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IWAKI WALCHEM Intuition-6 Series, Instruction Manual

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IWAKI WALCHEM Intuition-6 Series Instruction Manual Download Page 20

15

Figure 1

CONVEYORIZED SPRAY EQUIPMENT

W   A   L   C   H   E  M

COPPER

CAUSTIC

FORMAL-

DEHYDE

STABILIZER

POWER

POWER

20 FT

IMMERSIBLE

SENSOR

PLATING BATH

SODIUM

PERSULFATE

CIRCULATING

PUMPS

MANUAL

VALVE

FLOW

THROUGH

SENSOR

METERING PUMPS

TO

WASTE

TREATMENT

"BLEED"

3/8" TUBING

(< 20' PERFERRABLE)

WCU WITH FLOW-THROUGH SENSOR

(TYPICAL MICROETCH APPLICATION)

WCU WITH IMMERSIBLE SENSOR

(TYPICAL ELECTROLESS COPPER APPLICATION)

(80 FT MAX.)

80 FT. MAX.

Summary of Contents for Intuition-6 Series

Page 1: ... Instruction Manual Metal Finishing Controller ...

Page 2: ...24 months for electronics and 12 months for mechanical parts and electrodes from date of delivery from the factory or authorized distributor under normal use and service and otherwise when such equipment is used in accordance with instructions furnished by WALCHEM and for the purposes disclosed in writing at the time of purchase if any WALCHEM s liability under this warranty shall be limited to re...

Page 3: ...l Sensor Sample Loop Installation 11 3 6 Other Sensor Installation 13 3 7 Icon Definitions 18 3 8 Electrical installation 18 4 0 FUNCTION OVERVIEW 34 4 1 Front Panel 34 4 2 Touchscreen 34 4 3 Icons 34 4 4 Startup 36 4 5 Shut Down 38 5 0 OPERATION using the touchscreen 39 5 1 Alarms Menu 47 5 2 Inputs Menu 47 5 2 1 Copper Nickel 50 5 2 2 Contacting Conductivity 51 5 2 3 Electrodeless Conductivity 5...

Page 4: ... 11 Relay Dual Set Point Mode 70 5 3 12 Relay Timer Control Mode 71 5 3 13 Relay Probe Wash Control Mode 73 5 3 14 Relay Spike Control Mode 73 5 3 15 Relay Output Flow Meter Ratio Control Mode 75 5 3 16 Relay Output Flow Proportional Mode 75 5 3 17 Relay Counter Timer Control Mode 76 5 3 18 Relay Dual Switch Control Mode 76 5 3 19 Relay or Analog Output Lag Control Mode 77 5 3 20 Analog Output Ret...

Page 5: ...trode Maintenance 98 8 0 TROUBLESHOOTING 98 8 1 Calibration Failure 99 8 1 1 Copper or Nickel Sensors 99 8 1 2 pH Sensors 99 8 1 3 Contacting Conductivity Sensors 99 8 1 4 Electrodeless Conductivity Sensors 99 8 1 5 ORP Sensors 100 8 1 6 Disinfection Sensors 100 8 1 7 Analog Inputs 100 8 1 8 Temperature Sensors 101 8 2 Alarm Messages 101 8 3 Procedure for Evaluation of Conductivity Electrode 105 8...

Page 6: ...puts may be set to a variety of control modes Plating Control Plating Follow Flow Timer On Off set point control Time Proportional control Pulse Proportional control when purchased with Pulse solid state opto outputs PID control when purchased with Pulse solid state opto outputs Lead Lag control of up to 6 relays Dual set point Timer Feed as a percent of elapsed time Always on unless interlocked P...

Page 7: ...communication with PC based applications HMI SCADA programs Building Energy Management systems Distributed Control Systems DCS as well as stand alone HMI devices Our USB features provide the ability to upgrade the software in the controller to the latest version The Config file feature allows you to save all the set points from a controller onto a USB flash disk and then import them into another c...

Page 8: ...m 0 0001 mS cm 0 01 mS m 0 0001 S m 0 1 ppm Accuracy 1 of Reading or 0 1 µS cm whichever is greater 1 0 Cell Contacting Conductivity Range 0 30 000 µS cm Resolution 1 µS cm 0 001 mS cm 0 1 mS m 0 0001 S m 1 ppm Accuracy 1 of Reading or 1 µS cm whichever is greater 10 0 Cell Contacting Conductivity Range 0 300 000 µS cm Resolution 10 µS cm 0 01 mS cm 1 mS m 0 001 S m 10 ppm Accuracy 1 of Reading or...

Page 9: ...µS cm 0 01 mS cm 0 1 mS m 0 001 S m 1 ppm 1 of reading 3 000 40 000 µS cm 1 µS cm 0 01 mS cm 0 1 mS m 0 001 S m 1 ppm 1 of reading 10 000 150 000 µS cm 10 µS cm 0 1 mS cm 1 mS m 0 01 S m 10 ppm 1 of reading 50 000 500 000 µS cm 10 µS cm 0 1 mS cm 1 mS m 0 01 S m 10 ppm 1 of reading 200 000 2 000 000 µS cm 100 µS cm 0 1 mS cm 1 mS m 0 1 S m 100 ppm 1 of reading Temperature C Range Multiplier Temper...

Page 10: ...ly per channel 1 5 W maximum for each channel 2W 83 mA at 24 VDC total power consumption for all channels four total channels possible if two dual boards are installed 2W is equivalent to 2 Little Dipper sensors Digital Input Signals 6 State Type Digital Inputs Electrical Optically isolated and providing an electrically isolated 9V power with a nominal 2 3mA current when the digital input switch i...

