Hanna Instruments HI510 Universal Process Controllers Instruction Manual

: June 11, 2024
: HANNA instruments

Table of Contents

Single and DualChannel Universal Process Controllers
Features Displayed on Screen (HI520 display shown)
Inputs and Outputs
Data and Event Logging
Enclosure Features
Panel-Mount
Wall-Mount
Pipe-Mount
Specifications
Ordering Information
ORP and Temperature Industrial Smart Probes
- Dimensions
pH and Temperature Industrial Smart Probes
Documents / Resources

Hanna Instruments HI510 Universal Process Controllers

Single and DualChannel Universal Process Controllers

Waterproof IP65 (NEMA 4X) enclosure
Large backlit LCD
Multi-color LED status indicators
Audible alarm
Tactile rubberized keypad
Universal mounting
Universal Hanna digital probe

HI510 and HI520 are advanced process controllers that can be configured for applications requiring monitoring and/ or control of four main water-analysis parameters: pH, ORP, Conductivity, and Dissolved Oxygen.

These controllers feature a digital probe input(s) that automatically detects and updates the controller with the parameter that it measures.

HI520 is Hanna’s first dual-input process controller that accepts virtually any combination of compatible probes.

Designed to adapt to unique process control requirements, users have the option to enable or disable each channel independently.

Additionally, HI520 introduces enhanced industrial control by operating a control-loop system whereby users have the option to run channel control either independently or configure to be triggered sequentially upon reaching the other channel’s set point(s) (1, 2, or both). The device operates a logical channel with built-in mathematical functions.

This function is intended for when the controller works as an analyzer for monitoring high/low parameter levels between two identical inputs with identical measuring configurations.

These Universal Process Controllers offer wall, pipe, and panel mounting options and feature a large backlit dot matrix display for easy viewing and provide an intuitive interface for setup options.

The controllers utilize multi-color LEDs for easy viewing of the instrument’s status including relay activation, in alarm mode, or in hold status. All programming operations are done through the low profile vulcanized rubber keypad or with an RS485 connection to a Modbus-compliant supervisory computer

Features Displayed on Screen (HI520 display shown)

Control Modes
The control mode can be configured to be On/Off, Proportional, or PID.
The mode can be set high or low. High control mode is required if the process value is too high and needs to be decreased. Low control mode is required if the process value is too low and needs to be increased.
For On/Off control, the hysteresis band is adjustable, while in Proportional and PID modes, deviation, control period, and other tuning parameters can be set to optimize control around a set point.
For HI520, each channel can run control independently or sequentially.
Features Displayed on Screen

Hold Function
During calibration, cleaning, and configuration the controller automatically goes into Hold mode. During Hold mode all control loops related are disabled. The analog outputs may be configured to go to a fixed value or remain at the last value.
The Hold function can also be triggered manually, using an external digital input or by entering in Manual mode. This is useful for disabling control when performing maintenance.
Features Displayed on Screen

Auto-Cleaning Cycle
Difficult applications often require an almost continuous maintenance of the probe. Processes with high-suspended solids, fats, oils, pigments, and microorganisms will coat the pH sensing glass, ORP sensors, and the reference junction. The cleaning function allows programming of one or more wash cycles and uses the relays to activate valves, pumps or compressed air based on the type of washing that is required to maintain probes for reliable results.
Features Displayed on Screen

Configurable Alarm System
The alarm system is configurable for measured parameters. The alarm can also be activated by event triggers or abnormal operation. For example, if a dosing relay remains closed for an excessive period of time or if temperature exceeds an upper limit during an exothermic neutralization reaction. A blinking red LED signals an alarm state.
All relays configured for control are inactivated until the alarm state is resolved.
On HI520 use channel configuration to setup and trigger an alarm.
Features Displayed on Screen

LCD Information
Local visual indicators of measurement details as well as errors are displayed. The ? DIAG key provides details of the issue.
Features Displayed on Screen

? DIAG – Help and Diagnostic Key
The help and diagnostic key (? DIAG) provides information related to errors; or in setup mode, information about settings.
Features Displayed on Screen

