Walchem W100P Operating Manual

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Page 1

WCN/WPH/P100 Series Panel Mount Industrial Controller

Instruction Manual

Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA

TEL: 508-429-1110 WEB: www.walchem.com

Page 2

Notice

Proprietary Material

The information and descriptions contained herein are the property of WALCHEM. Such information and descriptions may not be copied or reproduced by any means, or disseminated or distributed without the express prior written permission of WALCHEM, 5 Boynton Road, Holliston, MA 01746.

This document is for information purposes only and is subject to change without notice.

Statement of Limited Warranty

WALCHEM warrants equipment of its manufacture, and bearing its identication to be

free from defects in workmanship and material for a period of 24 months for electronics and 12 months for mechanical parts and electrodes from date of delivery from the factory or authorized distributor under normal use and service and otherwise when such equipment is used in accordance with instructions furnished by WALCHEM and for the purposes disclosed in writing at the time of purchase, if any. WALCHEM’s liability under this warranty shall be limited to replacement or repair, F.O.B. Holliston, MA U.S.A. of any defective equipment or part which, having been returned to WALCHEM, transportation charges prepaid, has been inspected and determined by WALCHEM to be defective. Replaceable elastomeric parts and glass components are expendable and are not covered by any warranty.

THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EITHER EXPRESS OR IMPLIED, AS TO DESCRIPTION, QUALITY, MERCHANTABILITY, FITNESS FOR ANY PARTICULAR PURPOSE OR USE, OR ANY OTHER MATTER.

180537 Rev. I September 2018

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Contents

1.0 INTRODUCTION .........................................................1

2.0 SPECIFICATIONS ......................................................2

2.1 Measurement Performance ................................................ 2

2.2 Electrical: Input/Output ....................................................... 3

2.3 Mechanical ......................................................................... 5

2.4 Variables and their Limits ................................................... 5

3.0 UNPACKING & INSTALLATION ................................7

3.1 Unpacking the unit .............................................................. 8

3.2 Mounting the electronic enclosure ...................................... 8

3.3 Sensor Installation .............................................................. 11

3.4 IconDenitions ................................................................... 13

3.5 Electrical installation ........................................................... 13

4.0 FUNCTION OVERVIEW ............................................ 23

4.1 Front Panel ......................................................................... 23

4.2 Display ................................................................................ 23

4.3 Keypad ............................................................................... 23

4.4 Icons ................................................................................... 23

4.5 Startup ................................................................................ 25

4.6 Shut Down .......................................................................... 32

5.0 OPERATION .............................................................. 33

5.1 Alarms Menu ...................................................................... 33

5.2 Inputs Menu ....................................................................... 33

5.3 Outputs Menu ................................................................... 44

5.4 Settings Menu .................................................................. 62

6.0 MAINTENANCE ......................................................... 64

7.0 TROUBLESHOOTING ............................................... 65

7.1 Calibration Failure .............................................................. 65

7.2 Alarm Messages ................................................................. 67

8.0 SERVICE POLICY ..................................................... 71

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1.0 INTRODUCTION

The Walchem P100 Series controllers offer a high level of exibility in controlling

water treatment applications.

One sensor input is available that are compatible with a variety of sensors:

• Contacting conductivity with cell constant 0.01, 0.1, 1.0 or 10.0

• Electrodeless conductivity

• pH

• ORP

• Any Walchem disinfection sensor

• Generic sensor (Ion Selective Electrodes or any type of sensor with a

linear voltage output between -2 VDC and 2 VDC)

One digital input may be used for a variety of purposes:

• State type: Flow switch or other Interlock to stop control, or drum level

switch

• Water meter contactor: To control a relay to feed a chemical based on

ow total

• Paddlewheel owmeter: To control based on ow total or ow rate

Four relay outputs may be set to a variety of control modes:

• On/Off set point control

• Time Proportional control

• Pulse Proportional (when purchased with Pulse solid state opto out-

puts)

• PID Control (when purchased with Pulse solid state opto outputs)

• Activate with a contact closure

• Timed activation triggered by a Water Contactor or Paddlewheel ow

meter’s accumulated total ow

• Activate with another output

• Activate as a percent another output’s on-time

• Daily, Weekly, 2-week or 4-week timers with or without Biocide functions

• Intermittent sampling for boilers with proportional blowdown, con-

trolling on a trapped sample

• Dual set point

• Always on unless interlocked

• Probe Wash timer

• Diagnostic Alarm triggered by:

• High or Low sensor reading

• No Flow

• Relay output timeout

• Sensor error

An isolated analog output may be used to retransmit sensor input signals to a chart recorder, data logger, PLC or other device. It may also be connected to valves, actuators or metering pumps for linear proportional or PID control.

Our unique USB feature provides the ability to upgrade the software in the controller

to the latest version.

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2.0 SPECIFICATIONS

2.1 Measurement Performance

0.01 Cell Contacting Conductivity

Range 0-300 µS/cm

Resolution 0.01 µS/cm, 0.0001 mS/cm, 0.001 mS/m, 0.0001 S/m, 0.01 ppm

Accuracy ± 1% of reading

0.1 Cell Contacting Conductivity

Range 0-3,000 µS/cm

Resolution 0.1 µS/cm, 0.0001 mS/cm, 0.01 mS/m, 0.0001 S/m, 0.1 ppm

Accuracy ± 1% of reading

1.0 Cell Contacting Conductivity

Range 0-30,000 µS/cm

Resolution 1 µS/cm, 0.001 mS/cm, 0.1 mS/m, 0.0001 S/m, 1 ppm

Accuracy ± 1% of reading

10.0 Cell Contacting Conductivity

Range 0-300,000 µS/cm

Resolution 10 µS/cm, 0.01 mS/cm, 1 mS/m, 0.001 S/m, 10 ppm

Accuracy ± 1% of reading

pH ORP/ISE

Range -2 to 16 pH units Range -1500 to 1500 mV

Resolution 0.01 pH units Resolution 0.1 mV

Accuracy ± 0.01% of reading Accuracy ± 1 mV

Disinfection Sensors

Range (mV) -2000 to 1500 mV Range (ppm) 0-2 ppm to 0-20,000 ppm

Resolution (mV) 0.1 mV Resolution (ppm) Varies with range and slope

Accuracy (mV) ± 1 mV Accuracy (ppm) Varies with range and slope

Temperature

Range 23 to 500°F (-5 to 60°C)

Resolution 0.1°F (0.1°C)

Accuracy ± 1% of reading

Electrodeless Conductivity

Ranges Resolution

500-12,000 µS/cm 1 µS/cm, 0.01 mS/cm, 0.1 mS/m, 0.001 S/m, 1 ppm

3,000-40,000 µS/cm 1 µS/cm, 0.01 mS/cm, 0.1 mS/m, 0.001 S/m, 1 ppm

10,000-150,000 µS/cm 10 µS/cm, 0.1 mS/cm, 1 mS/m, 0.01 S/m, 10 ppm

50,000-500,000 µS/cm 10 µS/cm, 0.1 mS/cm, 1 mS/m, 0.01 S/m, 10 ppm

200,000-2,000,000 µS/cm 100 µS/cm, 0.1 mS/cm, 1 mS/m, 0.1 S/m, 100 ppm

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Temperature °CRange Multiplier Temperature °CRange Multiplier

0 181.3 80 43.5

10 139.9 90 39.2

15 124.2 100 35.7

20 111.1 110 32.8

25 100.0 120 30.4

30 90.6 130 28.5

35 82.5 140 26.9

40 75.5 150 25.5

50 64.3 160 24.4

60 55.6 170 23.6

70 48.9 180 22.9

Note: Conductivity ranges above apply at 25°C. At higher temperatures, the range is reduced per the range multiplier chart.

2.2 Electrical: Input/Output

Input Power

100 to 240 VAC, 50 or 60 Hz, 12VA

Input Signals

WCNP models:

Contacting Conductivity 0.01, 0.1, 1.0, or 10.0 cell constant OR

Electrodeless Conductivity OR

Disinfection OR

Amplied pH, ORP, or ISE OR

Generic

WPH models:

Non-Amplied pH, ORP or ISE

Temperature

100 or 1000 ohm RTD, 10K or 100K Thermistor

Digital Input Signals (1):

State-Type Digital Input

Electrical: Optically isolated and providing an electrically isolated 9VDC power with a nominal 2.3mA

current when the digital input switch is closed

Typical response time: < 2 seconds Devices supported: Any isolated dry contact (i.e. relay, reed switch) Types: Interlock

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Low Speed Counter-Type Digial Input

Electrical: Optically isolated and providing an electrically isolated 9VDC power with a nominal 2.3mA current when the digital input switch is closed 0-10 Hz, 50 msec minimum width Devices supported: Any device with isolated open drain, open collector, transistor or reed switch Types: Contacting Flowmeter

High Speed Counter-Type Digial Input

Electrical: Optically isolated and providing an electrically isolated 9VDC power with a nominal 2.3mA current when the digital input switch is closed, 0-500 Hz, 1.00 msec minimum width Devices supported: Any device with isolated open drain, open collector, transistor or reed switch Types: Paddlewheel Flowmeter

Outputs

Pulse Outputs (0 or 2 depending on model):

Opto-isolated, Solid State Relay

200mA, 40 VDC Max.

VLOWMAX = 0.05 V @ 18 mA

Dry contact mechanical relays (2 or 4 depending on model):

6 A (resistive), 1/8 HP (93 W) per relay

Dry contact relays are not fuse protected

4 - 20 mA (1):

Internally powered

Fully isolated

600 Ohm max resistive load

Resolution 0.0015% of span

Accuracy ± 0.5% of reading

Agency Approvals

Safety UL 61010-1:2012 3rd Ed.

CSA C22.2 No. 61010-1:2012 3rd Ed.

IEC 61010-1:2010 3rd Ed.

EN 61010-1:2010 3rd Ed.

EMC IEC 61326-1:2012

EN 61326-1:2013

Note: For EN61000-4-6, EN61000-4-3 the controller met performance criteria B. *Class A Equipment: Equipment suitable for use in establishments other than domestic, and those directly connected to a low voltage (100-240 VAC) power supply network which supplies buildings used for domestic purposes.

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2.3 Mechanical

Enclosure Material Polycarbonate

Enclosure Rating NEMA 4X (IP65)

Panel Cutout ¼ DIN (92 mm x 92 mm)

Dimensions See Figure 3

Display 128 x 64 graphic backlit display

Operating Ambient Temp -4 to 131 °F (-20 to 55 °C)

Storage Temperature -4 to 176°F (-20 to 80°C)

2.4 Variables and their Limits

Low Limit High Limit

Sensor input settings

Alarm limits Low end of sensor range High end of sensor range

Alarm dead band Low end of sensor range High end of sensor range

Cell constant (conductivity only) 0.01 10

Smoothing Factor 0% 90%

Comp Factor (conductivity linear ATC only)

Installation Factor (Electrodeless conductivity only)

Cable length 0.1 3,000

PPM conversion factor (conductivity only if units = PPM)

Sensor slope -1,000,000 1,000,000

Sensor Offset -1,000,000 1,000,000

Low Range -1,000,000 1,000,000

High Range -1,000,000 1,000,000

Default temperature -20 500

Calibration Required Alarm 0 days 365 days

Flow meter input settings

Totalizer alarm 0 100,000,000

Volume/contact for units of Gallons or Liters 1 100,000

Volume/contact for units of m

K Factor for units of Gallons or Liters 0.01 10,000

K Factor for units of m

Paddlewheel rate alarm limits 0 High end of sensor range

Paddleweel rate alarm deadband 0 High end of sensor range

Smoothing Factor 0% 90%

Set Flow Total 0 1,000,000,000

Relay output settings

Output Limit Time 1 second 86,400 seconds (0 = unlimited)

0% 20%

0.5 1.5

0.001 10.000

0.001 1,000

1 100,000

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Hand Time Limit 1 second 86,400 seconds (0 = unlimited)

Min Relay Cycle 0 seconds 300 seconds

Set Point Low end of sensor range High end of sensor range

Dead Band Low end of sensor range High end of sensor range

Duty Cycle Period (On/Off, Dual Set Point) 0:00 minutes 59:59 minutes

Duty Cycle (On/Off, Dual Set Point) 0% 100%

Feed duration (Flow Timer mode) 0 seconds 86,400 seconds

Accumulated volume (Flow Timer mode)

Feed percentage (Bleed then Feed) 0% 100%

Feed Lockout Time Limit (Bleed & Feed, Bleed then Feed)

Prebleed to Conductivity (Biocide mode)

Prebleed Time (Biocide mode) 0 seconds 86,400 seconds

Bleed Lockout (Biocide mode) 0 seconds 86,400 seconds

Event Duration (Biocide, Timer modes) 0 seconds 86,400 seconds

Proportional Band (Timer or Pulse Proportional, Intermittent Mode)