Page 11: ... 61326 1 2013 BS EN 61326 1 2013 For EN 61000 4 3 Radiated RF Immunity the controller meets Performance Criteria B In environments where severe radio frequency interference RFI is present the controller may reboot restart If this occurs the controller should be relocated away from the electromagnetic interference EMI source Class A equipment Equipment suitable for use in establishments other than ...

Page 12: ...end of sensor range Input alarm dead band Low end of sensor range High end of sensor range Cell constant conductivity only 0 01 10 Smoothing Factor 0 90 Temp Comp Factor conductivity linear ATC only 0 20 000 Installation Factor Electrodeless conductivity only 0 5 1 5 Cable length 0 1 3 000 PPM conversion factor only if units PPM 0 001 10 000 Default temperature 20 500 Deadband Low end of sensor ra...

Page 13: ...0 seconds 0 unlimited Min Relay Cycle 0 seconds 300 seconds Set Point Low end of sensor range High end of sensor range Spike Set Point Spike mode Low end of sensor range High end of sensor range Onset Time Spike Mode 0 seconds 23 59 59 HH MM SS On Delay Time Manual On Off Dual Setpoint modes Dual Switch Alarm modes 0 seconds 23 59 59 HH MM SS Off Delay Time Manual On Off Dual Setpoint modes Dual S...

Page 14: ...Flow Prop mode 0 gal hour or l hour 10 000 gal hour or l hour Pump Setting Flow Prop mode 0 100 Specific Gravity Flow Prop mode 0 g ml 9 999 g ml Target Flow Prop mode 0 ppm 1 000 000 ppm Analog 4 20 mA Output Settings Low Limit High Limit 4 mA Value Retransmit mode Low end of sensor range High end of sensor range 20 mA Value Retransmit mode Low end of sensor range High end of sensor range Hand Ou...

Page 15: ...ay at eye level on a vibration free surface utilizing all four mounting holes for maximum stability Do not install the enclosure in a lo cation where it will be exposed to direct sunlight Use M6 1 4 diameter fasteners that are appropriate for the substrate material of the wall The enclosure is NEMA 4X IP66 rated The maximum operating ambient temperature is 131 F 55 C this should be considered if i...

Page 16: ... combination thereof The shut off valve is to quickly isolate the system if necessary A cooling coil or plate is necessary to cool the cop per solution down to a temperature acceptable to a sample pump Cooling the solution is also recommended to help reduce the amount of plate out which may form in the sample loop The pump may be either a stand alone sample pump which typically have temperature re...

Page 17: ...see Application Notes below The solution inlet should draw sample from an area of good solution movement in order to respond quickly to chemical additions However the solution inlet should not draw too near to where the chemistry is added to avoid artificial spikes in concentration The solution discharge should be open to atmospheric pressure in order to ensure proper flow The cable connector to t...

Page 18: ...um required to obtain the desired control band however if the flow rate increases over the recommended rate of 500 mL min approx 0 13 gal min the rate of cooling will de crease This may be compensated for by re evaluating the system criteria length desired control band or to double up on the cooling plate coil Consult factory with any further installation questions 3 6 Other Sensor Installation Re...

Page 19: ...nductive items are consistently positioned Do not install the sensor in the path of any electrical current that may be flowing in the solution as this will shift the conductivity reading The pH ORP ISE electrode should be placed as close to the controller as possible to a maximum distance of 1000 feet 305 m from the controller A junction box and shielded cable are available to extend the standard ...

Page 20: ...T IMMERSIBLE SENSOR PLATING BATH SODIUM PERSULFATE CIRCULATING PUMPS MANUAL VALVE FLOW THROUGH SENSOR METERING PUMPS TO WASTE TREATMENT BLEED 3 8 TUBING 20 PERFERRABLE WCU WITH FLOW THROUGH SENSOR TYPICAL MICROETCH APPLICATION WCU WITH IMMERSIBLE SENSOR TYPICAL ELECTROLESS COPPER APPLICATION 80 FT MAX 80 FT MAX ...

Page 21: ...Back to the bath FLOW THROUGH SENSOR FLOW ADJUSTMENT VALVE DEGASSER pH ADAPTER Sample COOLING COIL Cool H 2 0 in Warm H 2 0 out NICKEL REDUCER OPTIONAL pH REPLENISHER MAX 80 FT 24m Filter Pump Figure 2 WNI with Flow through Sensor and Degasser Typical Electroless Nickel Application ...

Page 22: ...mmended pH ADAPTER pH ELECTRODE FLOW THROUGH SENSOR FLOW ADJUSTMENT VALVE Copper Nickel Bath Rinse COOLING COIL NICKEL REDUCER OPTIONAL pH REPLENISHER MAX 80 FT 24 m Filter Pump Figure 3 WNI with Flow Through Sensor without Degasser Typical Electrodless Nickel Application ...

Page 23: ... between 22 26 AWG Shield should be terminated at the controller at the most convenient shield terminal CAUTION 1 There are live circuits inside the controller even when the power switch on the front panel is in the OFF posi tion The front panel must never be opened before power to the controller is REMOVED If your controller is prewired it is supplied with an 8 foot 18 AWG power cord with USA sty...

Page 24: ...19 Sensors Analog Outputs Ethernet Digital Inputs Power Switch Relays Power Cord Figure 4 Conduit Wiring ...

Page 25: ...ble Power Supply Earth Ground Terminal Block Fuse Neutral Terminal Block Main Power Terminal Block Analog Output Sensor Digital Input Terminal Blocks Power Relay Board Relay Output Terminal Block Dual Analog Output Option I O Slot 2 Sensor Board Figure 5 Parts Identification ...

