Pulsafeeder MicroVision Installation & Operation Manual

MicroVision

MICROPROCESSOR – BASED

WATER TREATMENT

CONTROLLER

Installation Operation Manual

72-910-16 Rev. N Page 1 of 43

Table of Contents

1. INTRODUCTION ...................................................................................................................... 4

2. MICROVISION FEATURES ....................................................................................................... 4

2.1 Toroidal Probe .............................................................................................................................. 4

2.2 Output Relays ................................................................................................................................ 5

2.3 Drum Levels .................................................................................................................................. 5

2.4 Flow Switch .................................................................................................................................. 5

2.5 4-20mA Output ............................................................................................................................. 6

2.6 Water Meter .................................................................................................................................. 6

2.7 Alarm Relay .................................................................................................................................. 6

3. INSTALLATION ......................................................................................................................... 7

3.1 Opening The Enclosure ................................................................................................................. 7

3.2 Location ........................................................................................................................................ 8

3.3 Mounting Hardware ...................................................................................................................... 8

3.4 Sensor Installation ......................................................................................................................... 9

3.5 Flow Sensor Switch ...................................................................................................................... 9

3.6 TYPICAL INSTALLATION ...................................................................................................... 10

4. IMPORTANT SYMBOL INFORMATION ................................................................................. 10

5. ELECTRICAL WIRING ............................................................................................................ 11

5.1 RELAY BOARD CONNECTIONS ........................................................................................... 12

5.2 Conduit Models (Wiring High Voltage) ..................................................................................... 12

5.3 LOW VOLTAGE CONNECTIONS .......................................................................................... 13

5.4 Flow Switch Input ....................................................................................................................... 14

5.5 Sensor (probe) Connection Input ................................................................................................ 14

5.6 Water Meter Input ....................................................................................................................... 14

5.7 Drum Level Input ........................................................................................................................ 14

5.8 4-20mA Output ........................................................................................................................... 14

5.9 Alarm Relay ................................................................................................................................ 14

6. FRONT PANEL DESCRIPTION ............................................................................................... 15

6.1 Keypad Operation ....................................................................................................................... 15

7. CONTROLLER PROGRAMMING .......................................................................................... 16

7.1 Menu Tree ................................................................................................................................... 16

7.2 Menu Navigation ........................................................................................................................ 17

7.3 Home screen ................................................................................................................................ 17

7.4 Main Menu .................................................................................................................................. 17

7.5 Status Screen ............................................................................................................................... 18

7.6 Configure Menu .......................................................................................................................... 18

7.7 Date/Time Menu ......................................................................................................................... 19

7.8 HOA Outputs Menu .................................................................................................................... 19

7.9 Water Meter Menu ...................................................................................................................... 20

7.10 Languages Menu ......................................................................................................................... 20

7.11 Drum Levels Menu ..................................................................................................................... 20

7.12 Display Dampener ...................................................................................................................... 21

7.13 Rising/Falling Setpoint Option ................................................................................................... 21

7.14 Display Contrast Setting ............................................................................................................. 22

7.15 Password Setting ......................................................................................................................... 22

7.16 Troubleshoot Screen ................................................................................................................... 23

7.17 Software Version ........................................................................................................................ 23

7.18 Factory Reset Function ............................................................................................................... 24

7.19 Settings Menu ............................................................................................................................. 25

72-910-16 Rev. N Page 2 of 43

7.20 Conductivity Menu ..................................................................................................................... 25

7.21 Inhibitor Menu ............................................................................................................................ 26

7.22 Inhibitor - Inhibitor Feed Mode Menu ........................................................................................ 27

7.23 Inhibitor - Inhibitor Feed Mode – Pulse Timer Menu ................................................................. 27

7.24 Inhibitor - Inhibitor Feed Mode – % Post Blowdown Menu ...................................................... 28

7.25 Inhibitor – Bio Tracking Menu ................................................................................................... 28

7.26 Biocide A or B Menu .................................................................................................................. 29

7.27 Biocide A or B – Days/Weeks Menu .......................................................................................... 30

8. Probe Calibration ................................................................................................................ 31

9. Factory Defaults .................................................................................................................. 33

10. TROUBLESHOOTING GUIDE ................................................................................................. 34

11. MAINTENANCE ..................................................................................................................... 36

12. SPECIFICATIONS ................................................................................................................... 36

13. GLOSSARY ............................................................................................................................ 38

14. MOUNTING HOLE PATTERN (Footprint) .............................................................................. 41

15. Factory Service Policy ......................................................................................................... 42

16. Warranty ............................................................................................................................... 42

72-910-16 Rev. N Page 3 of 43

1. 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 system’s 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

2. MICROVISION FEATURES

2.1 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.

72-910-16 Rev. N Page 4 of 43

Input AC

voltage

Sample

Current field

Induced current dependent on the conductivity of the sample

RELAY STATUS

LED COLOR

ON (FORCED ON FOR 5 MIN.)

AMBER

OFF

RED

AUTOMATIC ‘ON’

GREEN

AUTOMATIC ‘OFF’

OFF

Fig. 1

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.

2.2 Output Relays

The control of the four HANDS – OFF – AUTO (HOA) output relays can be controlled using the HOA menu.

2.3 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 drum’s identity will be displayed on the screen.

2.4 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.

72-910-16 Rev. N Page 5 of 43

If a flow switch input or other alarm condition exists, the four (4) LED’s will flash until the alarm condition is cleared.

2.5 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.

2.6 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.