Sample period (Time Proportional

mode)

Sample Time (Intermittent Sampling

mode)

Hold Time (Probe Wash, Intermittent Sampling modes)

Maximum Blowdown (Intermittent Sampling mode)

Wait Time (Intermittent Sampling Mode 0 seconds 86,400 seconds

Max Rate (Pulse Proportional, Pulse PID modes)

Minimum Output (Pulse Proportional, Pulse PID modes)

Maximum Output (Pulse Proportional, Pulse PID modes)

Gain (Pulse PID Standard mode) 0.001 1000.000

Integral Time (Pulse PID Standard mode)

Derivative Time (Pulse PID Standard mode)

Proportional Gain (Pulse PID Parallel mode)

Integral Gain (Pulse PID Parallel mode) 0.001 /second 1000.000 /second

Derivative Gain (Pulse PID Parallel mode)

0 1,000,000

0 seconds 86,400 seconds

1 (0=no prebleed) High end of sensor range

Low end of sensor range High end of sensor range

10 seconds 3600 seconds

0 seconds 3600 seconds

10 pulses/minute 480 pulses/minute

0% 100%

0.001 seconds 1000.000 seconds

0 seconds 1000.000 seconds

0.001 1000.000

0 seconds 1000.000 seconds

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Input Minimum (Pulse PID modes) Low end of sensor range High end of sensor range

Input Maximum (Pulse PID modes) Low end of sensor range High end of sensor range

Analog (4-20 mA) output settings

4 mA Value (Retransmit mode) Low end of sensor range High end of sensor range

20 mA Value (Retransmit mode) Low end of sensor range High end of sensor range

Hand Output 0% 100%

Set Point (Proportional, PID modes) Low end of sensor range High end of sensor range

Proportional Band (Proportional mode) Low end of sensor range High end of sensor range

Minimum Output (Proportional, PID modes)

Maximum Output (Proportional, PID modes)

Off Mode Output (Proportional, PID modes, Flow Prop Modes)

Error Output (not in Manual mode) 0 mA 21 mA

Hand Time Limit (not in Retransmit

mode)

Output Time Limit (Proportional, PID modes, Flow Prop modes)

Gain (PID, Standard mode) 0.001 1000.000

Integral Time (PID Standard mode) 0.001 seconds 1000.000 seconds

Derivative Time (PID Standard mode) 0 seconds 1000.000 seconds

Proportional Gain (PID Parallel mode) 0.001 1000.000

Integral Gain (PID Parallel mode) 0.001 /second 1000.000 /second

Derivative Gain (PID Parallel mode) 0 seconds 1000.000 seconds

Input Minimum (PID modes) Low end of sensor range High end of sensor range

Input Maximum (PID modes) Low end of sensor range High end of sensor range

Pump Capacity (Flow Prop mode) 0 gal/hour or l/hour 10,000 gal/hour or l/hour

Pump Setting (Flow Prop mode) 0% 100%

Specic Gravity (Flow Prop mode) 0 g/ml 9.999 g/ml

Target (Flow Prop mode) 0 ppm 1,000,000 pm

0% 100%

0 mA 21 mA

1 second 86,400 seconds (0 =

unlimited)

1 second 86,400 seconds (0 =

unlimited)

Conguration Settings

Local Password 0000 9999

Alarm Delay 0:00 minutes 59:59 minutes

3.0 UNPACKING & INSTALLATION

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3.1 Unpacking the unit

Inspect the contents of the carton. Please notify the carrier immediately if there are any signs of damage to the controller or its parts. Contact your distributor if any of the parts are missing. The carton should contain a P100 series controller and an instruction manual. Any options or accessories will be incorporated as

ordered.

3.2 Mounting the electronic enclosure

Rear Cover

Rear Cover Screw

Mounting Clip Screw

Mounting Clip

Figure 1 Exploded View

Gasket

Controller

Micro-USB Connector

The enclosure is NEMA 4X (IP65) rated. The maximum operating ambient temperature is 131°F (55°C); this should be considered if installation is in a high

temperature location.

Create the mounting hole in the panel using a ¼ DIN punch. If a punch is not available, refer to Figure 2 below for dimensions. Install the gasket onto the controller, taking care not to twist it. Insert the controller into the panel. Install the

mounting clips and tighten the screws to secure the controller against the panel.

After wiring, the rear cover may be installed.

Maximum panel thickness: 0.45” ± 0.02” (11.43mm ± 0.50mm)

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Panel Cutout

3.62 x 3.62”

+0.03, -0.00

(92 x 92mm)

+0.76, -0.00

Panel Cutout

3.62 x 3.62”

+0.03, -0.00

(92 x 92mm)

+0.76, -0.00

minimum

clearance

1”

(25mm)

Panel Cutout

3.62 x 3.62”

+0.03, -0.00

(92 x 92mm)

+0.76, -0.00

Figure 2 Panel Cutout Dimensions

Panel Cutout

3.62 x 3.62”

+0.03, -0.00

(92 x 92mm)

+0.76, -0.00

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98 mm

3.86 in

98 mm

3.86 in

99.36 mm

3.91 in

88 mm

3.46 in

10 mm

0.39 in

108.5 mm

4.27 in

Figure 3 Controller Dimensions

Page 14

3.3 Sensor Installation

Refer to the specic instructions supplied with the sensor being used, for de-

tailed installation instructions.

General Guidelines

Locate the sensors where an active sample of water is available and where the sensors can easily be removed for cleaning. Position the sensor such that air bubbles will not be trapped within the sensing area. Position the sensor where

sediment or oil will not accumulate within the sensing area.

In-Line Sensor Mounting

In-line mounted sensors must be situated so that the tee is always full and the sensors are never subjected to a drop in water level resulting in dryness. Refer to Figures 2 through 4 for typical installation.

Tap off the discharge side of the recirculation pump to provide a minimum ow of 1 gallon per minute through the ow switch manifold. The sample must ow into the bottom of the manifold in order to close the ow switch, and return to a point of lower pressure in order to ensure ow. Install an isolation valve on both sides of the manifold to stop ow for sensor maintenance.

IMPORTANT: To avoid cracking the female pipe threads on the supplied plumbing parts, use no more than 3 wraps of Teon tape and thread in the pipe FINGER tight plus 1/2 turn! Do not use pipe dope to seal the threads of the ow switch because the clear plastic will crack!

Submersion Sensor Mounting

If the sensors are to be submersed in the process, mount them rmly to the tank, and protect the cable with plastic pipe, sealed at the top with a cable gland, to

prevent premature failure. Place the sensors in an area of good solution movement.

Sensors should be located such that they respond rapidly to a well-mixed sample of the process water and the treatment chemicals. If they are too close to the chemical injection point, they will see spikes in concentration and cycle on and off too frequently. If they are too far away from the chemical injection point, they will respond too slowly to the concentration changes, and you will over-

shoot the set point.

The contacting conductivity sensor should be placed as close to the controller

as possible, to a maximum distance of 250 ft. (76 m). Less than 25 ft. (8 m) is recommended. The cable must be shielded from background electrical noise. Always route low voltage (sensor) signals with at least a 6” (15 cm) separation

from AC voltage wiring.

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The electrodeless conductivity sensor should be placed as close to the control-

ler as possible, to a maximum distance of 120 ft. (37 m). Less than 20 ft. (6m) is recommended. The cable must be shielded from background electrical noise. Always route low voltage (sensor) signals with at least a 6” (15 cm) separation from AC voltage wiring. These sensors are affected by the geometry and conductivity of their surroundings, so either maintain 6 inches (15 cm) of sample around the sensor or ensure that any nearby conductive or non-conductive items are consistently positioned. Do not install the sensor in the path of any electrical current that may be owing in the solution, as this will shift the conductivity

reading.

The amplied pH/ORP/ISE electrode should be placed as close to the control-

ler as possible, to a maximum distance of 1000 feet (305 m) from the controller. A junction box and shielded cable are available to extend the standard 20 foot (6 m) length. pH and ORP electrodes must be installed such that the measuring surfaces will always remain wet. A U-trap provided in the manifold design should achieve this, even if the sample ow stops. These electrodes also must be installed with the measuring surfaces pointing down; that is 5 degrees above the horizontal, at a minimum. Non-amplied pH/ORP/ISE electrodes are only compatible with WPHNP or WPHBP models, and the coax cable should not be extended beyond 20 feet (6 m).

The disinfection sensor should be placed as close to the controller as possible, to a maximum distance of 100 feet (30 m) from the controller. A junction box and shielded cable are available to extend the standard 20 foot (6 m) length. The sensor should be mounted such that the measuring surfaces will always stay wet. If the membrane dries out, it will respond slowly to changing disinfectant values for 24 hours, and if dried out repeatedly, will fail prematurely. The ow cell should be placed on the discharge side of a circulation pump or downhill from a gravity feed. Flow into the cell must come from the bottom side that has the ¾” x ¼” NPT reducing bushing installed.

The reducing bushing provides the ow velocity required for accurate readings and must not be removed! A “U” trap should be installed so that if the ow stops, the sensor is still immersed in the water. The outlet of the ow cell must be plumbed to open atmosphere unless the system pressure is at or below 1 atmosphere. If the ow through the line cannot be stopped to allow for cleaning and calibration of the sensor, then it should be placed in a by-pass line with isolation valves to allow for sensor removal. Install the sensor vertically, with the measuring surface pointing down, at least 5 degrees above horizontal. Flow rate regulation must be done upstream from the sensor, because any ow restriction downstream can increase the pressure above atmospheric and damage the membrane cap!

Page 16

3.4 IconDenitions

Symbol Publication Description

IEC 417, No.5019 Protective Conductor Terminal

IEC 417, No. 5007 On (Supply)

IEC 417, No. 5008 Off (Supply)

ISO 3864, No. B.3.6 Caution, risk of electric shock

ISO 3864, No. B.3.1 Caution

3.5 Electrical installation

Refer to gures 4 through 12 for wiring.

Note: when wiring the 4-20 mA output or a remote ow switch, it is advisable to use stranded, twisted, shielded pair wire between 22-26 AWG. Shield should be

terminated at the controller.

CAUTION

1. There are live circuits inside the controller! The controller must never be opened before power to the controller is REMOVED!

2. When mounting the controller, make sure there is clear access to the disconnecting device!

3. The electrical installation of the controller must be done by trained personnel only and conform to all applicable National, State and Local codes!

4. Proper grounding of this product is required. Any attempt to bypass the grounding will compromise the safety of persons and property.

5. Operating this product in a manner not specied by Walchem may impair the protection provided by the equipment.

Page 17

No.

ECOND CCOND

XMT+

XMT

XMT–

SHIELD

14 15

RCV–

RCV+

RCV

18 19

TEMP–

TEMP+

SHIELD

Conductivity

Electrode

TEMP– WHT

TEMP+ GRN

RCV BLK

SHIELD

XMT RED

TERM 2

TEMP+ TEMP–

TERM 2

(1-10) (11-20)

(21-30)

11 12 13 14 15 16 17 18 19

Figure 4 Contacting Conductivity Sensor Input Wiring

Page 18

Econd

Sensor

RCV-

RCV+

TEMP-

TEMP+

(1-10) (11-20)

(21-30)

SHIELD

XMT-

TERM 2

XMT+

No. ECOND CCOND

XMT+

XMT

XMT–

SHIELD

RCV–

RCV+

RCV

18 19

TEMP–

TEMP+

SHIELD

TEMP+

TEMP–

11 12 13

15 16 17 18 19

TERM 2

Figure 5 Electrodeless Conductivity Sensor Input Wiring

Page 19

TERM 2

No.

11 12 13 14 15 16 17 18 19

PASSIVE pH/ORP

GLASS

REF TEMP+ TEMP–

SHIELD

(1-10) (11-20)

11 12 13 14

pH+

pH–

TEMP+ (optional)

TEMP– (optional)

15 16 17

SHIELD

18 19

TERM 2

(21-30)

pH/ORP/ISE

ELECTRODE

Figure6Non-AmpliedpH/ORP/ISE Sensor Input Wiring with BNC

Page 20

No.

