150 manual - Lakewood Instruments
Contents
1. 23 64 MODE saa Doe e n boa ooh erste 24 64 1 PYOCESS uoo eni kk at kn e RU ko a n tS 24 6 4 2 Configuring the Relays tute caue uices 25 6 4 2 1 Configuring the Blowdown Relay 25 6 4 2 1 1 Setpoint Values 26 6 4 2 1 1 1 26 6 4 2 1 1 2 Blow Alarm Time 27 6 4 2 1 2 When to 27 ay 6 4 2 1 3 Boiler 27 6 4 2 1 3 1 Continuous Sample 28 6 4 2 1 3 2 Sample Cycle 28 6 4 2 1 3 3 Sample Hold 29 6 4 2 1 4 Ball Valve 31 6 4 2 2 Configuring Relays 2 3 31 6 4 2 2 1 won 31 6 4 2 2 2 By 32 6 4 2 2 2 1 Selpolhb usu RR 32 6 4 2 2 2 2 Deadband 33 p 42 2 29 snm pike ns 33 6 4 2 2 2 4 When to Feed 34 6 4 2 2 3 By Water 34 6 4 2 2 4 By Yo of Blowdown Time 34 6 4 2 2 5 By Percent of Ti2. COM GND RELAY1 HOT NC RELAY HOT NO RELAY2 HOT NO COM RELAYS HOT COM GND REA ER CHEM PUMPS ALARM OUTPUTS 115 230 50 60 Hz A EN MOTORIZED BALL VALVE OR SOLENCID VALVE GND METER 1 500 GND FLOW NOTICE ON REPRODUCTIONS HIS DRAWING THE DESIGN AND THE PATENTS IT COVERS ARE THE PROPERTY OF LAKEWOOD INSTRUMENTS LLC THEY ARE LOANED MERELY ON THE BORROWERS EXPRESS RGREEMENT THAT THEY WILL NOT BE REPRODUCED COPIED LOANED EXHIBITED NOR USED EXCEPT IN THE LIMITED WAY AND THE PRIVATE USE PERMITTED BY WRITTEN CONSENT GIVEN BY THE LENDER THE BORROWER DIMENSIONING AND TOLERANCING PER ASME Y14 5M 1994 TITLE MATERIAL TOLERANCES UNLESS NOTED DECWALS ANGLES SURFACE FINISH PSG pare3 5 10 SE TA THIRD ANGLE PROJECT APVD DATE SCALE sHEET UERARY R 52 DWNIDATE APVDIDATE Lakewood INSTRUMENTS WIRING DIAGRAM FOR THE 150 POWER CONNECTIONS 1269089 Eg A DWG REV 1269089 5 NOTES ZX FOR INTERNAL 24VDC JUMPER WIRE IS REQUIRED NON ISOLATED 4 20mA OUTPUT WITH INTERNAL 24VDC POWER SUPPLY m DEVICE REVISION HISTORY DWG DESCRIPTION RELEASE ISOLATED 4 20 mA OUTPUT WITH EXTERNAL 24VDC POWER SUPPLY T24VDC 4 20 mA DEVICE METER 1 5VIC GND FLOW NOTICE ON REPRODUCTIONS HIS
3. a ie 12 9 T OnfiGe Sizing Chart sco tia ka pad suet 13 244 Elgctri al Installation aui e kk a ao 14 3 4 1 Incoming power 115 230 14 3 4 2 Relay OUIDUES cator cem co ette 15 374 3 Fow Switch Wg e adio kk Pa e ue Pi ee m 15 3 44 Sensor S ei eoe tht 16 3 4 5 Water 16 3 4 6 4 20 mA Output 16 4 0 Starang Up the Controller esa pice e aU exea nomas 17 5 0 Functional OVOLVIGWL aus sote doce a atio had eels ob e oi reden eub be e 18 Oo Front Panels LEM 18 AND ee re M e M M err rea Oo 19 9 2 rid derit oboe 19 54 WICH bk n ki a ko A e ak ap n bi De kk bi ik abo be 19 5 4 1 Menu Flow Chart ob oka once ect dede 20 6 0 Dberallor af the GONMNO NG kk 21 6 1 PFOCESS SKASON e T em 21 6 2 Manual Operation of the 22 6 3 Calibration of ke er deve hen epe Rt kt ke pk a ko ds 22 6 3 1 Calibration in Continuous Sample Boiler Control 22 6 3 2 Calibration in Sample Cycle Boiler Control 23 6 3 3 Calibration in Sample Hold Boiler Control
4. MAKE UP BOILER 1 2 or 3 4 BOILER SENSOR WIRE TO DRAIN MOTORIZED BALL VALVE ORIFICE UNION OR GLOBE VALVE OPEN FOR CONTINIJOUS zu CLOSED FOR SAMPLEACYOLE TO DRAIN ORIFICE UNION OR GLOBE VALVE BLOWDOWN ASSEMBLY BOILER SENSOR NOTICE ON REPRODUCTIONS HE DRAWING THE DESIGN AND THE PATENTS IT COVERS ARE THE PROPERTY OF Lakewoed AKEWOOD INSTRUMENTS LLC THEY ARE LOANED MERELY ON THE BORROWERS EXPRESS KGREEMENT THAT THEY WILL NOT BE REPRODUCED COPIED LOANED EXHIBITED NOR USED XCEPT IN THE LIMITED WAY AND THE PRIVATE USE PERMITTED BY WRITTEN CONSENT GIVEN INSTRUMENTS BY THE LENDER TO THE BORROWER DIMENSIONING AND TOLERANCING PER ASME Y14 5M 1994 TITLE MATERIAL SENSOR MUST BE MOUNTED TOLERANCES UNLESS NOTED DECIMALS HORIZONTALLY AND MUST BE INSTALLATION LAYOUT CONTINOUS avus SAMPLE CYCLE OR SAMPLE HO AT LEAST 2 FEET BELOW THE XX SURFACE WATER LEVEL OF THE BOILER MODEL 150 THE DISTANCE FROM THE SENSOR XXX TO THE ORIFICE UNION MUST BE FINIEH DWN PSG DATE 3 540 SEE gu RY Dey 5 FEET OR LESS 65 PROJECT APVD DATE SCALE DWG NO REV RL 1269089 2a 50 Y NOTES UNLESS OTHERWISE SPECIFIED IF NO FLOW SWITCH IS USED
5. ERMINAL P 2 INCOMMING POWER RELAYS Terminal blocks For i ERMINAL P 7 RELAY 1 RELAY RELAY Figure 2 Model 150 Electronics 3 4 1 Incoming Power 115 230 VAC The Model 150 can be powered from either 115 VAC or 230 VAC at 50 60 Hz There is a power selector switch located in the upper left hand corner of the control board To select the appropriate voltage simply slide the switch from one position to the other with a standard screwdriver The Model 150 controller comes with a power cord and female molded receptacles for the blowdown valve and chemical pumps The power cord and receptacles are rated for 115VAC the controller will be powered by 230 the power cord and receptacles will need to be removed and the incoming power and the relay outputs will need to be hard wired The incoming power is connected to terminal block P1 at the bottom left corner of the control board There is a hot or line input L1 a neutral input N and an earth ground input Refer to the drawing in the back of this manual for wiring instructions 14 3 4 2 Relay Outputs The relay outputs are of the same voltage as the power input Ensure that the devices that are to be connected to the relay outputs are of the same voltage rating or damage will occur The relay outputs are wired to the female molded receptacles The molded receptacle on the far left is relay 1 and the molded receptacle on the far right is
6. 1 inch and 2 inch turbine meters Contact Lakewood Instruments for other types of water meters To get to the water meter configuration screen From the main menu press 4 WATER METERS MTR1 GALS LTRS Bo 1 GALLONS e The water meter can be configured for gallons or liters Press 1 for GALLONS or press 2 for LITERS e This will take you to the WATER METER TYPES screen as shown below WATER MTR TYPES 1 CONTACT HEAD 3 AUTOTROL 1 IN 4 AUTOTROL 2 IN Use the keypad to select the type of water meter that you are using If CONTACTING HEAD is selected You will be taken to the GALLONS OR LITERS PER CONTACT screen Use the keypad to enter the number of gallons or liters per contact for your specific meter then press ENT You will then be asked if you want to reset the meter count to zero Press 1 for YES or press 2 for NO If PADDLE WHEEL is selected You will be taken to the K FACTOR screen Use the keypad to enter the K factor for your particular water meter then press ENT You will then be asked if you want to reset the meter count to zero Press 1 for YES or press 2 for NO If AUTOTROL TURB 1 IN is selected You will be asked if you want to reset the meter count to zero Press 1 for YES or press 2 for NO If the AUTOTROL TURB 2 IN is selected You will be asked if you want to reset the meter count to zero Press 1 for YES or press 2 for NO 37
7. As an Alarm Relay Relays 2 and 3 can be configured as alarm relays Any alarm will cause the relay to activate These alarms include HIGH Conductivity LOW Conductivity BLOW ALARM TIMEOUT RELAY 2 TIMEOUT RELAY 3 TIMEOUT and the NO FLOW alarm From the RELAY OPTIONS screen press 6 ALARM RELAY The controller will respond with the following screen ACTVE ON ANY ALM press any key NOTE A relay that is configured as an alarm relay will be activated any time any alarm including the NO FLOW alarm is present 6 4 3 Alarms The Model 150 is equipped with both high and low conductivity alarms This menu option allows you to program the specific values for these alarms When a conductivity alarm is received it will appear as a flashing message in the alarm screen and any configured alarm relays will be activated Consult your water treatment specialist when determining the proper High and Low Alarm values for your system To get to the alarm settings From the MAIN MENU press 3 ALARMS HIGH ALM 5000uS LOW ALM 100uS Use the keypad to enter a value for the high alarm Press ENT Use the keypad to enter a value for the low alarm and press ENT 36 6 4 4 Water Meter The model 150 controller will work directly with the following types of meters dry contacting head meters Seametrics open collector output meters paddle wheel meters such as the Signet 2535 and 2540 and the Autotrol
8. Blowdown relay for Sample Hold mode BOILER METHODS 3 SAMPLE HOLD e n the BOILER METHODS screen select 3 SAMPLE HOLD The Sample Time screen will appear SAMPLE TIME MM 00 55 00 e n the Sample Time screen use the number keys to input a minutes value press ENT and use the number keys to enter a seconds value and press ENT to go to the Cycle Time screen Note The maximum time setting is 59 minutes and 59 seconds CYCLE TIME HH 00 MM 00 e n the Cycle Time screen use the number keys to input an hours value press ENT and use the number keys to enter a minutes value and press ENT NOTE The maximum allowed time is 17 hour and 59 minutes BLOW TO RESAMPL 00 55 00 e Inthe Blow to Resample screen use the number keys to input a minutes value press ENT and use the number keys to enter a seconds value and press ENT NOTE The maximum allowed time is 59 minutes and 59 seconds A typical Sample Time is 1 to 2 minutes with a Cycle time of up to 17 hours and 59 minutes A short sample time is desired to prevent excessive loss of water and heat Once the sample time is set it should never have to be changed again The Cycle Time will need to be adjusted based on the steaming rate and make up water quality If using Sample Cycle control and the conductivity does not rise to the setpoint the Cycle time is probably set for too short of a time and will need to be adjusted
