Pulsafeeder MICROtrac Installation And Operation Manual

MICROtrac

MICROPROCESSOR – BASED
WATER TREATMENT
CONTROLLER

Installation and Operation Manual

MICROtrac Warranty

Pulsafeeder, Inc. warrants MICROtrac control systems (including the conductivity sensor) of its
manufacture to be free of defects in material or workmanship. Liability under this policy extends 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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1. I

NTRODUCTION

2. I

NSTALLATION

Table of Contents

....................................................................................... 4

........................................................................................ 4

2.1 Controller Location ........................................................................ 4

2.2 Sensor Installation ......................................................................... 4

3. E

LECTRICAL WIRING

............................................................................... 6

3.1 Electrical Connections ................................................................... 7

4. S

YSTEM OPERATION

............................................................................... 9

4.1 Front Panel .................................................................................... 9

4.2 System Functions .......................................................................... 10

4.3 Controller Programming ................................................................ 11

4.3.1 Control Modes .......................................................................... 11

4.3.2 Conductivity Set Point .............................................................. 13

4.4 Alarm Conditions ........................................................................... 13

5. S

ENSOR CALIBRATION

6. F

ACTORY DEFAULT VALUES

7. S

PECIFICATIONS

8. T

ROUBLE SHOOTING GUIDE

..................................................................................... 15

............................................................................ 14

.................................................................... 14

.................................................................... 17

9. C

ONTROLLER MOUNTING DIMENSIONS

10.

11.

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DDENDUM: MICROTRAC PC BOARD REPLACEMENT

MICRO

TRAC FACTORY SERVICE POLICY

..................................................... 18

..................... 19

...................................... 20

3

1. Introduction

Your microprocessor-based controller has been designed to monitor and control the conductivity of your
process water. The controller energizes two relay outputs based on a bleed and feed mode of operation.

- When the conductivity measurement goes above the user defined set point, (2) two relays are

energized until the conductivity goes below the set point minus the fixed differential value.

The feed relay will also de-energize when the user programmable feed limit time is
reached.

- Optional - The feed control relay will energize based on a percentage of a 10 minute feed cycle.

Your controller may or may not have the following optional configurations:

Pigtails (pre-wired)

The controller is pre-wired with a power cord and drop down receptacles for plugging in control
devices such as a solenoid valve or a metering pump.

Flow Switch

The controller is supplied with a flow switch that is installed into the process flow line to signal
the controller that your system has water flowing. When there is a no flow state, the controller
will not energize the outputs.

2. Installation

2.1 Controller Location

Select a mounting location convenient to grounded electrical and plumbing connections. Mount the
controller on a wall or other vertical surface with adequate lighting at a comfortable level. Remove
the four screws that retain the front panel and remove it, mounting passages are located in each of
the four corners in the back of the enclosure (See page 15). 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 0°F (-17,8°C) or greater than 122°F (50°C)}, direct sunlight, vibration,
vapors, liquid spills or EMI (electromagnetic interference; e.g., strong radio
transmission and electric motors). The controller could be damaged and void the
warranty!

2.2 Sensor Installation

The controller is supplied with a temperature compensated conductivity sensor (probe). Install the
sensor at some point in your process where chemical and water are thoroughly mixed. If the sensor
is to be placed in a tank or sump, ensure that it is installed so that the black shrink-wrapped part of
the probe cable is not submerged. The probe should also be located in a position where adequate
flow is going across and through the probe.

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Fig. 1: Typical Installation

For maximum accuracy, make sure that the conductivity sensor is installed so
the liquid stream passes straight through the round probe hole (see Fig.2).

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Fig. 2: Probe Alignment

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Flow Sensor

Devices attached to an

y Relay connection must be Single Phase and rated for the

A switch or circuit

-

breaker, marked as the unit’s disconnecting device

If your controller is provided with a flow switch, install the flow switch so that flow enters into the
bottom of the provided flow switch tee, and out of the side of the tee. The flow switch must always
be installed in a vertical position so that the sensor wire is coming out of the top, and the internal
(red) flow shuttle is able to rise when there is flow and drop when there is not flow. The flow switch
is activated when 1 GPM (3.8 LPM) is going through it, and is deactivated when the flow drops
below 1 GPM (3.8 LPM).

3. Electrical Wiring1

The controller electronic circuitry is fuse protected. Use of a surge protector and Ground Fault
Circuit Interrupter (GFCI) are strongly recommended!

Controller must be wired in accordance with all applicable electrical codes.

Input power must be 120 or 220VAC Single Phase.

Trained service personnel are required for all electrical connections. This product
does not contain operator serviceable parts.

same voltage as the input voltage to the product. (e. g. 120VAC MicroTrac
controllers support 120VAC relay attached devices exclusively and 220VAC
MicroTrac controller support 220VAC relay attached devices exclusively.) Do not
apply power until this condition is verified.

Input power cord must be disconnected from power source prior to opening the
product’s enclosure and making any electrical connections.

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.

should be included in the installation. It should be in close proximity to the
unit and easily reached by the user.

1

Trained service personnel are required for all electrical connections. This product does not contain operator serviceable

parts.

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Pre-wired controllers are supplied with 6 ft (1,8 m), 18 AWG (1,2 mm2) 3-wire grounded power
cords and clearly marked 18 AWG (1,2 mm2) 3-wire grounded receptacle cords for all controlled
line voltage outputs.

Controllers that are to use electrical conduit are factory pre-drilled with easily accessible connections
for hard wiring of input and output power connections. Use only 16 AWG (1,5 mm2) or 18 AWG
(1,2 mm2) wire for conduit power and load connections.

3.1 Electrical Connections2

If your controller was not ordered as a pre-wired controller, hard wiring will be required. With the
main power disconnected from the controller, loosen the four screws that retain the front panel of the
controller and remove the front panel. There are five terminal block connectors inside the controller
that will need to be wired.

Supply power

The controllers supply power is identified on the main PC board as location PL3 (refer to
Fig. 3 on page 8). There are three connections identified on the board for this terminal block,
HOT (LINE), RTN (return or Neutral), and Ground.

Flow and Water Meter Inputs

These two inputs are located on connector PL2. This is where the two wires from the flow
switch or water meter will connect. Polarity on this terminal block is not important.

If your controller is not equipped with a flow switch, there should be a jumper
wire installed across PL2. (See Fig.3)

Dose/Feed (metering pump)

This control output is identified on the controller PC board as location PL4. The terminal
block connections for PL4 are HOT (LINE), RTN (return or Neutral), and Ground.

This control output can drive pumping equipment based on the bleed and feed with limit
timer mode. This output energizes when the programmed conductivity set point is exceeded.
This output will de-energize when the conductivity reading falls below the set point minus
the fixed set point differential (-5% of set point) or when the programmed feed limit time is
exceeded.

Optional - This output energizes for a programmed percentage of a fixed 10 minute feed
cycle.

The controller is fused at 5 amps maximum. Both output devices combined can
not exceed 5 amps of current.

2

Trained service personnel are required for all electrical connections. This product does not contain operator serviceable

parts.

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