PASSIVE pH/ORP

GLASS

REF

SHIELD

14 15 16 17 18 19

TERM 2

TEMP+

TEMP–

TERM 2

(1-10) (11-20)

(21-30)

– (REFERENCE)

SHIELD

+SIGNAL

pH/ORP/ISE

ELECTRODE

TEMP+ (optional)

TEMP– (optional)

11 12 13 14 15 16 17 18 19

Figure7Non-AmpliedpH/ORP/ISESensorInputWiring

Page 21

No.

pH/ORP

DIS

11 12 13

SHIELD

14 15

IN–

16 17 18 19

TERM 2

TEMP+ TEMP–

TERM 2

(1-10) (11-20)

(21-30)

-5V WHT/BLU

IN– WHT/ORN

IN+ ORN/WHT

SHIELD

+5V BLU/WHT

pH/ORP

ELECTRODE

TEMP+ GRN/WHT (optional)

TEMP– WHT/GRN (optional)

11 12 13 14 15 16 17 18 19

IN+ +5V

–5V

Figure8AmpliedpH/ORP/ISESensorInputWiring

Page 22

(1-10) (11-20)

TERM 2

pH/ORP

No.

DIS

11 12 13 14 15 16 17 18 19

TEMP+ TEMP–

IN–

SHIELD

IN+ +5V

–5V

11 12 13 14 15 16 17 18 19

(21-30)

IN– WHT

SHIELD

IN+ GRN

+5V RED

-5V BLK

TERM 2

WFCB WCDB WOZB WPAB

Figure 9 Disinfection Sensor Input Wiring

Page 23

No.

1 2

4 5

6 7

8 9

(1-10) (11-20)

TERM 1

Function

LAC

100-420V

NAC

100-240V

SHIELD

SHIELD SHIELD

4-20

OUT+

4-20 OUT–

DIG IN + DIG IN –

1 2 3 4 5 6 7 8 9

TERM 1

(21-30)

SHIELD

+ –

SHIELD

Chart

Recorder

+ –

Reed Switch, Relay

(Flow Switch, Water Meter)

Polarity not critical

Figure 10 Digital Input /Analog Output Wiring

Page 24

TERM 1

No.

21 22 23 24 25 26 27 28 29

TERM 3

Relays

TERM 1

(1-10) (11-20)

BLK 120V, BRN 240V

22 23 24 25 26 27 28 29 30

TERM 3

BLK 120V, BRN 240V

(21-30)

WHT 120V

Fused

BLU 240V

External

GRN 120V

Power

GRN/YEL 240V

Source

BLK 120V, BRN 240V

Fused

WHT 120V

External

BLU 240V

Power

GRN 120V

Source

GRN/YEL 240V

PUMP

Fused

External

Power

Source

WHT 120V BLU 240V

GRN 120V GRN/YEL 240V

PLC

ALARM

No.

1 2

4 5

6 7

8 9

Function

LAC

100-420V

NAC

100-240V

SHIELD

SHIELD SHIELD

4-20

OUT+

4-20 OUT–

DIG IN + DIG IN –

1 2 3 4 5 6 7 8 9

GRN 120V, GRN/YEL 240V

BLK 120V, BRN 240V

WHT 120V, BLU 240V

(120 VAC or 240 VAC)

Figure 11 P110 AC Power & Relay Output Wiring

Power Supply

Page 25

(1-10) (11-20)

No.

Relays

21 22 23 24 25 26 27 28 29

TERM 3

R3+ R3–

R4+ R4–

21 22 23 24 25 26 27 28 29 30

TERM 3

(21-30)

BLK 120V,BRN 240V

WHT 120V, BLU 240V

Fused External

–

PLC

Power Source

External

Power

ALARM

GRN 120V GRN/YEL 240V

PUMP

External

Power

No.

8 9 10

TERM 1

Function

LAC

100-420V

NAC

100-240V

SHIELD

SHIELD SHIELD

4-20

OUT+

4-20 OUT–

DIG IN + DIG IN –

GRN 120V, GRN/YEL 240V

BLK 120V, BRN 240V

WHT 120V, BLU 240V

PUMP

(120 VAC or 240 VAC)

TERM 1

Figure 12 P120 AC Power & Relay Output Wiring

Power Supply

Page 26

4.0 FUNCTION OVERVIEW

4.1 Front Panel

Figure 13 Front Panel

4.2 Display

A Home screen is displayed while the controller is on. This display shows the sensor readings, active alarms and a row of icons that are used to navigate to

other screens.

4.3 Keypad

The keypad consists of 5 ATM type keys and a Home key used to return to the Home screen. The icon above the ATM keys will dene its purpose on the cur-

rent screen being displayed.

4.4 Icons

The following icons appear on the Home screen. Press the key below the icon to

get to the main menu selections.

Alarm Menu

Page 27

Inputs Menu

Outputs Menu

Settings Menu

Other icons may appear in the menu screens.

Calibration key appears in sensor input menus and brings up the calibration menu

Cancel key cancels any entry

The Page Down icon scrolls down to a new page in a list

of options.

The Page Up icon scrolls up to a new page in a list of options.

The Conrm icon accepts a choice and advances to the next calibration step

The Back/Return icon returns the display to the previous

screen

The Make Character Higher key is used when making an alphanumeric entry

The Make Character Lower key is used when making an alphanumeric entry

The Move Cursor key is used to scroll left to right within an alphanumeric entry

The ENTER key is used to nish entering data or enter a

highlighted menu choice

Overview of the use of keys

Changing Numeric Values

To change a number, use the Move Cursor key to the digit to be changed. If the new number will be negative, start with the sign using the Make Character Higher key. Move the cursor to each digit and change the value using either the Make Character Higher or Lower keys. Once the value of the number is correct use the Enter key to store the new value into memory, or use the Cancel key to leave the

Page 28

number at its previous value and go back.

Changing Names

To change the name used to identify an input or output, use the Move Cursor key to the character to be changed and change it using either the Make Character Higher or Lower keys. Upper case and lower case letter, numbers, a blank space, period, plus and minus symbols are available. Move the cursor to the right and modify each character. Once the word is correct, use the Enter key to store the new value into memory, or use the Cancel key to leave the word at its previous value and go back.

Choosing from a List

Selecting the type of sensor, the units of measure of an input, or the control mode used for an output, the selection is picked from a list of available options. Use the Page Up or Down keys to highlight the desired option, and then use the Enter key to store the new option into memory, or use the Return key to leave the option at its previous value and go back.

Hand-Off-Auto Relay Mode

Use the Left or Right Move Cursor keys to highlight the desired relay mode. In Hand mode the relay is forced on for a specied amount of time and when that time is up the relay returns to its previous mode, in Off mode the relay is always off until taken out of Off mode, and in Auto mode the relay is responding to control set points. Use the Conrm key to accept the option, or the Return key to leave the option at its previous value and go back.

Interlock and Force On Menus

To select which outputs to force on, or which outputs to be interlocked, use the Move Cursor key to highlight the output to be selected, then use the Make Character Higher or Lower keys to check or uncheck that output. When nished, press the Conrm key to accept the changes or the Cancel key to leave the selections at the previous settings and go back.

4.5 Startup

Initial Startup

After having mounted the enclosure and wired the unit, the controller is ready to be started. Plug in the controller and turn on the power switch to supply power to the unit. The display will briey show the model number and then revert to the normal summary display. Press the Home key if necessary to get to the Home screen. Refer to section 5 below for more details on each of the settings. Cong Menu (see section 5.4)

Page 29

Choose language

Press the Conguration Settings key. Press the Enter key. Press the Scroll Down key until the English word “Language” is highlighted. Press the Enter key. Press the Scroll Down key until your language is highlighted. Press the Conrm key to change all menus to your language.

Set date (if necessary)

Press the Scroll Up key until Date is highlighted. Press the Enter key. Press the Move Cursor key to highlight the Day, and then use the Make Character Higher or Lower keys to change the date. Press the Conrm key to accept the change.

Set time (if necessary)

Press the Scroll Down key until Time is highlighted. Press the Enter key. Press the Move Cursor key to highlight the HH (hour) and/or MM (minute), then use the Make Character Higher or Lower keys to change the time. Press the Conrm key to accept the change.

Set global units of measure

Press the Scroll Down key until Global Units is highlighted. Press the Enter key. Press the Scroll Down key until the desired units is highlighted. Press the Conrm key to accept the change.

Set temperature units of measure

Press the Scroll Down key until Temp Units is highlighted. Press the Enter key. Press the Scroll Down key until the desired units is highlighted. Press the Conrm key to accept the change. Press the Home key. Press the Inputs key.

Page 30

CONFIG

Alarms (1)

Sensor (S1)

Temp (S2)

CONFIG

Global Settings

Security Settings

Additional Config Settings: Display Settings File Utilities Controller Details

Config > Global Settings

Date 2017-Mar-22

Time 15:49:16

Config > Security Settings

Controller Log Out

Security

Config > Display Settings

Home 1

Home 2

Config > File Utilities

File Transfer Status

Export Event Log

Additional Global Settings: Global Units Temperature Units Alarm Delay HVAC Modes Language

Additional Security Settings: Local Password

Additional Display Settings: Adjust Display Key Beep

Additional File Utilities: Import User Config File Export User Config File Export System Log Restore Default Config Software Upgrade

Config > Controller Details

Controller

Product Name

Additional Controller Details: Control Board Software Version Sensor Board Software Version Power Board Battery Power Internal Temp 1 Internal Temp 2

Page 31

Inputs

CCond (S1) 0 µS/cm

INPUTS

Temp (S2) 74.7 °F

> > CCond (S1) > Calibration

One Point Process Calibration

(All)

One Point Buffer Calibration (CCond,ECond,pH,ORP,Generic) Two Point Buffer Calibration (ECond,pH,ORP,Generic) Three Point Buffer Calibration (pH) Open Air Calibration

(Cond)

Zero Calibration (Disinfection,Linear Generic)

No Alarms (1)

CCond (S1) 0 µS/cm

Temp (S2) 74.7°F

Inputs>CCond (S1)

Details Screen

Content varies with

output type

>>CCond (S1)

Alarms

Deadband

>>ECond (S1)

Alarms

Deadband

>>Temperature (S2)

Alarms

Deadband

>>pH (S1)

Alarms

Deadband

>>ORP (S1)

Alarms

Deadband

Only Available in some models

>>Disinfection (S1)

Alarms

Deadband

Additional Settings for CCond:

Reset Calibration Values Cal Required Alarm Alarm Suppression Smoothing Factor Default Temp Temp Compensation Temp Comp Factor

Additional Settings for ECond:

Reset Calibration Values Cal Required Alarm Alarm Suppression Smoothing Factor Default Temp Installation Factor Range Temp Compensation

Additional Settings for Temperature:

Reset Calibration Values

Cal Required Alarm Alarm Suppression Smoothing Factor Name Element

Additional Settings for pH:

Reset Calibration Values Cal Required Alarm Alarm Suppression Smoothing Factor Buffers Default Temp

Additional Settings for ORP:

Reset Calibration Values Cal Required Alarm Alarm Suppression Smoothing Factor Default Temp Cable Length

Additional Settings for Disinfection:

Reset Calibration Values Cal Required Alarm Alarm Suppression Smoothing Factor Cable Length Gauge

Cell Constant Cable Length Gauge Units Name Type

Temp Comp Factor Cell Constant Cable Length Gauge Units Name Type

Cable Length Gauge Electrode Name Type

Gauge Name Type

Sensor Name Type

>>Generic (S1)

Alarms

Deadband

>>DI State (D1)

Open Message

Closed Message

Contactor Type

>>Flowmeter (D1)

Totalizer Alarm

Reset Flow Total

Paddlewheel Type

>>Flowmeter (D1)

Alarms

Deadband

Additional Settings for Generic:

Reset Calibration Values Cal Required Alarm Alarm Suppression Smoothing Factor Sensor Slope Sensor Offset Low Range High Range

Additional Settings for DI State:

Interlock Alarm Total Time Reset Total Time Name Type

Additional Settings for Flowmeter:

Set Flow Total Scheduled Reset Volume/Contact Flow Units Name Type

Additional Settings for Flowmeter:

Totalizer Alarm Reset Flow Total Set Flow Total Scheduled Reset K Factor Flow Units Rate Units Smoothing Factor Name Type

Cable Length Gauge Units Electrode (Linear or Ion Selective) Name Type

Page 32

OUTPUTS

R1-R3

Outputs>On/Off (R1)

Details Screen

Content varies with

output type

>>On/Off (R1)>Settings

HOA Setting

Setpoint

>>Flow Timer (R1)

HOA Setting

Feed Duration

Only if HVAC mode is enabled

>>Bleed and Feed (R1)

HOA Setting

Feed Time Limit

Only if HVAC mode is enabled

>>Bleed then Feed (R1)

HOA Setting

Feed Percentage

>>Percent Timer(R1)

HOA Setting

Sample Period

Only if HVAC mode is enabled

>>Biocide Timer (R1)

HOA Setting

Bleed

>>Alarm (R1)

HOA Setting

Alarm Mode

Outputs

On/Off (R1) Off

Bleed (R2) Off

Additional Settings for On/OFF:

Deadband Duty Cycle Period Duty Cycle Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels

Additional Settings for Flow Timer:

