HydroAct 600 User Manual
Contents
1. Sensor Sel Inject 4 amp 20 mA Calibration Sensor Sel Follow Calibration Instructions Hold Sensor Sel On Off Delay Time 30 3600sec Outputs Cal Analog Output Sel 4 20 Sel Calibrate Test Analogues Output Sel mAOutput 0 25 50 75 100 A Relays i Relay Sel Relay State On Off Flush Now i Fac Reset i Mas Reset 3 2 1 Sensors OO Selects Conversion Calibration Hold 3 2 1 1 Conversion Technician For setting calibrating the input current loops 0 Selects Sensor To calibrate the loop following the on screen displays inject 4mA to continue press Next then inject 20mA to continue press Next Results are displayed Exit or Finishe 3 2 1 2 Calibration Please refer to information manuals supplied with sensors 3 2 1 3 Hold Each channel can have its output value placed on hold This will maintain the output signal and alarm state in their current state for the selected period of time The word Hold appears on the main display screen for the held channel for the duration of the hold delay OO Selects Sensor OK or Cancela Selecta Hold adjust On Off OK or Cancel 0O Selecta Delay 98 adjust 30 3600sec only appears when Hold is On OKe to put channel on hold or Cancels Exit2. Hold can be cancelled by selecting Hold to Off 3 2 2 Outputs 0O Selecta Calibrate Analogue Test 3 2 2 1 Calibrate Analogue QO then Selects Analogue channel O then Selecta 4mA or 20mA adjust the mA output OK to temporarily save the change or Cancela Exit or Finishe Manual date 14 July 2011 Page 15 of 38 HydroACT 600 3 2 2 2 Test 0O Selects Analogue Relays 3 2 2 2 1 Analogue OO Select Analogue channel D gt _ adjust the mA output in steps of 25 Bar graph shows current output OKe or Cancels to finish test Backa 3 2 2 2 2 Relays OO Select Relay channel to change the relay state OKe or Cancels to finish test Backa 3 2 3 Flush Now Optional Extra Select operates the AutoFlush software for sensor cleaning all settings are in Setup Options section of the menu 3 2 4 Factory Reset Technician Resets the unit Press Next then Yes to Reset the unit or Nom to exit NOTE All data will be lost 3 2 5 Master Reset Engineer Resets the unit Press Next then Yes to Reset the unit or Nom to exit NOTE All data and devices will be lost Manual date 14 July 2011 Page 16 of 38 HydroACT 600 3 3 Menu Setup 3 3 1 Analyzer 0O Selecta Language Date amp Time Display User Interface Buttons Tag Details Security Upgrade Add Device 3 3 1 1 Language Technician Selecta Language Then use the to adjust language OK or Cancels Exita 3 3 1
3. Name allows customer to identify the signal that initiates a flush cleaning sequence Name can changed up to 16 characters Restart Yes No No off Yes on Delay time between flush cycles Duration flush time Manual date 14 July 2011 Page 19 of 38 HydroACT 600 3 3 4 Alarms amp Thresholds Technician OO Selects Alarms or Thresholds 3 3 4 1 Alarms Technician O Selecta Sensor eg Flow or sensor name 3 3 4 1 1 Flow Alarm OO Selecta Flow Alarm Then use the adjust On Off OK or Cancel OO Selecta Signal 1 2 D These are the digital inputs 1 2 OK or Cancel Exit Active alarms cause the sensor screen to turn red This is a Sensor Alarm 3 3 4 1 2 Named Sensor eg Free Chlorine OO Selecta Alarm 1 2 Thenuse the adjust On Off OK or Cancela O Selecta Set Reset Delay Use the and 0O to adjust OKe or Cancels Exite Set point at which alarm activates Reset point at which alarm deactivates Delay wait time before alarm activates Active alarms cause the sensor screen to turn red This is a Data Alarm 3 3 4 2 Thresholds Technician OO Selects Sensor OO Selecta Threshold 1 2 Then use the adjust On Off OKe or Cancels OO Selects Set Reset Delay Use the gt and 0O to adjust OKe or Cancels Exit Set threshold activates Reset threshold deactivates Delay wait time before threshold activates 3 3 5 O
4. HydroACT 600 For more information about service and repair go to www chemtrac com Contamination sheet Dear customer Because of legal requirements and for the safety of our employees we need this Contamination sheet filled in with your signature before your instrument can be handled Please put the completely filled in declaration with the instrument and the shipping documents Add any safety data sheets MSDS and or specific handling instructions if necessary Type of instrument sensor Serial number Medium concentration Temperature pressure conductivity Cleaned with Please mark the appropriate warnings viscosity Radioactive Explosive Caustic Poisonous Harmful to health Biologically hazardous Inflammable Safe Company Contact name Address Telephone fax no e mail Order no hereby certify that the returned equipment has been cleaned and decontaminated according to good practices and is in compliance with all regulations This equipment poses no health or safety risks due to contamination Company stamp if available and legally binding signature Date Manual date 14 July 2011 Page 37 of 38 HydroACT 600 Appendix C Warranty Chemtrac Inc warrants its product to be free of defects in material and workmanship for a period of one 1 year from date of shipment to the original customer Upon receipt of written notice from the customer Chemtrac Inc sh
5. following proportional control Derivative control is rarely used It can be used to correct overshoot when using Integral control but can introduce other problems Proportional Gain is the simplest to understand and is simply that the further away from the setpoint the current measured parameter is the bigger the output signal e g if the current value being measured for chlorine is a long way below the setpoint then the pump is turned up high As the measured value gets close to the setpoint then the pump is turned down For nearly all recirculating processes Proportional control IS ALL THAT IS NEEDED and Integral and Derivative control are not needed at all If the proportional gain is set too high then the process can be unstable with the dosing overshooting the setpoint If the proportional gain is set too low then the process is unresponsive and setpoint may never be achieved In some processes the measured parameter is lost to the process e g chlorine from a pool heat from a boiler etc and sometimes in those circumstances the proportional control never quite catches up with the setpoint and users can see that although the process approaches the setpoint it rarely if ever gets to it This is known as droop If this droop is not a problem to the process then the recommendation would be to use only proportional control If the user wants to eradicate the droop then Integral gain can be applied to the signal to correct it err
