Microprocessor - Based Water Treatment Controller
Microprocessor - Based Water Treatment Controller
NOVA-TECH
I N T E R N A T I O N A L
800 Rockmead Dr Ste 102 Houston, TX 77339-2496 Tel: (281) 359-8538 Toll Free Tel: (866) 433-6682 Fax: (281) 359-0084 Toll Free Fax: (866) 433-6684 [email protected] www.novatech-usa.com
NOVA-TECH
I N T E R N A T I O N A L
800 Rockmead Dr Ste 102 Houston, TX 77339-2496 Tel: (281) 359-8538 Toll Free Tel: (866) 433-6682 Fax: (281) 359-0084 Toll Free Fax: (866) 433-6684 [email protected] www.novatech-usa.com
TABLE OF CONTENTS
INTRODUCTION.............................................................................................................................. 5 MICROVISION FEATURES....................................................................................................................... 5 Toroidal Sensor ........................................................................................................................ 5 Output Relays ............................................................................................................................ 6 Drum Levels ............................................................................................................................ 6 Flow Switch ........................................................................................................................................ 6 4-20mA Output ......................................................................................................................... 6 Water Meter ............................................................................................................................ 6 Alarm Relay ............................................................................................................................ 6 INSTALLATION ........................................................................................................................................ 7 Opening The Enclosure ............................................................................................................ 7 Location ................................................................................................................................... 8 Mounting Hardware ................................................................................................................... 8 Sensor Installation .................................................................................................................. 9 Flow Sensor Switch .................................................................................................................. 9 TYPICAL INSTALLATION ........................................................................................................... 10 IMPORTANT SYMBOL INFORMATION....................................................................................... 10 ELECTRICAL WIRING .................................................................................................................. 11 RELAY BOARD CONNECTIONS ................................................................................................. 12 Conduit Models ....................................................................................................................... 12 LOW VOLTAGE CONNECTIONS ................................................................................................ 13 Flow Switch Input..................................................................................................................... 14 Sensor (probe) Connection Input ......................................................................................... 14 Water Meter Input ........................................................................................................... 14 Drum Level Input ............................................................................................................... 14 4-20mA Output ....................................................................................................................... 14 Water Meter .......................................................................................................................... 14 Alarm Relay ............................................................................................................... 14 FRONT PANEL DESCRIPTION ................................................................................................... 15 Keypad Operation ................................................................................................................ 15 CONTROLLER PROGRAMMING ................................................................................................ 16 Menu Tree ............................................................................................................................. 16 Menu Navigation .................................................................................................................... 17 Home Screen ....................................................................................................................... 17 Main Menu ......................................................................................................................... 17 Status .......................................................................................................................... 18 Configure Menu ....................................................................................................................... 18 Date/Time Menu ................................................................................................................ 19 HOA Relay Output Menu......................................................................................................... 19 Water Meter Menu ................................................................................................................ 20 Drum Level Menu ................................................................................................................ 20 Display Dampener Settings ................................................................................................ 21 Rising/Falling Set Point Selection............................................................................................ 21 Display Contrast Setting .......................................................................................................... 21 Password Setting ................................................................................................................ 22 Troubleshoot Screen ............................................................................................................... 22 Software Version ................................................................................................................ 23 Factory Reset Function .......................................................................................................... 23 Settings Menu ............................................................................................................................ 24 Conductivity Menu ................................................................................................................... 24 4-20mA ............................................................................................................................. 25
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800 Rockmead Dr Ste 102 Houston, TX 77339-2496 Tel: (281) 359-8538 Toll Free Tel: (866) 433-6682 Fax: (281) 359-0084 Toll Free Fax: (866) 433-6684 [email protected] www.novatech-usa.com
Inhibitor Menu .......................................................................................................................... 25 Inhibitor Inhibitor Feed Mode Menu...................................................................................... 25 Inhibitor Inhibitor Feed Mode Pulse Timer Menu ............................................................. 26 Inhibitor - Inhibitor Feed Mode % Post Blowdown Menu ..................................................... 27 Inhibitor Bio Tracking Menu ................................................................................................. 27 Biocide A or B ......................................................................................................................... 28 Biocide A or B Days/Weeks Menu ...................................................................................... 28 CALIBRATION ............................................................................................................................. 29 FACTORY DEFAULT VALUES/ USER SETTINGS ..................................................................... 31 TROUBLESHOOTING GUIDE ................................................................................................... 32 MAINTENANCE .......................................................................................................................... 34 SPECIFICATIONS ....................................................................................................................... 34 GLOSSARY ................................................................................................................................. 35 MOUNTING HOLE PATTERN ...................................................................................................... 38 FACTORY SERVICE POLICY....................................................................................................... 39 WARRANTY ................................................................................................................................. 39 EC DECLARATION ...................................................................................................................... 40
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800 Rockmead Dr Ste 102 Houston, TX 77339-2496 Tel: (281) 359-8538 Toll Free Tel: (866) 433-6682 Fax: (281) 359-0084 Toll Free Fax: (866) 433-6684 [email protected] www.novatech-usa.com
INTRODUCTION
The MicroVision microprocessor based cooling tower controller has been designed to monitor and control Total Dissolved Solids (TDS) in terms of electrical conductivity measured in micro Siemens per centimeter (uS/cm). A set point of the desired conductivity is entered into the controller through the front panel. As this limit is exceeded, a bleed valve is opened via an onboard control relay. The systems water, with higher concentrations of TDS, is bled resulting in fresh make-up water being added, reducing the concentration of TDS in the cooling system. In addition to the bleed relay, MicroVision has three (3) other onboard control relays assigned as follows:
Relay 1 - Bleed control Relay 2 - Inhibitor timer (selectable) Relay 3 - Biocide A Relay 4 - Biocide B
MICROVISION FEATURES
Toroidal Probe
MicroVision uses a toroidal probe for conductivity measurement. The measurement is made by passing an AC current through a toroidal drive coil, which induces a current in the electrolyte solution (see Fig.1). This induced current in turn, induces a current in a second toroidal coil, called the pick-up toroid. The amount of current induced in the pick-up toroid is proportional to the solution conductivity.
