Spirax sarco BC3250 Blowdown Controller Installation and Maintenance Instructions

IM-P403-89
4033452 / 7
AB Issue 7
BC3250
Blowdown Controller
Commissioning password
Current legislation states that in order to prevent tampering and potentially hazardous
programming errors, access to the pass codes required to enter commissioning mode
should only be available to qualified and trained personnel.
Enter commissioning
Installation and Maintenance Instructions
This is done from the run mode by pressing and holding down the
PASS CODE
OK
button for 5 seconds.
The bar graphs will disappear and the display will show 'PASS
CODE' with '8888' at the bottom right corner of the screen. The
flashing leading digit indicates the position of the cursor. The
default, or factory set pass code is 7452 but this can be changed
from within the commissioning mode. The pass code can be
entered by using the
and
buttons to increase or decrease
the flashing value and the
and
buttons to move the cursor.
Pressing OK will enter the pass code. If an incorrect pass code is
used, the display automatically returns to the run mode.
1. Safety information
2. User instructions and delivery information
BC3250
3. System overview
100
8888
4. Mechanical installation
5. Electrical installation
50
0
%
SP
PV
AL
6. Commissioning
- Quick set-up
- Full
7. Communications
8. Maintenance
9. Fault finding
OK
10. Technical information
- Default settings
This page MUST be removed after
commissioning
and kept in a safe,
access controlled location.
11.Appendix
- Summary of the Modbus protocol
12. Menu map
© Copyright 2015
Printed in GB
IM-P405-89 AB Issue 7
1. Safety information
Special functions in run mode
Purge
Manually opens the blowdown valve for the purge time set during commissioning. If the
purge time has been set to zero,· the valve will open for 1 minute.
- Using the ' ' or ' ' buttons, select 'PURGE'.
- Pressing the ' ' or ' ' opens the blowdown valve for the purge time or 1 minute.
- The display will return to the process variable run menu.
- 'BLOWDOWN-PURGE' or 'BLOWDOWN-TDS TEST' will appear on the information line
during this period.
- On completion of the purge time, the controller will revert to normal control.
Cleaning
Activates a probe cleaning cycle for the period of time set during commissioning.
- Using the ' ' or ' ' buttons, select 'CLEAN'.
- Pressing the ' ' or ' ' to active the cleaning cycle and the blowdown valve will close.
- The display will return to the process variable run menu.
- 'CLEANING' will appear on the information line during this period.
- On completion of the cleaning time, the controller will revert to normal control after
20 seconds. This is to allow any bubbles to disperse.
CAL
Enables the water treatment engineer / specialist to calibrate the controller from the run
menu. A pass code is not required.
- Using the ' ' or '
- Pressing the ' '
' buttons, select 'CAL'.
or ' ' will access the calibration menu in commission mode. See
Section 6.4.6.5 INPUT-TDS-CAL.
- On completion or exiting calibration, the display will return to the process variable run
menu and normal control will be resumed.
This page MUST be removed after
commissioning
and kept in a safe,
access controlled location.
Safe operation of this product can only be guaranteed if it is properly installed,
commissioned, used and maintained by qualified personnel (see Section 1.11) in
compliance with the operating instructions. General installation and safety instructions
for pipeline and plant construction, as well as the proper use of tools and safety
equipment must also be complied with.
Your attention is drawn to IEE Regulations (BS 7671, EN 12953, EN 12952 and EN 50156).
Elsewhere, other regulations will normally apply.
All wiring materials and methods shall comply with relevant EN and IEC standards
where applicable.
Warning
This product is designed and constructed to withstand the forces encountered during
normal use. Use of the product other than as a boiler controller, or failure to install the
product in accordance with these Instructions, product modifications or repair could:
-
-
-
Cause injury or fatality to personnel.
Cause damage to the product / property.
Invalidate the
marking.
These instructions must be stored in a safe place near the product installation at
all times.
Warning
This product complies with Electromagnetic Compatibility Directive 2004 / 108 / EC
and all its requirements.
This product is suitable for Class A Environments (e.g. industrial). A fully detailed EMC
assessment has been made and has the reference number UK Supply BH BC3250 2008.
The product may be exposed to interference above the limits of Heavy Industrial
Immunity if:
-
-
The product or its wiring is located near a radio transmitter.
-
Cellular telephones and mobile radios may cause interference if used within
approximately 1 metre (39") of the product or its wiring. The actual separation
distance necessary will vary according to the surroundings of the installation and
the power of the transmitter.
Excessive electrical noise occurs on the mains supply. Power line protectors (ac)
should be installed if mains supply noise is likely. Protectors can combine filtering,
suppression, surge and spike arrestors.
This product complies with Low Voltage Directive 2006 / 95 / EC by meeting the
standards of:
-
EN 61010-1:2010 Safety requirements for electrical equipment for measurement,
control, and laboratory use.
Static precautions (ESD)
Static precautions must be observed at all times to avoid damage to the product.
IM-P405-89 AB Issue 7
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IM-P405-89 AB Issue 7
Symbols
Equipment protected throughout by double insulation or reinforced
insulation.
Functional earth (ground) terminal, to enable the product to function
correctly.
Not used to provide electrical safety.
Clean earth / ground.
Safety earth.
Caution, risk of electric shock.
Caution, risk of danger, refer to accompanying documentation.
Optically isolated current source or sink.
Caution, Electrostatic Discharge (ESD) sensitive circuit. Do not touch
or handle without proper electrostatic discharge precautions.
ac, alternating current.
IM-P403-89 AB Issue 7
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1.1 Intended use
i) Check that the product is suitable for use with the intended fluid.
ii) Check material suitability, pressure and temperature and their maximum and
minimum values. If the maximum operating limits of the product are lower than
those of the system in which it is being fitted, or if malfunction of the product could
result in a dangerous overpressure or overtemperature occurrence, ensure a
safety device is included in the system to prevent such over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may be
induced by any system to which they are fitted. It is the responsibility of the installer
to consider these stresses and take adequate precautions to minimise them.
v) Remove protection covers from all connections and protective film from all
name-plates, where appropriate, before installation on steam or other high
temperature applications.
1.2Access
Ensure safe access and if necessary a safe working platform (suitably guarded)
before attempting to work on the product. Arrange suitable lifting gear if required.
1.3Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline
Consider what is in the pipeline or what may have been in the pipeline at some
previous time. Consider: flammable materials, substances hazardous to health,
extremes of temperature.
1.5 Hazardous environment around the product
Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases,
extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive
noise, moving machinery.
1.6 The system
Consider the effect on the complete system of the work proposed. Will any proposed
action (e.g. closing isolation valves, electrical isolation) put any other part of the
system or any personnel at risk?
Dangers might include isolation of vents or protective devices or the rendering
ineffective of controls or alarms. Ensure isolation valves are turned on and off in a
gradual way to avoid system shocks.
1.7 Pressure systems
Ensure that any pressure is isolated and safely vented to atmospheric pressure.
Consider double isolation (double block and bleed) and the locking or labelling of
closed valves. Do not assume that the system has depressurised even when the
pressure gauge indicates zero.
1.8Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.
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IM-P403-89 AB Issue 7
1.9 Tools and consumables
Before starting work ensure that you have suitable tools and / or consumables
available. Use only genuine Spirax Sarco replacement parts.
1.10 Protective clothing
Consider whether you and / or others in the vicinity require any protective clothing
to protect against the hazards of, for example, chemicals, high / low temperature,
radiation, noise, falling objects, and dangers to eyes and face.
1.11 Permits to work
All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the
product according to the Installation and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where
there is no such system, it is recommended that a responsible person should know
what work is going on and, where necessary, arrange to have an assistant whose
primary responsibility is safety.
Post 'warning notices' if necessary.
1.12Handling
Manual handling of large and / or heavy products may present a risk of injury. Lifting,
pushing, pulling, carrying or supporting a load by bodily force can cause injury
particularly to the back. You are advised to assess the risks taking into account the
task, the individual, the load and the working environment and use the appropriate
handling method depending on the circumstances of the work being done.
1.13 Residual hazards
In normal use the external surface of the product may be very hot.
Many products are not self-draining. Take due care when dismantling or removing
the product from an installation.
1.14Freezing
Provision must be made to protect products which are not self-draining against
frost damage in environments where they may be exposed to temperatures below
freezing point.
1.15Disposal
On disposal of the unit or component, appropriate precautions should be taken in
accordance with Local / National regulations.
Unless otherwise stated in the Installation and Maintenance Instructions this product
is recyclable and no ecological hazard is anticipated with its disposal providing due
care is taken.
1.16 Returning products
Customers and stockists are reminded that under EC Health, Safety and Environment
Law, when returning products to Spirax Sarco they must provide information on any
hazards and the precautions to be taken due to contamination residues or mechanical
damage which may present a health, safety or environmental risk. This information
must be provided in writing including Health and Safety data sheets relating to any
substances identified as hazardous or potentially hazardous.
IM-P403-89 AB Issue 7
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2. User instructions
and delivery information
Certain computer programs contained in this product were developed by Spirax-Sarco
Limited ("the Work(s)").
Copyright © Spirax-Sarco Limited 2015
All rights reserved
Spirax-Sarco Limited grants the legal user of this product (or device) the right to use the
Work(s) solely within the scope of the legitimate operation of the product (or device).
No other right is granted under this licence. In particular and without prejudice to the
generality of the foregoing, the Work(s) may not be used, sold, licensed, transferred,
copied or reproduced in whole or in part or in any manner or form other than as expressly
granted here without the prior written consent of Spirax-Sarco Limited.
2.1 General description
The BC3250 is a blowdown controller for steam boilers. It controls TDS (total dissolved
solids – salts in solution) by opening and closing a blowdown valve. It also controls a bottom
blowdown valve, which removes precipitated solids from the bottom of the boiler shell.
The product works by controlling the conductivity of liquids, in conjunction with a Spirax Sarco
conductivity sensor, a boiler blowdown valve or condensate dump valve.
The bottom blowdown valve is controlled by a timer.
The front panel has an LCD graphics display and five-button keypad.
An additional filter can be selected to increase the damping effect where the probe is fitted
directly in the boiler. This avoids over-frequent valve operation.
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IM-P403-89 AB Issue 7
2.2 Front panel
The front panel has an LCD graphics display and five-button keypad:
BC3250
100
Graphic display
50
0
%
SP
PV
Scroll up menus
Scroll down menus
OK
AL
Horizontal arrows
are used to
toggle between the
Bar graph and the
Trend graph
Clears any
errors or alarms
(Press and hold
for 5 seconds)
Fig. 1 Front panel keypad and definitions.
2.3 Using the buttons
The
and
buttons are used to:
- scroll up and down through the menus.
The
The
and
OK
buttons are used to move between the Bar graph and the Trend graph.
button is used to clear errors or alarms.
IM-P403-89 AB Issue 7
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2.4 LCD display
After initially applying power to the product, it will automatically enter run mode. If a clean
time has been set, a cleaning cycle will start. The current conductivity or TDS will then be
displayed or 0000 if a purge time has been set.
The display is divided into three sections:
- Four
large digits, displaying the process variable and control parameters (last digit is
blanked off or always reads zero).
- Information line, displays the various control states and process units.
- Three bar graphs, which shows a percentage of full scale:
- PV Process Variable, the highest and lowest recorded value.
- SP Set Point (line and arrow) and the hysteresis point (dotted line).
- AL High Alarm level (line and arrow) with hysteresis point (dotted line).
Parameter value
Example:
PV
3570
BLOWDOWN
100%
50%
Process variable
Information line
Examples:
Units
ALARM STATE
Percentage scale
For bar graphs
10% steps
0%
SP PV
Set point
AL
Alarm
Process variable
Fig. 2 Graphics display definitions
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IM-P403-89 AB Issue 7
High alarm
Highest process variable
reached
This can be reset by
entering the commissioning
mode.
High alarm
hysteresis
Set Point
(TDS)
Current process variable
Graphical representation of
the process variable in terms
of percentage of full scale.
AL
Set Point
(hysteresis)
Fig. 4 SP and alarm bar
graph definitions
AL
Lowest process variable
This can be reset by entering
the commissioning mode.
