R&D Series Rotrol 1 E
Contents
1. PRE TREAT LOCKOUT o BLACK 5 WHITE COMMON i INLET SOLENOID LOW INLET PRESS 9 COMMON HIGH TANK LEVEL o COMMON LOW TANK LEVEL COMMON HIGH PUMP PRESS COMMON lt a 2 CABLE MEMBRANE FLUSH SIGNAL INPUTS 21 0 5 RELAY OUTPUTS ROTROL MODEL POWER REQUIREMENTS R amp D SPECIALTIES 7120 50 60 HZ 8 2 4 VA ODESSA TEXAS USA 240 50 60 HZ 2 4 Figure 2 Pump Motor Wiring The reverse osmosis and auxiliary pump motors are controlled by outputs of terminal strip P2 P2 7 amp P2 8 connect to a set of normally open contacts close to start pump of the RO Pump relay P2 5 amp P2 6 connect to a set of normally open contacts of the AUX Pump relay These outputs are isolated relay contacts and supply no power They must be wired in series with the hot lead feeding power to the respective motor in order to control the motor s operation By providing isolated relay contacts for control the customer has the flexibility of selecting motors with the same or different voltage ratings in any voltage combination No m2. 13 a unit is purchased which is calibrated for 0 250 uS conductivity the setpoint can only be set to readings within that range f the LCD is reading correctly and within he factory calibrated range of the unit nd if the setpoint cannot be adjusted to how the correct color R amp D Specialties hould be consulted for assistance Q9 Shutdown not working 14 pon the application of power to the unit r after pressing RESET a time delay is nitiated approx 5 min which prevents he unit from shutting down even though the ED may be red setpoint exceeded Also upon special order the shutdown feature may be disabled at the factory If your unit is equipped with the shutdown feature the LED shows red and more than 5 minutes have elapsed since power on or manual reset the unit may be malfunctioning Consult R amp D Specialties for assistance
3. CONTACTS ISOLATED DRY CONTACTS NO CONTACTS 00 NOT SUPPLY POWER 1 SOLENOID VALVE ROTROL MODEL moror SAMPLE WIRING DIAGRAM 240 MOTORS 4 120 VAC SOLENOIDS 1 HP N H Figure 48 8 SYSTEM OPERATION When power is initially applied the RO and AUX start delays are initiated and the green lamp above the power switch will light indicating that power is present When the delays time out the RO and AUX control relays will energize if the switches for the relays are on The green indicator lamps will light when their corresponding relays are energized Alarm Conditions All switch inputs are constantly monitored by the ROTrol I If a switch input becomes active a time delay is initiated to prevent false shutdown of the RO or AUX pumps If the pre treat lockout option is installed the unit will shut down if the signal is active and will stay down until the condition clears When the low feed pressure or high pump pressure inputs become active the time delay is started and the red lamp for that input will light If the input remains active until the delay times out the RO pump will be shut down The beeper will sound to alert the system operator that the system has been shutdown by an alarm condition The operator can reset the system by pressing the reset switch on the door of the ROTrol I If the alarm condition is clear the RO
4. end of the fuse to determine if it is blown Replace it if necessary Voltage on only one end of the fuse would indicate that it is blown On Off switch or wiring If voltage is present at Pl 1 and 1 2 but not present between 1 1 and either end of the fuse visually inspect the 2 white wires connected to 1 3 amp P1 4 and ensure that they are tight in the terminal strip and securely soldered to the faceplate circuit board Correct any problem found If voltage is present at all points tested the ROTrol may be defective and R amp D Specialties should be consulted for assistance Tank or Pressure LED on External wiring switch problem will not clear by RESET The RO pump never starts Disconnect the two wires bringing the signal into reference figure 2 or 4 If the LED goes out either the monitored condition actually exists the switch is bad or out of adjustment the switch contact configuration is incorrect N O contact is required by the ROTrol I ora wiring problem exists Isolate and correct the problem Operational check 11 Ensure that Tank Full or Pressure LEDs are on Either will cause the circuit to shut down the RO pump Ensure that the RO pump switch is on Allow time for the start delay to time out and if the RO Pump lamplights after the delay proceed to the next test If the LED never lights the ROTrol I may be defect