Input AC voltage
Sample
Current field
Fig. 1
72-910-16 Rev. E Page 5 of 40
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The main advantage of toroidal conductivity is that the toroidal coils are not in contact with the solution. They are encased in a polymeric material or are external to a flow through cell.
Output Relays
The control of the four HANDS OFF AUTO (HOA) output relays can be controlled using the HOA menu.
Drum Levels
Three (3) onboard dry contact inputs serve as Drum Level inputs. When a low level is detected (switch closure), the unit will go into an Alarm state and the low drums identity will be displayed on the screen.
Flow Switch
MicroVision has a dry contact flow switch input that will de-activate all of the control output relays upon a no-flow indication. An Alarm condition will be indicated and No Flow will be displayed. This input is active closed: Open = no flow; closed = flow.
If a flow switch input or other alarm condition exists, the four (4) LEDs will flash until the alarm condition is cleared.
4-20mA Output
Connect your 4-20mA equipment to J8 (Fig. 7) pins + and -. The 4-20mA output uses 24VDC as a supply voltage. See the Conductivity Menu section (Page 24) for setting up and calibrating the 4-20mA output.
Water Meter
MicroVision has a dedicated water meter that is capable of reading a dry contact or Hall effect type water meter. Through programming this input can be used to feed inhibitor as well as totalizing water consumption.
Alarm Relay
MicroVision has a dedicated dry contact relay that can be used to interface with process control equipment or visual indicators. This relay is un-powered
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INSTALLATION
Opening The Enclosure
Loosen the four (4) screws on the front of the controller and carefully swing the top of the case to the right (Fig. 2).
HINGE
RET
RET
RET
RET
RET
PL2 HOT
PL3 HOT
PL4 HOT
no HOT nc HOT
PL5 HOT
4-20mA
ORG
W METER
INHIB BLEED
BIO A
BIO B
SUPPLY
J3
J2
BLK
+5V
RED
BRN
J8
BIO A
BIO B J10 FLOW INHIB BLEED BIO A BIO B 5A HOT F2 5A RET F1 ALARM J5 J4
BOTTOM HALF
Fig. 2
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Location
Select a mounting location convenient to grounded electrical and plumbing connections. It is recommended that you mount the controller on a wall or other vertical surface with adequate lighting at a comfortable level. A mounting-hole template is supplied with your controller. Installation should comply with all national, state, and local codes.
AVOID LOCATIONS WHERE THE CONTROLLER WOULD BE SUBJECTED TO EXTREME COLD OR HEAT {LESS THAN 0F (-17,8C) OR GREATER THAN 122F (50C)}, DIRECT SUNLIGHT, VIBRATION, VAPORS, LIQUID SPILLS, OR EMI (ELECTROMAGNET INTERFERENCE; E.G., STRONG RADIO TRANSMISSION AND ELECTRIC MOTORS.)
SAFETY PROTECTION PROVIDED BY THE EQUIPMENT MAY BE IMPARED IF THE EQUIPMENT IS USED IN A MANNER NOT SPECIFIED BY THE MANUFACTURER. THIS CONTROLLER IS INTENDED FOR INDOOR USE ONLY.
RET
RET
RET
RET
PL2 HOT
PL3 HOT
PL4 HOT
no HOT nc HOT
INHIB BLEED
BIO A
BIO B
PL5 HOT
RET
SUPPLY
INHIB BLEED
BIO A
BIO B
5A HOT F2
5A RET F1
Fig. 3 Mount the bottom half of the controller using the four (4) holes provided (Fig. 3).
Mounting Hardware
Typically, use a #8 screw or equivalent. For hole locations, see the mounting hole 72-910-16 Rev. E Page 8 of 40
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Sensor Installation
The controller is supplied with a temperature compensated toroidal conductivity sensor (probe). Install the sensor at some point in your process where chemical and water are thoroughly mixed. The probe should also be located in a position where adequate flow is going around and through the probe (Fig. 4) so that the controller will be able to display a good measurement.
Fig. 4
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TYPICAL INSTALLATION
Bleed
DISPLAY SCREEN
MicroVision
Fig. 5
Chassis Ground Connect your equipments ground wire here for safe operation of your external devices.
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ELECTRICAL WIRING
CONTROLLER MUST BE WIRED IN ACCORDANCE WITH ALL APPLICABLE ELECTRICAL CODES.
The MicroVision electronic input circuitry is fuse protected on both the hot and neutral inputs using a replaceable five amp fuse (Fig .6). For additional protection of your instrument, use of a surge protector is recommended.
The controller should be connected to a dedicated power branch (i.e., its own wiring, circuit breaker, etc.). For best results, the ground should be independent (true earth) not shared.
