Hanna Instruments – Training Portal

Firmware & Language Update Tutorial

Firmware Update Procedure

Required tools: PC · USB A to micro-USB cable · HIDBootloader.exe · .hex firmware file

Entering Bootloader Mode & Flashing

1

Run HIDBootloader.exe on the PC.

2

Make sure the HI833XX is OFF and the USB cable is unplugged.

3

Hold ▲ + ▼ simultaneously, then plug in the USB cable. The app shows: “Device Attached… Device Ready” → Status: Connected

4

Click Step 1 → browse and load HI833xx_enc_vX.YY_YYYY-MM-DD.hex

5

Click Step 2 → start programming. Wait for completion.

6

Click Step 3 → reset the meter.

7

Verify: SETUP → Meter Information.

📷 HIDBootloader App
Screenshot

⚠ Do not disconnect USB or power off during programming — interrupting the flash may corrupt firmware.

Language Update Procedure

7 supported languages: EN · DE · ES · IT · PT · FR · NL

Language Files

File	Language
EN.lng	English
DE.lng	German (Deutsch)
ES.lng	Spanish (Español)
IT.lng	Italian (Italiano)
PT.lng	Portuguese (Português)
FR.lng	French (Français)
NL.lng	Dutch (Nederlands)

✓ After update: SETUP → Language. Current language shown under SETUP → Meter Information.

📷 Factory Mode & Drive Fact
Screenshot

Update Procedure

1

Enter factory mode: hold USR3 + SETUP + RECALL, then press ON/OFF.

2

Select Flash Partition → press Select.

3

Press Format → confirm Yes.

4

Connect micro-USB → press Connect. Drive Drive Fact appears.

5

Copy all 7 .lng files to Drive Fact.

6

Press Done on the meter.

7

Press ESC, unplug USB, restart.

⚠ Confidential — Restricted to authorised Hanna service personnel.

Spare Parts – HI833XX Family

Always verify serial number format before ordering — parts are valid for ACCxxxxxxx and ACDxxxxxxx serial numbers only.

⚠ Critical – Main Board & Optical System
The main board SP833XX-1N includes a calibrated optical system — no factory recalibration is required after replacement. The optical system is permanently bonded to the board and cannot be separated.

Model-Specific Part Numbers

Model	Description	Main Board	Keypad / Mask	Casing
HI83300	Multiparameter Photometer	SP83300-1N	SP83300-3N	SP83300-8N
HI83303	Aquaculture Photometer	SP83303-1N	SP83303-3N	SP83303-8N
HI83305	Boiler & Cooling Tower	SP83305-1N	SP83305-3N	SP83305-8N
HI83306	Environmental Analysis	SP83306-1N	SP83306-3N	SP83306-8N
HI83308	Water Conditioning	SP83308-1N	SP83308-3N	SP83308-8N
HI83314	Wastewater Treatment	SP83314-1N	SP83314-3N	SP83314-8N
HI83325	Nutrient Analysis	SP83325-1N	SP83325-3N	SP83325-8N
HI83326	Pool & Spa	SP83326-1N	SP83326-3N	SP83326-8N
HI83399	Multiparameter + COD	SP83399-1N	SP83399-3N	SP83399-8N

Main Board Replacement

Power OFF; remove 4 bottom screws
Disconnect LCD and keypad ribbon tapes from main board
Remove 4 main board screws; de-solder battery wires (if old board style)
Install new SP833XX-1N; re-solder or reconnect battery
Reconnect ribbon tapes; re-assemble casing
Power on and verify: SETUP → Meter Information

Keypad & Casing Replacement

Keypad (SP833XX-3N): Pry off old keypad; clear adhesive residue; peel backing on new keypad; align and press into position
Battery (SPBAT3.7): Peel from metal plate; replace; solder or reconnect wires
LCD (SPDY5035): Remove LCD frame screws (×3); gently pull LCD from clips; insert new; secure frame

FW & Language Update – HI977XX

Required Tools & Files

HI977XXADP USB adapter
Flash USB key
PC
HI977xx meter
HI977XX_enc_vX.YY_yyyy-mm-dd.hex
Language files: EN.lng ES.lng DE.lng IT.lng FR.lng PT.lng NL.lng

📷 HI977XXADP USB Adapter

⚠ Case-Sensitive Filename — The firmware file must be renamed to IMAGE.hex (uppercase, exactly as written) before copying to the USB key. The update will not start otherwise.

1 – Firmware Update Procedure

Ref: HI977xx_FW&Lang_Update_v1.0 – FW update key combo: 3rd func key + MENU + Power

Prepare USB Key

1

Copy HI977XX_enc_vX.YY_yyyy-mm-dd.hex to the USB key.

2

Rename the file to IMAGE.hex — case-sensitive.

3

Copy all 7 language .lng files to the same USB key.

Install Adapter & Start

4

Turn off the meter. Remove the battery cover by turning counterclockwise.

5

Insert the HI977XXADP USB adapter into the correct position.

6

Insert the USB key into the USB adapter.

7

Turn on the meter by pressing simultaneously: 3rd functional key + MENU key + Power key.

8

Wait for the update to complete.

📷 Battery cover removed
Maxell batteries visible

📷 USB adapter inserted
USB key plugged in

📷 Keypad diagram – FW update
3rd func + MENU + Power

2 – Language Loading Procedure

Language load key combo: 2nd func key + HELP + Power

1

Turn on the meter by pressing simultaneously: 2nd functional key + HELP key + Power key.

2

Choose “Factory calibration” and press Select.

3

Choose “Language loading” and press Select.

4

Wait for loading to complete.

5

Press the Power button twice to turn off the meter.

6

Remove the USB adapter and replace the battery cover.

7

Done.

📷 Keypad diagram – Language load
2nd func + HELP + Power

🌎 FW files and additional documentation are available on the Hanna documentation portal: documentation.hannainst.com — login required for the FW and spare parts sections.

Spare Parts – HI97XXX Portable Photometer Family

Ref: SP97XXXR1.1 — 05.11.2024 — Technical Office Nusfalau

⚠ Main Board includes calibrated Optical System — No factory recalibration is required after replacement. Order model-specific part numbers below.