Page 26: ...HT 5V BLU WHT pH electrode TEMP WHT GRN TEMP GRN WHT IN WHT ORN IN ORN WHT COM WHT BLU VM ORN WHT SHIELD Optional Temperature Compensation 1 2 3 4 5 6 7 8 9 10 11 12 TEMP TEMP IN IN 5V 5V SHIELD COM VM VR 5V 2 5V pH Cu Ni Cu Ni SHIELD USE TB3 12 5V WHT BLU 5V BLU WHT Figure 6 Copper Nickel pH Board Sensor Input Wiring ...

Page 27: ...ORP DIS 1 XMT 2 3 4 5 TEMP TEMP 6 TEMP TEMP 7 8 RCV IN 9 IN 10 5V 5V SHIELD Loop 2 Wire Pwrd 2 Wire 3 Wire 4 Wire 24V 11 12 XMTR XMTR XMTR XMTR XMTR XMTR 24V 24V 24V COM SHIELD or use DI SHIELD TB3 7 12 1 2 3 4 5 6 7 8 9 10 11 12 Conductivity Electrode SHIELD TEMP WHT TEMP GRN RCV BLACK XMT RED GRN WHT RED BLK General Purpose wiring is typical of all three sensor options High Pressure TB1 for Sens...

Page 28: ...MP TEMP 6 TEMP TEMP TEMP 7 8 RCV IN 9 IN 10 5V 11 5V 12 X SHLD SHIELD SHIELD R SHLD ELECTRODELESS CONDUCTIVITY SENSOR TEMP GRN TEMP BLK RCV BLK XMT WHT XMT BLK RCV RED R SHLD SHIELD X SHLD SHIELD SENSOR LABEL TB1 for Sensor 1 or TB2 for optional Sensor 2 Figure 8 Electrodeless Conductivity Sensor Input Wiring ...

Page 29: ...onal Sensor 2 1 2 3 4 5 6 7 8 9 10 11 12 18 CCOND pH ORP DIS 1 XMT 2 3 4 5 TEMP TEMP 6 TEMP TEMP 7 8 RCV IN 9 IN 10 5V 5V SHIELD Loop 2 Wire Pwrd 2 Wire 3 Wire 4 Wire 24V 11 12 XMTR XMTR XMTR XMTR XMTR XMTR 24V 24V 24V COM SHIELD or use DI SHIELD TB3 7 12 1 2 3 4 5 6 7 8 9 10 11 12 TB1 for Sensor 1 or TB2 for optional Sensor 2 pH ORP ISE electrode IN WHT ORN IN ORN WHT 5V BLU WHT 5V WHT BLU TEMP W...

Page 30: ...5 6 7 8 9 10 11 12 18 CCOND pH ORP DIS 1 XMT 2 3 4 5 TEMP TEMP 6 TEMP TEMP 7 8 RCV IN 9 IN 10 5V 5V SHIELD Loop 2 Wire Pwrd 2 Wire 3 Wire 4 Wire 24V 11 12 XMTR XMTR XMTR XMTR XMTR XMTR 24V 24V 24V COM SHIELD or use DI SHIELD TB3 7 12 1 2 3 4 5 6 7 8 9 10 11 12 TB1 for Sensor 1 or TB2 for optional Sensor 2 Disinfection Sensor IN WHT IN GRN 5V RED 5V BLK Disinfection Sensor SHIELD COMBINATION SENSOR...

Page 31: ...re Loop 2 Wire Powered 3 Wire 4 Wire 24V XMTR SHIELD SHIELD SHIELD SHIELD XMTR XMTR COM XMTR XMTR 24V 24V 24V Type of Transmitter XMTR SHIELD XMTR XMTR XMTR XMTR AI 1 2 24V SHIELD XMTR SHIELD 24V XMTR COM SHIELD 24V 24V TB Pin 1 2 3 4 5 6 7 8 9 10 11 12 4 20mA SOURCE SIMULATOR POWERED 4 20mA OUTPUT i e W100 POWERED 2 WIRE TRANSMITTER 3 WIRE TRANSMITTER Jumper wire Shield Jumper wire 24V Power UNPO...

Page 32: ...4V 24V COM SHIELD or use DI SHIELD TB3 7 12 SHIELD 1 8 9 10 11 12 CCOND pH ORP DIS 1 TEMP TEMP 8 9 10 Loop 2 Wire Pwrd 2 Wire 3 Wire 4 Wire 24V 11 12 XMTR XMTR XMTR XMTR XMTR XMTR 24V 24V 24V COM SHIELD or use DI SHIELD TB3 7 12 SHIELD 3 WIRE TRANSMITTER 24V POWER UNPOWERED 1 8 9 10 11 12 CCOND pH ORP DIS 1 TEMP TEMP 8 9 10 Loop 2 Wire Pwrd 2 Wire 3 Wire 4 Wire 24V 11 12 XMTR XMTR XMTR XMTR XMTR X...

Page 33: ...9 9 10 10 10 11 11 11 12 12 12 13 DIG IN 1 13 DIG IN 5 13 DIG IN 2 14 DIG IN 1 14 DIG IN 5 14 DIG IN 2 15 9 VDC 15 9 VDC 15 9 VDC 16 4 20 OUT1 16 DIG IN 6 16 4 20 OUT2 17 4 20 OUT1 17 DIG IN 6 17 4 20 OUT2 18 SHIELD 18 9 VDC 18 SHIELD TB1 TB3 TB2 FLOW SWITCH Contact Closure Polarity not critical Reed Switch FLOW METER Polarity not Critical Hall Effect FLOW METER SIGNAL IN POWER 9V TB 3 SHOWN Figur...