Inputs and Outputs

Digital Inputs

Two digital inputs for remotely triggering, cleaning and hold functions

Analog Outputs

Up to 4 analog outputs and 5 relays used for control and for sending a signal to data loggers, PLC, SCADA and other remote monitoring systems
0-20 mA or 4-20 mA
Scalable in selecting values for the range
Can be used for control of pumps and valves
On alarm state can output a 22 mA signal to the monitoring system

Digital Communication

The Modbus-compliant unit can be integrated within a Modbus-based network and connected to other industrial electronic devices. The following tasks may be accomplished remotely:
· Monitoring, using the virtual LCD (limited to a single remote control in the entire network)
· Setup
· Loading the Setup configuration file to a controller
RS485 Digital output for PC and other device connectivity

Relays

Up to 5 control and 1 alarm electromechanical relays
Replaceable 5A fuses to protect all relays
Extractable terminal blocks for easy wiring
Relay options include single pole double throw (SPDT) and single pole single throw (SPST)
Control relays can be programmed for On/Off, Proportional, or PID control as well as Cleaning and Hold functions
Configurable alarm relay
Relays terminal blocks and their wires paths are separated from the low voltage section for additional safety

Data and Event Logging

Automatic Data-logging
HI510 and HI520 have built-in data logging that stores data at selectable intervals along with relay control settings and calibration data.

Data stored in up to 100 lots with each holding 8600 records
Selectable log interval: from 10 seconds to 3 hours
Logged Data includes:
- Measured values and alarms for all supported parameters
- Calibration information including solutions used. For pH, the offset and slope is recorded.

Event Log
The Event Log file can hold a maximum of 100 events. It includes errors, alarms, warnings, calibration events, configuration changes, and cleaning events.

Password protection
The controllers feature password protected calibration and setup.

Enclosure Features

NEMA 4X Enclosure
The controllers are suitable for indoor or outdoor environments. The NEMA 4X enclosure ensures the electronics are protected against splashing and hose- directed water or windblown dirt, dust, rain or sleet. It also provides corrosion protection for use near salt water.

Cable Glands
To maintain the NEMA 4X enclosure rating during use, the conduit openings and connection cables are sealed against the environment using the provided cable glands, seals, and plugs.
Enclosure Features

Spring Loaded Screws
The front panel is hinged at the front of the enclosure for easy access to wiring locations.
It features spring loaded screws that won’t fall out when accessed.
Enclosure Features

USB Type-C Port
Logged data can be transferred to a flash drive as a .csv file using the USB Type-C port.
A rubberized plug helps protect the port against the ingress of water.
Enclosure Features

Panel-Mount

HI510-01 Panel-Mount Kit

The controllers can be securely panel mounted through a ½ DIN opening using the HI510-01 Panel-Mount Kit. The kit includes a sealing gasket, dual zinc coated brackets, and associated hardware.

Wall-Mount

The controllers can be surface mounted using the HI510-02 WallMount Kit. The kit includes a zinc coated mounting plate and associated hardware. The plate may be oriented vertically or horizontally.

HI510-02 Wall-Mount Kit

Pipe-Mount

The controller can be mounted to a vertical or horizontal pipe using the HI510-03 Pipe-Mount Kit. The kit includes a zinc coated mounting plate, associated hardware, and U-bolts to accommodate a 1”, 1 ½”, or 2” pipe.

Specifications

Specifications	HI510	H1520
Digital Probes	See the following pages
Channels	1	2
Display	Graphic LCD, 128 x 64 pixel B/W with backlight
Digital Inputs	2 independent galvanically isolated inputs (conf igurable for

Hold ET Cleaning functions) On state: 5 to 24 Vdc, low or high level active
Analog Outputs| 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

Analog Output Accuracy| ±0.2%f.s.
Digital Communication| R5485 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 SPOT and PST contact outputs

SA – 250 Vac; SA – 30 Vdc (resistive load) Fuse protected:5A, 250V slow blow fuse