A switch or circuit-breaker, marked as the units disconnecting device should be included in the installation. It should be in close proximity to the unit and be easily reached by the operator
Pre-wired controllers are supplied with a 3-wire grounded power cord and 3-wire grounded receptacle cords for all controlled line voltage outputs.
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PUMP (3-WIRE)
(RETURN / NEUTRAL) (EARTH / CHASSIS GROUND) (NORMALLY / OPEN)
HOT RET
AC POWER IN
RET
RET
RET
RET
PL2 HOT
PL3 HOT
PL4 HOT
no HOT nc HOT
INHIB BLEED
BIO A
BIO B
INHIB BLEED
BIO A
BIO B
5A HOT F2
5A RET F1
Fig. 6
MAKE SURE THAT YOUR CONTROLLER VOLTAGE MATCHES THE INPUT VOLTAGE. DO NOT APPLY POWER UNTIL THIS CONDITION IS VERIFIED.
PL5 HOT
RET
SUPPLY
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The four (4) output relay terminal blocks are identified as: PL1 (Bleed), PL2 (INHIB), PL3 (BIO A), and PL4 (BIO B). These terminal blocks can be removed in the same manner as PL5. The Bleed relay has a N.O. and a N.C. connection, the others are only N.O.
8 mA
20
TOROIDAL PROBE
04-000-18 16-171-81-2 26" (,66m) 16-171-81-1 26" (1,17m) 16-171-81-4 26" (1,52m)
DRUM LEVEL DETECTORS
+ J8
+ ORG BRN W METER
DRUM LEVEL
4-20mA
J3 J2
COND SENSOR
BLK
+5V
RED
INHIB
BIO A
(3X)
TOP BOARD
BIO B
J10 J4
FLOW SWITCH
FLOW
14-350-91
ALARM
J5
J3
DRY ALARM RELAY (N.O.)
CONTACT METER
+5V GND
OR
J3
+5V GND
FLOAT
Fig. 7
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Low voltage signal wires, e.g., water meter, must be run separate from AC power lines. These connections will be covered in the Low Voltage section of the manual.
If you do not have a flow switch, a jumper wire must be connected across J4.
4-20mA Output
Connect your 4-20mA equipment to J8 (Fig. 7) pins + and -. The 4-20mA output uses 24VDC as a supply voltage. See the Conductivity Menu section (Page 24) for setting up and calibrating the 4-20mA output.
Alarm Relay
Use J5 to connect your alarm reporting equipment. This relay will close when an alarm condition exists and will open when no alarm conditions are present. See the Trouble Shooting Guide (Page 33) for a description of alarm codes and their probable causes.
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Bleed
DISPLAY SCREEN
MicroVision
Fig. 8
Keypad Operation
UP/DOWN - Dual function keys. Used to move the select (highlighted) box and to increase and decrease values.
O O
displayed screen. The keys function appears above the key on the display.
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CONTROLLER PROGRAMMING
Menu Tree
HOME SCREEN
STATUS MENU
ENTER PASSWORD
CONFIGURE
DATE & TIME
SETTINGS
CONDUCTIVITY
HOA OUTPUTS
SETPOINT
LANGUAGE
LIMIT TIMER
WATER METER
DIFFERENTIAL
DRUM LEVELS
PROBE CAL
DISP.DAMP
ALARM SETP'T
RISE/FALL
4-20 OUTPUT
CONTRAST
INHIBITOR
PASSWORD
TROUBLESHOOT
BIO TRACKING
SOFTWARE VER
BIOCIDE A or B
FACTORY RST.
DAYS/WEEKS
START TIMES
FEED TIMES
PRE BLEED
BLEED LKOUT
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Menu Navigation
Microvision uses four front panel buttons to navigate through the different menus. Use these buttons to move up and down within a list of options or move right and left to enter or change parameter values. In some cases the Microvision display will prompt you to press the different buttons to assist you in selecting or changing data. Some menus may display highlighted menu options or a checkmark () next to a menu option. The highlighted menu option is used to indicate that another menu will be displayed if this option is chosen. The checkmark indicates that a particular control mode has been selected. Date/Time HOA Outputs Water Meter Back | Select Auto On 5 Min Off Back | Select
Home screen
This screen is displayed during normal operation when there are no alarm conditions on the Microvision. If an alarm condition occurs an alarm message will flash on the screen. The four LEDs to the right of the display will also flash indicating an alarm has occurred. The Microvision will return to this screen home screen if no buttons are pressed for five minutes after entering a menu.
01/23/07 | 11:42a
1256
Main Menu
uS
Status | Menu
The Main menu is the starting point for all subsequent menus.
Home Screen
Configure This menu allows you to set the time and date, display contrast, water meter, etc. Settings This menu allows you to set the conductivity, inhibitor feed modes, and biocide control timers.
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Status Screen
Home Screen Water Meter: 0000000000 Bleed: 123.4 Inhib 123.4 BioA: 123.4 BioB 123.4 Probe Temp: 24.4 C Last Error: Low Flow
Back | Reset This screen shows the real-time data relating to the controller. This screen can be used to log the amount of time a particular output was energized since it was last reset. Below is a description of each of the data fields: Water Meter The amount of water that has been registered by the controllers water meter input. Bleed The amount of time, in hours, the bleed output was energized since it was last reset. Inhib The amount of time, in hours, the inhibitor output was energized since it was last reset. BioA The amount of time, in hours, the biocide-A output was energized since it was last reset. BioB The amount of time, in hours, the biocide-B output was energized since it was last reset. Probe Temp Current probe temperature in Celsius. Last Error Shows the most recent error that was displayed on the controller. Pressing the reset key will cause the hour timers and water meter to reset to zero.