6. 2 Date amp Time Technician OO Selecta Date Time Weekday Format Then use the 2 and 0O to adjust OKe or Cancels Exita Time in 24 hour entry Date in Format entry Format eg D M Y 3 3 1 3 Display Technician OO Select Contrast Backlight Then use the and or QO to adjust OKe or Cancela Exita Backlight time light remains active from last keypress 0 sec is backlight permanently ON 3 3 1 4 User Interface Technician OO Selects Buzzer Display Ticker Then use the to adjust OKe or Cancels Exit Buzzer this is the keypad buzzer only If set to Off the keypad is silent but the alarm buzzer still sounds On Off Display Sensor Single Parameter Dual Parameter Application Sensor shows all functions of the probe eg pH probe pH as main display temp shown also Single Parameter main display shows only one sensor AO scroll to next sensor eg pH only scroll to temp Dual Parameter main display shows two sensors on a horizontally split screen AQ scroll to next sensor Application custom display eg AquaSense shows dosing information on the main display Ticker this is a line of information scrolling horizontally across the bottom of the main display Off Fast Normal Slow 3 3 1 5 Buttons Technician OO Selects Button 1 2 3 Then use the to adjust Oke or Cancels Exit Manual date 14 July 2011 Page 17 of 38 HydroACT 600 Allows
7. European standards Chemtrac Inc confirms compliance with the standards by affixing the CE symbol Waste electrical and electronic equipment WEEE Important information Disposal of old electrical amp electronic equipment This symbol on the product or on its packaging indicates that this product shall not be treated as household waste Instead it shall be handed over to the applicable collection point for the recycling of electrical and electronic equipment By insuring this product is disposed of correctly you will help prevent potential negative consequences for the environment and human health which could otherwise be caused by inappropriate waste handling of this product The recycling of materials will help to conserve natural resources For more detailed information about recycling of this product please contact your local council or city office your waste disposal service or the organization from which you purchased the product Manual date 14 July 2011 Page 35 of W oo HydroACT 600 Appendix B Returns Procedure and Free of Contamination Sheet If the analyzer has to be repaired please return it cleaned to your local sale organization or Chemtrac Inc service center Please enclose the completed Contaminant sheet copy the Contaminants page on the following page with the packaging and shipping documents No repair will be undertaken without a completed Contaminant sheet Manual date 14 July 2011 Page 36 of 38
8. digital inputs e g low flow switch Comms RS485 used for communicating with some probes System Eventlogging System Datalogging Graphing 8000 events 8000 data points per channel before overwriting or continuing on MicroSD card Last 400 logged data points Weight 1kg IP Rating IP65 Box material ABS Lid material Polycarbonate Seals EPDM Expansion slots 4 Micro SD slot 1 Manual date 14 July 2011 HydroACT 600 2 0 Installation As with all instrumentation the installation and commissioning of this instrument is crucial to its safe and accurate function This instrument must be used only for its purpose as outlined in this manual and must be installed and commissioned in accordance with this manual and by trained and qualified personnel 2 1 Site Selection Please choose a suitable location for the installation of the probe and the electronics The choice of installation point on any site is a compromise and is best undertaken by experienced installation personnel The following is a list of the factors that need to be taken into consideration This list is not intended as a checklist neither is it implied that the list is complete Ensure that the mounting allows access to all serviceable parts Try to mount the electronics in a position where they are not habitually hosed down in a cleaning process Consider the length of wiring runs when mounting the instrument Try to keep the electronics away from substation
9. oo 4 0 Commissioning It is recommended that the HydroACT 600 is commissioned by a trained commissioning engineer During HydroACT 600 the commissioning the engineer can train the operators in the correct operation of the HydroACT 600 The installation and commissioning should proceed in the following manner akon 5 0 Troubleshooting Guide Install the unit refer to all of section 2 0 Check the instrument for damage Make up the sensor s as required Setup the instrument refer to section 3 0 and any optional parts Calibrate instrument sensor s then the system is fully commissioned Symptom Possible cause Possible solution Check power is getting to the instrument No power and check connections No display or Open the unit and check the fuse LEDs Ribbon cable disconnected Turn off the power then connect ribbon cable onto board LEDs light up Display fault Return unit for repair no display Not selected in software Check assignment of output 4 20mA output not working Jumpers in wrong Contact Chemtrac position Relays not Not assigned in software Check assignment of relays working 5 1 Further help For more troubleshooting please visit www chemtrac com Manual date 14 July 2011 Page 34 of 38 HydroACT 600 Appendix A Certificates and approvals CE approval Declaration of conformity The product meets the legal requirements of the harmonized