PV
PV
Fig. 3 PV (conductivity) bar graph definitions
2.5 Trend graph
A second screen display appears if the
CAL, PURGE and CLEAN
or
button is pressed in run mode. Except
This shows a Trend graph, which displays a record of the variation in TDS over a set time. The
most recent event / value is to the left of the graph.
Time can be set in minutes, hours or days, up to 8 units. Time base setting is carried out via
the TREND menu.
Parameter value
Example:
PV
(e.g. 3570 µS / cm)
100
PV% value now
50
M
Fig. 5 Graphics display definition - trend graph
IM-P403-89 AB Issue 7
0
%
Information line
Examples:
Units
ALARM STATE
Markers
Minute or hour or day
PV% value
8 minutes
(or hours or day)
Percentage scale
Timescale designator
M = Minutes
H = Hours
D = Days
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2.6 Information line
The information line will show 'PPM' or 'US / CM' and will alternate with information about
alarms or the TDS / Bottom Blowdown Valve status.
If an alarm occurs, the TDS / Bottom Blowdown Valve status will not show. 'ALARM' will be
shown first followed by the type of alarm. See Section 9 – 'Fault finding' for types of errors.
Example of alarm status:
7000
PPM
7000
7000
ALARM
HIGH TDS
If a bottom or TDS blowdown occurs, 'BLOWDOWN' will be displayed, followed by the type
of blowdown.
Example of valve status:
5100
5100
PPM
BLOWDOWN
5100
HIGH TDS
If both the bottom and TDS blowdown occurs, the display will show the following:
10
5100
5100
PPM
BLOWDOWN
5100
BB DOWN
5100
HIGH TDS
IM-P403-89 AB Issue 7
Information line details (in priority order):
Alarm:
-
-
ALARM - Indicates the alarm relay has been de-energised / released.
-
-
-
BB ERROR - See details in the error screen in run mode and Section 9 - 'Fault finding'.
ALM TEST - the operator is testing the alarm relay. The relay is either energised (shown
without 'ALARM') or de-energised (shown with 'ALARM') for 5 minutes. See commissioning
mode TEST-OUTPUT-ALARM menu.
SCALED - See details in Section 9.3 - 'Operational error messages'
TDS HIGH - The PV value has exceeded the alarm level.
Bottom blowdown valve (BB):
-
-
BLOWDOWN - Indicates either the bottom or TDS blowdown relay is energised.
-
BB OPEN - the valve has been opened continuously i.e. manual override. See
commissioning TIMER-MODE-OPEN menu.
-
-
BB TEST - the operator is testing the bottom blowdown relay. The relay is either energised
('ON') or de-energised ('OFF') for 5 minutes. See commissioning mode TEST-OUTPUTBB VALVE menu.
BB OFF - the timer is switched off i.e. manual override. The timer will ignore all pre-recorded
times. See commissioning TIMER-MODE-OFF menu.
BB BLDN - a timed bottom blowdown is occurring i.e. the valve is open.
TDS blowdown valve (Conductivity / Total Dissolved Solids):
-
-
BLOWDOWN - Indicates either the bottom or TDS blowdown relay is energised.
-
-
CLEANING - Indicates the probe is being cleaned. The valve has been switched off.
-
-
TDS TEST - The operator is testing the TDS blowdown relay. The relay is either energised
('ON') or de-energised ('OFF') for 5 minutes. See commissioning mode TEST-OUTPUTVALVE menu.
PULSED - The TDS has increased above the Set Point (SP), and the TDS blowdown valve
is being pulsed open for 10 second on and 20 seconds off until the TDS drops below the
hysteresis of the SP.
TDS HIGH - The TDS has increased above the Set Point (SP), and the TDS blowdown valve
has been opened until the TDS drops below the hysteresis of the SP.
PURGE - is displayed during a purge period (valve open). At the end of this time the product
will either indicate 'TDS HIGH, PULSED ' or restart another purge interval.
TDS recalibration required:
-
TDS CAL + REQUIRED - If selected, the product can remind the user when another
calibration is required. The reminder will only be displayed if an alarm or a blowdown is not
occurring.
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2.7 Viewing parameters
In run mode the general data is displayed on several screens, which can be accessed by
pressing the
and
buttons. The parameter will appear on the display, alternating with
the value buttons.
4680
US / CM
9990
Process variable (PV) is displayed (current conductivity or TDS), in µS / cm
or ppm, depending on user choice.
Shows the range that has been selected by the user. e.g. 0 - 9990
RANGE
5000
SP
500
SP
HYST
9990
ALARM
300
AL
HYST
0.50
Set Point (SP), displays the desired water conductivity or TDS selected by
the user.
Shows the hysteresis value (dead-band) selected to prevent over-frequent
valve operation in a turbulent boiler.
Alarm (AL), displays the high alarm water conductivity or TDS.
Flashing AL and µS / cm or ppm.
Shows the alarm hysteresis chosen by the user.
A damping effect for turbulent conditions. Normally 3% of alarm figure.
Shows probe factor, an indication of the probe condition.
PROBE F
4150
Calibration (CAL) value. Displays the last calibration value.
CAL
0. 20
O/P
MA
239
OP TEMP
12
Displays the configuration of the re-transmit mode, either:
'0. 20' = 0 – 20 mA or '4. 20' = 4 – 20 mA
Operating temperature (OP TEMP) if Pt100 is fitted. Display alternates OP
TEMP and ºC
IM-P403-89 AB Issue 7
20
PURGE
S
10
CLEAN
S
Shows the cleaning time selected. Flashes CLEAN and 'S' (seconds).
Pressing the ' ' or ' ' to active the cleaning cycle and the blowdown valve
will close.
CLEAN is shown only if clean time > 0
S
Timer - duration - set. Shows the bottom blowdown time selected by the
user (in seconds).
Timer - duration - set is shown only if timer duration > 0
30
TIMER
29
TIMER
Shows purge time (probe in pipeline).
Flashes PURGE and 'S' (seconds).
Pressing the ' ' or ' ' opens the blowdown valve for the purge time or
1 minute.
S
12
TIMER HRS
11
TIMER
ERROR:
POWEROUT
Timer - duration – now. Shows elapsed duration time (in seconds).
Timer - duration – now is shown only if timer duration > 0
Timer - interval – set. Shows interval time selected by the user (in hours).
Timer - interval - set is shown only if timer duration > 0
Timer - interval – now. Shows elapsed interval time (in hours, minutes and
seconds).
Timer - interval – now is shown only if timer duration > 0
If there are any problems with the product, error or alarm will appear. The
example shows a power failure.
Please note that the display will always revert to displaying the current conductivity
or TDS valve if a button has not been pressed for 2 minutes.
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2.8 Alarm / error display messages
These are shown on a screen in the run mode. This screen is normally hidden and will only
appear if there's a problem. Alarm and error messages are prioritized, so if there are two
active problems, clearing the first will immediately cause the lower priority one to appear.
Some, such as the power-fail error message, can be cleared by pressing and holding
the OK button for three seconds. Others, such as a sensor error or a commissioning error
will need further action to clear them. See Section 9 – 'Fault finding'.
2.9 Equipment delivery, handling and storage
Factory shipment
The product is tested, calibrated and inspected prior to shipment to ensure proper operation.
Receipt of shipment
Each carton should be inspected at the time of delivery for possible external damage. Any
visible damage should be recorded immediately on the carrier's copy of the delivery slip.
Each carton should be unpacked carefully and its contents checked for damage. If it is found
that some items have been damaged or are missing, notify Spirax Sarco immediately and
provide full details. In addition, damage must be reported to the carrier with a request for their
on-site inspection of the damaged item and its shipping carton.
Storage
If the product is to be stored for a period prior to installation, the environmental storage
conditions should be at a temperature between 0°C and 65°C (32°F and 149°F), and between
10% and 90% relative humidity (non-condensing).
Ensure there is no condensation within the unit before installing and connecting the power.
Operators instructions
An alternative operator instruction manual, in place of this manual, for operating the equipment
is required. This will avoid the commissioning menu passcode being disclosed to the operator.
The alarm reset passcode may optionally be disclosed if this is deemed necessary.
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IM-P403-89 AB Issue 7
3. System overview
3.1Function
The controller has an adjustable alarm and set point levels.
The product can be configured to control TDS / conductivity of water. Once fully commissioned,
the TDS value is displayed in μS / cm (or ppm if selected).
Note: Conductivity is expressed in parts per million (ppm) or micro Siemens per
centimetre (µS / cm). Micro Siemens / centimetre is becoming the more common unit, and is
therefore the default setting.
If the water conductivity exceeds the set point level, 'BLOWDOWN' will be displayed and valve
relay will be energised until the conductivity drops below the set point level (plus a hysteresis
value).
The hysteresis setting is adjustable and provides a damping effect where water movement
at the probe may otherwise cause over-frequent switching of the blowdown or dump valve.
This could be caused, for example, by boiler firing rate variations, by the feedpump operating,
or by sudden changes in boiler load.
If the water conductivity exceeds the alarm level, 'HI ALARM' will be displayed and the alarm
relay will be de-energised until the conductivity drops below the alarm level (plus a hysteresis
value).
3.2Inputs
The BC3250 can accept a signal from a Spirax Sarco conductivity probe (CP10, CP30 or
CP32) and a Pt100 temperature sensor.
A Pt100 temperature sensor may be connected to the controller to display the boiler water
temperature (°C or °F) and provide temperature compensation (2% / °C). This is recommended
if the boiler is working at varying pressures, or for other applications such as condensate
monitoring or coil boilers, where the temperature may vary.
If a Pt100 is not fitted, the boiler operating temperature can be entered.
The default temperature value is 184°C @ 10 bar g.
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3.3Outputs
3.3.1 Continuous output
Used when the probe is mounted in the boiler. The probe is able to constantly monitor the
conductivity from the probe tip to the boiler shell.
Water
conductivity
SP
Hysteresis
High
conductivity
Valve
open
Closed
Fig. 6 Continuous output (purge time = 0s)
Blowdown
Keeps valve open until
conductivity drops below
hysteresis
Time
3.3.2 Purge output
Used only when the probe is mounted in the blowdown line, Purge ensures the sensor
measures the conductivity at boiler temperature. The purge duration time is the time the valve
is open to enable a representative boiler sample to reach the probe. A purge occurs every
PURGE - INTERVAL time either independent of burner firing, or dependent on cumulative
boiler firing time.
Water
conductivity
High conductivity
SP
Hysteresis
Interval
Valve
open
Closed
Purge
Fig. 7 Output with purge time set (>0s)
16
Purge
Blowdown
Keeps valve open until
conductivity drops below
hysteresis
Time
IM-P403-89 AB Issue 7
3.3.3 Pulsed output
For smaller boilers where the capacity of the blowdown valve is relatively high compared to
the boiler size, the blowdown may be set to pulsed, rather than continuous output, opening
for 10 seconds, and closing for 20 seconds. This slows the rate at which the boiler water
is removed so that the level is not unduly affected, avoiding the risk of triggering a low
water alarm.
Water
conductivity
Conductivity drops
below set point
SP
Hysteresis
Interval
20s
20s
10s
Valve
open
Closed
Purge Blowdown Blowdown Blowdown
Blowdown cycle
Purge
Blowdown
Time
Fig. 8 Pulse output with purge time set (>0s)
3.3.4 4 - 20mA retransmit
An isolated 0 - 20 or 4 - 20 mA output is provided as standard, and may be used for remote
display of the TDS level or as an output to a management system. The menu allows both
0 / 4 mA and 20 mA to be re-ranged.
3.3.5 Bottom blowdown timer
The timer can be used to control the interval and duration of a bottom blowdown cycle.
If a switch box is fitted to the bottom blowdown valve actuator, an alarm can be configured
to indicate if the valve fails to close or to lift off its seat.
3.4 Other features
A test function provides the operator with a diagnostic facility. Inputs can be measured and
outputs can be set from the front panel. The controller also displays the approximate probe
factor directly.
To prevent unwanted or inadvertent changes being made, all commissioning parameters are
protected with a pass code. This can be changed by the user if required.
