microFlex Blowdown Controller for Boilers
Contents
1. 38 BB IN Boiler Blowdown Controller Activity Meth dd _ Yearly Calibrate Conductivity Verify the boiler water conductivity tester annually Tester Observe a Blowdown Control Cycle Verify Water Meter AQB2_User 02 06 with a calibration solution using a solution that s as close as possible to the controller conductivity setpoints Replace outdated calibration solutions Sampling Blowdown Control How many Blowdown Measure cycles does it take to lower the conductivity below the TurnOFF setpoint If the conductivity is well below the TurnOFF setpoint it s likely that the Blowdown time is set too long If the conductivity increases markedly above the TurnON setpoint consider opening the throttling valve to allow a higher blowdown rate Check that the flash tank can handle higher blowdown volumes Continuous Blowdown Control Watch the conductivity as the blowdown valve turns ON Does it fall immediately You may not have enough throttling on the blowdown line You ll see the blowdown valve rapidly opening amp closing shortening valve life Does the conductivity take a long time to increase even when the boiler is loaded You may have to throttle the sensor flow to limit heat amp chemical loss If a make up water meter is installed verify that the controller measures an increase in make up volume when the boiler feedwater pump turns ON If you are using the meter to control inhibitor fee2. Since the controller feeds a single chemical it s likely to be fed into the feedwater line or directly into the dearator sump Inject water treatment chemical upstream of the boiler feedwater pump where pressure and temperature are limited to the deaerator sump levels The controller is not fused to power a fractional horsepower piston drive chemical pump A motor start relay is required with the 120VAC coil powered by the controller AQB2_User 02 06 41 BB IN Boiler Blowdown Controller A 4 BLOWDOWN VALVE amp LOCATION Steam rated solenoids are seldom used in boilers rated over 100psi steam Steam rated solenoids are commonly used and reliable on low pressure boilers Solenoids have the added advantage of being closed when solenoid power is OFF Motorized ball valves are typically the PowerON PowerOFF type AC power is required to both open and close the valve If the controller is powered OFF when the valve is open the valve will stay open Although this is seldom an operational problem sites may elect to use a spring loaded return type ball valve which does not require power to close PowerON PowerOFF motorized blowdown valves require 3 wires amp ground Power Open Power Closed and Neutral Steam rated solenoids amp Spring Return motorized valves require only 2 wires amp ground Power Open and Neutral The optimum blowdown location is after the surface blowdown safety isolation valves typically in a vertical run
3. Boiler Blowdown Controller Activity Methodd _ Weekly Verify Conductivity Check both current Temperature and Minimum Maximum temperature Note Make up Volume If make up meter installed Verify Interlock System Check Sample the boiler water conductivity Verify controller matches sample 50uS Conductivity sensors should not drift or require cleaning Scaling a conductivity sensor usually indicates flashing at the sensor due to a restriction upstream of the sensor Sampling Blowdown Control Temperature not used or measured during Sampling blowdown control Continuous Blowdown Control You would expect to see a relatively constant sensor temperature with only a small difference between Minimum amp Maximum temperatures if the boiler operates continuously You d expect to see only a small change in sensor temperature when the blowdown valve opens Weekly softened make up water usage indicates both average boiler load and percentage condensate return High water usage may result from a reduction in controller setpoints or faulted or failing softener If you are using the Interlock verify that Interlock shows OFF when the boiler is off line Visually inspect sensor and sensor piping for leaking fittings Inspect chemical injection tubing and entry for leaking Sidebar Maintenance Guidelines for water treatment testing are set by the chemical treatment program vendor AQB2_User 02 06
4. Inter lock ON 780 6min Sf Diagnostics on last 18 6hrs Sf Boiler Blowdown S N DO41B0248 Sf LAN IP gt 010 010 006 101 OR 4 20mA Output 15 4mA OR Alarm Relay a Closed 11 BB IN Boiler Blowdown Controller 2 2 Blowdown Mode Conductivity Setpoints The factory default Blowdown Mode is Sampling Control Refer to 3 2 Blowdown Controls to select one of three Blowdown Modes Press UP or DOWN until you see Blowdown Valve amp press ENTER Press ENTER to view or adjust Setpoints Displays current blowdown setpoints Display varies with Blowdown Mode Press ENTER adjust Turn ON or DOWN amp ENTER for TurnOFF Press UP DOWN to adjust and RIGHT to move the cursor Press EXIT to leave the Setpoints unchanged Press ENTER displays current Setpoints If you make Turn ON less than TurnOFF the setpoints will be switched Setpoints for Sampling amp Continuous Blowdown Mode Setpoints for Percentage Time Blowdown Mode Blowdown Valve ON 2 7 hrs day rv Setpoints v Blowdown Mode ea Turn ON 3000 TurnOFF 2990 y amp Edit amp Enter Turn ON 3025 gt 3 then 2 Turn ON 3025 TurnOFF 2990 Turn ON 3000 TurnOFF 2990 y Continuous Control Percentage Time 15 each 5min Time Control Sidebar The difference between Turn ON amp TurnOFF the deadband is usually set to 10uS For Sampling blowdown mode and
5. Press ENTER amp then DOWN to Alarms Press ENTER to view current alarms or adjust Press ENTER to adjust the High Alarm or DOWN amp ENTER to adjust the Low Alarm Press UP DOWN to adjust and RIGHT to move the cursor Press EXIT to leave Alarm unchanged ENTER updates the alarms amp displays the current High amp Low Alarms Conductivity Alarms display on the Alarms display and resets automatically Clear Alarms does not reset a conductivity alarm above the High or less than the Low Alarm level Conductivity v 1425 us 4 Calibrate Alarms 4 3 Alarms Calibrate High 3500us Low 2500us m Edit amp ENTER High 3750us gt a oe 5 then Ga High 3750us Low 2500uS y 4 Sidebar Conductivity alarms may occur when the boiler is offline and the sensor is cold The alarm clears automatically when the sensor measures a hot boiler water sample and the measured conductivity in between the High amp Low alarm levels AQB2_User 02 06 21 BB IN Boiler Blowdown Controller If Blowdown Mode is set to Sampling the Conductivity display updates at the end of each Sensor Watch Measure period 7 Sensor Watch shows the conductivity continuously Conductivity hi revealing problems with valves amp flashing 1425 us Press UP DOWN until you see Conductivity Calibrate Pr Alarms Y Press ENTER amp then DOWN to Sensor Watch 4 This option only d
6. Trim Ze Trim Sp Trim Ze now 4mA ro an 4 ro 6 lt y 201 t 4 20mA Output 15 2mA 4 20mA Output 15 4mA Gang Trim Sp an Select Span Trim Span now 20ma 91 4 2202 4 20mA Output 15 2mA 49 BB IN Boiler Blowdown Controller Appendix E Alarm Relay Option E 1 WIRING ALARM CONTACTS Alarm contacts rated 500mA at 24VDC Requires optional Alarm Relay Card Dry Contacts Open On Alarm ON when not Alarmed Alarm dry contacts OPEN on alarm loss of controller power amp alarm wiring disconnect Alarm Building Automation System Alarm Wire alarm contacts AWG22 to AWG18 2 conductor E 2 ALARM DISPLAYS Press UP DOWN until you see Alarms If the Alarm Relay Card is installed you ll see one of the following displays If Alarms amp none then the alarm contacts will be closed Alarm contacts open on alarm This display verifies the contact set state measured at the Building Automation System input terminals AQB2_User 02 06 Alarm Input Alarms Sf Alarm Contacts CLOSED No Alarm OR Alarm Contacts OPEN Alarm 50 BB IN Boiler Blowdown Controller Appendix F LAN Browser Option Download Sflex_LB manual from www Aquatrac com manuals Do not connect the controller to the site LAN without permission from the site IT staff This controller micro server uses a static IP assigned by the site IT staff and set