10. the desired outcome of the dosing pump control The PID mathematical manipulation can be assigned to an analogue output or a relay where the time that the relay is on is controlled by the PID loop This allows for any pump to be controlled by the PID loop Please see below for a discussion of the mathematics involved in calculating PID output values Manual date 14 July 2011 Page 24 of 38 HydroACT 600 Manual Output Mode Manual Value Control Setup L Auto Action Direct Reverse Setpoint Max Op m Vawe Delay sec Process Var Ramping PID Tuning Integral Windup L Setpoint Siatic 1l Sensor A Proportional Minimum L Variable Parameter Integral Fece Sensor Derivative D m Parameter F af Ramping Setpoint Source OO Selects Name Mode Use the gt and 09 to adjust OKe or Cancels Exita or Next Name allows the user to identify the PID loop Name can changed upto 16 characters Mode Off Manual Auto This either turns Off the PID control loop puts it into Manual where the user specifies an output value or puts it into Auto where the controller determines the appropriate output 3 3 6 1 1 Manual Manual Output Selects Value Use the gt and 09 to adjust OKe or Cancels Backe Exita or Next Value the output will be fixed to the specified eg if the user set
11. the selected Sensor above Ramping see Ramping in Setpoint section above Manual date 14 July 2011 Page 26 of 38 HydroACT 600 PID Tuning OO Selects Proportional Integral Derivative Use the and 0O to adjust OK or Cancela Backa Exit or Nexta Proportional 0 00 to 10 00 gain Zero is off Proportional to the size of the current error Integral 0 00 to 10 00 gain Zero is off Proportional to the sum of all errors Derivative 0 00 to 10 00 gain Zero is off Proportional to the rate of change of error PID control is a mathematical construct which can be understood and utilised mathematically or practically Don t turn the controller on until you have read ALL of this section Mathematics The output from the PID controller is simply the addition of the Proportional Integral and Derivative terms This is then subject to the controls described above such as Max Output Setpoint Output gt Process Variable Output Pout lout Dout Where Kp Proportional gain Ki Integral gain Kq Derivative gain e Current error t time Current error is the difference between the setpoint and the current measured value Proportional control is used when the process water is recirculated e g a Swimming Pool Manual date 14 July 2011 Page 27 of 38 HydroACT 600 Integral Control is used when the process is a once through process i e not recirculated or to correct a droop
12. wrong please contact the factory for individual advice on your process Back Exita or Finishe Manual date 14 July 2011 Page 29 of 38 HydroACT 600 3 3 6 2 VSD Controller The HydroACT 300 HydroACT 600 and HydroACT 1200 controllers are capable of controlling Variable Speed Drives OO Selecta Name Mode Delay Use the gt and 0O to adjust OK or Cancels Exit or Next Name allows customer to identify control loops Name can changed upto 16 characters Mode Off Manual Auto This either turns Off the control loop puts it into Manual where the user specifies an output value or puts it into Auto where the controller determines the appropriate output Delay the control loop time e g for a setting of 0 5 sec every half second the PID algorithm will run and the output will be updated Lower values will be used for fast responding processes small volumes of water longer values should be used for slower responding processes Manual Output Mode y Manual 9 gt Value VSD Input Night Mode Day Mode Control Day Mode Output L Auto 1 Sensor Start i B1 Centre m Band 1 L Parameter End B2 Deviation j Band 2 L Output i m B3 Deviation L Band 3 Dead Band 7 3 3 6 2 1 Manual Manual Output Selects Value Use the gt and 09 to adjust OKe or Cancels Backe Exi
13. 3 3 1 9 Add Device 3 3 2 Sensors 3 3 3 Signals 3 3 3 1 Signal 1 2 3 3 3 2 Flush Delay 3 3 4 Alarms amp Thresholds 19 3 3 4 1 Alarms 3 3 4 1 1 Flow Alarm 3 3 4 1 2 Named Sensor 3 3 4 2 Thresholds 3 3 5 Outputs 3 3 5 1 Map Analogue 3 3 5 1 1 Data 20 3 3 5 1 2 Control 3 3 5 2 Map Relay 3 3 5 2 1 Contact Manual date 14 July 2011 Page 2 of 38 HydroACT 600 3 3 5 2 1 1 Data Alarm 3 3 5 2 1 2 Data Status 3 3 5 2 1 3 System Alarm 3 3 5 2 1 4 System Status 3 3 5 2 1 5 Signal 3 3 5 2 1 6 Control 3 3 5 2 2 Pulse Width 3 3 6 Controls 3 3 6 1 PID Controller 3 3 6 1 1 Manual 3 3 6 1 2 Auto 3 3 6 2 VSD Controller 3 3 6 2 1 Manual 3 3 6 2 2 Auto 3 3 6 3 Boost 3 3 7 Options 3 3 7 1 Auto Flush 3 4 Menu Logs 3 4 1 System Logs 3 4 2 Data Logs 3 5 Alarm Information 4 0 Commissioning 5 0 Troubleshooting Guide 5 1 Further help APPENDICES A Certificates and approval statements B Returns Procedure and Free of Contamination Sheet C Warranty Manual date 14 July 2011 21 23 24 29 31 32 33 34 35 37 Page 3 of 38 HydroACT 600 SAFETY PRECAUTIONS BEFORE ATTEMPTING TO UNPACK SET UP OR OPERATE THIS INSTRUMENT PLEASE READ THIS ENTIRE MANUAL MAKE CERTAIN THE UNIT IS DISCONNECTED FROM THE POWER SOURCE BEFORE ATTEMPTING TO SERVICE OR REMOVE ANY COMPONENT N MAKE CERTAIN THE UNIT IS DISCONNECTED FROM OTHER SOURCES OF FORCE OR PRESSURE FOR EXAMPLE PNEUMATIC OR HYDRAULIC BEFORE ATTEMPTING
14. Auto Flush OO Selecta Name Control Signal Length Hold Delay Use the gt and 09 to adjust OKe or Cancels Exita Name allows customer to identify signals Name can changed upto 16 characters Control On Off Signal Flush Delay Signal 1 Signal 2 Flush Delay uses the Signal in 3 3 3 Signal 1 2 are the digital inputs Length flush length time Hold Delay hold the output signal relays etc associated with the sensor being cleaned Manual date 14 July 2011 Pa oq oS N e h oS oo HydroACT 600 3 4 Menu Logs 3 4 1 System Logs Selecta System Logs Use the 0 to review the log Cancel 3 4 2 Data Logs Selecta Data Logs OK or Cancel Selecta Sensor OK or Cancel Selecta Data or Graph to view on screen Use the 9 to review the Data log OKe or Cancels In Data Selecta Save to save a csv file to a MicroSD card if inserted OK or Cancela Exita 3 5 Alarm Information This page shows the state On Off of the following alarms Data Alarm Sensor Alarm Signal Alarm System Alarm An active On alarm causes the spanner light to flash and a buzzer to sound only in the main display otherwise buzzer is silenced Pressing the Ack button on this page acknowledges the alarm silences the buzzer in the main display and changes the spanner light from flashing to solid Manual date 14 July 2011 Pa oq oS oS Q a oS