The BC3250 can communicate via an infrared link between adjacent boiler house controllers
(Spirax Sarco products only). It is designated as a master or a slave unit as required – see
Section 7 – 'Communications'.
IM-P403-89 AB Issue 7
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3.5 Typical applications - Boiler control systems (BCS)
BC3250
100
50
0
%
SP
PV
AL
OK
Fig. 9 BCS1 system - smaller boiler
BC3250
100
50
0
%
SP
PV
AL
OK
Fig. 10 BCS2 system - coil boiler
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IM-P403-89 AB Issue 7
BC3250
100
50
0
%
SP
PV
AL
OK
Fig. 11 BCS3 system - TDS control with integral take-off and continuous monitoring
point from the side of the boiler.
BC3250
100
50
0
%
SP
PV
AL
OK
Fig. 12 BCS4 system - TDS control with intermittent monitoring point from the side
or the bottom of the boiler.
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3.6 Typical applications Condensation contamination detection system (CCD)
System description
WARNING: Most countries have regulations that limit temperature and contamination
levels for fluids being dumped to drain. It is essential to follow the guidelines issued by bodies
such as the UK Health and Safety Executive.
The Spirax Sarco CCD system monitors and displays the conductivity of condensate return,
and will redirect the flow to drain if the conductivity increases above a pre-set level to avoid
contaminated water being returned to the boiler feedtank. It will not detect contaminants that
do not change the conductivity, e.g. oils, fats, or sugars.
A conductivity sensor and a temperature sensor are mounted in a bypass line as shown in
Figure 13. A check valve in the main line ensures a flow past the sensor under low flow
conditions. The 500 mm head prevents flash steam flow in the bypass line. We recommend
a 3-port diverter valve such as the Spirax Sarco QL. A spring retract pneumatic actuator is
normally fitted to cause the valve to divert on failure of the air supply. Alternatively, two 2-port
valves (M20, for example) may be used as shown in Figure 14, one as a spring-to-close
isolating valve in the condensate return line, and one as a spring-to-open dump valve, in the
drain line. On detection of high conductivity, the isolating valve closes and the dump valve
opens, both under spring pressure. Suitable 3-port solenoid valves may be selected from the
Spirax Sarco range, and are described in separate literature.
Optional
Spring retract pneumatic
actuator
3-port QL diverter valve
Check valve
Bypass
line
500 mm
return
BC3250
100
50
Conductivity sensor
and
temperature sensor
Fig. 13 CCD system
20
0
%
SP
PV
AL
OK
BC3250
IM-P403-89 AB Issue 7
Isolating valve (spring-to-close) opens to
allow clean condensate
to be returned to the boiler.
Dump valve (spring-to-open).
Opens when conductivity level
is above set point allowing
contaminated condensate to flow
to drain.
Fig. 14 Alternative arrangement of a CCD system using separate valves
IM-P403-89 AB Issue 7
21
4. Mechanical installation
Note: Read the 'Safety information' in Section 1 before installing the product.
The product must be installed in a suitable industrial control panel or fireproof enclosure
to provide impact and environmental protection. A minimum of IP54 (EN 60529) or Type 3,
3S, 4, 4X, 6, 6P and 13 (UL50 / NEMA 250 ) is required. If installed in a harsh environment
(conductive dust and / or wet conditions), extra protection is required.
During installation or maintenance, the rear of the product must be protected from
environmental pollutants entering the product. Alternatively, the tasks can be performed
in a dry clean environment.
Caution 1: The product must only be installed in the vertical orientation.
Caution 2: Do not cover or obstruct the infrared beam between products.
Ensure that the display can be easily read by the operator.
Warning: The boiler control panel or enclosure doors must be kept closed at all
times unless installation or maintenance work is being carried out.
Do not attempt to open the product-it is sealed and has no replaceable parts or
internal switches.
4.1 Environmental conditions
Install the product in an environment that minimises the effects of heat, vibration, shock and
electrical interference (see Section 1 - 'Safety information').
Do not install the product outdoors without additional weather protection.
Do not attempt to open the product - it is sealed and has no replaceable parts or
internal switches.
4.2 Installation on a DIN rail
The product is provided with a clip and a set of self-tapping screws to secure it to a 35 mm DIN
rail. On the rear of the enclosure, two sets of holes are provided to give two height positions.
The clip can be adjusted to give further positions. Locate the clip onto one set of holes and
secure it using the two screws provided. Ensure the spring clip is fully engaged with the rail.
Warning: Only use the screws provided with the product.
4.3 Installation on a chassis plate:
- Drill holes in chassis plate as shown in Figure 15.
- Fit unit to chassis plate and secure with 2 screws, nuts and washers, using the slots provided
at the top and bottom of the case.
Warning: Do not drill the product case or use self-tapping screws.
4.4 Installation in a panel cutout:
(Minimum panel thickness 1 mm if the bezel is used).
- The product has integral threaded inserts (M4 x 0.7) at the top and bottom of the front
panel.
- Two M4 x 25 mm screws are provided, together with fibre washers and a bezel.
Warning:
Do not use screws over 25 mm in length - danger of electric shock.
22
IM-P403-89 AB Issue 7
- Cut the panel to the dimensions given in Figure 15. Drill the screw holes in the panel in the
positions indicated.
- Remove the backing from the gasket supplied and apply to front face of the product.
- The bezel can be used to enhance the appearance of the panel cutout. If required, fit this
to the outside of the panel.
- Fit the unit from the rear of the panel, and secure using the screws, washers (and bezel)
provided.
- Tighten the M4 screws to 1.0 - 1.2 Nm.
Warning: Do not drill the product case or use self-tapping screws.
Ø 4.2 mm
Ø 4.2 mm
10 mm
15 mm
45 mm
112 mm
92 mm
22.5 mm
22 mm
10 mm
Ø 4.2 mm
Ø 4.2 mm
67 mm
Fig. 15 Chassis plate / panel - cutout diagram
Fixing template cutout notes:
- Solid line indicates cutout required for panel mounting.
- Broken line indicates product outline.
- A minimum gap of 15 mm between units must be provided for product cooling.
- Mounting hole dimensions are the same for both panel and wall mounting.
IM-P403-89 AB Issue 7
23
5. Electrical installation
Note: Before installing observe the 'Safety Information' in Section 1.
Warning:
Isolate the mains supply before touching any of the wiring terminals as these
may be wired to hazardous voltages.
Use only the connectors supplied with the product, or spares obtained from
Spirax Sarco Ltd. Use of different connectors may compromise product
safety and approvals.
Connecting the mains supply incorrectly can cause damage and may
compromise safety.
5.1 General wiring notes:
Every effort has been made during the design of the product to ensure the safety of the user
but the following precautions must be observed:
1. Maintenance personnel must be suitably qualified to work with equipment having
hazardous live voltages.
2. Ensure correct installation. Safety may be compromised if the installation of the
product is not carried out as specified in this manual.
3. The design of the product relies on the building installation for overcurrent protection
and primary isolation.
4. Overcurrent protection devices rated at 3 amps must be included in all phase conductors
of the installation wiring. If overcurrent protection is included in both supply wires then
the operation of one must also cause the operation of the other. Refer to IEC 60364
(Electrical Installations of Buildings) or National or local standards for full details of
requirements for overcurrent protection.
5. A 1 A quick-blow overcurrent protection device must be fitted to the burner input if used.
6. A 3 A quick-blow overcurrent protection device must be fitted to the relay circuit(s).
7. Relay contacts must be supplied on the same phase as the mains supply.
8. The product is designed as an installation category III product.
9. Install wiring in accordance with:
- IEC 60364 - Low-voltage electrical installations.
- EN 50156 Electrical Equipment for furnaces and ancillary equipment.
- BS 6739 - Instrumentation in Process Control Systems: Installation design and practice
or local equivalent.
- National and Local Electrical Code (NEC) or Canadian code (CEC) for the US and
Canadian markets. Note: use NEC Class 1 wire with a temperature rating greater than
75°C. If the cable is to be exposed to a higher temperature, then a higher temperature
rating needs to be selected.
10.It is important that the cable screens are connected as shown in order to comply with
the electromagnetic compatibility requirements.
11.All external circuits must meet and maintain the requirements of double / reinforced
installation as stated in IEC 60364 or equivalent.
12.Additional protection must be provided to prevent accessible parts (e.g. signal circuits)
from becoming Hazardous Live if a wire or screw is accidentally loosened or freed. Ensure
all wires are secured to at least one other wire from the same circuit. The attachment
must be as close to the terminal block as possible but must not apply undue stress on
the connection. Example: Use a cable tie to secure the live and neutral wire together.
If one wire becomes loose the other wire will prevent it from touching accessible parts.
24
IM-P403-89 AB Issue 7
13.A disconnecting device (switch or circuit breaker) must be included in the building
installation. It must:
- Have a rating with sufficient breaking capacity.
- Be in close proximity to the equipment, within easy reach of the operator.
- Not be fitted in a position that makes it difficult to operate.
- Disconnect all phase conductors.
- Be marked as the disconnecting device for the product.
- Not interrupt a protective earth conductor.
- Not be incorporated into a mains supply cord.
- Comply with the requirements for a disconnecting device specified in IEC 60947-1
(Specification for low-voltage switchgear and control gear - General rules) and IEC
60947-3 (Switches, disconnectors, switch-disconnectors and fuse-combination units).
14.See Section 10 - 'Technical Information' for terminal and cable specification.
5.2 Mains wiring notes:
1. Read Section 5.1 before attempting to wire the supply to the product.
2. The wiring connections are identified on the terminal plugs.
3. Fuses should be fitted in all live conductors.
Disconnect device conforming to
IEC 60947-1 and
IEC 60947-3
Product
1
3 A fuse
4
L
Disconnect device conforming to
IEC 60947-1 and
IEC 60947-3
N
Product
1
Fig. 16
Fig. 17
L1
3 A fuses
L2
4
4. Double or reinforced insulation must be maintained between:
- Hazardous live conductors (mains and relays circuits) and
- Safety extra low voltages (All other components / connectors
/ conductors).
5. The wiring diagrams show relays and switches in the Power Off position.
6. Where the probe is fitted in the blowdown line and a purge is required 10 – 60 minutes of
boiler firing (cumulative), connect a live supply from the burner control to the burner input.
This supply should be live whenever the burner is firing – see Wiring Diagram.