Alarm Relay for All Measurement Alarms| Electromechanical relay SPOT contact output SA – 250 Vac; SA – 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
Environment| -20 to 50 °C (-4 to 122 °F); maximum 100% RH non-condensing
Enclosure”| Single case V2 DIN, type 4X, IP65 ingress protection
Weight| Approximately 1.6 kg (3.5 lb.)
Dimensions| Width:144.0 mm (5.7″) Height:144.0 mm (5.7″) Depth:151.3mm (6.0 “)
Ordering Information| HI510-0540 universal process controller with 5 relays and 4 analog outputs is supplied with 3m power cable, cable gland set, instrument certificate, and quick reference guide with instructions for manual download.

H1510-0320 universal process controller with 3 relays and 2 analog outputs is supplied with 3m power cable, cable gland set, instrument certificate, and quick reference guide with instructions for manual download.

HI520-0540 universal process controller with 5 relays and 4 analog outputs is supplied with 3m power cable, cable gland set, instrument certificate, and quick reference guide with instructions for manual download.

H1520-0320 universal process controller with 3 relays and 2 analog outputs is supplied with 3m power cable, cable gland set, instrument certificate, and quick reference guide with instructions for manual download.

Accessories| HI510-01 panel-mount kit| HI76510-10 patch cable, 10 m (32’91
HI510-02 wall-mount kit| HI76510-15 patch cable,15 m (49’2 “)
HI510-03 pipe-mount kit| H176510-25 patch cable, 25 m (82′)
HI76510-05 patch cable, 5 m (16’51| HI76510-50 patch cable, 50 m (164′)

For a water tight seal: Gland seals need to be used over cables and the four screws on the front casing need to be tightened to 13.3 lbf·in (1.5 N·m, maximum 2.0 N·m), of torque.

Specifications	example HI2004-18zz
ORP	Range
Resolution	1 mV
Accuracy	±2 mV
Calibration	Single point, value can be adjusted

±60 mV around measured mV

O-ring

| glass

NBR

Junction| PTFE
Matching pin| titanium
Protection Rating| IP68
Cable Length| zz, see Ordering Information

PTFE junction: Minimizing the potential for clogging and chemically resistant, PTFE is ideal for samples with high content of suspended solids or for high-pressure installations.
Ceramic junction: Porous chemically resistant plug that connects the reference electrode to the process electrically.

Ordering Information

Each probe is supplied with quick reference guide with probe quality certificate

Choose your configuration:

xx| 04

14

| PTFE junction

Ceramic junction

---|---|---
y| 1| Platinum sensor; –5.0 to 100.0 °C (23.0 to 212.0 °F); ±2000 mV
2| Gold sensor; –5.0 to 100.0 °C (23.0 to 212.0 °F);± 2000 mV
8| Smart probe, with RS485 connection
zz| 00 supplied with DIN connector (without cable). See page 15.56 (HI510 and HI520 accessories section) for patch cable ordering codes.

05, 10, 15, 25, 50 fixed cable length (in meters)

See compatible probe extension cables on page page 15.56, see additional mounting accessories on page 15.25, see probe holders on page 15.134 and 15.130.

ORP and Temperature Industrial Smart Probes

HI2004-18 • HI2014-18
HI2004-28 • HI2014-28

HI510 and HI520 Universal Process Controller compatibleHI20X4-18 and HI20X4-28 are ORP and temperature probes designed for use with the Hanna Instruments® HI510 or HI520. The system is designed to monitor and control disinfection chemicals or follow and control a critical oxidation (or reduction) reaction. mV measurements are auto-compensated for barometric pressure and temperature.

HI2004-18 and HI2014-18 platinum-sensor series are designed to provide the best response over a wide range of applications. Used in reducing processes such as chlorine dosing in pools and spas or chromate reduction.
HI2004-28 and HI2014-28 gold-sensor series are designed for oxidative processes such as cyanide oxidation in the mining industry.

The probe features a flat tip (ideal for solutions containing aggressive chemicals) which virtually eliminates dirt deposits and significantly reduces maintenance.