15. HydroACT 600 OPERATIONS MANUAL HydroACT 600 Analyzer Controller Transmitter Revised 07 18 11 JC CHEMTRAC PLEASE NOTE In an attempt to reduce our company carbon footprint this manual is normally supplied in an electronic format If you require a printed copy please ask your sales contact Tel 770 449 6233 Tel US 800 442 8722 Fax 770 447 0889 Email chemtrac chemtrac com Web www chemtrac com Manual date 14 July 2011 Page 1 of 38 HydroACT 600 TABLE OF CONTENTS Page No SAFETY PRECAUTIONS 4 1 0 Overview 5 1 1 Specification 2 0 Installation 6 2 1 Site selection 2 2 Unpacking 2 3 Mounting 7 2 4 Electrical connections 8 2 4 1 Power 2 4 2 RS 485 9 2 4 3 Relays 2 4 4 Probe s 2 4 5 4 20mA Inputs and Outputs 2 4 5 1 Inputs 2 4 5 2 Outputs 2 4 6 Digital Inputs 3 0 Operation Instrument 10 3 0 1 Display Buttons and Menu 3 1 Menu System Information 13 3 1 1 General Information 3 1 2 Device Codes 3 1 3 Installed Hardware 3 1 4 System Status 3 2 Menu Maintenance 14 3 2 1 Sensors 3 2 1 1 Conversion 3 2 1 2 Calibration 3 2 1 3 Hold 3 2 2 Outputs 3 2 2 1 Calibrate Analogue 3 2 2 2 Test 15 3 2 2 2 1 Analogue 3 2 2 2 2 Relays 3 2 3 Flush Now 3 2 4 Factory Reset 3 2 5 Master Reset 3 3 Menu Setup 16 3 3 1 Analyzer 3 3 1 1 Language 3 3 1 2 Date amp Time 3 3 1 3 Display 3 3 1 4 User Interface 3 3 1 5 Buttons 3 3 1 6 Tag Details 17 3 3 1 7 Security 3 3 1 8 Upgrade 18
16. TO SERVICE OR REMOVE ANY COMPONENT FAILURE TO FOLLOW THESE PRECAUTIONS COULD RESULT IN PERSONAL INJURY AND DAMAGE TO THE EQUIPMENT Manual date 14 July 2011 Page 4 of 38 HydroACT 600 1 0 Overview Thank you for purchasing a HydroACT 600 ANALYZER The HydroACT 600 analyzer is a compact electronic communication and control system It is designed for use with many different measuring probes Any other use than the one described here compromises the safety of persons and the entire measuring system and is therefore not permitted The manufacturer is not liable for damage caused by improper or non designated use Every analyzer is carefully checked before leaving the factory If for any reason you are unhappy with your purchase please contact the organization that you purchased the analyzer from or Chemtrac Inc directly Nearly all functions in this manual are common certain exceptions have been noted Ancillary items such as probes have their own additional manuals Ensure you refer to them 1 1 Specification Power 100 240VAC 12VDC version available as an option at approx 8W sensor no dependant Fuse 2A 100 240VAC 2A 9 36VDC Display LCD Backlit 128x64 graphical Outputs Up to 8 configurable contact relays 380VAC 8A 125VDC 8A OR up to 6 configurable solid state relays 100 240VAC 3A OR up to 8 configurable solid state relays 3 26VDC 3A Up to 6 4 20mA outputs Inputs Up to 6 sensors 4 20mA inputs 2
17. ad Band The amount that must be added to get back into a lower band Example B1 Centre 1 70mg l B2 Deviation 0 50mg l B3 Deviation 1 00mg l Dead Band 0 10mg I The variable moves away from B1 Centre until it reaches 1 20mg l At this it drops into Band 2 The variable then increases but only returns to Band 1 at 1 30mg I Band 2 starts at either 1 20 or 2 20mg I and ends at 1 30 or 2 10mg l Similarly Band 3 starts at either 0 70 or 2 70mg I and ends at 0 80 or 2 60mg l Day Mode Output OO Selects Band 1 Band 2 Band 3 Use the gt and 0O to adjust OKe or Cancels Backa Exita or Nexte Band 1 The fixed value to run the VSD at Band 2 The fixed value to run the VSD at Band 3 The fixed value to run the VSD at Example Band 1 at 44 Band 2 at 46 Band 3 at 48 So as the variable moves away from B1 Centre the pump speed increases Back Exita or Finishe Manual date 14 July 2011 Page 31 of 38 HydroACT 600 3 3 6 3 Boost The Pool and Spa Controller unit allows for chlorine boost or shot dosing OO Selecta Time Delay Output Use the and 0O to adjust OKe or Cancel Exite Time boost time Delay time before next boost Output pump output level during boost eg 50 Allows for chlorine shot dosing The Boost will operate the pump at the Output for the Time specified The Boost will then be inoperable for the Delay time 3 3 7 Options Technician 3 3 7 1
18. all repair or replace at the discretion of Chemtrac Inc the defective equipment or components Chemtrac Inc assumes no responsibility for equipment damage or failure caused by A Improper installation operation or maintenance of the equipment B Abnormal wear and tear on moving parts caused by some processes C Acts of nature i e lightning flooding etc This warranty represents the exclusive remedy of damage or failure of the equipment Under no circumstances shall Chemtrac Inc be liable for any special incidental or consequential damage such as loss of production profits or product quality The warranty cannot be guaranteed if the customer fails to service and maintain the equipment in accordance with Chemtrac Inc written instructions and policies as stated in the Operations Manual Manual date 14 July 2011 Page 38 of 38
19. e default passwords are User 1 Technician 2 Engineer 3 The access levels are shown by colour on the menu flow chart Manual date 14 July 2011 Page 10 of 38 HydroACT 600 You need to LOG OFF to swap between levels The instrument will automatically log off after a timeout period set in the menu at Setup Analyzer Security Timeout By pressing the Calib button you will be taken to the calibration section for the probe that was being displayed Password entry may be required If more than one sensor is fitted then pressing the up or down arrow buttons will scroll around the sensors By pressing the Alarms button refer to section 3 5 you will be taken to a page that shows the current status of the alarms password will be required When an alarm is active screen goes Red the alarm screen will also have a button marked Ack Pressing this button will acknowledge the alarm and silence the buzzer The main menu is shown below using 0O Selects the menu option required To return to the main menu at any time simply press the button marked Exit Cancel No or Back on any of the screens shown Manual date 14 July 2011 Page 11 of 38 HydroACT 600 Main Menu Enter Code System Inf User Technician Engineer C 0 Maintenance x Logout f a Manual date 14 July 2011 Page 12 of 38 HydroACT 600 NOTE the following statement is applicable to most of the following sections of Chapt
