Multiflex Technical Manual
Contents
1. Revised 04 29 09 33 M714_Tech doc Technical Manual 4 3 Module Testpoints continued Typical Relays 1 11 RUN Alarm ALT AL2 F R2oN R1 ON Relays 1 3 NO1 NC2 NO2 NC3 NO3 OSQODOYL PR Module Cable Q s 12VAC 12VAC Control Transformer 120VAC 120VAC 6 Q Q Q Eine Voltage Selector Power Relay Module Part PR10 RAON Fuse Fuse 1 5 6 10 R5 ON e AC Input modem AC L N SE Power OQO Relays 4 5 NC4 NO4 NC5 NO5 OSDO Neutral DDS LAC 100mV A q ise R9 ON amp R7 ON nhu Ri00N Relays 6 8 Relays 9 10 NO6 NC7 NO7 NC8 NOs Neutral NC9 NO9 NC10 NO10 ODVOYU QOOS 2 GOOG O D O N Tt ko 2 3 ao M714_Tech doc Technical Manual Appendix A Resource Index Spare parts documentation www text required Telephone Support text required Documentation Type Subject Filename Manual M714 Technical Manual M714 Tech Manual M714 Keypad LCD Manual M714 User App note CS Command Telnet State Stream AN_T001 API information for non browser user interfaces App note AM Command Admin Manufacturer AN_T002 Not in the public domain App note Controller Communications AN_T003 URL Encoding Telnet API information for non browser user interfaces App note Browsing a controller not connected to a LAN AN_T004 B Driver Boiler Condensate driver technical manual Driver_B Cl Driver Current Input2. User selects a relay amp selects Time Modulation Special Control User sets ON Time in minutes minimum 1 maximum 360 minutes User sets Period in minutes minimum 1 maximum 360 minutes Controller forces Period gt ON Time Setpoint Controls turn ON the relay Time Modulation turns OFF the relay after ON Time minutes Time Modulation keeps the relay OFF for Period ON Time minutes During the OFF period the system has time to respond to the ON Time feed Time Modulation ON Time 10 minutes Period 60 minutes Brine feed is controlled on conductivity using a Falling Setpoint Conductivity setpoint control turns ON the Pool Brine feed relay After 10 minutes the Pool Brine feed turns OFF After another 50 minutes the Pool Brine feed turns ON for another 10 minutes if below the Turn ON setpoint or remains OFF if the conductivity is above the Turn OFF setpoint Condensate systems are also slow to respond to amine feed However the response time may vary with time of year and steam production 20 Technical Manual 2 7 8 Holding Time Application Prebleed Holding Time averages the value of a control over a user defined Setup Operation Notes Revised 04 29 09 M714 _Tech doc period Averaging lowers the effect of process transients and limits the effect of the delay between feed and measuring the effect of the feed Control of amine feed by a pH sensor in the condensate return is a typical use of Holdin
3. Relay No 4 Biocide Pump turns ON At 07 50 Relay No 4 Biocide Pump turns OFF At 09 20 Relay No 2 can turn ON when the conductivity exceeds the Turn ON Setpoint 18 Technical Manual 2 6 4 Prebleed Lockout continued Notes The time required to lower the tower conductivity is dependent on tower load Subsequently most biocides are fed early in morning when cooling towers are not loaded Typical Lockout times of four hours may be a problem if tower load increases Since the bleed cannot operate tower conductivity may exceed chemistry limits 2 6 5 Captured Sample Boiler Controls Application Setup Operation Notes Revised 04 29 09 M714_Tech doc Captured Sample controls boiler blowdown using a conductivity sensor installed in a boilers surface blowdown line upstream of the blowdown valve An optional Fail to Sample sensor detects a failure to open the blowdown valve or an inadvertently closed isolation valve User selects Blowdown Valve relay amp selects Captured Sample Special Control User sets Sampling time in seconds typically 30 60 User sets Measure time in seconds typically 60 120 seconds User sets Blowdown time in seconds typically 60 300 seconds User sets Re Sample delay in minutes varies with boiler type and service from 30 minutes to 720 minutes 12 hours User sets location of optional Fail to Sample sensor a contact closure input from none through O to Z Captured
4. for mL pulse or contact closure PPM can be corrected for inhibitor concentration by calibrating the ppm analog input for the active Do not calibrate the feed verification meter input for active 24 2 10 Priming Setup Operation Technical Manual Select the target relay using either the keypad or the browser Then select Diagnostics Keypad users set Time Owed to 5 minutes on selecting Prime Browser users can set the Prime time in minutes Time Owed gt 0 minutes immediately turns ON the relay SAFETY Interlocked relays will not turn ON until the interlock contact set closes SAFETY Blocked relays will not turn ON until the blocking relay turns OFF Relays OFF alarmed on feed limit timers will not turn ON when primed Clearing the relay alarm will also end Priming requiring you to re Prime Relays with Special Control set to Captured Sample will bypass Captured Sample timing immediately turning ON the blowdown valve Ending Prime Notes Revised 04 29 09 M714 _Tech doc Clearing Alarm on the relay ends Prime by setting Time Owed 0 Time Owed is also incremented by water meter volume feed controls and timed events and is zeroed by Clearing Alarms 25 3 Sensors 3 1 Compensation Analog Sensors A N Technical Manual User set degree compensation Type Setup Notes Thermal User selected thermal Applied to conductivity sensors sensor A N Zero at 70F or 20C dependent on
5. Ie to to Corrosion Rate CR Red to S1 Red to S2 Black to S1 Black to S2 Not polarized Not polarized 4 20mA inputs Cl Loop to 1 Loop to 2 L L Loop to Loop to 4 20mA outputs IO Out to 1 Out to 2 Out to 1 Out to 2 Auto polarity correction Wiring Rules Analog sensors contact sets water meters and flowswitches may be cabled in a common conduit without causing operational problems Do not mix AC Line 120VAC amp 240VAC wiring with any sensor or communications cable in a common conduit Grounded metallic conduit is preferred in areas where variable frequency drives operate Sensor cables with the exception of pH sensors may be extended in paired AWG22 0 25mm cable Ensure that cabling splices are accessible in conduit fittings or junction boxes Verify that the shields on contact head water meters are also spliced when meter cables are extended Revised 04 29 09 7 M714_Tech doc Technical Manual 1 2 LAN Communications Stand Alone Controller not connected to site LAN Controllers not connected to a network may be browsed using a crossover cable anda notebook s or local PC s browser em IEB Y en en e j Or aw Refer to Application note AN_T004 for detail on notebook browser set up Controller Notebook or PC RJ45 Crossover Cable 10 100 TCP IP RJ45 network Ethernet NIC connector located top center of M7 or M14 module Controllers use a static IP address to communicate
6. amp Dual User configurable controls Manual amp Auto modes Interlocked loops go to 4mA M7 amp M14 Max eight 4 20mA outputs OP ORP pH Single and dual sensor User configurable to pH or ORP Single amp Dual Dual cards may be user configured for one pH amp one ORP or dual pH or dual ORP M7 Max 7 sensors M14 Max 14 sensors Driver installation removal sequence 1 2 N OA Unplug or turn the controller power OFF Do not install or remove driver cards with the controller power ON If removing a driver compress the locking tangs on the nylon card pin and pull the end of the driver up over the locking tangs Pull the driver out of its socket horizontally removing the driver Install a driver aligning the driver socket with the header on the M7 or M14 module and pushing the card down on the installation pin until the pin locks the driver in place CAUTION Verify that the driver is aligned with the white footprint on the M7 or M14 module Incorrectly aligned cards will immediately fail both the driver and M7 or M14 on power up Connect sensor s to the driver card Power up the controller and view the present value of sensor calibrating if necessary Corrosion Rate drivers require 16 seconds to measure All other drivers will measure sensors within a few seconds Revised 04 29 09 30 M714 _Tech doc 4 3 System Settings Technical Manual Accessed by System Configure Re
7. an ON OFF relay control Applies only to relays controlled by sensors A N Method Function Examples Rising Setpoint ON Sensor gt Turn ON Setpoint OFF Sensor lt Turn OFF Setpoint Tower Bleed Boiler Blowdown Condensate Bypass Acid Feed Falling Setpoint ON Sensor lt Turn ON Setpoint OFF Sensor gt Turn OFF Setpoint Oxidant Feed Caustic Feed Between Setpoints ON Sensor lt Turn ON Setpoint amp Sensor gt Turn OFF Setpoint OFF Sensor gt Turn ON Setpoint Sensor lt Turn OFF Setpoint Blocking Controls Level Controls Operates only during Timed Events Event Rising Rising Setpoint Acid wash flush Operates only during Timed Events Cleaning controls Event Falling Falling Setpoint Oxidant slug feeds Event Between Between Setpoints Operates only during Timed Events Blocking sequencing controls Revised 04 29 09 M714 _Tech doc Technical Manual 2 6 Special Controls 2 6 1 Bleed amp Feed Application Pumps cooling tower inhibitor proportional to tower load Setup Operation Notes The longer the bleed solenoid is ON the more inhibitor is pumped User selects Inhibitor Pump relay amp selects Bleed amp Feed Special Control User sets bleed solenoid relay number User sets of bleed time 1 100 Inhibitor Pump turns ON when Bleed Solenoid Relay turns ON Turns OFF when ON time is exceeded in every 300 seconds If of Bl
8. contact sets If any one of the OR ed contact sets is ON the relay can turn ON Up to four contact sets may be OR ed The forward slash separates OR ed contact sets Example Boiler Steam Line Treatment pump is interlocked with contact sets T X Y The pump can operate whenever any one of T X or Y is ON Typically T X amp Y are ON whenever boilers 1 2 or 3 are ON AND ing contact sets All of the AND ed contact sets must be ON before the relay can turn ON Up to four contact sets may be AND ed The plus sign separates AND ed contact sets Example A pH control operates when both Y Z contact sets are ON Where Y amp Z are ON when both the transfer pump and the tank full contact sets are closed Revised 04 29 09 15 M714 _Tech doc 2 4 Blocking Relays Technical Manual When a blocking relay turns ON it turns OFF blocks the relay with that relay number in it s blocking field Example Relay 1 feeds an inhibitor and has Relay 3 set in its Blocking field Relay 3 feed oxidant and has none set in its Blocking field Whenever Relay 3 turns ON Relay 1 turns OFF More than one blocking relay Up to four blocking relays may be set in any relay s blocking field as 2 4 8 9 where 2 4 8 amp 9 are enabled relays The sign separates more than one blocking relay The controller prevents a relay from blocking itself 2 5 Control Method Sets the deadband response of
9. example you do not have a phone line connected to the modem amp Pager has been selected you ll view Testing Pager Dial out and NO DIALTONE in sequence 5 If Pager is selected the controller modem will dial the target phone wait the pager delay send the pager message amp hang up 6 If Pager is not selected the controller modem dials out expecting to connect to another modem at 19200 After connecting the controller will send Controller Serial System Name Location Name Date Time Active Alarms one per line and then hang up 7 Each alarm line is comprised of an I O Letter or Number Name Alarm type Date Time alarm tripped Note that I O points with dial out on alarm checked will dial out every 60 minutes until cleared 8 Delays of several minutes occur between sequential modem tests to allow for recovery from fault conditions no carrier loss of carrier detect Revised 04 29 09 10 M714 _Tech doc Technical Manual 1 4 Water Meters Flowswitches Contact Sets Water meters flowswitches and contact sets are connected between input terminal O through 2 and a ground terminal 5VDC limited by 10K puts 1 2mA through a closed contact set Hall effect Turbines and Paddlewheel water meters are powered by the 15 22VDC controller supply thermally fused at 100mA Water Meters Flowswitches and Pace despre oreer cere oreei cere rere eieererere ricer Contact Sets may be connect