Page 34: ...BLU 240V BLK 120V BRN 240V BLK 120V BRN 240V BLK 120V BRN 240V BLK 120V BRN 240V GRN 120V GRN YEL 240V GRN 120V GRN YEL 240V GRN 120V GRN YEL 240V NC NO NC NO NC NO NC NO NC NO NC NO WHT 120V BLU 240V BLK 120V BRN 240V TO TB4 GRN 120V GRN YEL 240V Power Supply 115 VAC or 230 VAC TB7 N L TO TB4 GRN 120V GRN YEL 240V BLK 120V BRN 240V WHT 120V BLU 240V Figure 14 W600 AC Power Relay Output Wiring ...

Page 35: ...0V BLU 240V GRN 120V GRN YEL 240V BLK 120V BRN 240V GRN 120V GRN YEL 240V WHT 120V BLU 240V GRN 120V GRN YEL 240V WHT 120V BLU 240V BLK 120V BRN 240V GRN 120V GRN YEL 240V WHT 120V BLU 240V BLK 120V BRN 240V BLK 120V BRN 240V Power Supply 115 VAC or 230 VAC TB7 N L GRN 120V GRN YEL 240V BLK 120V BRN 240V WHT 120V BLU 240V Figure 15 W610 AC Power Relay Output Wiring ...

Page 36: ...V BRN 240V GRN 120V GRN YEL 240V WHT 120V BLU 240V GRN 120V GRN YEL 240V WHT 120V BLU 240V BLK 120V BRN 240V Power Supply 115 VAC or 230 VAC TB7 N L GRN 120V GRN YEL 240V BLK 120V BRN 240V WHT 120V BLU 240V External AC Power External AC Power BLK 120V BRN 240V Figure 16 W620 AC Power Relay Output Wiring ...

Page 37: ...V GRN YEL 240V WHT 120V BLU 240V BLK 120V BRN 240V Power Supply 115 VAC or 230 VAC TB7 N L GRN 120V GRN YEL 240V BLK 120V BRN 240V WHT 120V BLU 240V External AC Power External AC Power External AC Power External AC Power ALARM Figure 17 W640 AC Power Relay Output Wiring ...

Page 38: ...6 6 9 VDC 6 7 7 DI SHIELD 7 8 8 8 9 9 9 10 10 10 11 11 11 12 12 12 13 DIG IN 1 13 DIG IN 5 13 DIG IN 2 14 DIG IN 1 14 DIG IN 5 14 DIG IN 2 15 9 VDC 15 9 VDC 15 9 VDC 16 4 20 OUT1 16 DIG IN 6 16 4 20 OUT2 17 4 20 OUT1 17 DIG IN 6 17 4 20 OUT2 18 SHIELD 18 9 VDC 18 SHIELD TB1 TB3 TB2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 TB2 Chart Recorder SHIELD SHIELD Figure 18 Analog Output Wiring ...

Page 39: ...ining input readings or status of outputs Touching any of these fields on the Home Screen will bring up the item s Details Screen where you can access calibration and setting menus or graph that parameter If more than one page of items is selected to be displayed on the Home screen it will au tomatically scroll between them or swiping up or down manually moves to the next page A yellow bar on the ...

Page 40: ...closes a menu and returns to the previous menu Confirm icon saves changes and returns to the previous menu Filter icon is used in menus to limit the choices displayed when selecting items from a list Character Delete icon erases part of an alphanumeric entry Shift icon is used for upper case characters Double Arrow icons appear in Graphs menu and move the time frame of the graph Calendar icon appe...

Page 41: ...he selection is picked from a list of available options Swipe if necessary to find the desired option and then touch the option to highlight it Touch the Confirm icon to store the new option into memory or touch the Close icon to leave the selection at its previous value and go back The Filter icon may be used to limit the items displayed in the list Touch the Filter icon to bring up the types of ...

Page 42: ...h the Close icon until the list of inputs is displayed Repeat the process for each input The S12 input is the optional pH input for electroless nickel if a pH sensor will be used change the Type from No Sensor to pH This will bring you back to the Settings screen Finish the rest of the S12 settings The S13 temperature input Element should be set to RTD 1000Ω if the S12 pH sensor includes a tempera...

Page 43: ...not a priority choose On Off or Time Proportional R2 R4 default to Plating Follow mode These relays will activate at the same time as the relay feeding metal R1 is the default select the proper relay for your installation The intention is to feed pH adjustment reducing agent and or stabilizer in proportion to the metal Home Screen Setup see section 5 4 9 Once the controller has been programmed for...

Page 44: ...arameters that has been set touch the Home icon if not already there The menus for each of these parameters may be accessed directly by touching the parameter Keep in mind that even while browsing through menus the unit is still controlling The menu structure is grouped by alarms inputs and outputs graphs and HOA Under the Configuration menu will be general settings such as the clock the language ...

Page 45: ...AI Monitor Fluorometer Flowmeter Analog Type DI State Flow Meter Contactor type Flow Meter Paddlewheel type Feed Monitor Counter DI Counter Calculation Virtual Input Redundant Sensor Virtual Input Raw Value Virtual Input List of Possible Inputs OUTPUTS List of Possible Outputs INPUTS Home Inputs Outputs Graphs HOA Config Global Settings Security Settings Ethernet Settings Ethernet Details Remote C...

Page 46: ...ickel S11 Temp S12 5 25 g l 125 2 F pH S12 Flowswitch D1 4 60 Flow Unassigned D2 Unassigned D3 Unassigned D4 Unassigned D5 List of Possible Inputs Copper Nickel Contacting Conductivity Electrodeless Conductivity Temperature pH ORP Disinfection Generic Transmitter AI Monitor Fluorometer Flowmeter Analog Type DI State Flow Meter Contactor type Flow Meter Paddlewheel type Feed Monitor Counter DI Coun...

Page 47: ...sion Total Time Reset Time Total Name Type Additional Settings for Contactor Flowmeter Totalizer Alarm Reset Flow Total Set Flow Total Scheduled Reset Alarm Datalog Suppression Volume Contact Flow Units Name Type Additional Settings for Paddlewheel Flowmeter Deadband Alarm Datalog Suppression Set Flow Total Totalizer Alarm Reset Flow Total K Factor Flow Units Rate Units Smoothing Factor Name Type ...

Page 48: ...de Plating Follow R1 R6 C1 C6 Off HOA Setting Total Mode Reset Total Interlock Channels Additional Settings for Plating Follow Mode Activate with Channels Minimum Relay Cycle Hand Time Limit Control Name Mode On Off R1 Off Status Time On 24 hour time Total Time etc Details Screen Content varies with output type Alarms Input Value Mode Relay Type Additional Input Details On Off R1 R6 C1 C6 Off HOA ...

Page 49: ...Minimum Relay Cycle Hand Time Limit Reset Time Total Input Direction Name Mod Dual Setpoint R1 R6 C1 C6 Off HOA Setting Set Point Set Point 2 Deadband Additional settings for Dual Setpoint Mode Duty Cycle Period Duty Cycle On Delay Time Off Delay Time Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels Minimum Relay Cycle Hand Time Limit Reset Time Total Input Directio...

Page 50: ...Set Point Proportional Band Min Output PID Control A1 A2 C1 C6 Off HOA Setting Set Point Gain Proportional Gain Not available for virtual outputs Not available for virtual outputs Additional settings for Manual Control Mode Hand Time Limit Reset Time Total Name Mode Additional settings for Retransmit Mode Error Output Reset Time Total Input Name Mode Additional settings for Proportional Control Mo...

Page 51: ...tings Remote Communications Comm Status Data Format Data Port Verbose Logging Swipe for addional settings for Remote Communications Device ID Network File Utilities File Transfer Status Data Log Export Periodic Log Export Export Event Log Export System Log Export User Config File Import User Config File Repair Network File System Restore Default Config Software Upgrade Controller Details Controlle...

Page 52: ...s One Point Buffer Two Point Buffer Three Point Buffer One Point Analog or Two Point Analog Cali bration Not all calibration options are available for all types of sensor Water Sample Calibration Begin Calibration OK to disable control Touch Confirm to continue or Cancel to abort Remove Sensor Please provide water sample to sensor Place the immersible sensor in clean tap or DI water or circulate t...

Page 53: ...in the buffer solution or oxidizer free water for Zero Cal or air for the conductivity open air cal Touch Confirm when ready Stabilization When the temperature if applicable and signal from the sensor is stable the controller will automatically move to the next step If they don t stabilize you may manually go to the next step by pressing Confirm Cal Successful or Failed If successful touch Confirm...

Page 54: ...er recognition is used Enter the value of the buffer being used Rinse Sensor Remove the sensor from the process rinse it off and place it in the buffer solution Touch Confirm when ready Stabilization When the temperature if applicable and signal from the sensor is stable the controller will automatically move to the next step If they don t stabilize you may manually go to the next step by touching...

Page 55: ...ue Put the transmitter back into normal measurement mode if necessary and touch Confirm when ready to resume control Two Point Analog Calibration OK to disable control Touch Confirm to continue or Cancel to abort Input Value Enter the mA value that the transmitter will be sending Touch Confirm to continue or Cancel to abort Please set input signal to specified value Make sure that the transmitter ...

Page 56: ...logs and graphs containing the input will show no data for the duration of the activation Smoothing Factor Increase the smoothing factor percentage to dampen the response to changes For example with a 10 smoothing factor the next reading shown will consist of an average of 10 of the previous value and 90 of the current value Stabilization Time The sensor needs some time to warm up on power up Ente...

Page 57: ...f days between calibrations Set it to 0 if no reminders are necessary Alarm Datalog Suppression If any of the relays or digital inputs are selected any alarms related to this input will be suppressed if the selected relay or digital input is active At the same time all datalogs and graphs containing the input will show no data for the duration of the activation Smoothing Factor Increase the smooth...

Page 58: ...0 and the dead band is 0 05 the alarm will activate at 9 51 and deactivate at 9 45 Alarm Datalog Suppression If any of the relays or digital inputs are selected any alarms related to this input will be suppressed if the selected relay or digital input is active At the same time all datalogs and graphs containing the input will show no data for the duration of the activation Smoothing Factor Increa...

Page 59: ...ame The name used to identify the sensor may be changed Type Select the type of sensor to be connected 5 2 7 Disinfection Settings Touch the Settings icon to view or change the settings related to the sensor Alarms Low Low Low High and High High Alarms limits may be set Deadband This is the Alarm Deadband For example if the High Alarm is 7 00 and the dead band is 0 1 the alarm will activate at 7 0...

Page 60: ...low end of the range of the sensor High Range Enter the high end of the range of the sensor Smoothing Factor Increase the smoothing factor percentage to dampen the response to changes For example with a 10 smoothing factor the next reading shown will consist of an average of 10 of the previous value and 90 of the current value Cable Length The controller automatically compensates for errors in the...

Page 61: ...vate at 6 90 Reset Calibration Values Enter this menu to reset the sensor calibration back to factory defaults Cal Required Alarm To get an alarm message as a reminder to calibrate the sensor on a regular schedule enter the number of days between calibrations Set it to 0 if no reminders are necessary Alarm Datalog Suppression If any of the relays or digital inputs are selected any alarms related t...

Page 62: ...time base Flowmeter Max Enter the flow rate at which the meter outputs a 20 mA signal Input Filter Enter the mAbelow which the flow rate will considered 0 Typically any meter output below 4 02 mAis actually 0 flow Name The name used to identify the sensor may be changed Type Select the type of sensor to be connected 5 2 12 DI State Input Details The details for this type of input include the curre...