7. and to power 4 20mA current loops Alarms on short circuits recovers when wiring corrected Internal power used for blowdown valve and pump relays Always 11 8 to 12 2 Alarms on fault Conductivity sensor drive 72 76mV or 995 1010mV as sensor drive auto ranges Alarms and cannot measure conductivity if out of range Internal diagnostics Checks that user setpoints being saved amp that the controller timing is operating 3 6 System Alarms continued Boiler Blowdown S N DO41B0248 Current State l Select Units y Temperature 101 341 F v 4 Ext Power 102 15 6 VDC 4 4 Relay Power 103 12 1 VDC y 4 Drive 2107 73 3 mV y 4 Measure 105 998 5 mV y ih State 2106 244 163 y Sidebar System Diagnostics verifies the controller operation amp alerts you to wiring problems with conductivity temperature paddlewheel water meters and controller powered 4 20mA current loops AQB2_User 02 06 33 BB IN Boiler Blowdown Controller System Select Units Press UP DOWN until you see the Serial Number Press ENTER amp DOWN to Select Units Press ENTER to view or adjust current Select Units Press EXIT to leave changed or DOWN to change Key ENTER to Set to U S units degrees Fahrenheit amp Gallons Or Set to Metric degrees Centigrade amp Liters Sidebar 3 6 System Alarms continued Boi ler Blowdown S N DO41B0248 4a then 4 Select Units lt Cur
8. feed for 8 seconds Inhibitor Pump turns ON when the Blowdown Valve is ON Pump switches ON amp OFF during bleed at user set of 5 minutes NOTE If you change the Feed Mode press UP to Setpoints amp ENTER to adjust for the new Feed Mode 3 4 Inhibitor Controls Continued Inhibitor Pump lt ON 12 3min then 4 Feed Mode lt Limit Timer y Percentage Time lt Feed on Volume y lt Feed on Volume lt Blowdown amp Feed y gt Blowdown amp Feed 4 Percentage Time y 4s then T Setpoints v Feed Mode v Sidebar Percentage Time is used to base feed amp is the most commonly used chemical feed method for smaller boilers Feed on Volume is an accurate amp reliable way to feed chemical for boilers which have a softened make up meter or a dry contact closure from the feedwater pump Blowdown amp Feed requires reliable blowdown control and conductivity tracking The setpoint time is based on either the sum of Sample Measure time or Blowdown Measure time The sum of periods is used since a boiler that is blowing down may require a number of Blowdown Measure cycles to fall below the TurnOFF setpoint Chemical is lost any time the blowdown valve is open so feed is based on both Sample and Blowdown periods AQB2_User 02 06 29 BB IN Boiler Blowdown Controller Current State of the Inhibitor Pump Control Press ENTER then UP Inhibitor Pump Press ENTER Cur
9. 4 Your installation may Deaerator Ll not include a make up meter l E and or an operating interlock 5 Use a solenoid or valve for Ai o biowdown rated for steam service aa at boiler pressure _ Optional Make up isolation Water Meter Valve Injection Entry Steel surface blowdown piping Conductivity e isolation Sensor o m Valve Chemical injected po o into deaerator sump N Bleed Solenoid or into feedwater Pa i 5X or Valve line upstream of E ff NA the feedwater pump Boiler 250 psi Optional Throttling Throttling Needle Valve Valve maximum Operating Interlock A Contact Set Isolation Valve Flash Tank AQB2_User 02 06 BB IN Boiler Blowdown Controller 1 2 Controller Enclosure Install the controller enclosure corner mounting hardware available in the parts bag stapled to the controller manual Locate the controller at eye level 60 150cm above the floor Typical Equipment Layout MM Downstream of Controller Deaerator e nn Inhibitor Pump Plugs wiring amp tubing not EENEN Chemical shown Injection point SESS Flow Pump Shelf NOTES T 1 Controller is usually located within sight of the blowdown valve aa Upstream 2 Your installation may not include AR of Feedwater chemical injection Inhibitor Pump 3 Chemical is usually injected upstream of the feedwater pump at deaerator pressure 4 Conductivity sensor cable may
10. 50uS for Continuous blowdown mode Conductivity should decrease as Blowdown Valve ON time increases AQB2_User 02 06 12 BB IN Boiler Blowdown Controller 2 3 Inhibitor Feed Mode Setpoints Feed Limit The factory default Feed Mode is Percentage Time Refer to 3 6 Inhibitor Controls to select one of three Feed Modes Press UP or DOWN until you see Inhibitor Pump amp press ENTER Press ENTER to view or adjust Setpoints Displays current feed setpoints Inhibitor will be ON for 10 of the time that the Interlock is ON 30 seconds in every 5 minutes Press ENTER adjust of ON time Press UP DOWN to adjust and RIGHT to move the cursor Press EXIT to leave the Setpoint unchanged Press ENTER displays current setpoint 36 seconds in every 5 minutes If Feed Mode is set to Blowdown amp Feed Inhibitor Pump is ON for user set of each blowdown If Feed Mode is set to Feed on Volume Inhibitor Pump is ON for user set seconds for each user set make up volume Inhibitor Pump ON 0 5min 4i then T Setpoints lt Feed Mode y rv Percentage Time 10 each 5min lt Edit amp Enter 12 each 5min gt ty then a Percentage Time 12 each 5min Blowdown amp Feed 17 each Smin Blowdown amp Feed Measure 100 Gd Feed 12sec y Feed on Volume Sidebar Percentage Time base feeding is the most common way to feed inhibitor into small boilers which usually do
11. Controller 4 MAINTENANCE 4 1 Guidelines Modify the maintenance guidelines to reflect both the site priorities and the site water treatment program Guidelines are for controller function only Water treatment program maintenance requirements are provided by the site water treatment provider Identify and correct the cause of alarms on sensors and inhibitor pump Check for Alarms Make up water or Pump rate amp stroke may have changed The percentage of condensate return may have changed extending inhibitor ON times changing blowdown run times Debris may have partially blocked the blowdown line throttling valve Sampling Blowdown A low conductivity may indicate a failure to sample resulting in a cold sample at the Scan Sensors sensor Make up Meter The blowdown valve may not be operating or may be amp Flowswitch valved OFF upstream or downstream of the valve Continuous Blowdown A high conductivity may indicate a blocked or failed blowdown valve If there s a softened make up meter you d expect daily volume to vary with load if the condensate return doesn t vary High make up may indicate a low condensate return or a faulted blowdown control If the boiler is on line verify that the Interlock shows ON At the same boiler load and percentage condensate return you would expect consistent and repeatable Blowdown Valve and Inhibitor pump ON times in every 24 hour period AQB2_User 02 06 37 BB IN
12. amp Alarms Valve ON or OFF and ON time this blowdown cycle Press ENTER for Blowdown Setpoints Mode Test and Current State Water meter measured volume in most recent 0 24 hours Press ENTER to Install Select type View on line total amp days on line Inhibitor Pump ON or OFF and ON time this feed cycle Press ENTER for Inhibitor Setpoints Feed Mode Limit Timer Prime Pump and Current State AQB2_User 02 06 Enclosure keypad Response UP or DOWN to the display you wish to view or EDIT amp press ENTER Boiler Blowdown lt d S N D206NT248 Sf Alarms Sf Conductivity lt lt 1425 us Sf Blowdown Valve ON 125 6min Sf 16 4hr Make up 8050 G Sf Inhibitor Pump ON 96 4min 10 BB IN Boiler Blowdown Controller 2 1 Power up Display amp Keypad Interlock ON or OFF and ON time in most recent 24 hours Reset to zero on POWER OFF ON Diagnostics since power ON Reset to zero on POWER OFF ON Last blowdown average blowdown max min temperature If there is no option card installed you ll view the serial number power up display LAN Browser LB Option Displays current IP see Appendix F LAN for User Manual 4 20mA Output CL Option Displays loop current see Appendix D 4 20mA OUTPUT for User Manual Alarm Relay AR Option Displays relay state see Appendix E ALARM RELAY for User Manual AQB2_User 02 06 continued