5. for the membrane flush time TDS Conductivity If the optional TDS Conductivity package is installed it may be installed with or without an LCD readout to display actual TDS or Conductivity Except for the LCD both versions operate in the same fashion and require R amp D Specialties Model TDS 1 sensor to be installed in the unit piping and wired into terminal strip P5 When the RO Unit is running the circuitry will continuously monitor the sensor Signals to determin th quality of the monitored water Permeate This circuitry compares the sensor reading to a setpoint potentiometer setting and wi generate an alarm signal which will sound the audible alarm light the TDS Conductivity lamp red on the ROTROL I front panel and shut down the RO Pump Following a high TDS shutdown the unit may be restarted by pressing the reset switch on the front panel When the reset switch is pressed the unit will restart the RO Pump and initiate a start up delay to prevent the unit from shutting down on high conductivity TDS for 5 minutes After the 5 minute time out the circuitry will shut down the unit if the water quality is still poor TDS setpoint is exceeded If the water quality has improved the unit will continue to run The TDS setpoint potentiometer may be set for any value within the calibrated range of the unit normally 250 TDS or 250 uS conductivity The pote
6. pump motors up to 1 HP Motors larger than 1 HP can e controlled when the ROtrol SPECIFICATIONS POWER 120 240VAC 22F 0 955 RH ENCLOSURE 8 x 6 Lr INPUTS 50 60Hz ENVIRONMENT 300 140 4 NI Low pressure switch High pressu Tank full switch Tank low switch Pre treat lockout OPTIONAL re switch 6 Watts 60C ndensing closed TDS Conductivity Sensor ELAY OUTPUTS RO pump control AUX pump control Flush control Independent Inlet Solenoid control OPTIONAL max max 5A 120VAC Pump contro commercial and nhanc industrial reverse osmosis quipment nd provides time delays to 1 relays are provided to operate I is used in conjunction with an additional motor when motor overload blocks Convenient front panel indicators show the status of the ROtrol I Switches on the front panel are provided to allow easy control of the Auxiliary control relay and the ROtrol I power EMA 4X Standard Larger enclosures are provided starter contactors and fuse blocks are supplied on low pressure closed on lockout 120 240VAC 120 240VAC 2 5A 240VAC 5A 120 VAC closed on high pressure closed on tank full closed on tank low 2 5A 240VAC CONTROLS AND INDICATORS HI PRESSURE Lamp Lighted when the RO pump is shut down due to high pump pres
7. 05 D SP ECIALTIE ROTROL I ER S MANUAL TABLE OF CONTENTS INTRODUCTIONS 30229 9 33 E eade oq SSSI RA Se ec ud 2 LON Sis ee 499929 ced miae DOR PAS 43832440 d d Ratis 2 CONTROLS AND 333 ag es TP T PS 3 TEME DELAYS a ele stones 3 Buntes mand head d 4 ENS AAT GAT LON 30229 2 903 8 A ck UU ONT LT QR a 5 SYSTEM ge bod 8 59992 RUSO dus Rey eed 9 TROUBDBESHOOBEN G 13 OPT LONAT 333 35h39 4 49 Gies Mas a P 15 1 12 05 95 INTRODUCTION The R amp D Specialties ROtrol I is a microprocessor controller designed to tion of small to medium The ROtrol I contains all of the electronics and controls needed to y and safely control any reverse osmosis e the opera systems e everse Os fficientl barter T b 5 t ontrol system he RO Pump relay I monitors pressure and float switches a revent false system shutdowns mosis and auxiliary
8. be stabilized at room temperature The solution s temperature should be checked with a thermometer to ensure that it has stabilized before proceeding with the calibration When calibrating connect DVM 2 V SCALE to test points 1 and 2 and with the TDS sensor in the test fluid ensure that the numerical reading on the display is within a few digits of the DVM reading If the reading is off more than a few digits adjust Al and or A2 to obtain a 2 300 count reading on the DVM and adjust A3 until the display reading matches the DVM s CAUTION Adjustment of A3 is rarely necessary and should not be attempted unless an accurate DVM is being used Disconnect the DVM and use the ROTROL I s display to complete the calibration Remove the TDS sensor from the test solution and dry with a clean rag or paper towel While the sensor is clean and dry adjust A2 zero adjustment to get a reading of 000 on the ROTROL I s display Do not leave the probe out of the test solution more than a minute or so when making this adjustment Place the sensor back into the test fluid and adjust Al span adjustment to get the correct TDS or Conductivity reading There is some interaction between Al and 2 so it will be necessary to repeat the above zero and span adjustments until no further adjustment is needed as indicated by correct readings when switching the sensor in and out of the solution If the display option