9. Suggested Installation Layout 1269089 2A 10 3 Wiring Water Mole pata 1269089 3A 10 4 Wiring Power Connections 44 4 42 1 1269089 5A 10 5 Wiring 4 20 MA 1269089 6A 1 0 Introduction The Model 150 is a microprocessor based menu driven controller designed for use in boiler water applications The Model 150 provides for conductivity tracking and control flow monitoring and chemical injection The Model 150 is NTL CSA and CE approved The Model 150 uses the latest in microprocessor capability giving the user a high level of application flexibility digital display screen multiple inputs and an intuitive menu characterize this new technology The Model 150 is user friendly with a graphical screen numeric keypad LEDs for power alarm flow relay status and display lighting It accepts multiple inputs and is easily configured It s a combination of reliability accuracy security and simplicity The model 150 is designed to control boiler water blowdown by use of any of the three boiler control methods Continuous Sample Sample Cycle or Sample Hold In the Continuous Sample method the controller will continuously monitor the conductivity reading and control the blowdown relay based on setpoint In the Sample Cycle method the blowdown relay will energize for a user selected time called the Sample Time At the end of the Sample Time th
10. and calendar information The capacitive backup device will never need to be replaced and will hold data approximately 1 day after each power failure 8 2 2 BENEFITS e Easy to program the Model 150 Controller uses an intuitive menu and a numeric keypad for programming e No add on options Flow switch input 4 20mA output and three boiler conductivity control methods are standard e Multiple feed configuration methods available in a single controller 2 3 Specifications Conductivity range 100 10 000 uS Conductivity sensor Two electrode Conductivity Resolution 10 uS Accuracy amp repeatability 1 096 of scale Deadband Setpoint User programmable Auto Manual outputs Menu selectable Keypad 16 tactile steel dome push buttons Display 16 X 2 Character Enclosure NEMA 4x Water meter input 1 Contact head paddle wheel or Autotrol turbine Timer Relay run time exceeded Output Signal One 4 20 mA isolated or non isolated optionally powered output for conductivity Output relays 3 selectable use Relay ratings each 10 total Power 120 240 VAC 50 60 Hz 6W Ambient temp 32 150 F 0 60 Storage temp 4 150 F 20 65 2 4 Ordering Information Controller Options PART DESCRIPTION 1269089 Controller Model 150 controller only 1269092 Controller Model 150 w SR2 MBV 1 1 2 union 1 16 orifice 1269093 Controller Model 150 w SR2 and PLKT
11. high fouling environment Remove power from the controller and shut off the sample flow Remove the sensor from its plumbing Use a wire brush to lightly brush the sensor tips Do not use cloth to clean the sensor tips Cloth has oils that will foul the sensor If there is oil on the sensor tips use isopropyl alcohol to clean the tips If there is scale on the sensor tips use a 1096 Muriatic or HCL acid to clean the sensor Wash the sensor off with tap water Install the sensor in its plumbing Restore sample flow and check for leaks Restore power to the controller Perform a calibration of the conductivity Verify operation before leaving area 42 7 2 Replacing the Fuses The Model 150 contains a two 5 x 20 mm European style fuses Replacement fuses must be a Schurter 0034 1526 Littlefuse 217 010 or equivalent 10A 250V fast blow type for Fuse F1 and a Littlefuse 218 100 Schurter 0034 3107 or equivalent 100mA slow blow for Fuse F2 If a fuse is blown the display will be blank when the unit is connected to power Refer to the troubleshooting section of this manual for more information about blank displays 115 230VAC power selector switch 100mA 250V slow blow fuse 10A 250V fast blow fuse 43 8 0 Troubleshooting 8 1 Error Messages This section discusses some of the more common questions with the Model 150 These notes are not intended to be all inclusive only to cover the most common sit
12. operation by following section 6 4 2 Calibrate the conductivity by following section 6 3 Configure the 4 20 mA output by following section 6 4 5 Verify operation of the controller before leaving the area 17 5 0 Functional Overview 5 1 Front Panel Figure 3 Model 150 Front Panel with Display LCD A large 16 x 2 character display makes it easy to read the menu driven program ENCLOSURE A sturdy NEMA 4X enclosure protects your controller Make sure it is properly mounted on a flat non vibrating wall 16 BUTTON KEYPAD ENT For Menu selection and or acceptance of selected values CLR To exit a Menu selection and or skip input options PRO To program a Menu selection LIGHT BULB Display lighting on off 18 INDICATOR LIGHTS LEDs for Power Alarm and Relay status There are also LEDs that provide lighting to the display for 5 minutes when any button on the keypad is pressed 5 2 Display The model 150 uses a 16 x 2 LCD digital display for ease of viewing It has two lines to display information such as the conductivity reading alarms relay status relay configuration clock total flow and menu selections 5 3 Keypad The model 150 uses a 16 key steel domed numeric keypad for ease of programming The keys have the following functions ENT To accept a setting or to enter a screen CLR To exit a screen or to access the main menu PRO To calibrate the controller UP arrow
13. process conditions Relays Relay configuration screens Alarms Set the high and low conductivity alarms Water meter Configure water meter type and reset total flow 4 20 MA Out Set up and calibrate the 4 20 ma output System Setup Initialize the controller and view firmware version Clock Set the date and time hee ou Only one menu selection will appear on the screen at a time Main Menu always appears in the top half of the screen The bottom half of the display shows the selectable item in the menu The screen will look like this PROCESS RELAYS ALARMS WATER METER 4 20 MA OUT SYSTEM SETUP CLOCK MAIN MENU 1 PROCESS The MAIN MENU can be accessed from the PROCESS by pressing CLR To move about in the menu screens use the f and keys to display the desired selection and press ENT or press the number key for the desired selection to access that selection Use the ENT key to accept a setting or to enter a screen Use the CLR key to reject a setting or to exit a screen From anywhere in the menu pressing CLR will take you one step closer to the MAIN MENU Each of the MAIN MENU options is discussed in detail later in this manual 6 4 1 The Process Screen The process screen is where the conductivity value is displayed The process screen is discussed further in section 6 1 24 6 4 2 Configuring the Relays To access the relay confi
14. programming Watertight fittings for sensor water meters 4 20 and flow switch wiring Receptacles and power cord can be removed for 240 VAC applications Figure 1 Model 150 2 1 FEATURES e Controller is designed for use in boiler blowdown applications The controller can operate in the continuous sample mode sample cycle mode or sample hold mode e Removable power cord and receptacles for conduit installations Enclosure is rated NEMA 4X e Three user configurable relays for conductivity control and chemical addition These relays can be configured in multiple ways including by setpoint by water meter 96 of blowdown of time and as a general alarm relay e One 1 water meter inputs conductivity input flow switch input 4 20 mA output are all standard features e Designed with a single circuit board for high reliability and lower cost e Large open shallow enclosure for easy wiring e Heavy duty stainless steel domed numeric keypad and illuminated graphical display allow for quick and easy programming Steel domed switches improve the tactile sensing and life expectancy of the keypad e The Model 150 controller stores all setpoints calibration values and relay configurations in an EEPROM EEPROM does not require a battery to retain information so if power is lost these values will be retained for years The 150 includes a capacitive backup device to retain information such as water meter total and clock
15. relay 3 If 115 VAC is used simply plug your devices into the molded receptacles If 230 VAC is used remove the receptacles and hard wire your devices to the relay outputs Relay 1 has both a normally open and normally closed contact This is designed for use with any device that requires either or both types of contacts for operation such as a motorized blowdown valve The normally open NO contact energizes when the relay turns on and the normally closed NC contact is energized when the relay turns off The other three relays only have a normally open contact Each relay output has a neutral N connection and an earth ground connection connection To operate the terminal blocks to remove or add wiring insert a small screwdriver into the slot above each wiring connection and pry upward while removing or inserting the wire Refer to the drawing in the back of this manual for wiring instructions 3 4 3 Flow Switch Wiring The model 150 has a flow switch input The purpose of the flow switch input is to disable the relay 2 and 3 outputs on a loss of flow in the system Relay 1 is not controlled by the flow switch input The flow switch input requires a dryl contact Any digital contact rated for 24 VDC and 500 mA may be used such as a relay driven by the recirculating pump The flow switch input is wired to terminal block P7 terminals 1 and 2 If a flow switch is not used then a jumper must be installed across the flow sw
16. 0 Ibm hr To configure the Blowdown relay for Continuous Sample mode BOILER METHODS 1 CONTINUOUS e n the BOILER METHODS screen select 1 CONTINUOUS The controller will respond with CONTINUOUS SAMPLE press any key Press any key to return to the BOILER METHODS SCREEN 6 4 2 1 3 2 SAMPLE CYCLE In Sample Cycle boiler applications the controller will sample the water on a timed basis and then control based on a conductivity setpoint This mode is usually used for smaller boilers or boilers with a large amount of condensate return It is recommended that you use this mode if your blowdown rate requirement is less than 1000 Ibm hr The Blowdown relay will energize for a user selected time called the Sample Time the amount of time the blowdown valve will be open At the end of the Sample Time the controller will compare the conductivity reading to the setpoint and if the conductivity is higher than the setpoint the Blowdown relay will stay energized until the conductivity reading is less than the setpoint Once the setpoint is satisfied the Blowdown relay will turn off for a user selected time called the Cycle Time the amount of time the blowdown valve will be closed At the end of the Cycle Time the Blowdown relay will once again energize and go into the Sample Time and repeat the above sequence A typical Sample Time is 1 to 2 minutes with a Cycle time of up to 17 hours and 59 minutes A short sample time is desired
17. 6 4 5 Set Up of the 4 20 mA Output The model 150 has one 4 20 mA output that is configured for conductivity To set up the 4 20 mA output From the Main Menu press 5 4 20 mA OUT There are three things that can be done from the 4 20 mA Out Setup screen set the 4 20 mA range take manual control of the 4 20 mA output and calibrate the 4 20 mA output Below is the 4 20 mA Setup screen 4 20 MA OUTPUT gt MANUAL CTRL 1 SET RANGE 3 CALIBRATE 6 4 5 1 Set the 4 20 mA Range The 4 20 mA output range must be set for the output to be useful From the 4 20 mA OUTPUT screen press 1 Set the 4 20 mA RANGE Use the keypad to enter a conductivity value for the 4 mA point Press ENT Use the keypad to enter a conductivity value for the 20 mA point Press ENT 6 4 5 2 Manual Control Manual control is used to temporarily change the 4 20 mA output From the 4 20 mA Setup screen press 2 MANUAL CONTROL Use the up and down arrow keys to raise or lower the 4 20 mA output To exit this screen and restore automatic control of the 4 20 mA output press CLR 6 4 5 3 Calibrate the 4 20 mA Output The 4 20 mA needs to be calibrated to the actual output to be accurate A milliamp meter is necessary to calibrate the 4 20 mA output Connect the milliamp meter in line with one leg of the 4 20 mA output Refer to the drawing in the back of this manual for wiring instructions From the 4 20 mA OUT
18. BOILER SYSTEM OPTIONS SR2 PLKT MBVI 1168374 SR2 Boiler water sensor with 20 ft cable and elbow 34 NPT connection 1233981 PLKT Plumbing Kit gt NPT 1166355 Orifice Plate 1 16 1166354 Orifice Plate 1 a 1167244 Orifice Union 1 1268608 MBV1 gt in NPT Motorized valve 1268614 MBV2 34 in NPT Motorized ball valve 10 3 0 Unpacking Mounting and Installation 3 1 Unpacking Inspect the shipping carton for obvious external damage Note on the carrier s bill of lading the extent of the damage if any and notify the carrier Save the shipping carton until your Model 150 controller is started up If shipping damage has occurred call the Lakewood Instruments Customer Service Department at 800 228 0839 and return the controller to the factory in the original carton 3 2 Mounting the Enclosure The Model 150 can be mounted to a panel or to a flat non vibrating wall The Model 150 includes four removable mounting feet that can be attached in the horizontal or vertical position The mounting feet are attached to the enclosure using four screws To change the position of the mounting feet remove the screws from the feet and reposition either vertically or horizontally as desired and reattach the screws The dimensions of the enclosure in inches are es ed mo
19. DRAWING THE DESIGN AND THE PATENTS IT COVERS ARE THE PROPERTY OF LAKEWOOD INSTRUMENTS LLC THEY ARE LOANED MERELY ON THE BORROWERS EXPRESS RGREEMENT THAT THEY WILL NOT BE REPRODUCED COPIED LOANED EXHIBITED NOR USED EXCEPT IN THE LIMITED WAY AND THE PRIVATE USE PERMITTED BY WRITTEN CONSENT GIVEN By THE LENDER TO THE BORROWER DIMENSIONING AND TOLERANCING PER ASME Y 14 SIv 1994 TITLE MATERIAL TOLERANCES UNLESS NOTED DEALS ANOLES Lakewood INSTRUMENTS 4 20mA WIRING FOR THE 150 XX SURFACE XXX FINISH PSG b TEZ 8 10 SIZE AN PN REV D RA OS 1200089 A SCRE SHEET WENO REY n 1269089 53 54 55 For more information call toll free in the USA 800 228 0839 LAKEWOOD INSTRUMENTS 7838 North Faulkner Road Milwaukee WI 53224 USA Phone 800 228 0839 Fax 414 355 3508 http www lakewoodinstruments com Manufactured in the USA Copyright 2010 Lakewood Instruments LLC Printed in USA Rev 1
20. ETPOINT 3 WATER METER 1 DISABLED 4 9 BLOWDOWN 5 OF TIME 6 ALARM RELAY 6 4 2 2 1 Disabled Relays 2 and 3 can be disabled When a relay is disabled it will not energize automatically From the RELAY OPTIONS screen press 1 Disabled to disable the relay 31 6 4 2 2 2 By Setpoint To set up a relay to operate based on a setpoint e Press or select 2 SETPOINT The following screen will appear BASED ON SETPT 1 1 SETPT VALUES 6 4 2 2 2 1 SETPOINT In the SETPT VALUES screen you will set the SETPOINT the DEADBAND and the amount of time for the TIMEOUT alarm The SETPOINT is the conductivity value at which you want the relay to operate Check with your water treatment engineer to determine the conductivity setpoint for your system needs WARNING THE SETPOINT AND DEADBAND VALUES FOR THIS RELAY SHOULD BE SET AT THE SAME VALUES AS THE BLOW RELAY TO PREVENT OVER OR UNDER FEEDING OF CHEMICAL From the BASED ON SETPT screen follow these instructions to establish the relay s setpoint Press 1 or highlight SETPT VALUES and press ENT SETPOINT 4500 uS Use the keypad numbers to enter the proper conductivity setpoint and press ENT When finished you will automatically be prompted to set the deadband 32 6 4 2 2 2 2 DEADBAND After the setpoint is established the controller s deadband must also be set Deadband refers to the amount
21. LAKEWOOD INSTRUMENTS MODEL 150 BOILER WATER CONDUCTIVITY CONTROLLER INSTALLATION amp OPERATION MANUAL SERIAL Lakewood Instruments 7838 North Faulkner Road Milwaukee WI 53224 USA Phone 800 228 0839 Fax 414 355 3508 hitp www lakewoodinstruments com 10 11 12 Lakewood Instruments Model 150 Controller Quick Installation Sheet Install the controller on a flat non vibrating surface Use the four 4 supplied mounting feet Do not mount the controller to a steel object that has a large temperature change side of cooling tower etc This can cause water to condense inside the enclosure Install water meter chemical pumps plumbing assemblies and the conductivity sensor see drawing on back for suggested installation Open the front cover of the Model 150 Controller Wire the flow switch use jumper wire for no flow switch conductivity sensor water meter and 4 20 mA output if applicable see drawing in manual Ensure wiring connections are correct or damage may occur If doing a conduit installation remove receptacles and wire pumps and blowdown valve Refer to the instruction manual for more details Use a standard screwdriver to set the power selector switch to either 115 VAC or 230 VAC operation Reinstall the front cover keypad making sure the ribbon cable is properly attached Plug in chemical pumps and blowdown valve to controller unless hardwired in step 5 Apply power to t
