MICROPROCESSOR – BASED WATER TREATMENT CONTROLLER INSTALLATION MANUAL Quick Start

MICROPROCESSOR – BASED

WATER TREATMENT CONTROLLER

Quick Start

INSTALLATION MANUAL

Cooling Tower 9200, 9300, 9500 Series

72-900-28 Rev C

Page 1 of 27

1.

I

NSTALLATION

L

OCATION

: C

OOLING

T

OWER

..................................................................................... 3

1.1

Cooling Tower .................................................................................................................... 3

1.1.1

Installation Notes ........................................................................................................ 3

1.2

Electrical Wiring ................................................................................................................. 4

1.2.1

User Connections........................................................................................................ 5

1.3

Front Panel ......................................................................................................................... 9

2.

C ONTROLLER S ET U P 9200 S ERIES ................................................................................................. 10

2.1

Initialization ........................................................................................................................ 10

2.2

Menu Structure................................................................................................................... 10

2.3

Key Pad Operation ............................................................................................................. 11

2.4

Screen Format .................................................................................................................... 12

3.

9300 & 9500 S ERIES ...................................................................................................................... 14

3.1

Menu Structure................................................................................................................... 15

3.2

Keypad Operation .............................................................................................................. 16

3.3

Screen Format .................................................................................................................... 17

3.4

Change Verification............................................................................................................ 18

4.

A LTERNATE L ANGUAGE ................................................................................................................... 18

5.

F

ACTORY

D

EFAULT

V

ALUES

............................................................................................................ 20

6.

S TANDARD S ENSORS : ..................................................................................................................... 23

6.1

Cooling Tower Sensors...................................................................................................... 23

6.2

Hi-Pressure Sensors .......................................................................................................... 23

7.

S

PECIFICATIONS

............................................................................................................................. 24

7.

S PECIFICATIONS ............................................................................................................................. 25

8.

M AINTENANCE ................................................................................................................................ 27

9.

R

ELAY

A

SSIGNMENTS

..................................................................................................................... 27

9.1

Cooling Tower .................................................................................................................... 27

72-900-28 Rev C

Page 2 of 27

1. Installation Location: Cooling Tower

Select a mounting location convenient to grounded electrical and plumbing connections. Mount the controller on a wall or other vertical surface with adequate lighting at a comfortable level. Installation must comply with all national, state and local codes.

1.1 Cooling Tower

A

VOID LOCATIONS WHERE THE CONTROLLER WOULD BE SUBJECTED TO EXTREME COLD

OR HEAT

[<

THAN

0°F (-17.8°C)

OR

>

THAN

122°F (50°C)],

DIRECT SUNLIGHT

,

VIBRATION

,

VAPORS

,

LIQUID SPILLS OR

EMI (

ELECTROMAGNETIC INTERFERENCE

;

I

.

E

.,

STRONG RADIO TRANSMISSION AND ELECTRIC MOTORS

.) T

HE CONTROLLER COULD BE

DAMAGED AND VOID THE WARRANTY

!

1.1.1 Installation Notes

1. Install sensors{ XE " sensors " } or sample stream flow assembly at some point before chemical injection points where chemical and water are thoroughly mixed (see Figure 3).

2. Measuring surfaces of the sensor electrodes{ XE "electrodes" } must be continuously immersed in system water.

3. The difference between the inlet and output pressure must be sufficient to provide a flow rate between 1 to 5 GPM (3.81 to 19.05 l/m) to assure water will flow past the sensors{ XE " sensors "

} and they will read properly.

4. Most solenoid valves require a pressure differential{ XE "differential" } of 7 psi (0.48 BAR) to

15 psi (0.96 BAR) to close; if this is not available, install a zero pressure solenoid valve if blowdown is incorporated.

5. If chemicals are to be injected into sample line, always use a back check valve to prevent chemicals from backing up around sensors{ XE " sensors " }.

6. If a flow assembly or sample stream assembly is present, never install a blowdown valve{ XE

"blowdown valve" } off these lines. The system will not achieve proper blowdown and accuracy of controller readings may be affected.

72-900-28 Rev C

Page 3 of 27

5

6

7

8

9

1

2

3

4

Figure 3 – Typical Installation Cooling Tower

10 Heat Exchanger Isolation Valve

Float Valve

Cooling Tower

Drum Level (Typ.)

Computer for remote access

Flow Switch

Alarm

Blow Down Solenoid Valve

Drain

11

12

13

14

15

16

17

18

Conductivity Sensor pH Sensor

Redox (ORP) Sensor

Union

Chemical Feed tank

Feed Water Pump

Water Meter

Municipal Water Inlet

The standard flow assembly, is constructed of durable glass filled polypropylene (GFPPL).

Connection to the flow line is 3/4” NPT (19.05 mm). A PVC thread to slip adapter is provided so that a PVC weld joint, if preferred, can be made.

1.2 Electrical Wiring

U

NIT MUST BE WIRED IN ACCORDANCE WITH ALL APPLICABLE ELECTRICAL CODES

.

The controller electronic circuitry is fuse protected. In addition, each output relay is individually protected by a replaceable plug-in 5 amp fuse on the relay board{ XE "relay board" }. Use of a surge protector is strongly recommended! The device should satisfy the following minimum requirements:

Response: <1ns

Energy Dissipation: 400 Joules

EMI/RFI Noise Attenuation: 5-35dB

72-900-28 Rev C

Page 4 of 27

The controller should be connected to its own 15 amp power branch (i.e., its own wiring, circuit breaker, etc.). For best results, the ground should be independent (true earth) not shared.

Pre-wired units are supplied with 6 ft (1.8 m), 18 AWG (1.2 mm

2

) 3-wire grounded power cords and clearly marked 18 AWG (1.2 mm

2

) 3-wire grounded receptacle cords for all controlled line voltage outputs.

Use 16 AWG (1.5 mm

2

) or 18 AWG (1.2 mm

2

) wire for conduit power and load connections.