🔒 Login required — FW files and spare parts are also available on documentation.hannainst.com

Model-Specific Part Numbers

Model	Description	Main Board	Casing
HI97101	BR, CL, CYA, Iodine, Iron, LR, pH Photometer	SP97101-1	SP97101-8
HI97104	pH, Alkalinity, Free & Total Chlorine, CYA Photometer	SP97104-1	SP97104-8
HI97105	Marine Multiparameter Photometer	SP97105-1	SP97105-8
HI97106	Chemical Oxygen Demand Photometer	SP97106-1	SP97106-8
HI97115	Marine Master Multiparameter Photometer	HI97115-1	HI97115-8
HI97700	Ammonia Low Range Photometer	SP97700-1	SP97700-8
HI97701	Free Chlorine Photometer	SP97701-1	SP97701-8
HI97702	Copper HR Photometer	SP97702-1	SP97702-8
HI97704	Hydrazine Photometer	SP97704-1	SP97704-8
HI97705	Silica HR Photometer	SP97705-1	SP97705-8
HI97706	Phosphorus Photometer	SP97706-1	SP97706-8
HI97707	Nitrite LR Photometer	SP97707-1	SP97707-8
HI97708	Nitrite HR Photometer	SP97708-1	SP97708-8
HI97709	Manganese HR Photometer	SP97709-1	SP97709-8
HI97710	pH, Free & Total Chlorine Photometer	SP97710-1	SP97710-8
HI97711	Free & Total Chlorine Photometer	SP97711-1	SP97711-8
HI97712	Aluminium Photometer	SP97712-1	SP97712-8
HI97713	Phosphate Low Range Photometer	SP97713-1	SP97713-8
HI97714	Cyanide Photometer	SP97714-1	SP97714-8
HI97715	Ammonia Medium Range Photometer	SP97715-1	SP97715-8
HI97716	Bromine Photometer	SP97716-1	SP97716-8
HI97717	Phosphate Photometer	SP97717-1	SP97717-8
HI97718	Iodine Photometer	SP97718-1	SP97718-8
HI97719	Magnesium Hardness Photometer	SP97719-1	SP97719-8
HI97720	Calcium Hardness Photometer	SP97720-1	SP97720-8
HI97721	Iron High Range Photometer	SP97721-1	SP97721-8
HI97722	Cyanuric Acid Photometer	SP97722-1	SP97722-8
HI97723	Chromium VI HR Photometer	SP97723-1	SP97723-8
HI97725	Chlorine, CYA & pH Photometer	SP97725-1	SP97725-8
HI97726	Nickel HR Photometer	SP97726-1	SP97726-8
HI97727	Color of Water Photometer	SP97727-1	SP97727-8
HI97728	Nitrate Photometer	SP97728-1	SP97728-8
HI97729	Water Colour Photometer	SP97729-1	SP97729-8
HI97730	Molybdenum Photometer	SP97730-1	SP97730-8
HI97731	Zinc Photometer	SP97731-1	SP97731-8
HI97732	Dissolved Oxygen Photometer	SP97732-1	SP97732-8
HI97733	Ammonia High Range Photometer	SP97733-1	SP97733-8
HI97734	Free & Total Chlorine HR Photometer	SP97734-1	SP97734-8
HI97735	Total Hardness LR / MR / HR Photometer	SP97735-1	SP97735-8
HI97736	Total Hardness & pH Photometer	SP97736-1	SP97736-8
HI97737	Silver Photometer	SP97737-1	SP97737-8
HI97738	Chlorine Dioxide Photometer	SP97738-1	SP97738-8
HI97739	Fluoride HR Photometer	SP97739-1	SP97739-8
HI97740	Nickel LR Photometer	SP97740-1	SP97740-8
HI97741	Total Hardness & Iron Photometer	SP97741-1	SP97741-8
HI97742	Iron LR & Manganese LR Photometer	SP97742-1	SP97742-8
HI97745	Chlorine, Total Hardness, Iron LR & pH Photometer	SP97745-1	SP97745-8
HI97746	Iron LR Photometer	SP97746-1	SP97746-8
HI97747	Copper LR Photometer	SP97747-1	SP97747-8
HI97748	Manganese LR Photometer	SP97748-1	SP97748-8
HI97749	Chromium VI LR Photometer	SP97749-1	SP97749-8
HI97750	Potassium Photometer	SP97750-1	SP97750-8
HI97751	Sulfate Photometer	SP97751-1	SP97751-8
HI97752	Calcium & Magnesium Photometer	SP97752-1	SP97752-8
HI97753	Chloride Photometer	SP97753-1	SP97753-8
HI97761	Total Chlorine ULR Photometer	SP97761-1	SP97761-8
HI97762	Free Chlorine ULR Photometer	SP97762-1	SP97762-8
HI97769	Anionic Surfactants Photometer	SP97769-1	SP97769-8
HI97770	Silica HR Photometer	SP97770-1	SP97770-8
HI97771	Free & Total Chlorine UHR Photometer	SP97771-1	SP97771-8
HI97779	Chlorine Dioxide Photometer	SP97779-1	SP97779-8
HI97786	Nitrate Photometer	SP97786-1	SP97786-8

Repair Procedure

Disassembly & Replacement

Remove battery cover and batteries.
Remove rubber foot; unscrew 4 screws fixing top case to back case.
Carefully separate back case from top case.
Unsolder battery wires from main board; unscrew main board screws.
(Casing SP977XX-8) Remove old casing; install new casing.
(Main board SP977XX-1) Remove old board with optical system; install new board.
Fix main board to top casing with 4 screws; solder battery wires.
Mate top and back casing; fix with 4 screws.
Place rubber foot over screw holes.
Insert batteries; close battery cover.

📷 Fig. 1 – Screw locations
top case to back case

📷 Fig. 2 – Main board screws
& optical system

Functional Test

Turn ON the meter.
Verify all LCD tags display correctly at power-on.
Perform CAL Check validation per Instruction Manual.

Spare Parts – HI5XXX Bench Meters

Ref: ISSP5XXX_REV.1.0 — 2016-12-09 — Technical Office Nusfalau

⚠ Analog Board is factory-calibrated — no factory recalibration is required after replacement.

Model-Specific Part Numbers

Model	Description	ARM Board	Analog Board	Casing
HI5221	pH / mV Meter	SP5221-1	SP5221-2	SP5221-8
HI5222	pH / mV / ISE / 2-Channel Meter	SP5222-1	SP5222-2	SP5222-8
HI5321	EC / TDS / Salinity / Resistivity Meter	SP5321-1	SP5321-2	SP5321-8
HI5421	Dissolved Oxygen and BOD Meter	SP5421-1	SP5421-2	SP5421-8
HI5521	pH / mV and EC / TDS / Salinity / Resistivity Meter	SP5521-1	SP5521-2	SP5521-8
HI5522	pH / mV / ISE and EC / TDS / Salinity / Resistivity Meter	SP5522-1	SP5522-2	SP5522-8

SP5XXX-8 Casing Components

#	Code	Description	Qty
1	PP4KLNS	Full Lens	1
2	MWBOTPBM	New Top for HI4XXX	1
3	DY606	Display	1
4	VSP3X9RN	Self-Tap Screw for LCD	4
5	RON3X5PN	Washer for LCD	6
6	MWBREAR	Rear Panel	1
7	FA'S	Unchanged Board	1
8	MWBBOTTOM	Bottom Casing	1
9	VP3X14RN	Screw for Casing	4
10	VSP2.2X8RN	Screw for Main PCB	4
11	GOMMINOFT	Rubber Pad	4
12	—	Intermediate PCB	1
13	FAKEY	Capacitive Keypad	1
14	VSC2.2X6.5	Screw for Keypad	2

General Repair Procedure

ⓘ SP5XXX-1 (ARM board): complete steps 1–9 only.
ⓘ SP5XXX-2 (Analog board): complete steps 1–18 then 17–33.
ⓘ SP5XXX-8 (Casing): complete step 18 only.
ⓘ Steps 10, 25: Ref. connection applies to HI5221, HI5222, HI5521, HI5522 only.