IM-P403-89 AB Issue 7
25
5.3 Blowdown Valve wiring notes:
Note: The protective earth must be connected in accordance with National or
Local regulations
Viewed from the underside, relays are shown in the power off position
Link
Link
BCV30 230 / 115 Vac
Blowdown valve
3
4
5
3
4
C1
5
N Y1 Y2 22
C2
See Section 5.2 Mains wiring notes
N
1A
Fuse
1 2 3 4 5
AC supply Burner
supply
Caution
live
terminal
Alarm Input
Input
3A
Norm 3 A
Fuse
Fuse
6 7 8
9 10 11
Open
L
Alarm 1 relay Control relay
Bottom
blowdown
relay 20 21 22
FRONT
BACK
3A
Fuse
N
Open
Input
Fig. 18 BCV30 230 / 115 Vac Blowdown Valve
See Section 5.2 Mains wiring notes
Solenoid valve
(BCV1, BCV20 or BCV31)
L N
N
N
1 2 3 4 5
AC supply Burner
supply
Caution
live
terminal
Alarm Input
Input
3A
Norm 3 A
Fuse
Fuse
6 7 8
9 10 11
Alarm 1 relay Control relay
Bottom
blowdown
relay 20 21 22
Fig. 19 BCV1, BCV20 or BCV31 Solenoid Valves
26
1A
Fuse
Open
L
FRONT
BACK
3A
Fuse
Open
Input
IM-P403-89 AB Issue 7
Optional Limit Switch
Limit Switch Box
S1 ( Xs1 )
S2 ( Xs2 )
Valve Opening
Valve Closing
4
5
6
7
8
9
2a valve opening
2b valve closing
AVF234S
2b
2a
21
1
BCV4x,6x,7x & 8x
0V (Common) *
24 Vac / dc **
N
1A
Fuse
1 2 3 4 5
AC supply Burner
supply
Caution
live
terminal
Input
Alarm Input
3A
Norm 3 A
Fuse
Fuse
6 7 8
9 10 11
Open
L
Alarm 1 relay Control relay
Bottom
blowdown
relay 20 21 22
FRONT
BACK
3A
Fuse
Open
Input
* Must be common to both connection ends
** Must not be mixed between Vac and Vdc
Fig. 20 BCVxx Blowdown Valves with 24 Vac / dc Supply 2cable / 3pt
IM-P403-89 AB Issue 7
27
Optional Limit Switch
Limit Switch Box
S1 ( Xs1 )
S2 ( Xs2 )
Valve Opening
Valve Closing
4
5
6
7
8
9
2a valve opening
2b valve closing
Module 230V
2b
2a
21
N
BCV4x,6x,7x & 8x
N (Neutral) *
100-110 Vac / 230 Vac
N
1A
Fuse
1 2 3 4 5
AC supply Burner
supply
Caution
live
terminal
Input
Alarm Input
3
A
3A
Norm
Fuse
Fuse
6 7 8
9 10 11
Open
L
Alarm 1 relay Control relay
Bottom
blowdown
relay 20 21 22
FRONT
BACK
3A
Fuse
Open
Input
* Must be common to both connection ends
Fig. 21 BCVxx Blowdown Valves with 100-110 Vac / 230 Vac Supply 2cable / 3pt
28
IM-P403-89 AB Issue 7
Optional Limit Switch
Limit Switch Box
S1 ( Xs1 )
S2 ( Xs2 )
Valve Opening
Valve Closing
4
5
6
7
8
9
2a valve opening
2b valve closing
AVF234S
2b
2a
21
1
BCV4x,6x,7x & 8x
0V ( Common ) *
24 Vac / dc **
N
1A
Fuse
1 2 3 4 5
AC supply Burner
supply
Caution
live
terminal
Input
Alarm Input
3
A
3A
Norm
Fuse
Fuse
6 7 8
9 10 11
Open
L
Alarm 1 relay Control relay
Bottom
blowdown
relay 20 21 22
FRONT
BACK
3A
Fuse
Open
Input
* Must be common to both connection ends
** Must not be mixed between Vac and Vdc
Fig. 22 BCVxx Blowdown Valves with 24 Vac / dc Supply 1 cable / 2pt
IM-P403-89 AB Issue 7
29
Optional Limit Switch
Limit Switch Box
S1 ( Xs1 )
S2 ( Xs2 )
Valve Opening
Valve Closing
4
5
6
7
8
9
2a valve opening
2b valve closing
Module 230V
2b
2a
21
N
BCV4x,6x,7x & 8x
N (Neutral) *
100-110 Vac / 230 Vac
N
1A
Fuse
1 2 3 4 5
AC supply Burner
supply
Caution
live
terminal
Input
Alarm Input
3A
Norm 3 A
Fuse
Fuse
6 7 8
9 10 11
Open
L
Alarm 1 relay Control relay
Bottom
blowdown
relay 20 21 22
FRONT
BACK
3A
Fuse
Open
Input
* Must be common to both connection ends
Fig. 23 BCVxx Blowdown Valves with 100-110 Vac / 230 Vac Supply 1 cable / 2pt
30
IM-P403-89 AB Issue 7
5.4 Signal wiring notes
See Section 10, Technical Information, for terminal and cable specification.
An earth current loop is created if a wire or screen is connected between two earth points that
are at different potential (voltage). If the wiring diagram is followed correctly, the screen will
only be connected to the earth at one end.
The earth terminal is a functional earth rather than a protective earth.
A protective earth provides protection from electric shock under a single fault condition. A
functional earth is used in order for the product to operate. In this application, the functional
earth is used as a sink or drain for any electrical interference. The earth terminal must be
connected to a local earth in order to conform to the EMC directive.
5.5 Probe wiring
The maximum cable length for all probes is 100 m (9990 and 999.0 ranges), 10 m (9.990 range)
or 30 m (99.90 range). All cables must be of the same gauge.
Bottom blowdown switch
(shown with valve closed)
Connect to local
earth in the panel
screen
76 77 78
90 91 92 93 94 95 96 97 98
See RS485 / Modbus wiring notes
Drive
sense Com
E
Com
Drive sense SCN
Sense
Drive
50 51 52 53 54 55
56 57 58 59
CP10
conductivity probe
Red
Screen
Connect
to local
earth in
the panel
White
Screen
CP30 and CP32
conductivity probe
Com
Red
or
Red
tracer
73 74 75
Front
Back
70 71 72
Pt100
60 61 62
Screen
0 / 4 - 20 mA
output
Red Blue (internally connected to probe body)
Note:
Do not connect terminals 53, 54, 59, 60 or 78 to any other earth.
Ensure that resistance from the probe body to the pipework / boiler shell is less than 1 ohm.
E = Functional earth. Connect these pins to earth local to the panel.
Fig. 24 Signal circuit (view from the top)
IM-P403-89 AB Issue 7
31
5.6 Probe in blowdown (or condensate) line - CP10
For most applications the 1.25 m (4 ft) heat resisting probe cable will need to be extended
using a junction box. If not, link terminals 50 to 51, and 52 to 53.
Note: Whilst pairs of conductors are linked at the junction box, the four-wire connection is
required to compensate for voltage drop. See the Information and Maintenance Instructions
for the CP10 for further details.
5.7 Probe in boiler - CP30
The probe requires a 4 core screened cable connection.
Whilst pairs of conductors are linked at the probe, the four-wire connection compensates
for voltage drop along the cable. The CP30 UL recognized probe is supplied with four 18
AWG, 12" long colour coded flying leads. These are to be cut to length and wired to a
suitable terminal block housed in a suitable metal box. A length of flexible metal conduit is
required between the probe and the terminal box to provide environmental and impact
protection, and easy electrical connection. The cable socket is provided with a ½" NPT
conduit adaptor for this purpose.
See the Information and Maintenance Instructions for the CP30 for further details.
5.8 Probe in boiler - CP32
The probe requires 8-way screened cable.
See the Information and Maintenance
Instructions for the CP32 for further details.
Caution: Do not connect any wires to
the CP32 5-way terminal block, as it
houses the very fine wiring from the
probe, which could be easily damaged in
attempting to connect additional wires.
50
51
52 53 54
BC
controller
5.9 TP20 Temperature probe
wiring
Note: For the TP20, when the cable is to
be longer than the 1.25 m (4 ft) supplied,
a junction box and 3 core-screened cable
will be needed.
5.10 Four wire Pt100
Will have two wires one colour, and two
wires of another colour.
Link one of the pairs at the junction box, and
connect to terminal 56.
Connect one of the remaining two wires to
terminal 57, and the other to terminal 58.
32
Red
Black
1
2
3
Black
Red
Colour codes for sensor wires vary, but
a three-wire sensor will normally have
2 wires of one colour, and 1 wire of a
different colour.
Terminal box
CP30 (UL)
connector
Internal links
Probe tip
CP30 probe
Earthed to
probe body
Fig. 25 Alternative wiring for the UL version
IM-P403-89 AB Issue 7
5.11EIA / TIA-485 communication wiring diagram
Front
The product can be connected as a slave to a two or four-wire EIA / TIA-485 multi-drop
network.
Slave(s)
(Boiler controller)
- Remove link between terminals 91 and 90.
COM SCN Tx-
98
Tx+ Rx- Rx+ H / D H / D
97 96 95 94 93 92 91 90
Common
R*
R*
B'
A'
R*
R*
B
A
Rx
Earth*
* See
wiring
notes
Tx
Master
Fig. 26 RS485 / Modbus full duplex circuit (view from the top)
EIA / TIA-485 wiring notes:
EIA / TIA-485 symbols are used (A = Tx-, B = Tx+ and A' = Rx-, B' = Rx+)
The signal direction is relative to the product being the Modbus slave, i.e. Tx+ from the product
(slave) is to be connected to the Rx+ of the master.
- Twisted pair cable should not be required for short lengths of cable < 1.5 m (< 5 ft). Standard
screened cable should suffice.
- The H / D (Half duplex) pins are used to select two or four-wire Modbus:
i) For two-wire mode, connect terminal 91 and 90 together.
ii) For four-wire mode, do not connect terminals 91 and 90 together.
Continued on page 34
IM-P403-89 AB Issue 7
33
Front
Slave(s)
(Boiler controller)
COM SCN Tx-
98
Tx+ Rx- Rx+ H/ D H/ D
97 96 95 94 93 92 91 90
Add link between
terminals 91 and 90
Common
R*
R*
Earth*
* See wiring notes
Rx
Tx
Master
Fig. 27 RS485 / Modbus half duplex circuit (view from the top)
EIA / TIA-485 wiring notes continued:
- The bus common must be connected directly to protective ground / earth at one point only.
Generally this point is at or near the master device.
- Consider
terminating the two furthest ends of the bus to match the transmission
line impedance. A 150 ohm (0.5 W) resistor or a 120 ohm (0.25 W) resistor, in series with
a 1 nF (10 V) capacitor is commonly used, but ideally the line impedance should be matched
to each individual installation. Termination for short lengths of cable should not be
necessary < 300 m (< 1 000 ft) @ 9 600 Baud.
- See Section 10 - 'Technical information' for cable details.
34
IM-P403-89 AB Issue 7
6 .Commissioning
6.1 General information
All commissioning for the product is carried out using the front panel.
WARNING: On entering the commissioning mode the product will cease normal control.
All valves will close, the 4-20 mA and the timer will freeze. For safety reasons, the alarm
relay(s) will continue to operate as normal. To regain normal control, return to the run
menu by pressing the
button.
WARNING: If during commissioning, the keys are not pressed for a period of greater
than 5 minutes, the controller will revert back to run mode and an error will occur.
If the calibration was incomplete the controller may not provide the correct control.
The product has no battery. The programmed settings are held in non-volatile memory
(Flash) and are written to after changing a parameter and pressing OK .
BC3250
100
Graphic display.
50
Scroll up
menus / sub-menus.
Increase digits.
Scroll down
menus / sub-menus.
Decrease digits.
Exit sub-menus and shift left
to the next digit when the
parameter or digit is flashing.
0
%
SP
PV
AL
Enter sub-menus and shift
right to the next digit when the
parameter or digit is flashing.
OK
Enters parameters when the
parameter or digit is flashing.
Hold down for 5 seconds to
enter commissioning mode.
Fig. 28 Front panel keypad and definitions
IM-P403-89 AB Issue 7
35
6.2 Commissioning mode navigation
After the correct pass code has been entered the display shows:
MODE
To exit the commissioning mode at any stage, press and hold the
button to return to the run mode.
Pressing the
level menus.
and
buttons scrolls through the various first
Pressing the
button enters a particular sub-menu. The first
menu title will remain displayed at the top of the screen and the
new sub-menu will appear on the next line. As you progress through
the menu, the longer the list becomes. This aids navigation of the
menu structure.
36
IM-P403-89 AB Issue 7
6.2.1 Changing parameters
If a particular sub-menu requires a parameter to be modified,
the corresponding units (if any) will appear on the next line (in
brackets) and the parameter itself will appear on the bottom right
hand corner. The first digit will start flashing and the parameter
can be modified as described in the previous section (See the
adjacent example).
INPUT
T COMP
(°C)
200
6.3 Commissioning - Quick set-up
This section allows the user to carry out the minimum commissioning necessary to operate
the system.
It accepts the defaults set in the factory, so will only work if the original default settings have
not been altered. See the default settings in Section 10, Technical information, to confirm.
Settings can then be tailored to suit the individual requirements of the customer / application
if required.
Warning: - It is essential that you comply with National / Local regulations and
Guidance notes, and the boiler manufacturer's recommendations. It is imperative
that the settings you have accepted will allow the boiler to operate in a safe manner.
This procedure assumes a Pt100 temperature sensor is fitted to the system.
Parameter
CAL
Action
Enter actual water TDS or conductivity to calibrate product and
press the OK button to enter run mode.
DURATION
Enter time (S) for the bottom blowdown valve to be open and
press the OK button to enter run mode.
SET POINT
Set to TDS at which blowdown valve is to open and press
OK .
