aqb2_user copy pfc
Contents
1. Power Open Black 1 Valve connections Power Closed Red 1 vary with manufacturer Neutral White 1 and valve type Ground Green 1 Motorized Valve OR Power Open Black 1 L L m me A N Line y Black White White 1 Neutral White 1 Ground Green 1 Blowdown Solenoid or Spring Return Motorized Valve AQB2_User copy PFC 07 12 inhibit Sines ze NEUTRALS in Ba Bv SPAL OSDO In Black 2 White2 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 not 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 48 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 LOAD POWERED 4 20mA Output jenes ISS SSS SSSI F iL Satta La E Lot et et i hl ed ed Sd c ar AL LL SES MIS MES amp 20mA maere Drege Outputon TTT aeaita talvel vale Conductivity Mapapa aaae zs sus ss Auto Polarity N CB 3 B 3 3 LN i md 2 m Um Correction i x y j enses pss E E g asv Flow2. BB IN Boiler Blowdown Controller Frequency Activity Method Calibrate Conductivity Verify the boiler water conductivity tester annually with a calibration solution using a solution that s as close as possible to the controller conductivity setpoints Replace outdated calibration solutions Yearly Observe a Blowdown Sampling Blowdown Control Control Cycle How many Blowdown Measure cycles does it take to lower the conductivity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 Verify Water Meter 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 feed you ll be aware of the problem p
3. Mete 31 mm m mom n 4 20 LI LI ES SQ S z t z i s tondudbr The Monitoring or Distributed Control AWG22 to AWG18 System powers the controller current Cabling loop with 18 24VDC and reads boiler conductivity Terminate current loop at DCS input 24V IN with 50 to 250 ohms 4 20mA Input Controller display Distributed messages when current loop Control System disconnected CONTROLLER POWERED 4 20mA Output 1 N N NH NH NH H NH H H H H ujuja H aj NH NH NH HJ NH NH C MIN e a a N e a a a Li LER Li L poma VuUVOVIPLILNLI I Output on pie n ci Spee ore n e f Conductivity E ek RW Ra n z Pprcipoipeiporraroraparraor oro RUN Li LEN Auto Polarity oe ST STET EU U Dn i Correction P L elie Seach ne T pi 1 415V Flow gt Meter OT LA Lon ues 4207 aS x Rc a NUS QD S QD ODA LO 1 The Controller powers the current loop with output connected to a data logger or building automation system 4 20mA input Powered 15V Controller Supply 4 20mA Input Thermally fused at 50 ma to protect Controller and Monitor Proportional to Conductivity AQB2 User copy PFC 07 12 49 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 disconnec
4. 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 and 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 ON 12 4min OR Blowdown Valve a OFF 126 8min 4 then 4 Test Valve 4 Current State v Inhibitor Pump Inhibitor Pump e FF 8 then S Prime Pump aa Current State a Inhibitor Pump 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 copy PFC 07 12
5. 21 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 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 2 8 Check Controls Conductivity amp Blowdown Conductivity lt 1425 uS Sf Blowdown Valve a ON 17 1min Water Meter or Bleed amp Inhibitor Pump Blowdown Valve e ON 124 2min Sf Inhibitor Pump e ON 48 1min 24hr Make up 4 10450 G Sf Inhibitor Pump e ON 124 8min 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 Feed limited inhibi
6. 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 copy PFC 07 12 continued Interlock ON 780 6mi n Sf Diagnostics on last 18 6hrs Sf Boiler Blowdown S N D041B0248 Sf LAN IP 010 010 006 101 OR 4 20mA Output 15 4mA OR Alarm Relay d Cl osed 13 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 Blowdown Mode m Turn ON 3000 TurnOFF 2990 Y 4 Edit amp Enter Turn ON 3025 gt T then Turn ON 3025 TurnOFF 29
7. Meter 400 Hz max 0 5mA 5VDC measurement current Relay Outputs 1 SPDT Blowdown Solenoid or Motorized Valve 1 SPST Inhibitor Pump 4 20 ma Output 1 DC isolated loop powered on conductivity Nominal 0 1 of span resolution CL optional card Auto polarity correction field wiring Alarm Relay Dry contact set AR optional card Rated 500mA 24VDC Communications Rating Detail User Interface Keypad LCD 5 Key Tactile feedback UP DOWN ENTER EXIT RIGHT 2 Line x 16 Character Backlit Browser 10BaseT Ethernet RJ45 Jack LB optional card Full command amp control via browser XML real time controller data AQB2 User copy PFC 07 12 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 46 BB IN Boiler Blowdown Controller Blowdown Valve Controls Sampling Continuous and Percentage Time Inhibitor Pump Controls Percentage Time Blowdown amp Feed User sets Blowdown amp Feed Feed on of Blowdown ON time used for V