20. e note that the use of expansion board within the HydroACT 600 means that some connectors can be difficult to access This is a compromise to ensure that all possible functionality is available at a reasonable price inside a compact electronics unit Manual date 14 July 2011 Page 9 of 38 HydroACT 600 3 0 Operation Instrument The HydroACT 600 is a complex set of electronics 3 0 1 Display Buttons and Menu The display is a backlit LCD colour display The buttons are inductive and do not need to be pressed to activate An extremely light touch or even hovering a finger over the button will activate it Touching the button for an extended period will have the same effect as holding a key down on a PC keyboard The up and down buttons on the right hand side of the display are always up and down The remaining four buttons along the bottom are defined for each screen by the legend above the button on the display The main display will look like this 17 01 27 7 Jul 2011 Free Chlorine 3 16 inci 00 5 00 By pressing the Menu button you will be taken to the LOGON screen were a User Technician Engineer code is entered Note buzzer is silent during code entry Use the up or down and left or right to alter and OK enter Press Cancel to exit If the right code is entered the word User Tech Eng will appear in the top right of the display and you will be in the main menu where configuration of the instrument is performed Th
21. ela Back Exita or Nexte Sensor the signal source eg Chlorine Probe Parameter information only not alterable OO Selects Fault Mask Flow Mask Alarm 1 Mask Alarm 2 Mask Use the 2 to adjust OKe or Cancels Backa Exita or Nextel Fault Mask operates the relay for a sensor fault Flow Mask operates the relay for a flow alarm Alarm 1 Mask relay operates at set reset points Alarm 2 Mask relay operates at set reset points has to be On in 3 3 4 1 Selecta Action Normally Open or Normally Closed relay contacts OKe or Cancels Backa Exit or Nexta Backa Exita or Finishe Manual date 14 July 2011 Page 22 of 38 HydroACT 600 3 3 5 2 1 2 Data Status OO Selects Sensor Parameter Use the gt and 09 to adjust OKe or Cancels Backa Exita or Nexte Sensor the signal source eg Chlorine Probe Parameter information only not alterable 0O Selecta Warm up Mask On line Mask Off line Mask Threshold 1 Mask Threshold 2 Mask Use the 2 to adjust OKe or Cancels Backa Exita or Next Warm up Mask operates the relay for sensor warming up On line Mask operates the relay if the sensor is on line Off line Mask operates the relay if the sensor is off line Threshold 1 Mask relay operates at set reset points Threshold 2 Mask relay operates at set reset points has to be On in 3 3 4 2 Selecta Action Normally Open or Normally Closed re
22. er 3 of this manual Select an option so it is glfelalifelaltye Abbreviations Selecta Enter options using the Select button 00 Use the vertical arrow buttons cD Use the horizontal arrow buttons OKe Press to accept Cancels Press to cancel any changes Back Press to return to the previous screen Exite Press to leave that menu section without saving Next Press to continue to the next screen in this menu section Finishe Press to save System information Maintenance Setup D EBO Logs 04 47 12 1 Jan 2011 A Eo iv Manual date 14 July 2011 Page 13 of 38 HydroACT 600 3 1 Menu System Information Q g System Int General Inf Device Cod Inst Hw Sys Status 3 1 1 General Information Shows the Tag Name Tag ID Serial No software Version and the date the software Hex file was Created Cancels to exit 3 1 2 Device Codes Shows the current setup of the analyzer Exita to exit 3 1 3 Installed Hardware Shows hardware operating on the system either base board or add on cards Exit to exit 3 1 4 System Status Engineer Shows the Flash memory used of 256k the RAM used total HEAP dynamic memory used maximum used total High water mark highest address used Stack RAM allocated to task stacks used total Cancels to exit Manual date 14 July 2011 Page 14 of 38 HydroACT 600 3 2 Menu Maintenance Maintenance 1 Sensors 7 Conversion
23. ian The analyzer software may need to be upgraded This is achieved by using a MicroSD card in the front panel slot Following the on screen messages the following sections can be upgraded Resources this is the NODE base board software User this is the USER keypad display board software O NODE board input output GPRS Modem add on board Ethernet add on board Modbus add on board Profibus add on board 3 3 1 9 Add Device Technician The device security code is unit serial number specific and will be supplied with your equipment upgrade Use the gt and 09 to adjust OKe or Cancels Reset the power to the analyzer to finish the installation 3 3 2 Sensors Technician Please refer to separately supplied information Screen background colours are Grey offline Yellow warm up Red alarm Green normal operation 3 3 3 Signals Technician OO Selecta Signal 1 2 Flush Delay 3 3 3 1 Signal 1 2 OO Select Name Enabled Type Alarm Use the and 0O to adjust OKe or Cancela Exit Name allows customer to identify input signals eg Flow Name can changed up to 16 characters Enabled Yes No No off Yes on Type eg the input signal comes from either a normally open or normally closed contact Alarm On Off In fault On operates a Signal Alarm 3 3 3 2 Flush Delay OO Selects Name Restart Delay Duration Use the gt and 0O to adjust OKe or Cancels Exita