13. be extended up to 100ft in 4 x AWG22 5 Do not cable sensor and 120VAC valve wiring in the same conduit Although sensor cables and pump tubing may be extended ease of servicing occurs when water treatment components are located in the same area Ensure that the controller enclosure door is closed amp latched when not terminating sensor and water meter wiring AQB2_User 02 06 6 BB IN Boiler Blowdown Controller 1 3 Sensors Conductivity amp Interlock After isolating the surface blowdown line and installing the conductivity sensor open the sample piping downstream valve then the upstream valve Verify that the sensor entry seals leak and drip free Conductivity Temperature Interlock SENSOR GRN WHT BLK RED 15v TE Flow meter T S152 OOVODL OSLA RUN B Conductivity Sensor Operating Note The factory default Interlock jumpers the interlock so the controller will operate Dry contacts out of the box closed to operate E Jumper Flow to if aeai Feed cables through the entry seal amp re tighten a Controller Thermally Compensated Conductivity Sensors Compensated sensors are used for condensate monitoring bypass controls and for continuous blowdown controls with the compensated sensor located downstream of a sample cooler Thermally compensated sensors are identified by a four wire sensor cable Connect the GREEN WHITE BLACK RED cable to t
14. beside the boiler where the operation of the blowdown valve can be observed and the distance between sensor and boiler minimized Orient the valve so that the valve state is easily viewed Typically motorized valves have a shaft position indicator so it s easy to see the valve operate and if it s currently open or closed It s more difficult to see the state of a steam rated solenoid A non contact IR temperature meter is a low cost easy way to verify solenoid state by reading the temperature on either side of the solenoid A 5 MAKE UP METER Ensure that the meter is rated for the temperature Meters installed in feedwater lines upstream of the feedwater pump are typically stainless steel paddlewheel type Add meter isolation and or bypass valves so the meter can be serviced Ensure that the meter manufacturer s recommendations for orientation and upstream and downstream piping are observed Horizontal installation may be limited for contact head meters while straight upstream and downstream piping is required to prevent errors in turbine paddlewheel meters Contact head meters have a Gallon Contact or Liter Contact rating In some meters this value can be altered by moving magnets or gears Typical meters are rated 10 50 amp 100 Gallons contact Turbine Paddlewheel meters have a K Factor which is the number of pulses Gallon or pulses Liter Some manufacturers have both nominal values listed by meter size and calibration va
15. hour period Press ENTER to view or adjust Setpoints Setpoints vary with selected Blowdown Mode Press ENTER view current mode or to select from Sampling Continuous or Percentage Time Press ENTER Test Valve to turn ON Blowdown Valve See Sidebar Alarms Clear Alarms ends the test Sample Timing is only displayed if Blowdown Mode Sampling Press ENTER to view or adjust Sampling timing Press ENTER Current State to view control status Display varies with Blowdown Mode 3 2 Blowdown Control Blowdown Menu Blowdown Valve ON 8 7min a Setpoints v Blowdown Mode amp Blowdown Mode Test Valve 4 Test Valve Sample Timing 4 Sample Timing Current State Current State lt Setpoints 4 t Sidebar Test Blowdown will not turn ON the Blowdown Valve unless the Interlock is ON Warning Changing Blowdown Mode may require plumbing changes See manual Section 1 1 for piping configuration is each mode Test Valve starts a Sample period if Blowdown Mode Sampling Alarms Clear Alarms also starts a new Sample period if Blowdown Mode Sampling Test Valve turns ON the Blowdown Valve for 5 minutes 300 seconds if Blowdown Mode Continuous or Percentage Time AQB2_User 02 06 23 BB IN Boiler Blowdown Controller Blowdown Valve Modes Press ENTER then DOWN Blowdown Valve Press ENTER Blowdown Mode to view current mode and to select a new mode Most boile
16. is the time between conductivity checks when the conductivity is less than TurnOFF setpoint AQB2_User 02 06 26 BB IN Boiler Blowdown Controller 3 3 Make up Meter OPTIONAL Meter type selection amp installation detailed in Section 2 5 Check Interlock amp Install Water Meter Press UP DOWN until you see 0 24 hr Make up 18 2hr Make up amp press ENTER 10450 G Press ENTER to view current type or to select Meter Type lt Contact Head or Paddlewheel water meter Year to Date 4 Key DOWN amp ENTER for volume during the most Year to Date v recent 365 days Resets to zero every 365 days Days Online y Key DOWN amp ENTER for the number of 24 hour periodsof Days Online ON time in the current year zero Meter y Key ENTER to reset Year to date Days OnLine Zero Meter PT and 24 hr Make up to zero Meter Type Warning Cannot Undo yP Year to Date logged every 60 minutes power ON Year to Date 192 Displays in L iters if metric selected 265200 G Days water meter ON in current year i Resets to zero every 365 days Days Online 193 28 7 Press EXIT to return to previous display Sidebar Year to date divided by Days OnLine is average usage in any 24 hour period HELP 192 amp 193 and other help numbers display wherever more explanation is available at www aquatrac com AQB2_User 02 06 27 BB IN Boiler Blowdown Controller 3 4 Inhibitor Controls For inhibitor control setpoints
17. turn ON during Sampling and as the conductivity exceeds the Turn ON setpoint Sampling Controls will cycle between the Blowdown and Measure states Refer to Section 3 2 for details If the Inhibitor feed mode is set to Percentage Time and the of each 5 minutes is set to less than 100 the Inhibitor Pump will turn ON amp OFF while Interlock is ON If the Inhibitor feed mode is set to Blowdown amp Feed the Inhibitor Pump will turn ON as soon as the Bleed turns ON The pump will turn ON amp OFF to meet the setpoint in each blowdown period If the inhibitor pump is set to Feed on Volume the inhibitor pump will turn ON after measuring Make up Sidebar The Blowdown Valve and Pump will not turn ON unless the Interlock is ON The Inhibitor Pump turns OFF if the Feed Limit is exceeded Increase the Limit Timer to allow the pump to turn ON 2 8 Check Controls Conductivity amp Blowdown Conductivity v 1425 us Sf Blowdown Valve ON 17 1min ater Meter or Bleed amp Inhibitor Pump Blowdown Valve lt lt ON 124 2min Sf Inhibitor Pump ON 48 1min 24hr Make up 10450 G Sf Inhibitor Pump ON 124 8min Feed limited inhibitor pumps reset every 24 hours of controller run time or on power OFF ON AQB2_User 02 06 20 BB IN Boiler Blowdown Controller 3 OPERATION 3 1 Conductivity Sensor Sensor calibration is detailed in Section 2 5 Press UP DOWN until you see Conductivity
18. AQUATRAG SYSTEM DESIGN amp ENGINEERING microFlex Blowdown Controller for Boilers Measures Conductivity Temperature Make up Water Meter and Interlock Controls the Blowdown Valve and the Inhibitor Pump Part No BB IN BB IN Boiler Blowdown Controller CONTENTS Safety 1 INSTALLATION 1 1 Sample Piping 1 2 Controller Enclosure 1 3 Sensor Conductivity amp Temperature 1 4 Sensors Water Meter 1 5 Inhibitor Pump and Blowdown Valve 2 START UP 2 1 Power up Display amp Keypad 2 2 Blowdown Mode Conductivity Setpoints 2 3 Inhibitor Feed Mode Setpoints Feed Limit 2 4 Verify Temperature 2 5 Calibrate Conductivity Sensor 2 6 Check Interlock amp Install Water Meter 2 7 Plug in Pump and Blowdown Solenoid 2 8 Check Controls 3 OPERATION 3 1 Conductivity Sensor 3 2 Blowdown Controls 3 3 Make up Meter 3 4 Inhibitor Controls 3 5 Diagnostics 3 6 System Alarms 3 7 Password 4 MAINTENANCE 4 1 Guidelines 4 2 Spare Parts 4 3 Technical Support APPENDICES A INSTALL B SPECIFICATIONS C HARDWIRING D 4 20mA OUTPUT Option E ALARM RELAY Option F LAN BROWSER Option AQB2_User 02 06 BB IN Boiler Blowdown Controller Safety A Electrical Shock Hazard Opening the enclosure door with the controller plugged in exposes the user to AC line voltages Unplug the controller before opening the enclosure door A USER WARNING CAUTION This Boiler Blowdown Controller operate