Configure Menu
From the Configure menu you can select many different system configuration options.
Home Screen Configure
Date/Time HOA Outputs Water Meter Language Drum Levels Disp Damp Rise/Fall Contrast Password Troubleshoot Software Ver Factory Rst Back | Select
Date/Time Set the current date, date format, time, and time format. HOA Outputs Manually control the four output relays. 72-910-16 Rev. E Page 18 of 40
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Water Meter Set the water meter type and volume. Language Change the controller displayed language. Drum Levels Set the control output mode when a drum level goes low. Display Dampener Set the display and control update period. Rise/Fall Select between a rising or falling Setpoint mode of operation. Contrast Set the display contrast. Password Set the user password. Troubleshoot View the signal inputs in real-time to diagnose wiring problems. Software Version Displays the current software version. Factory Restore Restore the parameters to factory default.
Date/Time Menu
From the Date/Time menu you can set the data and time as well as the date and time display formats.
Home Screen Configure Date/Time
Set Date Set Time Date Format Time Format Back | Select
Set Date Set the current date. Set Time Set the current time. Date Format Pick the day/month/year format. Time Format Pick the 12-hour or 24-hour time of day format.
Bleed Force the bleed control output on or off. Inhibitor Force the inhibitor control output on or off. Biocide A Force the biocide A control output on or off. Biocide B Force the biocide B control output on or off. Auto Return the control output to normal operation. On 5 Min Energize the control output for five minutes. Off De-energize the control output indefinitely. 72-910-16 Rev. E Page 19 of 40
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Forcing the output to Auto may cause the control output to energize without warning.
Back | Select
Meter Type Select between a dry contact or Hall-effect water meter. Once the type is selected enter the resolution or volume per pulse. Units Select gallons or liters as a unit of measure for water calculations. Totalizer This displays the current amount of water the controller has counted. You can reset the totalizer from this menu.
Languages Menu
Home Screen Configure Language
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Pump Stops Selecting this mode causes the inhibitor, biocide A, or biocide B outputs to de-energize when their drum level goes low. Pump Runs Selecting this mode causes the inhibitor, biocide A, and biocide B outputs to remain energized even though their drum level has gone low. When a drum level goes low the controller will go into alarm regardless of this setting. Re-filling a low drum may cause the pump control output to energize without warning.
Display Dampener
From the Display Dampener setting option you select how often you want the actual conductivity reading updated on the Home Screen and dampening of the controller response to sudden changes in conductivity.
Home Screen Configure Disp Damp
Display Dampener Set this value to the number of seconds you want the controller to dampen the displayed conductivity and controller response. The controller takes a conductivity reading every second. Increasing this value above one second causes the controller to average the readings, hence, slowing down the control functions.
Rising Setpoint Select this option if a cooling tower is being controlled. Falling Setpoint Select this option if the conductivity tend to fall as a result of the process.
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Contrast Adjust this value up or down to give you the best display contrast.
Password Setting
From the Password setting you select the user password that will be required to gain access to the Configuration and Settings menus. Once the password is set to anything other than 0000 (4zeros) the password feature is enabled. To disable password protection return the password to 0000 (4-zeros).
Home Screen Configure Password
Password Set the user password. Once the password is set the controller will require a password to access any menus. If the password is lost or unknown you will have to call technical service to gain access to the controller menus. Please have the controller in front of you when you place the call.
Troubleshoot Screen
From the Troubleshot Screen you can view the Microvision control inputs in real-time. This is a great tool for checking the correct operation of sensors that are attached to the controller.
Home Screen Configure Troubleshoot
Flow: NoflowInhib: OK BioA: OK BioB: Empty Water Meter: Open Cond: 1256uS Temp:25.2 Wk: 2 Day:Mon Sec:23
Back | Back Flow Water flow switch input (J4 pins 1-2).Flow=closed, Noflow = open. Inhib Inhibitor drum level input(J10 pins 1-2). Empty=closed, OK=open. BioA Biocide A drum level input(J10 pins 3-4). Empty=closed, OK=open. Inhib Biocide B drum level input(J10 pins 5-6). Empty=closed, OK=open. Water Meter Water meter input (J3 pins 1-3). Open=contact open, closed=contact closed. 72-910-16 Rev. E Page 22 of 40
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Cond Probe conductivity reading. Temp Probe temperature. Wk Revolving week number between one and four. This is used in the biocide Days/Weeks settings. Day Day of week. This is used in the biocide Days/Weeks settings. Sec - Current clock seconds. While this screen is displaying information the controller is still functioning normally and relay outputs may energize without warning due to changing signal inputs.
Software Version
From the Software Version screen you can view the current software that is running in the Microvision controller.
Home Screen Configure Software Ver
Use this function to reset the controller back to the factory defaults. Be absolutely certain you want to reset all the parameters back to the factory defaults. Once the reset takes place there is no way to retrieve the previous parameters.
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Settings Menu
From the Settings menu you access the conductivity, inhibitor feed, and dual biocide feed parameter sections.
Home Screen Settings
Conductivity Set the conductivity setpoint, differential, probe calibration, alarms, and 4-20ma output parameters. Inhibitor Set the inhibitor feed and biocide tacking modes. Biocide A Set the biocide A days and weeks, start times, feed time, and bleed options. Biocide B Set the biocide B days and weeks, start times, feed time, and bleed options.