1.2.1 User Connections

1.2.1.1

L

INE VOLTAGE IS PRESENT ON THE POWER SUPPLY LOCATED BEHIND THE

S

AFETY COVER

BEHIND THE FRONT PANEL

. L

INE VOLTAGE IS ALSO PRESENT ON THE RELAY BOARD

{ XE

"

RELAY BOARD

" }

LOCATED IN THE BOTTOM OF ENCLOSURE

,

EVEN WHEN POWER IS OFF

.

POWER MUST BE DISCONNECTED WHILE CONNECTIONS ARE BEING

MADE!

Power

The controller should be connected to its own 15 amp power branch (i.e., its own wiring, circuit breaker, etc.). For best results, the ground should be independent (true earth) not shared.

1.2.1.2

Connect the incoming power to J12 on the Relay Board located at the bottom of the enclosure.

Connect the Neutral to position ‘1’ labeled ‘RTN.’ Connect the Earth Ground to position ‘2’ labeled with the earth ground symbol . Connect the Line to position 3 labeled ‘HOT.’ Use minimum

18 AWG (1.2 mm

2

) wire.

The control circuit is fuse protected. In addition, each output relay is individually protected by a replaceable plug-in 5 amp fuse (P/N: 05-051-82) on the relay board{ XE "relay board" }.

B

EFORE APPLYING POWER

,

INSURE THAT DEVICES BEING CONTROLLED ARE NOT IN A

POSITION TO CAUSE HARM OR DAMAGE IF ACTIVATED UPON INITIAL START

-

UP

.

Relay Connections

2

Relay connections are made to J3, J4, J5, J6, J7, J8 and J9. Use only 16 or 18 AWG (1.5mm

2

1.22mm

) wire. Both normally open and normally closed powered contacts are available. To

or complete the wiring, first locate your model number. Then note the relay positions and associated functions. Wire your blowdown device (e.g., motorized ball valve) to the appropriate position. Note all outputs are powered at line voltage and fused at 5A. Many motorized ball valves require connections to both the Normally Open (NO) and Normally Closed (NC) terminals.

72-900-28 Rev C

Page 5 of 27

1.2.1.3

1.2.1.6

Flow Switch or Interlock

It is recommended that a flow switch or auxiliary dry contact from the control panel be used to make outputs inoperative when the cooling tower is shut down. This connection is provided on all standard units.

Sensor Connections 1.2.1.4

1.2.1.5

Units come from the factory with all sensors{ XE " sensors " } pre-connected. Use of unapproved sensors will void the warranty.

For proper rejection of AC line voltage spikes, sensor EMI noise rejection and personal safety, the case ground (SAFETY GROUND) must be properly installed. If there is ANY doubt, consult a qualified electrician.

Inputs/Output Connections

(Water Meter (for Pulse Timer) / Drum Level / Alarm Dry Contact / 4-20mA)

Internal electrical wiring is not required for water meters, single point drum level sensors, alarm dry contact or 4-20mA inputs or outputs. Accessory cables are available for connection.

Receptacles

Non-CE Controllers are offered in a unique pre-wired package as standard. Each cord is clearly marked and readily accessible for connecting external electrical devices to be controlled.

* Excluding Sensors & Serial Communications, Cables shown connected to the enclosure are accessories and must be ordered separately.

72-900-28 Rev C

Page 6 of 27

72-900-28 Rev C

Page 7 of 27

Figure 4

CABLE WIRING INSTRUCTIONS

4-20mA OUTPUT

DIN CONN. TWISTED

5

6

7

8

PIN #

1

2

3

4

PAIRS

1

1

2

2

3

3

4

4

WIRE 4 - 20 mA

COLOR

Red

Black/Red

OUTPUT(S)

OUT #1 (+)

OUT #1 (-)

White OUT #2 (+) opt.

Black/White OUT #2 (-) opt.

Green OUT #3 (+) opt.

Black/Green OUT #3 (-) opt.

Blue OUT #4 (+) opt.

Black/Blue OUT #4 (-) opt.

4-20mA INPUT (9500)


PIN #

1

2

3

4

5

6

7

8

PAIRS

1

1

2

2

3

3

4

4

WIRE 4 - 20 mA

COLOR

Red

Black/Red

INPUT(S)

IN #1 (+)

IN #1 (-)

White IN #2 (+) opt.

Black/White IN #2 (-) opt.

Green IN #3 (+) opt.

Black/Green IN #3 (-) opt.

Blue IN #4 (+) opt.

Black/Blue IN #4 ( -) opt.

DRUM LEVEL WANDS (9500 only)


PIN # PAIRS

WIRE

COLOR

DRUM

LEVEL WANDS

3

4

5

6

1

2

7

8

2

2

3

3

1

1

4

4

Red

Black/Red

White

Black/White

Green

Black/Green

Blue

Black/Blue

LEVEL #1

LEVEL #1

LEVEL #2

LEVEL #2

LEVEL #3

LEVEL #3

LEVEL #4

LEVEL #4

WATER METER*


PIN # PAIRS

1

2

1

1

3

4

5

6

7

8

2

2

3

3

N/A

N/A

WIRE

COLOR

Red

Black/Red

HALL

EFFECT

METER #1+5V

METER #2+5V

DRY

CONTACT

White METER #1 SIG.

METER #1

Black/White METER #1 GND.

METER #1

Green METER #2 SIG.

METER #2

Black/Green METER #2 GRD.

METER #2

Blue

Black/Blue

N/A

N/A

N/A

N/A

DRY ALARM CONTACTS


PIN # PAIRS

3

4

5

6

1

2

2

2

3

3

1

1

WIRE

COLOR

Red

Black/Red

DRY

CONTACT

RELAY #1

RELAY #1

White RELAY #2

Black/White RELAY #2

Green

Black/Green

N/A

N/A

7

8

4

4

Blue

Black/Blue

N/A

N/A

Use these tables to connect your device(s) to the controller. First, locate the DIN connector labeled for your device, e.g. "WATER METERS" on the right side of the controller and attach your cable. Next, find the applicable table. For example: If you have

(2) two Dry Contact Water Meters, refer to the Water

Meters Table - Dry Contact Column. Find the first twisted pair that has a WHITE and BLACK/WHITE wire and connect these to Water Meter #1. Next find the second twisted pair that has a GREEN and

BLACK/GREEN wire and connect these to Water

Meter #2.