19. NING MOTORIZED BLOWDOWN Do not plug in controller pump VALVES are hardwired or blowdown valve until you ETET are ready to setup amp operate STEAM RATED SOLENOIDS may be plugged in or hardwired INHIBITOR See Appendix C PUMP Back for Hardwiring BLOWDOWN Grounded SOLENOID Front Power Plug START UP BEFORE you plug in the controller set the throttling valve to 20 open open the surface blowdown line and sensor piping isolation valves WARNING Plugging in the controller may immediately turn ON the blowdown valve Plug in the controller Set control modes and setpoints Set the feed limit on the Inhibitor Pump Verify that the sensors are reading correctly and set the alarms If you are using a water meter verify that meter is measuring the expected volume Verify that the operating Interlock is working An overview of system operation is available in the Yearly section of 4 1 Maintenance AQB2_User 02 06 9 BB IN Boiler Blowdown Controller 2 START UP 2 1 Power up Display amp Keypad UP amp DOWN to view options or to EDIT numbers ST Move RIGHT to select next field when EDITing ENTER to select an option 4 amp to execute EDITing EXIT to escape option S info display or EDITing Unique Controller Serial Number Press ENTER for Controller Diagnostic And US Metric select Press ENTER to clear Alarms Current Conductivity sensor value Press ENTER for Conductivity Calibrate
20. Sampling OR Measure OR B down OR Waiting Counts down time in the current state Key ENTER to end the state and go to next state If ON displays TurnOFF setpoint 2990 amp current conductivity 3042 If OFF displays TurnON setpoint 3000 amp Current conductivity 2993 If ON displays Owes 41 sec 7123 amp ON ENTER Stop If OFF displays seconds to turn ON ON Sampling 250 3 2 Bleed Controls Continued Blowdown valve lt ON 21 3min had then T Current State lt Setpoints rv 11 sec Stop Sampling Control off 2990 7121 ON 3042us Continuous Control On in 221sec 123 OFF Time Control HELP 2250 122 amp 2123 and other help numbers display wherever more explanation is available at www aquatrac com Sto p ends the current Sampling control period and starts the next period If you Stop the Measure period you will measure a high conductivity If you Stop the Sample period you may not measure a fresh representative sample of boiler water The Blowdown Valve is ON open during the Sample amp B down periods and OFF closed during the Measure and Waiting periods ON ENTER Stop ends Percentage Time blowdown control mode ON period AQB2_User 02 06 25 BB IN Boiler Blowdown Controller Sampling Control Mode Timing Press ENTER then UP Blowdown Valve Press ENTER Sample Timing to view or adjust timing This option only displays if Blowdown Mode Samplin
21. abling The Monitoring or Distributed Control system powers the controller current loop with 18 24VDC and reads boiler conductivity Terminate current loop at DCS input with 50 to 250 ohms Controller display messages when current loop disconnected CONTROLLER POWERED 4 20mA Output Conductivity f Auto Polarity b Correction 2809 Powered 4 20mA Input Proportional to Conductivity The Controller powers the current loop with output connected to a data logger or building automation system 4 20mA input 15V Controller Supply Thermally fused at 50 ma to protect Controller and Monitor 47 BB IN Boiler Blowdown Controller Appendix D 4 20mA Output Option D 2 VIEW amp ADJUST SPAN The displayed value of the 4 20mAloop current depends on both the Boiler conductivity and the Span If the current loop output is disconnected you ll see this display in place of the mA level Press ENTER Select Span to view or adjust the Span Span sets the conductivity at 4mA amp at 20mA Press ENTER Trim Zero to calibrate the 4mA level Press ENTER Trim Span to calibrate the 20mA level View amp Adjust Span Press ENTER 4 20mA Output amp then DOWN to Select Span Press ENTER Displays current Span Press ENTER to adjust 4mA level or DOWN amp ENTER to adjust 20mA level Press RIGHT to place the underline under the digit you wish to adjust Press UP DOWN to adjust ENTER updat
22. amp feed limit refer to Section 2 3 Inhibitor Feed Mode Setpoints Feed Limits Press UP DOWN until you see Inhibitor Pump Inhibitor Pump Displays ON with time on in the current 24 hour period ON 3 1min Press ENTER to view or adjust Setpoints Setpoints Setpoints vary with selected Feed Mode Feed Mode y Press ENTER view current mode or to select from Blowdown amp Feed Feed on Volume Percentage Time Feed Mode p Limit Timer Y l Limit Timer d Press ENTER to set maximum Inhibitor Pump ON time Prime Pump 4 in minutes in any 24 hours Prime Pump a Press ENTER Prime Pump to turn ON Inhibitor Pump Current State y for 5 minutes Alarms Clear Alarms ends Priming 3 Press ENTER Current State to view control status Current State lt e Display varies with Feed Mode Setpo1nts t Sidebar Prime Pump will not turn ON the pump unless Interlock is ON Inhibitor pumps with Feed Mode set to Blowdown amp Feed will not feed unless the Blowdown Valve is ON AQB2_User 02 06 28 BB IN Boiler Blowdown Controller Inhibitor Pump Feed Modes Press ENTER then DOWN Inhibitor Pump Press ENTER amp DOWN Feed Mode to view current mode and to select a new mode Percentage Time turns ON the Inhibitor Pump for a user set of 5 minutes if Interlock is ON Feed on Volume measures a user set volume on the Make up water meter then turns ON the pump for a user set time For example Measure 100 Gallons of make up amp
23. ate the measured conductivity The temperature value does not have to be accurate to correctly compensate but it does have to change as the boiler water temperature at the sensor changes If you select Continuous blowdown control without a thermally compensated sensor the controller will display a Temperature alarm Sidebar Sampling Blowdown Control The temperature is not used to compensate the measured conductivity since the MEASURE interval provides a fixed amp repeatable temperature at the conductivity sensor AQB2_User 02 06 15 BB IN Boiler Blowdown Controller 2 5 Calibrate Conductivity Sensor Open the downstream then the upstream sample line isolation valves immersing the conductivity sensor Select Alarms then Clear Alarms to force a Sample amp Measure sequence Calibrate after a Sample Measure sequence has updated Conductivity Press DOWN until you see Conductivity Sample the boiler water amp verify that the displayed conductivity matches the measured conductivity See Sidebar Adjust the displayed conductivity by pressing ENTER twice Press UP DOWN to adjust and RIGHT to move the cursor Press EXIT to leave Conductivity unchanged You ll see this screen if the sensor is fouled miswired not immersed or you keyed incorrectly NOTE Press ENTER to ignore OR EXIT to return to Factory Default 2141 indexes more explanation www aquatrac com Displays the current calibrated conductivity Calib
24. conductivity sensor Displays 1uS resolution Rated 250psi steam maximum Interlock Dry Contacts 250mS response Water Meter 400 Hz max 0 5mA 5VDC measurement current 1 SPDT Blowdown Solenoid or Motorized Valve 1 SPST Inhibitor Pump 1 DC isolated loop powered Nominal 0 1 of span resolution Auto polarity correction field wiring Dry contact set Rated 500mA 24VDC Rating Detail 5 Key Tactile feedback UP DOWN ENTER EXIT RIGHT 2 Line x 16 Character Backlit 10BaseT Ethernet RJ45 Jack Full command amp control via browser XML real time controller data Notes Autoranging from 100uS to 10000uS Contact head meter software debounced Turbine Paddle wheel rating Seametrics max pulse rate Relays rated 10A 120VAC Controller fused 5 Amps Alarm on open loop Auto configure on Driver installation and removal Software calibration of span amp zero Closed in the non alarmed state Contact set opens on alarm or loss of controller power Notes Scan rate 100mS nominal User adjustable LCD contrast User set fixed IP for non LAN connected controllers Fixed MAC 44 BB IN Boiler Blowdown Controller Controls Rating Detail Notes Blowdown Valve Controls Sampling Continuous and Percentage Time Controls Percentage Time Blowdown amp Feed Feed on Volume Feed cycle limit timer Inhibitor Pump Blowdown amp Feed Use