8. Timing Blowdown Valve Press ENTER then UP Blowdown Valve ON 21 3mi n 4 then T Press ENTER Sample Timing Sample Timing to view or adjust timing Setpoints Y This option only displays if Blowdown Mode Sampling rv Key DOWN to view current Sample Measure sample 20s e Blow dwn amp ReSample times Me asure 3 0s Y Key ENTER to adjust 4 Key UP amp DOWN to adjust Edit amp Enter EXIT ends with changing the time Sample 28 gt TE ENTER ends adjust and executes the new timing In this example we ve increased the Sample time from 20 Sample 285 seconds to 28 seconds Measure 305 Y 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 b
9. 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 copy PFC 07 12 3 5 Diagnostics Diagnostics on e last 6 3 days e Last B dwn ON 14 9 min 4 B dwn ended 86 9 min ago v amp Average B dwn 10 6 mn Y amp Last feed ON 26 sec Y e Feed ended 1 2 hrs ago v 4 Last make up 58 4 min ago v amp Temperature 194max 182min v B Last B dwn ON 14 9 mn Y 33 BB IN Boiler Blowdown Controller 3 6 System Alarms System Menu Options Boiler Blowdown S N D041B0248 m Press ENTER to view Current State Current Stat
10. me 12 each 5min Blowdown amp Feed 17 each 5min Blowdown amp Feed Measure 100 Ge Feed 12 sec v Feed on Volume Sidebar Percentage Time base feeding is the most common way to feed inhibitor into small boilers which usually do 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 copy PFC 07 12 15 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 Inhibitor Pump Press UP or DOWN until you see ON 48 1min Inhibitor Pump amp press ENTER Press DOWN until Limit Timer Limit Timer lt Press ENTER to view or adjust Limit Timer Prime Pump Y Displays feed limit in minutes Feed Li mt 7157 2157 indexes more explanation 18 min v www prominentcontroller com m Edit amp
11. mi ul mi ul ml ui mi umm Open Vus a eC dee eee On Alarm S e V e eS ae LIE LN URL OL URL OR I ce ooetete oo ete t eteoec eto ete Satata EIN NIE E NUN NT UNS HUBEBRREBEBEBEBEP IERI ERPENRENEERREREEREDSIO EAE EISREEDO lr PEER RED o e r r mlS Ta a a a n n n a n SS ELED EEE 2 mt Blead numen ee SOWO OEO OMO TON 4 MOM ON bOW BO om ow RO mom x Alarm B F OF E r OD OF t i Se Alarm dry contacts OPEN on alarm loss of controller power amp alarm wiring disconnect Alarm m f Building Automation System Alarm Input Alarm Wire alarm contacts AWG22 to AWG18 2 conductor E 2 ALARM DISPLAYS Press UP DOWN until you see Alarms Alarms If the Alarm Relay Card is installed you ll see one of the none following displays ST Alarm Contacts If Alarms amp none then the alarm contacts will be closed CLOSED No Alarm OR Alarm contacts open on alarm Alarm Contacts OPEN Alarm This display verifies the contact set state measured at the Building Automation System input terminals AQB2 User copy PFC 07 12 52 BB IN Boiler Blowdown Controller Appendix F LAN Browser Option Download Sflex_LB manual from www prominentcontroller com 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 using the controller keypad You can use a crossover cable to connect to
12. opening the enclosure door ab USER WARNING CAUTION This Boiler Blowdown Controller operates 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 copy PFC 07 12 5 BB IN Boiler Blowdown Controller 1 INSTALLATION 1 1 Sample Piping The Controller includes a 250psi steam rated conductivity sensor and 34 sensor entry T and can be operated in either Sampling or Continuous Blowdown mode Sample piping is plumbed in 34 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 NOTES S 1 Isolation valves on surface s blowdown l
13. password press ENTER to log in AQB2_User copy PFC 07 12 37 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 1 Current State rv Log Out Edit Password y 4 Edit Password Password OFF Y 4 Password OFF v Log Out Y Edit Password Edit amp ENTER 0094502 gt 7 then Qi Log Out Edit Password v 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 copy PFC 07 12 38 BB IN Boiler Blowdown Cont
14. 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 8 Up Time 00 09 22 8 Diagnostic Last blowdown ON 0 min Alarms Temperature Deaerator amp ended 10 5 min ago Avg Blowdown is 0 min Alarms Events Temperature 283F MAX and Timers Reset All 7200 G 281F MIN Soft Make u Part No BB IN Owes 288sec Serial Number US04B9999 BE Treatment Click a link in the View to operate the controller 1005 uS Conductivity Boiler Measure 25s Blowdown Valve Refresh View Closed 10 2min s Interlock Throttle Flash Tank Setup Configure Refresh AQB2 User copy PFC 07 12 53
15. 90 Turn ON 3000 4 TurnOFF 2990 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 50uS for Continuous blowdown mode Conductivity should decrease as Blowdown Valve ON time increases AQB2_User copy PFC 07 12 14 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 Q tren Setpoints lt Feed Mode Y r Percentage Ti me 10 each 5mi n 4 Edit amp Enter 12 each 5mi n gt ty then Percentage Ti
16. Blowdown Controller 3 2 Bleed Controls Continued Current State of the Blowdown Valve Control Blowdown Valve Press ENTER then UP Blowdown Valve ON 21 3min then T Press ENTER Current State Current State e Setpoints Displays Sampling OR Measure OR B down OR Waiting Counts down time in the current state ON Sampling 250 Key ENTER to end the state and go to next state ll sec Stops e Sampling Control If ON displays TurnOFF setpoint 2990 amp current conductivity 3042 Off 2990 2121 If OFF displays TurnON setpoint3000 ON 3042u5 amp current conductivity 2993 Continuous Control On in 221sec 123 If ON displays Owes 41 sec 123 OFF amp ON ENTER Stop If OFF displays seconds to turn ON Time Control HELP 2250 122 amp 123 and other help numbers display wherever more explanation is available at www prominentcontroller com lt Stop 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 copy PFC 07 12 27 BB IN Boiler Blowdown Controller 3 2 Bleed Controls Continued Sampling Control Mode
17. Boiler Blowdown Controller Frequency Activity Method Weekly Verify Conductivity 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 Check both current Continuous Blowdown Control Temperature and You would expect to see a relatively constant sensor Minimum Maximum temperature with only a small difference between temperature 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 Note Make up Volume Weekly softened make up water usage indicates both If make up meter average boiler load and percentage condensate installed return High water usage may result from a reduction in controller setpoints or faulted or failing softener Verify Interlock If you are using the Interlock verify that Interlock shows OFF when the boiler is off line System Check 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 copy PFC 07 12 40
18. Controller 3 2 Blowdown Controls Continued Blowdown Valve Modes Press ENTER then DOWN Blowdown Valve Press ENTER Blowdown Mode to view current mode and to select a new mode Most boilers 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 Sidebar Blowdown Valve ON 21 8min then 4 Blowdown Mode Test Valve Y Sampling lt Continuous Y Continuous Percentage Ti me 4 Percentage Ti me e Sampling Y e then T Setpoints Blowdown Mode 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 copy PFC 07 12 26 BB IN Boiler
19. Enter Press ENTER adjust Feed Limit 12 min gt T5 Press UP DOWN to adjust and RIGHT to move the cursor Press EXIT to leave the Feed Limit unchanged Feed Limit 27157 12 min Press ENTER displays current limit 12 minutes per feed cycle HELP 157 and other help numbers display wherever more explanation is available at www prominentcontroller 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 copy PFC 07 12 16 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 promi
20. NAL The factory default water meter is a 100 Gallons contact contact head meter Press UP DOWN until you see 0 24hr Make up Displays make up volume during the last 24 hours Make up volume resets every 24 hours and every power OFF ON to 0 0 hours Press ENTER twice to view or change meter type Key ENTER to view or change the gallons contact Metric users will view volumes in L iters amp L Contact 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 Sidebar 2 wire meters are usually Contact Head Interlock Interlock ON 780 6mi n Contact Head atermeter 24hr Make up 10450 G m Meter Type Year to Date 4 Contact Head Paddl ewheel e G Contact 100 amp Edit amp ENTER 25 ty then e Contact Head Paddl ewheel 3 wire meters are typically Turbine or Paddlewheel water meters Softened make up water meters are lower cost ambient temperature rated meters Feedwater meters are usually high temperature paddlewheel type AQB2 User copy PFC 07 12 19 gt Y BB IN Boiler Blowdown Controller 2 6 Check Interlock amp Install Water Meter continued OPTIONAL Turbine Paddlewheel type water meters provide f 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 6 4hr Make up Displays make up
