrong, etc.) The “NN” in the front of the answer is the Process ID (“00” to “99”). The time-out for the above answers is: 1) answer to “STS”, “PHR”, “MVR”, “TMR”, “AER” commands: 30 ms @ 19200 or 9600 bit/s, 40 ms @ 4800 bit/s, 60 ms @ 1200 bit/s (for the complete answer, from STX to ETX).
B2 B2 B2 B2 B2 B1 B1 bit 3 bit 4 bit 5 bit 6 bit 7 bit 0 bit 1,2 B1 bit 3 B1 bit 4 B1 bit 5 B1 B1 bit 6 bit 7 ON; bit 2 = 1 and bit 1 = 1: LED blinks) relay #1 (1: energized, 0: de-energized) relay #2 (1: energized, 0: de-energized) relay #3 (1: energized, 0: de-energized) relay #4 (1: energized, 0: de-energized) hold digital output (1: ON, 0: OFF) control (1: ON, 0: OFF) setup mode (bit 2=0 and bit 1=0: not in setup mode; bit 2=1 and bit 1=0: setup mode, view only; bit 2=1 and bit 1=1: setup mode
• for calibration events: date and time of a calibration; • for cleaning events: start date and time of cleaning action. The meaning of “end_datei” and “end_timei” is: • for errors: end date and time if the error is not active anymore; • for setup events: no meaning; • for calibration events: no meaning; • for cleaning events: no meaning.
The meaning of B1, B2, B3 is: B3 bit 0 Alarm for setpoint 1 B3 bit 1 Alarm for setpoint 2 Maximum relay ON time exceeded B3 bit 2 B3 bit 3 Life check error B3 bit 4 pH electrode broken or leakage B3 bit 5 Reference electrode broken or leakage B3 bit 6 Old pH probe B3 bit 7 Dead pH probe B2 bit 0 Calibration time-out B2 bit 1 Temperature probe broken B2 bit 2 free for future use (and set to 0) B2 bit 3 Digital transmitter error B2 bit 4 Power reset B2 bit 5 EEPROM corruption B2 bit 6 Watchdog reset B2 bit 7
When the desired phone number is entered, press CFM to confirm. The WRONG tag will blink if the user tries to confirm an incorrect number (the first digit of the number has to be on the first position and the “-” character have not to be present in the middle of the number). The WRONG tag will disappear only when a digit of the phone number is modified. By pressing the key, the first digit will be fixed on and it will be possible to select the next digit.
Note the cellular module initialized and the SMS service activated. During the reading of the SIM card, “CELL” and the MEM tag will blink alternatively on the LCD. Otherwise, if the instrument does not find any correct number, then it will not be possible to activate the SMS service and the WRONG tag will blink on the LCD. If the PIN set in P.01 is wrong, then it will be not possible to confirm the cellular module connection.
and no confirmation waited), while the P.06 item sets the delay (in minutes) between two subsequent messages. When the instrument receives a phone call (coming from one of the programmed cellular numbers), it interprets the calling as an information request and answers hanging up and sending an SMS with its current status report (number of remaining messages, pH or ORP and temperature values, current active errors). The message will be as for example: “Rem_msg: 150; pH: 8.32; Temp: 25.8; Alr set1; Rel on”.
reset when the expiration date is changed. If the expiration date is reached without any updating of the items P.07 - P.09, then the “Cellular error” will be switched on and no more messages will be sent by the instrument until the error is disactivated. To disactivate this error it is necessary to update the SIM expiration date. If the user has unlimited credit on the SIM card, the item P.04 has to be set to “222”, which is interpreted by the instrument as unlimited number of SMSs that can be sent.