2.7 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.

72-910-16 Rev. N Page 6 of 43

Input power cord must be disconnected from power source prior to opening the product’s enclosure.

3.1 Opening The Enclosure1

Loosen the four (4) screws on the front of the controller and carefully swing the top of the case to the right (Fig. 2).

J10

+5V

BLK

W METER

ALARM

ORG

BRN

RED

DRUM LEVEL

INHIB

BIO A

BIO B

FLOW

HINGE

BOTTOM HALF TOP HALF

(SWINGS OPEN TO THE RIGHT)

4-20mA

BLEED

INHIB

BIO A BIO B SUPPLY

BLEED

INHIB

BIO A BIO B

5AF25A

HOT

RET

HOT

RET

HOT

RET

HOT

RET

HOT

RET

HOT

RET

PL2

PL3

PL4

PL5

HOTnonc

Fig. 2

3. INSTALLATION

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

serviceable parts.

72-910-16 Rev. N Page 7 of 43

3.2 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 0°F (-17,8°C) OR GREATER THAN 122°F (50°C)}, 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.

MOUNTING HOLES .17 in. (4,4 mm) DIA.

BLEED

INHIB

BIO A BIO B SUPPLY

BLEED

INHIB

BIO A BIO B

5AF25A

HOT

RET

HOT

RET

HOT

RET

HOT

RET

HOT

RET

HOT

RET

PL2

PL3

PL4

PL5

HOTnonc

Fig.

Mount the bottom half of the controller using the four (4) holes provided (Fig. 3).

3.3 Mounting Hardware

For panel mounts without threaded inserts, four number 8 self taping screws are the minimum recommendation.

For panel mounts with threaded inserts, four 8-32 screws are the minimum

Page 8 of 43

72-910-16 Rev. N

recommendation.

Panel mount hardware should support 25lbs. For hole locations, see the mounting hole pattern (Fig. 9) found on the page 39 of manual.

3.4 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.

3.5 Flow Sensor Switch

If your controller is provided with a flow switch, install the flow switch so that flow enters into the bottom of the 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 no 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).

72-910-16 Rev. N Page 9 of 43

Fig. 4

MicroVision

Bleed Feed Biocide A Biocide B

DISPLAY SCREEN

3.6 TYPICAL INSTALLATION

Fig. 5

4. IMPORTANT SYMBOL INFORMATION

Warning indicates a condition that could cause damage to both

the equipment and the personnel operating it. Pay close attention

to any warning.

Primary Supply Ground must be connected to earth ground for safe

operation of your controller.

Chassis Ground – Connect your equipment’s ground wire here for

safe operation of your external devices.

72-910-16 Rev. N Page 10 of 43

5. ELECTRICAL WIRING2

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.

Devices attached to any Relay connection must be Single Phase and rated for the 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.)

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.

A switch or circuit-breaker, marked as the unit’s disconnecting device should be included in the installation. It should be in close proximity to the unit and easily reached by the user.

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.

Pre-wired controllers are supplied with a 3-wire grounded power cord and 3-wire grounded receptacle cords for all controlled line voltage outputs.

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

serviceable parts.

72-910-16 Rev. N Page 11 of 43

5.1 RELAY BOARD CONNECTIONS3

HOT

RET

HOT

RET

AC POWER IN

MOTORIZED BALL VALVE (4-WIRE)

PUMP (3-WIRE)

(RETURN / NEUTRAL) (EARTH / CHASSIS GROUND) (NORMALLY / OPEN)

(NORMALLY / CLOSED)

BLEED

INHIB

BIO A BIO B SUPPLY

BLEED

INHIB

BIO A BIO B

HOT

RET

HOT

RET

HOT

RET

HOT

RET

HOT

RET

HOT

RET

PL2

PL3

PL4

PL5

HOT

Do not apply power until this condition is verified.

Fig. 6

5.2 Conduit Models (Wiring High Voltage)4

Conduit controllers have openings for conduit connections for hard wiring. See Fig. 6 for input and output power connections. Use only 18 AWG (1,2 mm²) stranded wire

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

serviceable parts.

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

serviceable parts.

72-910-16 Rev. N Page 12 of 43

for conduit power and load connections. Supply (input) power is connected via PL5

J10

DRY ALARM RELAY (N.O.)

+5V

DRUM LEVEL DETECTORS

CONTACT METER

+5V GND

+5V

TOP BOARD

WATER METER TYPES

GND

BLK

W METER

ALARM

ORG

BRN

RED

DRUM LEVEL

INHIB

BIO A

BIO B

FLOW

COND SENSOR

HALL EFFECT

TOROIDAL PROBE

FLOW SWITCH

(3X)

FLOAT

04-000-18

16-171-81-2 26" (,66m)

04-350-91

16-171-81-1 26" (1,17m) 16-171-81-4 26" (1,52m)

+ -

4-20mA

located on the relay board (Fig. 6). The top part of this terminal block is removable to allow for easy access to the connector’s three (3) screws.

Make sure that all conduit connections are water tight.

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.

5.3 LOW VOLTAGE CONNECTIONS5

The low voltage connections are found on the low voltage (right side) board (Fig. 6). Use 22-24 AWG (,76 mm²) wire for: flow switch, drum levels, dry alarm, and water meter connections . These signal wires must be run separate from AC power lines.

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

serviceable parts.

72-910-16 Rev. N Page 13 of 43

Fig. 7

+ 30 hidden pages

Pulsafeeder MicroVision Installation & Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual