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SlimFlex Water Treatment Controller For Cooling Towers

1. Setpoints Feed Mode Feed Mode Limit Timer Limit Timer Prime Pump amp Prime Pump Current State 8 Current State Setpoints Sidebar Prime Pump will not turn ON the Pump if the flowswitch is OFF lt lt q Inhibitor pumps set to Bleed then Feed or Feed on Volume modes will not feed if the Bleed Solenoid is ON Feed starts as soon as Bleed ends AQCP_F_User 05 06 31 SlimFlex Water Treatment Controller Inhibitor Pump Feed Modes Press ENTER then DOWN Inhibitor Pump Press ENTER amp DOWN Feed Mode to view current mode and to select a new mode Inhibitor pump turns ON when Bleed solenoid ON Pump switches ON amp OFF during bleed at user set of 5 minutes Inhibitor pump turns ON after Bleed solenoid turns OFF Pump then is ON for the user set of Bleed time Percentage Time turns ON the Inhibitor Pump for a user set of 5 minutes Feed on Volume measures a user set volume on the Make up water meter then turns ON the Pump for a user set time For example Measure 100 Gallons of make up amp feed for 8 seconds NOTE If you change the Feed Mode press UP to Setpoints amp ENTER to adjust for the new Feed Mode 3 6 Inhibitor Controls Continued Inhibitor Pump ON 48 1min then 4 Feed Mode lt Limit Timer y s Bleed amp Feed lt Bleed then Feed y Bleed then Feed Percentage Time y 4 Percentage Time lt Feed on
2. TurnOFF 1140 4 Press ENTER adjust Turn ON J or DOWN amp ENTER for TurnOFF Edit amp Enter Press UP DOWN to adjust and RIGHT to move the cursor Turn ON 1180 id Press EXIT to leave the Setpoints unchanged BH tren 4 Press ENTER displays current setpoints Turn ON 1180 lt If you make Turn ON less than TurnOFF TurnoFF 1140 v the setpoints will be switched Sidebar The difference between Turn ON amp TurnOFF the deadband is usually set to 10uS If you are watching the tower conductivity as the sump float turns the make up water ON amp OFF you ll observe the operational deadband exceeds 10uS Delays in starting and stopping the make up due to sump float trip points increases the operational deadband beyond the controller ON OFF setpoints AQCP_F_User 05 06 11 SlimFlex Water Treatment Controller 2 3 Inhibitor Feed Mode Setpoints Feed Limits The factory default is Bleed amp Feed Refer to 3 6 Inhibitor Controls to select one of four Feed Modes Press UP or DOWN until you see Inhibitor Pump amp press ENTER Press ENTER to view or adjust Setpoints Displays current feed setpoints Inhibitor will be on for 32 of the time that the Bleed Solenoid is ON 96 seconds in every 5 minutes Press ENTER adjust of Bleed Time Press UP DOWN to adjust and RIGHT to move the cursor Press EXIT to leave the Setpoint unchanged Press ENTER displays current setpoint 90 seconds in every 5 minut
3. Users Manual Download AQCP_F_User from www Aquatrac com Manual Version Detail 05 06 First release of manual AQCP_F_User 05 06 50 SlimFlex Water Treatment Controller Appendix A INSTALL A 1 PLUMBING Typical sample chemical injection piping operates at 40 60psi and is plumbed in SCH80 PVC Sample piping is usually fed from the discharge side of the re circulation pump returning to either the suction side of the pump or to the tower basin Ensure that the sample piping flow exceeds 1 GPM and that the sample stream represents the tower water Avoid sample piping which drains whenever the tower is off line Solids will accumulate on the sensors requiring re calibration and cleaning A backcheck may be required at some sites to prevent reverse flow through the injection sensor piping when the recirculation pump is OFF Y strainers in the sample loop are not recommended unless the debris will mechanically damage the pH or conductivity sensors Strainer filters are usually the first location to plug turning OFF pumps and the bleed solenoid on no flow NEW CONSTRUCTION After pressure testing valve OFF the sample piping during post construction re circulation piping cleaning and passivation A 2 SENSORS Conductivity sensors may be installed in any orientation which allows them to be removed for cleaning Do not hang conductivity sensors in metallic tower sumps pH sensors must be installed vertically tip down to p
4. Press UP or DOWN until you read 4mA on the milli ammeter Press ENTER to view the output current and verify that the milli ammeter reads the same current Press ENTER amp then DOWN at 4 20mA Output Press ENTER at Trim Span to adjust the 20mA level Connect a DC milli ammeter in series with either of the current loop wires Press UP or DOWN until you read 20mA on the milli ammeter Press ENTER to view the output current and verify that the milli ammeter reads the same current AQCP_F_User 05 06 4 20mA Output 15 4mA Hag Trim Ze Trim Sp Trim Ze now 4mA ro an ea ro amp 6 lt v 201 t 4 20mA Output 15 2mA 4 20mA Output lt 15 4mA Qag Trim Sp an Select Span Trim Span now 20mA 91 4 202 4 20mA Output 15 2mA 59 SlimFlex Water Treatment Controller Appendix E AR Alarm Relay Option E 1 WIRING ALARM CONTACTS Alarm contacts rated 500mA at 24VDC Requires optional Alarm Relay Card Alarm dry contacts OPEN on alarm loss of controller power amp alarm Alarm wiring disconnect Relay Card Rala SD S Saas Alarm Building Automation System Alarm Input Alarm Wire alarm contacts AWG22 to AWG18 2 conductor E 2 ALARM DISPLAYS Press UP DOWN until you see Alarms If the Alarm Relay Card is installed you ll see one of the following displays If Alarms amp none then the alarm contacts will
5. Mode Bleed then Feed On in 267sec 156 OFF Mode Percentage Time On 9800 G 155 OFF 9700 G Mode Feed on Volume Sidebar Bleed amp Feed applies the of Bleed to each 300 seconds on Bleed ON time Bleed then Feed applies the of Bleed to the total Bleed ON time Feed on Volume feeds after the Bleed turns OFF ON ENTER Stop ends the current feed cycle or Time ON period HELP 150 154 2155 amp 156 and other help numbers display wherever more explanation is available at www Aquatrac com AQCP_F_User 05 06 33 SlimFlex Water Treatment Controller 3 7 Biocide Events Biocide Menu Options a Biocide Dayl12 Press UP DOWN until you see Biocide Displays ON or OFF and ON time from midnight E 38 0min Day in selected Cycle 1 28 or 1 7 or 1 4 Add Events v Press ENTER to Add a new biocide event Edit 4 Events y Press ENTER view or edit current events Edit 4 Events Displays of events 1 28 Delete Events y Edit not displayed if no events set 43 Press ENTER to delete all events Delete Events Delete not displayed if no events set Prebleed v Press ENTER to view or edit Prebleed Time amp Conductivity Prebleed PT Prebleed runs before each event Lockout Factory default is 0 minutes Prebleed Press ENTER to view or edit Bleed Lockout Time Lockout Lockout starts when each event starts Prime Pump y Factory default is 0 minutes Lockout rt Press ENTER to turn ON Bi
6. Sidebar System Diagnostics verifies the controller operation amp alerts you to wiring problems with conductivity temperature paddlewheel water meters and controller powered 4 20mA current loops AQCP_F_User 05 06 41 SlimFlex Water Treatment Controller 3 8 System Alarms continued System Adjust Clock Press UP DOWN until you see Day amp Time Adjust i a q Press ENTER amp DOWN to Adjust Clock Stop Inhibitor p DD MM YY HH MM 23 07 04 15 03 gt Press ENTER to view or adjust current Date amp Time Press EXIT to leave changed or RIGHT to move the underline Press UP DOWN to EDIT 3 then a After ENTER press UP DOWN to select day of the week Today is Tie 4 Day of the week is important for Biocide events t men g which use Sunday as Day 1 Tue 15 03 31 lt S N T044T9999 System Stop Inhibitor Press UP DOWN until you see Day amp Time Stop Inhibitor Press ENTER amp DOWN to Stop Inhibitor Select Units Press ENTER to view or adjust current No Bioblock lt Inhibitor feed sequence Biofeed Blocks y No Bioblock is the Factory Default Biofeed Blocks stops the Inhibitor Pump whenever the Biofeed Blocks Acid Pump or Biocide pump is ON No Bioblock Sidebar Sites where Biocide amp Acid are fed into the same sample feed piping as the Inhibitor may cause jelling or inhibitor degradation Blocking the inhibitor pump prevents product mixing in the sample feed piping
7. SlimFlex Water Treatment Controller Biocide Prebleed Press UP DOWN until you see Biocide Press ENTER amp DOWN to Prebleed Press ENTER to view and edit Prebleed This example turns ON the bleed for 20 minutes before each biocide event Prebleed ends if the tower conductivity falls below 650uS Press ENTER to adjust time or DOWN amp ENTER to adjust conductivity Press RIGHT to place the underline where you wish to adjust Press UP DOWN to adjust or EXIT to make no changes This example changes the prebleed conductivity from 650uS to 600uS 3 7 Biocide Events Continued Biocide Dayl2 OFF 20 0min QA then B Prebleed lt 4 Lockout y for 20min v or 650us y 4 for 20min A or 650us lt 4 Edit amp ENTER 600us gt p eo 5 then 4e for 20min v or 600us y Sidebar Prebleeding turns on the bleed solenoid before each biocide event to lower the tower conductivity Prebleeding limits bleed and sewering of the biocide during the kill time Biocides are usually fed during tower low load or no load so Prebleeding may not be required Prebleeding is also used to prevent overcycling during the Lockout period when the bleed is OFF AQCP_F_User 05 06 37 SlimFlex Water Treatment Controller Biocide Lockout Press UP DOWN until you see Biocide Press ENTER amp DOWN to Lockout Press ENTER to view and edit Lockout time Press ENTER to edit or press EXIT
8. Yearly Calibrate Conductivity Tester Replace pH test solutions Verify pH tester Observe a Bleed Control Cycle Verify Water Meter AQCP_F_User 05 06 The service life of an pH sensor is reduced by extreme temperature swings and frequent removal for calibration cleaning Incorrect sample line isolation valve sequencing stresses the sensor seal amp shortens sensor life Replace the pH sensor annually Verify the conductivity tester annually with a calibration solution using a solution tha s as close as possible to the controller conductivity setpoints Replace outdated calibration solutions If you are using pH calibration solutions replace outdated solutions If you are using a pH tester re calibrate it using a test solution Observe as the tower cycles up and the conductivity exceeds the Turn ON setpoint Observe the unobstructed flow from the bleed line if its visible Note the conductivity when the float opens the make up line Verify that the bleed solenoid shuts off flow when the conductivity falls below the lower setpoint Note the conductivity when the float closes the make up line Verify that the difference between Make up ON amp OFF conductivities is greater than the difference between Setpoint TurnON amp TurnOFF conductivities Optimal control occurs when the bleed setpoint deadband TurnON TurnOFF in less than the make up float ON OFF conductivity difference If a make up water meter
9. amp change the current password Press DOWN to Password OFF Pressing ENTER turns OFF PASSWORD Press RIGHT amp UP DOWN to change the current password ENTER changes the password Press EXIT to leave the password unchanged 3 9 Password continued Password lt Current State rv Log Out a Edit Password y 4 Edit Password Password OFF y 3 Password OFF Log Out Y Edit Password Edit amp ENTER 0094502 gt Ty then 4i Log Out v Edit Password y Sidebar If your controller is password protected Select Edit Password and change the password from the 123 factory default Passwords may be from 1 to 6 numbers Leading zeros are ignored If you forget your password you ll require the controller serial number to get a Reset Password The controller password is 123 after you key in the Reset Password AQCP_F_User 05 06 45 SlimFlex Water Treatment Controller 4 MAINTENANCE 4 1 Guidelines Modify the maintenance guidelines to reflect both the site priorities and the site water treatment program Guidelines are for controller function only Water treatment program maintenance requirements are provided by the site water treatment provider Frequency Activity Check for Alarms Scan Sensors Make up Meter amp Flowswitch Note ON times for Solenoids amp Pumps AQCP_F_User 05 06 Method Identify and correct the cause of alarms on sensors and pump
10. 2 or 3 conductor SEAS SIR OME BR AEG ee eee You ll need to know the gallons contact Red to set up the inhibitor feed rate Black Remove the seal insert Contact Head Feed the meter through the Water Meter seal amp re insert into the black cable entry fitting BEAR E SEARS Be ee a one ee ae en QSQOOO ADS OSDA You ll need to _ know the meter K Factor Wiring color differs to set up the oe with meter inhibitor feed rate Oe manufacturer Black Red Seametrics type Turbine Water Meters Do not install meter cabling in the same conduit at AC power wiring AQCP_F_User 05 06 SlimFlex Water Treatment Controller 1 5 Pumps amp Bleed Solenoid The controller supplies the AC power for the pumps and solenoid Controller relays switch power to pumps and the solenoid fused at a maximum of 5 Amps WARNING Do not plug in BIOCIDE controller pumps PUMP or solenoid until you are ready to setup ACID amp operate PUMP INHIBITOR PUMP BLEED Grounded SOLENOID Power Plug HARDWIRING refer to appendix C START UP BEFORE you plug in pumps and bleed solenoid A Plug in the controller B Set control modes and setpoints C Set the feed limits on the inhibitor and acid pumps D Verify that the sensors are reading correctly and set the alarms E If you are using a water meter force make up and verify that meter is measuring the expected volume F Verify that the flows
11. AQCP_F_User 05 06 42 SlimFlex Water Treatment Controller System Select Units Press UP DOWN until you see Day amp Time Press ENTER amp DOWN to Select Units Press ENTER to view or adjust current Select Units Press EXIT to leave changed Or DOWN to change Key ENTER to Set to U S units degrees Fahrenheit amp Gallons Or Set to Metric degrees Centigrade amp Liters System Adjust Temperature Press UP DOWN until you see Day amp Time Press ENTER twice to adjust Temperature Press UP DOWN to EDIT or RIGHT to move the underline Press EXIT to leave changed or ENTER to change the temperature A Temperature displaying Fault cannot be adjusted Temperature cannot be adjusted more than 18F or 10C from the factory default Press EXIT on this message to return to Temperature factory default setting 3 8 System Alarms continued Thu 16 54 10 lt S N T041T0486 then 4 Select Units gt a Current State y rv Deg F Gallons Deg C Liters y 3 Deg C Liters Deg F Gallons Temperature 101 87F y qa Edit amp ENTER 092F gt ty then 4 Advice 108 Fails Calibrate Sidebar Select Units changes make up meter units year to date units and volume per contact units Temperature compensation of conductivity switches automatically between C amp F as does the System Current State display of temperature NOTE If you adjust the Temperature you ll need to
12. The Bleed Solenoid will turn ON as the conductivity exceeds the Turn ON setpoint As the tower makes up the Conductivity will fall below the TurnOFF setpoint and the Bleed Solenoid will turn OFF Verifying a Meter Control or Percentage Time Bleed Mode differs If the Inhibitor feed mode is set to Bleed amp Feed the Inhibitor Pump will turn ON when the Bleed turns ON If the of each 5 minutes is set to less than 100 the Inhibitor Pump will turn ON amp OFF while the Bleed in ON If the Inhibitor feed mode is set Bleed then Feed the Inhibitor Pump will always be OFF when the Bleed is ON amp will turn ON as soon as the bleed turns OFF If the inhibitor pump is set to Feed on Volume the inhibitor pump will turn ON after measuring Make up If the Bleed is ON the Inhibitor Pump will wait until the Bleed turns OFF before turning ON 2 8 Check Controls Conductivity amp Bleed Conductivity v 1425 us ST Bleed Solenoid ON 564 2min ater Meter or Bleed amp Inhibitor Pump Bleed Solenoid ON 564 2min ST Inhibitor Pump lt ON 48 1min Make up Today 38200 G Sf Inhibitor Pump ON 124 8min Sidebar The Bleed Solenoid and Pumps will not turn ON unless the Flowswitch is ON The Inhibitor Pump turns OFF if the daily Feed Limit is exceeded Increase the Limit Timer to allow the pump to turn ON Bleed Solenoids may turn OFF if Biocide is set to Prebleed
13. ower Chemical Acid Acid may Pump o ia be fed directly L Injection Caustic into the tower 7 points E sump l a j Optional Inhibitor Make up Water Meter J Flow Isolation Valve _ Exchanger i Re circulation Pump a l W SA Flow Sample Injection oer Piping PVC 100psi MAX Isolation Valve Isolation n m rj BI a Valve ea i j pH Conductivity Sensor Flowswitch Sensor Typical Installation Piping Bleed Solenoid or Valve Warning Sulfuric acid cannot be fed Your installation may into PVC piping not include a make up meter Use a quill rated for acid injection Smaller towers place the Comply with quill vendors sensors in the tower re circulation line recommended installation AQCP_F_User 05 06 4 SlimFlex Water Treatment Controller 1 2 Controller Enclosure Remove the lower controller enclosure cover Hang the controller on a single 8 10 screw located 60 150cm above the floor Install the bottom left amp right mounting screws through the existing enclosure holes located behind the lower cover Flow Typical Equipment Layout Controller Chemical Injection points Chemical Feed Pumps Plugs wiring amp tubing not shown Pump Shelf Sensors Warning Sulfuric acid cannot be fed into PVC piping Use a quill rated for acid injection Comply with quill vendors recommended installation Although sensor cables and pump tubing ma
14. Controller 2 5 Verify Conductivity amp pH Sensors Open the downstream then the upstream sample line isolation valves immersing the conductivity amp pH sensors Press UP or DOWN until you see Day amp Time Press ENTER Press ENTER amp then press ENTER to view temperature at the conductivity sensor If the GREEN amp WHITE wires are connected to the controller terminals you ll view the current temperature Fault indicates a wiring or sensor problem Fault automatically removes conductivity temperature compensation Key EXIT twice to return to Day amp Time Press DOWN until you see Conductivity Sample the tower water amp verify that the displayed conductivity matches the measured conductivity Adjust the displayed conductivity by pressing ENTER twice Press UP DOWN to adjust and RIGHT to move the cursor Press EXIT to leave Conductivity unchanged You ll see this screen if the sensor is fouled miswired not immersed or you keyed incorrectly Press ENTER to ignore or EXIT to return to Factory Default 2141 indexes more explanation www 2eZnet com Displays the current calibrated conductivity AQCP_F_User 05 06 Verify Temperature Thu 16 54 10 v S N T04170486 a Current State l Adjust Clock y s Temperature 101 87F Y Calibrate Conductivit Conductivity 1425 us m Calibrate Alarms m Edit amp ENTER 1883 us gt Ts then 4a Advice 141 Fails Cali
15. K factor Press UP DOWN until you see Make up Today Displays make up volume from midnight Press ENTER twice to view or change meter type Key DOWN to select Paddlewheel type meter Key ENTER to view or change the pulses per Gallon Metric users view pulses per Liter Press UP DOWN to adjust and kK Factor unchanged ENTER or EXIT displays the current meter type continued atermeter Make up Today 38200 G m Meter Type gt Year to Date y 4 Paddlewheel Contact Head m kK Factor 100 0 PT Edit amp ENTER 104 5 gt Ty then Paddlewheel ao Contact Head y Sidebar Force make up by either opening the bleed solenoid bypass or lowering the Bleed Setpoints Verify that the make up meter displays an increasing volume as the float opens the make up line Close bypass or reset Bleed Setpoints after verifying the meter WARNING Verify paddlewheel meters immediately and disconnect if not verified Mis wired paddlewheel meters will fail the meter Hall Effect sensor AQCP_F_User 05 06 19 SlimFlex Water Treatment Controller 2 7 Plug in Pumps and Bleed Solenoid Sections 2 1 to 2 6 adjust setpoints and verify sensors We re now ready for the bleed solenoid and each chemical pump verifying each one as it s plugged in Remove the lower access panel on the controller enclosure Plug the bleed solenoid into the right bottom plugs Press UP or DOWN to view Bleed So
16. and a timed event is scheduled Bleed Solenoids may not turn ON if Biocide is set to Lockout and a timed event has started AQCP_F_User 05 06 22 SlimFlex Water Treatment Controller Watch the pH increase as the tower operates evaporates and increases alkalinity The Acid Pump will turn ON as the pH exceeds the Turn ON setpoint As acid feeds the pH falls below the TurnOFF setpoint and the Acid Pump will turns OFF Verifying a pH controlled by Feed on Volume water meter mode differs with pH falling after make up volume is measured If you have not set a Biocide Prebleed or Lockout the Biocide pump will turn ON for the preset time on the selected Day Prebleed time starts at the time set for the event amp ends after the Prebleed time OR when the conductivity target is met Lockout time starts after the timed event ends turning OFF the Bleed During Prebleed watch the Bleed Solenoid amp Conductivity During Lockout watch the Bleed Solenoid Status Press ENTER amp DOWN Bleed Solenoid for Prebleed and or Lockout end options 2 8 Check Controls continued pH Sensor 7 84 pH Sf Acid Pump v ON 10 4min Biocide Pump amp Bleed Valve Conductivit Biocide Day 4 OFF 20 0min Sf Bleed Solenoid ON 204 2min Sf Conductivity lt 415 us Sidebar There is a delay between the time the acid pump turns ON and the pH sensor measures the effect as low pH water travels through the
17. since most meters are used to control inhibitor feed and inhibitor ppm errors result when meters are incorrectly configured A 6 CONTROLLER ENCLOSURE The optimum location for sensors controller chemical pumps and drums is as close together as access allows You ll be able to see where all the wires plugs and tubing goes watch pumps turn ON as you prime grab samples to calibrate sensors If you have the space sample piping on the left pumps amp drums on the right with the controller in the middle Wall mount the controller enclosure at eye height for a 5 to 5 6 person so that an operator does not have to reach over drums or pumps to use the controller key pad In areas with daily ambient temperatures over 100F 40C locate the controller out of direct sunlight or beneath a sunshade Internal temperatures over 115F 45C will degrade the controller display Do not punch conduit access holes in the top of the enclosure to avoid condensation damage to the controller electronics Plug the controller into a dedicated Always ON utility outlet Maximum controller current 120VAC is 5 Amps AQCP_F_User 05 06 52 SlimFlex Water Treatment Controller Appendix B SPECIFICATIONS Each controller includes an option card slot Auto re configuration occurs on installation of one of LAN 4 20mA Output OR Alarm Relay option card Analog Digital I O Conductivity Flowswitch Sensor pH Water Meter Flowswitch Relay Ou
18. AQUATRACG SYSTEM DESIGN amp ENGINEERING SlimFlex Water Treatment Controller For Cooling Towers Measures Conductivity pH Temperature Make up Water Meter and Flowswitch Controls the Bleed Solenoid Inhibitor Acid and Biocide Pumps Includes CTF Conductivity Temperature Flowswitch and pH Sensors Part No CO IN PH TB SlimFlex Water Treatment Controller CONTENTS Safety 1 INSTALLATION 1 1 Sample Piping 1 2 Controller Enclosure 1 3 Sensors Conductivity amp pH 1 4 Sensors Water Meter amp Flowswitch 1 5 Pumps and Bleed Solenoid 2 START UP 2 1 Power up Display amp Keypad 2 2 Bleed Mode Conductivity Setpoints 2 3 Inhibitor Feed Mode Setpoints Feed Limits 2 4 Acid Setpoints Feed Limit 2 5 Verify Conductivity amp pH Sensors 2 6 Check Flowswitch amp Install Water Meter 2 7 Plug in Pumps and Bleed Solenoid 2 8 Check Controls 3 OPERATION 3 1 Conductivity Sensor 3 2 Bleed Controls 3 3 pH Sensor 3 4 Acid Controls 3 5 Make up Meter 3 6 Inhibitor Controls 3 7 Biocide Events 3 8 System Alarms 3 9 Password 4 MAINTENANCE 4 1 Guidelines 4 2 Spare Parts 3 10 4 3 Technical Support APPENDICES A INSTALL B SPECIFICATIONS C HARDWIRING D CL 4 20mA OUTPUT Option E AR ALARM RELAY Option F LB LAN BROWSER Option AQCP_F_User 05 06 SlimFlex Water Treatment Controller Safety Electrical Shock Hazard Removing the lower enclosure cover wit
19. Acid Pump Press ENTER Current State If the pump is OFF displays Turn ON setpoint 8 00 amp current pH 7 90 If the acid pump is ON displays TurnOFF setpoint 7 94 amp Current pH 8 04 If acid pump is ON displays Owes 38 sec 243 amp ON ENTER Stop Owed seconds count down to zero amp the pump turns OFF ENTER ends current feed time If OFF displays volume to turn ON 9800 amp Current meter volume 9700 2241 amp 2243 Help numbers display wherever more explanation is available at www 2eZnet com AQCP_F_User 05 06 3 4 Acid Controls Acid Pump lt OFF 210 4min qi and Feed Mode v Limit Timer y pH Control Feed on Volume y amp Feed on Volume lt lt pH Control y Acid Pump v OFF 210 4min and Current State l Setpoints m off 7 95 241 ON 8 04 pH Mode pH Control Owes 38sec 243 ON ENTER stop Mode Volume Control ON On 9800 G 243 OFF 9700 G Mode Volume Control OFF 29 SlimFlex Water Treatment Controller 3 5 Make up Meter Meter type selection amp installation detailed in Section 2 6 Check Flowswitch amp Install Water Meter Press UP DOWN until you see Make up Today Make up Today amp press ENTER 38200 G Press ENTER to view current type or to select Meter Type lt Contact Head or Paddlewheel water meter Year to Date 4 Key DOWN amp ENTER for volume this year Year to Date E Days Online y Key DOWN amp ENTER
20. Altern Altern weekly 35 min 4 ty then ga nt d weeks y weeks y weekly One Eve Advice Now 8 Biocide OFF nt y m 175 Events lt rv Day12 20 0min 35 SlimFlex Water Treatment Controller Biocide Edit Events Press UP DOWN until you see Biocide Press ENTER amp DOWN to Edit Events Press ENTER to view and edit current events Press UP DOWN to select an event for editing In this example select 1 of 8 events Press ENTER on the selected event Press RIGHT to place the underline where you wish to adjust Press UP DOWN to adjust This example changes the event start time from 6 00AM to 6 45AM Press ENTER to end or EXIT to make no changes Setting a run time to 0 removes the event 3 7 Biocide Events continued Biocide Dayl2 OFF 20 0min 4 then 4 Edit 8 Events Delete Events y ga Day 2 Q 14 30 on for 10 min ts Day 25 6 00 on for 25 min 6a Day 25 6 45 on for 25 min ac 5 then Edit 8 Events Delete Events Sidebar Events are re sequenced by Day amp Time whenever you Edit Events or Add Events Keying UP in Edit Events displays the event sequence from Day 1 to Day 28 Day 1 is always Sunday for 28 and 7 Day Cycles The range of Day numbers changes as the Cycle Days changes from 1 28 1 7 or 1 If you change Cycle Days all events are deleted AQCP_F_User 05 06 36
21. Factory default Lockout is set to 0 minutes Press ENTER to adjust Press RIGHT to place the underline where you wish to adjust Press UP DOWN to adjust or EXIT to make no changes Biocide Cycle Days Press UP DOWN until you see Biocide Press ENTER amp DOWN to Cycle Days Press ENTER to view and edit Cycle Days Press ENTER to edit or press EXIT Key UP DOWN to select 28 7 or 1 day amp then press ENTER Changing Cycle Days deletes existing events Biocide events repeat every 28 7 or 1 day 3 7 Biocide Events continued Biocide Dayl2 OFF 20 0min then Lockout v Prime Pump rv Lockout 2174 O min lt ga Edit amp ENTER 120 min gt Ty then Cycle Days lt Current State v p 28 Days lt 1 Day y 3 1 Day v 7 Days Cycle days lt Current State y Sidebar Lockout prevents the bleed solenoid from turning ON during the biocide kill time and sewering the biocide Lockout is usually used with Prebleed to prevent tower overcycling during the Lockout period Non Oxidizing biocides typically use a 28 or 7 Day cycle Oxidizing biocides typically use a 7 or 1 day cycle AQCP_F_User 05 06 38 SlimFlex Water Treatment Controller Biocide Current State Press UP DOWN until you see Biocide Press ENTER amp UP to Current State Press ENTER to view Current State If there are no Biocide feed events running displays
22. N verify that the green R3 light on the right side of the enclosure is ON Verify that the pump is stroking primed and feeding acid If OFF press ENTER amp DOWN to Prime Pump Press ENTER and the Acid Pump amp R3 light will turn ON for 5 minutes See Section 3 7 Biocide Events to set biotiming Plug the Biocide pump into the lowest of the 3 sidewall plugs Press UP or DOWN to view Biocide If ON verify that the green R4 light on the right side on the enclosure is ON Verify that the pump is stroking primed and feeding oxidant If OFF press ENTER amp DOWN to Prime Pump Press ENTER and the Biocide pump amp R4 light will turn ON for 5 minutes Reinstall the lower access panel on the controller enclosure continued Acid Pump Acid Pump v OFF 0 Omin 4a then 4 Prime Pump lt Current State y ga Acid Pump lt ON 0 1min Biocide Pump Biocide Day12 OFF 38 0min then 4 Prime Pump v Cycle days y Biocide Day12 ON 38 1min Sidebar The Bleed Solenoid and Pumps will not turn ON unless the Flowswitch is ON Priming the Biocide pump does not cause a bleed solenoid Prebleed or Lockout Press ENTER at Alarms and ENTER at Clear Alarms to end Test Bleed or Prime Pumps AQCP_F_User 05 06 21 SlimFlex Water Treatment Controller Verify that the controls work in the way that you expect for this site Watch the Conductivity increase as the tower operates
23. N ENTER Stop If bleed OFF displays turn on volume 10400 amp current volume 10 200 If bleed ON displays Owes 41 sec 123 amp ON ENTER Stop If bleed OFF displays seconds to turn ON 3 2 Bleed Controls Continued Bleed Solenoid ON 564 2min 4a then T Current State d Setpoints 4 off 975 121 ON 993uS Mode Conductivity Control On 10400 G 122 OFF 10200 G Mode Water Meter Control On in 221sec 123 OFF Mode Time Control HELP 121 122 amp 123 and other help numbers display wherever more explanation is available at www Aquatrac com ON ENTER Stop ends the current feed cycle or Time ON period AQCP_F_User 05 06 27 SlimFlex Water Treatment Controller Sensor calibration is detailed in Section 2 5 Verify Conductivity amp pH Sensors Press UP DOWN until you see pH Sensor Press ENTER amp then DOWN to Alarms Press ENTER to view current alarms or adjust Press ENTER to adjust the High Alarm or DOWN amp ENTER to adjust the Low Alarm Press UP DOWN to adjust and RIGHT to move the cursor Press EXIT to leave Alarm unchanged ENTER updates the alarms amp displays the current High amp Low Alarms pH Alarms display on the Alarms display and resets automatically Clear Alarms does not reset an pH alarm above the High or less than the Low Alarm level High alarms occur on a failure to feed acid or sensor fault Low alarms occur on a acid overfeed or s
24. OFF If a Biocide feed event is running counts down remaining time Press ENTER to end event or EXIT to return to Current State 3 7 Biocide Events continued Biocide Day 4 OFF 38 O0min ga then T Current State Add Events y Biocide 2170 OFF OK Po OR ON for 21 3min ON ENTER Stop Sidebar Bleed Solenoid Prebleeding starts when an event is scheduled Biocide pump turns ON after Prebleed time ends Bleed Solenoid Lockout starts when biocide pump turns ON HELP 170 and other help numbers display wherever more explanation is available at www Aquatrac com AQCP_F_User 05 06 39 SlimFlex Water Treatment Controller 3 8 System Alarms System Menu Options Thu 16 54 10 lt S N 1T041T0486 rv Press ENTER to view Current State Current State lt Controller diagnostics Adjust Clock y 4 Press ENTER to view and adjust clock Adjust Clock lt Stop Inhibitor v Press ENTER to stop inhibitor feed 3 during Acid and Biocide feeds Stop Inhibitor Select Units y amp Select Units Password ON Press ENTER to turn ON the user password lf PASSWORD on press ENTER for password tools Password ON lt Press UP DOWN until you see Day amp Time Press ENTER view System options Press ENTER to view or change US or Metric units Current State Alarms Press UP DOWN until you see Alarms Alarms The first alarm to trip will display or none if no alarms none P
25. Volume y 4 Feed on Volume Bleed amp Feed y 4a then T Setpoints v Feed Mode y Sidebar Bleed amp Feed is used on bleed limited towers where the bleed solenoid is ON for more than 50 of the time Bleed then Feed is used on towers which don t have a make up water meter typically reducing inhibitor usage over Bleed amp Feed since you are not pumping inhibitor with the Bleed ON Percentage Time is used to base feed during start up or when the tower is not loaded Feed on Volume is usually the most accurate amp reliable way to feed for towers which have a make up meter AQCP_F_User 05 06 32 SlimFlex Water Treatment Controller Current State of the Inhibitor Pump Control Press ENTER then UP Inhibitor Pump Press ENTER Current State If Bleed ON displays Owes 233sec 154 OR On in 86sec 150 Seconds count down to zero and pump changes state If Bleed OFF displays Bleed Off 150 If Pump ON displays Owes 101 sec 150 If Pump OFF displays Bleed Off If Pump ON displays Owes 41 sec 156 If Pump OFF displays seconds to turn ON Seconds count down to zero amp pump changes state If Pump ON displays Owes 38 sec 154 If Pump OFF displays turn on volume 9800 amp Current volume 9700 3 6 Inhibitor Controls Continued Inhibitor Pump ON 48 1min then T Current State Setpoints a Owes 162sec 154 ON ENTER Stop Mode Bleed amp Feed Bleed off 2150 OFF
26. ar to date amp days on line Inhibitor Pump ON or OFF and ON time today Press ENTER for Inhibitor Setpoints Feed Mode Limit Timer Prime Pump and Current State Flowswitch ON or OFF and ON time today Biocide Pump ON or OFF and ON time today amp Cycle Day Press ENTER for Add Edit amp Delete Events Prebleed Lockout Prime Pump Cycle Days and Current State If there are no options installed you ll view the power up display LAN Browser Option Displays current IP see Appendix F LAN 4 20mA Output Option Displays loop current see Appendix D 4 20mA OUTPUT for User Manual Alarm Relay Option Displays relay state see Appendix E ALARM RELAY for User Manual AQCP_F_User 05 06 continued Make up Today 10450 G Sf Inhibitor Pump ON 9 2min Sf Flowswitch ON 780 6min ST Biocide Day 5 OFF 30 0min Sf Thu 16 54 10 v S N T041X0486 LAN IP 10 10 6 106 OR 4 20mA Output lt 15 4mA OR Alarm Relay E Closed 10 SlimFlex Water Treatment Controller 2 2 Bleed Mode Conductivity Setpoints The factory default is Bleed on Conductivity Refer to 3 2 Bleed Controls to select one of three Bleed Modes Bleed Solenoid Press UP or DOWN until you see ON 564 2min Bleed Solenoid amp press ENTER Press ENTER to view or adjust Setpoints Setpoints lt lt Bleed Mode v Displays current bleed setpoints Varies with Bleed Mode Turn ON 1150
27. be closed Alarm contacts open on alarm This display verifies the contact set state measured at the Building Automation System input terminals AQCP_F_User 05 06 Alarms Sf Alarm Contacts CLOSED No Alarm OR Alarm Contacts OPEN Alarm 60 SlimFlex Water Treatment Controller Appendix F LB LAN Browser Option Download SFlex_LB manual from www Aquatrac com Do not connect the controller to the site LAN without permission and an IP address from the site IT staff You can use a crossover cable to connect to your notebook PC to view the controller state Information on browsing controllers is available in the SFlex_LB manual Cooling Tower Controls 2004 10 18 09 04 30 On Events oe COOLING Biocide Pump TOWER Alarms none On 8 00 Alarms Events Acid Pump and Timers FiReset All 6100 G Z Refresh View Part No CO IN PH TB Tower Make up Owes 274sec Inhibitor SerialNumber US04P9999 Click a link in the View to operate the controller 11 7 min Flowswitch 7 37 pH pH Sensor 1891 uS Conductivity CONDENSER Setup Configure Refresh ona 995 Bleed Valve AQCP_F_User 05 06 61
28. brate a Conductivity 1883 us 4 16 SlimFlex Water Treatment Controller 2 5 Verify Conductivity amp pH Sensors Open the downstream then the upstream sample line isolation valves immersing the conductivity amp pH sensors Press UP DOWN until you see pH Sensor Sample the tower water amp verify that the displayed pH matches the measured pH Adjust the displayed pH by pressing ENTER twice Press UP DOWN to adjust and RIGHT to move the cursor Press EXIT to leave pH unchanged You ll see this screen if the sensor is fouled miswired not immersed or you keyed incorrectly Press ENTER to ignore or EXIT to return to Factory Default 2211 indexes more explanation www 2eZnet com Displays the current calibrated pH continued Calibrate pH pH Sensor dq 7 84 pH Calibrate v Alarms y m Edit amp ENTER 7 89 pH gt ao then Advice 2211 Fails Calibrate m pH Sensor lt 7 89 pH Sidebar pH s in cooling towers typically vary from 7 0 to 10 0 with acid feed setpoints typically in the 8 0pH range The actual setpoints used in your tower will depend on both the make up chemistry and the water treatment program Acid feed setpoints are provided by your water treatment vendor AQCP_F_User 05 06 17 SlimFlex Water Treatment Controller 2 6 Check Flowswitch amp Install Water Meter Open the downstream then the upstream sample line isolation valves immersing th
29. e conductivity amp pH sensors Note The thermal flowswitch requires a maximum of 30 seconds to respond to the change from NO Flow to Flow Press UP DOWN until you see Flowswitch Displays ON or OFF and the total minutes ON from midnight NOTE An OFF flowswitch stops all pumps and the bleed solenoid The flowswitch can be bypassed by jumpering the Flow terminal to ground The factory default water meter is a 100 Gallons contact contact head meter Press UP DOWN until you see Make up Today Displays make up volume from midnight Press ENTER twice to view or change meter type Key ENTER to view or change the gallons contact Metric users will view volumes in L iters amp L Contact Press UP DOWN to adjust and RIGHT to move the cursor Press EXIT to leave Gallons contact unchanged ENTER or EXIT displays the current meter type Flowswitch Flowswitch ON 780 6min atermeter Make up Today 38200 G a Meter Type Year to Date 3 Contact Head Paddlewheel qa G contact 100 lt rv Edit amp ENTER 50 gt Ty then ga Contact Head Paddlewheel y 4 4t Sidebar 2 wire meters are usually Contact Head amp 3 wire meters are Turbine or Paddlewheel AQCP_F_User 05 06 18 SlimFlex Water Treatment Controller 2 6 Check Flowswitch amp Install Water Meter Turbine Paddlewheel type water meters provide pulses per Gallon or Liter The number of Pulses Unit Volume is the
30. ed setpoints therefore it s pH you ll need to adjust the Acid pump Feed Limit If you are not using Control Verification then acid feed requires regular maintenance to verify that the pH sensor is reading correctly and the Feed Limit timer is set correctly to prevent an acid overfeed and resulting corrosion A Feed Limit timer set too short will trip and result in no acid feed with possible scaling of heat exchanger tubing 49 SlimFlex Water Treatment Controller 4 1 Spare Parts 4 1 1 Line Fuse Protects Rating Type Manufacturer Vendor Controller Littlelfuse Type 217 250VAC Pumps and Bleed 5 Amps 115VAC Digikey Part F953 ND Solenoid 2 Amps 230VAC Digikey Part F950 ND 5mm x 20mm www digikey com 1 800 344 4539 Fast Acting 4 1 2 Controller Parts Part Description SFuse 120VAC Fuse Kit 10 x 5A Controller Fuses Conductivity Temperature Flowswitch sensor CTF Entry Conductivity entry fitting for PVC NPT T fitting A261100A 12mm pH sensor A261103 pH sensor holder NPT slip CO IN PH TB NS Spare Controller without sensors amp entry fittings R171232 Enclosure LAN cable entry weather seal R171230 Enclosure Power cable entry fitting PG11 R171231 Enclosure Sensor cable entry fitting PG9 On Line Help Browse to www Aquatrac com help with the 3 digit HELP from the controller LCD display LCD display HELP numbers are preceded by
31. ensor fault 3 3 pH Sensor pH Sensor d 7 84 pH ac gy Alarms Calibrate rv High 9 00pH Low 7 00pH amp High 9 00pH Low 7 00pH Edit amp ENTER Low 7 40pH gt ty then High 9 00pH Low 7 40pH Y 4 A Sidebar pH alarms may occur when the tower shuts down and drains the sample line or when an pH sensor fouls Scaled pH sensors can be cleaned HCI Immerse until the fizzing stops Organically fouled sensors may be cleaned with alcohol and soft brush Caution pH sensors will not measure correctly unless the GREEN solution ground wire on the bottom of the sensor entry T is connected to a controller ground terminal AQCP_F_User 05 06 28 SlimFlex Water Treatment Controller For pH Control setpoints amp Pump limit timer see Section 2 4 Acid Setpoints Feed Limit Acid Pump Control Modes Press ENTER then DOWN Acid Pump Press ENTER Feed Mode to view current mode and to select a new mode Most cooling towers operate with pH Control The Acid Pump turns ON at TurnON pH setpoint and OFF at TurnOFF setpoint Feed on Volume turns ON the Acid Pump for a user set time after measuring a user set make up volume It s amode that may be used to bypass a pH sensor NOTE If you change the Feed Mode press UP to Setpoints amp ENTER to adjust for the new Feed Mode Current State of Acid Pump Control State Display changes with the selected Feed Mode Press ENTER then UP
32. er power Notes Scan rate 100mS nominal User adjustable LCD contrast User set fixed IP Fixed MAC 53 SlimFlex Water Treatment Controller Controls Rating Detail Notes Bleed Solenoid Controls Conductivity Water Meter amp Percentage Time Inhibitor Pump Controls Bleed amp Feed Bleed then User sets of Bleed ON time Feed Feed on Volume amp used for Inhibitor feed Percentage Time User selected block on Oxidant Daily feed limit timer amp Biocide feed Acid Pump Controls pH amp Volume Time User selected reset of feed limit Feed limit timer on each ON OFF timeout at midnight sequence Biocide 28 Events in a cycle User selected 1 7 or 28 day Timed Events 1 minute resolution cycle Lockout Prebleed on both time and conductivity Thermal Flowswitch Bleed Solenoid amp Pumps OFF CTF sensor combines when no flow Conductivity Temperature Flowswitch in one sensor Flowswitch trips at 1GPM within 30 seconds System Rating Detail Notes Controller Configuration User settings and biocide events Makes current configuration written on silicon factory default Clock Battery backed 5 years of normal CR2032 clock battery available usage at Radio Shack AQCP_F_User 05 06 54 SlimFlex Water Treatment Controller Electrical Rating Detail Notes Fusing 5 Amps 120VAC 5x20mm 120VAC fusing 2 Amps 240VAC Surge Spike Suppression Bleed solenoid relay contacts Controller e
33. es Inhibitor Pump lt ON 48 1min Setpoints Feed Mode rv Bleed amp Feed 32 each 5min oh Edit amp Enter 30 each 5min gt 22 5 then 4 Bleed amp Feed 30 each 5min vy Sidebar Bleed amp Feed is the most common but usually not the best way to feed inhibitor If you are not bleed limited use Bleed then Feed mode to reduce inhibitor use If you are using a make up water meter to control inhibitor feed the controller will delay feeding when the bleed valve is ON to avoid pumping inhibitor down the drain AQCP_F_User 05 06 12 SlimFlex Water Treatment Controller 2 3 Inhibitor Feed Mode Setpoints Feed Limits The Inhibitor feed limit timer turns OFF the inhibitor pump to prevent overfeeding The factory default feed limit 180 Minutes Day Press UP or DOWN until you see Inhibitor Pump amp press ENTER Press DOWN until Limit Timer Press ENTER to view or adjust Limit Timer Displays feed limit in minutes 2157 indexes more explanation www Aquatrac com Press ENTER adjust Feed Limit Press UP DOWN to adjust and RIGHT to move the cursor Press EXIT to leave the Feed Limit unchanged Press ENTER displays current setpoint 210 minutes day continued Inhibitor Pump ON 48 1min Limit Timer v Prime Pump v m Day Limit 157 180 min day J ga Edit amp Enter 210 min day gt 3 then 4a Day Limit 157 210 min day lt HELP 157 and ot
34. for days on line this year Days Online lt Zero Meter 4 Key ENTER to reset Year to Date Days OnLine Zero Meter lt and Make up Today to zero Meter Tvpe 4 Warning Cannot Undo yP Volume this year to date Year to Date 192 Displays in L iters if metric selected 765200 G Days controller installed and operating this year Days Online 7193 Does not count days controller powered OFF 215 Press EXIT to return to previous display Sidebar Year to Date volume divided by Days OnLine is average usage a figure of merit for a tower tonnage HELP 192 amp 193 and other help numbers display wherever more explanation is available at www Aquatrac com AQCP_F_User 05 06 30 SlimFlex Water Treatment Controller For inhibitor control setpoints amp feed limit refer to Section 2 3 Inhibitor Feed Mode Setpoints Feed Limits Press UP DOWN until you see Inhibitor Pump Displays ON or OFF and ON time from midnight Press ENTER to view or adjust Setpoints Setpoints vary with selected Feed Mode Press ENTER view current mode or to select from Bleed amp Feed Bleed then Feed Percentage Time OR Feed on Volume Press ENTER to set maximum feed minutes day Press ENTER Prime Pump to turn ON Inhibitor Pump for 5 minutes Alarms Clear Alarms ends Priming Press ENTER Current State to view control status Display varies with Feed Mode 3 6 Inhibitor Controls Inhibitor Pump ON 48 1min
35. h the controller plugged in exposes the user to AC line voltages There are no user serviceable parts behind the upper enclosure cover do not remove A USER WARNING CAUTION Cooling Tower Water Treatment Controllers operate 120VAC bleed solenoids amp pumps and may pump hazardous corrosive and toxic chemicals Opening the controller enclosure exposes user to the risk of electrical shock at power line voltages Understand fully the implications of the control setpoints feed limits and alarms that you select Harm to personnel and damage to equipment may result from mis application Unplug or turn OFF the AC power to the controller if you have any concerns regarding safety or incorrect controller operation and notify supervisory staff YOUR CONTROLLER Controllers are supplied with default bleed and feed and oxidant pump setpoints that will not be applicable to your cooling tower Select control modes adjust setpoints and set biocide pump timing for your site and its water treatment program AQCP_F_User 05 06 3 SlimFlex Water Treatment Controller 1 INSTALLATION 1 1 Sample Piping Controller includes sensors and PVC sensor entry fittings if you have not previously installed this type controller read Appendix A INSTALL for plumbing and wiring guidelines CAUTION Do not exceed 100psi on pH sensor or flowswitch Always close upstream isolation valves first Biocide i Cooling iocide T z
36. her help numbers display wherever more explanation is available at www Aquatrac com If you are using water treatment controls for the first time the language and application of some of the controller options and settings requires more detail than a 2 line display can deliver AQCP_F_User 05 06 13 SlimFlex Water Treatment Controller 2 4 Acid The factory default is pH Control Refer to 3 4 Acid Controls to select one of two Control Modes Press UP or DOWN until you see Acid Pump The pump is OFF amp has been ON for 210 4 minutes from midnight Press ENTER Press ENTER to view or adjust Setpoints Displays current acid feed setpoints Pump turns ON when the pH is above 8 00 pH and OFF when the pH is below 7 95 pH Press ENTER adjust TurnON or DOWN amp ENTER for TurnOFF Press UP DOWN to adjust and RIGHT to move the cursor Press EXIT to leave the Setpoints unchanged Press ENTER displays current setpoints If you make TurnON less than TurnOFF the setpoints will be switched Setpoints Feed Limit Acid Pump v OFF 210 4min amp Setpoints v Feed Mode m Turn ON 8 00 TurnOFF 7 95 y amp Edit amp Enter Turn ON 8 10 gt ty then a Turn ON 8 10 TurnOFF 7 95 y Sidebar Acid control setpoints are usually set by measuring or estimating the pH at the target cycles of concentration If make up water alkalinity changes the amount of acid required to maintain the setp
37. is installed verify that the controller measures an increase in make up volume while the make up float opens the make up line Is the expected volume measured for the size of the line and the float ON time If not the meter Volume Contact or K factor may have been set incorrectly or the water meter may have been cabled in a common conduit with AC power 48 SlimFlex Water Treatment Controller Activity Methodd _ Observe an Acid Yearly Feed Cycle This may take some time but it s worth doing whenever you make changes to setpoints or when make up chemistry changes AQCP_F_User 05 06 Observe the slow rise in pH as the tower evaporates water and increases alkalinity Note the time when the Acid pump turns ON Initially there may be a delay in pH response as acid feeds depending on feed point pump setting and the time for acidified water to reach the sensor Note the elapsed time when the Acid pump turns OFF pH will continue to fall after the Acid pump turns OFF due to pumping and sump transit delay If this is a fully loaded tower on a hot day then the pump elapsed time should be nominally of the Feed Limit timer setting to prevent nuisance trips The piping sump delay between adding acid and measuring the change in pH widens the effective ON OFF control range The effect is minimized by using TurnON and TurnOFF setpoints not more than 0 1pH apart If you change the tower ble
38. lectronics snubbed 0 1uF 150R oe isolated from AC Varistor on AC power input AC Terminals AC Input amp Output maximum Stranded AWG 14 150mm Sensor Digital Input AWG 22 0 25 0 50mm Terminals Paddlewheel Meter Power 14 20 VDC unregulated 4 20mA output option can be 4 20mA output loop power Thermally fused 50mA powered by load or by controller Mechanical Rating Notes Enclosure Non metallic NEMA4X IP65 Nominal dimensions excluding 7 W x 6 H x 4 D entry fittings and flexible conduit 180mm W x 150mm H x 100mm D Enclosure door hinged left Allow 12 right for pump Allow 18 below for cable conduit access AQCP_F_User 05 06 55 SlimFlex Water Treatment Controller Appendix C HARDWIRING Ground Line l Neutral 120VAC Service Power from a dedicated 15A GFI circuit breaker awg14 stranded Green 1 Redi Red2 Bleed Solenoid Green 2 White 2 Black 2 Inhibitor Pump Green3 White 3 Black 3 Acid Pump Green 4 White 4 Black 4 Biocide Pump AQCP_F_User 05 06 White 3 White 4 Ground Green Green 1 Green 2 Green 3 Green 4 Connect grounds in a common wire nut HARDWIRING REQUIREMENTS If you are hardwiring anything more than the AC power an external terminal enclosure is required 5 amps 120VAC total Do not exceed AWG14 for AC power wiring Pump and Bleed Solenoid outputs a
39. lenoid If ON verify that the green R1 light on the right side of the enclosure is ON Verify that the bleed solenoid is open and that tower water is going to drain If OFF press ENTER amp DOWN to Test Bleed Press ENTER and the Bleed amp R1 light will turn ON for 5 minutes Plug the inhibitor pump into the top of the 3 sidewall plugs Press UP or DOWN to view Inhibitor Pump If ON verify that the green R2 light on the right side of the enclosure is ON Verify that the pump is stroking primed and feeding inhibitor If OFF press ENTER amp DOWN to Prime Pump Press ENTER and the Inhibitor Pump amp R2 light will turn ON for 5 minutes Bleed Solenoid Bleed Solenoid ON 68 2min OR Bleed Solenoid OFF 0 1min 4a then 4 Test Bleed End Prebleed y Inhibitor Pump Inhibitor Pump lt OFF 2 min then 4 Prime Pump lt Current State y m Inhibitor Pump lt ON 2 8min Sidebar The Bleed Solenoid and Pumps will not turn ON unless the Flowswitch is ON The R1 R2 R3 amp R4 lights will not turn ON unless the Flowswitch is ON Inhibitor pumps set to Bleed then Feed or Feed on Volume modes will not feed if the Bleed Solenoid is ON Feed starts as soon as Bleed ends AQCP_F_User 05 06 20 SlimFlex Water Treatment Controller 2 7 Plug in Pumps and Bleed Solenoid Plug the acid pump into the middle of the 3 sidewall plugs Press UP or DOWN to view Acid Pump If O
40. ng a quill Select a sump location where mixing will occur and acid pooling will not occur AQCP_F_User 05 06 51 SlimFlex Water Treatment Controller A 4 BLEED LOCATION The optimum bleed solenoid location is after the condenser heat exchanger Never install the bleed on the sample line upstream of the sensors and flowswitch If you are installing a bleed solenoid on the tower sump ensure that the head or pressure at the bleed solenoid is sufficient to operate the solenoid Verify that the solenoid is sized for the maximum tower load at the target cycles on the hottest day of summer If the bleed is on for more than 50 of the time inhibitor feed options will be limited A 5 MAKE UP METER Ensure that the meter manufacturers recommendations for orientation and upstream and downstream piping are observed Orientation may be limited for contact head meters while straight upstream and downstream piping is required to prevent errors in turbine paddlewheel meters Contact head meters have a Gallon Contact or Liter Contact rating In some meters this value can be altered by moving magnets or gears Typical meters are rated 10 50 amp 100 Gallons contact Turbine Paddlewheel meters have a K Factor which is the number of pulses Gallon or pulses Liter Some manufacturers have both nominal values listed by meter size and calibration values on the meter body Take the time to get the meter volume contact or K factor correct
41. ocide Pump for 5 minutes Prime Pump Alarms Clear Alarms ends Prime Pump Cycle Days y Prebleed amp Lockout do not run when Prime Pump runs 4 Press enter to view or edit Cycle Days Cycle Days bA Events repeat every 28 days 7days or 1 day Current State Factory default is 28 Days 4 TEE Current State lt H Press ENTER Current State to view Biocide status Add Events AQCP_F_User 05 06 34 SlimFlex Water Treatment Controller Biocide Add Events Press UP DOWN until you see Biocide Press ENTER Press ENTER to Add an Event Press RIGHT to move the underline to the value you wish to change amp then UP DOWN to adjust Days 1 8 15 amp 22 are Sundays on 28 Day Cycles Time is 24 hour format 14 00 is 2 00PM Press ENTER after selecting your event Key UP DOWN to select how often you wish to run the event 28 Day Cycle offers Once Weekly or Alternate Weeks 7 Day Cycle offers Once Daily or Alternate Days 1 Day Cycle offers Once Hourly or Alternate Hours Press ENTER to select frequency Displays revised total events We started with 4 events added a Weekly event amp now have 8 events You can set up to 28 Biocide events This example turns ON the pump for 35 minutes every Tuesday at 7 15 AM AQCP_F_User 05 06 3 7 Biocide Events Biocide OFF Add Eve Edit 4 continued Dayl2 20 0min ga nts Pa Events 4 Day 3 7 15 gt on for One Eve
42. oint pH and the acid pump ON times will also change AQCP_F_User 05 06 14 SlimFlex Water Treatment Controller 2 4 Acid Setpoints Feed Limit continued The feed limit timer turns OFF the acid pump to prevent overfeeding The factory default fed limit is 30 Minutes Acid Pump lt Press UP or DOWN until you see Acid Pump amp press ENTER wd 210 4min m Press DOWN until Limit Timer Limit Timer K Press ENTER to view or adjust Limit Timer Prime Pump y 4a E Displays feed limit in minutes Limit Timer 244 2244 indexes more explanation www 2eZnet com 30 minutes Press ENTER adjust Feed Limit Edit amp Enter 100 minutes gt Press UP DOWN to adjust and RIGHT to move the cursor BH tren 4 Press EXIT to leave the Feed Limit unchanged Limit Timer 244 Press ENTER displays current feed limit 100 minutes lt 100 minutes Sidebar The pH must be less than the TurnOFF setpoint within the feed limit time in minutes The limit timer prevents acid overfeeding and resulting corrosion if the pH sensor fouls or fails The Limit Time is typically set to 125 to 150 of the longest acid pump run time Usually the longest run time occurs under highest cooling load Note The Acid feed limit restarts every time the pump turns ON amp does not reset at midnight Exceeding the feed limit timer may indicate problems with pH sensor or acid feed AQCP_F_User 05 06 15 SlimFlex Water Treatment
43. piping basin and back to the re circ Pump A similar delay occurs when the acid pump turns OFF These two delays increase the control deadband Although the Setpoints are 8 00 amp 7 95 the actual tower pH may vary from 7 8 to 8 1 due to piping transit delays The Acid Pump turns OFF if the Feed Limit is exceeded Press ENTER Alarms amp Clear Alarms to reset AQCP_F_User 05 06 23 SlimFlex Water Treatment Controller 3 OPERATION 3 1 Conductivity Sensor Sensor calibration and temperature verify is detailed in Section 2 5 Verify Conductivity amp pH Sensors Press UP DOWN until you see Conductivity Press ENTER amp then DOWN to Alarms Press ENTER to view current alarms or adjust Press ENTER to adjust the High Alarm or DOWN amp ENTER to adjust the Low Alarm Press UP DOWN to adjust and RIGHT to move the cursor Press EXIT to leave Alarm unchanged ENTER updates the alarms amp displays the current High amp Low Alarms Conductivity Alarms display on the Alarms display and resets automatically Clear Alarms does not reset a conductivity alarm above the High or less than the Low Alarm level Conductivity v 1425 us m Calibrate Alarms 4 3 Alarms Calibrate High 1600us lt Low 1200us v m Edit amp ENTER High 1550us gt 2 eo then Ga High 1550us H Low 1200us y 4 Sidebar Conductivity alarms may occur when the tower shuts down and d
44. play in place of the mA level Select Span to view or adjust the Span Span sets the conductivity at 4mA amp at 20mA Press ENTER Trim Zero to calibrate the 4mA level Press ENTER Trim Span to calibrate the 20mA level AQCP_F_User 05 06 View amp Adjust Span Press ENTER 4 20mA Output amp then DOWN to Select Span Press ENTER Displays current Span Press ENTER to adjust 4mA level or DOWN amp ENTER to adjust 20mA level Press RIGHT to place the underline under the digit you wish to adjust Press UP DOWN to adjust ENTER updates the Span EXIT leaves Span unchanged 4 20mA Output 15 4mA OR 4 20mA Output Disconnected m Select Span v Trim zero y Trim zero v Trim Span Trim Span lt Select Span y Select Span Trim Zero Y rv 4mA 100uS 20mA 5000us y 8 Edit amp ENTER 4ma 2500us gt ty then 4 4mA 2500uS 20mA 5000us y 58 SlimFlex Water Treatment Controller Appendix D CL 4 20mA Output Option D 3 CALIBRATE Calibration is seldom necessary amp is used to correct to offset errors The range of Zero amp Span adjustment is limited If you are not able to calibrate A Verify your milli ammeter B If Load Powered verify you have at least 15VDC available Press ENTER amp then DOWN at 4 20mA Output Press ENTER at Trim Zero to adjust the 4mA level Connect a DC milli ammeter in series with either of the current loop wires
45. rains the sample line or when a Biocide event Prebleed lowers the conductivity AQCP_F_User 05 06 24 SlimFlex Water Treatment Controller 3 2 Bleed Controls For conductivity control setpoints Section 2 2 Bleed Mode Conductivity Setpoints Bleed Solenoid lt lt Press UP DOWN until you see Bleed Solenoid ON 564 2min Displays ON or OFF and ON time from midnight rv Press ENTER to view or adjust Setpoints setpoints Setpoints vary with selected Bleed Mode Bleed Mode M Press ENTER view current mode or to select from Bleed Mode PT Conductivity Control Percentage Time OR Meter Control Test Bleed Press ENTER Test Bleed to turn ON bleed solenoid Test Bleed J for 5 minutes Alarms Clear Alarms ends the Test End Prebleed y Press ENTER End Prebleed to a start Biocide Event on a End Prebleed v prebleeding Bleed Solenoid End Lockout 4 Press ENTER End Lockout to a return to normal Bleed Solenoid control End Lockout lt Current State y Press ENTER Current State to view control status s Display varies with Bleed Mode Current State lt I Setpoints v Sidebar Test Bleed will not turn ON the solenoid if the flowswitch is OFF End Prebleed amp End Lockout have no effect if the Bleed Solenoid is not Prebleeding or Locked Out AQCP_F_User 05 06 25 SlimFlex Water Treatment Controller 3 2 Bleed Controls Continued Bleed Solenoid Bleed Modes Press ENTER then DOWN Bleed Solenoid P
46. re calibrate conductivity AQCP_F_User 05 06 43 SlimFlex Water Treatment Controller Password is turned OFF in new controllers Press UP DOWN until you see Day amp Time Press ENTER amp UP to select Password ON If you press ENTER you ll be prompted for a password then next time you press ENTER Press UP or DOWN to view the current state of the controller Any ENTER key will prompt for the password displaying the default password 123 Use the UP DOWN amp RIGHT keys to enter a password then key ENTER A correct password displays Password OK Press any key to start operating the controller 3 9 Password Turning ON Password Thu 16 54 10 J S N 1T041T0486 fa Current State d Adjust Clock y t Password ON v Current State vy Password ON Enter Password 0000123 gt T then Advice 2110 Password OK pn OR Advice 7111 Wrong Password Sidebar When you first select Password ON the default password is 123 Whenever you Enter Password the controller displays the default password If you have not changed the default password press ENTER to log in AQCP_F_User 05 06 44 SlimFlex Water Treatment Controller Press UP DOWN until you see Day amp Time Then press ENTER amp UP to view Password tools Password tools are available when Password is ON and you are logged in Press ENTER to view the tools Press ENTER to Log Out Press DOWN amp then ENTER to view
47. re fused at AC wiring must be minimum AWG18 rated 300V Do not use solid conductors Use multiple strand copper AC power wiring 56 SlimFlex Water Treatment Controller Appendix D CL 4 20mA Output Option The optional 4 20mA output on conductivity is DC isolated from the controller amp may be either powered by the load or by the controller DC supply The 4 20mA output is auto polarity correcting amp detects an open or unpowered loop D1 WIRING LOAD POWERED 4 20mA Output 2 Conductor The Monitoring or Distributed Control ner oo system powers the controller current loop with 18 24VDC and reads controller conductivity OY Terminate current 24V IN loop at DCS input with 50 to 250 ohms 4 20mA Input Controller alarms Distributed when monitoring current loop Control System disconnected 4 20 mA S CONTROLLER POWERED 4 20mA Output Card The Controller powers the current loop output used to control the pump or valve on conductivity Loop Powered 15V Controller Supply Pump or Valve Thermally fused at 100 ma to protect Proportional Controller and Pump Control AQCP_F_User 05 06 57 SlimFlex Water Treatment Controller Appendix D CL 4 20mA Output Option D 2 VIEW amp ADJUST SPAN The d isplayed value of the 4 20mA loop current depends on both the conductivity and the Span If the current Press ENTER loop output is disconnected you ll see this dis
48. ress ENTER Bleed Mode to view current mode and to select a new mode Most cooling towers operate with Conductivity Control Bleed solenoid opens at TurnON conductivity setpoint and closes at TurnOFF setpoint Meter Control Measures a user set volume on the Make up water meter then turns ON the bleed solenoid for a user set time For example Measure 100 Gallons of make up amp bleed for 10 seconds Percentage Time turns ON the bleed solenoid for a user set of 5 minutes NOTE If you change the Bleed Mode press UP to Setpoints amp ENTER to adjust for the new Bleed Mode Bleed Solenoid ON 564 2min 4t then 4 Bleed Mode Test Bleed y m Conduct Control Meter Control y D Meter Control Conduct Control y Percentage Time Meter Control y a then T Setpoints v Bleed Mode Y Sidebar Meter Control is used where sensor fouling from silica or organics continuously fouls the conductivity sensor Percentage Time is used short term to bleed while replacing a sensor or installing a water meter AQCP_F_User 05 06 26 SlimFlex Water Treatment Controller Current State of the Bleed Solenoid Control Press ENTER then UP Bleed Solenoid Press ENTER Current State If bleed ON displays TurnOFF setpoint 975 amp current conductivity 993 If bleed OFF displays TurnOFF setpoint 1000 amp current conductivity 993 If bleed ON displays Owes 101 sec 7122 amp O
49. ress ENTER to Clear Alarms Clearing alarms sets all pump amp solenoid owed times to zero Clear Alarms Sensor Alarms Out of Calibration and System Alarms auto clear when the fault is corrected AQCP_F_User 05 06 40 SlimFlex Water Treatment Controller System Current State Press UP DOWN until you see Day amp Time Press ENTER view System options Press ENTER to view Current State Controller diagnostics Temperature at the conductivity sensor Press ENTER to adjust Displays Fault if not used to compensate conductivity Indicates wiring or sensor problem Power used for paddlewheel water meters and to power 4 20mA current loops Alarms on short circuits recovers when wiring corrected Internal power used or bleed solenoid and pump relays Always 11 8 to 12 2 Alarms on fault Auto ranging conductivity sensor drive 70 80mV or 950 1050 mV Alarms and cannot measure conductivity if out of range pH ORP sensor offset 2475 to 2525mV Alarms and cannot measure any sensors if out of range Firmware version amp internal diagnostic Checks that user setpoints being saved amp Clock valid 3 8 System Alarms continued Thu 16 54 10 lt S N 1T041T0486 Current State Adjust Clock y 4 Temperature 7101 87F y tb Ext Power 102 15 6 VDC 4 gt Relay Power 103 12 1 VDC y Drive 107 73 3 mV Y Measure 105 2502 3 mV 3 ver 80805 106 244 163 1 y
50. revent air blocking of the reference junction Water meter and sensor wiring cannot be installed in the same conduit as 120VAC power pump or solenoid wiring Even a short section of shared conduit may cause operational problems Conductivity flowswitch and water meter sensor wires may be extended up to 200 feet using multiple pair AWG22 cable Always splice sensor wires in an electrical fitting to allow both inspection and sensor replacement Do not extend pH sensor wiring Extend the conductivity sensor using the same colors as the sensor to avoid wiring errors at the controller terminals Contact head water meters and mechanical flowswitches are not polarized simplifying cable extension CAUTION Three wire turbine paddlewheel meters are polarity sensitive and can be permanently damaged by miswiring Wait until you are ready to start up the controller before connecting this type of meter to the controller Meter wiring errors are easily detected and corrected at start up A 3 CHEMICAL INJECTION Inject water treatment chemicals downstream of sensors as recommended by the chemical supplier Do not inject acid or oxidants upstream of a recirculating pump or condenser heat exchanger CAUTION Acid injection is exothermic heating water at the injection location PVC injection piping can heated to failure under low flow or high feed rates Acid is therefore frequently injected directly into the tower sump or into the recirculation line usi
51. s Make up water or Pump rate amp stroke may have changed Higher temperatures or make up chemistry changes may be extending acid pump run times Debris may have partially blocked the bleed line A high conductivity may indicate a blocked or failed bleed solenoid A low conductivity may indicate an overflowing tower basin or a scheduled prebleed before a biocide feed A high pH may a loss or prime no acid or a pump timed out on feed limit A low pH may indicate a siphoning pump or a failed pH sensor If there s a make up meter you d expect daily volume to increase with temperature High make up may indicate a stuck make up float No make up may indicate a valved off or faulted meter amp a cause of low run time on the inhibitor pump If the tower in on line very the Flowswitch shows ON If you check at the same time every day you would expect the bleed solenoid and inhibitor pumps ON times to vary only with temperature No Bleed solenoid time may indicate a fouled conductivity sensor Typical cooling towers bleed no more than 40 of the time and feed 5 10 of the time At noon you d expect to see 100 to 200 minutes of bleed amp 20 to 50 minutes in inhibitor pump time If this morning was a biocide feed day verify that the Biocide ON time shows the event time 46 SlimFlex Water Treatment Controller Activity Methodd _ Weekly Verify Conductivity Verify pH Note Make up Volume Verify Flo
52. tputs 4 20 ma Output on conductivity CL optional card Alarm Relay AR optional card Communications User Interface Keypad LCD Browser LB optional card AQCP_F_User 05 06 Rating Detail 1 Temperature Compensated conductivity sensor Displays 1uS resolution Rated 100psi 35 120F 2 50C Flowswitch switches 1GPM 1 pH sensor 1 14pH Displays 0 01pH resolution Measures 0 003pH resolution Rated 100psi 35 120F Flowswitch Dry Contacts 250mS response Water Meter 400 Hz max 0 5mA 5VDC measurement current 4 SPST 1 DC isolated loop powered Nominal 0 1 resolution Auto polarity correction field wiring Dry contact set Rated 500mA 24VDC Rating Detail 5 Key Tactile feedback UP DOWN ENTER EXIT RIGHT 2 Line x 16 Character Backlit 10BaseT Ethernet RJ45 Jack Full command amp control via browser XML real time controller data Notes Conductivity autoranging from 100uS to 10000uS Flowswitch Max 30 second ON OFF amp OFF ON response over rated temperature Includes solution ground Contact head meter software debounced Turbine Paddle wheel rating Seametrics max pulse rate Relays rated 10A 120VAC Controller fused 5 Amps Alarm on open loop Auto configure on Driver installation and removal Software calibration of span amp zero Closed in the non alarmed state Contact set opens on alarm or loss of controll
53. witch is working An overview of system operation is available in the Yearly section of 4 1 Maintenance AQCP_F_User 05 06 8 SlimFlex Water Treatment Controller 2 START UP 2 1 Power up Display amp Keypad UP amp DOWN to view options or to EDIT numbers Sf Move RIGHT to select next field when EDITing ENTER to select an option a amp to execute EDITing EXIT to escape option S info display or EDITing Day of Week amp current time Press ENTER for Controller Diagnostic Clock System configure US Metric set Press ENTER to clear Alarms Current Conductivity sensor value Press ENTER for Conductivity Calibrate amp Alarms Solenoid ON or OFF and ON time today Press ENTER for Bleed Setpoints Mode Test End Prebleed or Lockout and Current State Current pH sensor value Press ENTER for pH Calibrate amp Alarms Acid ON or OFF and ON time today Press ENTER for Acid Setpoints Feed Mode Limit Timer Prime Pump and Current State AQCP_F_User 05 06 Enclosure keypad Response UP or DOWN to the display you wish to view or EDIT amp press ENTER Thu 16 54 10 S N T041T0486 Sf Alarms lt 4 Sf Conductivity lt 1425 us Sf Bleed Solenoid ON 25 6min ST pH Sensor lt 8 14 pH ST Acid Pump ON 14 6min Sf SlimFlex Water Treatment Controller 2 1 Power up Display amp Keypad Water meter measured volume from midnight Press ENTER to Install Select type View ye
54. wswitch Y Strainer Filter System Check Sample the tower water conductivity Verify controller matches sample 25uS Conductivity sensors should not drift or require cleaning Scaling sensors may indicate a restricted bleed varying make up alkalinity incorrect setpoints or water treatment program Fouled sensors may indicate organic biofilms oils or silica Depending on the type of foulant a change in program or a switch in the bleed control method may be required Verify controller pH matches sampled pH 0 1pH If the conductivity sensors is fouling usually the pH sensor also fouls Weekly water usage indicates both average tower load and maximum daily temperature High water usage may result from a change in controller setpoints or a leak or overflow in the cooling water system Close the upstream sample line isolation valve then the downstream valve amp verify that the Flowswitch displays OFF If the sample line has a Y strainer clean the filter to prevent a unplanned no flow outage Open the downstream then the upstream valve and verify that the Flowswitch displays ON Visually inspect sample injection piping for leaking fittings feed injection points and sensor entries Sidebar Maintenance Guidelines for water treatment are set by the chemical treatment program vendor AQCP_F_User 05 06 47 SlimFlex Water Treatment Controller Activity Method _ pH Sensor
55. y be extended ease of servicing occurs when water treatment components are located in the same area Ensure that the lower enclosure cover is installed when not terminating sensor and water meter wiring AQCP_F_User 05 06 5 SlimFlex Water Treatment Controller 1 3 Sensors Conductivity amp pH After installing the conductivity and pH sensors open the sample piping downstream valve then the upstream valve Verify that both sensor entries seal leak and drip free Controllers are supplied with sensors and optional flowswitch pre wired The following graphic details connection points for sensors Conductivity Temperature amp Flowswitch Sensor pH Sensor pH sensors include a coaxial cable with tinned ends amp a sensor entry T with GREEN solution ground Ss Controller Controllers are supplied with the Sensors prewired Feed the sensor cable through the entry seal amp tighten the seal Flowswitch Alternative A dry contact set closed when there is flow past the sensors may be used as an operating interlock in place of the flowswitch built into the conductivity sensor Disconnect the BROWN Flow wire and connect the alternative flowswitch to the Flow and adjacent Ground terminals AQCP_F_User 05 06 SlimFlex Water Treatment Controller 1 4 Sensors Water Meter Refer to manufacturer s recommendations on meter orientation and upstream and downstream piping Extend meter cables with AWG22

SlimFlex Water Treatment Controller For Cooling Towers

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