Pulsafeeder MicroVision EX Installation & Operation Manual
EX
MicroVision
MICROPROCESSOR – BASED
WATER TREATMENT
CONTROLLER
Installation Operation Manual
72-900-06 Rev. F
Page 1 of 38
Table of Contents
1. GENERAL WARNINGS ............................................................................................................................... 4
2. MicroVision
3. INSTALLATION ............................................................................................................................................ 6
3.1 Location ...................................................................................................................................................... 6
3.2 Mounting Hardware ............................................................................................................................... 6
3.3 Opening the Enclosure ......................................................................................................................... 6
3.4 Sensor Installation ................................................................................................................................. 7
3.5 TYPICAL INSTALLATION ...................................................................................................................... 7
3.6 IMPORTANT SYMBOL INFORMATION .............................................................................................. 8
3.7 ELECTRICAL WIRING ............................................................................................................................ 8
3.8 Flow Switch Input ................................................................................................................................ 12
3.9 Sensor (probe) Connection Input .................................................................................................. 12
3.10 Water Meter Input ........................................................................................................................... 12
3.11 Drum Level Input ............................................................................................................................. 12
3.12 4-20mA Output ................................................................................................................................. 12
3.13 4-20mA Input .................................................................................................................................... 12
3.13.1 Fluorometer – Trace Chemical ............................................................................................ 13
3.13.2 Calibrating PTSA Probe .......................................................................................................... 14
3.14 Alarm Dry Contact Relay ............................................................................................................... 14
3.15 Keypad Operation ............................................................................................................................ 15
3.16 Communications (Optional) ......................................................................................................... 15
4. CONTROLLER PROGRAMMING ............................................................................................................. 16
4.1 Menu Map ................................................................................................................................................ 16
4.2 Menu Navigation ................................................................................................................................... 16
4.3 Home screen .......................................................................................................................................... 16
4.4 Main Menu ............................................................................................................................................... 17
4.5 Relay HOA ............................................................................................................................................... 17
4.6 Configure ................................................................................................................................................. 17
4.6.1 Date/Time ....................................................................................................................................... 17
4.6.2 Digital Inputs ................................................................................................................................. 18
4.6.3 4-20mA Out and 4-20mA In .................................................................................................... 18
4.6.4 Gal/Lit ............................................................................................................................................... 18
4.6.5 Meter Totals .................................................................................................................................... 18
4.6.6 Languages Menu ........................................................................................................................... 18
4.6.7 Display Settings ............................................................................................................................ 19
4.6.8 Password Setting .......................................................................................................................... 19
4.6.9 Software Version .......................................................................................................................... 20
4.6.10 Factory Reset Function ........................................................................................................... 20
4.7 Settings .................................................................................................................................................... 20
4.7.1 Conductivity ................................................................................................................................... 20
4.7.2 pH and ORP .................................................................................................................................... 22
4.7.3 4-20mA Outputs (Optional Accessory) ................................................................................ 24
4.7.4 4-20mA Inputs (Optional Accessory) ................................................................................... 24
4.8 Timers - Modes ..................................................................................................................................... 24
4.8.1 Timers – Pulse Timer .................................................................................................................. 25
4.8.2 Timers – Percent Timer ............................................................................................................. 25
4.8.3 Timers - 28 day (Biocide Timer) ............................................................................................ 25
4.8.4 Timers – % Post Bleed ............................................................................................................... 26
4.8.5 Timers – Limit Timer (Bleed and Feed) ............................................................................... 26
4.8.6 Timers – Alarm .............................................................................................................................. 26
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EX
FEATURES .......................................................................................................................... 4
4.8.7 Timers – Set Point Control Mode ........................................................................................... 26
4.8.8 Timers – Disabled (Default) ..................................................................................................... 27
4.8.9 Timers – Bio Tracking (In All Timer Modes) ...................................................................... 27
4.9 Communications ................................................................................................................................... 27
4.10 USB ........................................................................................................................................................ 27
4.10.1 USB Graphing Tool .................................................................................................................. 28
4.10.2 USB Data log Timer and Tamper Codes: ........................................................................ 28
4.11 Ethernet (Optional) ......................................................................................................................... 29
4.11.1 Programming your controller PulsaLink........................................................................... 29
4.11.2 Setting Up Your Controller on PulsaLink ......................................................................... 29
5. FACTORY DEFAULTS ............................................................................................................................... 30
6. TROUBLESHOOTING GUIDE ................................................................................................................. 32
7. MAINTENANCE ........................................................................................................................................... 33
7.1 Conductivity Sensor removal and cleaning ................................................................................ 33
To remove the conductivity sensor from its tee for cleaning: .................................................... 33
To clean conductivity sensor: .................................................................................................................. 33
7.2 pH sensor Information ....................................................................................................................... 33
7.2.1 Preparation ..................................................................................................................................... 33
7.2.2 Sensor Storage ............................................................................................................................. 34
7.2.3 Sensor Cleaning ............................................................................................................................ 34
7.3 ORP Sensor Information .................................................................................................................... 34
7.3.1 ORP Maintenance and Troubleshooting ............................................................................... 34
7.3.2 Testing ORP Sensor ..................................................................................................................... 34
7.3.3 Flow Sensor .................................................................................................................................... 35
8. SPECIFICATIONS ...................................................................................................................................... 35
9. FORSEABLE MISUSE ............................................................................................................................... 36
10. MOUNTING HOLE PATTERN (Footprint) ........................................................................................... 37
72-900-06 Rev. F
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Introduction
RELAY STATUS
LED COLOR
ON (FORCED ON FOR 5 MIN.)