Disassembly

Remove 4 screws from bottom casing.
Carefully separate bottom from top casing.
Disconnect ground cable from metallic plate on bottom casing (Fig. 1).
Remove upper 2 screws from analog board (Fig. 2).
Carefully lift combined ARM + analog board to remove back casing.
Remove 2 screws holding ARM board (Fig. 3).
Unsolder 2 wires R/B from ARM board (Fig. 4).
Disconnect ribbon cable from ARM board.
Remove old ARM board → replace with new SP5XXX-1.
(Analog board only) De-solder Ref. connection from Analog Board pH/mV (Fig. 5). HI5221/5222/5521/5522 only.
De-solder shield wire from analog board pin (Fig. 6).
De-solder red wire connecting analog board to keyboard.
Remove screws holding analog board to front casing.
Carefully remove shield from analog board.
De-solder ground wires from LCD shield and back casing plate (Fig. 7).
De-solder DO connection cable (SP5421-2) or EC ribbon cable — 7 wires (SP5321-2 / SP5521-2 / SP5222-2) (Fig. 8).
Replace old analog board with new SP5XXX-2.
Replace old casing and LCD with new SP5XXX-8.

Reassembly

Solder DO connection cable or EC ribbon cable to analog board (Fig. 8).
Solder ground wires to analog board (Fig. 7).
Cover analog board with shield.
Fix analog board to front casing with screws.
Solder shield wire to analog board ground pin (Fig. 6).
Solder red wire from LCD to analog board.
Solder Ref. connection to Analog Board pH/mV (Fig. 5). HI5221/5222/5521/5522 only.
Solder 2 wires R/B to ARM board (Fig. 4).
Connect ARM board to corresponding connector on analog board.
Reconnect ribbon cable to ARM board.
Fix ARM board to analog board with screw and black spacers (Fig. 3).
Place back casing over boards in top casing position.
Fix analog board to top casing with upper 2 screws (Fig. 2).
Reconnect ground cable to metallic plate on bottom casing (Fig. 1).
Place bottom case over top case and fix with 4 screws.

📷Fig. 1 – Ground cable & bottom casing screw

📷Fig. 2 – Upper 2 screws on analog board

📷Fig. 3 – ARM board screws & pliers

📷Fig. 4 – LCD backlight wires R/B on ARM board

📷Fig. 5 – Reference wires on Analog Board pH/mV

📷Fig. 6 – Shield wire on analog board pin

📷Fig. 7 – Back plate ground wire & LCD shield wire

📷Fig. 8 – DO connector wires / EC ribbon cable

Functional Test

Connect meter to 12 VDC power adapter.
Turn ON the meter.
Verify LCD display works correctly — HANNA logo appears and backlight is ON.
Verify instrument model and firmware version shown during logo display.
Verify all features work correctly — refer to instruction manual.

Factory Calibration – HI5XXX Benchtop Meter

Required Tools

Model	Required Calibrator
HI5221	TP8427 mV simulator
HI5222	TP8427 mV simulator
HI5321	TP8432 calibrator
HI5421	TP8432 calibrator
HI5522	TP8427 & TP8432 calibrators

Entering Factory Calibration Mode

1

Power on the meter and wait 1–2 seconds for the capacitive keyboard to self-calibrate.

2

Press and hold simultaneously: CAL + MODE + TOP RIGHT functional key until the meter enters Factory Calibration mode.

⚠ Before any calibration, the meter must be ON for at least 20 minutes to reach thermal equilibrium. Fix the real-time clock using the SETUP key.

📷 HI5XXX keypad layout
CAL + MODE + TOP RIGHT held simultaneously

1 – EC Temperature Calibration TP8432

1

Press the TEMP functional key.

2

Select 0 °C on TP8432. Wait for “ACCEPT” on LCD → press ACCEPT.

3

Select 50 °C on TP8432. Wait for “ACCEPT” → press ACCEPT.

4

Select 100 °C on TP8432. Wait for “ACCEPT” → press ACCEPT.

5

Verify “The Calibration was terminated successfully” on LCD.

6

Press SAVE to save the temperature calibration.

📷 TP8432 temperature selector
0 °C · 50 °C · 100 °C

2 – Conductivity Calibration TP8432

1

Connect the EC cable to TP8432.

2

Press the COND functional key.

3

Meter asks for 0.000 µS — select it on TP8432. Wait for “ACCEPT” → press ACCEPT.

4

Meter asks for 0.10 µS — select it on TP8432. Wait for “ACCEPT” → press ACCEPT.

5

Continue selecting each successive value on TP8432 and pressing ACCEPT up through 1000.0 mS.

6

Verify “The Calibration was terminated successfully” on LCD.

7

Press SAVE to save conductivity calibration.

📷 TP8432 conductivity selector
0.000µS → 0.10µS → … → 1000.0mS

3 – ID Calibration Recognized Probe Calibration · CONDREC key

1

Press CAL to enter the Recognized Probe Calibration screen.

2

Point 1: EC input disconnected. Confirm with ACCEPT.

3

Point 2: Connect EC input to the CONDREC key (10 KΩ between pin 8 and pin 7 of CONLK8PF). Confirm with ACCEPT.

4

Press SAVE to save the Recognized Probe Calibration.

5

Press ESCAPE to exit Factory Calibration mode.

📷 CONDREC key – 10KΩ between pin 8 & pin 7
of CONLK8PF

4 – mV & Temperature Calibration TP8427 · pH input

mV Calibration – 3 points

1

Connect TP8427 to the pH input.

2

Press the mV functional key.

3

Set TP8427 to −1800.0 mV → press Accept.

4

Set TP8427 to 0.0 mV → press Accept.

5

Set TP8427 to +1800.0 mV → press Accept.

6

Press Save → meter returns to Factory Calibration screen.

Temperature Calibration – 3 points

1

Press the Temp functional key.

2

Connect the 0.0 °C key to Temperature input (NTC10K · 32 650 Ω · 0.1% accuracy) → press Accept.

3

Connect the 50.0 °C key (NTC10K · 3 603 Ω · 0.1% accuracy) → press Accept.

4

Connect the 100.0 °C key (NTC10K · 680 Ω · 0.1% accuracy) → press Accept.