Set to TDS at which the alarm is to operate and press
than SP).
(must be higher
ALARM
OK
Test the system to ensure that it is working correctly.
IM-P403-89 AB Issue 7
37
6.4 Commissioning - Full
Sub-menus and their functions are outlined within this section, and enables the user to
programme the unit. Additional information is given in the sub-menu notes where further
choices can be made.
6.4.1Main menu structure
MODE
Allows the user to view and change the valve status
(OPEN or CLOSED).
See MODE sub-menu.
DATA
Allows displayed units to be configured.
See DATA sub-menu.
INPUT
Configures the input type and commissioning parameters.
See INPUT sub-menu.
OUTPUT
TIMER
ALARM 1
TEST
SW. VER
SET PASS
TREND
38
Configures the outputs.
See OUTPUT sub-menu.
Allows the user to set bottom blowdown time.
See TIMER sub-menu.
Configures the high alarm.
See ALARM sub-menu.
Allow the product to test various functions.
See TEST sub-menu.
Indicates the software version.
Allows the user to set their own password.
Shows historical conductivity level graphically.
Time base can be selected - minutes, hours or days.
IM-P403-89 AB Issue 7
6.4.2 MODE sub-menu
Allows the user to switch from automatic or manual control of the valve.
Entering this menu (press the
button) will always show 'CLOSE' – flashing. The the
buttons will toggle the state and can be selected by pressing the OK button.
and
To exit the submenu and return to the run mode, press the
button. On exit the valve will revert to 'CLOSE' position.
MODE
OPEN
6.4.3 DATA sub-menu
Allows measurement units to be changed – (operating temperature, TDS or conductivity
measurement), and the conversion factor to be changed.
DATA
TEMP
°F or °C (default)
DATA
UNITS
µS / cm
(default) or ppm.
DATA
PH TERM
0.5 to 1.0
(default = 0.7)
PH term
Used to compensate for the changes in water
conductivity due to pH. In the UK, it is recommended
that boilers operate at a pH of 10.5 – 12. During
the calibration procedure, the water sample is
neutralised, typically changing the conductivity
by a factor of 0.7. This factor is the 'pH TERM'.
Neutralised (µS / cm)
pH TERM =
Un - neutralised (µS / cm)
With higher-pressure boilers or where countries
require a different pH, the actual factor / pH TERM
can be calculated and entered.
Example: A water sample measures 6122
µS / cm (un-neutralised) and 3061 µS / cm
(neutralised) at 25°C. Enter a pH TERM of '0.50'.
If the calibrated conductivity value is an unneutralised reading, set pH term = 1.00
IM-P403-89 AB Issue 7
39
6.4.4 INPUT menu
Allows selection of the type of measurement to be performed.
INPUT
T COMP
Temperature compensation.
If no Pt100 is fitted, a constant temperature can be entered.
e.g. 184°C (default).
INPUT
TDS
Allows selection of all the TDS control features: Sensor type,
purge, filter, range, set point, hysteresis, calibration, and calibration
interval.
6.4.5 INPUT – TDS sub-menu
40
INPUT
TDS
SENSOR
Selects the sensor type – CP10, CP30 or CP32. If a CP32 is fitted
and selected the user can select 'flt mode' ­­– 'action on fault': OFF,
ALARM, CLEAN, or AL + CLEAN. See INPUT – TDS – SENSOR –
FLT MODE notes.
INPUT
TDS
PURGE
Selects the purge duration when the sensor is in the pipeline –
See Purge sub-menu notes.
INPUT
TDS
FILTER
This feature is only shown if no purge time is selected, i.e. probe in
boiler. Increases the damping effect on the probe output. If the probe
is installed directly in the boiler, select ON. Filter ON – 64 seconds
(default) or OFF, which gives an 8 second delay.
INPUT
TDS
RANGE
Sets range, 9.990, 99.90, 999.0 or 9990, for ppm or µS / cm.
INPUT
TDS
SP
Set point. The conductivity value at which the blowdown valve will
open. 0 – 100% FS, 1% resolution.
INPUT
TDS
HYST
Select a hysteresis value (dead-band) to prevent over-frequent valve
operation in a turbulent boiler.
Hysterisis – 5% (default), 0 – 100% FS, 1% resolution.
Example:- SP = 3000 ppm - 5% hysterisis = 150 ppm.
The valve will open at 3000 ppm and close at 2850 ppm.
INPUT
TDS
CAL
The calibration figure is found by sampling the boiler water. This figure
is used to calibrate the controller in µS / cm or ppm.
See INPUT – TDS – CAL notes.
INPUT
TDS
CAL INT
Calibration interval – a countdown timer to remind the user to
recalibrate the system. Can be configured in 1-26 week steps. If 0
CAL INT is not active.
IM-P403-89 AB Issue 7
6.4.6INPUT sub menu notes
6.4.6.1 INPUT – TDS – SENSOR – FLT MODE
Only shown if the CP32 probe is selected.
Allows selection of the action to be taken if the probe detects a fault.
'OFF'
No action.
'CLEAN' If the probe is scaled then the time between probe conditioning cycles will
change from the CLEAN-INTERVAL time set to 10 minutes, until the probe is
clean. The display will flash 'CLEANING' during the conditioning cycle.
'ALARM'
Alarm relay released, and the display will flash 'SCALED'.
'AL + CLEAN' Recommended setting – alarm relay released, display shows 'SCALED', and
the probe conditioning circuit is activated.
The fault will be recorded in the error menu. Caution: The probe may be damaged if
'cleaning every 10 minutes' is allowed to continue for long periods. The probe should be
examined and mechanically cleaned after 12 hours of 'fault condition'.
Note: Certain probe / wiring faults will also trigger the probe scale detect feature.
6.4.6.2 INPUT – TDS – PURGE
Used only when the probe is mounted in the blowdown line, Purge ensures the sensor
measures the conductivity at boiler temperature.
Note
If the purge time is set to any figure other than zero, the controller will automatically limit the
cleaning (conditioning) time to 9 seconds (max.) to avoid bubbles forming on the probe during
the purge, and causing an inaccurate reading. The display will also only be updated when the
blowdown valve is open. This means that when the controller is switched on, the display will
show the last valid reading until the next purge.
6.4.6.3 INPUT – TDS – PURGE – DURATION
The duration is the time the valve is open to enable a representative boiler sample to reach
the probe. The duration time is set to zero if the probe is installed in the boiler or for a CCD
system. On BCS1 and BCS4 systems, 30 seconds is normally sufficient time to ensure the
sensor reaches boiler temperature. Where a slow-opening valve is used, or where there is
long or large bore pipework between the boiler and the sensor, a longer purge time will be
required. Alternatively the time can be manually entered from 000 (default) to 180 seconds
in 1-second steps.
To manually find the best purge time:
- Allow the blowdown pipework to cool for 15 minutes.
- Set the purge time to 60 (or greater if required) and calibrate the controller.
- Note the time taken for the display to stabilise. Set this time as the purge time. Enter a manual
duration time from 000 (default) to 180 seconds in 1-second steps.
6.4.6.4 INPUT – TDS – PURGE – INTERVAL / BURNER
Note: This feature is not visible if the duration is set to zero (i.e. sensor in boiler). Interval is
the time between purges.
Interval can be set between 10 to 60 minutes either independent of burner firing, (normal)
or dependant on cumulative boiler firing time (cumulative).
IM-P403-89 AB Issue 7
41
6.4.6.5 INPUT - TDS - CAL
The boiler must be at working temperature when calibrating a system. This is particularly
important if a temperature sensor is not fitted.
To ensure accuracy, the figures entered for both Set Point and Calibration must be greater
than 10% of the chosen range. For the best accuracy, calibrate the controller with the TDS as
close as possible to the Set Point. In some cases the boiler may need to be run for a period
of time to allow the TDS to build up before calibration. Recalibrate the boiler at the Set Point
once the boiler has settled down (after a few days in most cases). Check the calibration (as
close to the Set Point as is practical) weekly to ensure optimum performance.
Take a sample of the boiler water and measure its conductivity (in µS / cm) using a meter
such as the Spirax Sarco MS1. If the controller is required to be calibrated as neutralised
conductivity or TDS, neutralise the sample and measure again using the meter.
Enter the measured sample and press the ok button. 'CAL' will be displayed for the purge
time (if set) or for 1 minute (if purge = 0s). At the end of this period the calculated cell / probe
factor (K) will be displayed for 5 seconds. The menu will revert back to the normal run time
menu (PV) or if in commission menu, INPUT-TDS-CAL INT.
INPUT
INPUT
INPUT
TDS
TDS
TDS
CAL
CAL
CAL
(US / CM)
(US / CM)
(US / CM)
Exits automatically
after 5 seconds
Purge time
or 1 min
Press OK
V = 0.510
5010
Enter the measured
conductivity / TDS reading
42
CAL..
See note
below
K=
0.51
SAVED
Flashes
every
second
IM-P403-89 AB Issue 7
If the cell / probe factor is outside normal range (0.20- 0.70), 'WARNING' will be displayed.
If the cell / probe factor is excessive (< 0.01 or > 1.00), 'ERROR' will be displayed.
See Section 9, Fault Finding.
INPUT
INPUT
TDS
TDS
CAL
CAL
(US / CM)
or
(US / CM)
WARNING:
ERROR:
K=
K=
0.75
SAVED
1.00
SAVED
Note: If the calibration is accessed via the commissioning mode, the input voltage from
the probe circuit is displayed during 'CAL ..'. This ranges from 0 - 2.500 V and is used
for diagnostic purposes. The valve varies with conductivity, temperature and probe condition / installation.
Probe in blowdown line
The correct purge time needs to be selected first to ensure the sensor measures conductivity
at boiler temperature. Enter the valve of measured sample and press the OK button. The
controller will start a purge cycle and record the conductivity of the boiler water at the end
of the purge time.
Probe in a CCD system:
We recommend that a competent water treatment company be consulted to establish
the most suitable conductivity level for individual plant. Conditions vary widely, as do the
chemical properties and conductivity of contaminants.
In many cases, the normal measured value of ‘clean’ condensate will be very low, perhaps
only 1 or 2 μS / cm in some cases, whereas the set point may be much higher, perhaps 30 or 40 μS / cm.
To calibrate a CCD system, a liquid at approximately the maximum allowable conductivity
is introduced into the system. Use a mixture of tap water and condensate, to simulate
condensate at approximately the maximum allowable conductivity level (the set point).
5 litres (1.3 US gallons) will be plenty for most systems. Use the Spirax Sarco MS1
conductivity meter to check the conductivity. Close both stop valves and open the drain
valve and ‘water for flushing and calibration’ valve. Pour in the prepared water, and let it
run through the system until bubble free. Close the drain valve. Allow the display to settle
for two minutes.
Calibrate the controller as described in the main text. It is advisable to check calibration after
the system has been running for a few days, then periodically depending on the individual
plant conditions. Consult your water treatment specialist if in any doubt.
Note: Ensure purge time is set to zero and a Pt100 is installed.
IM-P403-89 AB Issue 7
43
6.4.7 OUTPUT sub-menu
Allows the selection of the type of measurement to be performed.
OUTPUT
DRIVE
OUTPUT
CLEAN
44
Selects standard or pulsed. Standard (valve remains open during
blowdown cycle – default). Pulsed – valve open 10 seconds, closed
20 seconds. Pulsed prevents the water level from falling too quickly
in a small boiler, which could cause a low water alarm.
Sets the probe cleaning cycle duration, interval, and pulsed or
constant. Removes / softens probe scaling.
After a leaning cycle, the process variable will not be updated for
20 seconds this allows any bubbles on the probe to disperse.
OUTPUT
RETRANS
0 or 4 mA, set, or check. Allows mA output signal to be selected,
referenced to specific TDS levels, and adjusted if required.
See OUTPUT - RETRANS notes.
OUTPUT
COMMS
Sets Modbus address baud rate and infrared master / slave
configuration, and verifies the number of units on the IR bus.
See OUTPUT COMMS sub-menu.