21. at deaerator pressure 4 Conductivity sensor cable may be extended up to 100ft in 4 x AWG22 Do not cable sensor and 120VAC valve wiring in the same conduit o ERN 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 copy PFC 07 12 8 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 RUN ENSOR 2 5 SENSO zs Chit WHT BE MED Sey oe How si Mae ce T S152 OSVON 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 mnm TLEL Controller Jumper Flow to if A used Feed cables through the entry seal amp re tighten Oc 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 fou
22. down 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 WARNING as MOTORIZED BLOWDOWN Do not plug in controller pump VALVES are hardwired or blowdown valve until you ETTEI 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 Power Plug SOLENOID Front 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 copy PFC 07 12 11 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 4 8 Move RIGHT to select next ub field when EDITing ENTER to select an option e amp to execute EDITi
23. e Controller diagnostics select niis V Press ENTER to view or change Select Units lt US or Metric units Current State Press UP DOWN until you see the Serial Number Press ENTER view System options Alarms Press UP DOWN until you see Alarms Alarms al The first alarm to trip will display or none if no alarms ae Press ENTER to Clear Alarms 4 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 copy PFC 07 12 34 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 and to powe
24. e Deg F Gallons 4 Deg C Liters amp Deg C Liters Deg F Gallons v 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 copy PFC 07 12 36 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 Blowdown S N D206NT042 m Current State Select Units Y Sc J Password ON 1 Current State Password ON Enter Password 000123 gt 7 then e Advice 110 Password OK 1 OR Advi ce 111 Wrong Password e 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 changed the default
25. e as long as 12 hours for stand by boilers ReSample is the time between conductivity checks when the conductivity is less than TurnOFF setpoint AQB2 User copy PFC 07 12 28 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 e amp press ENTER 10450 G Press ENTER to view current type or to select Meter Type 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 periods of Days Online ON time in the current year z ro Meter Y Key ENTER to reset Year to date Days OnLine Zero Meter and 24 hr Make up to zero Warning Cannot Undo Meter Type M 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 7 Resets to zero every 365 days Da 4 4 Line 193 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 prominentcontroller com AQB2_User copy PFC 07 12 29 BB IN Boiler Blowdown Controller 3 4 Inhib
26. eel surface blowdown piping Conductivity i Isolation Sansor p IE Valve Chemical injected into deaerator sump EX Bleed Solenoid or into feedwater wt or Valve line upstream of the feedwater pump zd Boiler 250 psi Optional Throttling Throttling Needle H maximum AQB2_User copy PFC 07 12 Operating Interlock Contact Set 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 5 Use a solenoid or valve for blowdown rated for steam service at boiler pressure Isolation Valve Valve Valve Isolation Valve Flash Tank 7 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 ENN Downstream of Controller Deaerator E E Inhibitor Pump Plugs wiring amp tubing not EEn Chemical shown Injection point 858358 Flow Pump Shelf NOTES EMEN 1 Controller is usually located within sight of the blowdown valve UE Upstream 2 Your installation may not include of Feedwater chemical injection Inhibitor Pump 3 Chemical is usually injected upstream of the feedwater pump