9. e is present on both terminals of P2 check the wiring between the ROTrol I and motor Check for correct wiring of the motor leads also If voltage is measured on only one P4 terminal the ROTrol I assuming no alarms are present may be malfunctioning Consult R amp D Specialties for assistance OPTIONAL FEATURES Inlet Solenoid not operating Operational check Ensure that the RO Pump switch is on and no alarm conditions exist Wiring valve check Using a voltmeter check the voltage between the unswitched power lead feeding the solenoid and P4 1 4 2 If no voltage is present check all wiring If voltage is present on 4 terminals check the voltage on to the solenoid leads directly at the solenoid Correct any wiring problem or replac th solenoid as necessary to correct the problem If voltage is present at only one P4 terminal the RO Pump switch is on and no alarm conditions exist the ROTrol I may be defective Contact R amp D Specialties for assistance Flush Solenoid not operating Operational check The solenoid will only operate when a membrane flush cycle is initiated by the ROTrol I s program Ensure that the cycle should be currently operating before e roceeding with any further testing ontact R amp D Specialties if you are unsure of the correct operation of your program version If you determine that the membrane fl
10. hts If the input remains active until the delay times out the AUX pump will shutdown to prevent the AUX pump from running dry When the tank evel rises and the tank low input clears a second time delay is started When the delay times out the AUX pump is then started This delay allows the water evel in the tank to rise and prevents unnecessary cycling of the AUX pump Status LED The status LED Located slightly above P4 on the main circuit board gives an indication of the current status of the ROTrol I The following list shows the different modes indicated by the status LED Slow Flash Normal system operation Fast Flash RO pump start delay after low or high pressure Double Flash Tank fu input or tank full restart delay active Triple Flash Tank fu overide active OPTIONAL FEATURES Membrane Flush If the optional membrane flush relay is installed a timed membrane flush cycle can be initiated The flush cycle is initiated in one of two ways depending on the type of flush ordered In the first mode the membrane flush cycle is initiated each time the tank full switch time delay times out The unit will then activate the flush relay for the membrane flush time In the second mode the membrane flush cycle is initiated after either X hours of time or Y hours of RO pump operation The flush relay will then be activated
11. ive Consult R amp D Specialties for assistance AUX pump will not operate Wiring motor test Using voltmeter check the voltage between the power lead feeding the motor directly and the switched power lead routed through amp P2 8 The correct voltage should be measured between the unswitched lead and both 2 7 amp P2 8 If no voltage is detected check all wiring and connections all the way back to the source disconnect breaker etc If the correct voltage is present on both terminals of P2 check the wiring between the ROTrol I and motor Check for correct wiring of the motor leads also If voltage is measured on only one P4 terminal the ROTrol I assuming no alarms are present may be malfunctioning Consult R amp D Specialties for assistance Operational check Ensure that the Tank Low LED is off and the AUX pump switch is on If the AUX LED lights proceed to the next test If the LED never lights consult R amp D Specialties for assistance Wiring motor test 12 Using voltmeter check the voltage between the power lead feeding the motor directly and the switched power lead routed through P2 5 amp P2 6 The Correct voltage should b measured between th unswitched lead and both P2 5 amp P2 6 If no voltage is detected check all wiring and connections all the way back to the source disconnect breaker etc If the correct voltag
12. k Full Switch Delay Tank Low Switch Delay RO Pump Power On Delay RO Pump Tank Full Restart Delay AUX Pump Tank Low Restart Delay High Low Pressure Automatic Reset Optional Time Delays Membrane Flush RO Flush Interval RO RO Flush Interval RO Pump Delay High TDS Lockout Delay apsed Time seco seco seco seco seco minu minu minu nds nds nds nds nds tes tes Ces minutes hours hours seconds minutes INSTALLATION Physical Installation Mount the ROTrol I in a convenient location on the RO equipment using the four mounting lugs and screws supplied with the enclosure or the optional Panel mounting bracket Power Wiring The 120 240VAC power for the control electronics must be connected to terminal strip Pl The neutral wire connects to 1 1 the hot wire connects to 1 2 the ground wire can be connected to one of the back panel mounting bolts Ensure that the 120 240 jumper setting matches the selected voltage The power as well as all other terminal strips and their signals are shown in Figure 2 INLET SOL RELAY