24. isy or rapidly changing measurement parameters when combined with very low values of Delay can result in unstable control In these circumstances apply averaging to the measured parameter and increase the delay time Setpoint Static or Variable Static This is the value that the user requires in the process and can be manually entered at Setpoint Value below Variable Setpoints are normally entered via the keys in the controller In some circumstances the setpoint may vary based on external factors and this can be achieved by the setpoint tracking a 4 20mA input signal Setpoint Source see below Process Variable OO Selects Sensor Parameter Use the gt and 0O to adjust OKe or Cancela Backa Exita or Nexte Sensor The process variable is the measurement parameter that the user is measuring in order to control the dosing Usually the sensor and the parameter are the same thing i e the chlorine sensor measures the chlorine parameter chlorine Parameter information only not alterable This is defined by the selected Sensor above Setpoint OO Selects Value Ramping Use the gt and 09 to adjust OKe or Cancels Backa Exit or Nexta Value the control point value this is the setpoint discussed above Ramping 0 01 to 1 00 Setting this value to zero turns it off Ramping is for use during the startup of a process PID control will often maintain a setpoint extremely well but during star
25. lay contacts OK or Cancel Backa Exit or Nexta Back Exita or Finishe 3 3 5 2 1 3 System Alarm 0O Selecta All Alarms Mask Data Alarms Mask Sensor Fault Mask Signal Alarm Mask System Fault Mask Use the 2 to adjust OK or Cancels Backa Exita or Next All Alarms Mask operates the relay for any alarm Data Alarms Mask operates the relay for any sensor alarm Sensor Fault Mask operates the relay for any sensor showing a fault Signal Alarm Mask operates the relay for any signal alarm System Fault Mask operates the relay for any system fault has to be On in 3 3 4 1 Selecta Action Normally Open or Normally Closed relay contacts OKe or Cancela Backa Exit or Nexta Backa Exita or Finishe 3 3 5 2 1 4 System Status OO Select Normal Mask Alarm Active Mask Alarm Acknowledge Mask Use the 2 to adjust OK or Cancel Backe Exit or Nexta Normal Mask operates the relay for normal operation no active alarms Alarm Active Mask operates the relay when any alarm is active until the alarm is acknowledged Alarm Acknowledge Mask operates the relay when any alarm has been acknowledged stays active until alarm is cleared Manual date 14 July 2011 Page 23 of 38 HydroACT 600 Selecta Action Normally Open or Normally Closed relay contacts OKe or Cancels Backa Exit or Nexta Back Exita or Finishe 3 3 5 2 1 5 Signal Select Source Signal 1 2 these are
26. main display shortcut buttons to be defined eg Button 1 Cal calibrate Button 2 Alarms Button 3 Blank The password must still be entered to access these menus 7 Jul 2011 Options are Blank Unused Alarms Alarm Information page Cal Calibrate Hold Hold Parameters Senor Sensors Signal Signals Cirls Controls Comms Communication Info System Information Status System Status Boost Boost Chlorine 3 3 1 6 Tag Details Technician OO Selecta Tag Name Tag ID Then use the and 0O to adjust OK or Cancels Exita Allows customer to identify instruments two ways by name or number up to 16 characters 3 3 1 7 Security OO Selecta User Technician Engineer Then use the and 99 to adjust the password OK or Cancela Exita Default passwords are User 1 Technician 2 Engineer 3 Allows customer to set passwords by name or number up to 8 characters 00 Selects Timeout Then use the and 09 to adjust the login time OK to save the change or Cancels Exita When this time is exceeded in either a menu or main screen then you will be logged out Note if the HydroACT 600 is in a data entry screen then the time out is inhibited Manual date 14 July 2011 Page 18 of 38 HydroACT 600 If you lose you password please contact PI with the serial number of your instrument We will supply a password that is only valid on the day you call 3 3 1 8 Upgrade Technic
27. on the menu If the Integral Gain is enabled and for some reason a positive or negative error occurs for a long time then the integral of that error will increase or be wound up When whatever occurred is corrected it will then take a long time for the integral error to be unwound Take for example a swimming pool where the controller is calling for the pump to output at 50 If the pump is broken then the controller will start to wind up as there will be no chlorine going into the pool This will result in a large error between the setpoint and the measured parameter When the pump is repaired and back in service the integral gain will have the effect of overdosing until the integral gain has been unwound The Integral Windup Protection feature allows the user to set maximum and minimums in percentage of the setpoint This protects against overshoot following large errors Derivative Warning 99 9 of processes can be controlled without the use of this term Only use this term if you are very confident of what you are doing The Derivative term is used to reduce the overshoot caused by the Integral term It does this by looking at the rate of change of the error and reducing it based on the derivative gain The Derivative term is sensitive to noise and can have the effect of reducing the stability of the control Practically Using PID practically is not nearly as hard as the above might suggest Following this guide can help 1 If you
28. or time Integral Gain is the bit that adds up the amount of time that the measurement parameter has been below or above the setpoint i e it records the time and degree that the measurement parameter has been above the setpoint and below the setpoint It subtracts one from the other and then adds or subtracts an extra bit of signal The Integral function is used instead of the Proportional term if the process is not recirculating e g chlorine control on a water treatment plant This term is often used when the primary control function is flow i e flow proportional with residual trim Alternatively the user can see that under a droop condition see above then the Integral Gain function can increase the control signal to achieve the setpoint Setting the Integral signal too low will have little or no effect while setting the Integral Gain too high will again cause overshoot and instability If the Integral Gain is turned on then an additional option will appear Manual date 14 July 2011 Page 28 of 38 HydroACT 600 Integral Windup Protection OO Selects Minimum Maximum Use the gt and 0O to adjust Oke or Cancels Backe Exite or Next Minimum 100 00 to 0 00 Zero is off ie the Minimum is not longer held within the limits Maximum 0 00 to 100 00 Zero is off ie the Maximum is not longer held within the limits If Integral gain is set to a value greater than 0 then Integral Windup protection will be