* HALL EFFECT AVAILABLE ON 9300/9500 SERIES ONLY

72-900-28 Rev C

Page 8 of 27

1.3 Front Panel

Take a moment to review diagram and become familiar with the controller front panel.

1 Redox (ORP) Sensor

2 pH Sensor

3 Power LED

4 Flow Switch

5 Flow LED

6 Level LED

7 Alarm LED

8 Display

9 Panel Screws

Diagram: Front Panel

Figure 5

10 Logic Power Switch

11 Cover

12 HOA Switches

13 Relay Indicators

14 Provision for Lock

15 Thumb Screw

16 Pigtail (Non-CE Units)

17 Sample Valve

18 Conductivity Sensor

72-900-28 Rev C

Page 9 of 27

2. Controller Set Up 9200 Series

2.1 Initialization

B

EFORE APPLYING POWER

,

INSURE THAT DEVICES BEING CONTROLLED ARE NOT IN A

POSITION TO CAUSE HARM OR DAMAGE IF ACTIVATED UPON INITIAL START

-

UP

.

Note: If unit has been disconnected from power for a long time period (more than 2 weeks), when powered up the display may indicate charging with a percent value. When adequately charged, the display will AUTO SCROLL to MAIN MENU.

Unit requires initialization upon start-up. Before applying power, insure that devices being controlled are not in a position to cause harm or damage if activated upon initial start-up. With the controller now installed in a convenient location, INITIALIZE the Controller. Supply power to the controller and turn the Logic Power switch on. The power LED indicator light will be illuminated.

When controller is powered up, the MAIN MENU-DISPLAY DATA (shown below) will be displayed.:

1. Press SCROLL DOWN until MAIN MENU-CONFIGURE is displayed and press ENTER.

2. Press SCROLL DOWN until CONFIGURE-FACTORY REINIT is displayed and press ENTER.

3. The Factory Re-Init Warning will be displayed. Continue to scroll down to the end of the warning and then press ENTER. Press the ENTER key to execute Factory Re-initialization. The unit will revert to AUTO SCROLL. Press the HOME key repeatedly to return to the MAIN MENU. NOTE:

You may need to adjust the contrast after completing factory reinit!

2.2 Menu Structure

The Controller menu structure as well as the hardware were designed with the user in mind. The

“MENU MAP” supplied on the CD Rom with your controller reflects your specific system with options.

Display Data This menu displays system parameters only. No settings or adjustments are made through this menu. Present System Conductivity and System pH conditions are displayed along with any active alarms.

72-900-28 Rev C

Page 10 of 27

Calibrate Sensor(s) This menu is for analog input sensor calibration, such as conductivity and pH.

In this menu, the user is prompted to choose either 2 or 3 point calibration. After a choice is made, the user is prompted to enter values of LO, MID (if 3 point is chosen) and HI calibration solution.

Set Points and Alarms In this menu, the user is prompted to enter settings pertaining to alarms and set points that control the system operation.

Inhibitor Feed Set In this menu, the user is prompted to enter settings pertaining to the inhibitor feed mode chosen in the System Configure menu.

Biocide Programs In this menu the user is prompted to enter all settings pertaining to the biocide program timer.

System Configure This is generally the first selection made at start up. In this menu, the user is prompted to configure system functions and options to your specific application. System Configure can include such things as time of day, week, date, security code, track set point or independent set of high/low alarm, display dampener, rising or falling set points, conductivity scale, the selection of the inhibitor feed mode, water meter pulse totalizer, and analog output selection.

2.3 Key Pad Operation

The Key Pad is easy to use and will guide you through all the sub menus and functions of the controller. Feel free to try out these keys as you read about them. You will not hurt the controller and the values will need to be reprogrammed later anyway.

Figure 6

Home Press this key to return to previously displayed menu.

Scroll Up/Scroll Down Some menus contain more than one page. Press either scroll key to reveal other items on menu displayed. If no other choices are present, nothing will happen when pressing

Scroll Keys. The Menu Map supplied with your controller will show you which menus need to be scrolled to show additional choices.

Contrast Up/Contrast Down Press these keys to control contrast of viewing screen.

Arrows The Arrow Keys are used to change the numerical values associated with the various settings you will be entering. Use “down” arrow to select lower numbers and the “up” arrow to select higher numbers.

72-900-28 Rev C

Page 11 of 27

Enter This key has two functions:

FIRST, within the sub menu, pressing the Enter Key will activate the selection.

SECOND, after selecting the value needed with the Arrow Keys, press the Enter Key to

“lock-in” the value. The next value to be set (if one exists) in that particular sub-menu will be displayed.

Language This key is used for alternative Spanish language for our international customers.

Spanish is installed as standard feature on these controllers.

Help When pressed, this key will display simple instructions for the operation of the Enter, Home,

Arrows, and Scroll keys.

Relays (1-4) These Hand/Off/Auto (HOA) keys allow immediate control of pumps, solenoid valves, etc. affected by the controller without scrolling through the menus. Press a Relay Key once to force relay on for 5 minutes (an amber light will appear below that key). Press the Relay Key again to force the relay off (a red light will appear below that key, relay will be forced off until key is pressed again). Press the Relay Key a third time to return the relay to auto control (green light will indicate that relay is on, no light indicates that relay is not activated).

2.4 Screen Format

The following is a detailed example of how to program your controller. Once you have mastered this exercise, you will be ready to set up the controller to your specifications.