10. metric units switch setting The defaults are 0 97 F or 1 746 C Rate to Volume User selected water meter O Z displays and logs resulting volume User selected rate minute or rate hour Typically a 4 20mA input proportional to gom makeup rate or Ibh steam production is converted to volume to feed ON OFF based on volume amp time setpoints Corrosion Rate User set alloy number default 1 00 Carbon Steel User selected conductivity sensor A N corrects corrosion rate for conductivity Controller sets alloy to default and conductivity sensor to none on CR driver installation Conductivity sensor optional Remove driver to remove compensation Manual Entry Logs the results of ppm testing or any analog value Any analog input without a driver card or with an IO 4 20mA output driver may be used for Manual Entry Remove by setting compensation to none tank volume log Calculated Feed Verification calculated Remove by setting to none in Feed Verify ppm log control Inventory Feed Verification calculated Remove by setting to none in Feed Verify control Water Meter Sensors O Z Switching from Contact Set to Water Meter clears log Type Setup Notes Contact Head User set volume contact Contact Head compensation turns ON software debouncing Volume counts on contact closure Contact opening ignored Turbine User set K fact
11. the Biocide Pump relay has the Prebleed Lockout Special Control selected Clear Alarms on a relay zeroes Time Owed ending a timed event and prebleed Clear Alarms on a Locked Out bleed relay will end the Lock Out Timed events can operate in parallel with other controls For example a water meter could add oxidant a low rate proportional to load with a Timed event providing a weekly slug feed Each relay 1 10 can have up to 28 timed events Each event has a user defined start time using a 24 hour clock with 1 minute resolution from 00 00 to 23 59 User set relay ON time from 1 to 1440 minutes per event Each biocide control relay can have its own prebleed lockout timing user defined bleed relay and conductivity sensor Support for user with multiple systems or cooling towers For example four towers with four bleeds and four biocide pumps each of the four with it s own prebleed conductivity sensor Each relay can select a 1 7 or 28 day event cycle You may elect to feed alternating organic biocides on a 28 day cycle daily oxidant on a 7 day cycle and an every 4 hour sensor wash on a 1 Day cycle One day cycle is always Day 1 Sunday is Day 1 for seven and twenty eight day cycles Twenty Eight day cycles have the option to set the most recent Sunday to Day 1 using System Configure command sequence Varies with selected Event Cycle Allows user to quickly enter repeating events 1 Day Cycle Once Alternate Hours Hou
12. 3 M714 _Tech doc Technical Manual 4 20 mA Output Controls Control equation may be one of an analog sensor A N OR A Relay number 1 10 If a Relay number is used then the current value of the relay control equation is used to control the current level Current Output in mA 4mA 16mA x Sensor Value 4mA Value Span Example Current Output C2 is controlled by pH sensor connected to input E Tower pH E 7 91 pH C1 is set to AUTO with 4mA 5 pH and 20mA 10 C1 output currentis 13 3mA 4mA 16mAx 7 91 5 10 5 Revised 04 29 09 14 M714 _Tech doc Technical Manual 2 3 Interlocks When an Interlock contact set OPENS the interlocked relay turns OFF When an Interlock contact set OPENS the interlocked 4 20mA output is 4mA An open interlock contact set displays OFF A closed interlock contact set displays ON Interlocks may be used with all three types of controls analog sensors A N water meters O Z and contact sets O Z Note 4 20mA outputs are limited to a single interlock O Z ANDing amp Oring interlocks does not apply to 4 20mA outputs Contact sets used in Interlocks cannot be disabled Example Relay 2 controls a bleed solenoid It s interlocked with contact set T Contact set T would typically be a flowswitch When contact set T opens amp displays OFF Relay 2 will turn OFF or will not turn ON The state on Relay 2 will be Interlocked T when T is OFF OR ing
13. 4 29 09 M714 _Tech doc 31 Technical Manual 4 3 Module Testpoints Supplied for bench testing only not intended for field use A D inputs will scan too quickly for DVM s Constantly changing levels indicate that the MUX and driving logic is functional Unregulated 15 22VDC supply accessible both before and after Thermal Fuse 1000 1 Current Transformer level 100mV A after rectification SRO NOONE Modem Serial Port pPRModila Gape G INGA M7 Module Tesipoints J12 2V5 Calibration Level 2 Vin A D Input after MUX 5VA Analog 5VDC 3V3 Microcontroller DC supply 5VD Digital DC Supply J12 Current Transformer DC level CD Modem Carrier Detect Unreg supply before fuse 12V Relay supply 15VF Unreg supply after fuse RUN Low when relays enabled Sensorocuic C amp D Revised 04 29 09 32 M714_Tech doc Technical Manual 4 3 Module Testpoints continued M14 Module Testpoints 2V5 Calibration Level 2 Vin1 A D Input A G after MUX 5VA Analog 5VDC A G 3V3 Microcontroller DC supply 5VD Digital DC Supply IAC Current Transformer DC level CD Modem Carrier Detect Sinpoyy losues aINpo W 4osuas 15V Unreg supply before fuse Vin2 A D Input H N after MUX 15V 11 Unreg supply 11 fused 12V 11 Relay supply 11 IGA SE oe RUN Low when relays enabled Hod Blas Wepo QVDOSYVODY DY Ltsuodo O Nv 7 81929 NPON Yd DC volts mpow10su 35 ainpoysosuas
14. H OP OFFSET OFFSET Type pH 0 017 7 8 6 Type ORP 1 0 50 50 Temperature CT OFFSET OFFSET US units 0 18 459 4 430 590 Metric units 0 1 273 253 293 Water meter Contact Head 100 None none Turbine 100 Revised 04 29 09 28 M714_Tech doc Technical Manual 4 System Configuration 4 1 Power Relay and I O Modules Controllers consist of two circuit boards installed on a metal frame in a non metallic enclosure with optional driver cards and communications accessories Controller Part Status Services AC input and ON OFF power relay terminal blocks PR10 Module Required Alarm relay and field wiring terminals Power relay and Control Fusing surge suppression and or 1 snubbing on relays 2 5 and 7 10 per NEON relay ON indicators Hardware watchdog PR5 Module controller PR10 10 Power relays Eight of ten with Power Open Power Closed terminals Fused in two groups of 5 6 3 Amps ea Controller alarms on loss of each relay fuse Current transformer measures total load current PR5 5 Power relays Four of five with Power Open Power Closed terminals Fused at 6 3 Amps Controller alarms on loss of relay fuse 4 lines x 20 character backlit LCD supply amp 5 key keypad M7 Module Required 15 22VDC output for current loops and three wire water meters or 1 Automatic controller re configuration on sensor driver card installation and or removal per M14 Module controller M7 6 Digital inputs individual
15. If the calibration OFFSET or GAIN is outside fault limits users are offered the option to OVERRIDE OFFSET or GAIN outside of the fault limits typically indicates a sensor cabling or driver fault Users have the option to enter OFFSET and GAIN by selecting Sensor then Configure The value of a sensor Measured Level mV x GAIN OFFSET This value may be modified by sensor compensation Compensation Temperature Rate Volume Corrosion Rate is applied after GAIN amp OFFSET Revised 04 29 09 27 M714 _Tech doc 3 2 2 Two Point Calibration Two point calibration is limited to type Cl the dual 4 20mA input driver There are no fault limits on GAIN or OFFSET for Cl drivers Reference Driver_Cl doc See Appendix A for list of supporting documents 3 2 3 Reset to Factory Installed sensor driver cards amp reconfigured water meters are Reset to Factory on Power on Technical Manual User selected Reset to Factory loads the GAIN OFFSET set from the following table Sensor Type Driver Factory Factory Fault Fault Type Gain Offset MAX MIN Boiler Condensate B GAIN GAIN Conductivity Type Boiler 2 0 15 10 0 5 Type Condensate 8 0 90 12 3 0 Calculated Value 100 0 none none Conductivity CT GAIN GAIN Range gt 100uS 5 6 35 10 2 5 Range lt 100uS 0 4 10 0 55 0 25 Corrosion Rate CR 1 0 none none 4 20mA Current Input Cl 1 0 none none Manual Entry 1 0 0 0 ORP p
16. Sample Blowdown Control is a four step process SAMPLE The blowdown valve opens purging the surface blowdown line and delivering a sample of boiler water to the conductivity sensor MEASURE The blowdown valve closes the sample at the sensor cools amp at the end of the Measure period the controller measures the conductivity If the conductivity is greater than the Turn ON Setpoint go to Blowdown else go to Re sample BLOWDOWN The blowdown valve opens for a user set time then the controller goes to Measure RE_SAMPLE The blowdown valve is closed for a user set time and then the controller goes to Sample FAIL TO SAMPLE An optional normally open thermal switch installed opposite the conductivity sensor closes at nominally 200F 95C The controller checks the state of the Fail to Sample switch at the end of the Measure period A closed Fail to Sample switch indicates a functioning blowdown As long as the measured conductivity is more than Turn ON Setpoint the controller will repeat the Measure Blowdown Measure Blowdown cycle The Measure period provides thermal compensation The initial temperature is fixed by the boiler pressure A rapid but repeatable temperature drop occurs during the Measure period 19 Technical Manual 2 6 6 Time Modulation Application Cycles a chemical feed pump ON OFF decreasing the ON time as the Setup Operation Example Notes controlling sensor approaches the Turn OFF setpoint Typic
17. Technical Manual Multiflex Technical Manual Revised 04 29 09 1 M714_Tech doc Technical Manual Contents M714_ Tech Manual Safety 1 Installation Commissioning 1 1 Cabling Wiring 1 2 LAN Communications 1 3 Modem Communications 1 4 Water Meters Flowswitches Contact Sets 2 Control Configuration 2 1 Methods 2 2 Control Equations 2 3 Interlocks 2 4 Blocking Relays 2 5 Control Method 2 6 Special Controls 2 6 1 Bleed amp Feed 2 6 2 Bleed then Feed 2 6 3 Percentage Time 2 6 4 Prebleed Lockout 2 6 5 Captured Sample Boiler Controls 2 6 6 Time Modulation 2 7 7 Timed Cycling 2 7 8 Holding Time 2 7 Timed Events 2 8 Variable Cycles 2 9 Feed Verification 3 Sensors 3 1 Compensation 3 2 Calibration 4 System Configuration 4 1 Power Relay and I O Modules 4 2 Installing Sensor amp 4 20mA Drivers 4 3 System Settings 4 4 Module Testpoints Appendix A Resource Index Revised 04 29 09 2 M714_Tech doc 11 25 28 34 Technical Manual Safety A Electrical Shock Hazard Opening the controller enclosure with the controller plugged in exposes the user to AC line voltages on the lower of the two controller circuit boards A Water Treatment Controllers operate steam and water valves and may pump hazardous corrosive and toxic chemicals Opening the controller enclosure exposes user to the risk of electrical shock at power line voltages USER WARNING CAUTION Understand f
18. User selects relay Configure and sets the Feed Verification User selects relay Feed Verification and sets Verify Meter The water meter input O Z connecting to the meter on the output of the inhibitor feed pump Inventory location The analog sensor input A N used to log the calculated inhibitor tank volume ppm location The analog sensor input A N used to log the calculated ppm ppm method select Fixed Cycles User sets a fixed number of cycles default 3 500 Meter Cycles User selects Bleed water meter input O Z Uses the ratio of the tower make up to the Bleed meter as concentration for ppm calculation Bleed Cycles User select Bleed Relay number 1 10 Use the value of the Bleed Relay control equation as concentration assuming that the relay is controlled by the ratio of Tower to Make up conductivity Assumes that the feed verification meter measures mL The controller calculates ppm based on the make up volume fed from midnight the ml of inhibitor fed and concentration from the user selected ppm method Failure to measure volume after the relay has been ON for 30 seconds sets a Fail to Feed alarm on the Feed Verification meter Every 10mL of inhibitor fed reduces the inhibitor inventory Inventory is calculated in Gallons If the metric units switch is set inventory is calculated in liters The default feed verification meter provides 1 pulse mL Any type of meter can be used for metering inhibitor feed and should calibrated
19. al Manual 1 3 2 Modem Test Controller Power Up Modem Status LEDs ON red MR HS TR AA amp green PWR OFF red CD OH SD RD Press modem power switch if no status LEDs ON Browser Select Communicate Diagnostic displays OK verifying modem power ON amp controller to modem serial connection operational Dialing in to a Controller Modem Dial in to a controller requires an application like Trackster which will make the telephone connection and then switch to Telnet for controller command and control If you manually dial a controller it will pick up time out and hang up because it cannot establish a modem to modem connection Browser Dial Out Test Sequence 1 Select Communicate Modem Setup and verify that a phone number exists in one of the four dial out slots If no phone numbers exist select Modify No 1 add Phone amp Submit If you wish to test Page out check Pager before Submit Entering your cell phone and selecting Pager is a simple test that verifies the site telephone service 2 If you selected Pager you now have the option to change the pager message max 4 numbers and modify the Pager Delay max 250 seconds Pager delay in seconds occurs after the number has been dialed and before the pager message is sent 3 Start the modem test by selecting Communicate Diagnostic amp set Force Dial Out to YES select one of the four phone numbers then submit 4 Key Refresh frequently if you wish to follow the test sequence If for
20. ally used for pH control reducing acid feed as the Turn OFF setpoint is approached User selects a relay amp selects Time Modulation Special Control User sets Time Period in seconds minimum 60 maximum 600 seconds Relay ON time Control Turn OFF Setpoint Deadband x Period where Deadband Turn ON Turn OFF setpoints Relay ON 100 of Period when Control is greater than Turn ON setpoint Relay is OFF when Control is less than Turn OFF setpoint Acid Pumps Turn ON 10 and Turn OFF 8 Period 120 seconds At pH gt 10 Pump ON for 120 seconds in every 120 seconds At pH 9 5 Pump ON for 90 seconds in every 120 seconds At pH 9 0 Pump ON for 60 seconds in every 60 seconds At pH 8 5 Pump ON for 30 seconds in every 120 seconds At pH lt 8 0 Pump OFF Time Modulation control is not applicable when the system response time is faster than 5x the Period In the previous Example If the measured pH moves from 10 to 8 in less than 300 seconds Time Modulation may not improve control Process buffering pump setting feed point and system volume all affect the response to chemical feed Time modulation also works on Falling Setpoints 2 7 7 Timed Cycling Application Large volume systems where the response to a chemical feed or control action Setup Operation Example Notes Revised 04 29 09 M714 _Tech doc is delayed in time Swimming pool pH conductivity and ORP controls are typical applications
21. driver technical manual Driver_Cl CR Driver Corrosion Rate driver technical manual Driver_CR CT Driver Conductivity Temperature driver technical Driver_CT manual IO Driver Current Output driver technical manual Driver_lO OP Driver ORP pH driver technical manual Driver_OP Revised 04 29 09 M714 _Tech doc 35
22. ed any A digital input O to Z A Contact Head Water Meters Red am Ba ae i Ha A A faces SOODDSOOVDS jt Bi ERA PR A Flowswitches a o Kh PEA ee Turbine Water TF ee ee ee eee Meters IKIE Connect cabling shields at the controller ends of the cable only to any ground terminal either on the M7 or M14 module or on the aluminum backplate bottom center Revised 04 29 09 11 M714_Tech doc Technical Manual 2 Control Configuration 2 1 Methods 2 1 1 ON OFF RELAYS Relay Outputs 1 10 without a control equation are OFF unless turned ON by a timed event priming bleed and feed bleed then feed percentage time or pre bleed Sensor Control ON OFF setpoint control by sensors A N Control equations combine up to four sensor A N Modified by 2 5 Control Method Volume Control Measure setpoint Volume then turn ON for setpoint Seconds Measure setpoint Volume O then turn ON for setpoint Volume P Control equations combine up to four meters O Z Status Control Turn ON setpoint seconds after contact set closes Timed Controls Biocide Timing turn ON for user set period at user set Day amp Time Prebleed and Lockout on each Biocide timed event Bleed amp Feed and Bleed then Feed based on bleed ON time Percentage ON time in every 5 minutes Detailed in 2 6 Special Controls 2 1 2 PROPORTIONAL 4 20 mA OUTPUTS 4 20mA Outputs C1 C8 without a control equation in AUTO mode are 4mA Sen
23. eed 40 Inhibitor Pump would be ON for 120 seconds in every 300 seconds of Bleed ON time Bleed amp Feed use is limited to sites where the bleed OR the inhibitor pump is undersized and there not enough time between bleed periods to pump inhibitor Bleed then Feed is the preferred inhibitor feed method for sites which do not have a make up water meter Sites which have wide variation in make up conductivity typically will have problems maintaining the target inhibitor level using Bleed amp Feed Poor location of feed point and bleed take off may result in inhibitor being pumped down the drain Bleed setpoint dead band should be set to 1 for short bleed and short feed periods 2 6 2 Bleed then Feed Application Pumps cooling tower inhibitor proportional to tower load after the bleed solenoid Setup Operation Notes Revised 04 29 09 M714 _Tech doc turns OFF The longer the bleed solenoid is ON the more inhibitor is pumped User selects Inhibitor Pump relay amp selects Bleed then Feed Special Control User sets bleed solenoid relay number User sets of bleed time 1 100 Inhibitor Pump turns ON after Bleed Solenoid Relay turns OFF Turns OFF when of Bleed ON time is exceeded If of Bleed 60 and Bleed was ON for 8 6 minutes the Inhibitor Pump would pump for 310 seconds 0 6 x 8 6 x 60 sec minute Bleed then Feed is the preferred inhibitor feed method for sites that do not have a make up water meter Do no
24. ers U to Enabled RUN light SO SDDSSPODVE SO QDDSDDSO PR10 Power Relay Relay ON Digital Inputs Module neons O to T On Relay ON E neons Line Fuse Relays 1 5 e s Vr DSIDA FIPS FOSA VSoo DDVEO QDOS SODY Field Wirin Alarm Field Wiring 120 240VAC Relays ee Field Wiring Contacts Field Wiring Relays 4 5 Power In Relays 9 10 Relays 1 3 Revised 04 29 09 4 M714_Tech doc Technical Manual 120 VAC Controllers Plug Box es Controllers with pump controls are supplied one or more prewired120VAC plug boxes Wired as shown in the following graphic Individual plugs are labeled with the pump type Inhibitor Acid Pump Oxidant Bleed etc PlugBox No 1 gt gt T2 pees cB Brom O Relay 1 Relay 3 D a D CBS Z Green1 Green1 A J PlugBox No 2 White2 White2 EEN SON SON VON VON G p shejoy pe Pa Sooo Power Cord gt g Relay 5 ai 522 Relay 6 120VAC oF Service G L asn4 N 1 dul 9y DOSY Z Pi 9 lt G 2 Lan 3 GreenP GreenL mee ne A Green1 EE So a 3 58 Aluminum j Backplate e PlugBox No 3 a Sesopo 8 9 SAej y 80N 89N ZON Z N 9ON L Ps o 2 Yellow3 Oo io 1 _ jeajneN Relay 8 Relay 10 Revised 04 29 09 5 M714_Tech doc Technical Manual AC Power Wiring Connect AC power ground to the aluminum backplate grounding scre
25. g Time control User selects relay amp selects Holding Time Special Control User sets averaging Period in minutes Minimum 30 and maximum 1440 minutes Holding Time controls use the controller data logs limiting the control equation to a single analog sensor A N Controller retrieves the controlling sensor data log average entries for the most recent Period It averages the sensor value over the number of log entries and use the average for setpoint control If the number of log entries x log rate is less than Period the controller uses all of the available log entries If there are no log entries the controller uses the current value of the sensor for control The number of samples used for control is the Period Log Rate Log entries are an average over the Log Period You may choose to reduce the Log Period to increase response to transients or increase the Log Period to limit transient response The same effect may be achieved by altering the Holding Time Period 21 Technical Manual 2 7 Timed Events Operation Number of Events Start Time ON Time Prebleed Lockout Event Cycles Event Frequency Revised 04 29 09 M714 _Tech doc Timed events load Time Owed with ON Time when they are scheduled Timed events always start on the minute If a timed event is prevented from turning ON a relay it will turn ON when the block clears or the flowswitch closes Time Owed is loaded after Prebleed if
26. ly configurable as water meters or dry contacts Three dual and one single analog input sockets M14 12 Digital inputs individually configurable as water meters or dry contacts Seven dual analog input sockets V 90 56K Data Fax Modem with 12VAC power cube Modem Optional Controller to Modem serial flat cable DB9 to polarized IDC 10 socket Revised 04 29 09 29 M714 _Tech doc Technical Manual 4 2 Installing Sensor amp 4 20mA Drivers There are 6 types of optional driver cards Four of the six types are provided as either a single or dual I O card Driver Cards Services B Boiler Condensate Single or dual boiler condensate sensor driver Single amp Dual Each sensor may be set to boiler or condensate M7 Max 7 sensors M14 Max 14 sensors Cl Current Input Loop powered 4 20mA input thermally fused polarity protected Dual Loop active LEDs at more than 3 5mA M7 Max 7 inputs M14 Max 14 inputs CR Corrosion Rate Single or dual sensor Support for steel copper admiralty and zinc Single amp Dual or dual metals on dual CR drivers M7 Max 7 sensors M14 Max 14 sensors CT Conductivity Sensor driver for single conductivity temperature sensor Temperature Conductivity and temperature logged alarmed amp available for control Two ranges lt 100uS amp gt 100uS M7 Max 3 sensors M14 Max 7 sensors 10 4 20mA Output DC isolated loop or controller powered Single
27. n Setup Operation Example Revised 04 29 09 M714 _Tech doc Prebleed lowers the tower conductivity before a biocide is fed to prevent bleeding and subsequent biocide loss or dilution during biocide kill time Lockout prevents the bleed from operating during the biocide kill time Prebleed and Lockout execute on every timed event User selects Biocide pump relay amp selects Prebleed Lockout Special Control User sets Bleed Relay number This is the relay that will be Prebled and then Locked Out every time a Biocide Event occurs on the Biocide pump relay User sets Lock out time in minutes Zero minutes no lockout User sets Prebleed time in minutes Zero minutes no prebleed User sets prebleed conductivity OR none if Prebleed is to be based on time only User sets prebleed conductivity value Prebleed time starts when the timed event is scheduled on the Biocide relay Prebleed ends when the target conductivity is achieved or when the prebleed time completes Biocide turns ON for the user set time Lockout starts at the start of the Biocide timed event Biocide Event on relay No 4 starts at 07 00 for 30 minutes Prebleed Relay No 2 is set for 30 minutes amp 750uS on Conductivity Sensor E Lockout time is set for 120 minutes At 07 00 Relay No 2 turns ON and the tower conductivity start to decrease At 07 20 the Tower Conductivity is 749uS At 07 20 Relay No 2 Bleed turns OFF and is Locked Out until 09 20 At 07 20
28. or pulses unit volume Counts pulse on falling edge 400Hz max Ignores rising edge Revised 04 29 09 M714 _Tech doc 26 Technical Manual Contact Sets Flowswitches Fail to Sample Sensors O Z Switching from Water Meter to Contact Set clears log Type Setup Notes Contact Set User selects Contact Set Contact sets are ON when closed and OFF when open ON time is logged Contact sets used for interlocking prevent relays from turning ON when contact set is OFF or open 3 2 Calibration 3 2 1 Single Point Calibration All inputs A Z with the exception of 4 20mA type CI inputs are single point calibrations Calibration of contact set inputs is blocked SENSORS A N Conductivity Calculated Sensor GAIN is adjusted so that the sensor value matches the user s calibration value Temperature pH ORP Corrosion Rate Sensor OFFSET is adjusted so the sensor value matches the user s calibration value Inventory Manual Sensor OFFSET is set so the sensor value matches the user s calibration value Since the GAIN on these inputs is zero the OFFSET is the input value for control and logging WATER METERS The user calibration value is Volume contact for contact head meters and kK factor Pulses per unit volume for turbine and paddlewheel meters During calibration users have the option to Reset to Factory refer to Section 3 2 3 for Factory GAIN amp OFFSET values