29. r controller comes pre set up with defaults such as in an AquaSense then use these before making any changes Defaults for AquaSense are 60s Delay time with a Proportional Gain of 2 and both Integral Gain and Derivative Gain off 2 If your process is a flow through process not recirculated then start with just Integral In nearly all cases Integral with windup protection is enough 3 If you are using Integral control then put windup protection On Then start very small and get bigger 0 1 perhaps to start 4 If your process is recirculating then start with proportional only in nearly all cases proportional is enough Keep the Delay time as long as possible depending on how quick your process is The quicker the process then the smaller the delay time The delay time is very unlikely to be longer than 300s or shorter than 10s 5 A setting of 1 for Proportional gain is directly proportional Increasing the number makes the control much quicker but could make it unstable Go up or down slowly until you get the balance you want Don t forget that going from 1 to 2 is a 100 change but from 3 to 4 is only a 25 change Also from 1 to 0 5 is also a 100 change 6 If you have a recirculated process and you have setup your proportional and you do decide to use the integral function as well to eliminate droop then put a windup protection on and start very small and get bigger slowly 7 If you think you need Derivative control you are probably
30. rands current rating 6A 300V rated E 3 Power connector and the fuse F1 AC 2A Page 8 of 38 Manual date 14 July 2011 HydroACT 600 2 4 2 RS 485 Cable type and rating one pair 22awg conductors 1200 impedance 300V rated Can be reserved for probe connection SoliSense OxySense or Conductivity Salinity Total dissolved solids 2 4 3 Relays The unit has either up to 4 normally open NO relay contacts or up to 4 solid state relays Cable type and rating 6 15mm overall diameter 3 x 0 75mm conductors 24 strands current rating 6A 300V rated 2 4 4 Probe s The probes connect via the connections at the base of the HydroACT 600 board Cable type and rating 4mm overall diameter 2 x 0 25mm conductors HaloSense sensors all types or multicore co axial cable together with multiple stranded cores for pH ORP fluorine sensors or RS485 cable for SoliSense OxySense 2 4 5 4 20mA Inputs and Outputs Cable type and rating 2 x 24awg conductors 7 strands 300V rated PVC outer sheath 2 4 5 1 Inputs The AIP 4 20mA inputs are user selectable via jumpers Consult Chemtrac Inc before attempting to change an input configuration The powered input supplies 15Vdc 50mA max NOTE incorrect use of the input can cause failure to the board 2 4 5 2 Outputs AOP Maximum loop loading is 700Q at 14Vdc 2 4 6 Digital Inputs 0 12Vdc Can be used for low flow fail indication Note Pleas
31. s or other large emi emitters Consider whether the sample will be representative and well mixed Consider sample return points In a plastic run with a low conductivity liquid sample consider earthing the sample 2 2 Unpacking Please have a copy of your order with you when you unpack your instrument All orders are checked when they leave the factory Please double check that you have all the parts that were ordered as soon as you open the box If anything is missing or damaged please contact your sales outlet immediately If the instrument needs to be returned for any reason please follow the instructions given in Appendix D of this manual Manual date 14 July 2011 Page 6 of 38 HydroACT 600 2 3 Mounting Mounting the HydroACT 600 Please refer to the drawings below 230 Power System alarm Alarm 1 Alarm 2 Front view 135 203 5 J I 1 g 3 rp or gt l l Pe S 2 l s l S Q oS 70 Side view Rear view The instrument electronics enclosure should be mounted away from sources of heat or direct sunlight For mounting of optional parts please refer to the manual supplied with that unit Manual date 14 July 2011 Page 7 of 38 HydroACT 600 2 4 Electrical connections RLY 1 RLY2 AOP3 eer ae R3 DIGWUP AOP2 RLY 4 AOP1 2 4 1 Power Cable type and rating 6 15mm overall diameter 3 x 0 75mm conductors 24 st
32. s the output to 50 then the analogue output would be fixed at 12mA or the pulse width control relay would stop after half the loop time set at 3 3 5 2 2 Back Exita or Finishe 3 3 6 1 2 Auto Control Setup OO Selecta Action Setpoint Maximum Output Delay Use the gt and 0O to adjust OK or Cancels Backa Exita or Next Action Direct or Reverse This sets the controller to increase the signal or decrease the controller signal either with Direct or against Reverse the measured parameter So if the value of the measured parameter goes up with increased chemical addition then this needs to be set to Direct eg Sodium Hypochlorite for Cl If the measured parameter goes down with increased chemical addition e g adding acid makes pH go down then this needs to be set to Reverse Maximum Output whatever the PID wants to do this is the maximum that the output will go to This is a useful common sense limit to the controller and stops ridiculous over dosing if something goes wrong Manual date 14 July 2011 Page 25 of 38 HydroACT 600 Delay the control loop time e g for a setting of 0 5 sec every half second the PID algorithm will run and the output will be updated Lower values will be used for fast responding processes small volumes of water longer values should be used for slower responding processes Note AquaSense pool controllers use 60sec as a default value It should be noted that no