AMBER
OFF
RED
AUTOMATIC ‘ON’
GREEN
AUTOMATIC ‘OFF’
OFF
The MicroVisionEX 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). Some models also include pH, and
ORP control. A set point of the desired value to control is entered into the controller
through the front panel. As this limit is exceeded, a valve, pump or other control device
is activated via an onboard control relay to adjust the reading being measured.
1. GENERAL WARNINGS
Symbol hereinafter and upon the unit means WARNING!
If the equipment is used in a manner not specified by the manufacture, the overall
safety may be impaired.
The plug is considered mains power. Disconnection means should be readily
identifiable and easily accessible to the operator after install
Adequately rated and APPROVED/CERTIFIED power supply cord and plug (supplied
by Pulsafeeder), or cable gland suitable for the applicable country is to be attached
and replaced by manufacturer’s authorized qualified person or as per applicable local
and national regulations
Controller is for indoor use only and not suitable for wet location. Controller housing
is IP65 compliant and may be configured as such.
Verify the mains supply ratings (e.g. Volts, Amps, and Hz) where the controller is to
be powered from and ratings of the accessories as well as ratings of the controller’s
receptacles/outlets before powering up.
2. MicroVisionEX FEATURES
Toroidal Probe
MicroVisionEX 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. 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.
Output Relays
The control of the HANDS – OFF – AUTO (HOA) output relays can be controlled using the
HOA menu.
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Drum Levels
Three (3) onboard dry contact inputs serve as Drum Level inputs. When a low level is
detected the unit will go into an alarm state and the low drum’s identity will be displayed
on the screen. The user can program the alarm to deactivate a timer if desired. Drum
level #1 is assigned to timer #1, drum level #2 is assigned to timer #2 and drum level
#3 is assigned to timer #3.
Flow Switch
MicroVisionEX 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 “Flow
Switch Alarm” will be displayed. This input is active closed:
Open = no flow; closed = flow.
If a flow switch input or other alarm condition exists, the LED’s on the front
panel will flash until the alarm condition is cleared.
4-20mA Outputs and Inputs
Optional 4-20mA inputs or outputs can be installed to increase the capabilities of the
MicroVisionEX. Connect 4-20mA equipment to the + and – terminals as shown on page 9.
Water Meter
MicroVisionEX has a dedicated water meter input that is capable of reading a dry contact
or Hall effect type water meter. Through programming this input can be used to signal a
pulse timer as well as totalizing water consumption. Some models offer up to six (6)
water meter inputs.
Alarm Relay
MicroVisionEX 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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3. INSTALLATION
3.1 Location
Select a mounting location convenient to grounded (True Earth) electrical and
plumbing connections. It is recommended that the controller is mounted on a wall or
other vertical surface with adequate lighting at a comfortable level. Installation
should comply with all national, state, and local codes.
Avoid locations where the controller would be subjected to direct
sunlight, extreme cold, heat, or humidity {less than 36°F (2.2°C) or
greater than 122°F (50°C), or greater than 95% RH non-condensing,
direct sunlight, vibration, vapors, liquid spills, or EMI (electromagnetic
interference; e.g., strong radio transmission and electric motors.)
