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HG-702 User Manual - Blue I Water Technologies

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1. sssessseesseessiresrrssrrssrnssrrssrnssrrssrrssrns 50 725 3 Routine Malntenance r iavumnvditrnedd eds ed daa add 50 7 5 3 1 Conductivity Calibration ss 50 7 5 3 2 Cleaning the Conductivity Meter 50 7 5 3 3 Replacing the Conductivity Meter 50 7 5 4 Shut down and Wimtertzing 51 7 6 le 51 761 Install tton uaus cacti ieee ammet edie ee ee ead die sk nes katten 51 7 6 2 Routine Maintenance and Troublesbootng ann 52 7 7 Modbus Communication Protocol 52 7 8 Communication OPTIONS dresse nr entente le 57 7 8 1 Internal 4 to 20mA Output sise 57 K DEN Perllan 57 7 9 Chlorine Shock Mode iii 58 Appendix A Relays and Closed Loop Control 60 Connecting external equipment to the relays ccccceeeeceeeeeeeeeeeeeeaeeseeeeeseaeeesaeeeeneeseeeee 60 Wiring to Dosing Systems rrunnrrnannvnnnnvnnrnrrvnnnrrnnnnnnnnnnnnrnnrennnrnnennnnnennennnrreennrnnsnnnnnennenenn 60 Proportional Control Overview sisi 61 Il teleielute ue te 61 Step By Step Proportional Settings 63 Setting Pump Period 63 Appendix B Technical Specifications ss 64 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com v O Blue I Water Technologies Table of Figures Figure 1 HydroGuard 702 Main Components ssseesseesseessesssesiesiesinttnnttnnntnnnnnnnnnsnnnsen nenn 12 Figure 2 HydroGuard 70
2. View conductivity Displays measurement value on LCD Address Controller ID used with external communications Ver Current SW version Max flow range Maximum Flow Rate flow at 20mA of 4 20mA module 4 20mA Output Settings Configures outputs for internal 4 20mA module On alarm go to 4 20mA output during an alarm condition Reagent pump time Enables to tune the amount of reagents according to the water ingredients Modbus com format Modbus communications protocol options Operator password Change operator s password Technical password Change technician s password Optional features 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 25 Table 5 Technician Menu and Variable Limits Function Name Min Value Max Value Default Units Cl P factor 0 1 50 1 CI pump period 0 5 4 0 30 min CI pump freq 0 0 0n off 120 0 max pulses min pump Cl averaging OFF ON ON CI lt 0 1 alarm OFF ON ON pH p factor 0 1 100 1 0 pH pump period 0 5 4 0 30 min pH pump freq 0 0 0n off 120 0 max pulses min pump pH balance type Acid Base Acid Flow Sensor OFF ON OFF Flow rate M7 hour GPM M7 hour Celsius Fahrenheit de OF iG Turbidity OFF ON OFF NTU wiper interval 1 60 2 min
3. appears on the LCD Refer to Installing DPD3 Reagent Section 7 2 2 for information on reagent replacement 7 2 5 2 Calibration Calibration of the free chlorine will automatically update calibrate the total chlorine 7 3 pH ORP and Temperature Measurements 7 3 1 Installation If the HYDROGUARD system was ordered with these components some steps in this process will have been completed in the factory and may be skipped Required Components e pH ORP Temp Module electronics card e 150mm flat cable e pH probe e ORP probe e Temperature probe Note The system may be operated with only pH or only ORP but must always have the temperature probe as this provides additional grounding to ensure reliable pH and ORP measurements The following procedure describes how to install the Redox ORP and pH sensors in the HYDROGUARD unit The installation of all the sensors in the flow cell is similar except for the connecting wires Caution Make sure the pH and Redox sensors have plastic or rubber plugs covering their ends Use another sensor if the plug of any sensor is missing or has fallen off Make sure to connect the appropriate wire to the appropriate sensors Labels are located on the wires near the probe connection and on the connection on the pH Redox Temp Module 1 Turn off all power and water supplies to the analyzer 2 Install the pH ORP Temp module electronics card in the control module on the top left above the co
4. Blue I Water Technologies Table 2 Operator Menu Functions and Descriptions Function Name Shock Chlorination Description Activate Chlorination according to Cl shock set point Menu Relays Manual activation of Relays Reagent pump Manual activation of Reagent Pumps Cl set point1 Controls Cl relay 1 On Off or Proportional Cl shock set point Controls Cl relay according to the set point level for a period of time Cl set point2 Controls Cl relay 2 On Off only F Cl calibrated to sensor value was Most recent calibration amp sensor value at calibration for troubleshooting purposes Cl low alarm Initiates an alarm when CI is below value CI high alarm Initiates an alarm when CI is above value Cl interval Time between Cl measurements pH set point Controls pH relay 3 On Off or Proportional pH 7 calibrated to sensor value was Most recent calibration amp sensor value at calibration for troubleshooting purposes pH 4 10 calibrated to sensor value was Most recent calibration amp sensor value at calibration for troubleshooting purposes pH low alarm Initiates an alarm when pH is below value pH high alarm Initiates an alarm when pH is above value ORP set point1 ORP set point for emergency mode only ORP calibrated to sensor value was Most recent calibration amp sensor value at calibration for troubleshooting purposes ORP low al
5. 6 Reconnect the terminal blocks 7 4 5 Shut down and Winterizing Disable the Turbidity measurement in the technician menu oO MN Shut off the flow of water to the turbidity flow cell Open the drain at the bottom of the flow cell to drain all water 4 If temperatures will drop below freezing remove the turbidity sensor and store it in a safe location where temperatures will not drop below freezing 7 5 Conductivity Measurements 7 5 1 Installation If the HYDROGUARD system was ordered with Conductivity pre installed some of these steps will have been completed in the factory Supplied Components e Conductivity 4 20 input Module electronics card e 150mm Flat Cable ribbon cable e Conductivity meter e Conductivity flow cell Caution Prior to opening the analyzer or installing any electrical components turn off all power supplies to the analyzer 1 Attach the module to the inside of the control panel door below the control panel module using the 4 supplied screws 2 Attach the ribbon cable from the conductivity module to any open connector on the I O module 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 49 Oe Blue I Water Technologies 5 6 Oo oO N 0 Mount the conductivity flow cell and meter on a solid wall or surface using appropriate hardware not supplied Make sure that the distance is le
6. Disconnect the flat cable plug from the card Disconnect all terminal blocks Unscrew the four 4 mounting screws Put in the new card and tighten the 4 mounting screws Connect the flat cable plug to the card TZ I Z DH Reconnect the terminal blocks 7 5 4 Shut down and Winterizing 1 Shut off the flow of water to the conductivity flow cell 2 Drain the water from the flow cell 3 If temperatures will drop below freezing remove the conductivity sensor and store in a safe location where temperatures will not drop below freezing 7 6 Flow Meter Blue Water Technologies does not supply flow meters only input connections and display 7 6 1 Installation Required Components e Flow meter frequency or 4 20 e 4 20 input module if using 4 20 flow meter e 150 mm flat cable if using 4 20 input module Prior to opening the analyzer or installing any electrical components turn off all power supplies to the analyzer Frequency Output Flow Meter A flow meter with either two 2 or three 3 wires for a frequency output can be connected to the input switch section on the I O module Installation 1 Install the flow meter following the manufacturer directions Be sure to install close enough to HYDROGUARD that the wires will reach 2 Pass the flow sensor cable through an open glad on the bottom of the analyzer 3 Connect the two or three wires from the sensor cable to the input switch terminal block on the lower
7. that were on the new probes with tap water or preferably KCI potassium chloride solution and insert over the end of each probe DO NOT use DI water 3 Screw the plastic cap over the top of each probe to protect the connector 4 Store in a safe location that will not drop below freezing preferably in the original probe box for additional protection 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 44 O Blue I Water Technologies 7 4 Turbidity Measurements 7 4 1 Installation If the HYDROGUARD system was ordered with Turbidity pre installed some of these steps may have been completed in the factory Supplied Components e Turbidity Input Module electronics card e 250mm flat cable e Turbidity Sensor wiper optional e Turbidity Flow Cell bubble remover optional e Flow Cell Mounting Bracket Caution Prior to opening the analyzer or installing any electrical components turn off all power supplies to the analyzer There are five 5 wires contained in a single cord from the sensor that must be connected to the analyzer The standard wire length is 22 ft 7m and may be cut or extended up to 650 ft 200m as needed The turbidity flow cell and sensor must be securely mounted using appropriate hardware for the mounting location Unfiltered water will need to be supplied to the turbidity flow cell at a flow between 0 25 to 1 GPM and less than 30 psi 2
8. 29 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com ili O Blue I Water Technologies 6 2 Replacing R agents m v unik DEER ee hist heeded ied eee ete Lieder cet eee 31 6 3 Cleaning th Fitefaz ss stue meme nent mn de l eran 31 6 4 Shut Down and Winterizing su 31 6 5 Start up and Preventive Maintenance rrannrrnannvnnrnvnnrnrrvnnnrnnnnnnnrnrrensnrnnsnnnnsennenenn 32 6 5 1 Replacing Reagent Pump Head and Tubes sessesrssssrrsserrssrrrrssrrrrnsrsenss 32 6 6 Troubleshooting sssi me E dee AM AIRE ere 33 6 7 Replacing Components A 36 6 7 1 Replacing Flow Switch sus 36 6 7 2 Replacing Reagent Siphons ss 36 6 7 3 Replacing the reagent level sensor 36 6 7 4 Replacing Reagent PUMPS issus 37 6 7 5 Replacing Colorimeter ss 37 6 7 6 Replacing Colorimeter Solenoid Valve csccceecceeeeeeeeeeeeeeeeeceeeeeseaeeeseeeeeeeeeaas 38 6 7 7 Replacing Control Panel Module electronics card 38 6 7 8 Replacing V O Module nedre betente 38 6 7 9 Replacing Colorimetric Module 39 6 7 10 Module Software Update ss 39 Additional Measurements and Features rrrrnnronnrrnnnnnnvrnnnnnnrrnnnnnnrrnnrennrrnnrensrrnnrennrrnnrenn 39 7 1 Additional Measurement si 39 7 2 Free Total Chlorine Measurements sseeseeeseresrrssrssirssirssinssinssrissrinsrnnsrnnsrnnte 40 fed Installation T T 40 7 2 2 Installing DPD3 Reagent s
9. Blue I Water Technologies 2 Note Optional features appear in the selection as well Choose only a viable option e g choose NTU only if NTU card was ordered e Select read or control function for F CL only i If control was selected set control to Normal or invert and press OK f Select Set value for 4mA and press OK g Select Set value for 20mA and press OK h Select Set Test channel to be used for troubleshooting purposes or initial tests 2mA 4mA 12mA 20mA and press OK i Press Escape to return to the set up menu and repeat the above steps for all active 4 20mA Set the 4 20mA alarm output output value in case of measurement or communication error This is the 4 20mA output value that will indicate whenever an alarm condition exists or communication between the analyzer and 4 20 module is interrupted a on alarm go to option follows the 4 20mA output settings on the technician menu b Select on alarm output 2mA 4mA 20mA or hold Note The 4 20 alarm output is the output value that will be sent in case of an insufficient flow problem to the HYDROGUARD In case of low or high level i e low chlorine no 4 20mA alarm will be activated Confirming Operation and Communication Prior to connecting to the external monitoring or control system it is best to confirm that all desired outputs are working properly using a digital multimeter This must be done wit
10. Connect the top union to the valve and to the bottom of the Colorimeter unit and tighten 8 Connect the solenoid valve cable to the Colorimeter module 6 7 7 Replacing Control Panel Module electronics card Disconnect the power supply to the unit before opening the control unit 1 Disconnect the flat cable plug from the card 2 Unscrew the four 4 mounting screws 3 4 Put in the new card and tighten the 4 mounting screws Connect the flat cable plug to the card Figure 10 Replacing all types of electronic modules cards 6 7 8 Replacing I O Module Disconnect the power supply to the unit before opening the control unit 1 Disconnect the flat cable plug from the card 2 Unscrew the four 4 mounting screws 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 38 Cla Blue I Water Technologies 3 Putin the new card and tighten the 4 mounting screws 4 Connect the flat cable plug to the card 6 7 9 Replacing Colorimetric Module Disconnect the power supply to the unit before opening the control unit If pH ORP and or Temperature is being measured first remove the pH Redox and Temperature card 1 Disconnect the flat cable plug from the colorimetric card 2 Unscrew the four 4 mounting screws 3 Putin the new colorimetric card and tighten the 4 mounting screws 4 Connect the flat cable plug to the colorimetric card 6 7
11. Maintenance Table titi eege ege eee sad ae 29 Table 8 Alarm Description and Result 30 Table 9 Troubleshooting Table 33 Table 10 Additional Menus in the Operator Menu 40 Table 11 Additional Menus in the Technician Menu 40 Table 12 Modbus Configuration Options ss 54 Table 13 Modbus Communications Options ss 55 Table 14 Relays and their controlled dosing systems 61 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com vi Blue I Water Technologies 1 General Safety Precautions This section presents important information intended to ensure safe and effective use of this product Read the following carefully before handling the product These warnings and cautions must be followed carefully to avoid injury to yourself or damage to equipment Warning Only properly trained and licensed electricians should attempt to wire or service the electronic components of the analyzer controller There is an Electrical Shock Hazard when servicing this system Always verify that all electrical power source s are off before opening the analyzer controller unit or attempting to service electronic components or wiring Caution Extreme caution should be used when installing operating and maintaining the HYDROGUARD Analyzer Only properly trained technicians are authorized to install and maintain the analyzer controller Only properly trained and
12. Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 61 Note After each cycle of dosing please take into account the system cycle time e g the time it takes the chlorine to dissolve in the water reservoir before measuring the chlorine levels Set point Cl X Measured Cl X Cl P factor Y y One cycle of CI adding y Cl lt X Yes CI P factor too low y Se Change P factor Y AY Cl P factor OK af Yes X lt CI lt X 1 1 One ae of GI adding we Sea lt X lt CI lt X 1 1 CI P factor too high Yes CI gt T lt y a Change P factor y YAY CI P factor OK y Wait until CI lt X y One cycle of Cl adding lt CD wn y CI P factor OK Figure 16 P factor computation example 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 62 Step By Step Proportional Settings 1 Finish the installation of all controllers electrical water feeding systems and electrodes 2 Calibrate the controller to the water chemical values at the sample point 3 Set the proportional factor and the pump period of the chlorine and the pH at an initial setting 4 Letthe controller operate the chlorinator and the pH correction devices and make sure that chemicals are injected into the water 5 Watch the chlorine and pH as they change We recommend t
13. a A O Turn the power off to the analyzer Disconnect the two 2 red wires from the reagent level connector on the colorimetric module Remove the four 4 mounting screws Install the new reagent siphons Attach the four 4 mounting screws Connect the two 2 red wires to the colorimetric module 6 7 3 Replacing the reagent level sensor Turn the power off to the analyzer Disconnect the two 2 red wires from the reagent level connector on the colorimetric module Unscrew the old sensor by hand and pull out the sensor along with its 2 red wires Install the new sensor by first pushing the 2 red wires into the sensor tube Screw in the sensor by hand 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 36 O Blue I Water Technologies 6 Reconnect the 2 red wires to the colorimetric module 6 7 4 Replacing Reagent Pumps 1 Turn the power off to the analyzer 2 Disconnect both pipes from the reagent pump 3 Remove the four 4 mounting screws 4 Disconnect the Red and Blue wires from the Pumps connector on the colorimetric module 5 Install the new pump and reconnect in this order the pipes the 4 screws and the wires to the colorimeter module 6 Turn the reagent pumps on until reagents are injected into the colorimeter cell approximately 90 Sec Note If only the motor is to be replaced the pump head will need
14. and Installation HYDROGUARD requires a 115 120 or 200 230 VAC 50 60 Hz electrical power source on a separate 16A circuit in the plant room s electrical board The main HYDROGUARD power supply should be connected to a non dependent power supply so that the unit remains powered constantly The active relays should be connected to a dependent power supply interlocked power supply 4 5 1 Connecting the Main Electrical Power Note HG 702 default configuration is 115 120VAC unless 200 230VAC configuration was ordered The Main Power Supply may be connected to either 115 120 or 200 230VAC 50 60Hz Switching between voltages is accomplished by changing two 2 jumpers Figure 4 located above the main power connection to the left of the transformer Figure 5 amp 6 e For 115 120VAC a 1amp fuse should be used Figure 4 Jumper e For 200 230VAC a 0 5amp fuse should be used Note These changes must be completed prior to wiring 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 15 To change the configuration use jumpers J21 amp J22 on the I O card For 115 120VAC see the jumpers setting per Figure 5 For 200 230VAC see jumpers setting per Figure 6 Figure 5 115 120VAC setting Figure 6 200 230VAC setting Caution Before making a connection to a power source confirm that both jumpers are located on the correct voltage and that the appropriate fuse i
15. asample of water from the flow cell 2 Test the sample using an accurate digital turbidly meter 3 Press Menu until NTUI Calibrated to or NTUh Calibrated to appears in the LCD display If calibrating below 1 0 NTU use NTUI low if calibrating above 1 0 NTU use NTUh high 4 Press OK 5 Enter the password Press the up arrow or down arrow until the password is reached 6 Press OK 7 The value that appears is the last calibrated value 8 Press OK again 9 Press the up arrow or down arrow until the value is the same as the independent digital turbidity meter 10 Press OK to save the new calibration or Esc to abort without saving 11 Press Esc to return to the main display Note Only 1 Turbidity calibration will be active If the measured Turbidity is less than 1 0 only the NTUI calibration will be active if the turbidity is greater than 1 0 only the NTUh calibration will be active 7 4 4 2 Cleaning the Turbidity Sensor The turbidity meter will need to be periodically cleaned to ensure proper operation and reliability The cleaning frequency will depend on the water source being tested The meter should be cleaned whenever the measurement accuracy is questionable and before calibration 1 Turn off power to the analyzer 2 Shut off the flow to the turbidity flow cell and remove the turbidity meter 3 Rinse out the flow assembly with clean water to remove any sediment that may have been trapped in the
16. being maintained at low levels Therefore this alarm feature may be turned off For cases when the Cl level is always expected to be above 0 5ppm Blue Water Technologies highly recommends that this alarm remain in use except for start up pH p factor Proportional Factor for pH Relay 3 pH pump period 1 pump cycle on off time for pH Relay 3 pH pump freq pH pump max pulses min 0 for on off pump pH balance type To select if Acid or Base is being added to adjust pH Flow sensor Turns Flow sensor on off optional module Flow rate Choose between metric and US units Celsius Fahrenheit Choose between metric and US units Turbidity Turns Turbidity module on off optional module NTU wiper interval Cleaning glass interval for turbidity module optional module Minutes Current time for Data Logger Hour Current time for Data Logger Day Current time for Data Logger Month Current time for Data Logger Year Current time for Data Logger Recording interval Time interval between readings to be stored on the on board data logger Tot chlor Turns Total chlorine measurements on off will only operate in the Free Or Total FOT version Chlor ratio The ratio of Free Chlorine measurements to Total Chlorine measurements View free chlor Displays measurement value on LCD View pH Displays measurement value on LCD View ORP Displays measurement value on LCD