IMPORTANT! Please note that in all programming instructions, keypad instructions are presented as all capitals—“ENTER,” items as they appear in the display are presented as all capitals and bold face—“DISPLAY DATA.”

For this exercise, you will set “DAY, WEEK, DATE, and TIME.”

1. If not already displayed, press HOME until MAIN MENU

DISPLAY DATA is displayed.

2. Press SCROLL DOWN repeatedly until MAIN MENU

CONFIGURE is displayed. Press ENTER.

3. CONFIGURE DATE/DAY/TIME will be displayed.

Press ENTER.

4. The DATE menu will be displayed with “month” flashing.

Use the ARROW keys to select the current month. Press

ENTER.

5. “Day” will begin flashing. Use the ARROW keys to select the current date. Press ENTER.

72-900-28 Rev C

Page 12 of 27

6. “Year” will begin flashing. Use the ARROW keys to select the current year. Press ENTER to complete date programming.

7. Press SCROLL DOWN. The TIME menu will display with “hours” flashing. Use the ARROW keys to select current hour (24 hour clock). Press ENTER.

8. “Minutes” will begin flashing. Use the ARROW keys to select current minutes. Press ENTER.

If Biocide Option E or F is present on your controller, you will also configure “Week/Day”. If not, configuring “Date/Day/Time” would be complete at step 8 above.

9. Press SCROLL DOWN. The Week/day menu will display with “1st wk” flashing. Use the ARROW keys to select either 1st, 2nd, 3rd, or 4th wk.

Press ENTER.

10. “Day” will begin flashing. Use the ARROW keys to select the day of the week you prefer.

Press ENTER.

Nothing should be flashing and that completes the Date, Day, and Time programming.

Congratulations, you’ve done it! All menu programming functions operate in this manner. Feel free to repeat this exercise as often as you like until you are comfortable with the programming

Procedure.

Now, press the HOME key repeatedly to return to MAIN MENU,

DISPLAY DATA.

72-900-28 Rev C

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3. 9300 & 9500 Series

With the controller now installed in a convenient location, apply power and turn the power switch{

XE " power switch " } on. The power LED{ XE "LED" } indicator light will illuminate.

Figure 7

When the controller is powered up, the PLEASE WAIT and SYSTEM WARMING UP screens are displayed until the internal diagnostics tests are complete, then the MAIN MENU is displayed.

SYSTEM WARMING UP

SER558

VERSION SER558.2.00

CHECKSUM 5886

Press ENTER to Clear

Figure 8

===== MAIN MENU =====

? DISPLAY DATA

CALIBRATION

SETPOINTS

TIMERS

DATA COLLECT

CONFIGURE

––––––––––––

If the display{ XE "display" } contrast requires adjustment, use

[CONTRAST{ XE "CONTRAST" } UP] or [CONTRAST DOWN] keys on the control panel keypad to adjust the screen for best viewing.

The default values for all control features have been factory set, but you will want to fine tune the controller to meet your specific application.

W

HEN POWER IS SUPPLIED TO THE UNIT

,

LINE VOLTAGE IS PRESENT ON THE

R

ELAY

B

OARD LOCATED IN THE BOTTOM OF THE ENCLOSURE EVEN WITH THE

L

OGIC

P

OWER SWITCH OFF

.

72-900-28 Rev C

Page 14 of 27

3.1 Menu Structure

The Controller’s menu structure is designed to be user friendly. The MAIN MENU structure diagram shows the first level of all sub-menus in the controller. Not all sub-menus shown here may be present on your controller. The “MENU MAP” supplied on the CD Rom with your controller reflects your specific system with options.

Screen Type: “Main Menu”

Menu selection cursor or prompt. Use [SCROLL] to move.

User definable controller name

(default is model number).

====== MAIN MENU ======

DISPLAY DATA

? CALIBRATION

SETPOINTS

TIMERS

DATA COLLECT

CONFIGURE

–––––– SER 9500 ––––––

Sub-menu Selections.

Figure 9

For help with menu locations, please refer to the “Menu Map” supplied in the literature packet with your controller.

?? Display Data – Displays date, time, week number, software version, present sensor readings, set-points, system alarms, and relay on times. Use [SCROLL] to move between screens of data manually. Press [ENTER] to unlock the screens and allow them to scroll automatically. This menu displays information only. No settings or adjustments are made through this menu.

After five minutes of no keypad activity, the controller will always return to the Display Data screens regardless of the currently active menu.

?? Calibration – This menu is for analog{ XE "analog" } input sensor calibration, such as conductivity, pH, and ORP. In this menu, you can choose either 1 or 2 point calibration. The calibration values and “LAST CAL” date stamp are displayed on the menu. You can also use the “TUNE” feature to adjust the current value to a hand held tester’s measurement.

?? Setpoints – In this menu, you are prompted to enter settings pertaining to setpoints that control the system’s operation and associated alarms.

?? Timers – In this menu, you are prompted to enter settings pertaining to the Timers. You can select between five different timer types.

?? Data Collection – In this menu you make manual recordings of field data.

?? Configure{ XE "System Configure" } –In this menu, you are prompted to configure system functions and options to your specific application. System Configure includes such things as time of day, date, security{ XE "security" }, communications, diagnostics, relay on time and factory re-initialization{ XE "initialization" }.

72-900-28 Rev C

Page 15 of 27

3.2 Keypad Operation

The Keypad is easy to use and will guide you through the sub menus and functions of the controller.

Feel free to try out these keys as you read about them. You will not hurt the controller and the values will need to be reprogrammed later anyway.

Figure 10

– Press [HOME] to return to the previously displayed menu. Press [HOME] to exit and edit field. Press [HOME] to reject a setting.

– Press [SCROLL] to move the triangular cursor or “prompt” to the next line.

– Press [CONTRAST] to control the contrast of the viewing screen. Pressing [UP] will darken the display{ XE "display" }, pressing [DOWN] will lighten it.

– The Arrow keys are used to change the numbers or values associated with the various settings you will be entering. Use [DOWN] to select lower numbers and [UP] to select higher numbers.