22. LY1 SETTING DISPLAY RLY2 SETTING DISPLAY RLY3 SETTING DISPLAY WTR MTR TOTAL IENT MANUAL CONTROL OF RELAYS IPRO CALIBRATION OF CONDUCTIVITY 2 RELAYS 1 BLOW RELAY 1 SETPOINT VALUES SETPOINT DEADBAND BLOW ALARM TIME 2 WHEN TO BLOW ABOVE THE SETPOINT BELOW THE SETPOINT 3 BOILER METHODS CONTINUOUS SAMPLE CYCLE SET SAMPLE TIME SET CYCLE TIME SET RESAMPLE TIME SAMPLE HOLD 4 BALL VALVE DELAY SET DELAY TIME 2 RLY 2 1 DISABLED 2 SETPOINT SETPOINT VALUES WHEN TO FEED 3 WATER METER SET FEED TIME 4 BLOWDOWN SET BLOWDOWN 5 TIME SET ON TIME 6 ALARM RELAY 3RLY3 1 DISABLED 2 SETPOINT SETPOINT VALUES WHEN TO FEED 3WATER METER SET FEED TIME 4 BLOWDOWN SET 9o BLOWDOWN 5 TIME SET ON TIME 6 ALARM RELAY 20 3 ALARMS HIGH ALARM LOW ALARM 4 WATER METER GALLONS CONTACT HEAD ENTER GALS CONTACT RESET METER COUNTS PADDLE WHEEL ENTER K FACTOR RESET METER COUNTS AUTOTROL 1 IN RESET METER COUNTS AUTOTROL 2 IN RESET METER COUNTS LITERS CONTACT HEAD ENTER GALS CONTACT RESET METER COUNTS PADDLE WHEEL ENTER K FACTOR RESET METER COUNTS AUTOTROL 1 IN RESET METER COUNTS AUTOTROL 2 IN RESET METER COUNTS 5 4 20 MA OUT SET RANGE 4 MA VALUE 20 MA VALUE MANUAL CONTROL CALIBRATE 4 MA VALUE 20 MA VALUE 6 SYSTEM SETUP PROCESS PARAMETERS ANTI FLASHING ENABLE DISABLE CONDUCTIVITY 2 INITIALIZE CALIBRATION WHOLE CONTROLLER 3 FIRMWARE VERSION 7 CLOCK SET THE DATE AND TIME 6 0 Operation of th
23. PLEASE HAVE THE MODEL NUMBER SERIAL NUMBER AND ANY OPTIONS PERTAINING TO YOUR UNIT AVAILABLE FOR REFERENCE Mail and returns should be sent to Lakewood Instruments 7838 North Faulkner Road Milwaukee WI 53224 USA When any merchandise is to be returned to the factory please call and obtain a Return Goods Authorization RGA number and have the following information available Customer s name address telephone and fax numbers shipping and billing e A hard copy purchase order number for cases where repairs or parts are required that are not under warranty e contact person s name and telephone number to call if the equipment is beyond repair or to discuss any other warranty matter Equipment model and serial numbers Reason for return e g repair warranty incorrect part etc We will then fax to your attention an RGA form that must accompany the returned item NOTE THE RGA NUMBER MUST BE CLEARLY WRITTEN ON THE OUTSIDE OF THE PACKAGE S BEING RETURNED ANY ITEMS SENT BACK TO THE FACTORY WITHOUT AN RGA NUMBER WILL BE REFUSED AND RETURNED TO SENDER 46 Service Guide When calling Lakewood Instruments please have your controllers complete model number and serial number available together with the firmware version so that the Technician can better assist you Refer to the Ordering Information section of this manual for part numbered replacement parts Write your controllers complete model number ser
24. PUT screen press 3 CALIBRATE Use the keypad to enter the milliamp reading from the milliamp meter for the 4 mA point Press ENT Use the keypad to enter the milliamp reading from the milliamp meter for the 20 mA point Press ENT 38 6 4 6 System Setup Menu The system setup menu is used to initialize the controller or calibration and check the firmware version To reach the SYSTEM SETUP MENU e From the MAIN MENU press 6 SYSTEM SETUP The following screen will appear SYSTEM SETUP 1 PROCESS PARMS 1 PROCESS PARMS innwwWAREVER 6 4 6 1 Process Parameters The Process Parameters screens allow the user to enable the Anti Flashing feature and to enable or disable the conductivity input To reach the PROCESS PARAMETERS MENU From the SYSTEM SETUP MENU press 1 PROCESS PARMS The following screen will appear PROCESS PARAMS 1 ANTI FLASHING 1 ANTI FLASHING 6 4 6 1 1 Anti Flashing The anti flashing menu selection inserts a damping circuit value into the conductivity circuit to slow down the rate of change of the conductivity when steam flashing is occurring To enable the anti flashing feature From the Main Menu press 6 SYSTEM SETUP Press 1 PROCESS PARAMS Press 1 ANTI FLASHING Press 1 YES to enable anti flashing press 2 NO to disable anti flashing 39 6 4 6 1 2 Enable Disable the Conductivity Input The Model 150 can be used with or wi
25. SHORT OUT PINS 1 CONTACTING HEAD TYPE WATER METER FLOW WATER METER RED A BLK WHT SHLD AUTOTROL TURBINE BLK 24VDC amp 2 WTH WIRE P8 0000 DOSS gt gt a P7 DOVES SB6 HISTORY DESCRIPTION eee Poor NDUCTIVITY S WAT ER ME FLOW SWITC DWG 1869089 la Sie RESISTOR 10K RED SIGNAL NOTICE ON REPRODUCTIONS BE 5 4 Lakewood WOR UED IN TAE LUITED MAC ANDTHE PERMITTED BY 5 j mbi eem INSTRUMENTS P E TITLE SHD GND dat WIRING DIAGRAM FOR WATER gt A 27 ORDER NO DWN PSG DATE 3 5 10 METER INPUTS ON THE 150 SIGNET CUSTOMER CHKD DATE ea DWE d 2535 2540 PADDLE WHEEL CUSTOMER 102 C S va 1269089 3a had DO NOT SCALE SCALE NONE FILE TYPE DWG SHEET 1 OF 1 P N 61577 REV A POLE 4 3 A 2 1 51 115 230 SECECTOR SWITCH REVISION HISTORY DESCRIPTION RELEASE ADIS WOOT is 8 2 RELAY RELAY OUTPUT SSOVAC EACH TO EXCEED 106
26. SOR TO CONTROLLER 15 20 FEET B CHANGED CABLE TO 2 WIRE 10427 PSG 5 5 11 JB 3 ene D eese se ed IMPORTANT NOTICE WARNING CHEMICAL FEED electromechanical devices are subject to failure from a variety of causes These include mechanical stress component degradation electromagnetic fields mishandling improper setup physical abuse chemical abuse improper installation improper power feeds and exposure While every precaution is taken to insure proper functioning extra precautions should be taken to limit the ability of over feeding by limiting chemical quantities available secondary shut downs alarms redundancy or other available methods CAUTION POWER SOURCE AND WIRING Low voltage wiring and high voltage 110 plus should not be run in the same conduit Always run separately Even shielded low voltage is not a guarantee of isolation Every precaution should be taken to insure proper grounding and elimination of shorting or Electromagnetic field EMF interference WARNING ELECTRICAL SHOCK To reduce the risk of electrical shock this equipment has a grounding type plug that has a third grounding pin This plug will only fit into a grounding type outlet If the plug does not fit into the outlet contact a qualified electrician to install the proper outlet DO NOT change the plug in any way Lakewood Instruments We thank you for your selection and purchase of a Lakewood Instruments pr
27. TAINING SAMPLE At the end of the 30 second sample time the Blowdown relay will turn off and the controller will display the following screen CALIBRATION 03200 uS 59 Use the keypad to input the conductivity reading from the hand held Press E Take another hand held sample to verify calibration Note The controller will remain in the calibration mode for only 1 minute before resuming normal operation 6 3 3 Calibration in Sample Hold Boiler Control Ensure that the controller is operating with good flow past the sensor Take a sample of the water and measure with a hand held conductivity tester From the PROCESS screen press PRO to enter the calibration mode and will start obtaining a sample The controller will display the following message PLEASE WAIT OBTAINING SAMPLE After the sample is obtained the controller will display CALIBRATION 03200 uS 59 Use the keypad to input the conductivity reading from the hand held before the timer reaches 0 00 Press ENT The controller will respond with CALIBRATION COMPLETE Take another hand held sample to verify calibration Note It takes approx 1 minute and 30 seconds to obtain a sample then the controller will remain in the calibration mode for only 1 minute before resuming normal operation 23 6 4 Main Menu The MAIN MENU of the model 150 consists of 7 menu selections Process Displays
28. To move about in the menu DOWN arrow To move about in the menu Number keys To input a value or to select a menu item Light bulb To turn on or off the display lighting LEDs Any Key When any key on the keypad is pressed the display lighting LEDs will turn on for five minutes To manually turn off these LEDSs press the light bulb button 5 4 Menu The model 150 is programmed and calibrated by the use of a menu The complete Main Menu has 7 available options that can be accessed However only one option can be viewed on the display at a time Use the W keys to scroll through the options Press ENT to enter the displayed programming option As an introduction here is a graphic overview of the first level of each option in the Main Menu to see how it operates Complete details of each option are provided later in this manual The entire menu is shown on the next page MAIN MENU 1 PROCESS 2 RELAYS 3 ALARMS 4 WATER METER 5 4 20 MA OUT 6 SYSTEM SETUP 7 CLOCK 1 3 4 2 B 6 7 1500 S WHICH RELAY HIGH ALM 2000uS GALS LTRS 4 20 MA OUTPUT SYSTEM SETUP THU 18 FEB 10 1 BLOW LOW ALM 1000 8 1 GALLONS 1 SET RANGE 1 INITIALIZE RLY BO 20 3 2 RLY2 2 LITERS 2MANUAL CTRL 2 FIRMWARE VER 05 42 40 3 RLY3 3 CALIBRATE 19 5 4 1 Menu Flow Chart MAIN MENU 1 PROCESS DISPLAY DATE DISPLAY TIME DISPLAY ALARMS DISPLAY RELAY STATUS DISPLAY RLY 1 STATUS DISPLAY R
29. age to the controller Use orifice plates or globe valves to prevent steam flash orifice plates or the globe valve should be mounted within 5 feet of the sensor Orifice plates or globe valve and the sensor must be installed horizontally as shown in the drawing e The sensor should be located at least two feet below the water level in the boiler Ensure that there are no restrictions between the skimmer line and the orifice plates or globe valve and all valves upstream of the boiler sensor are fully open sure to provide isolation valves in the sample line to allow for maintenance of the sensor Refer to section 3 3 1 for the orifice sizing chart NOTE DO NOT RUN THE SENSOR WIRING IN THE SAME CONDUIT AS THE MOTORIZED VALVE WIRING 3 3 1 Orifice Sizing Chart Refer to the chart below to determine the orifice size that is required for a specific flow rate Throughput Flow Rate as a function of Orifice Size amp Steam Pressure 15 PSIG 100 PSIG 150 PSIG 0 500 Orifice 0450 250 PSIG Diameter0 400 500 PSIG Inches 0 350 ye 0 300 lt lt 900 PSIG 0 250 0 200 0 150 0 100 0 050 0 000 0 3 10 15 20 25 30 Flow Rate Ib hr X 1000 13 3 4 Electrical Installation POWER RIBBON CABLE SELECTOR SWITCH e A A i d Li e DISPLAY FUSES euo ERMINAL P 8 100mA E j DORNANA TII Ji 10A t rz S MM
30. del 150 has a shipping weight of less than 6 Ibs 11 3 3 Plumbing Installation There are three methods of automatic control of the conductivity in a boiler sample cycle continuous sample and sample hold To decide if you should use continuous sample or sample cycle or sample hold control determine your blowdown rate requirement If your boiler requires greater than 1000 pounds per hour of blowdown to maintain conductivity then the continuous sample method should be used If your blowdown requirement is less than 1000 pounds per hour the sample cycle or sample hold methods are appropriate The model 1575e can be used for either sample cycle control sample hold control or continuous sample control of the conductivity in the boiler The installation drawing in the back of this manual shows how to plumb the boiler sample line so that it can be used as sample cycle sample hold or continuous sample To prevent steam flashing and damage to the sensor and controller refer to the installation drawings in the back of this manual and the notes below e Use piping from the boiler skimmer line as the sample and blowdown line NOTE DO NOT USE THE BOTTOM BLOWDOWN OF THE BOILER AS THE SAMPLE OR AUTOMATIC BLOWDOWN LINE e The maximum allowed wire distance between the controller and the sensor is 20 ft e If using conduit between the sensor and controller allow a place for water to escape if the sensor leaks This will help prevent water dam
31. e Controller 6 1 Process Screen The screens that are used the most in the model 150 controller are the Process Screens Below are the process screen views The process screen has two Sections The top section shows the conductivity reading The bottom section has user selectable readings as shown below e There are many different screens available in the PROCESS screen These screens allow you to view the controller settings incl Date time setting relay 1 DATE SCREEN 1000 us set ups total flow relay status etc without the 25 FEB 10 danger of altering them Access these screens by using the 4 and keys to scroll through the available screens Press ENT to manually control a relay for testing or troubleshooting purposes Press PRO to calibrate the conductivity 2 TIME SCREEN 3 ALL RELAY SCREEN 4 WATER METER SCREEN 1000 uS 1000 uS 1000uS 15 58 11 RLY BU 20 3 MTR 100273 G Note A flashing box next to the relay number indicates that the relay is manual control 5 BLOWDOWN RELAY SCREEN 6 BLOWDOWN SAMPLE CYCLE 6 RELAY 2 SCREEN SCREEN 1000 uS 1000 uS 1000 uS LIB SET 99999 uS SMPL 00 00 59 g2 DISABLED Note This screen does not appear while in Continuous sample mode 7 RELAY 3 SCREEN 8 ALARM SCREEN Note The display lighting 1000 uS 100 uS LEDs will turn on for five minutes when an
32. e conductivity requires periodic calibration Calibration is usually required after cleaning the sensor A calibration should always be performed with the sensor in the piping assembly with good flow past the sensor It is necessary to have an accurate reading of the system water to properly calibrate the controller A hand held conductivity meter that tests the sample works well for this purpose Note The controller will allow up to one minute to enter a calibration value while the controller is in the calibration mode 6 3 1 Calibration in Continuous Sample Boiler Control Ensure that the controller is operating with good flow past the sensor Take a sample of the water and measure with a hand held conductivity tester From the PROCESS screen press PRO to enter the calibration screen Use the keypad to input the conductivity reading from the hand held Press ENT Take another hand held sample to verify calibration Note The controller will remain in the calibration mode for only 1 minute before resuming normal operation 22 6 3 2 Calibration in Sample Cycle Boiler Control Ensure that the controller is operating with good flow past the sensor Take a sample of the water and measure with a hand held conductivity tester From the PROCESS screen press PRO to enter the calibration mode The controller will turn on the Blowdown relay for 30 seconds and display the following screen PLEASE WAIT OB
33. e controller will compare the conductivity reading to the setpoint and if the conductivity is higher than the setpoint the Blowdown relay will stay energized until the conductivity reading is less than the setpoint Once the setpoint is satisfied the blowdown relay will turn off for a user selected time called the Cycle Time At the end of the Cycle Time the Blowdown relay will once again go into the Sample Time and repeat the above sequence In the Sample Hold mode the blowdown relay will energize for a user selected time called the Sample Time At the end of the Sample Time the blowdown relay will turn off and the controller will go into a 30 second Hold Time The Hold Time allows time for the sample to stop flashing before actually reading the conductivity value At the end of the Hold Time the controller will go into a Reading Time of 15 seconds At the end of the Reading Time the controller will compare the conductivity reading to the setpoint If the conductivity is higher than the setpoint the controller will go into a user selected Blow to Resample Time and re energize the blowdown relay repeat the above sequence Once the setpoint is satisfied the controller will keep the blowdown relay turned off for a user selected time called the Cycle Time At the end of the Cycle Time the Blowdown relay will once again go into the Sample Time and repeat the above sequence 2 0 Features Benefits Specifications Steel domed numeric keypad for easy
34. ercent of blowdown time to activate this relay Press ENT 34 6 4 2 2 5 By Percent of Time The Percent of Time feature allows you to feed chemical strictly based by a percent of time This relay control scheme works in patterns of 20 second time blocks A relay is on for some multiple of 20 seconds and off for some multiple of 20 seconds Below is a chart showing some of the operation times for Percent of Time 255 205 7 60Sec 335 205 4085 66 405 7 20586 755 6osec 7 205 Note In the case of 33 once every 66 minutes the off time would extend an extra 20 seconds to make up for the accumulation of the odd Yo value vs a 24 hour clock since the percent of time is based on a 24HR clock in 20 second increments The same could be said for the 66 timer except it will remain ON for the additional 20 seconds every 66 minutes To determine the total amount of chemical fed over a 24 hour period multiply the percent of time by the number of hours a day that your controller is operating then multiply by your chemical pump flow rate per hour For example We select 10 of the time our controller operates 24 hours a day and our chemical pump flow rate is 1 gallon per hour 10 x 24 hours x igallon 2 4 Gallons Day Hour Day From the RELAY OPTIONS screen press 5 PERCENT OF TIME Use the keypad to enter the percentage of time desired Press ENT 35 6 4 2 2 6
35. established the controller s deadband must also be set Deadband refers to the amount of conductivity above and below the setpoint a range within which the controller will not react Due to continuous fluctuations in the conductivity level it is necessary to have this deadband range or stable readings will be difficult to obtain The Deadband should be a small percentage of the setpoint Half the deadband amount will be automatically put above the setpoint and the other half below it For example a conductivity setpoint of 1 000 uS with a deadband of 100 uS would result in the BLOWDOWN relay opening at 1 050 uS and closing at 950 DEADBAND 000100 uS Use the keypad numbers to enter the proper deadband setpoint and press ENT When finished you will automatically be switched to the BLOW ALARM TIME alarm screen 26 6 4 2 1 1 2 BLOW ALARM TIME The BLOW ALARM TIME alarm is designed to notify the operator of a problem in the blowdown system such as a clogged strainer or the blowdown valve did not open The blowdown timeout function is strictly a visual alarm feature displayed on the model 150 controller it will not close the blowdown valve f a relay is configured as an alarm relay the BLOW ALARM TIME alarm will energize the alarm relay To disable this function simply program 0 hours 0 minutes BLOW ALARM TIME 00 00 Use the keypad numbers to enter the time in hours and minutes before
36. guration screen from the MAIN MENU press 2 or highlight RELAYS and press ENT The following screen will appear WHICH RELAY d 1 BLOW 3 RLY3 6 4 2 1 Configuring the Blowdown Relay The blowdown relay can be configured to operate in three different modes Continuous Sample Sample Cycle or Sample Hold Each of these modes are explained further in the Boiler Methods section of this manual NOTE The blowdown relay is not affected by the flow switch input In Continuous Sample mode the Blowdown relay works strictly by setpoint control In Sample Cycle mode the Blowdown relay will energize for a user selected time called the Sample Time At the end of the Sample Time the controller will compare the conductivity reading to the setpoint and if the conductivity is higher than the setpoint the Blowdown relay will stay energized until the conductivity reading is less than the setpoint Once the setpoint is satisfied the Blowdown relay will turn off for a user selected time called the Cycle Time At the end of the Cycle Time the Blowdown relay will once again go into the Sample Time and repeat the above In the Sample Hold mode the Blowdown relay will energize for a user selected time called the Sample Time At the end of the Sample Time the Blowdown relay will turn off and the controller will go into a 30 second Hold Time The Hold Time allows time for the sample to stop flashing before actually reading the conductivity va
37. he maximum allowed time is 17 hour and 59 minutes 6 4 2 1 3 3 SAMPLE HOLD In the Sample Hold boiler applications the controller will sample the water on a timed basis and then control based on a conductivity setpoint just like in the Sample Cycle method above but with an added Hold feature The Blowdown relay will energize for a user selected time called the Sample Time At the end of the Sample Time the Blowdown relay will turn off and the controller will go into a 30 second Hold Time The Hold Time allows time for the sample to stop flashing before actually reading the conductivity value At the end of the Hold Time the controller will go into a Reading Time of 15 seconds At the end of the Reading Time the controller will compare the conductivity reading to the setpoint If the conductivity is higher than the setpoint the controller will go into a user selected Blow to Resample Time and re energize the Blowdown relay to repeat the above sequence Once the setpoint is satisfied the controller will keep the Blowdown relay turned off for a user selected time called the Cycle Time At the end of the Cycle Time the Blowdown relay will once again go into the Sample Time and repeat the above sequence 29 The sample time is set in minutes and seconds and the cycle time is set in hours and minutes Lakewood Instruments recommenas that you consult your water treatment professional for more information on using these settings To configure the
38. he model 150 controller press CLR twice press 6 System setup press 2 INITIALIZE press 2 WHOLE CTRLR press 1 Yes After initialization press the CLR key several times until you get to the main menu Press 1 Process Press ENT This screen allows manual control of the relay outputs to test the chemical pumps and blowdown valve Press the number for the relay you want to operate 1 for bleed 2 for relay 2 and 3 for relay 3 The box will flash to show that that relay is in manual control To restore automatic control press that number again Press CLR to return to the Process screen To calibrate conductivity take a sample with a handheld conductivity meter press the PRO button type in conductivity value press ENT skip if not using conductivity sensor For more details refer to appropriate section of this manual Program the model 150 relays for blowdown chemical feed schemes water meter input and 4 20 mA output See instruction manual for more details REVISIONHISTORY d n T 5 MANDA 10118 PSG 03 05 2010 DI ORIACE UNION MUST AA THE 150 MUST DF HEAT AS POSSI EET MINIMUM MMENDED MAKE UP BUILER SENSOR TI A ORIFICE UNION OR GLOBE VALVE p OIGE ON REPRODUCTIONS Lakewood x 7 INSTRUMENTS TME INSTALLATION LAYOUT CONTINOUS SAMPLE CYCLE OR SAMPLE HOLD MODEL 150 NOTES fh MAXIMUM DISTANCE FROM SEN
39. ial number and firmware version here so that you will have them available if you wish to contact a Lakewood Instruments technician Model Number Serial Number Firmware Version 47 10 0 Drawings 48 REVISION H STORY NOTES 4 MAXIMUM DISTANCE FROM SENSOR TO CONTROLLER 15 26 FEET RELAY OUTRUTI EACH crue 30 ULLA NOTICE ON REPRODUCTIONS oH THE FE GATE KE ORE RRR RY rF 1RRELEHI OHS THEY SEL EF oD BEBE HOF LEFI HE EDs Ir OH LEE FERT EH GR F HO A HEL FREE TIT THE Rock HS E a eee b A 49 NOTES UNLESS OTHERWISE SPECIFIED REVISION 1 ORIFICE UMIONS MUST BE INSTALLED TO REVISIONHISTORY PREVENT STEAMFLASH REFER TO USER MANUAL 1106840 FOR PART DESCRIPTION eco DWNDATE APVOIDATE PROPER ORIFICE SIZING RELEASE 10118 PSG 03 05 2010 SENSOR MUST BE MOUNTED HORIZONTALLY AND MUST BE_AT LEAST 2 FEET BELOW THE WATER LEVEL THE BOILER THE DISTANCE FROM THE SENSOR TO THE ORIFICE UNION MUST BE 5 FEET OR LESS 150 MUST BE LOCATED WITHIN 20 THE BOILER SENSOR AND AS FAR FROM STEAM HEAT AS POSSIBLE MANUAL VALVE cooocoo 1 LA SKIMMER BLOWDOWN LINE BOILER 1 MINIMUM RECOMMENDED i w TO DRAIN MANUALBLOWDOWN VALVE MANUAL WALVE
40. itch connections in order for relays 2 and 3 to function Refer to the drawings in the back of this manual for wiring instructions 15 3 4 4 Sensor Wiring The model 150 uses the Lakewood Instruments two electrode conductivity boiler sensor The maximum recommended wiring distance for sensor is 20 feet The conductivity sensor is wired directly to the P8 terminal block on the upper right corner of the control board The black and white wires are wired to terminal 1 I The red and green wires are wired to terminal 2 Terminals 3 and 4 are not used NOTE DO NOT RUN THE SENSOR WIRING IN THE SAME CONDUIT AS THE MOTORIZED VALVE WIRING ERE GREEN RED BOILER SENSOF Li 3 4 5 Water Meter The Model 150 will accept one water meter input Refer to the water meter manufacturer s manual for plumbing information The 150 series controller will work directly with the following types of meters dry contacting head meters Seametrics open collector output meters Signet 2535 and 2540 paddle wheel meters and the Autotrol 1 inch and 2 inch
41. lue At the end of the Hold Time the controller will go into a Reading Time of 15 seconds At the end of the Reading Time the controller will compare the conductivity reading to the setpoint If the conductivity is higher than the setpoint the controller will go into a user selected Blow to Resample Time and re energize the Blowdown relay repeat the above sequence Once the setpoint is satisfied the controller will keep the Blowdown relay turned off for a user selected time called the Cycle Time At the end of the Cycle Time the Blowdown relay will once again go into the Sample Time and repeat the above When the blowdown relay is selected for programming the following screen will appear 1 SETPNT VALUES BLOWDOWN SETUP 1 SETPT VALUES 4BALL VALVE DL 25 6 4 2 1 1 Setpoint Values In the SETPT VALUES screen you will set the SETPOINT the DEADBAND and the BLOW ALARM TIME alarm The SETPOINT is the conductivity value that you are trying to maintain Check with your water treatment engineer to determine the conductivity setpoint for your system needs Follow these instructions to establish the controller s setpoint Press 1 or highlight SETPT VALUES and press ENT SETPOINT 4500 uS Use the keypad numbers to enter the proper conductivity setpoint and press ENT When finished you will automatically be moved down to the deadband 6 4 2 1 1 1 DEADBAND After the setpoint is