33. te or Next Value the output will be fixed to the specified eg if the user sets the output to 50 then the analogue output would be fixed at 12mA or the pulse width control relay would stop after half the loop time set at 3 3 5 2 2 Back Exita or Finishe 3 3 6 2 2 Auto VSD Input OO Selects Sensor Parameter Use the gt and 09 to adjust OKe or Cancels Backa Exita or Nexte Sensor This is the measurement parameter that the user is measuring in order to control the VSD Parameter information only not alterable This is defined by the selected Sensor above Manual date 14 July 2011 Page 30 of 38 HydroACT 600 Night Mode OO Selects Start End Output Use the gt and 09 to adjust OKe or Cancels Backa Exita or Next Start The Night Mode start time End The Night Mode end time Output The fixed value to run the VSD at overnight Example start at 11 00pm end at 06 00am run the pumps at 85 00 of the normal frequency ie 42 5Hz for a 50Hz electric motor Day Mode Control OO Selects B1 Centre B2 Deviation B3 Deviation Dead Band Use the gt and 09 to adjust OKe or Cancels Backe Exita or Next B1 Centre The target value to be held by the system B2 Deviation The amount away from B1 Centre or that causes a change of Band ie into Band 2 B3 Deviation The amount away from B1 Centre or that causes a change of Band ie into Band 3 De
34. the digital inputs or Flush Delay Use the 2 to adjust OKe or Cancela Backa Exit or Nexta Selecta Action Normally Open or Normally Closed relay contacts OK or Cancela Backa Exit or Nexta Back Exita or Finishe 3 3 5 2 1 6 Control Selects Source Auto Flush 1 2 Use the 2 to adjust OKe or Cancels Backa Exita or Nexte Selecta Action Normally Open or Normally Closed relay contacts OK or Cancela Backa Exit or Nexta Backa Exita or Finishe 3 3 5 2 2 Pulse Width OO Selects Source Pulse Width Dead Band Use the gt and 09 to adjust OK or Cancel Exita or Next Source select PID or VSD Controller Pulse Width the loop control time during which the relay may be On Off depending on the controller Dead Band if the PID controller On time for the loop is below this setpoint do not operate the relay Backa Exita or Finishe 3 3 6 Controls Technician OO Selects Controller eg VSD PID Boost 3 3 6 1 PID Controller The HydroACT 300 HydroACT 600 and HydroACT 1200 controllers are capable of controlling processes such as chemical dosing with a pump and turning the pump on or off or up or down to maintain a setpoint This is done using a PID control loop PID stands for Proportional Integral and Derivative It is a mathematical manipulation of a measurement signal e g the actual chlorine level and the deviation of that signal from the setpoint the setpoint being
35. tup it struggles to get the process from zero to a stable setpoint This is normally due to the process oscillating around the setpoint which in turn is due to the PID loop control making very large adjustments which then overshoot the setpoint and first one way and then the other and so on It is possible to reduce this effect by either dosing manually until the measurement parameter is reading close to the setpoint and then turning on the control this is often done in a swimming pool application Alternatively the user can use the Ramping function The Ramping function effectively introduces the setpoint slowly It does this by making small adjustments to the setpoint so that the setpoint itself changes until it is at the correct setpoint It gradually changes the initial setpoint set at the current reading to the target setpoint set in the menu A setting of 1 00 will follow the target setpoint instantaneously the Ramping has been turned off while a setting of 0 01 will take a very long time The exact amount of time depends on the PID delay setting This has the effect of getting the PID to make a lot of small step changes rather than one very large stepchange Setpoint Source OO Select Sensor Parameter Ramping Use the gt and 0O to adjust OK or Cancel Backa Exit or Nexta Sensor the remote input signal to be tracked eg The 4 20mA input from a DCS Parameter information only not alterable This is defined by
36. utputs Technician 0O Selects Map Analogue or Map Relay 3 3 5 1 Map Analogue Technician OO Selecta Analogue 1 2 3 OK or Cancel 0O Selecta Name Enabled Mode Use the gt and 09 to adjust OK or Cancel Exit or Next Name allows customer to identify output signals Name can changed up to 16 characters Enabled Yes No No off Yes on Mode options Unused Data Control Unused off Manual date 14 July 2011 Page 20 of 38 HydroACT 600 Data outputs the selected probe signal selected at Data 3 3 5 1 1 below Control uses the output for PID or VSD control 3 3 5 1 1 Data OO Selects Sensor Parameter Use the gt and 0O to adjust OK or Cancel Back Exita or Nexte Sensor the signal source eg Chlorine Probe Parameter information only not alterable OO Selects Minimum Maximum scaling range Use the gt and 0O to adjust the 4 20mA output range OK or Cancela Backa Exit or Nexta Back Exita or Finishe 3 3 5 1 2 Control Selects Source PID or VSD controllers Use the gt and 0O to adjust OKe or Cancels Backa Exita or Nexte Back Exita or Finishe The output is now reserved for use by the selected controller See relevant menu section 3 3 5 2 Map Relay Technician OO Selecta Relay 1 2 3 4 0O Selecta Name Enabled Mode Use the gt and 0O to adjust OK or Cancel Exit or Next Name allows customer to identif
37. y relay signals Name can changed up to 16 characters Mode options Unused Contact Pulse Width Unused off Contact operates on signal set below 3 3 5 2 1 Pulse Width uses the output for PID or VSD control 3 3 5 2 1 Contact see flow diagram below Select Source Use the gt and 9 to adjust see options listed below OKe or Cancels Back Exita or Next None off Data Alarm set reset on sensor level Data Status thresholds warm up calibrating set to off line System Alarm sensor disconnected flow alarm System Status alarm acknowledged unacknowledged Signal clock or digital in Control AutoFlush Manual date 14 July 2011 Page 21 of 38 HydroACT 600 Contact None m Data Alarm sensor T Fault Mask Action Parameter m Flow Mask a Alm 1 Mask Alm 2 Maski m Data Status Sensor JPE Warm up M Action Parameter m On ine M Off ineM Thold 1M T hold2 M sys Alarm Al Alarm Mi mi Action E Data A M m Sen F M p sig A M L Sys F M m Sys Status NormalM Action Al Act Mo L Al Ack M m Signal Sig Source Action Control Cn Source Action 3 3 5 2 1 1 Data Alarm OO Selects Sensor Parameter Use the and 0O to adjust OKe or Canc
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