13. ntiometer 9 Scale corresponds to the of the full scale value The TDS Conductivity circuit is shown in figure 5 TDS CALIBRATION The ROTROL I is calibrated at the factory and normally should not require field calibration If however it is necessary to re calibrate the unit an accurate Digital Voltmeter an accurate thermometer a small screwdriver and a calibrated sample of fluid wi be required to calibrate the unit MA N USA R amp D SPECIALTIES 1898 RO1EFP REV START UP DELAY JUMP FOR 5 MIN s J1 m 2 0000000000000006000 d au e 105 SHUTDOWN NO TDS COND SHUTDOWN TEST POINT 1 0000000000000000000H TOS CONDUCTIVITY SETPOINT ADJUST X SPAN TEST POINT 2 AZ ZERO ADJ Figure 5 calibrate the unit the TDS 1 sensor must be connected to the unit and the unit must be powered up for at least 15 minutes before calibration is attempted Also if possible the ambient room temperature should be approximately 75 deg F the probe should be submersed in the test solution to stabilize the temperature sensor and the temperature of the sample should
14. ond time delay before starting the RO Pump Terminals P2 1 and P2 2 connect to the normally open contacts of this relay which should be wired in series with the hot lead feeding power to the solenoid 240 VAC max DS Conductivity Sensor The TDS Conductivity Sensor cable connects to Terminal Strip P5 as follows 1 1 P5 4 White wire 5 2 Black wire 5 5 Shield bare wire P553 Green wire Wiring Samples Sample hookups for 115 VAC operation are shown in Figures 3 amp 4 and other voltage combinations are shown in Figures 4A amp 4B ROTROL MODEL 10 8 We ROTROL MODEL SAMPLE WIRING DIAGRAM 120 VAC MOTORS amp SOLENOIDS LEGEND WIRE e WIRE CONNECTION 7 NO CONNECTION LEVEL SWITCH N O CONTACTS 9 SOLENOID VALVE MOTOR Figure 4A 5 e amo SIGNAL INPUTS 2 1 M CONTACTS ISOLATED DRY CONTACTS DO NOT SUPPLY POWER 240 VAC POWER IN ROTROL MODEL RO1D SAMPLE WIRING DIAGRAM 240 VAC MOTORS amp SOLENOIDS x4 AP MAX 8A oz ro C umo Ls amo ao amo HIGH PUMP PRESS LOW TANK LEVEL LEGEND WIRE WIRE CONNECTION 2 CONNECTION SIGNAL INPUTS TES
15. otor rating should exceed 240 VAC or 1 HP unless a motor starter contactor is used Input Signal Wiring The pre treat lockout pressure and tank level switches are connected to All switches should have normally open switch contacts that close to generate th active signal The connections are not polarity sensitive and the two leads can be connected to their corresponding terminals in either direction The low feed pressure switch connects to P4 pins 3 and 4 The high pump pressure switch connects to P4 pins 9 and 10 The tank full switch connects to P4 pins 5 and 6 the tank low switch connects to pins 7 and 8 and terminals 1 and 2 of are connected to the Pre treat Lockout contacts if the optional feature is present Membrane Flush Relay As an option a relay to control membrane flush can be provided This relay has a normally open contact that closes to provide membrane flush The relay can be connected to whatever voltage is required to operate the flush solenoid up to the ROTrol I s 240 VAC maximum rating The connections for membrane flush are P2 pins 3 and 4 and they should be connected in series with the hot lead feeding power to the solenoid Inlet Solenoid Relay An additional relay is offered as an optional feature which is utilized to control th Inlet Solenoid independent of the RO Pump This relay operates immediately when the ROtrol I power switch is turned on and initiates a 5 sec
