Single and Dual-Channel Universal Process Controllers
HI510 and HI520
with new Turbidity Probe
HI510 and HI520 Universal Process Controllers are advanced controllers that can be configured for applications requiring monitoring and/or control of industrial, commercial and municipal processes when used with supported pH, ORP, Conductivity, Dissolved Oxygen, and Turbidity liquid measurement sensors.
The HI510 is a single-channel model while the HI520 is dual-channel.
These versatile multiparameter platforms offers wall, pipe, and panel-mounting options as well as a large backlit dot matrix LCD. The HI520 can also display two channels simultaneously.
The IP65 rated rugged enclosure and low profile vulcanized rubber keypad makes these controllers ideal for harsh environments.
These controllers feature plug-and-play operation with digital probe input(s) that automatically detect supported probes and update the controller with the parameter that it measures.
Designed to adapt to unique process control requirements, HI520 operates a control‑loop system whereby users have the option to run channel control independently or configure to be triggered sequentially upon reaching the other channel’s set point(s) (1, 2, or both).
The HI520 also 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.
An intuitive interface for control setup, relay activation, alarm signaling (hold status) and the help and diagnostic features, guide users to identify problems and suggest possible action(s) to be taken. On the front panel, Blue LEDs indicate when relays are energized, and multi‑color LEDs indicate status such as Alarm and HOLD.
Configuring control parameters can be done locally or remotely using
the Modbus protocol and a compatible Modbus server.
Shared-function management between controller and probes
Smart probes store information including serial number, type, probe temperature and measurement limits, calibration data (including slope and offset), manufactured date, expiration date (optical DO caps), and calibration due reminder.
When paired up with the controller, the system allows for shared management of settings between controller and probes, where the controller manages only settings related to the intended application, as defined by the requirements of the industrial process, and the probes manage measurement settings and warnings, including temperature compensation and calibration.
- IP65 rated enclosure
- Wide variety of compatible probes
- Universal mounting options
- Modbus compliant
- ON/OFF, proportional or PID channel control
- Automatic datalogging of process control information and events
- USB-C port for data transfer
- Large backlit LCD
- Tactile rubberized keypad
- Multi-color LED status indicators
- Configurable high and low alarms
- Safety Features
- All electrical connections enclosed in an IP65 rated enclosure
- Galvanically isolated inputs and outputs
- EMC (electromagnetic compliant) hardware and software design
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.
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.
? DIAG - Help and Diagnostic key
The help and diagnostic key (? DIAG) provides information related to errors; or in setup mode, information about settings.
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.
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.
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.
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 units 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 automatically logs the process control information in an interval log, and various event alarms and errors in an event log
- Logged data can be retrieved and events visualized on the screen, in Log Recall menu
- Interval logs store up to 8600 records per lot, maximum lot number is 100 lots
- Logging interval can be set in the General settings menu
- Logged data includes: measurement variables and temperature measurements, last calibration data, setup configuration, start/end date and time, previous values, event data and event code
- Event log can store up to 100 records of events, alarms, errors-related data
- Log files can be uploaded to a USB flash drive via USB-C port
Password protection
The controllers feature password protected calibration and setup.
IP65 rated enclosure
The HI510 and HI520 are suitable for indoor or outdoor environments. The rugged IP65 rated 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 IP65 enclosure rating during use, the conduit openings and connection cables are sealed against the environment using the provided cable glands, seals and plugs.
Spring loaded screws
To maintain the IP65 enclosure rating during use, the conduit openings and connection cables are sealed against the environment using the provided cable glands, seals and plugs.
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.
Automation with the HI510 Universal process controller
NEW: Low Range Turbidity Probe for HI5x0 Controller
The HI7660-28 are nephelometric turbidity probes designed for use with Hanna Instruments® HI510 or HI520 Universal Process Controller.
The system is designed to measure low turbidity values according to the nephelometric method (ISO 7027 – EN 27027).
An integral temperature sensor measures water temperature and adjusts the probe signal for temperature-related changes over the range of 0 to 50 °C (32 to 122 °F).
The controller displays both measurements simultaneously. Turbidity is a key indicator of water quality and effectiveness of water filtration.
The system is suitable for applications in drinking water, municipal and industrial water treatment, desalination and water quality monitoring.
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