27. er set time For example Measure 100 Gallons of make up amp 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 Sidebar 3 4 Inhibitor Controls Continued Inhibitor Pump ON 12 3min 4 then 4 Feed Mode lt Limit Timer Y m Percentage Ti me Feed on Volume v S Feed on Volume Blowdown amp Feed v e Blowdown amp Feedq Percentage Time y es then 4 Setpoints 4 Feed Mode Y 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 copy PFC 07 12 31 BB IN Boiler Blowdown Controller 3 4 Inhibitor Controls Continued Current State of the I
28. face blowdown safety isolation valves typically in a vertical run 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 manufacture
29. fault AQB2 User copy PFC 07 12 24 BB IN Boiler Blowdown Controller 3 2 Blowdown Control For conductivity control setpoints Section 2 2 Blowdown Mode Conductivity Setpoints Blowdown Valve 4 Press UP DOWN until you see Blowdown Valve ON 8 7min Displays ON or OFF and ON time in the current 24 hour period Press ENTER to view or adjust Setpoints Setpoints Setpoints vary with selected Blowdown Mode Blowdown Mode Y Press ENTER view current mode or to select from Sampling Continuous or Percentage Time A f E ET i is de 1 Press ENTER Test Valve to turn ON Blowdown Valve Test Valve lt Alarms Clear Alarms ends the test Sample Timing is only displayed if Sample Timing Blowdown Mode Sampling Current State Y Press ENTER to view or adjust Sampling timing 3 Press ENTER Current State to view control status Curre nt State Display varies with Blowdown Mode Setpoints Y 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 copy PFC 07 12 25 BB IN Boiler Blowdown
30. ily detected and corrected at start up A 3 CHEMICAL FEED 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 copy PFC 07 12 43 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 sur
31. ine not shown 2 Feedwater pump not shown 3 Refer to Appendix A for installation notes D 4 Your installation may eaerator Tr not include a make up meter E and or an operating interlock 5 Use a solenoid or valve for i Bad blowdown rated for steam service Em afc Ao at boiler pressure ae Isolation ater Meter Valve Injection Entry Steel surface 5 blowdown piping Conductivity Sensor Chemical injected into deaerator sump Bypass or into feedwater Valve line upstream of a ie the feedwater pump Boiler Bleed Solenoid 250 psi or Valve maximum Operating Interlock ras ie pull Isolation Throttling Flash Valve Needle Tank Valve 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 copy PFC 07 12 6 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 Softener 7 Deaerator f f 1 i a Optional Make up Water Meter Jl Injection Entry 34 St
32. itor Controls For inhibitor control setpoints 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 Feed Mode Pr Blowdown amp Feed Feed on Volume Percentage Time Limp Timer 4 e Limit Ti mer v Press ENTER to set maximum Inhibitor Pump ON time Prime Pum in minutes in any 24 hours bas Y Prime Pump 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 Curre nt State Display varies with Feed Mode Setpoints 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 copy PFC 07 12 30 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 us
33. 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 AQB2_User copy PFC 07 12 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 copy PFC 07 12 BB IN Boiler Blowdown Controller AQB2_User copy PFC 07 12 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
34. nentcontroller com Sidebar Continuous Blowdown Control 2 4 Verify Temperature Verify Temperature Boiler Blowdown S N D206NT248 amp Current State Select Units Y Temperature 101 Type NT v Temperature 101 196F Type NT v Temperature is used to compensate 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 copy PFC 07 12 17 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 t
35. ng 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 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 copy PFC 07 12 Enclosure keypad Response UP or DOWN to the display you wish to view or EDIT amp press ENTER Boiler Blowdown lt S N D206NT248 Sf Al ar ms lt Sf Conductivity H 1425 uS Sf Blowdown Valve ON 125 6mi n Sf 16 4hr Make up e 8050 G Sf Inhibitor Pump ON 96 4min 12 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