29. quires Admin password Parameter Function Default Access Site Name Location Name maximum 17 characters Browser Site Location System Name maximum 17 characters Browser This Sunday Day1 YES 28 Day Cycle biocide cycle reset day 1 to NO Browser the most recent Sunday Metric Units YES NO Browser amp Driver temperature inputs immediately Celsius Keypad FV calculations immediately in Liters 4 20mA inputs which measure temperature are unaffected Temperature compensation factors for conductivity unmodified Corrected if compensation set to none then reset to Thermal On Reset amp New Type water meters default to Liters Keypad Passwords YES Keypad users prompted for userid NO Browser amp whenever modifying controller parameters Keypad Alarm Opens YES Alarm contacts default to closed in the YES Browser amp Contacts non alarm state Alarm loss of power or cable Keypad break opens alarm contacts Load Configuration YES Shuts controller down and loads the most NO Browser amp recent Save Configuration on restart Keypad Factory Default is loaded if user has never executed Save Configuration Save Configuration YES Shuts controller down Takes about 5 NO Browser amp minutes to write controller configuration to Keypad FLASH memory then restarts controller System restart Shuts controller down amp restarts NO Browser Checks for new amp removed driver cards Revised 0
30. response to make up and tower conductivity levels Users are able to view but not modify ON amp OFF Setpoints A 1 deadband applies to both Cycles and Maximum Conductivity setpoints A ratio control equation is required in the form of E F where E Tower Basin conductivity and F Makeup Conductivity If the control equation is not a ratio the Special Control state will be set to OFFLINE Any ratio of analog sensors A N may be used in a Varying Cycles control When setting Varying Cycles setpoints calculate the time delay effect of system holding time on bulk system chemistry A change in makeup conductivity may take considerable time to modify the bulk chemistry of a cooling tower particularly at low load 23 Technical Manual 2 9 Feed Verification Controller Option Field upgrade available Services Application Setup Operation Notes Revised 04 29 09 M714 _Tech doc Calculates and logs inhibitor ppm based on make up volume cycles of concentration and volume of inhibitor fed Alarms on fail to feed inhibitor Calculates tank level eliminates tank level sensing Requires a feed meter on the output of the inhibitor feed pump Measures the make up volume and feeds inhibitor based on user set control mode Meters the volume of inhibitor fed and calculates current ppm based on fixed cycles meter cycles or bleed cycles on concentration Reduces the inhibitor inventory by the volume of inhibitor fed
31. rly 7 Day Cycle Once Alternate Days Daily 28 Day Cycle Once Alternate Weeks Weekly 22 Technical Manual 2 8 Variable Cycles Problem Solutions Setup Operation Notes Revised 04 29 09 M714 _Tech doc Tower make up conductivity may change rapidly If hardness tracks make up conductivity then controlling a cooling tower on tower basin conductivity may over cycle at low make up conductivities and under cycle at high make up conductivities Overcycling may exceed water treatment chemistry for scale control Undercycling wastes water amp increases sewerage charges Variable Cycles sets three ranges of cycles of concentration bleed control with ranging switched on make up conductivity Variable Cycles also sets a maximum tower basin conductivity that overrides the cycle controls at high tower conductivities User selects relay Configure and sets the Variable Cycles User selects relay Variable Cycles and sets Low Range Makeup conductivity less than Low Range Low Cycles Controls the bleed at Low Cycles Med Range Makeup conductivity between Low amp Medium Range Med Cycles Controls the bleed at Medium Cycles High Range Makeup conductivity between High and Medium Range High Cycles Controls the bleed at High Cycles Max Conduct Tower Conductivity greater than Max Conduct controls the bleed on tower basin conductivity The controller overrides the Setpoint controls modifying the setpoints in
32. sor Control Analog sensor A N using the sensor value to control current level Relay Control Relay 1 10 using the value of the relay control equation to control current level Auto Manual Switch between user set Manual output and automatic control by Sensor or Relay value 2 1 3 USEABLE NON EXISTANT I O Analog and Digital inputs and Relays that do not physically exist can be used for logging and control or as placeholders for blocking or as 4 20mA controls Examples Input M in an M7 controller is used to log the results of a manual inhibitor ppm test Relay 8 in a PR5 controller is controlled by a C D temperature difference and the difference is used to control a 4 20mA output Water V in an M7 controller is used to log the volume measured as GPM on analog input E Input E compensation is set to Rate to Volume targeting input V The resulting volume on V is used to control relay 1 Inhibitor pump feed Revised 04 29 09 12 M714 _Tech doc Technical Manual 2 2 Control Equations There are three types of sensors used for control Analog Sensors A N Watermeters O Z and Contact Sets O Z Sensor types cannot be combined in a Control Equation The first Input letter of the Control Equation is used to provide the Output units and resolution grouping within the Browser view and LCD Display sequencing The controller blocks illegal control equations Control equations are