The modem connection (both with HI504900 and HI504902) allows the user to ask the controller from a remote position about its status, measurements and to change some parameters, while for receiving alarm indications it is necessary to install the HI504900 cellular module. Many devices can be monitored through a remote modem connection, simply connecting all the devices and the modem or cellular module to the same RS485 network. When making a call, after the data connection is established, the “NNPWD...
pH/ORP PROBE CHECK Note Note 82 The pH electrode and the reference electrode for both pH and ORP can be automatically monitored through HI 504. Setup items involved are I.13 (pH electrode impedance test enable), I.14 (reference electrode impedance test enable), I.15 (maximum reference electrode impedance) and I.04 (potential matching pin enable). A “pH electrode broken or leakage error” (error code: 10) is generated whenever the pH electrode impedance is less than approximately 1 MΩ.
For quickly changing the temperature value press and hold down the æ (or ) key: the temperature will be incremented (decremented) of 0.1°C until the total amount is 0.4°C, and then the increment (decrement) will turn to 1°C. During these operations both the temperature value displayed and setup item G.02 are updated (the last one is updated with a maximum delay of 10s). TEMPERATURE COMPENSATION If the setup item G.
Pressing the key, the meter will cycle through the following steps in reverse order, i.e. beginning from last buffer. LAST CALIBRATION DATA If the meter is set as pH controller, the following data about the last calibration are stored in the EEPROM: • Date • time • offset, in mV • slope, in mV/pH • up to two buffers. If the meter is set as ORP controller, the data stored in the EEPROM are the following: • Date • time • first calibration point • second calibration point.
• If an offset calibration has been made, the instrument will turn to “slope” calibration (as indicated by the “SLO” message on the secondary display. The slope value is shown on the primary LCD and the first digit is blinking to permit modifications). • Press the æ or key to modify the value or key to move to the next digit. • Once selected the desired value, press CFM to confirm. • After confirmation the instrument will turn back to normal mode.
• for cleaning events: • start date • start time • type of cleaning (“AdCL” for advanced cleaning; “SICL” for simple cleaning). Once entered the log event scrolling, press the æ or key to move through the events. If the event is an error still active, the error code on the primary LCD will blink, otherwise it will be fixed. To have a look at the additional information of a selected event press the key (it will cycle through the additional information).
If the error is due to impossible communication with the EEPROM or the RTC, all the pH/ORP controller tasks are stopped, the alarm relay is de-energized, the red LED blinks and the “Serial bus error” slides forever (repair can not be postponed). FAULT CONDITIONS The below fault conditions may be detected by the software: • EEPROM data error • serial communication internal bus failure • software dead loop.
• The display test is announced by a scrolling “Display test” message. For example, if SETUP and æ keys are pressed together the LCD will look like this: • All the segments light up for a few seconds and then switch off before exiting the display test procedure and moving to the next setup item (t.01). KEYBOARD TEST • To enter the keyboard test procedure select setup item t.01. A blinking “OFF” message will appear on the primary LCD.
• During this time the instrument performs the EEPROM check, and if the checksum is correct, the “Stored data good” message will scroll on the primary display. • After that, the meter will remain in setup menu and move to the next setup item. • If the checksum fails, a fault alarm is generated and the following message appears on the LCD: “Stored data error - Press “UP” button to reset stored data or “RIGHT” button to ignore”.
value of the analog output type chosen with setup item O.11 (analog output 1) and O.21 (analog output 2). • A new output value can be edited manually. It is possible to change the value of the first blinking digit by pressing the æ or key. • To move to the next digit press the key once; the first digit will be fixed and the second one will start blinking. • Pressing repeatedly the key will result in cycling through the digits on the primary LCD.
ing (setup item L.14). • To exit the test press the CFM key; the instrument will remain in the setup menu and move to the next setup item (t.08). Note ALARM - ERROR CONFIGURATION During the test the relays are activated, the primary LCD will always show the “ACLE” message and on the secondary display will be shown the actual status of the digital input (“On” or “OFF”). WATCHDOG TEST This test executes a dummy dead loop that causes a watchdog reset signal to be generated.