– Enter has three functions:

??

After moving the prompt using the [SCROLL] key to a menu choice, press

[ENTER] to display{ XE "display" } the sub menu of the choice you selected.

??

(Within the sub menu), after moving the prompt with [SCROLL] to the selection of your choice, press [ENTER] to edit the selection (the prompt will disappear and the value to be changed will reverse - a white character is displayed against a black background ).

??

After changing / selecting the value needed with [UP] / [DOWN] press [ENTER] to

“lock-in” the value. The prompt and value selected will appear normal.

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NEVER

LEAVE A SCREEN IN THE MIDDLE OF EDITING A FIELD

! C

ONTROLLER ACCURACY

MAY BE AFFECTED

,

AND

/

OR THE CONTROLLER MAY NOT OPERATE PROPERLY

. I

F YOU

FORGET

,

SIMPLY RETURN TO THAT MENU AND COMPLETE YOUR PROGRAMMING

.

– When pressed, the controller displays a CAL-TUNE menu where you can “TUNE” the calibration of any of the controllable inputs (e.g., system conductivity, pH ORP, etc.).

– When pressed, this key will display{ XE "display" } simple instructions for the operation of the [ENTER], [HOME], [ARROW], and [SCROLL] keys.

– These Hand/Off/Auto (HOA){ XE "(HOA)" } keys allow immediate control of the relays powering attached pumps, solenoid valves, etc. Press a [RELAY] key once to force the relay on for 5 minutes (an amber light is displayed below that key). Press the [RELAY] key again to force the relay off (a red light is displayed below that key, relay will be forced off until the key is pressed again). Press the [RELAY] key a third time to return the relay to auto control (green light will indicate that relay is on, no light indicates that relay is off).

3.3 Screen Format

The controller screens are formatted in a manner that will help you understand what you can and cannot do.

?? List Field: “TYPE: 28 DAY”

A line that has a “ : ” means that you can change a value by selecting from a list.

?? Value Field: “RUN TIME = 01:30”

A line on the screen with an “ = ” sign means that you may change the value.

?? Sub-Menu: “<PROGRAMS>”

A line on the screen with “<_>” means there is a Sub-Menu that can be accessed.

The following is a sample screen that demonstrates all 3 field types:

Screen Type:

“Timer 1 Setup”

Relay # controlled by this timer.

List Field. Select: disabled,

Slaved to, Limit, Percent, %Post

B.D, Pulse, Cycle and 28 day.

Sub-Menu Field: “<_>”

Move prompt to this line and press [ENTER] to access the Sub-Menu.

TIMER 1 R#

? TYPE:

28 DAY

RUN TIME = 01:30 H:M

LOCK OUT = 00:00 H:M

PRE Bleed = 00:00 H:M

?

COND MIN = 0

?

ORP MAX = 0

<PROGRAMS>

Figure 11

Value Field. Enter values in HH:MM.

Value Field. Enter values to 20000.

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3.4 Change Verification

Whenever you make changes to a menu on your controller, a change verification screen appears when you leave that menu. To accept your changes, press [ENTER]. To reject your changes press

[HOME].

–––– SYSTEM CHANGES ––––

HAVE BEEN MADE !

?? SAVE CHANGES ??

Press ENTER to SAVE

Press HOME to ABORT

Figure 12

When you accept your changes, the value will be changed and the previous menu will be displayed.

When you reject your changes, the menu values will be restored to their original values and the menu will be re-displayed. Press [HOME] to exit the menu.

4. Alternate Language

To change to your controllers alternate language:

?? Turn the power “OFF”

?? Open cover and find the dip switch “S1”, located on the main board.

?? Set S1-1 to the “ON” position

?? Turn power “ON”

?? Perform a “Factory Reinit”, use [SCROLL], [ENTER] and follow these steps

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====== MAIN MENU ======

DISPLAY DATA

CALIBRATION

SETPOINTS

TIMERS

DATA COLLECT

? CONFIGURE

––––––

–––––– CONFIGURE ––––––

DATE TIME

SECURITY

COMMUNICATIONS

DIAGNOSTICS

RELAY TIME

? FACTORY INITIALIZE

The controller will return to Factory Defaults

.

–––––– FACTORY INIT ––––––

?

INITIALIZE to

FACTORY DEFAULTS

<ALARM INFO>

Your controller should now display its alternate language.

–––––– FACTORY INIT ––––––

FACTORY ReINIT WILL

OVERWRITE ALL

PREVIOUS SETTINGS

Press ENTER to ReINIT

Press HOME to ABORT

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Page 19 of 27

SYSTEM CONDUCTIVITY SCALE

Set Point Type

Set Point

Set Point Differential

High Alarm

Low Alarm

Alarm Offset

Alarm LED/RELAY/CALLBACK

Limit Timer

Limit Timer Alarm

LED/RELAY/CALLBACK

Alarm Delay

MAKE-UP CONDUCTIVITY SCALE

Setpoint Format

Setpoint Scale

Setpoint Ranges

Setpoint Range Cycle

Setpoint Differential

High Alarm

Low Alarm


Alarm Delay

SYSTEM pH SCALE

Set Point Type

Hi Setpoint

Lo Setpoint

Set Point Differential

Alarm Offset

High Alarm

Low Alarm


Alarm Delay

Limit Timer

Limit Timer Alarm

LED/RELAY/CALLBACK

SYSTEM ORP SCALE

Setpoint Type

Setpoint

Setpoint Differential

High Alarm

Low Alarm


Alarm Delay

Limit Timer

5. Factory Default Values

Your controller may not include all of these features

9200

5000 µS/CM

RISING/HI

1500 µS/CM

100 µS/CM

1700 µS/CM

1300 µS/CM

200 µS/CM

-

-

-

00 Sec.

-

-

2000 µS/CM

-

-

0.4 Cycles

700 µS/CM

500 µS/CM

-

-

0-14 pH

RISING/HI

7.2 pH

-

0.2 pH

2.0 pH

9.4 pH

5.4 pH

-

-

01:30 (HH:MM)