Accumulated Volume Reset Timer Reset Output Timeout Interlock Channels Activate with Channels Min Relay Cycle

Additional Settings for Bleed and Feed:

Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels Min Relay Cycle

Additional Settings for Bleed then Feed:

Feed Time Limit Reset Timer Reset Output Timeout Interlock Channels Activate with Channels Min Relay Cycle

Additional Settings for Percent Timer:

Feed Percentage Interlock Channels Activate with Channels Min Relay Cycle

Additional Settings for Biocide Timer:

Event 1 (through 10) Repetition Week Day Start Time Duration Prebleed Time Prebleed To Cond Input

Additional Settings for Alarm:

Output Interlock Channels Activate with Channels Min Relay Cycle

Min Relay Cycle Hand Time Limit Reset Time Total Input Direction Name Mode

Hand Time Limit Reset Time Total Flow Input Name Mode

Hand Time Limit Reset Time Total Bleed Name Mode

Hand Time Limit Reset Time Total Name Mode

Bleed Lockout Add Last Missed Interlock Channels Activate with Channels Min Relay Cycle

Hand Time Limit Reset Time Total Name Mode

No Alarms (1)

CCond (S1) 0 µS/cm

Temp (S2) 74.7°F

>>Time Prop (R1)

HOA Setting

Setpoint

Only if HVAC mode is enabled

>>Int Sampling (R1)

HOA Setting

Setpoint

>>Manual (R1)

HOA Setting

Interlock Channels

Only if model W120/power relay bd installed

>>Pulse Prop (R1)

HOA Setting

Setpoint

>>Dual Setpoint (R1)

HOA Setting

Setpoint

>>Probe Wash (R1)

HOA Setting

Input

Only if HVAC mode is disabled

>>Timer (R1)

HOA Setting

Add Last Missed

Additional Settings for Time Prop:

Proportional Band Sample Period Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels Min Relay Cycle

Additional Settings for Int Sampling:

Proportional Band Deadband Sample Time Hold Time Maximum Blowdown Wait Time Trap Sample Output Time Limit Reset Output Timeout

Additional Settings for Manual:

Min Relay Cycle Hand Time Limit Reset Time Total Name Mode

Additional Settings for Pulse Prop:

Proportional Band Min Output Max Output Max Rate Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels

Additional Settings for Dual Setpoint:

Set Point 2 Deadband Duty Cycle Period Duty Cycle Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels

Additional Settings for Probe Wash:

Input 2 Event 1 (through 10) Repetition Week, Day Events per Day Start Time Duration Sensor Mode Hold Time

Additional Settings for Timer:

Event 1 (through 10) Repetition Week, Day Events per Day Start Time Duration Interlock Channels Activate with Channels

Hand Time Limit Reset Time Total Input Direction Name Mode

Interlock Channels Activate with Channels Min Relay Cycle Hand Time Limit Reset Time Total Cond Input Name Mode

Min Relay Cycle Hand Time Limit Reset Time Total Input Direction Name Mode

Interlock Channels Activate with Channels Min Relay Cycle Hand Time Limit Reset Time Total Name Mode

Min Relay Cycle Hand Time Limit Reset Time Total Name Mode

Page 33

OUTPUT

Output>Retrans (A1)

Details on this page

vary with type of

output

Output

On/Off (R1) Off

Retrans (A1) 0.0%

No Alarms (1)

CCond (S1) 0 µS/cm

Temp (S2) 74.7°F

>>Retransmit (A1)

HOA Setting

4 mA Value

>>Proportional (A1)

HOA Setting

Setpoint

Only available if HVAC is disabled

>>PID (A1)

HOA Setting

Setpoint

>>Manual (A1)

HOA Setting

Interlock Channels

>>Flow Prop (A1)

HOA Setting

Target

Additional Settings for Retransmit:

20 mA Value Hand Output Interlock Channels Error Output

Additional Settings for Proportional:

Proportional Band Min Output Max Output Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels Hand Output

Additional Settings for PID:

Gain Proportional Gain Integral Time Integral Gain Derivative Time Derivative Gain Reset PID Integral Min Output Max Output Max Rate Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels

Additional Settings for Manual:

Activate with Channels Min. Relay Cycle Hand Output Hand Time Limit Reset Time Total

Additional Settings for Flow Prop Control Mode: Pump Capacity Pump Setting Specific Gravity Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels Hand Output

Reset Time Total Input Name Mode

Hand Time Limit Reset Time Total Off Mode Output Error Output Input Direction Name Mode

Hand Output Hand Time Limit Off Mode Output Error Output Reset Time Total Input Direction Input Min Input Max Gain Form Name Mode

Name Mode

Hand Time Limit Off Mode Output Error Output Reset Time Total Flow Input Name Mode

Page 34

Inputs (see section 5.2)

Program the settings for each input

The S1 sensor input will be highlighted. Press the Enter key to get to the Details screen. Press the Settings key. If the name of the sensor does not describe the type of sensor connected, press the Scroll Down key until Type is highlighted. Press the Enter key. Press the Scroll Down key until the correct type of sensor is highlighted, then press the Conrm key to accept the change. This will bring you back to the Details screen. Press the Settings key again to nish the rest of the S1 settings. For disinfections sensors, choose the exact sensor in the Sensor menu. For contacting conductivity sensors, enter the cell constant. Select the units of measure. Enter the alarm set points and alarm deadband. Set the default temperature that will be used for automatic temperature compensation if the temperature signal becomes invalid.

When nished with S1, press the Return key until the list of inputs is displayed. Press the Scroll Down key and repeat the process for each input.

The S2 temperature input Element should be set correctly once the S1 sensor type has been set. If not, select the correct temperature element and set the alarm set points and alarm deadband. Generic, ORP and disinfection sensors do not

have temperature signals and are preset to No Sensor.

To calibrate the temperature, return to the S2 Details screen, press the Calibrate key, and press the Enter key to perform a calibration.

If a ow switch or liquid level switch is connected, D1 should be set to DI State type (if no switch is connected, select No Sensor). Set the state that will possibly interlock control outputs (refer to the Outputs settings to program which outputs, if any, will be interlocked by the switch). Set the state, if any, that will result in

an alarm.

If a contacting head or paddlewheel ow meter is connected, D1 should be set to that type (if no ow meter is connected, select No Sensor). Set the units of measure, volume/contact or K factor, etc.

Calibrate the sensor

To calibrate the sensor, return to the list of inputs, highlight S1, press the Enter key, press the Calibrate key, and select one of the calibration routines. For Disinfection and Generic sensors, start with the Zero Calibration. For electrodeless conductivity, start with the Air Calibration. Refer to section 5.2. Press the Home key. Press the Outputs key.

Outputs (see section 5.3)

Program the settings for each output

The R1 relay output will be highlighted. Press the Enter key to get to the Details

Page 35

screen. Press the Settings key. If the name of the relay does not describe the control mode desired, press the Scroll Down key until Mode is highlighted. Press the Enter key. Press the Scroll Down key until the correct control mode is highlighted, then press the Conrm key to accept the change. This will bring you back to the Details screen. Press the Settings key again to nish the rest of the

R1 settings.

If you want the output to be interlocked by a ow switch or by another output being active, enter the Interlock Channels menu and select the input or output channel that will interlock this output. The default is for the output to be in Off mode, where the output does not react to the settings. Once all settings for that output are complete, enter the HOA

Setting menu and change it to Auto. Repeat for each output.

Normal Startup

Startup is a simple process once your set points are in memory. Simply check your supply of chemicals, turn on the controller, and calibrate the sensor if necessary and it will start controlling.

4.6 Shut Down

To shut the controller down, simply turn off the power. Programming remains in memory.

Page 36

5.0 OPERATION

These units control continuously while power is applied. Programming is accomplished via the local keypad and display.

To see the top level menu keys, press the Home key if not already there. The menu structure is grouped by Alarms, Inputs, Outputs, and conguration Settings. Each input has its own menu for calibration and unit selection as needed. Each output has its own setup menu including set points, timer values and operating modes as needed. Under Settings will be general settings such as the clock, the language, etc.

Keep in mind that even while moving through menus, the unit is still controlling.

5.1 Alarms Menu

Press the key below the Alarms icon to view a list of active alarms. If there are more than two active alarms, the Page Down icon will be shown, and this key press will bring up the next page of inputs.

Press the Back/Return button to go back to the previous screen.

5.2 Inputs Menu

Press the key below the Inputs icon to view a list of all sensor and digital inputs. The Page Down icon scrolls down the list of inputs, the Page Up icon scrolls up the list of inputs, the Return icon brings back the previous screen.

Press the Enter key with an input highlighted to access that input’s details, calibration (if applicable) and settings.

Sensor Input Details

The details for any type of sensor input include the current value read, alarms, the raw (uncalibrated) signal, the sensor type, and the calibration gain and offset. If the sensor has automatic temperature compensation, then the sensor’s temperature value and alarms, the temperature resistance value read, and the type of temperature element required are also displayed.

Calibration

Press the Calibration key to calibrate the sensor. Select the calibration to perform: One Point Process, One Point Buffer or Two Point Buffer Calibration. Not all calibration options are available for all types of sensor.

Page 37

One Point Process Calibration

New Value

Enter the actual value of the process as determined by another meter or laboratory analysis and press Conrm.

Cal Successful or Failed

If successful, press Conrm to put the new calibration in memory. If failed, you may retry the calibration or cancel. Refer to Section 7 to troubleshoot a calibration failure.

One Point Buffer Calibration, Disinfection /Generic Sensor Zero Cal, Conductivity Air Cal

Cal Disables Control

Press Conrm to continue or Cancel to abort

Buffer Temperature (only appears if no temperature sensor is detected for sensor types that use automatic temperature compensation)

Enter the temperature of the buffer and press Conrm.

Buffer Value (only appears for One Point Calibration except when automatic buffer recognition is used)

Enter the value of the buffer being used

Rinse Sensor

Remove the sensor from the process, rinse it off, and place it in the buffer solution (or oxidizer-free water for Zero Cal, or air for the conductivity open air cal). Press Conrm when ready.

Stabilization

When the temperature (if applicable) and signal from the sensor is stable, the controller will automatically move to the next step. If they don’t stabilize you may manually go to the next step by pressing Conrm.

Cal Successful or Failed

If successful, press Conrm to put the new calibration in memory. If failed, you may retry the calibration or cancel. Refer to Section 7 to troubleshoot a calibration failure.

Resume Control

Replace the sensor in the process and press Conrm when ready to resume

control.

Two Point Buffer Calibration

Cal Disables Control

Press Conrm to continue or Cancel to abort

Page 38

Buffer Temperature (only appears if no temperature sensor is detected for sensor types that use automatic temperature compensation)

Enter the temperature of the buffer and press Conrm.

First Buffer Value (does not appear if automatic buffer recognition is used)

Enter the value of the buffer being used

Rinse Sensor

Remove the sensor from the process, rinse it off, and place it in the buffer solution. Press Conrm when ready.

Stabilization

Second Buffer Temperature (only appears if no temperature sensor is detected for sensor types that use automatic temperature compensation)

Enter the temperature of the buffer and press Conrm.

Second Buffer Value (does not appear if automatic buffer recognition is used)

Enter the value of the buffer being used

Rinse Electrode

Remove the sensor from the process, rinse it off, and place it in the buffer solution. Press Conrm when ready.

Stabilization

Cal Successful or Failed

If successful, press Conrm to put the new calibration in memory. The calibration adjusts the offset and the gain (slope) and displays the new values. If failed, you may retry the calibration or cancel. Refer to Section 7 to troubleshoot a calibration failure.

Resume Control

Replace the sensor in the process and press Conrm when ready to resume

control.

Three Point Buffer Calibration (pH sensors only)

Cal Disables Control

Press Conrm to continue or Cancel to abort

Page 39

Buffer Temperature (only appears if no temperature sensor is detected)

Enter the temperature of the buffer and press Conrm.

First Buffer Value (does not appear if automatic buffer recognition is used)

Enter the value of the buffer being used

Rinse Sensor

Remove the sensor from the process, rinse it off, and place it in the buffer solution. Press Conrm when ready.

Stabilization

Second Buffer Temperature (only appears if no temperature sensor is detected)

Enter the temperature of the buffer and press Conrm.

Second Buffer Value (does not appear if automatic buffer recognition is used)

Enter the value of the buffer being used

Rinse Electrode

Remove the sensor from the process, rinse it off, and place it in the buffer solution. Press Conrm when ready.

Stabilization

Third Buffer Temperature (only appears if no temperature sensor is detected)

Enter the temperature of the buffer and press Conrm.

Third Buffer Value (does not appear if automatic buffer recognition is used)

Enter the value of the buffer being used

Rinse Electrode

Remove the sensor from the process, rinse it off, and place it in the buffer solution. Press Conrm when ready.