16. pump will restart When the RO system shuts down due to a pressure alarm an automatic reset timer is started If the reset button is not pressed before this timer times out the ROTrol I will reset itself and if the alarm condition is clear the RO pump will restart If the alarm condition is still active the RO system will stay shutdown and the ROTrol I will continue to periodically reset until the alarm is cleared If the low pressure switch is located downstream of the inlet solenoid the low pressure lamp wil ight when the unit is shut down for any reason if the inlet solenoid is closed When the unit is restarted the inlet solenoid will open the low pressure condition will clear and the unit will start up normally When the tank full input becomes active a time delay is started and the yellow tank full lamp will light If the input remains active until the delay times out the RO pump will shutdown to prevent overflow of the storage tank When the tank level drops and the tank full input clears a second time delay is started When this delay times out the RO pump is then restarted This delay allows the level in the tank to drop and prevents unnecessary cycling of the RO pump When the RO unit is shut down due to a tank full condition pressing the reset switch starts a 5 minute tank full override When the tank low input becomes active a time delay is started and the yellow tank low lamp lig
17. sure LO PRESSURE Lamp Lighted when the RO pump 15 shut down due to low feed pressure TANK FULL Lamp Lighted when the RO pump is shut down due to storage tank full TANK LOW Lamp Lighted when the AUX pump is shut down due to storage tank low Membrane Flush Lamp Lighted when the mem bran flush control relay is energized LOW PRESS Water Quality Lamp Lighted green acceptable water quality lighted red when th TDS exceeds the allowable 4 high limit QUALITY TDS Conductivity Display Displays the actual TDS or Conductivity selectable reading POWER Lamp Lighted when the power switch is on POWER Switch Controls the ROTROL I power to the ROTrol electronics Gl RO PUMP Lamp Lighted when 1 the RO pump control relay is energized RO PUMP RO PUMP Switch Enables the pump control relay AUX Lamp Lighted when the ear TO 4 2 2 auxiliary pump control relay is energized 2 R amp D SPECIALTIES ODESSA TEXAS AUX Switch Enables the auxiliary pump control Figure 1 relay RESET Switch Resets the ROTrol I when it is shut down on low feed pressure high pump pressure or high TDS TIME DELAYS Standard Time Del lays Low Pressure Switch Delay High Pressure Switch Delay Tan
18. ush should be occurring check to ensure that the MEMB FLUSH LED is on and no alarms are present If the LED is on and the Solenoid is not operating test for proper power at 4 3 amp 4 4 test the wiring and test the solenoid as explained above for testing the Inlet Solenoid TDS Conductivity problems Operational check Ensure that the TDS 1 sensor is correctly wired to P5 see figure 4 and is submersed in water If you have not done so please read the text 10 to familiarize yourself with the operational aspects of this optional featur befor proceeding with testing LCD reading questionable If you suspect the LCD reading is in error check and tighten all connections to P5 and check the cable for possible damage If no obvious problems are detected it may be necessary to calibrate the unit as explained in the TDS CALIBRATION section of the text page 11 If the unit will not calibrate consult R amp D Specialties for assistance LED not indicating correctly The LED is controlled color by both the LCD reading and the setpoint adjustment see Figure 5 The ROTrol I is normally factory calibrated for one of several standard measurement ranges The setpoint adjustment range is factory set and is not field adjustable Ensure that you operating the unit within the factory calibrated range of your unit Example if
19. was not purchased connect a DVM to test points 1 amp 2 as described above and use the DVM readings to adjust Al and A2 as described above NOTE The unit s readings are compensated for temperature and the readings are corrected to display the conductivity TDS at 75 deg F This is accomplished by algebraically adding a temperature correction value to the uncorrected probe output It is normal to see the display fluctuate slightly if the temperatur fluctuates This is due to the temperature correction circuit attempting to add or subtract a value from the probe signal This fluctuation is more pronounced when the probe is left laying on a table or work bench for long periods of time a t nd the room temperature fluctuates due to air conditioning or heating units urning on and off Fortunately the temperatur sensor responds slowly to emperature changes which allows proper calibration of the unit when the instructions above are followed 10 TROUBLESHOOTING Problem System dead no lights or display Cause No incoming power Blown Using a voltmeter measure the voltage between 1 1 1 2 to ensure that 120 240 vac is present Ensure also that the voltage select jumpers are correctly set see figure 4 Correct any incoming voltage problem as necessary fuse Either visually inspect the fuse or measure the voltage between 1 1 and each
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