Page 63: ...nsor to be connected to the digital input channel 5 2 14 Flow Meter Paddlewheel Type Input Details The details for this type of input include the current flow rate total volume accumulated through the flow meter alarms and the current type of input setting Settings Touch the Settings icon to view or change the settings related to the sensor Alarms Low and High Alarm limits may be set Alarm Datalog...

Page 64: ...y alarm should be activated The Flow Alarm Delay setting MM SS contains the time to trigger the alarm if the output is activated and no pulses are registered To avoid nuisance alarms at very low flow rates if the linked output is a solid state relay set with a pulse proportional or PID control mode or an analog 4 20 mA output the alarm will only be activated if no input pulses are monitored while ...

Page 65: ...nter this menu to reset the accumulated flow total to 0 Touch Confirm to accept Cancel to leave the total at the previous value and go back Set Flow Total This menu is used to set the total accumulated volume stored in the controller to match a specified volume Scheduled Reset Choose to automatically reset the flow total and if so Daily Monthly or Annually Total Alarm Mode Choose to Interlock or M...

Page 66: ...this menu to reset the accumulated total to 0 Touch Confirm to accept or Cancel to leave the total at the previous value and go back Set Total This menu is used to set the total number of contact closures stored in the controller a certain value Scheduled Reset Choose to automatically reset the flow total and if so Daily Monthly or Annually Units Type in the units of measure for the what the conta...

Page 67: ...for the calculated value A value above this will trigger a Range Alarm and deactivate any control output using the virtual input Smoothing Factor Increase the smoothing factor percentage to dampen the response to changes For ex ample with a 10 smoothing factor the next reading shown will consist of an average of 10 of the previous value and 90 of the current value Name The name used to identify th...

Page 68: ...ct which mode for determining the value for the virtual sensor input Input Select the physical input for the primary sensor Input 2 Select the physical input for the backup sensor Name The name used to identify the input may be changed Type Select the type of input either Calculation Redundant Raw Value Disturbance or Not Used 5 2 19 Virtual Input Raw Value A Raw Value type Virtual Input is not a ...

Page 69: ...elay will deactivate until the Reset Output Timeout menu is entered Reset Output Timeout Enter this menu to clear an Output Timeout alarm and allow the relay to control the process again Interlock Channels Select the relays and digital inputs that will interlock this relay when those other relays are activated in Auto mode Using Hand or Off to activate relays bypasses the Interlock logic Activate ...

Page 70: ...terlock status accumulated on time total feed volume or turns if enabled alarms related to this output current value of the assigned input sensor current cycle on time relay type and the current control mode setting Settings Touch the Settings icon to view or change the settings related to the relay Set point Enter the sensor process value at which the relay will activate Deadband Enter the sensor...

Page 71: ... the relay Total Mode Enter this menu to select the method and program feed totalization Pump Capacity Only appears for As Volume Enter the maximum feed rate of the pump connected to this relay Pump Setting Only appears for As Volume Enter the stroke length setting for the metering pump in percent Reset Total Enter this menu to reset the accumulated time or volume to zero Touch Confirm to accept C...

Page 72: ...nt control mode setting Settings Touch the Settings icon to view or change the settings related to the relay Set point Enter the sensor process value at which the relay will be off for the entire Sample Period Proportional Band Enter the distance that the sensor process value is away from the set point at which the relay will be on for the entire Sample Period Sample Period Enter the duration of t...

Page 73: ... derivative the rate of change for the error param eters With proper tuning the PID control algorithm can hold the process value close the set point while minimiz ing overshoot and undershoot Normalized Error The error value versus set point that is calculated by the controller is normalized and represented as percent of full scale As a result tuning parameters entered by the user are not dependen...

Page 74: ... Output percentage close to the value that the process is expected to require for optimal control in Auto mode Wind up Suppression The Current Integral value that is accumulating while the output is set to Auto can become very large or very small if the process value remains on the same side of the set point for a prolonged period of time However the control ler may not be able to continue to resp...

Page 75: ...ccumulated area under the error curve Current Integral When this menu option is selected this total is set to zero and the PID algorithm is reset to its initial state Minimum Output Enter the lowest possible pulse rate as a percentage of the Maximum Stroke Rate set below normally 0 Maximum Output Enter the highest possible pulse rate as a percentage of the Maximum Stroke Rate set below Maximum Rat...

Page 76: ...he operation of the timer control A digital input or output interlock condition does not delay the relay activation The relay activation duration timer will continue even if the relay is deactivated due to an interlock condition This will prevent delayed events which can potentially cause problems in they do not occur at the correct time Activate With Conditions Activate with channels settings ove...

Page 77: ...gh 10 Enter these menus to program timer events via the menus below Repetition Select the time cycle to repeat the event Hourly Daily 1 Week 2 Week 4 Week or None An event means that the output is turned on at the same time of day for the same amount of time and except for the Daily cycle on the same day of the week Week Only appears if Repetition is longer than 1 Week Select the week during which...

Page 78: ...ile the first one is still active the second event will be ignored An Event Skipped alarm will be set 5 3 14 Relay Spike Control Mode Basic Timer Operation This algorithm is typically used to provide a baseline amount of chlorine for disinfection and periodically shocking the system with a larger dose During normal operation the relay will be reacting to sensor to maintain a set point within a pro...

Page 79: ...the controller will not start the duration timer until the spike set point is achieved or until the onset time is over whichever comes first Duty Cycle Period Using a duty cycle helps to prevent overshooting the set point in applications where the response of the sensor to chemical additions is slow Specify the amount of time for the cycle and the percentage of that cycle time that the relay will ...