-

0-1000 mV

FALLING/LOW

400 mV

50 mV

500 mV

300 mV

-

-

-

9300

0-5000 (Hardware) µS/cm

RISING/HI

1500 µS/cm

50 µS/cm

1700 µS/cm

1300 µS/cm

-

BOTH/BOTH/BOTH

00:00 (HH:MM)

9500

0-5000 (Hardware) µS/CM

RISING/HI

1500 µS/CM

50 µS/CM

1700 µS/CM

1300 µS/CM

-

BOTH/BOTH/BOTH

00:00 (HH:MM)

YES / YES / YES YES / YES / YES

00 Sec.


00 Sec.


CYCLES CYCLES

0-2000 µS/CM

'0-400 / 401-800 / 801-1200 /

1201-1600 / 1601

0-2000 µS/CM

'0-400 / 401-800 / 801-1200 /

1201-1600 / 1601

6.0 / 5.0 / 4.0 / 3.0 / 2.0 Cycles 6.0 / 5.0 / 4.0 / 3.0 / 2.0 Cycles

40 µS/CM

840 µS/CM

360 µS/CM

40 µS/CM

840 µS/CM

360 µS/CM

BOTH/BOTH/BOTH

00 Sec.

0-14 pH

RISING/HI

7.2 pH

-

0.2 pH

-

8.3 pH

6.3 pH

BOTH/BOTH/BOTH

00 Sec.

01:30 (HH:MM)

BOTH/BOTH/BOTH

00 Sec.

0-14 pH

DUAL

7.8 pH

6.8 pH

0.2 pH

-

8.3 pH

6.3 pH

BOTH/BOTH/BOTH

00 Sec.

01:30 (HH:MM)

BOTH/BOTH/BOTH

0-1000 mV

FALLING/LOW

400 mV

50 mV

500 mV

300 mV

BOTH/BOTH/BOTH

00 Sec.

01:30 (HH:MM)

BOTH/BOTH/BOTH

0-1000 mV

FALLING/LOW

400 mV

50 mV

500 mV

300 mV

BOTH/BOTH/BOTH

00 Sec.

01:30 (HH:MM)

72-900-28 Rev C

Page 20 of 27

Limit Timer Alarm

LED/RELAY/CALLBACK

4-20mA INPUT

Units

High Alarm

Low Alarm


Alarm Delay

4-20mA OUTPUT

Type

Scale

LEVEL INPUT

Type

Active

Time

Relay Links


FLOW INPUT

Type

Active

Time

Relay Links


TIMER

Type

TIMER: LIMIT

Run Time

TIMER: PERCENT

Percent

Percent Minutes

TIMER: PERCENT POST BLEED

Bleed Percent

Maximum Time

TIMER: PULSE

Run Time

Pulse Set

Water Meter

TIMER: 28-DAY

Run Time

Lock Out

Pre Bleed

ORP Maximum

Conductivity Minimum

Program: Start Time

Program: Month

Program: Week

Program: Day

9200

-

-

LIMIT

01:30 HH:MM

0%

00:10

0%

01:30 HH:MM

00:30 MM:SS

10

-

01:30 HH:MM

00:00 HH:MM

00:00 HH:MM

-

0 µS/CM

00:00 HH:MM

N/A

NO WEEK

FRI

-

-

-

-

-

-

-

4-20 mA

None

-

-

-

-

-

Flow

Open

1.5 Seconds

9300 9500

BOTH/BOTH/BOTH BOTH/BOTH/BOTH

4-20 mA

NONE

0

0

BOTH/BOTH/BOTH

00 Sec

0-20 mA

Disabled

None

-

-

4-20 mA

NONE

0

0

BOTH/BOTH/BOTH

00 Sec

0-20 mA disabled

None

Level

Closed

-

-

-

Flow

Closed

5 Seconds

NO / NO / NO / NO / NO / NO

YES / YES / YES

Flow

Closed

1.5 Seconds 1.5 Seconds

YES / YES / YES / YES / YES /

YES

YES / YES / YES / YES / YES /

YES

YES / YES / YES YES / YES / YES

DISABLED DISABLED

01:30 HH:MM

0%

01:30 HH:MM

0%

00:00

0%

00:00

0%

01:30 HH:MM

00:30 MM:SS

10

One

01:30 HH:MM

00:00 HH:MM

00:00 HH:MM

0 mV

0 µS/CM

00:00 HH:MM

EVERY MONTH

EVERY WEEK

NO DAY

01:30 HH:MM

00:30 MM:SS

10

One

01:30 HH:MM

00:00 HH:MM

00:00 HH:MM

0 mV

0 µS/CM

00:00 HH:MM

EVERY MONTH

EVERY WEEK

NO DAY

72-900-28 Rev C

Page 21 of 27

TIMER: CYCLE

Off Time

On Time

Cycles/Day

Program: Month

Program: Week

Program: Day

TIMER: SLAVED TO

Relay Links

WATER METER

Multiplier

Active

Time

Units

SECURITY

Master Password

User Password

Calibration

Setpoints

Timers

Data Collect

COMMUNICATIONS

Baud Rate

Interval

Event Driven

Modem Setup String


Callback: Active

Callback: Device ID

Callback: Remote Number

Callback: Pager Number

Callback: Pager ID

FACTORY INITIALIZE


-

-

-

-

-

-

-

-

CLOSED

.80 sec

NONE

(NONE)

(NONE)

-

-

-

-

2400

1 minute

-

&FE0V0X4S0=1&D0

N/A

OFF

DEVICE0

(NONE)

(NONE)

,1,2,3,4,*001*?*#

-

01:30

00:30

12

EVERY MONTH

EVERY WEEK

01:30 HH:MM

00:30 HH:MM

12

EVERY MONTH

EVERY WEEK

NO DAY NO DAY

NO / NO / NO / NO / NO / NO NO / NO / NO / NO / NO / NO

100 100

CLOSED

.80 sec

GALLONS

(NONE)