Stabilization

When the temperature (if applicable) and signal from the sensor is stable, the controller will automatically move to the next step.

Cal Successful or Failed

If successful, press Conrm to put the new calibration in memory. The calibration adjusts the offset, gain (slope) and calibration midpoint and displays the new values. If failed, you may retry the calibration or cancel. Refer to Section 7 to troubleshoot a calibration failure.

Page 40

Resume Control

Replace the sensor in the process and press Conrm when ready to resume

control.

5.2.1 Contacting Conductivity

Settings

Press the Settings key view or change the settings related to the sensor.

Alarms

Deadband

Reset Calibration Values

Cal Required Alarm

Alarm Suppression

Smoothing Factor

Cable Length

Gauge

Cell Constant

Default Temp

Temp Comp

Comp Factor

Units

Name

Type

Low-Low, Low, High and High-High Alarms limits may be set.

This is the Alarm Deadband. For example, if the High Alarm is 3000, and the deadband is 10, the alarm will activate at 3001 and deactivate at 2990.

Enter this menu to reset the sensor calibration back to factory

defaults.

To get an alarm message as a reminder to calibrate the sensor on a regular schedule, enter the number of days between calibrations. Set it to 0 if no reminders are necessary.

If any of the relays or digital inputs are selected, any alarms related to this input will be suppressed if the selected relay or digital input is active. Typically this is used to prevent alarms if there is no sample ow past the ow switch digital input.

Increase the smoothing factor percentage to dampen the

response to changes. For example, with a 10% smoothing factor, the next reading shown will consist of an average of 10% of the previous value and 90% of the current value.

The controller automatically compensates for errors in the reading caused by varying the length of the cable.

The cable length compensation depends upon the gauge of wire used to extend the cable

Change the cell constant to match the sensor connected.

If the temperature signal is lost at any time, then the controller will use the Default Temp setting for temperature compensation.

Select between the standard NaCl temperature compensation

method or a linear %/ degree C method.

This menu only appears if Linear Temp Comp is selected. Change the %/degree C to match the chemistry being measured. Standard water is 2%.

Select the units of measure for the conductivity.

The name used to identify the sensor may be changed.

Select the type of sensor to be connected.

Page 41

5.2.2 pH

Settings

Press the Settings key view or change the settings related to the sensor.

Alarms

Deadband

Reset Calibration Values

Cal Required Alarm

Alarm Suppression

Smoothing Factor

Buffers

Default Temp

Cable Length

Gauge

Electrode

Name

Type

Low-Low, Low, High and High-High Alarms limits may be set.

This is the Alarm Deadband. For example, if the High Alarm is 9.50, and the deadband is 0.05, the alarm will activate at 9.51 and deactivate at 9.45.

Enter this menu to reset the sensor calibration back to factory defaults.

To get an alarm message as a reminder to calibrate the sensor on a regular schedule, enter the number of days between calibrations. Set it to 0 if no reminders are necessary.

digital input.

Increase the smoothing factor percentage to dampen the

response to changes. For example, with a 10% smoothing factor, the next reading shown will consist of an average of 10% of the previous value and 90% of the current value.

Select if calibration buffers will be manually entered, or if they will be automatically detected, and if so, which set of buffers will be used. The choices are Manual Entry, JIS/ NIST Standard, DIN Technical, or Traceable 4/7/10.

If the temperature signal is lost at any time, then the controller will use the Default Temp setting for temperature

compensation.

The controller automatically compensates for errors in the reading caused by varying the length of the cable.

The cable length compensation depends upon the gauge of wire used to extend the cable

Select Glass for a standard pH electrode, or Antimony. Antimony pH electrodes have a default slope of 49 mV/pH and an offset of -320 mV at pH 7.

The name used to identify the sensor may be changed.

Select the type of sensor to be connected.

5.2.3 ORP

Settings

Press the Settings key view or change the settings related to the sensor.

Alarms

Low-Low, Low, High and High-High Alarms limits may be

set.

Page 42

Deadband

Reset Calibration Values

Cal Required Alarm

Alarm Suppression

Smoothing Factor

Cable Length

Gauge

Name

Type

This is the Alarm Deadband. For example, if the High Alarm is 800, and the deadband is 10, the alarm will activate at 801 and deactivate at 790.

Enter this menu to reset the sensor calibration back to factory defaults.

To get an alarm message as a reminder to calibrate the sensor on a regular schedule, enter the number of days between calibrations. Set it to 0 if no reminders are necessary.

input.

Increase the smoothing factor percentage to dampen the

response to changes. For example, with a 10% smoothing factor, the next reading shown will consist of an average of 10% of the previous value and 90% of the current value.

The controller automatically compensates for errors in the reading caused by varying the length of the cable.

The cable length compensation depends upon the gauge of wire used to extend the cable

The name used to identify the sensor may be changed.

Select the type of sensor to be connected.

5.2.4 Disinfection

Settings

Press the Settings key view or change the settings related to the sensor.

Alarms

Deadband

Reset Calibration Values

Cal Required Alarm

Alarm Suppression

Smoothing Factor

Low-Low, Low, High and High-High Alarms limits may be

set.

This is the Alarm Deadband. For example, if the High Alarm is 7.00, and the deadband is 0.1, the alarm will activate at

7.01 and deactivate at 6.90.

Enter this menu to reset the sensor calibration back to factory

defaults.

To get an alarm message as a reminder to calibrate the sensor on a regular schedule, enter the number of days between calibrations. Set it to 0 if no reminders are necessary.

Increase the smoothing factor percentage to dampen the

response to changes. For example, with a 10% smoothing factor, the next reading shown will consist of an average of 10% of the previous value and 90% of the current value.

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Cable Length

Gauge

Name

Sensor

Type

The controller automatically compensates for errors in the reading caused by varying the length of the cable.

The cable length compensation depends upon the gauge of wire used to extend the cable

The name used to identify the sensor may be changed.

Select the specic type and range of disinfection sensor to be

connected.

Select the type of sensor to be connected.

5.2.5 Electrodeless Conductivity

Settings

Press the Settings key view or change the settings related to the sensor.

Alarms

Deadband

Reset Calibration Values

Cal Required Alarm

Alarm Suppression

Smoothing Factor

Default Temp

Temp Comp

Comp Factor

Installation Factor

Cable Length

Gauge

Low-Low, Low, High and High-High Alarms limits may be set.

This is the Alarm Deadband. For example, if the High Alarm is 3000, and the deadband is 10, the alarm will activate at 3000 and deactivate at 2990.

Enter this menu to reset the sensor calibration back to factory defaults.

To get an alarm message as a reminder to calibrate the sensor on a regular schedule, enter the number of days between calibrations. Set it to 0 if no reminders are necessary.

digital input.

Increase the smoothing factor percentage to dampen the

response to changes. For example, with a 10% smoothing factor, the next reading shown will consist of an average of 10% of the previous value and 90% of the current value.

If the temperature signal is lost at any time, then the controller will use the Default Temp setting for temperature

compensation.

Select between the standard NaCl temperature compensa-

tion method or a linear %/ degree C method.

This menu only appears if Linear Temp Comp is selected. Change the %/degree C to match the chemistry being measured. Standard water is 2%.

Do not change unless instructed by the factory.

The controller automatically compensates for errors in the reading caused by varying the length of the cable.

The cable length compensation depends upon the gauge of wire used to extend the cable

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Cell Constant

Range

Units

Name

Type

Do not change unless instructed by the factory.

Select the range of conductivity that best matches the con-

ditions the sensor will see.

Select the units of measure for the conductivity.

The name used to identify the sensor may be changed.

Select the type of sensor to be connected.

5.2.6 Generic Sensor

Settings

Press the Settings key view or change the settings related to the sensor.

Alarms

Deadband

Reset Calibration Values

Cal Required Alarm

Alarm Suppression

Smoothing Factor

Cable Length

Gauge

Units

Electrode

Sensor Slope

Low-Low, Low, High and High-High Alarms limits may be set.

This is the Alarm Deadband. For example, if the High Alarm is 7.00, and the deadband is 0.1, the alarm will activate at 7.01 and deactivate at 6.90.

Enter this menu to reset the sensor calibration back to factory defaults.

To get an alarm message as a reminder to calibrate the sensor on a regular schedule, enter the number of days between calibrations. Set it to 0 if no reminders are necessary.

digital input.

Increase the smoothing factor percentage to dampen the

response to changes. For example, with a 10% smoothing factor, the next reading shown will consist of an average of 10% of the previous value and 90% of the current value.

The controller automatically compensates for errors in the reading caused by varying the length of the cable.

The cable length compensation depends upon the gauge of wire used to extend the cable

The word to be used for units of measure may be entered (ppm, for example)

Select the type of electrode to be connected. Select Linear

if the sensor slope is a linear voltage per Units. Select Ion

Selective if the electrode voltage output is logarithmic, dened as “mV/decade”.

Enter the slope of sensor in mV/Units (if Electrode selection is Linear) or mV/Decade (if Electrode selection is Ion Selective).

Page 45

Sensor Offset

Low Range

High Range

Name

Type

Only appears if the Electrode selection is Linear. Enter the offset of the sensor in mV if 0 mV is not equal to 0 units.

For Ion Selective Electrodes, the Sensor Offset is not

calculated until the rst calibration is performed, and

the sensor will read Zero until a calibration has been successfully completed!

Enter the low end of the range of the sensor

Enter the high end of the range of the sensor

The name used to identify the sensor may be changed.

Select the type of sensor to be connected.

5.2.7 Temperature

Settings

Press the Settings key view or change the settings related to the sensor.

Alarms

Deadband

Reset Calibration Values

Cal Required Alarm

Alarm Suppression

Smoothing Factor

Name

Element

Low-Low, Low, High and High-High Alarms limits may be set.

This is the Alarm Deadband. For example, if the High Alarm is 100, and the deadband is 1, the alarm will activate at 100 and deactivate at 99.

Enter this menu to reset the sensor calibration back to factory defaults.

To get an alarm message as a reminder to calibrate the sensor on a regular schedule, enter the number of days between calibrations. Set it to 0 if no reminders are necessary.

digital input.

Increase the smoothing factor percentage to dampen the

response to changes. For example, with a 10% smoothing factor, the next reading shown will consist of an average of 10% of the previous value and 90% of the current value.

The name used to identify the sensor may be changed.

Select the specic type of temperature sensor to be con-

nected.

5.2.8 DI State

Input Details

The details for this type of input include the current state with a custom message for open versus closed, alarms, and the status of the interlock.

Settings

Press the Settings key view or change the settings related to the sensor.

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Open Message

Closed Message

Interlock

Alarm

Total Time

Reset Total Time

Name

Type

The words used to describe the switch state may be customized.

Choose whether the input should be in the interlocked state

when the switch is either open or closed.

Choose if an alarm should be generated when the switch is open, or closed, or if no alarm should ever be generated.

Choose to totalize the amount of time that the switch has been open or closed. This will be displayed on the input details

screen.

Enter this menu to reset the accumulated time to zero. Press Conrm to accept, Cancel to leave the total at the previous value and go back.

The name used to identify the switch may be changed.

Select the type of sensor to be connected to the digital input

channel.

5.2.9 Flow Meter, Contactor Type

Input Details

The details for this type of input include the total volume accumulated through the ow meter and alarms.

Settings

Press the Settings key view or change the settings related to the sensor.

Totalizer Alarm

Reset Flow Total

Set Flow Total

Scheduled Reset

Volume/Contact

Flow Units

Name

Type

A high limit on the total volume of water accumulated may be set.

Enter this menu to reset the accumulated ow total to 0. Press Conrm to accept, Cancel to leave the total at the previous value and go back.

This menu is used to set the total volume stored in the controller to match the register on the ow meter. Enter the desired

value.

Choose to automatically reset the ow total, and if so, Daily, Monthly or Annually.

Enter the volume of water that needs to go through the ow

meter in order to generate a contact closure.

Select the units of measure for the water volume.

The name used to identify the sensor may be changed.

Select the type of sensor to be connected to the digital input

channel.

5.2.10 Flow Meter, Paddlewheel Type

Input Details

The details for this type of input include the current ow rate, total volume accumulated through the ow meter and alarms.

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Settings

Press the Settings key view or change the settings related to the sensor.

Alarms

Deadbands

Totalizer Alarm

Reset Flow Total

Set Flow Total

Scheduled Reset

K Factor

Flow Units

Rate Units

Smoothing Factor

Name

Type

Low and High Alarm limits may be set.

This is the Alarm Deadband. For example, if the High Alarm is 100, and the deadband is 1, the alarm will activate at 100 and deactivate at 99.

A high limit on the total volume of water accumulated may be

set.