25. d you ll be aware of the problem prior to an annual check Chemical levels will be either higher or lower than target 39 BB IN Boiler Blowdown Controller 4 1 Spare Parts 4 1 1 Line Fuse Protects Rating Type Manufacturer Vendor Controller Littlelfuse Type 217 250VAC Pump and 5 Amps 115VAC Digikey Part F953 ND Eien VEMS 5mm x 20mm www digikey com 1 800 344 4539 Fast Acting 4 1 2 Controller Parts Part Description SFuse 120VAC Fuse Kit 10 x 5A Controller Fuses A261000 Boiler Conductivity Temperature sensor y NPT maximum 250psi steam BB IN NS Spare Controller without sensors amp entry fittings R171230 Enclosure Power cable entry fitting PG11 R717231 Enclosure Sensor cable entry fitting PG9 On Line Help Browse to www aquatrac com help with the 3 digit HELP from the controller LCD display LCD display HELP numbers are preceded by Users Manual Download AQB2_User from www aquatrac com 03 06 BB IN Production AQB2_User 02 06 40 BB IN Boiler Blowdown Controller Appendix A INSTALL A 1 PLUMBING Safety Follow the site s valve off and tag out procedures prior to making any plumbing changes to the surface blowdown line Multiple boiler sites may require both more than one upstream and downstream isolation valve Ensure the isolation and needle valves are rated for steam service at a pressure exceeding the maximum expected steam pressure Plumb senso
26. d the default password press ENTER to log in AQB2_User 02 06 35 BB IN Boiler Blowdown Controller Press UP DOWN until you see Boiler Blowdown Then press ENTER amp UP to view Password tools Password tools are available when Password is ON and you are logged in Press ENTER to view the tools Press ENTER to Log Out If you forget to Log Out the controller logs you out 30 minutes after the last key press and on controller power OFF ON Press DOWN amp then ENTER to view amp change the current password Press DOWN to Password OFF Pressing ENTER turns OFF Password Press RIGHT amp UP DOWN to change the current password ENTER changes the password Press EXIT to leave the password unchanged 3 7 Password continued Password lt Current State rv Log Out a Edit Password y 4 Edit Password Password OFF y 3 Password OFF gt a Log Out Y Edit Password Edit amp ENTER 0094502 gt BH then 4i Log Out v Edit Password y Sidebar If your controller is password protected Select Edit Password and change the password from the 123 factory default Passwords may be from 1 to 6 numbers Leading zeros are ignored If you forget your password you ll require the controller serial number to get a Reset Password from the controller manufacturer The controller password is 123 after you key in the Reset Password AQB2_User 02 06 36 BB IN Boiler Blowdown
27. e sake Current State lt ommroner diagnostics select units y Press ENTER to view or change Select Units gi US or Metric units Current State Press UP DOWN until you see the Serial Number Press ENTER view System options Alarms l Press UP DOWN until you see Alarms Alarms i The first alarm to trip will display or none if no alarms none Press ENTER to Clear Alarms p Clearing alarms sets pump amp blowdown owed times to zero Clear Alarms lt Sensor Alarms Out of Calibration and System Alarms auto clear when the fault is corrected Sidebar If Blowdown Mode Sampling A Clear Alarms starts a new Sampling period B A Fail to Sample alarm indicates a low temperature at the sensor at the end of the Measure period The Blowdown Valve has failed to operate an isolation valve upstream or downstream of the sensor is closed the throttling valve is closed or blocked Blowdown control will not work correctly until this fault is corrected Find amp fix the cause Clear Alarms to start a new Sample period AQB2_User 02 06 32 BB IN Boiler Blowdown Controller System Current State Press UP DOWN until you see the Serial Number Press ENTER view System options Press ENTER to view Current State Controller diagnostics Temperature at the conductivity sensor Displays Fault if not used to compensate conductivity Indicates wiring or sensor problem Power used for paddlewheel water meters
28. easing Average Blowdown time may indicate a change in make up chemistry or a restricted bleed or a higher boiler load Pump ON time verifies setpoints and feed mode selection For example If you are feeding Blowdown amp Feed at 25 of bleed time amp the Last Bdown ON 5 min then Last Feed ON 75 sec If your Inhibitor Pump is controlled by the Blowdown Valve you would see that the last Feed Ended when the B dwn Ended If your Inhibitor Pump is controlled by the Make up you would see that the last Feed Ended when the Last make up occurred If the Last make up occurred several days ago there s understandably a metering problem Requires optional thermal sensor Temperature max min may reflect variation in sample cooler water temperature or condensate usage if used for condensate monitoring The usefulness of Diagnostic information varies with each site s boiler piping water chemistry and treatment program AQB2_User 02 06 3 5 Diagnostics Diagnostics on lt last 6 3 days rv Last B dwn ON 14 9 min 4G B dwn ended 86 9 min agoy A Average B dwn 10 6 min y amp Last feed ON 26 sec amp Feed ended 1 2 hrs ago y Last make up 58 4 min ago vy 4 Temperature 194max 182min y 4 Last B dwn ON 14 9 min y 31 BB IN Boiler Blowdown Controller 3 6 System Alarms System Menu Options Boiler Blowdown S N DO41B0248 4 Press ENTER z e
29. es the Span EXIT leaves Span unchanged AQB2_User 02 06 4 20mA Output 15 4mA OR 4 20mA Output Disconnected m Select Span v Trim zero y Trim zero v Trim Span Trim Span lt Select Span y Select Span Trim Zero Y rv 4mA 100uS 20mA 5000uSs y 8 Edit amp ENTER 4ma 2500us gt ty then 4 4mA 2500uS 20ma 5000us y 48 BB IN Boiler Blowdown Controller Appendix D 4 20mA Output Option D 3 CALIBRATE Calibration is seldom necessary amp is used to correct to offset errors The range of Zero amp Span adjustment is limited If you are not able to calibrate A Verify your milli ammeter B If Load Powered verify you have at least 15VDC available Press ENTER amp then DOWN at 4 20mA Output Press ENTER at Trim Zero to adjust the 4mA level Connect a DC milli ammeter in series with either of the current loop wires Press UP or DOWN until you read 4mA on the milli ammeter Press ENTER to view the output current and verify that the milli ammeter reads the same current Press ENTER amp then DOWN at 4 20mA Output Press ENTER at Trim Span to adjust the 20mA level Connect a DC milli ammeter in series with either of the current loop wires Press UP or DOWN until you read 20mA on the milli ammeter Press ENTER to view the output current and verify that the milli ammeter reads the same current AQB2_User 02 06 4 20mA Output 15 4mA Gann gy
30. g Key DOWN to view current Sample Measure Blow dwn amp ReSample times Key ENTER to adjust Key UP amp DOWN to adjust EXIT ends with changing the time ENTER ends adjust and executes the new timing In this example we ve increased the Sample time from 20 seconds to 28 seconds 3 2 Bleed Controls Continued Blowdown Valve ON 21 3min then T Sample Timing lt lt Setpoints v Sample 20s lt Measure 30s y 3 Edit amp Enter Sample 28 gt 1e then ie sample 28s e Measure 30s v Sample May be set a short as 5 seconds if the sensor is located at the boiler or as long as 60 seconds for a sensor 100 feet from a boiler It s the time required to fill the piping between boiler amp sensor and reflects both the length of pipe and the setting of the throttling valve Measure Usually never less than 30 seconds May be as long as 120 seconds Allows a stable sample with a fixed and repeatable amount of cooling Blow dwn Never less than Sample time seconds amp typically no more than 5 times Sample time The conductivity is checked every Blow dwn time amp Blow dwn continues if conductivity above TurnOFF setpoint Long Blow dwn times may overblow the boiler ReSample Waiting As short as 15 minutes for heavily loaded boilers that increase conductivity rapidly Typically 30 minutes to 4 hours May be as long as 12 hours for stand by boilers ReSample