with the cellular engine (for example because the serial cable is broken or because the cellular engine is not powered), if the number of available SMS is finished (menu item P.04) or if the SIM expiration date is overrun. • The “Power reset” and the “Watchdog reset” errors are active only for the short time of the start-up session (selftests, process name and version displaying). That start-up session ends when the first measurement is acquired and displayed.
pH VALUES AT VARIOUS TEMPERATURES Temperature has a significant effect on pH. The calibration buffer solutions are effected by temperature changes to a lesser degree than normal solutions. For manual temperature calibration please refer to the following chart: TEMP °C °F 32 0 41 5 10 50 15 59 20 68 25 77 30 86 35 95 40 104 45 113 50 122 55 131 60 140 65 149 70 158 4.01 4.01 4.00 4.00 4.00 4.00 4.01 4.02 4.03 4.04 4.05 4.06 4.07 4.09 4.11 4.12 6.86 6.98 6.95 6.92 6.90 6.88 6.86 6.85 6.84 6.84 6.83 6.83 6.
- Make sure cable and connections are not damaged nor lying in a pool of water or solution. • Slow Response/Excessive Drift: soak the tip in Hanna Solution HI 7061 for 30 minutes, rinse thoroughly in distilled water and then follow the Cleaning Procedure above. • For ORP Electrodes: polish the metal tip with a lightly abrasive paper (paying attention not to scratch the surface) and wash thoroughly with water. PERIODIC MAINTENANCE Inspect the electrode and the cable.
DEFINITIONS ACCESSORIES DEVIATION pH CALIBRATION SOLUTIONS Same as proportional band, but expressed in units of the controlled magnitude (e.g. 1pH, 50 mV). EEPROM Electrically Erasable Programmable Read-only Memory (permanent memory). FAIL SAFE ALARM Signaling of the alarm by de-energizing the alarm relay instead of energizing it. That protects against power failures and interruptions of the alarm relay external wires. GLP Good Laboratory Practice.
pH AND ORP ELECTRODE HOLDERS HI 7611 HI 7621 HI 60542-0 HI 60545-0 HI 60501-0 HI 605011 1 set of O-rings for HI 60542 electrode holder 1 set of O-rings for HI 60545 electrode holder 1 set of O-rings for HI 60501 electrode holder PVC mounting flange for HI 60501 electrode holder HI 8427 HI 931001 HI 931002 HI 8614 HI 8614L HI 8615 HI 8615L pH / ORP Electrode Simulator pH / ORP Electrode Simulator with LCD Display 4-20 mA Simulator pH Transmitter pH Transmitter with LCD ORP Transmitter ORP Transmitter w
HI 60501 Immersion electrode holder for tanks, vessels, baths and open channels pH AND ORP ELECTRODES Hanna Instruments produces a wide range of pH and ORP electrodes specifically designed for needs of industrial uses. For a complete list of available electrodes visit our web site at www.hannainst.com or contact your dealer.
CE DECLARATION OF CONFORMITY UNDERWRITERS LABORATORIES APPROVAL The HI 504 process controllers series complies with the production standards required by the Underwriters Laboratories (UL), one of the most important international authority for devices' safety, and has therefore obtained the UL certification. Recommendations for Users Before using these products, make sure that they are entirely suitable for the environment in which they are used.
SALES AND TECHNICAL SERVICE CONTACTS MAN504R5 05/05 Australia: Tel. (03) 9769.0666 • Fax (03) 9769.0699 China: Tel. (10) 88570068 • Fax (10) 88570060 Egypt: Tel. & Fax (02) 2758.683 Germany: Tel. (07851) 9129-0 • Fax (07851) 9129-99 Greece: Tel. (210) 823.5192 • Fax (210) 884.0210 Indonesia: Tel. (21) 4584.2941 • Fax (21) 4584.2942 Japan: Tel. (03) 3258.9565 • Fax (03) 3258.9567 Korea: Tel. (02) 2278.5147 • Fax (02) 2264.1729 Malaysia: Tel. (603) 5638.9940 • Fax (603) 5638.9829 Singapore: Tel. 6296.