36. nhibitor Pump Control Press ENTER then UP Inhibitor Pump Inhibitor Pump al ON 0 5min e then T Current State Setpoints Press ENTER Current State If Feed Mode Blowdown amp Feed es If Sampling or Blowing Down displays 2 Owes 162sec 154 o ao OR Onin 86sec 150 Ad If Blowdown Valve OFF displays Blowdown Off 150 Blowdown amp Feed i If ON displays Owes 41 sec 156 m n 267sec 156 and ENTER Stop If OFF displays seconds to turn ON Percentage Time If ON displays Owes 38 sec 154 If OFF displays turn on volume 9800 ie pott d amp current volume 9700 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 150 154 155 amp 156 and other help numbers display wherever more explanation is available at www prominentcontroller com AQB2 User copy PFC 07 12 32 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 Increasing Average Blowdown time
37. o 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 prominentcontroller com Displays the current calibrated conductivity Sidebar Calibrate Conductivity Conductivity lt d 1425 uS Calibrate Alarms Y Edit amp ENTER 1883 uS gt 7 then Qi Advice 141 Fails Calibrated m Conductivity 1883 uS 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 copy PFC 07 12 18 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 in the last 24 hours NOTE An OFF open Interlock contact set stops 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 OPTIO
38. olume Inhibitor feed Feed cycle limit timer Interlock Blowdown Valve amp Inhibitor Pump Requires dry contact set from OFF when Interlock contact set boiler controls or site DCS opens Controller Configuration User settings and configuration Makes current configuration written on silicon factory default 5 Amps 115VAC 5x20mm 120VAC fusing Surge Spike Suppression Bleed solenoid relay contacts Controller electronics snubbed 0 1uF 150R transformer isolated from AC Varistor on AC power input line AC Terminals AC Input amp Output maximum Stranded AWG 14 150mm Sensor Ka ww Input peso l 22 0 25 0 50mm Ka ww Paddlewheel Meter Power 14 20 VDC a 4 NENNEN output option can be 4 20mA output loop power Thermally fused 50mA powered by load or by controller Enclosure Non metallic NEMA4X Nominal dimensions excluding 5 9W x 5 9H x 3 5 D entry fittings and flexible 150mmW xi50mm Hx90mm p COU l Enclosure door hinged left Allow 8 right for door opening Allow 18 below for cable access AQB2_User copy PFC 07 12 47 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 Solenoid plug from terminals White1 amp Bs Black to hardwire a motorized ball valve Neutral 120VAC Service Power from a dedicated 15A GFI circuit breaker AWG14 stranded
39. r 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 BI owdown S N D041B0248 m Current State Select Units Y rw Temperature 101 341 F Y amp Ext Power 102 15 6 VDC Y 3 Relay Power 103 12 1 VDC Y Drive 2107 13 3 mV Y 8 Measure 105 998 5 mV Y L State 106 244 163 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 copy PFC 07 12 35 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 Boiler Blowdown S N D041B0248 then 4 Select Units d Current State Y
40. r wire sensor cable Connect the GREEN WHITE BLACK RED cable to the SENSOR GRN WHT BLK amp RED terminals The controller will automatically measure the temperature and thermally correct the measured conductivity AQB2_User copy PFC 07 12 9 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 Connecting a contact head Water Meter SEN SENSOR RSE REX amp che Plow ab Men cde T 81 82 SODS OSDA 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 m aaa Feed cables through the Poole entry seal amp re tighten ue w Connecting a Turbine Paddlewheet Water Meter ae SENSOR mm SNC WHT BLR PES pure ch qne T BIER AAN DISD OSDA You ll need to Wiring color differs know the meter K Factor with meter to set up the White manufacturer inhibitor feed rate m Black _ Red Meter must be rated for are feedwater temperature sah ia Meters Do not install meter cabling in the same conduit as AC power wiring AQB2_User copy PFC 07 12 10 BB IN Boiler Blow
41. re exceeding the maximum expected steam pressure Plumb sensor 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 34 T in any orientation Do not install sensors in T s larger than 34 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 eas