5

Press Save → meter returns to Factory Calibration screen.

6

Press Escape to enter measurement mode.

📷 TP8427 connected to pH BNC input
mV output: −1800 / 0 / +1800 mV

📷 NTC10K temperature keys
0 °C · 50 °C · 100 °C on Temperature input

Firmware & System Update – HI6000

⚠ Only one .hiup file allowed on the USB stick. Make sure no other .hiup file is present before inserting.

Firmware Update Procedure

1

Download the latest firmware package from documentation.hannainst.com — authentication required.

2

Copy the .hiup file to a USB stick. Ensure it is the only .hiup file on the drive.

3

Make sure the meter is powered off.

4

Insert the USB stick into the meter.

5

Power on the meter. The package is recognized automatically and the update begins.

6

Wait for the update to complete. The meter will start the application automatically when done.

📷 USB stick inserted into HI6000
.hiup package recognized on power-on

First Boot – Admin Setup SW 2.0.0 and higher

On first power-on after update, the meter requires an admin user name and password to be configured.

1

At the first power-on prompt, enter the admin credentials below.

2

User name: admin

3

Password: 12345678 — minimum 8 characters required.

ⓘ These credentials are recommended for production-line testing. Change the password before deploying to end users.

📷 First-boot admin setup screen
User name & password entry

Factory Calibration – HI6000 Multichannel Meter

Ref: HI6000_Technical_Calibration_rev1.1 — 2024-10-17 — Hanna Instruments Confidential

⚠ Before starting, make sure the modules that require calibration are attached to the meter and assigned to a measurement channel: MENU → System Settings → Channels.

Enabling Technical Calibration (common to all modules)

1

Press MENU on the capacitive keyboard → press Users.

2

Tap in this exact order: User Name ×2 → Full Name ×1 → Password ×2.

3

The Technical Menu appears. Enable the Technical Calibration toggle.

📷 User Settings – tap sequence
User Name ×2 · Full Name ×1 · Password ×2

1 – HI6000-1 / HI6000-2 pH / ORP / ISE Calibration

Required Tools

TP8427 Benchtop Calibration tool
BNC cable for mV measurement
RCA cable for temperature measurement

Preparation

Connect BNC-to-BNC cable from TP8427 to the meter module
Connect RCA-to-RCA cable from TP8427 (+ output) to the meter module
Power on TP8427 and the meter at the same time
Wait for READY LED to turn GREEN before any calibration
High Z must NOT be active

📷 TP8427 connected to HI6000 pH module
BNC + RCA cables

pH Technical Calibration

Enter pH measurement settings → Calibration tab → scroll to Technical Calibration → press Calibrate.

mV Calibration – 3 points (order not important)

1

Press Start Calibration from the mV field.

2

Set TP8427 to -1800 mV. Wait for measured mV to fill.

3

Set TP8427 to 0 mV. Wait.

4

Set TP8427 to +1800 mV. Wait.

5

Press Accept when all 3 points are measured.

Temperature Calibration – 3 points (order not important)

1

Press Start Calibration from the Temperature (ATC) field.

2

Set TP8427 to 0 °C. Wait.

3

Set TP8427 to 50 °C. Wait.

4

Set TP8427 to 100 °C. Wait.

5

Press Accept when all 3 points are measured.

✓ Press Save when both mV and temperature are calibrated. Meter returns to measurement screen.

📷 Factory Calibration – MOD1 pH screen
mV cal points: -1800 / 0 / +1800

Factory Calibration Check – pH/ORP/ISE

Check	Meter Settings	TP8427 Set	Admissible Reading
mV	Res: 0.1 · Stability: Accurate · Mode: Direct	-1800 mV	-1800.0 ± 0.1 mV
		+1800 mV	1800.0 ± 0.1 mV
		0 mV	0.0 ± 0.1 mV
	HIGH Z active	-177.5 mV	-177.5 ± 0.2 mV
Temperature	Source: Automatic · Unit: °C · Clear user cal	0 °C	0 ± 0.1 °C
		50 °C	50 ± 0.1 °C
		100 °C	100 ± 0.1 °C
Info	Menu → System Settings → Info: verify Factory Calibration date matches date set on meter

2 – HI6000-3 EC Calibration

Required Tools

TP8432 Benchtop Calibration tool
DIN adapter cable between TP8432 and EC module

Preparation

Connect DIN cable from TP8432 to the EC module
Power on the meter
Enable Technical Calibration (unlock sequence above)

📷 TP8432 EC Calibrator – conductivity keys
0nS · 0.1µS · 1µS · 10µS · 100µS · 1mS · 10mS · 100mS · 1000mS · 500mS/TEST

EC Technical Calibration

Enter EC channel settings → Calibration tab → Technical Calibration field → press Calibrate.

EC Calibration Points

1

Insert EC cable and connect to the TP8432 conductivity keys.

2

Press Start Calibration from the EC field.

3

First point is 0 nS = air (cable disconnected from key).

4

Calibrate each range in the order indicated on the meter. The high point of one range is the low point of the next.

5

Measure the indicated values using the conductivity keys on TP8432.

6

Press Accept when the EC Calibration Results field is fully filled.

Temperature Calibration

1

Go to the Temperature field → press Start Calibration.

2

Insert the cable into the TEMP/ID key on TP8432.

3

Set the EC TEMP (°C) switch to 0 °C, 50 °C, then 100 °C. Wait for each measured temperature to appear.

4

Press Accept when all 3 points are measured.

✓ Check Results field. Press Save when both EC and temperature are calibrated.

📷 Technical Calibration – MOD2 EC screen
EC Calibration Results + Temperature Results

📷 TP8432 TEMP/ID key
EC TEMP (°C) switch: −10 to 110 °C

Factory Calibration Check – EC

Conductivity Check

Settings: Parameter=Conductivity · Unit=AutoRanging · Stability=Accurate · Mode=Direct

TP8432 Key	Admissible Reading
10.00 µS	10.00 ± 0.04 µS
1.000 mS	1.000 ± 0.004 mS
10.00 mS	10.00 ± 0.04 mS
100.0 mS	100.0 ± 0.4 mS
500.0 mS	500.0 ± 4 mS

Temperature Check

Settings: Source=module under test (e.g. MOD2) · Unit=°C

TP8432 Set	Admissible Reading
−10 °C	−10.0 ± 0.1 °C
25 °C	25.0 ± 0.1 °C
80 °C	80.0 ± 0.1 °C
110 °C	110.0 ± 0.1 °C

✓ Info Check: Menu → System Settings → Info → verify Factory Calibration date.

3 – HI6000-4 DO Calibration

Required Tools

TP8432 Benchtop Calibration tool
Cable adapter – DO module to TP8432 (DIN connector)

Preparation

Connect cable from TP8432 to the DO meter module
Power on the meter
Enable Technical Calibration (unlock sequence above)

📷 Technical Calibration – MOD3 DO screen
DO + Pressure + Temperature results

DO Technical Calibration

Enter DO channel settings → Calibration tab → Technical Calibration field → press Calibrate.

DO Calibration – 2 points (order not important)

1

From Parameter, select DO.

2

Press Start Calibration from the %Sat field.

3

Set TP8432 to 0 % Sat. Wait for measured value.

4

Set TP8432 to 100 % Sat. Wait for measured value.

5

Press Accept when both points are measured.

Temperature Calibration – 3 points

1

From Parameter, select Temperature.

2

Set TP8432 to 0 °C. Wait for measured temperature.

3

Set TP8432 to 50 °C. Wait.

4

Set TP8432 to 100 °C. Wait.

5

Press Accept when all 3 points are measured.

✓ Check Results field. Press Save when DO, Pressure, and Temperature are all calibrated.

📷 Parameter selector: DO / Pressure / Temperature

Factory Calibration Check – DO

DO Check

Settings: Unit=%Sat · Stability=Accurate · Mode=Direct

TP8432 Set	Admissible Reading
10 % DO	10 % Sat ± 0.2 %
50 % DO	50 % Sat ± 0.2 %
100 % DO	100 % Sat ± 0.2 %
400 % DO	400 % Sat ± 0.2 %

Temperature Check

Settings: Source=Automatic · Unit=°C · Clear user cal

TP8432 Set	Admissible Reading
0 °C	0 ± 0.1 °C
50 °C	50 ± 0.1 °C
100 °C	100 ± 0.1 °C

✓ Info Check: Menu → System Settings → Info → verify Factory Calibration date.

HI968XX – Factory Calibration

Required Materials

Item	Details
Distilled / DI water	First-point calibration for all models
Sucrose solution – 50% Brix	HI96800, HI96801, HI96803, HI96811, HI96813, HI96820, HI96823, HI96831, HI96832, HI96833, HI96841
NaCl solution – 20 g / 100 g	HI96821
NaCl solution – 10 g / 100 g	HI96822
Sucrose solution – 25% Brix	HI96841 (second cal point)

1 – Temperature Calibration

Temperature calibration is the same for all HI968XX models.

1

Power on the refractometer.

2

Hold READ + ZERO + ON/OFF simultaneously until the display changes.

3

Release the buttons. The meter enters temperature calibration mode.

4

Repeat the same key combination (READ + ZERO + ON/OFF) a second time to confirm and save the temperature calibration.

5

The meter exits temperature cal mode automatically after saving.

2 – RI (Refractive Index) Calibration

RI calibration requires two calibration points: DI water (all models) and a model-specific second solution. Refer to the table below for your instrument's second calibration solution.

Step 1 – Calibrate with DI Water (all models)

1

Clean the prism with DI water and dry carefully.

2

Apply a few drops of DI water to the prism.

3

Press ZERO to zero the instrument on DI water.

4

Confirm the reading is at zero / baseline value before proceeding.

Step 2 – Calibrate with Model-Specific Solution

Model	2nd Calibration Solution
HI96800	50% Brix sucrose
HI96801	50% Brix sucrose
HI96803	50% Brix sucrose
HI96811	50% Brix sucrose
HI96813	50% Brix sucrose
HI96820	50% Brix sucrose
HI96821	20 g / 100 g NaCl solution
HI96822	10 g / 100 g NaCl solution
HI96823	50% Brix sucrose
HI96831	50% Brix sucrose
HI96832	50% Brix sucrose
HI96833	50% Brix sucrose
HI96841	25% Brix sucrose (1st point), 50% Brix sucrose (2nd point)
HI96842	50% Brix sucrose

1

Clean the prism and apply the model-specific calibration solution.

2

Press READ to take the calibration measurement.

3

Confirm the displayed value matches the expected standard for the solution used.

4

Clean the prism with DI water after calibration is complete.

HI968XX – Spare Parts & Repair Procedure

📄 Download Full Spare Parts PDF

Generic Spare Parts (All HI968XX Models)

Part Code	Description
SP968XX-1	Mainboard with optical system (standard)
SP968XX-1N	Mainboard with optical system (N variant)
SP96XXX-3	Front mask
SP96XXX-8	Casing (standard)
SP96XXX-8N	Casing (N variant)

Model-Specific Part Numbers

Model	Part Code	Description
HI96800	SP96800-8	Casing assembly
HI96801	SP96801-8	Casing assembly
HI96803	SP96803-8	Casing assembly
HI96811	SP96811-8	Casing assembly
HI96813	SP96813-8	Casing assembly
HI96820	SP96820-8	Casing assembly
HI96821	SP96821-8	Casing assembly
HI96822	SP96822-8	Casing assembly
HI96823	SP96823-8	Casing assembly
HI96831	SP96831-8	Casing assembly
HI96832	SP96832-8	Casing assembly
HI96833	SP96833-8	Casing assembly
HI96841	SP96841-8	Casing assembly
HI96842	SP96842-8	Casing assembly
HI96800N	SP96800N-8	Casing assembly (N variant)

SP968XX-8 Casing Kit – Components

#	Component
1	Upper casing
2	Lower casing
3	Screws and fixings

Repair Procedure

Disassembly

1

Remove the battery / disconnect power.

2

Remove the rubber boot / protective cover if fitted.

3

Locate and remove all external screws on the casing.

4

Carefully separate upper and lower casing halves.

5

Disconnect the display ribbon cable from the mainboard.

6

Disconnect the keypad membrane connector.

7

Remove any internal screws securing the mainboard.

8

Lift the mainboard / optical assembly out of the lower casing.

9

Remove the front mask if replacing (SP96XXX-3).

10

Set aside all hardware for reassembly.

Reassembly

11

Fit the front mask into position (if replaced).

12

Place the mainboard / optical assembly into the lower casing.

13

Fasten the mainboard securing screws.

14

Reconnect the keypad membrane connector.

15

Reconnect the display ribbon cable.

16

Bring the upper and lower casing halves together.

17

Insert and tighten all external casing screws.

18

Refit the rubber boot / protective cover.

19

Install the battery / reconnect power.

Front Mask Note: When replacing the front mask (SP96XXX-3), ensure the keypad membrane is correctly seated before closing the casing. The membrane must align with the switch contacts on the mainboard.

Functional Test After Repair

1

Power on the instrument and confirm the display activates correctly.

2

Verify all keys respond correctly.

3

Apply DI water to the prism and press ZERO — confirm the instrument zeros without error.

4

Apply the model-specific calibration solution and verify the reading is within tolerance.

Task 1 – Connect a Digital Probe

📷 Terminal 2 board
PROBE 1 / PROBE 2 connectors labeled — A, B, +5V, mA, −

🔌 Patch cable DIN connector
Pin-out detail — show wire colour / pin mapping

📷 Cable gland installation
Correct seating of seal + nut tightening sequence

Goal: Wire a smart RS-485 probe to the HI520 and verify automatic recognition on the display.

Required Materials

Item	Notes
HI520 controller	Powered off before wiring
Smart probe (HI10x6, HI20x4, HI7630, HI7640, or HI7660 series)	With RS-485 interface (part code ending in -y8zz)
Patch cable (HI76510-xx)	Select length; DIN connector on probe end
Flat-head screwdriver	For cable gland and terminal screws

Procedure

1

Disconnect the HI520 from power.

2

Loosen the four captive spring screws on the front panel. Swing the front bezel open to the left to expose the terminal boards.

3

Identify the correct cable gland: conduit opening 1 for Probe 1 (CH1), conduit opening 3 for Probe 2 (CH2).

4

Thread the patch cable through the cable gland. Do not share the gland with the power cable.

5

On Terminal 2, locate the PROBE 1 or PROBE 2 connector block. Connect the cable leads following the marked polarity:
A, B (RS-485 data) · +10/5V (probe power) · mA · − (ground).

6

Tighten the cable gland to maintain IP65 sealing. Close and secure the front panel.

7

Reconnect power and power on the controller.

8

The controller automatically detects the probe. The Measure screen displays the parameter (e.g. pH °C) with a live reading.

9

If the probe is not recognised, check the wiring polarity and cable gland seating. For turbidity probes (HI7660-28), use Technical Menu → Restore HI7660-28XX if needed.

Probe info (model, firmware, serial number, factory calibration date) can be viewed at: m → Channel → Setup → Probe Settings → Probe Info.

Task 2 – pH Calibration

📷 Calibration menu on LCD
m → Channel → CAL — show buffer group selection screen

📷 CalData screen
Post-calibration — slope %, offset mV, date, temp offset

Goal: Perform a 2-point pH calibration using Hanna buffer solutions.

Required Materials

Item	Notes
pH 7.01 buffer (HI7007)	1st calibration point — always start here
pH 4.01 buffer (HI7004) or pH 10.01 buffer (HI7010)	2nd calibration point — choose based on application range
DI / distilled water	For rinsing probe between points
Soft tissue or cloth	To gently blot probe tip (do not rub)

Allow the probe to stabilise in the buffer for at least 1 minute before confirming. Calibrate at process temperature for best accuracy.

Procedure

1

Rinse the probe with DI water and gently blot dry.

2

Press m → select Channel (CH1 or CH2) → press CAL.

3

Enter the passcode if prompted. Press YES to place the controller in Hold.

4

Select buffer group: Hanna (1.68 / 4.01 / 7.01 / 10.01 / 12.45) or NIST (1.68 / 4.01 / 6.86 / 9.18 / 12.45).

5

Select 2-point calibration. The display prompts for the first buffer (pH 7.01).

6

Immerse the probe in pH 7.01 buffer. Wait for the reading to stabilise, then press CFM.

7

Rinse the probe with DI water and blot dry.

8

Immerse the probe in the second buffer (e.g. pH 4.01). Wait for stabilisation, then press CFM.

9

The controller saves calibration data to the probe. The controller exits Hold and returns to Measure mode.

10

Verify calibration: m → Channel → Setup → Probe Settings → CalData — displays slope, offset, date, and temperature offset.

Task 3 – Configure a Digital Input

📷 Inputs menu — Function drop-down
LCD screen: Disabled / Hold / Cleaning options visible

📊 Active level diagram
Signal timeline: High active (5–24 Vdc triggers) vs Low active (0 V triggers) — show both waveforms with relay state below

Goal: Configure Input 1 for each of the three available functions: Disabled, Trigger Hold, and Trigger Cleaning.

Navigation

1

Press m → navigate to Inputs.

2

Select Input 1 → press Setup.

3

Enter passcode if prompted. Press YES for Hold.

4

Navigate to Function → press Modify to open the drop-down.

5

Use ↑↓ to scroll between options → press Select to confirm.

Option A — Disabled

Select Disabled. The physical input signal is ignored. Use this when no external switch is connected to prevent false triggers.

Option B — Trigger Hold

Select Hold. When the input transitions to active, the controller enters Hold mode — control outputs freeze, Hold LED illuminates yellow.

Setting	Value
Active Level	High — input active when signal is 5–24 Vdc Low — input active when signal drops to 0 V

Typical use: external PLC signal or safety switch that holds the controller during maintenance or cleaning without using the keypad.

Option C — Trigger Cleaning

Select Cleaning. A transition on the input starts a cleaning cycle (Simple or Advanced, as configured in the Cleaning menu). The input appears as Ext. Trigger in the Cleaning setup.

Cleaning must be Enabled in the Cleaning menu for the external trigger to work. If cleaning is disabled, the input signal is ignored.

Task 4 – On/Off Control: CH1 pH + CH2 ORP

Goal: Configure CH1 for On/Off pH dosing control and CH2 for On/Off ORP control. The relay must be assigned in the Outputs menu before entering Control Settings — the setpoint only appears as a relay source after it has been created.

On/Off Low Mode – pH Control Chart

Hysteresis Direction – Critical Concept:

Mode	Relay turns ON when	Relay turns OFF when	Typical use
ON/OFF Low	PV falls below SetP1	PV rises to SetP1 + Hysteresis (above SP)	Base dosing — raises pH
ON/OFF High	PV rises above SetP1	PV falls to SetP1 − Hysteresis (below SP)	Acid dosing — lowers pH

Chart above: SetP1 = 7.00, Hysteresis = 2.00 → relay OFF at 9.00 pH. Alarm High at 10.00, Alarm Low at 5.00.

Step 1 – Assign Relay First (Outputs menu)

1

Press m → Outputs → press Setup.

2

Select Relay 1 → Setup. Set Function → Control.

3

Source: press Modify → select CH1 SetP1 → Select. Save and exit.

Why first? The HI520 only lists an active setpoint as a relay source. Assigning the relay before configuring Control Settings avoids a second trip to Outputs.

Step 2 – Configure CH1 pH Setpoint

1

Press m → Channel (CH1) → Setup → Control Settings → Setup. Enter passcode → YES for Hold.

2

Setpoint → SetP1 → Enabled: press Enable.

3

Value: set 7.00 pH → CFM.

4

Mode: press Modify → select ON/OFF Low (base dosing) → Select.

5

Hysteresis: set 2.00 pH → CFM. Pump will stop when pH reaches 9.00.

Step 3 – Safety Settings

Parameter	Recommended	Purpose
Min ON Time	3 s	Prevents relay chatter when PV hovers near setpoint
Overtime	60 min	Triggers alarm + stops relay if setpoint unreached — prevents overdosing
Delay Off	30 s	Keeps relay ON briefly after setpoint satisfied — allows reagent to mix

Step 4 – Alarm Configuration

1

In Control Settings → Alarm → SetP1 Alarm.