Install at less than 2000m above sea level.
SAFETY PROTECTION PROVIDED BY THE EQUIPMENT MAY BE IMPAIRED IF THE
EQUIPMENT IS USED IN A MANNER NOT SPECIFIED BY THE MANUFACTURER.
THIS CONTROLLER IS INTENDED FOR INDOOR USE ONLY AND NOT SUITABLE
FOR WET LOCATION.
3.2 Mounting Hardware
Mount the controller using the four (4) holes provided.
Typically, use a #8 screw or equivalent. The mounting screw should be appropriate
for the location mounting on, i.e., sheet metal screws for mounting onto sheet metal,
wood screws for mounting onto wood or wall studs, and hollow wall drywall anchors
for mounting to drywall. Mount should be designed for 7.5 Kg, 17 lbs.
Mount the unit ergonomically, such that the unit is visible without excessive
bending or lowering of the body, and not too high such that the internals are
not visible with opening the enclosure.
3.3 Opening the Enclosure
Loosen the knob that secures the clear front cover. Then loosen four (4) screws in
the four corners of the front of the controller and carefully swing the top of the case
forward.
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3.4 Sensor Installation
Over pressurization of the plumbing can occur when cooling tower is higher than the
piping and controller system. Ensure all pressures have been accounted for. Verify piping
and sensor allowable temperatures are above maximum temperatures of the system.
Conductivity
The controller is supplied with a temperature compensated toroidal conductivity probe
installed in a tee. The probe should only be installed where adequate flow is going around
and through the hole in the center of the probe in the tee provided.
pH and ORP
When ordered as a pH or ORP model the controller will be supplied with standard pH and
ORP probes. The probes are supplied installed in a tee. The probes should only be installed
where flow between 1 and 5 GPM is going around the probe.
Flow Switch
If the 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 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).
3.5 TYPICAL INSTALLATION
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3.6 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 the controller.
Chassis Ground – Connect the equipment’s ground wire here for safe
operation of external devices.
Notes to provide tips and hints
3.7 ELECTRICAL WIRING
CONTROLLER MUST BE WIRED IN ACCORDANCE WITH ALL APPLICABLE
ELECTRICAL CODES, NEC, CSA, EN, OR LOCAL AUTHORITY HAVING
JURISDICTION.
The MicroVisionEX electronic input circuitry is fuse protected on both the hot and
neutral inputs using a replaceable eight amp fuse (see page 9). For additional
protection of this instrument, use of a surge protector is recommended.
The controller should be connected to a dedicated power branch (i.e., its
own wiring, GFCI 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 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.
Plug is considered as mains power disconnecting device which shall be readily
identifiable and easily accessible.
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RELAY BOARD CONNECTIONS
Energy Usage and Duty
The unit utilizes a variety of probes and input signals to control valves, pumps,
and numerous other devices. These items are not all used in a continuous
fashion. The typical unit has a complicated duty cycle dependent on application.
For 120V and a max of 8A, a typical duty cycle of 15 minutes on and 45 minutes
off can be used. This results in an energy calculation of
120V * 8A *Power Factor* 25%
The Power Factor is the cosine of the phase angle between the Current and
Voltage of an AC circuit. Typically, 0.8 is a good estimate for US power.
The 25% is the estimate of a typical duty cycle of 15 on and 45 off.
For 240V, the amperage remains constant.
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Relay Assignments
Relay 1
Relay 2
Relay 3
Relay 4
Relay 5
Relay 6
Relay 7
Relay 8
Dry contact
Model
OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
OUT 7
OUT 8
P4
MVECXXX
Bleed
Timer 1
Timer 2
Timer 3
Alarm
MVEC5XX
Bleed
Timer 1
Timer 2
Timer 3
Timer 4
Alarm
MVECPXX
Bleed
pH
Timer 1
Timer 2
Timer 3
Timer 4
Timer 5
Timer 6
Alarm
MVECOXX
Bleed
ORP
Timer 1
Timer 2
Timer 3
Timer 4
Timer 5
Timer 6
Alarm
MVECPOX
Bleed
pH
ORP
Timer 1
Timer 2
Timer 3
Timer 4
Timer 5
Alarm
MVECPOM
Bleed
pH
ORP
Timer 1
Timer 2
Timer 3
Timer 4
Timer 5
Alarm
Conduit Models (Wiring High Voltage)
Conduit controllers have openings for conduit connections for hard wiring. Use only 18
AWG (1,2 mm²) stranded wire for conduit power and load connections. Supply (input)
power is connected via P10 located on the relay board. The top part of this terminal block
is removable to allow for easy access to the connector’s three (3) screws. For CE rated
models ensure all ferrites are installed in their specified configuration.