31. he SENSOR GRN WHT BLK amp RED terminals The controller will automatically measure the temperature and thermally correct the measured conductivity AQB2_User 02 06 7 BB IN Boiler Blowdown Controller 1 4 Sensors Water Meter OPTIONAL SENSOR Refer to manufacturer s recommendations on meter orientation and upstream and downstream piping Extend meter cables with AWG22 2 or 3 conductor WARNING Do not install water meters downstream of the feedwater pump Ensure that the temperature rating of the meter exceeds the feedwater temperature You ll need to know the gallons contact Meter must be rated for to set up the feedwater temperature inhibitor feed rate Red Black Contact Head Water Meter mmmam Feed cables through the aatal entry seal amp re tighten J nnecting a Turbine Paddlewhee Water Meter _ You ll need to Wiring color differs know the meter K Factor a with meter to set up the White manufacturer inhibitor feed rate a Black A h Red gt s Seametrics type Meter must be rated for feedwater temperature Turbine Water Meters Do not install meter cabling in the same conduit as AC power wiring AQB2_User 02 06 8 BB IN Boiler Blowdown Controller 1 5 Inhibitor Pump amp Blowdown Valve The controller supplies the AC power for the pump and blowdown valve or solenoid Controller relays switch power to the pump and blowdown solenoid fused at a maximum of 5 Amps WAR
32. isplays when Blowdown Mode Sampling Alarms v Sensor Watch v B Sensor watch lt Calibrate y 4a watching 254 Press ENTER to view current sensor conductivity Press Exit to end watching 655 us Sidebar Sensor Watch Sampling or Blowdown The valve opens and Conductivity increases as the sensor heats up If the conductivity doesn t change the valve didn t open or an upstream or downstream isolation or throttling valve is closed Correct this fault If the conductivity is unstable showing values less than 2001S it s likely that flashing is occurring indicating a partially closed valve or orifice union upstream of the sensor Correct this fault Measure The valve closes Sensor Watch displays a stable value falling as the sensor cools If the Sensor Watch displays a low value and the boiler has cycled up to operating conductivity the sensor may be partially immersed measuring a mix of vapor and water Correct this fault If Sensor Watch displays a value which does not fall or a value which moves up and down the blowdown valve may not have closed or may have closed but not sealed more common with blowdown solenoids Correct this fault AQB2_User 02 06 22 BB IN Boiler Blowdown Controller For conductivity control setpoints Section 2 2 Blowdown Mode Conductivity Setpoints Press UP DOWN until you see Blowdown Valve Displays ON or OFF and ON time in the current 24
33. line upstream of the feedwater pump Boiler 250 psi maximum Operating Interlock i wt Contact Set S Steel surface blowdown piping NOTES 1 Isolation valves on surface blowdown line not shown 2 Feedwater pump not shown 3 Refer to Appendix A for installation notes 4 Your installation may not include a make up meter and or an operating interlock Use a solenoid or valve for blowdown rated for steam service at boiler pressure ea Isolation Valve Conductivity Sensor Bypass Valve Bleed Solenoid or Valve aul tsolation Throttling Valve Needle Flash Valve Tank Sampling Blowdown Control is the most commonly used blowdown method It provides the most accurate control at the lowest energy and chemical cost for most boilers and it s relatively insensitive to the setting of the throttling needle valve AQB2_User 02 06 4 BB IN Boiler Blowdown Controller Continuous blowdown control is an older method requiring a continuous sample steam past the conductivity sensor It lacks the accuracy of Sampling blowdown control and is more difficult to set up Percentage Time blowdown control mode uses the same piping configuration as Continuous Blowdown Control Continuous Blowdown Control NOTES 1 Isolation valves on surface blowdown line not shown k Q Cc 2 Feedwater pump not shown k 3 Refer to Appendix A for f installation notes f K al
34. lues on the meter body Take the time to get the meter volume contact or K factor correct since most meters are used to control inhibitor feed and inhibitor ppm errors result when meters are incorrectly configured AQB2_User 02 06 42 BB IN Boiler Blowdown Controller A 6 CONTROLLER ENCLOSURE The optimum location for blowdown valve sensor and controller allows the keypad user to see the blowdown valve operate Typically the chemical feed pump is more remote from the controller at the deaerator Wall mount the controller enclosure at eye height for a 5 to 5 6 person so that an operator does not have to reach over drums or pumps to use the controller key pad Do not punch conduit access holes in the top of the enclosure to avoid condensation damage to the controller electronics Plug the controller into an Always ON utility outlet Maximum controller current 120VAC is 5 Amps AQB2_User 02 06 43 BB IN Boiler Blowdown Controller Appendix B SPECIFICATIONS Each controller includes an option card slot Auto re configuration occurs on installation of one of LAN 4 20mA Output OR Alarm Relay option card Analog Digital I O Conductivity Water Meter Interlock Relay Outputs 4 20 ma Output on conductivity CL optional card Alarm Relay AR optional card Communications User Interface Keypad LCD Browser LB optional card AQB2_User 02 06 Rating Detail 1 Temperature Compensated
35. mbers display wherever more explanation is available at www aquatrac com If you are using water treatment controls for the first time the language and application of some of the controller options and settings requires more detail than a 2 line display can deliver AQB2_User 02 06 14 BB IN Boiler Blowdown Controller OPTION The default sampling blowdown controller does not require or include temperature measurement Ensure that the conductivity sensor is immersed at operating temperature Press UP or DOWN until you see Serial Number Press ENTER Press ENTER amp then press ENTER to view temperature at the conductivity sensor A sampling blowdown controller will display With sensor type NT No Temperature Display on Thermally Compensated Sensor Connected If the GREEN amp WHITE wires are connected to the controller terminals you ll view the current temperature A low temperature may indicate a closed valve upstream or downstream of the sensor Fault automatically removes conductivity temperature compensation see Sidebar Key EXIT twice to return to Serial Number 2101 indexes more explanation www aquatrac com 2 4 Verify Temperature Verify Temperature Boiler Blowdown lt S N D206NT248 Current State lt Select Units y a Temperature 101 Type NT y 4 Temperature 101 196F Type NT y Sidebar Continuous Blowdown Control Temperature is used to compens
36. nd that boiler water is going to the flash tank See Sidebar If OFF press ENTER amp DOWN to Test Valve Press ENTER and the Blowdown amp Bleed light will turn ON for 5 minutes Plug the inhibitor pump into the bottom right plug Press UP or DOWN to view Inhibitor Pump If ON verify that the green Inhibit light on the inside of the enclosure is ON Verify that the pump is stroking primed and feeding inhibitor If OFF press ENTER amp DOWN to Prime Pump Press ENTER and the Inhibitor Pump amp Inhibit light will turn ON for 5 minutes Blowdown Valve Blowdown Valve ON 12 4min OR Blowdown Valve OFF 126 8min s then 4 Test Valve lt Current State yy Inhibitor Pump Inhibitor Pump OFF then 4 Prime Pump H Current State y qa Inhibitor Pump lt ON 0 2min Sidebar The Blowdown Valve and Pump will not turn ON unless the Interlock is ON The internal Bleed amp Inhibit lights will not turn ON unless the Flowswitch is ON An IR non contact temperature meter is the easiest way to verify that valves are open and that there is a high temperature path past the sensor to the flash tank AQB2_User 02 06 19 BB IN Boiler Blowdown Controller Verify that the controls work in the way that you expect for this site Watch the Conductivity increase as the boiler operates Sampling controls update the Conductivity at the end of every Measure period The Blowdown Valve will