2

High Alarm: 10.00 pH — fire alarm if pH overshoots (pump fault or overdose).

3

Low Alarm: 5.00 pH — fire alarm if pH drops too low (underdose or probe fault).

4

Mask Time: 30 s — delay before alarm activates after setpoint change (avoids false alarms during dosing transients).

Optional – SetP2: Acid Back-Dosing

Add SetP2 if the process can also rise above target and needs acid correction. Works alongside SetP1 on the same channel.

1

Assign Relay 2 → CH1 SetP2 via Outputs → Relay 2 → Control → CH1 SetP2.

2

In Control Settings → SetP2 → Enabled → Enable.

3

Value: 9.50 pH · Mode: ON/OFF High · Hysteresis: 0.50 pH → acid pump stops at 9.00 pH.

Step 5 – CH2 ORP On/Off Control

1

First: Outputs → Relay 3 → Control → CH2 SetP1. Save.

2

Press m → Channel → highlight CH2 → Setup → Control Settings.

3

SetP1 → Value: 700 mV · Mode: ON/OFF Low (dose oxidant when ORP too low) · Hysteresis: 50 mV.

4

Overtime: 30 min. Exit and save. Assign Relay 3 alarm to a buzzer or indicator relay.

Step 6 – Commissioning Checklist

Check	How
Relay source correct	m → Outputs → Relay 1 → Source shows CH1 SetP1
Manual relay test	Outputs → Relay 1 → Manual Override → ON → verify pump runs → OFF
Stable measurement	CH1 displays stable pH before activating control
Hold released	Exit Setup — Hold icon disappears
Observe first cycle	Watch relay LED and pH. Confirm pump stops at SetP1 + Hysteresis (9.00 pH)

Troubleshooting

Symptom	Likely cause	Fix
SetP1 not visible as relay source	Control Settings not yet saved	Save Control Settings, re-enter Outputs
Relay chatters rapidly	Hysteresis too small	Increase Hysteresis; set Min ON Time = 3 s
Overtime alarm fires	Pump too weak or reagent empty	Check pump flow, reagent level, or increase Overtime limit
pH overshoots well above stop value	Delay Off too long or pump too large	Reduce Delay Off or lower pump flow rate
Alarm on every dosing cycle	Alarm Mask Time too short	Increase Mask Time to 30–60 s
SetP2 relay fires immediately	SetP2 in wrong mode	Confirm SetP2 mode = ON/OFF High (not Low)

Task 5 – Pool Control with Sequential Triggering

🔀 Sequential control system diagram
Pool → pH probe (CH1) → Relay 1 acid pump + Relay 2 base pump · ORP probe (CH2) → Relay 3 Cl pump · CH2 enabled only when CH1 SetP1 satisfied

Sequential Control Timeline

Goal: Implement pool water control where chlorine (ORP) dosing only activates when pH is within the correct range — replicating the safety interlock of a dedicated pool controller.

Comparison: BL13X vs HI520

Feature	BL13X (dedicated pool controller)	HI520 (universal process controller)
pH control	Built-in, fixed logic	CH1 — On/Off, fully configurable
Cl / ORP control	Built-in — Cl dosing blocked if pH out of range (e.g. <7.2 or >7.4)	CH2 — linked to CH1 setpoint via sequential triggering
Interlock logic	Hardware/firmware fixed	Configured by linking CH2 to CH1 SetP1
Flexibility	Pool-specific	Any parameter, any application

Why the interlock matters: Chlorine is only effective when pH is in range (7.2–7.4). Dosing Cl with incorrect pH wastes chemical and can cause safety issues. In BL13X, this interlock is automatic. In HI520, it is achieved through sequential control.

Setup – CH1 pH Control (7.2–7.4 target)

1

Configure CH1 SetP1: pH 7.3 · Mode ON/OFF Low (acid corrects high pH) · Hysteresis 0.10 pH → relay ON above 7.3, OFF below 7.2.

2

Configure CH1 SetP2: pH 7.3 · Mode ON/OFF High (base corrects low pH) · Hysteresis 0.10 pH → relay ON below 7.3, OFF above 7.4.

3

Assign Relay 1 → CH1 SetP1 (acid pump). Assign Relay 2 → CH1 SetP2 (base pump, if used).

Setup – CH2 ORP / Cl Control (sequential)

1

Press m → Channel → highlight CH2 → Setup → Control Settings.

2

Configure CH2 SetP1: ORP 700 mV · Mode ON/OFF Low (dose chlorine when ORP too low) · Hysteresis 50 mV.

3

In the CH2 Control Settings, find the Trigger (or linked channel) parameter. Set it to CH1 SetP1 — CH2 control only runs when CH1 SetP1 is satisfied (pH in range).

4

Assign Relay 3 → CH2 SetP1 (chlorine dosing pump).

5

Verify: when pH is outside 7.2–7.4, CH1 relay corrects pH and CH2 (Cl) relay remains off. When pH enters range, CH1 is satisfied and CH2 begins ORP control.

This replicates the BL13X interlock: pH must be in the correct window before Cl dosing is permitted.

Task 6 – Math Channel Setup

📷 Math channel on LCD
Single-channel display: "MathБ Difference: 139.1 µS/cm" — show actual screen

🔀 Differential monitoring setup
Diagram: Process flow → EC probe CH1 (inlet) → filter/membrane → EC probe CH2 (outlet) → HI520 Math channel → AO to PLC

Goal: Use the Math channel to display and monitor the difference between two identical parameter probes — for example, EC inlet vs EC outlet to track membrane or filter performance.

Requirements

Requirement	Details
Two probes	Must be the same parameter type (e.g. both EC, both pH) and identical measurement configuration
Channels	CH1 and CH2 both wired and enabled
Math output	Displays: CH1 − CH2 (difference)

Viewing the Math Channel

1

From the Measure screen, press ↓ to select CH2 as active channel (Б symbol moves to CH2).

2

Press ↓ again — the display switches to single-channel Math view showing the difference value (e.g. Difference: 139.1 µS/cm).

3

Press ↓ once more to return to dual-channel view.

Assigning an Analog Output to the Math Channel

1

Press m → Outputs → select the desired AO (e.g. AO 1) → Setup.

2

Parameter: press Modify → select Math from the parameter list → Select.

3

Set the 0/4 mA and 20 mA values to span the expected difference range (e.g. 0 µS/cm to 500 µS/cm).

4

The AO now outputs a signal proportional to the difference between CH1 and CH2 — usable by a PLC or SCADA for differential monitoring or alarm triggering.

The Math channel is display and output only — it cannot be assigned to a control setpoint or relay. It is intended for monitoring applications.