(NONE)

NO

NO

NO

NO

19200

1 minute

On

&FE0V0X4S0=1&D0

NO / NO / NO

OFF

DEVICE0

(NONE)

(NONE)

,1,2,3,4,*001*?*#

YES / YES / YES

Closed

.80 Sec

GALLONS

(NONE)

(NONE)

NO

NO

NO

NO

19200

1 minute

On

&FE0V0X4S0=1&D0

NO / NO / NO

OFF

DEVICE0

(NONE)

(NONE)

,1,2,3,4,*001*?*#

YES / YES / YES

72-900-28 Rev C

Page 22 of 27

6. Standard Sensors:

6.1 Cooling Tower Sensors

STAINLESS STEEL SENSOR– Part No. 04-600-02

Pressure Rating ……………..125 PSI (8.6 BAR)

Temperature Rating …………125º F (51.7º C)

Temperature Compensation ...45ºF (7.2ºC) to 105ºF (40.6ºC)

Construction …………………Glass Filled Polypropylene S.S.

Cell Constant…………………0.5 pH SENSOR – Part No. 04-040-00

Double Junction pH Range ................................. pH 0 to 14 (Na+ < 0.1 N)

Accuracy ................................................ +/- 0.1 pH Unit

Response Time .......................< 10 Sec. (95% Response)

Operating Temp. Range ....23º F (-5º C) to 176º F (80º C)

Operating Pressure Range .................... 100 psi (6.8 BAR)

6.2 Hi-Pressure Sensors

CONDUCTIVITY SENSOR – Part No. 04-600-30

Pressure Rating ……………….250 PSI (17.3 BAR)

Temperature Rating …………..32º F to 212º F (0º C to 100º C)

Temperature Compensation ….45ºF to 105ºF (7º C to 40ºC)

Construction …………………..S.S. with CPVS Insulator

Cell Constant ………………….1.5

ORP SENSOR – Part No. 04-045-05

ORP Range ………………….0 - 1000mV

Response Time ……………...< 20 sec. (95% response)

Operating Temperature ……...23º F (-5º C) to 248º F (120º C)

Operating Pressure Rating …..250 psi (17.3 BAR)

CARBON GRAPHITE SENSOR – Part No. 04-035-00

Pressure Rating ……………..125 PSI (8.6 BAR)

Temperature Rating …………125º F (51.7º C)

Temperature Compensation .. 45ºF (7.2ºC) to 105ºF (40.6ºC)

Construction ………………..Glass Filled Polypropylene Carbon

Graphite

Thread Size………………….3/4" (19.05mm) NPT

Cell Constant………………..1.0

ORP SENSOR – Part No. 04-045-00

ORP Range ................................................... 0-1000 mV

Response Time .......................< 20 Sec. (95% Response)

Operating Temp. Range ... 23º F (-5º C) to 176º F( +80º C)

Operating Pressure Range ... .. 50 psi (3.4 BAR) @ 176º F

(80ºC)

................................... 100 psi (6.8 BAR) @ 77º F (25ºC)

Reference Type ..................................... Annular Ceramic

Reference Sensor .............................. Polysaccharide Gel,

Outer Solution 4 M KCl sat‘d with AgCl pH SENSOR – Part No. 04-048-00 pH Range …………………..pH 0 to 14 (Na+ < 0.1N)

Accuracy ……………………+ 0.1 pH Unit

Response Time …………….< 10 sec. (95% response)

Operating Temperature …….23º F (-5º C) to 248º F (120º C)

Operating Pressure Rating …250 psi (17.3 BAR)

72-900-28 Rev C

Page 23 of 27

7.

72-900-28 Rev C

Page 24 of 27

Standard CE

Specifications

(Factory settings are default values)

General

Power Input{ XE "Power Input" } 90-250 VAC @ 50/60 Hz 100 VA.

Control Output{ XE "Control Output" } Line voltage @ 600 VA (5 amps @ 120 VAC) per relay.

Enclosure Pre-wired .................High impact resistant Polystyrene™ designed to NEMA 4X

(IP65), with convenient molded receptacle cords and power cord with molded plug for electrical connections.

Enclosure Conduit{ XE "Enclosure Conduit" } High impact resistant Polystyrene designed to NEMA 4X (IP65), factory predrilled with easily accessible terminals for hard wiring.

Display......................................Alphanumeric 2 line by 16 character lighted LCD display 9200,

64 X 128 pixel dot matrix backlit display{ XE "display" } (8 line by 20 characters), 9300 & 9500.

Logic Power Switch ..................Recessed front panel.

H/O/A Switches ........................Front panel keypad.

Contrast Adjustment..................Front panel keypad.

Lockable Viewing Window{ XE "Lockable Viewing Window" } Standard

Security Code{ XE "Security Code" } Standard.

Environment..............................Ambient temp. 0°F (-17.8°C) to 122°F (50°C); relative humidity 0 to 95%.

Dimensions{ XE "Dimensions" } Width 10” (25.40 cm) X height 10” (25.40 cm) X depth

7.08” (17.98)

Controller Weight......................Max 18 lbs. (8.16 kg)

Shipping Weight........................Max 22 lbs. (9.98 kg)

Flow Switch or Interlock ..........Connection provided. Function activated by dip switch if mounted flow switch or remote flow switch not ordered with controller.

Inputs{ XE "Inputs" } ................8 analog{ XE "analog" } and 8 digital (max - depends on model).

Outputs{ XE "Outputs" } ...........4 analog{ XE "analog" } and 7 relays (max - depends on model).

Conductivity Function

Sensor .......................................Temperature compensated from 45°F (7.2°C) to 105°F

(40.6°C), quick-release 3/4” (19.05 mm) glass filled polypropylene flow tee. Pressure 125 psi (8.6 BAR) @ 125°F

(51.7°C).