IM-P403-89 AB Issue 7
6.4.8 OUTPUT sub-menu notes
OUTPUT DRIVE notes
If standard (default) is selected the valve will remain open until the conductivity drops
below the Set Point (plus the corresponding hysteresis). If 'pulsed' is selected the valve will
open for 10 seconds and close for 20 seconds. The pulsed feature is suitable for use with
solenoid or pneumatic valves only. It must not be used with motorised valves.
OUTPUT CLEAN notes
To select this feature, enter a duration time from 1 – 99 seconds or if a purge time is
selected 1 – 9 seconds. A typical setting would be 20 seconds, increasing if the scaling on
the probe (and in the boiler) is causing frequent recalibration to be needed. Set the duration
to zero if the feature is not required.
Duration
Interval
Constant
Pulsed
Fig. 29
Enter an interval time from 1 to 99 hours in 1 hour steps to set how often a cleaning cycle
should occur. A cleaning cycle will also occur whenever the unit is switched off and on.
During the cleaning cycle (duration) the cleaning current can be PULSED (1 second on and
1 second off) or CONSTANT. For most installations PULSED should be selected. If a new
style CP32 is being used, select CONSTANT as a pulsing circuit is already fitted. To determine
which type is fitted, look for the pulsing relay or the style of tip (see Figures 25 and 26).
1 2 34 5 6 78
Pulsing
relay
12345
Fig. 30 New style CP32
(with a pulse circuit)
Select: 'CONSTANT'
IM-P403-89 AB Issue 7
Fig. 31 Old style CP32
(pulse circuit not fitted)
Select: 'PULSED'
45
An automatic probe scale detect feature is available if a CP32 two-tip probe is fitted
and selected. It selects the action taken by the controller to a probe with too high a
resistance, caused, for example, by scaling. If 'CLEAN' or 'AL + CLEAN' is selected, the
interval time is automatically set to 10 minutes until the scale is removed – see Figure 26.
Duration
10 minutes
Constant
Pulsed
Fig. 26
OUTPUT RETRANS notes
This sets the controller outputs to suit the two current loop standards in common use. It
retransmits the actual conductivity or TDS with the respect the full-scale range (default) or a
user configurable range. For example: 0 µS = 4 mA and 100 µS = 20 mA.
Note: If a purge time has been selected, the 0-20 mA or 4-20 mA is held at the value recorded
at the end of the last purge cycle.
0 or 4 mA
This selects either 0 or 4 mA (default). When entering this menu the currently selected option
will be displayed in the key right part of the screen.
Set
4 mA and 20 mA retransmission output is set to equivalent PV value.
Normally 0 or 4 mA = 0 µS / cm (or ppm), and 20 mA = PV full scale µS / cm (or ppm), though
this can be changed if required. The minimum value that can be set is 0000, the maximum is
PV full scale.
Check
Enables the user to make adjustments to the 4 mA and 20 mA settings, to calibrate to a
DVM reading.
OUTPUT – COMMS notes
Address is set to 1 unless there are other units on the same system.
Baud rate - Set to match the Baud rate of the line or system.
IR COMMS - Infrared, select as a master or slave device. See Section 7 - 'Communications'.
46
IM-P403-89 AB Issue 7
6.4.9 TIMER sub-menu
This timer controls the bottom blowdown intervals and their duration. It can be wired to a
switch box on the blowdown valve actuator to monitor valve operation. An alarm can occur
if the valve fails to close fully or lift off its seat within a certain period. The product cannot,
however, be used to indicate that the valve has opened fully.
The parameters will vary according to the type of boiler. Seek advice from a boiler
manufacturer, insurance company, or a competent water treatment company.
TIMER
DURATION
The time the blowdown valve is open for. If = 0, the bottom
blowdown function is disabled.
TIMER
INTERVAL
Will not show if the duration is zero. The time between each blowdown.
12 hours (default), 00 – 99 hour can be selected in 1 hour steps.
Many boilers are set to blowdown once every 24 hours or once a shift.
TIMER
SWITCH
Will not show if the duration is zero. Senses whether the valve has
fully closed or not. Select FITTED if a switch box is to be fitted to
the blowdown valve actuator. If a switch box is not fitted, select
NONE (default).
TIMER
CLOSING
Will not show if the duration is zero. The time the valve takes to
close. Only shows if a switch is fitted. If time elapses an alarm is
triggered. 5 (default), 1 – 10 seconds, 1 – second steps.
TIMER
LIFT
Will not show if the duration is zero. Only shows if a valve is fitted.
Time to lift the valve off the seat. If time elapses, an alarm is triggered.
5 (default), 1 – 10 seconds, 1 – second steps.
TIMER
RESET
Will not show if the duration is zero. Press the OK button to reset
the elapsed duration or interval times and any alarms related to the
bottom blowdown feature.
TIMER
MODE
Will not show if the duration is zero.
OFF: Blowdown is prevented on this boiler.
OPEN: The blowdown valve on this boiler is held open, for example
to drain a cold boiler. An alarm will be triggered while open
is selected.
AUTO: Automatic timed blowdown. Pressing OK will select the mode.
The selected mode will flash
WARNING: This product will remain in the mode selected in both run and commissioning
mode. If left in OPEN mode, the boiler could empty sufficiently to cause dangerously low
water level. An excessively long blowdown time can cause the boiler water level to become
dangerously low.
IM-P403-89 AB Issue 7
47
6.4.10 ALARM sub-menu
ALARM
PV
ALARM
PV HYST
ALARM
DELAY
ALARM
BB LIFT
ALARM
LATCH
An alarm is triggered at a set PV figure (TDS / conductivity).
Hysteresis – 3% (default), 0 – 100% FS, 0.1% resolution. Prevents
over-frequent switching of the alarm in a turbulent boiler. Do not set to
more than 15% unless exceptional operating conditions are present.
A further damping effect for very turbulent boilers (0 - 99s).
Only available if timer switch is fitted and selected. Bottom blowdown
alarm. In the ON position, an alarm will occur if the valve fails to lift off
the seat after the predetermined time set in the timer menu.
Select on to latch the alarm relay when the PV reaches the alarm
level. The relay will only reset when the commissioning mode is
entered (pass code protected).
Select off to alarm only when PV reaches the alarm level and switches
off when PV drops below the hysterisis.
Alarms are either all latching or all non-latching.
48
IM-P403-89 AB Issue 7
6.4.11 TEST sub-menu
Allows access to the diagnostic tools.
TEST
DISPLAY
Turns on all the segments on the display. The screen should be
completely black if all pixels are working. Press the
button to enter
test input mode, or the
button to exit the test mode and return to
the main menu.
TEST
INPUT
Displays the signal on each input.
TEST
OUTPUT
Tests the outputs to the required configuration.
IM-P403-89 AB Issue 7
49
6.4.12 TEST INPUT sub-menu
Allows access to the diagnostic features.
50
TEST
INPUT
INT TEMP
Displays the internal temperature of the microcontroller.
TEST
INPUT
RESIST
Displays the calculated water resistance in ohms, Kohms or Mohms.
TEST
INPUT
OP TEMP
Not visible if no Pt100 is fitted. Displays the equivalent operating
temperature, measured by the Pt100 (if connected).
TEST
INPUT
PROBE F
Displays the equivalent calculated Cell or Probe Factor, indicating
the condition of the probe.
TEST
INPUT
SWITCH
Shows if the bottom blowdown switch is OPEN or CLOSED (if
connected).
TEST
INPUT
BURNER
Displays whether the burner is ON or OFF (if connected).
IM-P403-89 AB Issue 7
6.4.13 TEST OUTPUT sub-menu
TEST
OUTPUT
RETRANS
Enables the output to be adjusted between 4 mA and 20 mA to test
the system.
TEST
OUTPUT
VALVE
Energises / de-energises the TDS valve relay for test purposes.
TEST
OUTPUT
BBVALVE
Energises / de-energises the bottom blowdown valve relay for test
purposes.
TEST
OUTPUT
ALARM 1
Energises / de-energises the alarm relay for test purposes.
TEST
OUTPUT
CANCEL?
Resets the system to automatic control. (The system automatically
resets after five minutes). Press OK to select Reset
SOFTWARE VERSION sub-menu
SW VER
Allows the software version to be viewed.
PASS CODE sub-menu
SET PASS
This allows the default pass code to be changed to a user-defined
value. It is important that if the default pass code is changed that the
new value is noted and kept safe.
TREND sub-menu
TREND
IM-P403-89 AB Issue 7
Shows the historical conductivity level graphically. Timebase can be
selected – minutes, hours, or days.
Scroll using the
and
buttons, then press the button to select
the timebase and return to the main menu.
51
7. Communications
7.1 Infrared (IR)
All products in the range can communicate via an infrared bus between adjacent controllers.
It enables the parameters of up to seven products to be passed to a product fitted with an
RS485 (products with a graphics display).
The product connected to the RS485 network must be fitted on the left of all the slaves fitted
to the IR bus (Figure 32) and have 'master' selected in the 'output-comms' menu.
RS485
Master
Slave
Fig. 32
Slave
Slave
Slave
IR Bus
Two or more IR buses can share the same panel or DIN rail by selecting another IR master.
Master 2 will ignore bus 1. See Figure 33.
RS485
Master
Fig. 33
RS485
Slave
Slave
Slave
Slave
Master
IR Bus 1
Slave
Slave
Slave
Slave
IR Bus 2
To add another slave into an existing IR bus, either re-select 'master' or turn its power OFF
and then ON. Only an IR master can pass the IR bus parameters to the RS485 network. If a
slave is also connected to the RS485 network, only its parameters are passed.
7.2 RS485 addressing
An offset is added to the register addresses (see above) for each device, depending on their
position on the IR bus, ie. the master's offset is 0, the device to its right has an offset of 100,
the one to its right hand side 200 and so on.
RS485
Master
Slave
1
0
2
100
Slave
Slave
Slave
4
300
5
400
IR Bus
IR address
RS485 offset
3
200
Fig. 34
52
IM-P403-89 AB Issue 7
8. Maintenance
Note: Read the 'Safety information' in Section 1 before starting any maintenance.
No special servicing, preventative maintenance or inspection of the product is required.
During installation or maintenance, the rear of the product must be protected from
environmental pollutants entering the product. Alternatively, the tasks can be performed
in a dry clean environment.
8.1Cleaning instructions
Use a cloth dampened with tap / de-ionised water or isopropyl alcohol. Use of other cleaning
materials could damage the product and invalidate the warranty.
8.2TDS controls
Boiler blowdown controls and alarms do, however, require testing and inspection.
General guidance is given in Health and Safety Executive Guidancenotes BG01 and
INDG436 in the UK.
8.3General weekly maintenance:
– Take a sample of the boiler water through a sample cooler, measure its conductivity
(calculate the TDS).
– Check the conductivity controller calibration with the boiler at normal operating pressure.
– Check that the blowdown valve shuts when the power is removed.
– Operate any stop valves to ensure that they shut off, and move freely.
8.4General six months maintenance:
– Isolate the system (or with the boiler empty), remove the conductivity probe.
– Clean the tip with fine abrasive paper / pad and wipe the insulation with a cloth.
– Examine the control / solenoid / stop valves and other fittings.
– Clean and refit or replace any parts necessary.
IM-P403-89 AB Issue 7
53
9. Fault finding
WARNING:
Before fault finding read the Safety information in Section 1 and the General
wiring notes in Section 5.1.
Please note that there are hazardous voltages present and only suitably
qualified personnel should carry out fault finding.
The product must be isolated from the mains supply before touching any of
the wiring terminals.
Safety may be compromised if the fault finding procedures are not carried out
in line with this manual.
Relay fuses to be replaced by manufacturer or accredited service department.
During installation or maintenance, the rear of the product MUST be protected
from environmental pollutants entering the product. Alternatively, the tasks can
be performed in a dry clean environment.
9.1Introduction
The most likely time for faults to occur is during installation and commissioning. The most
common type of fault is incorrect wiring. If after applying power to the product an error
message is displayed, it may be necessary to fault find. To simplify and aid in this process,
the product has a Test menu.
There are six viewable input channels. This will prove whether or not the product is
functioning correctly.
54
IM-P403-89 AB Issue 7
9.2 System faults
Symptom
1
Display not
illuminating
2
Display
flashes
on and off
(1 second
approx.)