Conductivity Menu
From this menu configure the parameters that trigger the bleed control output and optionally the inhibitor feed functions. Additionally, the conductivity probe calibration, alarm setpoints, and the scalable 4-20ma output functions are also configured in this section.
Setpoint Differential Limit Timer Probe Cal Alarm Setpt 4-20 Output Back | Select
Setpoint Set the conductivity setpoint. This is the conductivity point where a bleed function will begin. Once the conductivity has reached this value the bleed function will begin. Differential The differential setting controls when the bleed function stops. This value subtracted from the conductivity setpoint causes the bleed function to stop. Example: Setpoint=1200, Differential=100, the bleed function begins when the conductivity reaches 1200 and ends when the conductivity reaches 1100. Limit Timer Set this value to the maximum amount of time the bleed output can stay energized before a Bleed Limit alarm is reported. The limit time setting only reports the 72-910-16 Rev. E Page 24 of 40
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alarm and does NOT turn off the bleed output. If the next bleed cycle completes without an alarm the alarm will clear itself. Setting this value to 00:00 turns off this function. Probe Calibration Use this function to calibrate the probe. Enter the calibrated conductivity value that you would like the controller to display. The conductivity probe is very sensitive to temperature changes. Allow the probe roughly 10 minutes to adjust to the temperature of the test solution or sample. Calibrating the probe without allowing the probe to equilibrate to the sample temperature could result in erroneous controller conductivity readings. Only use a calibration meter that incorporates temperature compensation when performing a probe calibration. Alarm Setpoint Pick the type of conductivity alarm tracking you want to use. Track Setpoint Use this type if you want an alarm when the conductivity reaches above or below the conductivity setpoint an equal amount. Example: Setpoint=1200, Track Setpoint=200, an alarm will be reported when the conductivity reaches above 1400 or below 1000. Independent Setpoint Use this type if you want to specify an upper and lower conductivity value for alarm reporting. Example: Setpoint=1200, low=900, high=1450, an alarm will be reported when the conductivity reaches above 1450 and below 900. 4-20 Output Use this option to configure how you want the 4-20ma output to behave with respect to the conductivity reading. Adjust Range Use this option to set the low and hi conductivity readings used to scale the 4-20ma output. Example: Low Range=500, High Range=2000, when the conductivity reading is 500 the 4-20 ma output would be 4ma, when the conductivity reading is 2000 the 4-20ma output would be 20ma. Calibrate Output Use this option to calibrate or fine-tune the 4-20ma output. You can adjust both the 4ma and 20ma settings a small amount to compensate for un-calibrated downstream meters or displays.
Inhibitor Menu
From this menu configure the parameters that control the inhibitor chemical feed control output.
Home Screen Settings Inhibitor
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Pulse Timer Limit Timer Cycle Timer % Post Bld Back | Select
Pulse Timer See the menu for this function in the following section. Limit Timer Set this value to the maximum amount of time you want the inhibitor to feed while the bleed function is running. If this time is exceeded the controller will go into alarm and the inhibitor feed control output will de-energize. Cycle Timer Set the inhibitor feed time period and percentage of the time period. Example: Cycle Time=60minutes, % Minutes to run=10, the inhibitor will feed for 10% of 60 minutes, or 6 minutes every 60 minutes. %Post Blowdown See the menu for this function in the following section.
Feed Time Set this value to the amount of time you want the inhibitor to feed when the water meter accumulator reaches its target. Accumulator Set Set this value to the amount of water that needs to accumulate prior to an inhibitor feed. The units will be in gallons or liters depending on what you set the water meter units to. Accumulator Count This is the current running count of the inhibitor water meter accumulator.
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Percentage Set this value to the amount of time, as a percentage, you want the inhibitor to feed after a blowdown function has completed. Example: % of Bleed=25%, the most recent blowdown cycle took 20 minutes, the inhibitor will now feed for 25% of 20 minutes, or 5 minutes. Limit Time Set this value to the maximum amount of time you will allow inhibitor to feed after a blowdown cycle has completed. Setting the timer to 00:00 turns off this function.
Skip Choose this option if you want the inhibitor to skip a feed cycle if a biocide happens to be feeding. Pause Choose this option if you want the inhibitor feed cycle to pause or delay until the biocide feed cycle is complete. When the biocide feed cycle is complete the inhibitor will then feed. None Choose this option if you want the inhibitor to feed regardless of what the biocide feed cycles are doing. Any inhibitor feed time that was paused or skipped due to a biocide feed cycle will not be added to the next inhibitor feed cycle. 72-910-16 Rev. E Page 27 of 40
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Biocide A or B Menu
From this menu configure how often and the duration you want the biocide to feed. This controller can also perform a pre-bleed, using a conductivity minimum and a fixed time, and bleed-lockout function with each biocide feed.
Home Screen Settings Biocide A or B
Days/Weeks Start Times Feed Time Pre-Bleed Bleed Lkout Back | Select
Days/Weeks Set the days and weeks you want the biocide to feed. See the next section for details on how to set the days and weeks. Start Times Set up to four start times. Setting the value to 00:00 means the start time is ignored. Feed Time Set this value to the amount of time you want the biocide to feed each time a feed cycle is started. Pre-Bleed Set the pre-bleed time to the maximum amount of time you want the prebleed function to force a bleed cycle without reaching the conductivity minimum. Set the conductivity minimum to the value you want the conductivity to reach before the bleed cycle finishes and the biocide is feed. Bleed Lockout Set this value to the amount of time you want to lock-out a bleed function after a biocide feed cycle has completed.