Setpoint .....................................Factory set rising @ 1500

?

S/CM, rising.

Range........................................Selectable 0 to 500, 2000, 5000, 10,000 & 20,000. Factory set

@ 5000

?

S/CM.

Accuracy...................................+/- 1% of full scale, at point of measurement, excluding sensor.

Differential................................Adjustable. Factory setting @ 100

?

S/CM 9200, 50

?

S/CM

9300 & 9500.

72-900-28 Rev C

Page 25 of 27

High/Low Alarm .......................Adjustable. Select track set point or independent. Factory track set point @ +/- 200

?

S/CM (9200). Independently adjustable high and low (9300 & 9500).

Limit Timer{ XE "Limit Timer" } Adjustable in 1 minute increments up to 23:59. Alarm function only.

pH Specifications

Sensor .......................................Sealed combination type; KCl-AgCl reference with 3/4” (19.05 mm) glass filled polypropylene flow tee, 100 psi (6.8 BAR) @

176° F(80° C).

Setpoint .....................................{ XE "caustic" }Factory set Hi 7.8 pH, Lo 6.8 pH.

Range........................................0 to 14 pH.

Accuracy...................................+/- 1% of full scale, at point of measure, excluding sensor.

Differential................................Adjustable from 0.0 to 14.0; factory setting 0.2 pH.

High/Low Alarm .......................Adjustable. Select track set point or independent. Factory track set point @ +/- 1 pH (9200). Independently adjustable high and low (9300 & 9500).

Limit Timer{ XE "Limit Timer" } Adjustable in 1 minute increments up to 23 hours, 59 minutes; factory set at 1:30 hr/min.

ORP Specifications

Sensor .......................................Sealed combination type; Polysaccharide Gel reference with

KC1- AgC1 outer. Provided with 3/4" (19.05 mm) glass filled polypropylene flow tee 100 psi (6.8 BAR) @ 77ºF (25ºC).

Setpoint .....................................Falling 400 mV.

Range........................................0 to 1000 mV.

Accuracy...................................+/- 1% of full scale, at point of measure, excluding sensor.

Differential................................Adjustable; factory setting 50 mV.

High/Low Alarm .......................Independently adjustable high and low.

Limit Timer{ XE "Limit Timer" } Adjustable in 1 minute increments up to 23 hours, 59 minutes; factory set at 1:30 hr/min.

Summary Of LED{ XE "LED" } Indicator Lights

Power Indicator ........................Illuminates green when power is supplied to unit.

Flow Indicator ...........................Illuminates when flow is present through flow switch.

.........................GREEN -

.........................RED -

Indicates flow

Indicates no flow

.........................OFF - Indicates disabled

Level Indicator ..........................GREEN if level OK (switch open).

..........................RED if level low (switch closed).

Alarm Indicator .........................Flashes red when an alarm condition is present.

Relay Indicators{ XE "Relay Indicators" } AMBER if forced on.

.........................RED -

.........................OFF -

.........................GREEN -

If forced off.

If in auto mode and control function is not automatically activated.

If activated automatically.

72-900-28 Rev C

Page 26 of 27

8. Maintenance

The only maintenance required on your controller is periodic cleaning and calibration of the sensors{ XE

" sensors " }. It is recommended that you establish a regular maintenance schedule designed to meet the needs of your particular application. All other service should be performed by factory authorized personnel only. Modifications to or tampering with the circuit level components makes all warranties, written or implied, and/or manufacturer’s responsibility for this controller null and void.

9. Relay Assignments

9.1 Cooling Tower

Model “C” (J3)

[RELAY1]

“D” (J4)

[RELAY2]

“E” (J5)

[RELAY3]

9210 Tower #1 Bleed Timer #1

9210XA Tower #1 Bleed Timer #1

9210XB Tower #1 Bleed Timer #1

9220

9220XA

9220XB

9230 pH

PH pH

Tower #1 Bleed

Timer #1

Timer #1

Timer #1 pH

-

Bio A

Bio A

-

Bio A

Bio A

Timer #1

9230XA Tower #1 Bleed

931X pH Timer #1

Tower #1 Bleed Timer #1 Timer #2

932X Tower #1 Bleed ORP Feed Timer #1

933XXA Tower #1 Bleed

933XXB Tower #1 Bleed

951X

952X

Acid

Acid

Timer #1

Caustic

Tower #1 Bleed Timer #1 Timer #2

Tower #1 Bleed ORP Feed Timer #1

Acid Timer #1 953XXA Tower #1 Bleed



Acid pH

Caustic

Timer #1

Caustic

ORP




956X

957X

Acid pH

Acid

Open Loop

Bleed (e.g.,

Tower)

Closed

Loop

Bleed (e.g.

Chiller).

Tower #1 Bleed Tower

Bleed #2

Caustic

Timer #1

(Open Loop

System)

Timer #1

(Tower #1)

“F” (J6)

[RELAY4]

-

-

Bio B

-

-

Bio B

-

Bio A

Timer #3

Timer #2

Timer #2

Timer #1

Timer #3

Timer #2

Timer #2

Timer #1

Timer #2

Timer #1

Timer #1

ORP

Timer # 2

(Closed

Loop

System)

Timer #2

(Tower #2)

“G” (J7)

[RELAY5]

-

-

-

-

-

-

-

Timer #4

Timer #3

Timer #3

Timer #2

Timer #4

Timer #3

Timer #3

Timer #2

Timer #3

Timer #2

Timer #2

Timer #1

Timer # 3

(Open Loop

System)

Timer #3

(Tower #1)

“H” (J8)

[RELAY6]

-

-

-

-

-

-

-

-

Timer #4

Timer #4

Timer #3

-

Timer #4

Timer #4

Timer #3

Timer #4

Timer #3

Timer #3

Timer #2

Timer #4

(Closed

Loop

System)

Timer #4

(Tower #2)

“I” (J9)

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

Alarm

72-900-28 Rev C

Page 27 of 27

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