37. noid plug from terminals White1 amp Bs Black to hardwire a motorized ball valve Power Open Black 1 Valve connections Power Closed Red 1 vary with a en Se _ Ground Green 1 and valve type Motorized Valve OR Neutral White 1 Ground Green 1 Blowdown Solenoid or Spring Return Motorized Valve AQB2_User 02 06 C Ground Green Line Black Neutral White 120VAC Service Power from a ONA dedicated 15A GFI er circuit breaker AWG14 stranded Power Open E Black 1_ Bv Red 1 Bs Black 1 In Black 2 Ground Green Green 1 Green 2 Connect grounds in a common wire nut Line Black 2 Neutral White 2 _ Ground Green 2 Inhibitor Pump WARNING 1 Use multiple strand copper AC power wiring Do nat use solid conductors 2 Pump and Solenoid Outputs are fused at 5 Amps total AC wiring must be minimum AWG18 rated 300V 3 Do not exceed AWG14 46 BB IN Boiler Blowdown Controller Appendix D 4 20mA Output Option The optional 4 20mA output on conductivity is DC isolated from the controller amp may be either powered by the load or by the controller DC supply The 4 20mA output is auto polarity correcting D1 WIRING AQB2_User 02 06 LOAD POWERED 4 20mA Output 4 20mA Output on Conductivity Auto Polarity Correction DZ 24V IN 4 20mA Input S Distributed Control System 2 Conductor AWG22 to AWG18 C
38. not have a softened make up or feedwater meter If you are using the Operating Interlock chemical feed stops when the boiler is off line If your condensate return is fixed and the blowdown control is reliable consider using Blowdown amp Feed If you have a water meter on the softened make up use Feed on Volume Operating Interlock is a set of dry contacts which open when the boiler is off line When the Interlock contact set opens blowdown and chemical feed stop The Interlock contact set may be supplied by the building automation system or the boiler burner control AQB2_User 02 06 13 BB IN Boiler Blowdown Controller 2 3 Inhibitor Feed Mode Setpoints Feed Limit continued The Inhibitor feed limit timer turns OFF the inhibitor pump to prevent overfeeding The factory default feed limit 20 Minutes per feed cycle p T tanh Inhibitor Pump ress or until you see Inhibitor Pump amp press ENTER ON 48 1min Press DOWN until Limit Timer Limit Timer lt Press ENTER to view or adjust Limit Timer Prime Pump 4 Displays feed limit in minutes Feed Limit 157 157 indexes more explanation www aquatrac com 18 min v Press ENTER adjust Feed Limit Edit amp Enter 12 min gt Press UP DOWN to adjust and RIGHT to move the cursor ty then 4a Press EXIT to leave the Feed Limit unchanged Feed Limit 157 Press ENTER displays current limit 12 min lt 12 minutes per feed cycle HELP 157 and other help nu
39. plays the current meter type continued atermeter 6 4hr Make up 31450 G rv Meter Type we Year to Date y Paddlewhee1l lt Contact Head y m K Factor 100 0 lt rv Edit amp ENTER 104 5 gt T then Paddlewhee lt Contact Head y Sidebar A typical operating boiler will require softened make up If a make up meter exists take the time to verify that the meter displays an increasing volume as the boiler operates An accurate and working make up or feedwater meter is required to meter inhibitor feed using Feed on Volume mode Dry contact closures from the boiler feedwater pump are frequently used to control chemical feed Whenever the pump turns ON the controller measures a user set volume of make up WARNING Verify paddlewheel meters immediately and disconnect if not verified Mis wired paddlewheel meters will fail the meter Hall Effect sensor AQB2_User 02 06 18 BB IN Boiler Blowdown Controller 2 7 Plug in Pump and Blowdown Solenoid Sections 2 1 to 2 6 adjust setpoints and verify sensors We re now ready for the blowdown solenoid and the inhibitor pump verifying each one as it s plugged in Blowdown motorized ball valves are hardwired Plug the blowdown solenoid into the top right plug Press UP or DOWN to view Blowdown Valve If ON verify that the green Bleed light on the inside of the enclosure is ON Verify that the blowdown valve is open a
40. r piping in the same metallurgy and schedule as the surface blowdown line Warning Throttling needle valves will block with flashed solids if not correctly installed Follow the manufacturer s recommendation for upstream downstream orientation Remove needle valves and orifice unions upstream of the conductivity sensor A 2 SENSORS Conductivity sensors may be installed in a T in any orientation Do not install sensors in T s larger than The required reducers may result in a non immersed or intermittently immersed sensing surface Water meter and sensor wiring cannot be installed in the same conduit as 120VAC power pump or blowdown valve wiring Even a short section of shared conduit may cause operational problems Sensor wires may be extended up to 200 hundred feet using multiple pair AWG22 cable Always splice sensor wires in an electrical fitting to allow both inspection and sensor replacement Extend the conductivity sensor using the same colors as the sensor to avoid wiring errors at the controller terminals Contact head water meters and interlock contact sets are not polarized simplifying cable extension CAUTION Three wire turbine paddlewheel meters are polarity sensitive and can be permanently damaged by miswiring Wait until you are ready to start up the controller before connecting this type of meter to the controller Meter wiring errors are easily detected and corrected at start up A 3 CHEMICAL FEED
41. r sets of Blowdown ON time used for Inhibitor feed Interlock Blowdown Valve amp Inhibitor Pump Requires dry contact set from OFF when Interlock contact set boiler controls or site DCS opens System Rating Detail Notes Controller Configuration User settings and configuration Makes current configuration written on silicon factory default Electrical AC Input Rating Detail 115 VAC 50 60Hz Notes 5 Amps 115VAC 5x20mm 120VAC fusing Bleed solenoid relay contacts snubbed 0 1uF 150R Varistor on AC power input Surge Spike Suppression AC Input amp Output maximum Stranded AWG 14 150mm AC Terminals Controller electronics transformer isolated from AC line Sensor Digital Input AWG 22 0 25 0 50mm Terminals 14 20 VDC unregulated Thermally fused 50mA Paddlewheel Meter Power 4 20mA output loop power 4 20mA output option can be powered by load or by controller Mechanical Rating Notes Non metallic NEMA4X 5 9W x 5 9H x 3 5 D 150mmW x150mm H x 90mm D Enclosure Nominal dimensions excluding entry fittings and flexible conduit Enclosure door hinged left Allow 8 right for door opening Allow 18 below for cable access AQB2_User 02 06 45 BB IN Boiler Blowdown Controller Appendix C HARDWIRING Controllers are shipped with pre wired AC power cord Blowdown Solenoid amp Inhibitor plugs Remove the Blowdown Sole
42. rate Conductivity Conductivity aa 1425 us m Calibrate Alarms Edit amp ENTER 1883 us gt ty then 4 Advice 141 Fails Calibrate Conductivity lt 1883 us 4 Sidebar Measuring boiler water conductivity requires a sample cooler to obtain a non flashed sample Flashed samples of boiler water do not represent the boiler water conductivity A low temperature at the conductivity sensor indicates that the sensor is not measuring a hot sample of boiler water Do not calibrate a cold sensor Check the isolation valves upstream and downstream of the sensor ensure the blowdown valve is opening amp closing and verify that the throttling valve is not blocked AQB2_User 02 06 16 BB IN Boiler Blowdown Controller 2 6 Check Interlock amp Install Water Meter Press UP DOWN until you see Interlock Displays ON or OFF and the total minutes ON Interlock in the last 24 hours Interlock NOTE An OFF open Interlock contact set stops ON 780 6min the inhibitor pump and the blowdown valve The Interlock can be bypassed by jumpering the Flow terminal to Ground Controllers are shipped with the Interlock jumpered Contact Head atermeter 24hr Make u OPTIONAL The factory default water meter is 10450 a 100 Gallons contact contact head meter Press UP DOWN until you see 0 24hr Make up 4 Displays make up volume during the last 24 hours Meter Type lt Make up volume resets every 24 ho