ALL | SUN| MON| TUE WED| THU| FRI | SAT Days On|Off Cancel | Enter
ALL | EVN| ODD| 1ST 2ND | 3RD| 4TH | Weeks On|Off Wk#2 Cancel | Enter
- Select the biocide start days and weeks by using the up and down buttons to the right of the display. Move the cursor to the right or left by using the button to the bottom of the 72-910-16 Rev. E Page 28 of 40
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display. The selected day or week will flash as the cursor is moved to each setting. The flashing On|Off text indicates if the current setting is on or off. - If a day or week is highlighted, or appears as reverse video, that particular day or week will have biocide feed. - The week # shown in the lower right of the display indicates which week number the controllers time is currently set to.
Probe Calibration
Because there are no metal electrodes to foul no re-calibration is required of this toroidal probe on a regular basis. However, you may want to calibrate the probe initially to get a base-line reading for future reference. There are two methods of probe calibration that can be used to calibrate this probe.
Step 2 Draw a sample of the process flow water and measure the conductivity using a calibrated meter. Be certain the meter you are using to measure conductivity is temperature compensated. Write down the conductivity value and sample temperature. Conductivity____________uS/cm Sample Temperature__________ C
Do not allow the sample to sit for any length of time after being drawn as this will cause the temperature of the sample to be different from the probe. Step 3 Enter the calibrated conductivity value into the Probe Calibration screen.
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If the conductivity reading varies more than 25 counts from the reading of the calibration meter verify the sample temperature is within 1 C of the probe temperature. Step 4 Return to the Home Screen and verify the proper conductivity reading is displayed.
Step 3 Enter the standard solution conductivity value into the Probe Calibration screen.
Home Screen Settings Conductivity Probe Cal
Step 4 Return to the Home Screen and verify the proper conductivity reading is displayed.
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Factory Defaults
Parameter Configuration Date Format Time Format Water Meter Type Water Meter Pulse Volume Water Meter Units Drum Levels Display Dampener Rise/Fall Setpoint Display Contrast Password Language Settings Conductivity Setpoint Conductivity Differential Conductivity Limit Timer Alarm Setpoint 4-20ma Low Range 4-20ma High Range Inhibitor Feed Mode Inhibitor Limit Timer Inhibitor Biocide Tracking Biocide A and B Days/Weeks Biocide A and B Start Times Biocide A and B Feed Time Biocide A and B Pre-Bleed Time Biocide A and B Pre-Bleed Conductivity Minimum Biocide A and B Bleed Lockout Default MM/DD/YY 12hr Clock Dry Contact 100 Gallons Pumps Run 1 Second Rising 26 0000(disabled) English 1500 50 00:00(disabled) Track Setpoint/200us 0 9999 Limit Timer 1-hour, 30-minutes None All Days/All weeks 00:00(disabled) 1-minute 00:00(disabled) 1475 00:00(disabled)
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TROUBLESHOOTING GUIDE
Symptom Controller does not power up. Probable Cause No power supplied to controller. Possible Solution Insure that correct voltage is supplied to controller. Check circuit breaker supplying power to the controller. check/replace fuses F1-F3 (see Figure X, Page X) Check ribbon cable connecting upper and lower pc boards inside controller. Insure there is enough water flow through the assembly. At least 1 GPM (3.8 LPM) of flow. Check flow switch connections (see Figure X, Page X). Clean flow switch sensor mechanicals. Clean inside flow assembly. Install jumper if flow switch is not used. Adjust conductivity low limit setting (See Figure X, Page X). Prime flow assembly. Replace/clean bleed valve. Adjust conductivity high limit setting (See Figure X, Page X). Clean flow assembly.
Fuse is blown. Ribbon cable. Controller displays No Flow alarm message. No flow thru flow assembly. Flow switch wiring or connector loose. Flow switch stuck. Flow assembly clogged. Flow switch input jumper missing. Conductivity reading below programmed low limit. Excessive amount of air in and around conductivity probe. Bleed valve stuck open. Conductivity reading above programmed high limit. Excessive amount of solids and/or debris in and around conductivity probe. Faulty bleed valve. Clogged bleed valve or drain. Inhibitor drum fluid level low. Drum level switch wiring or connector loose. Drum level switch stuck. Biocide A drum fluid level low. Drum level switch wiring or connector loose. Drum level switch stuck. Biocide B drum fluid level low. Drum level switch wiring or connector loose. 72-910-16 Rev. E Page 32 of 40
Replace bleed valve. Clean valve or drain. Refill drum. Check switch connections (See Figure X, Page X). Clean switch sensor mechanicals. Refill drum. Check switch connections (See Figure X, Page X). Clean switch sensor mechanicals. Refill drum. Check switch connections (See Figure X, Page X).
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Drum level switch stuck. Programmed inhibitor feed limit timer set too short. Clogged bleed valve or drain. Faulty bleed valve. Probe temperature too high. Probe temperature compensation circuitry failure. Conductivity probe wiring or connector loose. Bad Conductivity probe Internal controller clock failure. Conductivity Limit timer set too short. Bleed valve/drain failure. Internal controller failure. Conductivity reading is within specification.
Clean switch sensor mechanicals. Adjust limit timer value to longer duration (See Figure X, Page X). Clean valve or drain. Replace bleed valve. Allow process water to cool. Replace probe. Check probe connections (See Figure X, Page X). Replace probe. Replace controller. Adjust limit timer. Clear obstruction around drain. Replace controller. Due to variations in hand-held meters, conductivity standard solutions, temperature compensation, and the controllers accuracy of +/- 2% of scale, the reading on the controller may not match that of your hand-held tester exactly.