3
Action
1. Switch off the mains supply to the product.
2. Check all wiring is correct.
3. Check external fuse(s) are intact. Replace if necessary.
4. Check the mains voltage is within specification.
5. Switch on mains supply.
If symptoms are still present return and replace the product.
Consider the likelihood that the product has been damaged from
mains borne surges / spikes. Consider installing additional ac
power line protector between the product and the mains supply.
The protector needs to be positioned close to the product to gain
full protection.
1. Switch off the mains supply to the product.
2. Disconnect all signal wires.
3. Switch the mains supply on: If symptoms are still present, return
the product for examination.
4. Replace each signal wire in turn until the fault occurs.
5. Investigate and rectify any faults in the wiring, external sensors /
transducers and modules associated with that connection.
Explanation
The internal power supply is unable to power up. If the voltages
cannot be generated, the power supply switches off for approx.
1 second. The power supply then attempts to power up again. If the
fault is still present, the cycle is repeated until the fault is removed.
This is a safety feature and does not damage the product.
1. Monitor the mains supply and ensure it is continuous and within
the specification limits.
2. Measure the ambient temperature and ensure it is less than
specified.
3. Investigate symptom 2.
Product
powers up
for a period Explanation
A re-settable thermal cut-out device will operate if one or more of
of time
following occurs:
(greater than the
- The power drawn exceeds the specification.
1 minute),
- The input mains voltage is lower than specified.
- The ambient temperature is higher than specified.
then
- The internal power supply will switch off until the product
switches
temperature drops below 65°C. This is a safety feature and does
off
not damage the product.
IM-P403-89 AB Issue 7
55
9.3 Operational error messages
Any operational errors that occur will be displayed in the run mode, on the alarms and errors
screen.
Error
message
1
Powerout
2
SETUP
MENU
TIME OUT
3
PV ALARM
4
VALVE
FAILED
TO OPEN
5
VALVE
FAILED
TO CLOSE
56
Cause
Action
There has been a
loss of power to
the product during
operation.
1. Remove power from product.
2. Check that all wiring is correct. Power
fail.
3. Check that the power supply is secure,
i.e. does not suffer from ‘brown outs’
4. Reapply power.
5.Press OK to Clear.
The operator
has entered the
commissioning
mode and has not
pressed a button
for 5 minutes or
more.
1. Re-enter the commissioning mode if
required.
2.Press OK to Clear.
The TDS has
increased above
the alarm level.
1. Check product is working correctly.
Recalibrate if necessary.
2. Check blowdown valve operation.
3. Check boiler feed water conditioning
regime.
4.Press OK to Clear.
Blowdown valve
fails to start to
open
1. Check the correct open time has been
entered in the INPUT-LIFT menu.
2. Check BB valve switch in the test menu.
3. Check the wiring between switch and the
product.
4. Check the operation of the switch.
5. Check the operation of the valve.
6. Check and replace the switch and / or
valve if necessary.
7.Press OK to Clear.
Blowdown valve
fails to close fully
1. Check the correct closing time has been
entered in the INPUT - CLOSING menu.
2. See VALVE FAILED TO OPEN.
3. Enter the commissioning mode and enter
the correct passcode.*
4.Press OK to Clear.
IM-P403-89 AB Issue 7
Error
message
6
PROBE
SCALED
(CP32 Only)
7
ALARM IS
LATCHED!
Cause
Action
The probe drive
has increased
to the maximum
voltage.
1. The probe tip may be scaled. Ensure the
correct water treatment is be used.
2. Ensure the boiler water is not been
contaminated.
3. Check the probe wiring.
4. Inspect the probe tip for damage.
5.Press OK to Clear.
Some errors latch
the alarm relay for
safety. Clearing
the error from
the error screen
just removes the
message.
1. Enter the commissioning (setup) mode.
If the correct password is entered all the
latched alarms will be cleared.
2.Press OK to Clear.
9.4 Determining the probe condition
The probe condition can be checked without removing it from the boiler.
From the run menu select probe factor (PF) and compare it with the following table:
Probe factors
Typical
BCS1, BCS2, and BCS4
0.2 – 0.6
BCS3
0.3 – 0.7
A low cell constant (PROBE F) indicates that the probe is able to conduct well, whereas a
high cell constant indicates that the probe tip has become less conductive, perhaps due to a
build-up of scale.
A very low cell constant, however, could indicate an internal short circuit. The further the
probe tips from any part of the boiler, the higher the cell constant.
IM-P403-89 AB Issue 7
57
10. Technical information
10.1 For technical assistance
Contact your local Spirax Sarco representative. Details can be found on order / delivery
documentation or on our web site: www.spiraxsarco.com
10.2 Returning faulty equipment
Please return all items to your local Spirax Sarco representative. Please ensure all items
are suitably packed for transit (preferably in the original cartons).
Please provide the following information with any equipment being returned:
1. Your name, company name, address and telephone number, order number and invoice
and return delivery address.
2. Description and serial number of equipment being returned.
3. Full description of the fault or repair required.
4. If the equipment is being returned under warranty, please indicate:
- Date of purchase.
- Original order number.
Please return all items to your local Spirax Sarco representative. Ensure all items are suitably
packed for transit (preferably in the original cartons).
10.3 Power supply
Mains voltage range
110 Vac - 240 Vac at 50 / 60 Hz
Power consumption
7.5 W maximum
10.4 Environmental
General
Indoor use only
Maximum altitude
2 000 m (6 562 ft) above sea level
Ambient temperature limits
0 - 55°C (32 - 131°F)
Maximum relative humidity
80% up to 31°C (88°F) decreasing linearly to 50% at 40°C
(104°F)
Overvoltage category
III
2 (as supplied)
Pollution degree
3 (when installed in an enclosure) - Minimum of IP54 or
UL50 / NEMA Type 3, 3S, 4, 4X, 6, 6P or 13.
See Section 4, Mechanical Installation.
Enclosure rating
(front panel only)
NEMA type 4 hose down only (UL approval), and IP65
(verified by TRAC Global)
Torque rating for panel screws 1 - 1.2 Nm
Electrical Safety EN 61010-1
UL61010-1, 3rd Edition, 2012-05
CAN / CSA-C22.2 No. 61010-1, 3rd Edition, 2012-05
LVD (safety)
EMC:
Immunity /
emissions
Suitable for heavy industrial locations
Enclosure
Material
Polycarbonate
Front panel Material
Silicone rubber, 60 shore.
Solder
Tin / lead (60 / 40%)
58
IM-P403-89 AB Issue 7
10.5 Cable / wire and connector data
Mains and signal connector
Termination
Rising clamp plug-in terminal blocks with screw connectors
Cable size
0.02 mm² (24 AWG) to 2.5 mm² (12 AWG).
Stripping length
5 – 6 mm
Note: Use only the connectors supplied by Spirax Sarco Ltd – Safety and Approvals may be
compromised otherwise.
TDS probe
Type
High temperature
Shield type
Screened
Number of cores
4 (CP32), 4 (CP10 and CP20 - For most applications the
1.25 m (4 ft) heat resistant cable will need to be extended
using a junction box) or 2 (CP10 and CP30)
Gauge
1 – 1.5 mm² (18 - 16 AWG)
100 m (9990 and 999.0 ranges)
Maximum length
Recommended type
30 m (99.90 range)
10 m (9.990 range)
Prysmian (Pirelli) FP200,
Delta Crompton Firetuf OHLS
Pt100 probe
Type
High temperature, twisted
Shield type
Screened
Number of cores
3
Gauge
1 – 1.5 mm² (18 - 16 AWG)
Maximum length
100 m (328 ft)
Recommended type
various
0 / 4 - 20 mA output
Type
Twisted pair
Shield type
Screened
Number of pairs
1
Gauge
0.23 - 1 mm² (24 - 18 AWG)
Maximum length
100 m (328 ft)
Recommended type
various
RS485 communication
Type
EIA RS485 twisted pair
Shield type
Screened
Number of pairs
2 or 3
Gauge
0.23 mm² (24 AWG)
Maximum length
1 200 m (4000 ft)
Recommended type
Alpha Wire 6413 or 6414
LAN Cat 5 or Cat 5E ScTP (screened), FTP (foil) or STP (shielded) cable can be used, but
limited to 600 m.
IM-P403-89 AB Issue 7
59
10.6 Input technical data
Water conductivity
Probes type:
CP10, CP30 and CP32
Ranges
Accuracy
pH factor
Neutralising factor
Resolution
Drive
Minimum ≥ 1 µS @ 25°C
0 – 9.99 ppm or µS / cm
0 – 99.9 ppm or µS / cm
0 – 999 ppm or µS / cm
0 – 9990 ppm or µS / cm
± 2.5% FSD (Poss > if high EMC)
± 5% FSD for 0 - 9.999 range
0.50 – 1.00 (0.7 default)
0.7
0.1% FSD
ac – 4 wires
Temperature compensation (TC)
Sensor type
Pt100 – Class B or better
Range
0 - 250°C
(With Pt100 not fitted – user programmed temperature 100 - 250°C, 1°C steps)
± 2.5% FSD – system accuracy ± 5%
Accuracy
Resolution
1% FSD
Drive
dc – 3 wires
Burner input
Input voltage range
Maximum current input
60
110 Vac - 240 Vac
2 mA maximum
IM-P403-89 AB Issue 7
10.7 Output technical data
Probe cleaning
Maximum voltage Drive
32 Vdc
CONSTANT (dc) or PULSED, 1 second on, 1 second off.
4-20 mA(s)
Minimum current Maximum current
Open circuit voltage (maximum) Resolution Maximum output load Isolation Output rate 0 mA
20 mA
19 Vdc
0.1% FSD
500 ohm
100 V
10 / second
Relay(s)
Contacts Voltage ratings (maximum)
Resistive load
Inductive load1 amp @ 250 Vac
ac motor load
Pilot duty load
Electrical life (operations)
Mechanical life (operations)
2 x single pole changeover relays (SPCO)
250 Vac
3 amp @ 250 Vac
¼ HP (2.9 amp) @ 250 Vac
1 / 10 HP (3 amp) @ 120 Vac
C300 (2.5 amp) - control circuit / coils
3 x 10 5 or greater depending on load
30 x 10 6
RS485
Physical layer Protocol Isolation Receiver unit load Output rate RS485 4-wire full or 2-wire half duplex
Modbus RTU format
60 Vac / dc
(256 devices - maximum)
Up to 10 frames / second
Infrared
Physical layer Baud
Range
Working angle
Eye safety information
IM-P403-89 AB Issue 7
IrDA
38400
10 cm
15°
Exempt from EN 60825-12: 2007 Safety of laser
products ~ does not exceed the accessible emission
limits (AEL) of class 1
61
10.8 Default settings
10.8.1 MODE MENU
Allows the valve to be manually opened or closed
Ranges
OPEN or CLOSE
DefaultCLOSE
10.8.2 DATA MENU
TEMP (temperature units)
Ranges
Default
°C or °F
°C
UNITS (TDS or conductivity units)
Ranges µS / cm or ppm
Default
µS / cm
PH TERM
Ranges 0.50 - 1.00
Default0.7
Resolution (steps)
0.01
Assuming µS / cm to ppm conversion = 0.7
10.8.3 INPUT MENU
T COMP (Temperature compensation)
Ranges
100 - 250°C or 212 - 482°F
Default184°C (10 bar g) or 363°F
Resolution (steps)
1°
Units
°C or °F
TDS - SENSOR (Probe selection)
Ranges
CP10, CP30, CP32
DefaultCP10
TDS - SENSOR - FLT MODE (Fault mode) Only available if CP32 is selected
Ranges
OFF, ALARM, CLEAN or AL+CLEAN
DefaultOFF
CLEAN or AL+CLEAN is only available if a clean duration is selected
TDS - PURGE – DURATION (Purge time)
Ranges
0 - 180
Default000
Resolution (steps)
1
UnitsSeconds
62
IM-P403-89 AB Issue 7
TDS - PURGE – INTERVAL (Time between purges)
Ranges
10 - 60
Default30
Resolution (steps)
1
UnitsMinutes
TDS - PURGE – BURNER (Purge time dependant on time or burner firing time)
Only available if PURGE - DURATION is greater than 0 seconds.