Task 7 – PID Controller Configuration

Tx Tuning – Step Response Method

P-only vs PID – Overshoot Comparison

📊 PID block diagram
SP → error → P term + I term + D term → Σ → PWM relay / AO output → Process → PV feedback loop. Label Deviation, Reset Time, Rate Time, Dead Band.

Goal: Configure a PID control loop on CH1 pH. Start with P-only, then add I and D terms after tuning.

Step 1 – Configure PID Mode

1

Press m → Channel (CH1) → Setup → Control Settings → Setup.

2

Enter passcode → YES for Hold.

3

Setpoint → SetP1 → Enabled: press Enable.

4

Value: set desired pH setpoint (e.g. 7.00).

5

Mode: press Modify → select PID → Select → press Setup.

Step 2 – Configure PID Parameters (start P-only)

Parameter	Start Value	Effect
Mode	PID Low or PID High	Low = dose to raise value; High = dose to lower it
Deviation	1.00 pH (adjust based on process)	Range where output scales 0–100%
Control Period	1.00 min	Update interval — start with 1.5× process reaction time
Reset Time	16:40 h (max — disables I term)	Start with I disabled; reduce only after P is tuned
Rate Time	0 s (disables D term)	Start with D disabled; add only for fast-changing processes
Dead Band	0.20 pH	Zone near setpoint where output = 0
Dead Band Gain	0 %	0% = full I suppression near setpoint (reduces overshoot)

Step 3 – Tuning Procedure

1

Set Log Interval to 10 seconds (General Settings).

2

Run the process from a value at least 3 pH away from setpoint. Dose at maximum capacity. Note start time.

3

Watch for the point of maximum rate of change (steepest slope). Stop dosing. Export the log to USB.

4

Plot the data. Draw a tangent at the steepest slope. Read the system time delay Tx on the time axis.

5

Calculate:
Deviation = Tx × max slope (pH/min)
Reset Time = Tx / 0.4 (minutes)
Rate Time = Tx × 0.4 (minutes)

6

Enter calculated values. If overshoot persists, increase Deviation or Reset Time slightly. Adjust one parameter at a time.

Reset Time and Rate Time should be configured by technical personnel only. Fine-tune incrementally and observe several control cycles before changing again.

Task 8 – Modbus Connection to PLC / SCADA

RS-485 Bus Topology – Multi-drop with Termination

📷 COMM connector wiring detail
Terminal 2 COMM block: A(+) and B(−) leads inserted. 120 Ω resistor bridging A–B at the end-of-bus terminal.

Goal: Wire the HI520 RS-485 port to a PLC or SCADA system and enable Modbus RTU remote control.

Step 1 – Physical Wiring

1

Power off the HI520. Open the front panel.

2

Thread the RS-485 cable through conduit opening 1 (signal path, same side as probe 1).

3

On Terminal 2, locate the COMM connector. Connect:
A (+) → RS-485 positive (data+)
B (−) → RS-485 negative (data−)

4

Connect the same A/B wires to the RS-485 port of the PLC or SCADA interface card, observing polarity.

120 Ω Termination Resistor: For RS-485 cable runs longer than approximately 10–15 m, install a 120 Ω resistor across A and B at each end of the bus (at the HI520 and at the PLC/SCADA). Without termination, signal reflections cause communication errors on long cables. Short bench connections typically do not need termination.

Step 2 – Enable Modbus on HI520

1

Press m → navigate to General → press Setup.

2

Navigate to Remote Control → press Enable.

3

Configure RS-485 communication parameters to match the PLC/SCADA:

Parameter	Common values
Baud rate	9600 / 19200 / 38400 bps
Parity	None / Even / Odd
Stop bits	1 or 2
Controller ID (Modbus address)	1–247 (unique per bus)

4

When connected, the Й icon appears in the top bar of the Measure screen. When in Remote Edit mode, Л is shown.

Step 3 – Modbus Register Map

The full register map is documented in the dedicated Modbus manual. Key register categories include:

Category	Examples
Measurement values	CH1 parameter value, CH2 parameter value, temperatures
Status & flags	Alarm status, Hold status, relay states, error codes
Control setpoints	SetP1/SetP2 values, alarm limits — read and write
Configuration	Control mode, hysteresis, AO range — via Remote Edit + Save
Commands	Force Hold, start/stop cleaning, manual relay override

Modbus Manual: Full register addresses and function codes are in MANMB5X0_09_23.pdf (static/Process folder).
Use Modbus function codes FC03 (Read Holding Registers) and FC16 (Write Multiple Registers) for most operations.

Task 9 – Advanced Cleaning Configuration

Advanced Cleaning Sequence – One Cycle

📷 Relay wiring for pumps
Relay 3 and Relay 4 NO–C terminals with pump power wiring. Use external contactor for loads >5 A / 250 Vac.

Goal: Wire a rinse water pump and a chemical wash pump to two relays, then configure Advanced Cleaning with a timed trigger.

Step 1 – Physical Wiring

1

Power off the HI520.

2

Wire the rinse pump to Relay 3 (or any unassigned relay): connect the load between NO and C terminals. Relay energised = pump ON.

3

Wire the chemical wash pump to Relay 4: same NO–C wiring.

4

Verify pump supply voltage does not exceed relay rating: 5 A / 250 Vac or 5 A / 30 Vdc. Use an external contactor for higher loads.

5

Power on the HI520.

Step 2 – Assign Relays to Cleaning

1

Press m → Outputs → select Relay 3 → Setup.

2

Function: press Modify → select Cleaning – Rinse → Select. Save.

3

Select Relay 4 → Function → Cleaning – Wash → Select. Save.

Step 3 – Configure Advanced Cleaning

1

Press m → Cleaning → press Setup. Enter passcode → YES for Hold.

2

Enabled: press Enable (check mark appears).

3

Type: press Advanced.

4

Int. Trigger: press Modify → select Timer → Select.

5

Cleaning Interval: set the desired cycle frequency (e.g. 60 min) → CFM.

Step 4 – Advanced Cleaning Parameters

Parameter	Typical Value	Description
Pre-wash rinse time	15 s	Rinse relay ON before chemical wash
Wash time	30 s	Wash relay ON — chemical detergent phase
Post-wash rinse time	30 s	Rinse relay ON to flush detergent
Wash cycles	1	Number of full rinse + wash cycles
Rinse-only cycles	1	Additional rinse-only passes after wash cycles
Recovery time	60 s	Time for probe to stabilise before control resumes

Step 5 – Verify

1

Trigger a manual cleaning: press the left virtual key while Cleaning is highlighted in the menu.

2

Observe the Rinse relay (Relay 3 LED on front panel) activating during pre-wash rinse phase.

3

Observe the Wash relay (Relay 4 LED) activating during the chemical wash phase.

4

The HOLD LED remains ON throughout the entire cleaning cycle. Control resumes after recovery time.

5

To stop cleaning early: hold ↓ + → keys simultaneously. The current rinse phase completes before stopping.