Controller displays "Probe Comm" alarm message. Controller displays "Clock Err" alarm message. Controller displays "Bleed Limit" alarm message. Controller displays "Watchdog" alarm message. Conductivity reading on controller does not match portable hand-held reading.
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MAINTENANCE
The only recommended maintenance required on your controller is periodic inspection of the conductivity sensor every 6 months. It is recommended that you establish a regular maintenance schedule designed to meet the needs of your particular application. All other service should be performed by factory authorized personnel only. Modifications to or tampering with the circuit level components makes all warranties, written or implied, and/or manufacturers responsibility for this controller, null and void.
DISCONNECT POWER BEFORE OPENING THE UNIT TO ACCESS FUSES. MAKE SURE THAT REPLACEMENT FUSES ARE OF SAME TYPE TO MAINTAIN SAFTEY APPROVALS.
FUSE F1 & F2
SPECIFICATIONS
Controller
Enclosure Enclosure Dimensions Power supply Display Accuracy NEMA 4X/IP67 6.4" x 3.2" x 3.2" (163 x 82 x 82mm) 120 or 220 VAC; 50/60Hz. LCD 0 - 9,999 S/cm range 1S/cm resolution +/- 2% of scale 120 VAC: 5 A Resistive/General use 4LRA/4FLA,1/10HP (motors) 220 VAC: 5 A Resistive/General use Not rated for motors
Probe
Maximum temperature Temperature compensation range Maximum pressure Probe type Maximum cable length Materials of construction Thread size Maximum outside diameter Conductivity reading 122 F (50C) 32F 122F (0 50C) 125 PSI (8,6 BAR) Toroidal 100 Feet (30,5 Meters) Polypropylene Standard thread -Excludes Tee and Reducer 1.5 (38 mm)- Excludes Tee and Reducer 0-9999 uS/cm; 1 uS/cm increments
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Flow Switch
Maximum temperature Maximum pressure Activate flow rate Materials of construction 127F (52C) 125 PSI (8,6 BAR) Approximately 1 GPM (3,785 LPM) PVC and Glass filled Polypropylene
GLOSSARY
Alarm Relay an electric circuit when triggered by a predetermined signal will activate an externally connected alarm Analog a continuous signal (4-20mA) that can be used to represent a physical variable, e.g., conductivity Biocide an agent used to control the growth of algae and other organic substances Bleed to release water from the system, used to control conductivity Bleed Valve the valve that opens or closes to release water from the system activated by a signal from the Controller Buffer Solution a solution with a specific pH value used as a control in calibrating probes. Calibration a procedure to match values read by probes to actual real world values Chattering a situation that occurs when relay controlled device repeatedly turns off and on Chemical Feed Pump a relay or proportionally controlled pump that disperses chemical into the system (e.g., PULSAtron) Chemical Metering Pump see Chemical Feed Pump Conductivity the ability of a substance to conduct electrical current, concentrations of dissolved and suspended solids in water directly determine the conductivity of the water Conduit tubing through which wire is run Configure procedure to setup basic functions of the controller, i.e., date, time, set point control, etc. Contacting head water meter a water meter that outputs a dry contact signal every time it pulses Contrast difference in brightness between adjacent objects, e.g., darkness of text in screen display verses background Cooling Tower a structure of various sizes that allows heat to radiate away from the system water Cursor See prompt Cycle Timer a timing device that can be preset to turn off and on at specific intervals Differential also referred to as dead band or hysteresis, this is a range or offset applied to a set point value (see chattering) Dry Contact relay contacts without power Electrodes or probes, the metal protrusions that measure conductivity in the conductivity probe assembly Float Switch a mechanical switch that provides an electrical contact when the water level rises to a predetermined height Flow refers to the movement of water through the system Flow Assembly an option, which attaches to the controller and incorporates a flow switch, probe/probe ports, and sample valve Hall Effect Water Meter Solid state flow detection device Heat Exchanger a mechanical device that facilitates the transfer of heat between two mediums High Current 20 mA signal Hi Lo Alarm a function of the controller that signals the user when conditions exceed a predetermined high or low value HOA abbreviation for Hands-Off-Auto relay control Inhibitor a chemical or compound used to aid the control of corrosion or scaling in the cooling tower system
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Inhibitor Feed term referring to the disbursement of inhibitor in to the system Inhibitor Timer a function of the controller that regulates the amount of time inhibitor is introduced to the system Initialization a procedure to reset the controller to original factory conditions Inorganic Scale Deposits undesirable precipitate formations within the cooling tower system Inputs receptacles or hock-ups for signals delivered to the controller Interval the amount of time between bleed events Isolated Input an input (analog or digital) that is electrically isolated from main power supply and its ground (ISO) Isolation Valves general term that refers to valves in the system used to isolate various components of the system from the main flow Jumper a wire connector (shunt) that connects two (2) points LED abbreviation for Light Emitting Diode Limit Timer also referred to as lockout timer or feed limit timer, it limits the amount of time output is activated Line Voltage voltage equivalent to outside source voltage to the controller Lockout intentionally preventing bleed or other functions of the system Low Current 4 mA signal Menu Map printed document supplied with controller illustrating all menu item locations Metering Pump see chemical feed pump Micro Siemens unit of measure of conductivity expressed as S/CM Outputs receptacles or hook-ups for signals originated at the controller Overfeed a condition in which the quantity of an ingredient dispersed into the system exceeds the amount desired Percent Post Bleed refers to the amount of time as a percentage of bleed time that chemical feed pumps are activated when bleed down is deactivated