Enter this menu to reset the accumulated ow total to 0. Press Conrm to accept, Cancel to leave the total at the previous value and go back.

This menu is used to set the total volume stored in the controller to match the register on the ow meter. Enter the desired

value.

Choose to automatically reset the ow total, and if so, Daily, Monthly or Annually.

Enter the pulses generated by the paddlewheel per unit volume

of water.

Select the units of measure for the water volume.

Select the units of measure for the ow rate time base.

Increase the smoothing factor percentage to dampen the response to changes. For example, with a 10% smoothing factor, the next reading shown will consist of an average of 10% of the previous value and 90% of the current value.

The name used to identify the sensor may be changed.

Select the type of sensor to be connected to the digital input

channel.

5.3 Outputs Menu

Press the key below the Outputs icon to view a list of all relay and analog outputs. The Page Down icon scrolls down the list of outputs, the Page Up icon scrolls up the list of outputs, the Return icon brings back the previous screen. Press the Enter key with an output highlighted to access that output’s details and

settings.

NOTE: When the output control mode or the input assigned to that output is changed, the output reverts to OFF mode. Once you have changed all settings to match the new mode or sensor, you must put the output into AUTO mode to start

control.

5.3.1 Relay, Any Control Mode

Output Details

The details for this type of output include the relay on/off state, HOA mode

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or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay. Settings that are available for any control mode include:

HOA Setting

Output Time Limit

Reset Output Timeout

Interlock Channels

Activate With Channels

Min Relay Cycle

Hand Time Limit

Reset Time Total

Name

Mode

Select Hand, Off or Auto mode (see section 4.4).

Enter the maximum amount of time that the relay can be continuously activated. Once the time limit is reached, the relay will deactivate until the Reset Output Timeout menu

is entered.

Enter this menu to clear an Output Timeout alarm and allow

the relay to control the process again.

Select the relays and digital inputs that will interlock this relay, when those other relays are activated in Auto mode. Using Hand or Off to activate relays bypasses the Interlock

logic.

Select the relays and digital inputs that will activate this relay, when those other relays are activate in Auto Mode. Using Hand or Off to activate relays bypasses the ‘Activate

With’ logic.

This menu allows for the use of a motorized ball valve that needs time to fully open and close. Enter the number of seconds that the valve needs to fully actuate

Enter the amount of time that the relay will activate for

when it is in Hand mode.

Press the Conrm icon to reset the total accumulated ontime stored for the output back to 0.

The name used to identify the relay may be changed.

Select the desired control mode for the output.

5.3.2 Relay, On/Off Control Mode

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay.

Set point

Deadband

Enter the sensor process value at which the relay will activate.

Enter the sensor process value away from the set point at which the relay will deactivate.

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Duty Cycle Period

Duty Cycle

Input

Direction

Using a duty cycle helps to prevent overshooting the set point

in applications where the response of the sensor to chemical

additions is slow. Specify the amount of time for the cycle, and the percentage of that cycle time that the relay will be active. The relay will be off for the rest of the cycle, even if the set point has not been satised. Enter the length of the duty cycle in minutes:seconds in this menu. Set the time to 00:00 if use of a duty cycle is not

required.

Enter the percentage of the cycle period that the relay will be active. Set the percentage to 100 if use of a duty cycle is not

required.

Select the sensor to be used by this relay.

Select the control direction.

5.3.3 Relay, Alarm Mode

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay.

Alarm Mode

Output

Select the alarm conditions that will put the relay into the alarm state:

All Alarms

S1 Low Alarms (+LoLo Alarm, Sensor Range Error, or Sensor Fault) S1 High Alarms (+HiHi Alarm, Sensor Range Error, or Sensor Fault) S2 (Temperature) Low Alarms (+LoLo Alarm, Sensor Range Error, or Sensor Fault) S2 (Temperature) High Alarms (+HiHi Alarm, Sensor Range Error, or Sensor Fault) D1 Alarms (Flowswitch/State, Flow Total, Flowmeter Range) D2 Alarms (Flowswitch/State, Flow Total, Flowmeter Range) Relay Alarms (Output Timeout, Control Failure, Event Skipped) for ALL relays

Select if the relay will be active when in the alarm state (Normally Open) or if the relay will be active when not in the alarm state (Normally Closed).

5.3.4 Relay, Time Proportional Control Mode

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay.

Page 50

Set point

Proportional Band

Sample Period

Input

Direction

Enter the sensor process value at which the relay will be off for

the entire Sample Period.

Enter the distance that the sensor process value is away from the set point at which the relay will be on for the entire Sample

Period.

Enter the conductivity value above the set point at which the maximum blowdown time will occur. For example, if the Set point is 2000 uS/cm, and the Proportional Band is 200 uS/cm, then if the conductivity is above 2200 uS/cm the blowdown valve will open for the Maximum Blowdown time described below. If the conductivity of the trapped sample is 2100 uS/ cm, the blowdown valve will open for half the Maximum Blowdown time.

Enter the duration of the sample period.

Select the sensor to be used by this relay.

Select the control direction.

5.3.5 Relay, Pulse Proportional Control Mode

ONLY AVAILABLE IF HVAC MODE IS DISABLED IN CONFIG MENU – GLOBAL SETTINGS

Output Details

The details for this type of output include the relay pulse rate, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay.

Set point

Proportional Band

Minimum Output

Maximum Output

Maximum Rate

Input

Direction

Enter the sensor process value at which the output will pulse

at the Minimum Output % set below.

Enter the distance that the sensor process value is away from the set point beyond which the output will be pulsing at the Maximum Output % set below.

Enter the lowest possible pulse rate as a percentage of the Maximum Stroke Rate set below (normally 0%).

Enter the highest possible pulse rate as a percentage of the Maximum Stroke Rate set below.

Enter the maximum pulse rate that the metering pump is designed to accept (10 - 360 pulse/minute range).

Select the sensor to be used by this relay.

Set the control direction.

5.3.6 Relay, PID Control Mode

ONLY AVAILABLE IF CONTROLLER INCLUDES PULSE OUTPUT HARDWARE AND HVAC MODE IS DISABLED

The PID algorithm controls a solid state relay using standard Proportion-

Page 51

al-Integral-Derivative control logic. The algorithm provides feedback control

Output (%) = Kp e(t) + f e(t)dt + Td

de(t)

based on an error value continuously calculated as the difference between a measured process variable and a desired set point. Tuning settings specify the response for proportional (the size of the error), integral (the time that the error has been present), and derivative (the rate of change for the error) parameters. With proper tuning, the PID control algorithm can hold the process value close the set point while minimizing overshoot and undershoot.

Normalized Error

The error value versus set point that is calculated by the controller is normalized and represented as percent of full scale. As a result, tuning parameters entered by the user are not dependent upon the scale of the process variable and the PID response with similar settings will be more consistent even when using different types of sensor inputs.

The scale used to normalize the error is dependent upon the type of sensor selected. By default, the full nominal range of the sensor is used. This range is editable by the user if tighter control is desired.

PID Equation Formats

The controller supports two different forms of the PID equation as specied by the Gain Form setting. The two forms require different units for entry of the PID tuning parameters.

Standard

The standard form is more commonly used in industry because its time-based settings for the integral and derivative coefcients are more meaningful. This form is selected by default.

Parameter Description Units

Gain unitless

Integral Time seconds or seconds/repeat

Derivative Time seconds

Parameter Description Units

e(t) Current Error % of full scale

dt Delta Time Between Readings seconds

de(t) Difference Between Current Error

& Previous Error

Parallel

The parallel form allows the user to enter all parameters as Gains. In all cases, larger gain values result in faster output response.

% of full scale

Page 52

Parameter Description Units

de(t)

Proportional Gain unitless

Integral Gain 1/seconds

Derivative Gain seconds

Output (%) = Kp e(t) + Ki f e(t)dt + Kd

Integral Value Management

To determine the integral component of the PID calculation, the controller software must maintain a running total of the accumulated area under the error curve (Current Integral). The sign of the value added to the accumulated Current Integral during each cycle may be positive or negative based on the current Direction setting as well as the relative values of the current process

reading and the set point.

Override Control

The Current Integral accumulates when the output is set to Auto mode. If

the controller is switched to Off mode, the value no longer accumulates, but it is not cleared. Therefore, PID control will resume where it left off if the controller is switched from Off back to Auto. Similarly, accumulation of the Control Integral will be suspended if the output is interlocked and resume after the lock-out is removed.

Bumpless Transfer

When the output is switched from Hand to Auto mode, the controller calcu-

lates a value for the Current Integral using the current error to generate the same output percent as the Hand Output setting. This calculation does not use

the Derivative tuning setting to minimize errors from momentary uctuations

in the input signal. This feature ensures a smooth transition from manual to automatic control with minimal overshoot or undershoot as long as the user

sets the Hand Output percentage close to the value that the process is expect-

ed to require for optimal control in Auto mode.

Wind-up Suppression

The Current Integral value that is accumulating while the output is set to

Auto can become very large or very small if the process value remains on the same side of the set point for a prolonged period of time. However, the controller may not be able to continue to respond if its output is already set to the minimum or maximum limits (0-100% by default). This condition is referred to as Control Wind-Up and can result severe overshoot or undershoot after a

prolonged upset has ended.

Page 53

the set point, negative errors will begin to decrease the Current Integral value. However, the value may remain large enough to keep the output at

100% long after the set point is satised. The controller will overshoot the

set point and the process value will continue to rise.

To optimize system recovery after wind-up situations, the controller suppresses updates to the Current Integral that would drive the output beyond its minimum or maximum limit. Ideally, the PID parameters will be tuned and the control elements (pump, valves, etc.) will be sized properly so that the output never reaches its minimum or maximum limit during normal control operations. But with this wind-up suppression feature, overshoot will be minimized should that situation occur.

Output Details

The details for this type of output include the pulse rate in %, HOA mode or Interlock status, input value, current integral, current and accumulated ontimes, alarms related to this output, relay type, and the current control mode

setting.

Set Point

Gain

Proportional Gain

Integral Time

Integral Gain

Derivative Time

Derivative Gain

Numeric entry of a process value used as a target for PID control. The default value, units and display format (number of decimal places) used during data entry are dened based on the Input channel setting selected.

When the Gain Form setting is Standard, this unitless value is multiplied by the total of the proportional, integral, and derivative terms to determine the calculated

output percent.

When the Gain Form setting is Parallel, this unitless value is multiplied by the normalized error (current process value versus set point) to determine the proportional com-

ponent of the calculated output percent.

When the Gain Form setting is Standard, this value is divided into the integral of the normalized error (area under the error curve), then multiplied by the Gain to

determine the integral component of the calculated output percent.

When the Gain Form setting is Parallel, this value is multiplied by the integral of the normalized error (area under the error curve) to determine the integral compo-

nent of the calculated output percent.

When the Gain Form setting is Standard, this value is multiplied by the change in error between the current reading and the previous reading, then multiplied by the

Gain to determine the derivative component of the calculated output percent.

When the Gain Form setting is Parallel, this value is multiplied by the change in error between the current

reading and the previous reading to determine the derivative component of the calculated output percent.

Page 54

Reset PID Integral

Minimum Output

Maximum Output

Maximum Rate

Input

Direction

Input Minimum

Input Maximum

Gain Form

The PID Integral Value is a running total of the accumulated area under the error curve (Current Integral). When this menu option is selected, this total is set to zero and the PID algorithm is reset to its initial state.

Enter the lowest possible pulse rate as a percentage of the Maximum Stroke Rate set below (normally 0%).

Enter the highest possible pulse rate as a percentage of the Maximum Stroke Rate set below.

Enter the maximum pulse rate that the metering pump is designed to accept (10 – 480 pulse/minute range).

Select the sensor to be used by this relay

Set the control direction. This setting is used to determine the sign of the calculated error (current process

value versus set point) and allows exible control with only positive values for all PID tuning parameters.

The low end of the sensor input range, used to normalize

errors into percent of full scale units. These values are

set to the nominal range of the selected input sensor by

default.

The high end of the sensor input range, used to normalize errors into percent of full scale units. These values

are set to the nominal range of the selected input sensor

by default.

Select the PID Equation Format used to enter tuning

parameters.

5.3.7 Relay, Dual Set Point Mode

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay.

Set point

Set point 2

Deadband

Enter the rst sensor process value at which the relay will

activate.

Enter the second sensor process value at which the relay will

activate.

Enter the sensor process value away from the set point at which the relay will deactivate.

Page 55

Duty Cycle Period

Duty Cycle

Input

Direction

Using a duty cycle helps to prevent overshooting the set

point in applications where the response of the sensor to

chemical additions is slow. Specify the amount of time for the cycle, and the percentage of that cycle time that the relay will be active. The relay will be off for the rest of the cycle, even if the set point has not been satised.