43. rent State If Feed Mode Blowdown amp Feed lf Sampling or Blowing Down displays Owes 162sec 154 OR On in 86sec 150 If Blowdown Valve OFF displays Blowdown Off 150 If ON displays Owes 41 sec 156 and ENTER Stop If OFF displays seconds to turn ON If ON displays Owes 38 sec 154 If OFF displays turn on volume 9800 amp current volume 9700 3 4 Inhibitor Controls Continued Inhibitor Pump lt ON 0 5min then T Current State Setpoints Owes 162sec 2154 ON ENTER Stop Blowdown amp Feed On in 267sec 156 OFF J Percentage Time On 9800 G 155 OFF 9700 G Feed on Volume Sidebar Blowdown amp Feed applies the user set of Blowdown valve ON time to each 300 seconds of Blowdown Valve ON time ON ENTER Stop ends the current feed cycle or Time ON period HELP 150 154 2155 amp 2156 and other help numbers display wherever more explanation is available at www aquatrac com AQB2_User 02 06 30 BB IN Boiler Blowdown Controller Diagnostics displays operating information from the last power OFF ON Average Blowdown amp Temperature MAX MIN are reset on every power ON The time that the Blowdown Valve is open depends on throttling valve open load and conductivity setpoints A loaded boiler will blowdown more frequently than a standby boiler Boilers in commercial institutional sites will blowdown frequently during business hours Incr
44. rent State y rv Deg F Gallons lt Deg C Liters y 4 Deg C Liters Deg F Gallons y Select Units changes make up meter units total volume units and volume per contact units Temperature compensation of conductivity switches automatically between Centigrade amp Fahrenheit as does the System Current State display of temperature AQB2_User 02 06 34 BB IN Boiler Blowdown Controller Password is turned OFF in new controllers Press UP DOWN until you see Boiler Blowdown Press ENTER amp DOWN to select Password ON If you press ENTER you ll be prompted for a password then next time you press ENTER Press UP or DOWN to view the current state of the controller Any ENTER key will prompt for the password displaying the default password 123 Use the UP DOWN amp RIGHT keys to enter a password then key ENTER A correct password displays Password OK Press any key to start operating the controller Press ENTER to re key an incorrect password 3 7 Password Turning ON Password Boiler Blowdownd S N D206NT042 4 Current State lt Select Units y S Jy Password ON prn Current State Password ON Enter Password 000123 gt T then Advice 2110 Password OK lt OR Advice 7111 Wrong Password Sidebar When you first select Password ON the default password is 123 Whenever you Enter Password the controller displays the default password 123 If you have not change
45. rs operate with Sampling blowdown control The Blowdown Valve opens to Sample the conductivity If above the TurnON setpoint Blowdown Measure periods occur until below the TurnOFF setpoint If below the TurnON setpoint waits ReSample time until next Sample Continuous control turns ON the Blowdown Valve above the TurnON setpoint and OFF below the TurnOFF setpoint Percentage Time turns ON the Blowdown Valve for a user set of 5 minutes if Interlock is ON NOTE If you change the Blowdown Mode press UP to Setpoints amp ENTER to adjust for the new Blowdown Mode Warning See Sidebar 3 2 Blowdown Controls Continued Blowdown Valve lt lt ON 21 8min 4e then 4 Blowdown Mode Test Valve rv Samp ling lt H Continuous y Continuous lt Percentage Time y 4 Percentage Time lt Sampling 4 4a then T Setpoints v Blowdown Mode Sidebar Warning Changing Blowdown Mode may require plumbing changes See manual Section 1 1 for piping configuration is each mode Sampling control requires the blowdown valve downstream on the conductivity sensor Continuous and Percentage Time modes require the Blowdown Valve parallel to the sensor piping so the sensor can continuously read the boiler water conductivity AQB2_User 02 06 24 BB IN Boiler Blowdown Controller Current State of the Blowdown Valve Control Press ENTER then UP Blowdown Valve Press ENTER Current State Displays
46. s a 120VAC blowdown valve or steam rated solenoid amp chemical feed pump and may pump hazardous corrosive and toxic chemicals Opening the controller enclosure exposes user to the risk of electrical shock at power line voltages Understand fully the implications of the control setpoints feed limit and alarms that you select Harm to personnel and damage to equipment may result from mis application Unplug or turn OFF the AC power to the controller if you have any concerns regarding safety or incorrect controller operation and notify supervisory staff YOUR CONTROLLER Controllers are supplied with default blowdown valve and inhibitor feed setpoints that will not be applicable to your boiler Select control modes adjust setpoints and set pump timing for your site and its water treatment program AQB2_User 02 06 3 BB IN Boiler Blowdown Controller 1 INSTALLATION 1 1 Sample Piping The Controller includes a 250psi steam rated conductivity sensor and 3 sensor entry T and can be operated in either Sampling or Continuous Blowdown mode Sample piping is plumbed in schedule 80 black iron or steel If you have not previously installed this type controller read Appendix A INSTALL for plumbing and wiring guidelines Sampling Blowdown Control b Q N Deaerator Ci A L A o pere Optional Make up Water Meter Injection Entry Chemical injected into deaerator sump or into feedwater
47. urs and Year to Date M every power OFF ON to 0 0 hours 4 Contact Head lt lt Press ENTER twice to view or change meter type Paddlewheel 4 Key ENTER to view or change the gallons contact G Contact Metric users will view volumes in L iters amp L Contact 100 el Press UP DOWN to adjust and RIGHT to move the cursor Press EXIT to leave Gallons contact unchanged ENTER or EXIT displays the current meter type ei Edit amp ENTER 25 ty then al Contact Head Padd1lewheel gt P v 2 wire meters are usually Contact Head 3 wire meters are typically Turbine or Paddlewheel water meters Sidebar Softened make up water meters are lower cost ambient temperature rated meters Feedwater meters are usually high temperature paddlewheel type AQB2_User 02 06 17 BB IN Boiler Blowdown Controller 2 6 Check Interlock amp Install Water Meter OPTIONAL Turbine Paddlewheel type water meters provide pulses per Gallon or Liter The number of Pulses Unit Volume is the K factor Press UP DOWN until you see 0 24hr Make up Displays make up volume during the last 24 hours Fewer hours are displayed if the controller has not been ON for 24 hours Press ENTER twice to view or change meter type Key DOWN to select Paddlewheel type meter Key ENTER to view or change the pulses per Gallon Metric users view pulses per Liter Press UP DOWN to adjust and K Factor unchanged ENTER or EXIT dis
48. using the controller keypad You can use a crossover cable to connect to your notebook PC to view the controller state Information on browsing controllers is available in the Sflex_LB manual Boiler Blowdown Controls 5 BOILER BLOWDOWN CONTROLS S Up Time 00 09 22 a Diagnostic Last bowdown ON 0 min Alarms Temperature Deaerator amp ended 10 5 min ago Avg Blowdown is 0 min Alarms Events Temperature 283F MAX and Timers DReset All 281F MIN Sof Make up Part No BB IN SerialNumber US04B9999 ON Owes 268sec Treatment Click a link in the View 1005 uS Conductivity to operate the controller Boiler Measure 25s Setup Configure Blowdown Valve 7 Refresh View Closed Refresh 10 2min MMi Interlock Throttle Flash Tank AQB2_User 02 06 51
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