Page 80: ...pplicable or leave at None Bleed Meter Select the bleed water meter from the pulldown list Bleed Meter 2 Select the bleed water meter from the pulldown list if applicable or leave at None 5 3 16 Relay Output Flow Proportional Mode ONLY AVAILABLE IF CONTROLLER INCLUDES PULSE OUTPUT HARDWARE Overview In Flow Proportional control mode the controller monitors the rate of flow through an analog or digi...

Page 81: ...ivation Input Select the input to be used to control this output 5 3 18 Relay Dual Switch Control Mode Dual Switch mode is typically used to fill or empty a tank using a level switch contact closure to activate the relay when the liquid level is at one extreme and deactivate the relay at the other extreme It is more versatile than that the on and off triggers may be any digital input or relay outp...

Page 82: ...eveling mode selects a different output each time the group is activated Additional modes vary the activation of the pumps within the group based on the time on for each output with the intent to either balance the usage of each pump or to energize the primary output most often and periodically exercise auxiliary pumps to insure proper operation when they are needed Output Activation Modes Dependi...

Page 83: ...ts in the group have been exercised for one feed cycle the process begins again with the first output R1 Time Balanced Time balanced mode alternates outputs in a manner that equalizes the runtime of all connected pumps This mode takes into account how long each output in the Lead Lag group has been running since a manual reset and selects the output that has the lowest on time during each cycle If...

Page 84: ... Lead R1 output set for Dual Setpoint control is pro grammed to energize its output when the D O reading is outside the 4 0 4 5 ppb control range with a deadband of 0 1 ppb Time based output activation is selected with a delay time of 15 minutes When the D O value falls below 4 0 ppb R1 is activated After 15 minutes if the D O has not risen to 4 1 ppb or higher R2 will also be activated When the p...

Page 85: ...ation R1 R2 R3 as in Example 1 except the delay time is set for 1 hour When the high level switch closes the R1 pump is activated If the high high level switch closes the R2 pump is also activated If the tank level remains above the high high level switch for another 1 hour the R3 pump is activated When D2 opens R3 is turned off When D1 opens both R2 and R1 are turned off In this configuration the...

Page 86: ...output in the Lead Lag group those that are selected as a Lead output from another Lag mode output offer a more limited list of settings Lag Settings Menus with are shown only in the Last Lag output settings HOA Setting Select Hand Off or Auto mode by touching the desired mode Lead Select the output that will be the lead output for this relay Wear Leveling Select the wear leveling scheme to use Re...

Page 87: ...open and close set this high enough that the valve has time to complete its movement Hand Time Limit Enter the amount of time that each relay in the group will activate for when it is in Hand mode Hand Output This menu only appears for pulse relay or analog output Lead outputs Enter the output desired for each output in the group when the output is in Hand mode Off Mode Output This menu only appea...

Page 88: ...trol Mode Output Details The details for this type of output include the output HOA mode or Interlock status accumulated on time alarms related to this output current cycle on time relay type and the current control mode setting Settings Touch the Settings icon to view or change the settings related to the relay Set point Enter the sensor process value at which the output will be the programmed mi...

Page 89: ...nits for entry of the PID tuning parameters Standard The standard form is more commonly used in industry because its time based settings for the integral and deriva tive coefficients are more meaningful This form is selected by default Parameter Description Units Kp Gain unitless Ti Integral Time seconds or seconds repeat Td Derivative Gain seconds Output Kp e t f e t dt Td de t dt 1 Ti Parameter ...

Page 90: ...main large enough to keep the output at 100 long after the set point is satisfied The controller will overshoot the set point and the process value will continue to rise To optimize system recovery after wind up situations the controller suppresses updates to the Current Integral that would drive the output beyond its minimum or maximum limit Ideally the PID parameters will be tuned and the contro...

Page 91: ...ng parameters Input Minimum The low end of the sensor input range used to normalize errors into percent of full scale units These values are set to the nominal range of the selected input sensor by default Input Maximum The high end of the sensor input range used to normalize errors into percent of full scale units These values are set to the nominal range of the selected input sensor by default G...

Page 92: ...nfiguration Settings Menu is used for settings and activities that are not tied to Inputs or Outputs 5 4 1 Global Settings Date Enter the current year month and day Time Enter the current hour military time minute and second Name Enter the name to help identify the controller when it connects to Fluent Location Enter the location to help identify the controller when it connects to Fluent Global Un...

Page 93: ...nly appears if Webserver Mode is HTTPS and Upload PEM is selected Insert a USB stick containing the desired Private Key file The files must be named private key and must be in the root folder on the stick Enter this menu to import the file from the stick onto the controller If the network IT administrator is installing their own certificates they must install a server private key and a server cert...

Page 94: ...last attempt to send a data to the Fluent server 5 4 5 Remote Communications Modbus and BACnet This menu will appear only if one of the optional Remote Communications activation keys has been imported into the controller either by the factory at the time of ordering or later using a field activation file To add the Remote Communications feature in the field purchase the activation key file and sav...

Page 95: ...rt Type is Datalog Graph or Summary Only appears if the repetition is set to Weekly Choose the day of the week on which the report will be sent Day of Month Only appears if Report Type is Datalog Graph or Summary Only appears if the repetition is set to Monthly Choose the day of the month on which the report will be sent If the current month has less days than the number en tered the report will b...

Page 96: ...reen view can be customized to show the desired parameters in any order in cards that can be adjusted to the desired size The largest size card is one half of one screen A maximum of 6 half screens can be created If there are more than two half screens the controller will automatically scroll between the screens To customize a half screen touch the Add Card icon in the empty screen to create one l...

Page 97: ...er calibrations alarms relay state changes file exports etc Export System Log Save the System Log file to a USB stick This records hardware changes software upgrades automatic calibrations power loss system level issues etc Export User Config File The User Configuration file contains all settings for the controller Enter this menu to save the controller s settings to a USB stick or download the fi...