33. t use Bleed then Feed at sites where the bleed or inhibitor feed pump is undersized There will not be enough time between bleed periods to feed inhibitor Sites which have wide variation in make up conductivity typically will have problems maintaining the target inhibitor level using Bleed then Feed Bleed setpoint dead band should be set to 1 for short bleed then feed periods Technical Manual 2 6 3 Percentage Time Application Setup Operation Notes Base feeds chemicals by cycling a relay ON OFF every 5 minutes Reliable method of control for static systems or where users manually adjust feed rates in response to on site testing or process changes NOTE Particularly useful where a contact set or flowswitch opens when the system is offline Time controls do NOT accumulate time when the interlock is OFF User selects relay amp selects the Percentage Time Special Control User sets of ON Time 1 100 Every 5 minutes 300 seconds the relay will turn ON for the user set If ON time 24 relay would be ON for 72 seconds in every 300 seconds If the interlocking contact set opens the relay will turn OFF and Time is suspended in it s current state resuming when the contact set closes Commonly used method to feed boiler chemicals where a contact set closes when the boiler is on line Typically boiler chemistry is verified by the operator adjusting time as required 2 6 4 Prebleed Lockout Applicatio
34. ully the implications of the control setpoints interlocks 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 INDIVIDUAL CONTROLLERS Controllers are supplied in many different configurations The HELP section in the M714_User manual contains the information for terminating the sensors supplied with each controller The HELP section in the M714 User manual depicts the installation plumbing header showing the sensor set supplied with each controller Revised 04 29 09 3 M714_Tech doc Technical Manual 1 Installation Commissioning 1 1 Cabling Wiring Controllers consist two circuit boards an upper sensor module and a lower power module The top circuit board is either an M7 7 Analog I O amp 6 digital Input or an M14 14 Analog input amp 12 digital input module Both M7 amp M14 include a LCD display and microcontroller module The lower circuit board is either a PR5 5 Power Relay or PR10 10 Power Relay module Both PR5 amp PR10 include an alarm relay Controller Orientation M14 Ana og Digital Modem 7 Dual i Analog I O Serial Cable Sockets LCD Display i Contrast Ethernet 15 22 VDC LAN LAN RJ45 Jack Supply for Link amp Active Current Loops i p cs amp Turbine un Digital T Relays Met
35. using TCP IP 10 base T Site IT provides LAN IP addresses and they may also wish to modify the ports used for HTML default 80 and Telnet default 23 They may also require the controller MAC Key ENTER System and DOWN to LAN Setup to view amp modify IP Netmask amp Gateway MAC HTML amp Telnet ports are view only Ports can be modified using a browser connection Networked Controller connected to site LAN Controller Firewall e e00999 20 RJ45 Cable Internet Local 10 100 Hub or TCP IP Access Point RJ45 network connector located top center of M7 or M14 module Notebook on site LAN CAUTION Exercise caution in making the controller Internet accessible At a minimum modify the factory default passwords for Admin and Users 1 7 before making a controller Internet accessible Revised 04 29 09 8 M714_Tech doc Technical Manual 1 3 Modem Communications 1 3 1 Installation Terminate the site telephone service in an RJ11 jack and plug it into the LINE modem jack Modem Serial Cable Back of Modem Cabling M7 Analog Digital I O Module QDDSDODVE Control PR5 Power Relay Ei amp Mod oaem 5 Module 6 Q Q Neutral Va NY SDE PSSOODDVO SSD SSoo Modem power cube WHITE to neutral f BLACK to Modem AC Power AC Power Modem a y Status LEDS Revised 04 29 09 9 M714_Tech doc Technic
36. verified on power up and Load from Flash Illegal control equations are removed Sensors used in control equations cannot be disabled Analog Sensors A N Operators Sum Difference Division Multiply Control Equation limited to four Inputs and three Operators The first letter of a control equation must be a letter A N All sensors used in a control equation must be enabled The relay ON OFF state on setpoints is controlled by 2 5 Control Method Examples E F A B C D G N Watermeter Sensors O Z Operators Sum Difference Sequence Sum amp Difference control equations limited to four meters The first letter of a control equation must be a letter water meter O Z All water meters used in a control equation must be enabled Volume ON Time Example Measure Water Meter Volume 200 Then Turn ON for 15 seconds Turn ON times accumulate amp are displayed as Time Owed Sequence Example O P measures a volume on O and the turns ON until the turn OFF volume is measured on P Sequence can be used for Water Meter Cycle Control and for volumetric chemical feeds Measure 100 Gallons Feed 10mL Contact Sets O Z Limited to one letter O Z Turn ON setpoint seconds after the contact set closes Turn OFF setpoint ignored Example Control equation T Turn ON setpoint 30 Relay turns ON 30 seconds after contact set T displays ON and stays ON until contact set T displays OFF Revised 04 29 09 1
37. ws located center bottom Relay Neutral terminal blocks are commoned to the AC power input terminal N When a relay is ON the NO terminal is at AC input L voltage and the neon light is ON When a relay is OFF the NC terminal is at AC input L voltage and the NO terminal is disconnected Analog Sensor Wiring Each analog sensor Conductivity pH ORP Corrosion Rate is identified by a letter A N Assigning a fixed letter to each sensor allows the user to modify the sensor name while maintaining the physical location of the sensor driver and field wiring terminals The user manual HELP section includes wiring information specific to the controller part number M7 Module Sensor Locations Sensor G Sensor E Sensor F Sensor B Sensor A Sensor D Sensor C QDOSDDVSA GOD M14 Module Sensor Locations Sensor E Sensor F Sensor G Sensor H Sensor M Sensor N Sensor K Sensor L Sensor B Sensor A Sensor D Sensor C Sensor J QO SD OSDDVE OD SDPSDODVE Revised 04 29 09 6 M714_Tech doc Analog Sensor Wiring Technical Manual Sensor Type Driver Sensor 1 Sensor 2 Type wiring Wiring Conductivity amp Temperature CT Red to S No sensor 2 Black to S White to T Green to T Boiler Condensate B Black to S1 Black to S2 Conductivity White to S1 White to S2 Not polarized Not polarized PH ORP OP Coax Center to 1 Coax Center to 2 Shield to 1 Shield to 2 Solution ground Solution ground L a
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