42. me 35 6 4 2 2 6 an Alarm 36 eh a D AR dixe AE 36 GAA Water Mele ce eto ron Crate 37 6 4 5 Setup of the 4 20 MA 38 6 4 5 1 Set the 4 20 mA 38 9 4 5 2 Manual COME O bebe xe sekey ce ke 38 6 4 5 3 Calibrate the 4 20 MA 38 6 4 6 System Setup 39 6 4 6 1 Process 39 6 4 6 1 1 Ariti Flashirig eie ar p t eios 39 6 4 6 1 2 Enable Disable the Conductivity Input 40 6 4 6 2 Initialize nd Cats AE 40 6 4 6 3 Firmware Version 40 6 4 7 Setting COCKS titus gun sans 41 e A a kn ke ie 42 7 1 Sensor Mai l N ANCO eee kone rea trap creda ak aa 42 7 2 Replacing the FUS S 2 rrty bib kenken p b di Us H2 43 B OTTEOUDIGSIDOLUTIG n due e te ONE dda come enone UE E e 44 8 1 Error Messaggs s 1s uote ee eoe et benson itle vetat 44 S GESGIDIV SRV IC ac is See tak its E cA HALLA LAE A Ld M d 46 10 0 Drawings 10 1 Wiring Boiler Sensor ehe erra 1269089 1A 10 2
43. meters Contact Lakewood Instruments for other types of water meters The water meters are wired to terminal block P7 on the right hand side of the control board Refer to the drawing in the back of this manual for wiring instructions 3 4 6 4 20 mA Output Wiring The model 150 has one 4 20 mA output for conductivity This output can be isolated or non isolated externally powered or internally powered If the 4 20 mA output is internally powered then it is non isolated If the 4 20 mA output is externally powered then it is isolated The 4 20 mA output is wired to terminal block P2 on the right hand side of the control board Refer to the drawing in the back of this manual for wiring instructions 16 4 0 Starting Up the Controller Once the Installation is complete it is time to start up the controller Initiate sample flow to the controller by opening the sample line isolation valves Check for leakage Power up the controller by turning on the circuit breaker or plugging the power cord into a 120 VAC receptacle For the initial startup it is best to initialize the whole controller to remove any settings that may be in the memory before programming the controller Refer to section 6 4 6 2 of this manual to initialize the controller Set the clock by following section 6 4 7 Configure the water meter input by following section 6 4 4 Set the high and low conductivity alarms by following section 6 4 3 Configure the relays for
44. n will be displayed along with a checksum value The checksum value is used to verify that the program has not been corrupted To exit this screen press any key 40 6 4 7 Setting the Clock The clock uses the 24 hour or military time 06 00 00 is 6 a m 18 00 00 is 6 p m To set the clock From the Main Menu press 7 CLOCK The following screen will appear WED 24 FEB 10 15 02 41 Press PRO to change the clock settings The day will start flashing Use the up and down arrow keys to change the day of the week Press ENT Use the number keys to change the date Press ENT Use the arrow keys to change the month Press ENT Use the number keys to change the year Press ENT Use the number keys to change the hour Press ENT Use the number keys to change the minutes Press ENT Use the number keys to change the seconds Press ENT Press CLR to exit this screen You must press ENT all the way through this menu for the settings to take affect 41 7 0 Maintenance Periodic maintenance is required to ensure trouble free operation of the model 150 controller The following sections cover the required maintenance 7 1 Sensor Maintenance Routine maintenance is necessary in order to maximize the efficiency and accuracy of your sensor Clean the electrode end of the conductivity sensor at least once per month Cleaning of the conductivity sensor may need to be performed more frequently if it is in a
45. nts Technical Service for more information The flow switch float may be stuck or no flow is present Flow switch may be bad Replace reed switch in plumbing assembly NO FLOW alarm Flow input switch is not closed If no flow switch is used a jumper wire should be installed across the flow switch input Removing the jumper disables the relay outputs for relays 2 and 3 but does not affect the Blow relay 44 PROBLEM Alarm Flashing RELAY TIMEOUT Motorized ball valve functions but will not remain open or closed as expected WHAT THIS MEANS This indicates that the controller has been trying to operate a relay for longer than the user programmed time and is unable to reach the setpoint The motorized ball valve is not indicating to the 150 that it has actually reached the open or closed position 45 CORRECTIVE ACTION Check for proper operation of the pump or valve Use the manual relay control to help Check the relay configuration and verify settings Check chemical levels in the drums or totes Verify operation of water meters Momentarily shut off system flow to reset alarms Adjust the limit switch for the motorized ball valve 9 0 Factory Service Technical Support for Lakewood Instruments can be reached by calling 800 228 0839 or faxing 414 355 3508 Monday through Friday 7 30 a m 4 30 p m CST NOTE IF YOU CALL FOR TROUBLESHOOTING HELP
46. oduct With proper care and maintenance this device should give you many years of trouble free service Please take the time to read and understand this Installation and Operation Manual paying special attention to the sections on OPERATION and MAINTENANCE If in the future any parts or repairs are required we strongly recommend that only original replacement parts be used Our Customer Service Department is happy to assist you with your parts or service requests Lakewood Instruments Customer Service and Technical Support Departments can be reached by calling 800 228 0839 or faxing 414 355 3508 Monday through Friday 7 30 a m 4 30 p m CST Mail should be sent to Lakewood Instruments 7838 North Faulkner Road Milwaukee WI 53224 USA MODEL 150 Table of Contents 11 e fe a 7 2 0 Features Benefits and 8 EB ponpe se vo UD ERE 8 2 BONE SA bene 9 2 3 Specifications ndira Es 9 2 4 Ordering Information 2 0 424 0 10 3 0 Unpacking Mounting and 11 3 1 LI ek kn E a a a n n 11 3 2 Mounting the Enclosure moe eno All 11 3 3 Plumbing
47. of conductivity above and below the setpoint a range within which the controller will not react Due to continuous fluctuations in the conductivity level it is necessary to have this deadband range or stable readings will be difficult to obtain The Deadband should be a small percentage of the setpoint Half the deadband amount will be automatically put above the setpoint and the other half below it For example a conductivity setpoint of 1 000 uS with a deadband of 100 uS would result in the relay turning on at 1 050 uS and turning off at 950 uS DEADBAND 000100 uS o Use the keypad numbers to enter the proper deadband setpoint and press ENT When finished you will automatically be switched to the TIMEOUT alarm screen 6 4 2 2 2 3 Timeout The TIMEOUT alarm is designed to prevent overfeeding chemicals in case of a problem in the blowdown system such as a clogged strainer or the blowdown valve did not open The relay timeout function is an alarm feature that is displayed on the 150 series display process screen and it will turn off the relay If a relay is configured as an alarm relay the TIMEOUT alarm will energize the alarm relay To disable the timeout function simply program 0 hours 0 minutes TIMEOUT 00 00 Use the keypad numbers to enter the time in hours and minutes before this alarm will appear and press ENT 33 6 4 2 2 2 4 When to feed The relay can be configured to operate ei
48. ther above the setpoint or below the setpoint When the relay is configured to operate above the setpoint the relay will turn on when the conductivity rises above the setpoint plus one half of the deadband When configured to operate below the setpoint the relay will turn on when the conductivity falls below the setpoint minus one half of the deadband In the BASED ON SETPT screen press 2 or highlight WHEN TO FEED and press ENT WHEN TO FEED 1 ABOVE SETPT In the WHEN TO FEED screen select either 1 ABOVE SETPT or 2 BELOW SETPT Then press any key 6 4 2 2 3 By Water Meter Relays 2 and 3 can be configured to operate for a specified amount of time based on a specified amount of flow through the water meter input The water meter total is used to activate the relay From the RELAY OPTIONS screen press 3 WATER METER Use the keypad to enter the amount of flow before the relay is activated Press ENT Enter the amount of time that the relay will be activated This time is in minutes and seconds Press ENT 6 4 2 2 4 By Percent of Blowdown Time Relays 2 and 3 can be activated by a percent of the time that the blowdown was on The relay will activate after the blowdown shuts off For example if 5096 is entered and the blowdown relay is on for 10 minutes the relay will be energized for 5 minutes From the RELAY OPTIONS screen press 4 BLOWDOWN e Use the keypad to enter a p