Suitable for continuous measurement of ORP required for monitoring and/or controlling oxidizers and reducing agents in water treatment monitoring, industrial effluent treatment, and swimming pools, the probe can be submersed/immersed using the 3/4” NPT threads, or installed directly in-line or in a flow cell installation, using the lower sensor threads.

The probe is also available with an integral connector that permits cable connections after installation.

Patch cables may be purchased separately to connect between the probe and controller up to 50 meters (164 ft).

Rugged, chemically-resistant PVDF body
3/4” NPT external thread
6 bar (87 psi) maximum pressure at 25 °C (77 °F)
Built-in temperature sensor for measurement
Digital probe stores model, firmware, serial number, and calibration information
Minimum maintenance

Dimensions

pH and Temperature Industrial Smart Probes

HI1006-18 • HI1006-38 • HI1006-48
HI1016-18 • HI1016-38 • HI1016-48

pH and Temperature Industrial Smart Probes

HI510 and HI520 Universal Process Controller compatible
These industrial pH probes are intended for industrial process control when paired with the HI510 or HI520 Universal Process Controller.

HI1006-18 and HI1016-18 series, designed for low conductivity or low-temperature process environments
HI1006-38 and HI1016-38 series, designed for extended pH range or high-temperature process environments
HI1006-48 and HI1016-48 series, designed for process environments where hydrofluoric acid is present

An integral temperature sensor measures water temperature and adjusts the probe signal over the specified temperature range.
The flat tip eliminates deposits that can foul the sensor and significantly reduces necessary maintenance.
The PVDF body material is easy to clean and disinfect, and resistant to most chemicals (e.g. solvents, sodium hypochlorite), ultraviolet light, and fungal growth.
Suitable for continuous measurement of pH required in applications such as urban wastewater treatment, industrial effluent treatment, and surface water monitoring, the probe (and accessories) can be installed directly in-line, immersed in a tank, or in a flow cell.
The probe is available with an integral connector that permits connections after installation.
Patch cables may be purchased separately to connect between the probe and controller up to 50 meters (164 ft).

Rugged, chemically-resistant PVDF body
Specialized glass sensor for fast stabilization and accurate results
3/4” NPT external thread for mounting
Built-in temperature sensor for measurement and compensation
Matching pin helps avoid typical problems caused by grounding loop current
Digital probe stores model, firmware, serial number, and calibration information

Specifications	HI1006-18zz – example

pH

PTFE junction: Minimizing the potential for clogging and chemically resistant, PTFE is ideal for samples with high content of suspended solids or for high-pressure installations.
Ceramic junction: Porous chemically resistant plug that connects the reference electrode to the process electrically.
LT glass: Fast stabilization and accurate results at lower temperatures or lower ion content.
HT glass: Fast stabilization and accurate results at higher temperatures and over a larger pH range.
HF glass: Fast stabilization and accurate results for aggressive applications that have fluoride ions (F¯<2 g/L, temperature<60 °C, pH>2).

Ordering Information
Each probe is supplied with quick reference guide with probe quality certificate.

Choose your configuration:

xx	06	PTFE junction
16	Ceramic junction

y

| 1| Low Temperature (LT) glass sensor, titanium matching pin

–5.0 to 80.0 °C (23.0 to 176.0 °F)

0.00 to 12.00 pH

3| High Temperature (HT) glass sensor, titanium matching pin 0.0 to 100.0 °C (32.0 to 212.0 °F)

0.00 to 14.00 pH

4| Fluoride-resistant (HF) glass sensor, titanium matching pin

–5.0 to 60.0 °C (23.0 to 140.0 °F)

0.00 to 10.00 pH

8| Smart probe, with RS485 connection

zz

| 00 supplied with DIN connector (without cable). See Accessories section for patch cable ordering codes.

05, 10, 15, 25, 50 fixed cable length (in meters)

Dimensions

Documents / Resources

| Hanna Instruments HI510 Universal Process Controllers [pdf] Instruction Manual
HI510 Universal Process Controllers, HI510, Universal Process Controllers, Process Controllers, Controllers
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