Ranges
Normal or Cumulative
DefaultCumulative
TDS - FILTER Only available if PURGE - DURATION is = 0 seconds
Ranges ON or OFF (TC = 64 or 8* seconds)
DefaultON
*8 second filter, also includes a 5% (FSD) Jump out function for CCD systems
TDS - RANGE
Ranges 9.99, 99.9, 999, 9990
Default9990
UnitsµS / cm or ppm
TDS - SP (Set Point)
Ranges
0 – FSD
Default
50% FSD
Resolution (steps)
0.1% FSD
UnitsµS / cm or ppm
TDS - HYST (Set Point hysteresis)
Ranges
0 – SP
Default
5% FSD
Resolution (steps)
0.1% FSD
UnitsµS / cm or ppm
TDS - CAL (Actual water TDS or conductivity to calibrate product)
Ranges
0 – FSD
Default4000
Resolution (steps)
0.1% FSD
UnitsµS / cm or ppm
TDS - CAL INT (Calibration Interval – reminder to recalibrate product)
Ranges
0 – 26
Default
0 (0 = off)
Resolution (steps)
1
UnitsWeeks
IM-P403-89 AB Issue 7
63
10.8.4 OUTPUT MENU
CLEAN - DRIVE (Action on blowdown / solenoid valve)
Ranges
STANDARD or PULSED - 10 sec open, 20 sec closed
DefaultSTANDARD
CLEAN - DURATION (Time to clean probe)
Ranges
0 – 99 seconds or 0 – 9 seconds (If purge time > 0)
Default
20 (9 seconds (If purge time > 0))
Resolution (steps)
1
UnitsSeconds
CLEAN - INTERVAL (Time between probe cleaning)
Only available if CLEAN - DURATION is greater than 0 seconds.
Ranges
1 – 99
Default12
Resolution (steps)
1
UnitsHours
CLEAN
Only available if CLEAN - DURATION is greater than 0 seconds.
PULSED - 1 second on, 1 second off, or CONSTANT
Ranges
(for CP32 already fitted with a pulse circuit)
DefaultPULSED
RETRANS – 0 or 4 mA (Lowest output signal)
Ranges
0 mA or 4 mA
Default
4 mA
UnitsmA
RETRANS – SET – 0 / 4 mA (Set PV to correspond to 0 or 4 mA)
Ranges
0 – FSD
Default0
Resolution (steps)
0.1% FSD
Units
µS / cm or ppm
RETRANS – SET – 20 mA (Set PV to correspond to 20 mA)
Ranges
0 – FSD
DefaultFSD
Resolution (steps)
0.1% FSD
Units
µS / cm or ppm
COMMS – ADDRESS (MODBUS communication)
Ranges
1 – 247
Default1
COMMS – BAUD (MODBUS communication)
Ranges
1200, 9600, 19200
Default9600
COMMS – IR (Infrared communication)
Ranges
SLAVE or MASTER
DefaultSLAVE
64
IM-P403-89 AB Issue 7
10.8.5 TIMER MENU - Bottom blowdown (BB)
DURATION (bottom blowdown valve open time)
Ranges
0 – 999
Default0
Resolution (steps)
1
UnitsSeconds
INTERVAL (Time between bottom blowdown)
Only available if TIMER DURATION is greater than 0 seconds
Ranges
1 - 99
Default12
Resolution (steps)
1
UnitsHours
SWITCH (If a switch is fitted to valve, select fitted)
Only available if TIMER DURATION is greater than 0 seconds
Ranges
FITTED or NONE
DefaultFITTED
CLOSING (Time allowed for valve to close)
Only available if TIMER DURATION is greater than 0 seconds
Ranges
1 – 10
Default5
Resolution (steps)
1
UnitsSeconds
LIFT (Time allowed for valve to lift off the seat)
Only available if TIMER DURATION is greater than 0 seconds
Ranges
1 – 10
Default5
Resolution (steps)
1
UnitsSeconds
MODE (Allow the valve to be manually opened, closed or automatically opened and
closed under the control of the timer)
Only available if TIMER DURATION is greater than 0 seconds
Ranges
AUTO, OPEN, OFF
DefaultAUTO
IM-P403-89 AB Issue 7
65
10.8.6 ALARM 1 MENU
PV (Process Variable alarm limit)
Ranges
0 – FSD
DefaultFSD
Resolution (steps)
0.1% FSD
UnitsµS / cm or ppm
HYST (Process Variable alarm hysteresis)
Ranges
0 – PV ALARM
Default
3% FSD
Resolution (steps)
0.1% FSD
UnitsµS / cm or ppm
DELAY (Process Variable alarm delay)
Ranges
0 – 99
Default0
Resolution (steps)
1
UnitsSeconds
BB LIFT (Alarms occurs if valve does not lift off the seat within lift time)
Only available if TIMER – SWITCH – FITTED is selected
Ranges
ON or OFF
DefaultON
LATCH (Alarm relay can be latched until commissioning mode is entered)
Ranges
ON or OFF
DefaultOFF
66
IM-P403-89 AB Issue 7
10.8.7 TEST MENU
DISPLAY
Ranges
Black-on-white or white-on-black
DefaultBlack-on-white
INPUT – INT TEMP (Maximum internal temperature of the electronics)
Ranges
Resolution (steps)
Units
-40 to 85°C or -40 to 185°F
1
°C or °F
INPUT – RESIST (Calculated water resistance at temperature)
Ranges
1.33 ohms – 1.4 Mohms
Only available if a Pt100 is fitted.
INPUT – OP TEMP (Boiler water operating temperature)
Ranges
0 – 250°C or 32 – 482°F
Resolution (steps)
1
Units
°C or °F
INPUT – PROBE F (Calculated cell or probe factor)
Ranges
Resolution (steps)
0.01 – 1.00
0.1
INPUT – SWITCH (Detects if the BB Switch is open or closed)
Ranges
OPEN or CLOSED
INPUT – BURNER (Detects if the Burner is on or off)
Ranges
ON or OFF
OUTPUT – RETRANS (Sets the output between 4-20 mA manually)
Ranges
4 or 0 – 20 mA
Default20.00
Resolution (steps)
0.01
UnitsmA
OUTPUT – VALVE (Opens or closes blowdown valve manually)
Ranges
ON or OFF
DefaultON
Press the OK button to activate relay – Automatic control of relays is selected by selecting
cancel or after 5 minutes has elapses.
IM-P403-89 AB Issue 7
67
OUTPUT – BB VALVE (Opens or closes bottom blowdown valve manually)
Only available if TIMER – DURATION is > 0.
Ranges
ON or OFF
DefaultON
Press the OK button to activate the relay – Automatic control of relays is selected by selecting
cancel or after 5 minutes has elapses.
OUTPUT – ALARM 1 (Energises or de-energises the alarm relay manually)
Ranges
ON or OFF
DefaultON
Press the OK button to activate the relay – Automatic control of relays is selected by selecting
cancel or after 5 minutes has elapses.
SET PASS MENU (Set pass code)
Ranges
Default
0000 - 9999
See Section 2
TREND MENU (Sets time base of trend graph)
Ranges
MINS, HRS, DAYS
DefaultMINS
68
IM-P403-89 AB Issue 7
11. Appendix
Summary of the Modbus Protocol
Format: Byte
Start Data
Parity
Stop
1 bit
8 bit
0 bit
1 bit
Format: Request frame
Address Function code Start address Quantity of registers Cyclic redundancy check (CRC) Total 1 byte
1 byte
2 bytes
2 bytes
2 bytes
8 bytes
Format: Response frame
Address 1 byte
Function code 1 byte (or error code = function code plus 128)
Byte count 1 byte (or exception code, see below)
Register data 2 times the quantity of 16-bit register
Error check (CRC) 2 bytes
Total 9 bytes if correct (or 5 bytes if in error)
Only Function Code 03, 'Read holding registers' is allowed.
Parameters and register data
RegisterParameters
0
1 (Identity)
Note: When the device is an IR slave and there is
a temporary error in the IR Master-Slave comms,
an offset of +32768 is added to the identification
value of that particular slave stored in the master's
database.
1
Process variable (PV) - TDS @ 25°C
2
Set Point (SP)
3
µS / cm or ppm (general data)
4
Alarm 1
5
Range index
6
Probe factor
7
Temperature compensation (°C or °F)
8
Purge time (seconds)
9
Clean duration (seconds)
The format of the register data is 16 bit integer, with the most significant byte transmitted first.
IM-P403-89 AB Issue 7
69
Parameter
Byte 1
Byte 2
Byte 3
Byte 4
Byte 5
Device Function Exception CRC
CRC
AddressCode Code (LSB) (MSB)
Illegal function
XX 83 01 XXXX
Illegal data addressXX 83 02 XX XX
70
IM-P403-89 AB Issue 7
199
8888
IM-P403-89 AB Issue 7
Invisible if clean time = 0, Pt100
NOT fitted, timer duration = 0 and
purge time = 0.
PV
SP
SP HYST
ALARM
AL HYST
CELL (K)
RETRANS
OP TEMP
PURGE
CLEAN
TIMER DURATION SET
TIMER DURATION NOW
TIMER INTERNAL SET
TIMER INTERNAL NOW
(ERROR)
PASSCODE
71
0
CAL INT
FITTED
SWITCH
5
LIFT
0
ON
DELAY
BB LIFT
OFF
CANCEL?
OFF
ON
DAYS
BB VALVE
OFF
ON
MINS
TREND
ON
BURNER
ALARM 1
8888
SET PASS
OPEN
SWITCH
ON
0.7
PROBE K
VALVE
239
OP TEMP
4
22
RESIST
RETRANS
70
INT TEMP
ON
OFF
Shown if switch fitted
Shown if switch fitted
19200
0
9600
1200
0
mA
°C
OHMS
°C
Shown if Pt100 fitted
Explanation
If ON, product alarms if valve is manually opened.
If OFF, the valve can be opened and closed manually
without an alarm occurring.
SEC
US / cm
US / cm
SEC
SEC
Not shown if duration
=0
Not shown if duration
=0
MASTER
0
SLAVE
0
ADJUST
^ 0/ v
001
0
ADJUST
US / cm
9990
20mA
0
^ 0/ v
US / cm
Not shown if duration
=0
0000
HRS
SEC
Weeks
US / cm
US / cm
4mA
0
HRS
1
OUTPUT
INPUT
DISPLAY
LATCH
300
HYST
OFF
BURNER
7000
PV
OFF
OPEN
AUTO
5
CLOSING
NONE
12
IR
BAUD
ADDRESS
CHECK
HRS
4mA
0
O or 4mA
SET
12
0
INTERVAL
0mA
0
0
DURATION
PULSED
INTERVAL
MODE
SEC
XXXX
CAL
STANDARD
500
HYST
Limited to 9 seconds if
purge time is > 0 seconds
In run mode, will not display the last 0
99.0
US / cm
In run mode, will not display the last 0
999.0
9990
In run mode, will not display the last 0
Visible ONLY when Purge - Duration MANUAL = 0 seconds (Note: default
= ON, but OFF if AUTO of Duration manual > 0)
9990
OFF
ON
CUMULATE
Not shown if duration
MINS
SEC
Shown if
CP32 selected
NORMAL = 0
30
INTERVAL
BURNER
0
5000
000
RESET?
AL +
CLEAN
CP32
OFF
CLEAN
CP30
FLT
MODE
ALARM
CP10
DURATION
°C
<TEMP> flashing if no Pt100 fitted –
adjustable
<TEMP> NOT flashing if Pt100 fitted –
shows measured value
Note
The up and down buttons allow
the operator to scroll up and
down.
SP
RANGE
FILTER
DURATION
COMMS
RETRANS
CLEAN
DRIVE
SENSOR
TDS
PURGE
184
0.7
PPM
US/CM
T COMP
SW. VER
TEST
ALARM 1
TIMER
OUTPUT
INPUT
PH TERM
UNITS
°F
OPEN
°C
DATA
TEMP
CLOSE
MODE
12. Menu map
72
IM-P403-89 AB Issue 7
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