49. this alarm will appear and press ENT Note The BLOW ALARM TIME alarm only applies to the Continuous Sample control mode 6 4 2 1 2 When to Blowdown Most applications for boilers will blowdown above the setpoint If desired it is possible to configure the relay with a reverse setpoint That is blowdown occurs below the setpoint If using this method be sure that the high conductivity alarm is set as high as possible In the BLOWDOWN SETPT screen press 2 or highlight WHEN TO BLOW and press ENT WHEN TO BLOWDOWN 1 ABOVE SETPT In the WHEN BLOWDOWN screen select either 1 ABOVE SETPT 2 BELOW Then press any key An asterisk will appear next to the current selection 6 4 2 1 3 BOILER METHODS The Blowdown relay can be configured for Continuous Sample Sample Cycle or for Sample Hold mode The Boiler Methods screen is selectable under the Blowdown setup screen BLOWDOWN SETPT 3 BOILER METHOD Inthe BLOWDOWN Setup screen select 3 BOILER METHOD 27 6 4 2 1 3 1 CONTINUOUS SAMPLE In Continuous Sample boiler applications blowdown water is continuously flowing past the conductivity sensor and the controller is controlling the Blowdown relay based on a setpoint This mode is usually used for large boilers or boilers with very little condensate return It is recommended that you use this mode if your blowdown rate requirement is greater than 100
50. thout the conductivity input If conductivity is not being used disable the conductivity input e From the Main Menu press 6 SYSTEM SETUP Press 1 PROCESS PARAMETERS Press 27 ENABL DISABL e Press 1 YES to enable the conductivity input or press Z2 NO to disable the conductivity input NOTE When the conductivity is disabled the Process screen will display the status of the three relays in the top section of the display in place of the conductivity reading 6 4 6 2 Initialize Initialization restores the factory default settings to the controller The whole controller can be initialized or just the calibration It is suggested that you initialize the whole controller before you program the controller for the first time This will clear any random settings that may be in the controller To do so follow these instructions From the Main Menu press 6 SYSTEM SETUP Press 2 INITIALIZE e Press 2 WHOLE CTRLR You will then be asked ARE YOU SURE Press 1 for YES or press 2 for NO To initialize just the calibration Press 1 CALIBRATION instead of 2 WHOLE CONTROLLER in the procedure above The same message will appear 6 4 6 3 Firmware Version Sometimes it is necessary to verify the firmware version of the controller for troubleshooting purposes To get to the firmware version From the Main Menu press 6 SYSTEM SETUP e Press 3 FIRMWARE VER e The firmware versio
51. to a longer period of time If the conductivity is always above the setpoint the Cycle time is probably set at too long of a time and will need to be adjusted to a shorter period of time 30 The Blow to Resample Time is user selectable and is designed to allow the user to set the amount of time the blowdown relay will be re energized for when the conductivity is higher than the setpoint after a sample is taken 6 4 2 1 4 BALL VALVE DELAY Motorized ball valves require a few seconds to open and close If the valve is commanded to close before it completes the process of opening it may enter a state where it is half open The ball valve delay feature prevents this from occurring To use this feature determine how many seconds it takes to open and close the valve Use the longest time and round up 1 second Use this value as your Ball valve delay time This delay time will also be observed when manually operating the BLOWDOWN relay 6 4 2 2 Configuring Relays 2 and 3 Both relays can be configured to operate based on Disabled Setpoint Water Meter Percent of blowdown Percent of Time or by Alarm From the WHICH RELAY screen select either relay 2 or relay 3 When relay 2 3 is selected for programming the RELAY OPTIONS screen will appear The asterisk next to one of the options tells you how that relay is currently configured to feed Use the and keys to view all of the relay options 1 DISABLED RELAY 2 3 OPTIONS 2 S
52. to prevent excessive loss of water and heat Once the sample time is set it should never have to be changed again The Cycle Time will need to be adjusted based on the steaming rate and make up water quality If using Sample Cycle control and the conductivity does not rise to the setpoint the Cycle time is probably set for too short of a time and will need to be adjusted to a longer period of time If the conductivity is always above the setpoint the Cycle time is probably set at too long of a time and will need to be adjusted to a shorter period of time 28 The Sample time is set in minutes and seconds and the Cycle time is set in hours and minutes Lakewood Instruments recommenas that you consult your water treatment professional for more information on using these settings To configure the Blowdown relay for Sample Cycle mode BOILER METHODS 2 SAMPLE CYCLE e n the BOILER METHODS screen select 2 SAMPLE CYCLE The Sample Time screen will appear SAMPLE TIME MM 00 55 00 e n the Sample Time screen use the number keys to input a minutes value press ENT and use the number keys to enter a seconds value and press ENT to go to the Cycle Time screen Note The maximum time setting is 59 minutes and 59 seconds CYCLE TIME HH 00 00 e n the Cycle Time screen use the number keys to input an hours value press ENT and use the number keys to enter a minutes value and press ENT NOTE T
53. uations If you have other questions or are need support contact the Lakewood Instruments Technical Service Department toll free at 800 228 0839 PROBLEM WHAT THIS MEANS CORRECTIVE ACTION See problem RELAY TIMEOUT Check the chemical pump operation Conductivity is too high or low The chemical drum is empty with respect to the high or low Check the High or Low Alarm Value alarm setpoint Check relay setpoints and deadbands Insure the system is not overflowing Flashing CONDUCTIVITY HIGH OR CONDUCTIVITY LOW Approximately 5 volts DC should be present at the input terminal when the water meter contact is closed That should change to zero VDC when the contact opens Check these voltages and for correct wiring There may be a problem with the wiring or the reed switch in the meter may be bad Water meter not accumulating For water meters other than the contacting head type check the manufacturer s user manual for that particular water meter Is the controller configured for your type of water meter Check the fuse F1 Replace with 5 x 20 mm 10A 250V fast blow fuse Check the fuse F2 Replace with 5 x 20 There may be a problem with the mm 100mA 250V slow blow fuse incoming power the fuses or the circuit board Open the front Does the unit have power panel to troubleshoot Display is blank If there is power to terminals AC and ACC on P1 call Lakewood Instrume
54. y button on 3 BY WATER MTR LOW CONDUCTIVITY ihe keypad is pressed The display lighting can be NOTE THE DISPLAYED ALARMS turned manually WILL ROTATE THROUGH ALL pressing the light bulb ACTIVE ALARMS button 21 6 2 Manual Operation of the Relays All three of the relays can be operated manually To manually operate the relays Go to the Process screen Press ENT You will be taken to a screen that looks like MANUAL RLY 5 MIN RLY BO 20 3 Note A flashing box next to the relay number indicates that the relay is in manual control Press 1 3 to manually change the state of a particular relay If the relay is already on pressing that number will turn it off A five minute countdown timer will start and the box next to the relay number will start to flash After five minutes has expired the relay will return to automatic control The relay will remain in manual control even if this screen is exited A relay that is in manual control will stay in manual control until the five minutes expires or until that relay number is pressed again The five minute timer helps to prevent damage to the system if a relay is left in manual WARNING Manual control overrides all automatic control functions including the flow switch lockout Use care when operating relays manually with no flow in the system 6 3 Calibration of Conductivity Th
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