Page 98: ...ply is used for powering all the I O 3 3 Volt Supply The normal range is 3 135 to 3 465 VDC The 3V supply is used to run the system 5 5 HOA Menu The HOA Hand Off Automatic Menu is used to quickly and easily test all relay outputs and to stop or enable auto matic control Swipe up or down to view the output to change Touch the Hand Off or Auto button to change the HOA state of that output The curren...

Page 99: ...ust the right Y axis scale enter the low limit here High Axis Limit The graph auto scales based on the sensor value if both Low and High Axis Limit are set to 0 To manually adjust the right Y axis scale enter the high limit here Time Range Select the time range for the X axis of the graph The time range may also be accessed from the graph view by touching the time range icon in the lower right cor...

Page 100: ...assword a prompt will appear to change to new credentials The option to close the prompt window and continue using the existing credentials exists however the Admin and View Only level user names and passwords can and should be changed by browsing to the Config menu Security Settings webpage Log into the page using the current Admin level username and password then change to new ones 6 3 Navigatin...

Page 101: ...greyed out until the refresh button has been clicked In order to see what the report settings are click the Load Report Settings button The graph email will contain an html attachment showing the graphs The Export Graph button can be used to save the graphs as an image that can be copied to a document The same button is also available directly from the Graphs web page The graphs will display the p...

Page 102: ... is available on the input s webpage To initiate a sensor calibration click on the One Point Process Calibration button A popup will open that displays the current value for that input and allow entry of the new value Type the value of that parameter as determined by another meter or laboratory analysis and click Begin Calibration Click Cancel to abort the calibration and retain the previous calib...

Page 103: ... control you require The best way to determine the optimum number of days between calibrations is to remove the electrode from the process periodically weekly in clean water applications daily in dirty or hot applications and check its accuracy in a buffer solution If using manu al temperature compensation remember to change the temperature from that of the process to that of the buffer If the acc...

Page 104: ...an electrode Improper wiring of sensor to controller Correct wiring Incorrect temperature reading or setting Ensure that the temperature is accurate Incorrect cable length or wire gauge setting Set to the correct values Faulty electrode Replace electrode Faulty preamplifier Replace preamplifier 8 1 3 Contacting Conductivity Sensors The calibration will fail if the adjustment to the gain is outside...

Page 105: ...sufficient sample flow Increase flow rate to between 30 and 100 liter per hour Air bubbles on membrane Dislodge bubbles Adjust flow rate higher if necessary Air bubbles in electrolyte Refill membrane cap with electrolyte Dirty membrane Clean membrane Loose membrane cap Tighten membrane cap Faulty membrane Replace membrane cap High Pressure Reduce pressure to below 1 atmosphere and refill cap with ...

Page 106: ... Input Details menu both the Sample Measurement and Sample Reference mV will be less than 0 01 times what the readings were in water during the last Water Sample Calibration Water Measurement and Water Reference mV Possible Cause Corrective Action Sensor wire s disconnected Reconnect Lamp failure Replace lamp Dirty sensor Clean or etch sensor Faulty sensor Repair or replace sensor Controller is fa...

Page 107: ...ping for closed valves blockage etc Check recirculation pump Faulty flow switch cable Check with ohmmeter Faulty controller Check by shorting digital input in controller TOTALALARM Occurs if the flow meter or feed monitor totalizer alarm limit is exceeded Possible Cause Corrective Action Normal operation Reset the total to clear alarm or wait for the automatic total reset to occur AC coupled onto ...

Page 108: ...ND mode or activate with force on condition Possible Cause Corrective Action Incorrect programming Reprogram to eliminate overlapping events Long duration interlock condition Normal operation SENSOR FAULT This error indicates that the signal from the sensor is no longer valid at all This error condition will stop control of any output using the sensor Possible Cause Correction Action Sensor wires ...

Page 109: ...This alarm occurs if the sensor s Cal Reminder Alarm has been set to more than 0 days and if the sensor has not been calibrated within that number of days Possible Cause Correction Action Time to calibrate Calibrate the sensor Reminder set in error Set the Cal Reminder Alarm to 0 CALCULATION ERROR This alarm occurs if a virtual input calculation cannot be completed for example if it has to divide ...

Page 110: ...n incorrect model Reinstall the correct board or reprogram the output to a valid type for the board installed Fluent LIVE CONNECT ERROR This alarm occurs if the controller is unable to establish an encrypted connection to the Fluent server If there is also a Fluent Data Comm Error fix that first Possible Cause Correction Action No UDP support on Port 9012 or TCP support on Port 44965 Open ports pr...

Page 111: ...tware application Normal operation is that 5 seconds after power up it does one long blink on two short blinks on long blink off If it is not doing this Possible Cause Correction Action Controller software is not running Try a power cycle to reset it Faulty controller board Replace controller board CONTROLLER BOARD D3 LED Indicates the status of the 5 VDC power supply Normal operation is ON If not...

Page 112: ... N to M for Modbus BACnet 103859 USA Power Cord or 100234 Power Cord or 104121 1 Brazil Power Cord 103938 Strain Relief power cord 104270 Power Switch 104271 Switch Boot 192628 Power Switch Cable Fuse 192134 Safety Cover 191739 Ribbon Cable 192632 6 Powered Relay Board or 192633 2P 4 Dry Relay Board or 192634 20 opto 4 Dry Relay Board or 192635 40 opto 2 Dry Relay Board 191730 Sensor Board or 1917...

Page 113: ...parts and service If a controller is not functioning properly circuit boards may be available for exchange after the problem has been isolated Authorized distributors will provide a Return Material Authorization RMA number for any products being returned to the factory for repair Repairs are generally completed in less than one week Repairs that are returned to the factory by next day air freight ...

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