Percent Timer also referred to as a cycle timer that runs continuously that activates an output to run as a percent of total cycle time Pre Bleed refers to the time bleed is executed before biocide feed Program Parameters the user programmed settings that determine how the controller responds to conditions of the system under control Prompt a curser used to indicate the active menu line Pulse the action of a water meter that when equipped with a contact head, can generate a dry contact closure that can be read by the controller Pulse Timer a feature of the controller in which a timer accepts pulses from a water meter to actuate a chemical feed pump Relay Indicators lights (LEDs) located on the face of the control panel that indicate the status of individual relays Sample to obtain a quantity of water for test purposes, Sample Cock see Sample Valve Sample Line a line through which a portion of the system water flows, where probes and other monitoring devices are located controlled with isolation valves Sample Valve small valve on the flow assembly that provides user a means to drain small quantities of water from the system for testing Security Code a code that can be entered by the user when configuring the system to secure access to the controller settings Probe a device connected to the controller which monitors or measures a characteristic value in the water, like the conductivity Sensor see Probe
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Set point the user determined value within a monitored range at which the controller initiates action (e.g., activates a relay) Set point Differential also referred to as dead band or hysteresis; the offset applied to a set point to prevent chattering of an output relay around a set point Soft Keys Buttons on front panel used to input information Solenoid an electromagnetically controlled switch System Overfeed usually a malfunction condition where a feed pump fails in the Run (ON) condition System Parameters see program parameters TDS abbreviation for Total Dissolved Solids, measured in terms of electrical conductivity (S/CM) Temperature Compensation displays conductivity as if measured at 77F (25C) Toroidal Conductivity Non-contacting conductivity sensor used for high values Totalizer a re-settable function of the controller that keeps count of the number of water meter pulses S/CM conductivity unit of measure. Often referred to as micro Siemens Y-Strainer inline filter or screen to remove debris from system flow assembly
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Fig. 9
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Your MICROVISION is a state of the art microprocessor based controller. If you are experiencing a problem with your process control instrument, first consult the troubleshooting guide in this manual. If the problem is not covered or cannot be solved, contact Technical Services for assistance: PULSAFEEDER INC. (SPO) 27101 AIRPORT ROAD PUNTA GORDA, FL 33982 941-575-3800 Trained technicians are available to diagnose your problem and arrange a solution. Solutions may include purchase of replacement parts or returning the controller to the factory for inspection and repair. All returns require a Return Authorization number to be issued by Pulsafeeder. Parts purchased to correct a warranty issue may be credited after an examination of original parts by Pulsafeeder. Warranty parts returned as defective which test good will be sent back freight collect. No credit will be issued on any replacement electronic parts. Any modifications or out-of-warranty repairs will be subject to bench fees and costs associated with replacement parts.
Warranty
Pulsafeeder, Inc. warrants control systems of its manufacture to be free of defects in material or workmanship. Liability under this policy extends for 24 months from date of shipment. Electrodes/probes are considered maintenance items and as such are warranted for six (6) months from the date of shipment of the controller. Electrodes/probes purchased as spare parts are warranted for 24 months from date of shipment. The manufacturer's liability is limited to repair or replacement of any failed equipment or part, which is proven defective in material or workmanship upon completion of the manufacturer's examination. This warranty does not include removal or installation costs and in no event shall the manufacturer's liability exceed the selling price of such equipment or part. The manufacturer disclaims all liability for damage to its products through improper installation, maintenance, use, or attempts to operate such products beyond their functional capacity, intentionally or otherwise, or any unauthorized repair. The manufacturer is not responsible for consequential or other damages, injuries, or expense incurred through the use of its products. The above warranty is in lieu of any other warranty, whether expressed or implied. The manufacturer makes no warranty of fitness or merchantability. No agent of ours is authorized to provide any warranty other than the above.
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EC Declaration of Conformity
We, Pulsafeeder Inc., declare under sole responsibility that Microvision equipment to which this declaration relates is in sole conformity with relevant sections of the applicable EC standards and other normative documents listed on this document. If changes are made to the product which is covered by this declaration of conformity, the declaration of conformity is no longer valid.
- Radiated emissions EN 61326 - Harmonic current emissions (EN 61000-3-2-1995+A14:1998) - Voltage fluctuations and flicker (EN 61000-3-3: 1995) - Electrostatic Discharge Immunity Test (EN 61000-4-2:95) - Radiated immunity test (EN 61000-4-3:96) - Electrical Fast Transient/Burst Immunity Test (EN 61000-4-4:95) - Surge Immunity Test (EN 61000-4-5:95) - Immunity to conducted disturbances (EN 61000-4-6:96) - Power Frequency Magnetic Field Immunity Test (EN 61000-4-8:93) - Voltage Dips,Short Interruptions and Voltage Variations Immunity Tests (EN61000-4-11:1994) - 2002/96/EG (WEEE) compliant - RoHS complient
USA Pulsafeeder, Inc. 27101 Airport Rd. Punta Gorda, FL 33982 USA (941) 575-3800 www.pulsa.com
European Union (EU) Knight UK Limited 15 Brunel Centre Newton Road Crawley, West Sussex RH10 9TU, UK
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