MAKE SURE THAT THE CONTROLLER VOLTAGE MATCHES THE INPUT VOLTAGE
AND OUTPUT VOLTAGES. DO NOT APPLY POWER UNTIL THIS CONDITION IS VERIFIED.
Make sure that all conduit connections are water tight.
The output relay terminal blocks are identified as: OUT 1 through OUT 8 these terminal
blocks can be removed in the same manner as P10. The first four relay outputs have a
N.O. and a N.C. connection, the others are N.O.
Ensure the snubber’s remain on
each of the relay outputs in the
specified wiring configuration.
Unit is to be connected to supply
mains by a qualified personnel in
accordance with local and
national codes e.g. NEC in the U.S. and CEC in Canada.
A suitable power disconnection means is to be provided
e.g. circuit breaker or switch which is identifiable and
easily accessible to the end user.
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DIGITAL BOARD CONNECTIONS
Digital
Inputs
Input 1
Input 2
Input 3
Input 4
Input 5
Inputs 6 & 7
Inputs 8,9
and 10
Function
Flow
Switch
Drum
Level #1
Drum
Level #2
Drum
Level #3
Water
Meter
Water
Meter
Water Meter
Assignment
N/A
Timer #1
Timer #2
Timer #3
WM #1
WM #2 & 3
WM #4 to #6
Location
P1
P2
P3
P4
P5
P6 and P7
P8, P9, P10
Dry Contact
√ √ √ √ √ √ √
Hall Effect
√ √
The low voltage connections are found on the top board.
Use 22-24 AWG (,76 mm²) wire for: flow switch, drum levels, dry alarm, and water meter
connections. A recommended wire is OMNI cable DS92203. These signal wires must be
run separate from AC power lines.
Clock Battery # 09-710-04
Low voltage signal wires, e.g., water meter, must be run separate from AC power lines.
Digital Input assignments
There are 5 digital inputs on base conductivity models and up to 10 on featured models.
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3.8 Flow Switch Input
It is recommended that a flow switch or auxiliary dry contact be used to make outputs
inoperative when the cooling tower is shut down. Connect detection wires to P1 to use
this interlock feature. This is active – closed: open = no flow; closed = flow.
If the controller does not have a flow switch, a jumper wire must be
connected across P1.
3.9 Sensor (probe) Connection Input
The controller is supplied with sensors prewired. Depending on the model, the
conductivity probe wires are connected to Probe 1, pH sensor on Probe 2, ORP sensor on
Probe 3, and Make up conductivity on Probe 4.
Always depressurize the unit prior to removing a sensor.
3.10 Water Meter Input
Connect the water meter to P5 on the top board. Some models have additional water
meters on P6 through P10. In order to wire a dry contact type water meter or contact
closure to a 3-port digital input, connect the two leads to the signal and ground ports.
3.11 Drum Level Input
The drum level connections are labeled as, P2 for Level 1, P3 for Level 2, and P4 for level
3. These are active closed: closed = low level; open = level is OK. The input can also be
reversed (NO or NC) in the programming.
3.12 4-20mA Output
The 4-20mA outputs, ordered separately, can be used to remotely measure any of the
controllers probe inputs and any of the 4-20mA inputs. Connect the 4-20mA receiving
equipment to the 4-20mA boards pins are marked + (positive) and – (negative). The
polarity must be observed for proper operation. The 4-20mA output current range is
approximately 0 mA to 24mA. Resistive load range should typically be 300 Ohms with a
max rating of 1200 Ohm.
3.13 4-20mA Input
Model dependent, MicroVision EX can support up to two 4-20mA analog inputs. The 420mA inputs, ordered separately, can be used to receive and data log signals from
sensors that transmit a 4-20mA output. Connect the 4-20mA equipment to the 4-20mA
boards pins are marked + (positive) and – (negative). The polarity must be observed for
proper operation.
Each 4-20mA analog input supports 2 wire loop or transmitter powered configurations.
Input resistance load is approximately 265 Ohms. Input voltage range is commonly 12V
or 24V. Up to 60V is permissible.
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