Enter the length of the duty cycle in minutes:seconds in this menu. Set the time to 00:00 if use of a duty cycle is not

required.

Enter the percentage of the cycle period that the relay will be active. Set the percentage to 100 if use of a duty cycle is not

required.

Select the sensor to be used by this relay.

Select the control direction. In Range will activate the relay when the input reading is between the two set points. Out of Range will activate the relay when the input reading is

outside the two set points.

5.3.8 Relay or Analog Output, Manual Mode

Output Details

The details for this type of output include the relay on/off state or analog output %, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

A Manual relay will activate if the HOA mode is Hand, or if it is Activated With another channel. There are no additional programmable parameters.

5.3.9 Relay, Flow Timer Control Mode

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time and alarms.

Settings

Press the Settings key view or change the settings related to the relay.

Feed Duration

Accumulated Volume

Input

Reset Timer

Enter the amount of time for the relay to activate for once the accumulated volume through the water meter has been

reached.

Enter the volume of water to pass through the water meter required to trigger the chemical feed.

Select the input to be used to control this output.

Use this menu to cancel the current feed cycle.

Page 56

5.3.10 Relay, Percent Timer Control Mode

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, cycle time, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay.

Sample Period

Feed Percentage

Enter the duration of the sample period.

Enter the % of the sample period time to use for the feed

relay activation time

5.3.11 Relay, Timer Control Mode

ONLY AVAILABLE IF HVAC MODES ARE DISABLED IN CONFIG MENU – GLOBAL SETTINGS

Basic Timer Operation

When a timer event triggers the algorithm will activate the relay for the

programmed time.

Special Condition Handling

Overlapping timer events

If a second timer event occurs while the rst one is still active, the second event will be ignored. An Event Skipped alarm will be set.

Interlock Conditions Interlocks override the relay control, but do not change the operation of the

timer control.

A digital input or output interlock condition does not delay the relay activation. The relay activation duration timer will continue even if the relay is deactivated due to an interlock condition. This will prevent delayed events which can potentially cause problems in they do not occur at the correct time.

“Activate With” Conditions “Activate with channels” settings override the relay control, but do not

change the operation of the timer control. The relay activation duration timer continues counting when the timer relay is forced on, and ends at the expected time (event start time plus duration). If the “activate with” condition continues after the end of the event time, the relay remains activated.

Alarms

An Event Skipped alarm is set when a second timer event occurs while one

event is still running.

An Event Skipped alarm is also set when the timer relay never turns on during an event because of an interlock condition.

The alarm is cleared when the relay is next activated for any reason (the next timer event or HAND mode or “activate with” force on condition).

Page 57

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type. The current week number and day of the week is displayed (even if there is no multi-week repetition event programmed). Cycle Time shows the time counting down of the currently active part of the cycle.

Settings

Press the Settings key view or change the settings related to the relay.

Event 1 (through 10)

Repetition

Week

Day

Events Per Day

Start Time

Duration

Add Last Missed

Enter these menus to program timer events via the menus

below:

Select the time cycle to repeat the event: Hourly, Daily, 1 Week, 2 Week, 4 Week, or None. An event means that the output is turned on at the same time of day, for the same amount of time, and except for the Daily cycle, on the same day of the week.

Only appears if Repetition is longer than 1 Week. Select the week during which the event will occur.

Only appears if Repetition is longer than Daily. Select the day of the week during which the event will occur.

Only appears if Repetition is Hourly. Select the number of events per day. The events occur on the Start Time and then evenly spaced throughout the day.

Enter the time of day to start the event.

Enter the amount of time that the relay will be on.

Select Enabled if the controller should delay start the most recent Biocide cycle until immediately after an Interlock clears, or Disabled if all Biocide feed should be skipped if there is an Interlock condition at the time the add was due

to start.

5.3.12 Relay, Probe Wash Control Mode

Basic Timer Operation

When a Probe Wash event triggers, the algorithm will activate the relay for the programmed time. The relay will activate a pump or valve to supply a

cleaning solution to the sensor or sensors. The output of the selected sensors

will either be held or disabled during the cleaningctcle, and for a programmable hold time after the cleaning cycle.

Special Condition Handling

Overlapping timer events

If a second timer event occurs while the rst one is still active, the second event will be ignored. An Event Skipped alarm will be set.

Interlock Conditions Interlocks override the relay control, but do not change the operation of the

timer control.

Page 58

“Activate With” Conditions “Activate with channels” settings override the relay control, but do not

Alarms

An Event Skipped alarm is set when a second timer event occurs while one

event is still running.

An Event Skipped alarm is also set when the timer relay never turns on during an event because of an interlock condition.

The alarm is cleared when the relay is next activated for any reason (the next timer event or HAND mode or “activate with” force on condition).

Output Details

Settings

Press the Settings key view or change the settings related to the relay.

Event 1 (through 10)

Repetition

Week

Day

Events Per Day

Start Time

Duration

Input

Input 2

Enter these menus to program timer events via the menus

below:

Only appears if Repetition is longer than 1 Week. Select the week during which the event will occur.

Only appears if Repetition is longer than Daily. Select the day of the week during which the event will occur.

Only appears if Repetition is Hourly. Select the number of events per day. The events occur on the Start Time and then evenly spaced throughout the day.

Enter the time of day to start the event.

Enter the amount of time that the relay will be on.

Select the sensor that will be washed.

Select the second sensor, if applicable, that will be washed.

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Sensor Mode

Hold Time

Select the effect that the probe wash event will have on any control outputs that use the sensor(s) being washed. The options are to either Disable the sensor readings (turn the control output off) or Hold the sensor reading at the last valid sensor reading prior to the start of the probe

wash event.

Enter the amount of time needed to hold the sensor reading

after the event has nished, in order for the wash solution to be replaced by process solution.

5.3.13 Analog Output, Retransmit Mode

Output Details

The details for this type of output include the output %, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the analog output.

4 mA Value

20 mA Value

Hand Output

Input

Enter the process value to correspond to a 4 mA output signal.

Enter the process value to correspond to a 20 mA output signal.

Enter the output % desired when the output is in Hand mode.

Select the sensor input to retransmit.

5.3.14 Analog Output, Proportional Control Mode

Output Details

The details for this type of output include the output %, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the analog output.

Set point

Proportional Band

Minimum Output

Maximum Output

Hand Output

Input

Direction

Enter the sensor process value at which the output % will

be the programmed minimum %.

Enter the sensor process value away from the set point at which the output % will be the programmed maximum %.

Enter the lowest output %. If the output should be off at the set point, this will be 0%.

Enter the highest output %.

Enter the output % desired when the output is in Hand mode.

Select the sensor input to use for proportional control.

Select the control direction.

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Off Mode Output

Error Output

Enter the output mA value desired when the output is in

Off mode, or being Interlocked, or during a calibration of the sensor being used as an input. The acceptable range is 0 to 21 mA.

Enter the output mA desired when the sensor is not giving the

controller a valid signal. The acceptable range is 0 to 21 mA.

5.3.15 Analog Output, PID Control Mode

ONLY AVAILABLE IF CONTROLLER INCLUDES ANALOG OUTPUT HARDWARE AND HAVC MODE IS DISABLED

The PID algorithm controls an analog (4-20 mA) output using standard Proportional-Integral-Derivative control logic. The algorithm provides feedback control based on an error value continuously calculated as the difference between a measured process variable and a desired set point. Tuning settings specify the response for proportional (the size of the error), integral (the time that the error has been present), and derivative (the rate of change for the error) parameters. With proper tuning, the PID control algorithm can hold the process value close the set point while minimizing overshoot and undershoot.

Normalized Error

PID Equation Formats

The controller supports two different forms of the PID equation as specied by the Gain Form setting. The two forms require different units for entry of the PID tuning parameters.

Standard

The standard form is more commonly used in industry because its time-based settings for the integral and derivative coefcients are more meaningful. This form is selected by default.

Parameter Description Units

Gain unitless

Integral Time seconds

Derivative Gain seconds or seconds/repeat

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de(t)

Output (%) = K

Parameter Description Units

e(t) Current Error % of full scale

dt Delta Time Between Readings seconds

e(t) + f e(t)dt + T

de(t) Difference Between Current Error &

Previous Error

Parallel

The parallel form allows the user to enter all parameters as Gains. In all cases, larger gain values result in faster output response. This form is used in the WebMaster controller and is used internally by the Control Module.

Parameter Description Units

Proportional Gain unitless

Integral Gain 1/ seconds

Derivative Gain seconds

Output (%) = Kp e(t) + Ki f e(t)dt + Kd

% of full scale

de(t)

Integral Value Management

To determine the integral component of the PID calculation, the controller

software must maintain a running total of the accumulated area under the error

curve (Current Integral). The sign of the value added to the accumulated Current Integral during each cycle may be positive or negative based on the current Direction setting as well as the relative values of the current process reading and

the set point.

Override Control

The Current Integral accumulates when the output is set to Auto mode. If

Bumpless Transfer

When the output is switched from Hand to Auto mode, the controller calcu-

lates a value for the Current Integral using the current error to generate the

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same output percent as the Hand Output setting. This calculation does not use

the Derivative tuning setting to minimize errors from momentary uctuations

in the input signal. This feature ensures a smooth transition from manual to automatic control with minimal overshoot or undershoot as long as the user

sets the Hand Output percentage close to the value that the process is expect-

ed to require for optimal control in Auto mode.

Wind-up Suppression

The Current Integral value that is accumulating while the output is set to

prolonged upset has ended.

For example, if the process value remains far below the set point despite a control output being pinned at 100%, the Current Integral will continue to accumulate errors (wind-up). When the process value nally rises to above the set point, negative errors will begin to decrease the Current Integral value. However, the value may remain large enough to keep the output at 100% long after the set point is satised. The controller will overshoot the set point

and the process value will continue to rise.

Output Details

The details for this type of output include the analog output value in %, HOA mode or Interlock status, input value, current integral, current and accumulated on-times, alarms related to this output, and the current control mode

setting.

Set Point

Gain

Numeric entry of a process value used as a target for PID control. The default value, units and display format (number of decimal places) used during data entry are dened based on

the Input channel setting selected.

When the Gain Form setting is Standard, this unitless value is multiplied by the total of the proportional, integral, and deriva-

tive terms to determine the calculated output percent.

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Proportional Gain

Integral Time

Integral Gain

Derivative Time

Derivative Gain

Reset PID Integral

Minimum Output

Maximum Output

Off Mode Output

Error Output

Input

Direction

Input Minimum

Input Maximum

When the Gain Form setting is Parallel, this unitless value is multiplied by the normalized error (current process value versus set point) to determine the proportional component of the

calculated output percent.

When the Gain Form setting is Standard, this value is divided into the integral of the normalized error (area under the error curve), then multiplied by the Gain to determine the integral

component of the calculated output percent.

When the Gain Form setting is Parallel, this value is multiplied by the integral of the normalized error (area under the error curve) to determine the integral component of the

calculated output percent.

When the Gain Form setting is Standard, this value is multiplied by the change in error between the current reading and the previous reading, then multiplied by the Gain to determine

the derivative component of the calculated output percent.

When the Gain Form setting is Parallel, this value is multiplied by the change in error between the current reading and

the previous reading to determine the derivative component of the calculated output percent.

The PID Integral Value is a running total of the accumulated area under the error curve (Current Integral). When this menu option is selected, this total is set to zero and the PID algo-

rithm is reset to its initial state.

Enter the lowest possible output value (normally 0%).

Enter the highest possible output value as a percentage.

Enter the output mA value desired when the output is in Off

mode, or being Interlocked, or if the Output Time Limit has expired, or during a calibration of the sensor being used as an input. Also if there is a Probe Wash programmed for the sensor, and the Sensor Mode option is set to Disable the output during the Wash cycle (if the Sensor Mode option is set to Hold the output holds its last setting and the Integral is not updated during the Wash). The acceptable range is 0 to 21 mA.

Enter the output mA desired when the sensor is not giving the

controller a valid signal. The acceptable range is 0 to 21 mA.

Select the sensor to be used by this output.

Set the control direction. This setting is used to determine the sign of the calculated error (current process value versus set

point) and allows exible control with only positive values for all PID tuning parameters.

The low end of the sensor input range, used to normalize errors into percent of full scale units. These values are set to the nominal range of the selected input sensor by default.

The high end of the sensor input range, used to normalize errors into percent of full scale units. These values are set to the nominal range of the selected input sensor by default.

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Gain Form

Select the PID Equation Format used to enter tuning parame-

ters.

5.3.16 Analog Output, Flow Proportional Mode

Overview

In Flow Proportional control mode, the controller monitors the rate of ow through an analog or digital ow meter, and continuously adjusts the analog (4-20 mA) output proportional band to achieve a target PPM level.