42. ries 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 copy PFC 07 12 4 20mA Output 15 4mA Qag Trim Ze Trim Sp Trim Ze now 4mA ro an rv ro amp 6 201 t 4 20mA Output lt 15 2mA 4 20mA Output 15 4mA qd Trim Sp Sel ect Trim Sp an Span e an now 20mA 4 IL 202 t 4 20mA Output 15 2mA 51 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 a ml ul nl m a nl al o a a a a a a a u a a a a a un x 2 u u a Ww Wu mi mi mi wi MI E i al mi owl mi i mi ui mi ul miu Dry Contacts LJ LJ or guo LES sysUsDDDDBIIEMMEHReeeeme J i E LJ LJ m LJ LJ Pw mi ui mi m iu
43. rior to an annual check Chemical levels will be either higher or lower than target AQB2 User copy PFC 07 12 41 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 Blowdown Valve 5mm x 20mm www digikey com 1 800 344 4539 Fast Acting 4 1 2 Controller Parts Pane Desripin 120VAC Fuse Kit 10 x 5A Controller Fuses A261000 Boiler Conductivity Temperature sensor 34 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 prominentcontroller 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 prominentcontroller com ManualVersion Detl O 03 06 BB IN Production AQB2 User copy PFC 07 12 42 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 pressu
44. roller 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 copy PFC 07 12 39 BB IN
45. rs have both nominal values listed by meter size and calibration values 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 copy PFC 07 12 44 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 copy PFC 07 12 45 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 Rating Detail Conductivity 1 Temperature Compensated conductivity sensor Displays 1uS resolution Rated 250psi steam maximum Water Meter Interlock Dry Contacts Interlock 250mS response Water
46. sly revealing problems with valves amp flashing Press UP DOWN until you see Conductivity Press ENTER amp then DOWN to Sensor Watch This option only displays when Blowdown Mode Sampling Press ENTER to view current sensor conductivity Press Exit to end watching Sidebar Sensor Watch Sensor Watch Conductivity 1425 u Calibrate Alarms v 4 Alarms Sensor Watch Y 3 RN Sensor Watch ri Calibrate v Wat chi ng 2254 655 uS f 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 200uS 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
47. ted 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 Q 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 updates the Span EXIT leaves Span unchanged AQB2 User copy PFC 07 12 4 20mA Output 15 4mA OR 4 20mA Output Di sconnected e Select Span Trim Zero amp Trim Zero Trim Span s Trim Span Select Span Select Span Trim Zero 100uS 5000uS E Edit amp ENTER 4mA 2500uS ty then e 4mA 2500uS 20mA 5000uS 4mA 20mA 50 4 4 gt Y 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 se
48. tor pumps reset every 24 hours of controller run time or on power OFF ON AQB2 User copy PFC 07 12 22 BB IN Boiler Blowdown Controller 3 OPERATION 3 1 Conductivity Sensor Sensor calibration is detailed in Section 2 5 Alarms Press UP DOWN until you see Conductivity Conductivity 1425 Us Calibrate lt H Press ENTER amp then DOWN to Alarms Alarms 4 Press ENTER to view current alarms or adjust Alarms 1 Calibrate Y m Press ENTER to adjust the High Alarm High 3500uS or DOWN amp ENTER to adjust the Low Alarm Low 2500uS Press UP DOWN to adjust and RIGHT to move the cursor Edit amp ENTER Press EXIT to leave Alarm unchanged High 3750uS gt T5 ENTER updates the alarms amp displays the current High amp Low Alarms High 3750uS d o l l Low 2500uS Y 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 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 copy PFC 07 12 23 BB IN Boiler Blowdown Controller If Blowdown Mode is set to Sampling the Conductivity display updates at the end of each Measure period Sensor Watch shows the conductivity continuou
49. volume during the last 24 hours 31450 6 Fewer hours are displayed if the controller m has not been ON for 24 hours Meter Type lt Year to Date Y t Key DOWN to select Paddlewheel type meter Paddl ewheel 4 Contact Head Y Em Press ENTER twice to view or change meter type Key ENTER to view or change the pulses per Gallon K Factor Metric users view pulses per Liter 100 0 Press UP DOWN to adjust and K Factor unchanged Edit amp ENTER 104 5 gt T3 9 Paddl ewheel h ENTER or EXIT displays the current meter type Contact Head 4 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 copy PFC 07 12 20 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
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