The user enters the target PPM and the data necessary to calculate the proportional band (the water ow rate at which the maximum pulse rate will occur) required to maintain the target PPM with that ow rate of water.

% output = Target PPM x Water Flow Rate (liter/min or gal/min)

Cycles x Pump Capacity (liter or gal/hr) x Pump Setting (%) x Specic Gravity x 166.67

% output = Target PPM x Water Flow Rate (m3⁄min)

Cycles x Pump Capacity (liter/hr) x Pump Setting (%) x Specic Gravity x 0.16667

Control Operation

If the output is continuously on for longer than the Output Time Limit, then

output will deactivate.

Output Details

The details for this type of output include the output %, HOA mode or Interlock status, alarms related to this output, current cycle on time, total accumulated on-time, cycles of concentration, mA output, and the current control

mode setting.

Settings

Touch the Settings icon to view or change the settings related to the relay.

Target

Pump Capacity

Pump Setting

Specic Gravity

Hand Output

Enter the desired PPM set point for the product.

Enter the maximum ow rate for the metering pump.

Enter the stroke length setting for the metering pump, in percent.

Enter the specic gravity of the product to be added.

Enter the output % desired when the output is in Hand mode.

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Off Mode Output

Error Output

Flow Input

Enter the output mA value desired when the output is in

Off mode, or being Interlocked, or during a calibration of the sensor being used as an input. The acceptable range is 0 to 21 mA.

Enter the output mA desired when the sensor is not

giving the controller a valid signal. The acceptable range is 0 to 21 mA.

Select the ow meter to be used as an input for this control relay.

5.4 Settings Menu

The conguration Settings Menu is used for settings and activities that are not

tied to Inputs or Outputs.

5.4.1 Global Settings

Date

Time

Global Units

Temperature Units

Alarm Delay

HVAC Modes

Language

Enter the current year, month and day.

Enter the current hour (military time), minute, and second.

Select the units to be used for cable length and wire gauge settings, metric or Imperial.

Select between Fahrenheit and Celsius.

Enter how much time to wait after powering up the controller

before alarm conditions are considered valid.

Enable HVAC modes for cooling tower and boiler applications where the relay control modes for Biocide timer, Bleed and Feed, Bleed then Feed, and Intermittent Sampling are required. Disable HVAC Modes if these control modes are not necessary and a more generic timer control mode will replace the Biocide timer.

Select the language the software will use

5.4.2 Security Settings

Controller Log Out

Security

Logging Out when Security is Enabled, and after the password has been entered, requires immediate use of a password to calibrate or change settings. If not manually logged out, the controller will automatically log out after 10 minutes of inactivity.

Select Enable to require a password in order to calibrate or change settings, or Disable to allow calibration and set point

changes without a password.

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Local Password

Used to change the password needed for full conguration capability if Security has been enabled. The default local password is 5555. This can and should be changed using this menu if Security is enabled.

5.4.3 Display Settings

Home 1

Home 2

Adjust Display

Key Beep

Select the input or output to display on the 1 play Home screen.

Select the input or output to display on the 2 play Home screen.

Change the contrast using the arrow keys. If the display becomes unreadable, it is possible to reset the defaults by powering down and pressing the bottom right button while powering back on.

Select enable to hear a beep when a key is pressed, or disable

for silence

5.4.4 File Utilities

line of the dis-

File Transfer Status

Export Event Log

Import User Con-

g File

Export User Con-

g File

Export System Log

Reset Default Cong

Displays the status of the last attempt to export a le

Save the Event Log le to a USB stick. A micro-USB male to USB A female adapter is required. This records set point changes, user calibrations, alarms, relay state changes, le exports, etc.

Remove power from the controller and insert a USB stick (a micro-USB male to USB A female adapter is required) that contains the settings that you want to import to this controller (see Export User Cong le below). Press the Enter key and then press the Conrm key to transfer those settings to this controller.

The User Conguration le contains all settings for the con-

troller. Enter this menu to save the controller’s settings to a

USB stick for using later to restore settings to this controller,

or to program additional controllers with the same settings as

this one. It takes several minutes to create the le and transfer it to the stick. Remove power from the controller and insert a USB stick (a micro-USB male to USB A female adapter is required). Press the Enter key and then press the Conrm key to transfer a le containing the controller’s settings to the USB stick.

Save the System Log le to a USB stick. A micro-USB male to USB A female adapter is required. This records hardware changes, software upgrades, automatic calibrations, power loss, system-level issues, etc.

Enter this menu to restore all of the settings to the factory default values. Any changes to settings that were previously made will be lost!

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Software Upgrade

Remove power from the controller and insert an USB stick that has the upgrade le stored in the root directory into the micro-USB connector (see gure 1). A micro-USB male to USB A female adapter is required. Press the Enter key, and then press the Conrm key to start the upgrade.

NOTE: Remove power before inserting or removing the micro-USB adapter!

5.4.5 Controller Details

Controller

Product Name

Control Board

Software Version

Sensor Board

Software Version

Power Board

Display Board

AO Board

Battery Power

Processor Temp

Sensor Temp

Displays the name for the group of default settings used as built

Displays the model of the controller as built

Displays the revision number of the front panel circuit board

Displays the software version on the control board

Displays the revision number of the sensor board

Displays the software version on the sensor board

Displays the revision number of the power/relay board

Displays the revision number of the display board

Displays the revision number of the analog output board

Displays the VDC output of the battery that is used to hold the date and time. The acceptable range is 2.4-3.2 VDC.

Displays the temperature of the main processor. The acceptable range is -10 to 65 C.

Displays the temperature of the sensor input processor. The acceptable range is -10 to 65 C.

6.0 MAINTENANCE

The controller itself requires very little maintenance. Wipe with a damp cloth. Do not spray down the controller unless the panel door is closed and latched.

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7.0 TROUBLESHOOTING

CAUTION: Disconnect power to the controller before opening front panel!

Troubleshooting and repair of a malfunctioning controller should only be attempted by qualied personnel using caution to ensure safety and limit unnecessary further damage. Contact the factory.

7.1 Calibration Failure

Calibrations will fail if the adjustments to the reading are outside of the normal range for a properly functioning system. Refer to the instruction manual for the specic sensor being used for further information.

7.1.1 Contacting Conductivity Sensors

The calibration will fail if the adjustment to the gain is outside of 0.5 to 2.0.

Possible Cause Corrective Action

Dirty electrode Clean electrode

Improper wiring of sensor to controller Correct wiring

Wrong cell constant entered Program the controller cell constant

Incorrect temperature reading or setting Ensure that the temperature is accurate

Incorrect cable length or wire gauge

setting

Faulty electrode Replace electrode

setting at the value that matches the

electrode being used

Set to the correct values

7.1.2 Electrodeless Conductivity Sensors

The calibration will fail if the adjustment to the gain is outside of 0.2 to 10, or the offset is outside of -10,000 to 10,000.

Possible Cause Corrective Action

Dirty sensor Clean sensor

Improper wiring of sensor to controller Correct wiring

Sensor placed too close to container walls Relocate sensor

Sensor placed in the direct path of electrical

current ow

Incorrect temperature reading or setting Ensure that the temperature is

Incorrect cable length or wire gauge setting Set to the correct values

Faulty sensor Replace sensor

Relocate sensor

accurate

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7.1.3 pH Sensors

The calibration will fail if the adjustment to the gain is outside of 0.2 to 1.2, or if the calculated offset is outside of -140 to 140.

Possible Cause Corrective Action

Dirty electrode Clean electrode

Improper wiring of sensor to controller Correct wiring

Incorrect temperature reading or setting Ensure that the temperature is

Incorrect cable length or wire gauge setting Set to the correct values

Faulty electrode Replace electrode

Faulty preamplier Replace preamplier

accurate

7.1.4 ORP Sensors

The calibration will fail if the adjustment to the gain is outside of 0.5 to 1.5, or if the calculated offset is outside of -300 to 300.

Possible Cause Corrective Action

Dirty electrode Clean electrode

Improper wiring of sensor to controller Correct wiring

Faulty electrode Replace electrode

Faulty preamplier Replace preamplier

7.1.5 Disinfection Sensors

The calibration will fail if the adjustment to the gain is outside of 0.2 to 10.0, or if the calculated offset is outside of -40 to 40.

Possible Cause Corrective Action

Insufcient conditioning Wait for the appropriate amount of

Insufcient sample ow Increase ow rate to between 30 and

Air bubbles on membrane Dislodge bubbles. Adjust ow rate

Air bubbles in electrolyte Rell membrane cap with electrolyte.

Dirty membrane Clean membrane

Loose membrane cap Tighten membrane cap.

Faulty membrane Replace membrane cap.

High Pressure Reduce pressure to below 1 atmo-

time before attempting a calibration.

100 liter per hour.

higher if necessary.

sphere and rell cap with electrolyte

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No electrolyte ll solution in membrane

cap

Improper wiring of sensor to controller Correct wiring

Faulty sensor Replace sensor

Faulty analysis equipment or reagents Consult test equipment instructions

Sample contaminated with interfering

molecule (refer to Sensitivity specication in sensor instructions)

Fill membrane cap with electrolyte. Replace membrane cap if it will not

hold solution.

Remove source of contamination

7.2 Alarm Messages

Alarm messages will include the Name of the input or output as dened in the Settings menu, the hardware identifying type and number (S for sensor input, D for digital input, R for relay output, A for analog output), and the type of alarm.

HIGH or HIGH-HIGH ALARM Occurs if the sensor reading rises above the high alarm set points. If your unit is programmed for an alarm relay output, the alarm relay will activate. The controller will continue to check the sensor reading, and any outputs using the sensor will remain active.

Possible Cause Corrective Action

The process went further out of control than normal.

The chemical supply has run out. Replenish the chemical supply.

The pump or valve or supply line is faulty. Repair or replace the control device.

Wrong chemical is being controlled. Replace with correct chemical.

The sensor is not responding to changes. Repair or replace sensor. Evaluate mix-

The pump is siphoning, valve leaking. Repair or replace the control device or

Control output has been left in “HAND”

mode.

It may be a normal part of the process. None required.

LOW or LOW-LOW ALARM Occurs if the sensor reading drops below the low alarm set points. If your unit is programmed for an alarm relay output, the alarm relay will activate. The controller will continue to check the sensor reading, and any outputs using the sensor will remain active.

Possible Cause Corrective Action

The process went further out of control than normal.

The chemical supply has run out. Replenish the chemical supply.

The pump or valve or supply line is faulty. Repair or replace the control device.

Wrong chemical is being controlled. Replace with correct chemical.

May have to increase chemical ow

rate.

ing or recirculation.

re-route tubing.

Switch back to “AUTO”.

May have to increase chemical ow

rate.

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The sensor is not responding to changes. Repair or replace sensor. Evaluate mix-

ing or recirculation.

The pump is siphoning, valve leaking. Repair or replace the control device or

re-route tubing.

Control output has been left in “HAND” mode. Switch back to “AUTO”.

It may be a normal part of the process. None required.

DI STATE CUSTOM MESSAGE A digital input that is a DI State type can be set such that either the open or closed state generates an alarm. The alarm message may be customized. The most common use for this will be a Flow Switch.

Possible Cause Corrective Action

No ow Check piping for closed valves, block-

age, etc. Check recirculation pump.

Faulty ow switch/cable Check with ohmmeter.

Faulty controller Check by shorting digital input in

controller.

TOTAL ALARM

Occurs if the ow meter totalizer alarm limit is exceeded.

Normal operation Reset the total to clear alarm

AC coupled onto ow meter cable Route cable at least 6 inches (150 mm)

away from any AC voltage

Noise coupled onto ow meter cable Shield cable

OUTPUT TIMEOUT This error condition will stop control. It is caused by the output (either relay or analog) being activated for longer than the programmed Time Limit.

Possible Cause Corrective Action

The process went further out of control than

Increase time limit or reset timer.

normal.

The chemical supply has run out. Replenish the chemical supply.

The pump or valve or supply line is faulty. Repair or replace the control device.

Wrong chemical is being controlled. Replace with correct chemical.

The sensor is not responding to changes. Replace sensor. Evaluate mixing or

recirculation.

RANGE ALARM It indicates that the signal from the sensor is out of the normal range. This error condition will stop control of any output using the sensor. This prevents controlling based upon a false sensor reading. If the temperature sensor goes into range alarm, then the controller will go into manual temperature compensation using the Default Temperature setting.

Possible Cause Corrective Action

Sensor wires shorted Disconnect short

Faulty sensor Replace sensor

Faulty controller Replace or repair controller

Page 72

SENSOR FAULT This error indicates that the signal from the sensor is no longer valid at all. This error condition will stop control of any output using the sensor.