17. cell will flash continuously until the reagents are replaced or they are depleted resulting ina NO REAGENTS alarm and an opening of the chlorine relays preventing any additional chlorine from being added Prior to receiving the NO REAGENTS alarm replace the reagents as described in Section 5 2 Note Once mixed salt into the solution the reagents have a shelf life of 2 months and will lose accuracy if used beyond this time limit 6 3 Cleaning the Filter The HYDROGUARD unit is sent to the site mounted on a mounting panel Several other units are mounted on the panel alongside the analyzer including a water filter which filters out sand rust course debris oil and other impurities in the sampled water These impurities may clog the HYDROGUARD s internal pipes contaminate the sensors or dirty the analyzing cell reducing its accuracy This filter must be cleaned regularly as it becomes clogged with debris and impurities The frequency at which the filter requires cleaning depends entirely on how much debris is in the water The following procedure describes how to remove clean inspect and if necessary replace HYDROGUARD s water filter 1 Locate the water filter mounted below the HYDROGUARD unit and the valve that is located on the water supply pipe 2 Turn off water supply to the filter and remove the filter 3 Remove any loose debris with your fingers 4 Wash the filter under running water 5 Inspect the filter and re
18. com 20 5 3 1 HYDROGUARD Control Panel The HYDROGUARD control panel is a simple intuitive interface for monitoring and controlling water quality with the following components 150 F CI 7 62 pH Measurement Display 1 235 NTU 498 uS Menus and Alarm Display Buttons for Menu Navigation Table 1 Control panel structure Figure 9 HydroGuard Control Panel LCD Display At the top of the control panel is an LCD display which shows all measured variables at top and all Alarms and Menus at bottom Menu Button Enters setting change mode and accepts setting change Up Down Arrows Changes value up or down When an alarm is issued the bottom row of the LCD displays the alarm Pressing the up and down arrows together will display the Langelier index for approximately five 5 seconds and then returns to the previous display mode 5 3 2 Operator Menu HYDROGUARD has two menu levels Operator and Technician The Operator menu includes settings that may be controlled by on site operators The Technician menu includes settings and calibrations that should be restricted to specially trained HYDROGUARD maintenance technicians Each menu has a separate password The technician level password may be used whenever a password is required however the operator password will only be accepted in the operator menu 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 21 O
19. container when the countdown timer reaches zero 0 3 Test the water sample for chlorine using a digital photometer 4 Press Menu until Cl Calibrated to appears in the LCD display The top line will display Cl Calibrated to and a number The number displayed is the last value entered for the calibration The bottom line will display Cl Sensor was and a number This number is the sensor reading without any calibration at the time of the last calibration If there is a large discrepancy between the above two numbers the sensor was calibrated improperly or there is a problem with the analyzer The analyzer uses the calibrated value as shown on the main screen to determine dosing rates Note Chlorine calibration should always be performed within 25 of the set point If current chlorine level is 25 above or below the set point do not perform calibration until the chlorine level is closer to the set point 5 Press OK 6 Enter the password Press the up arrow or down arrow until the password is reached 7 Press OK 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 27 Cie Blue I Water Technologies 8 Press OK again The display will now show Calibrate Cl to on the top line and Sensor Reading on the bottom line The Sensor Reading is the current reading of the sensor with no calibration The Calibrate CI to value
20. flow cell 4 Wash the turbidity meter under clean water and a cloth to remove any debris and oil Be careful not to scratch the sensor covers 5 If installed inspect the wiper for signs of wear and replace if necessary 6 Reinstall the meter and turn the flow back to the meter 7 Confirm that the meter is operating properly and that the flow cell is sealed 7 4 4 3 Replacing Components Replacing the Turbidity Meter 1 Turn off the inlet and outlet water to the flow cell and the power to the analyzer 2 Open the door of the control module 3 Remove the 5 wires from the bottom of the Turbidity input module 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 48 O Blue I Water Technologies 4 Remove the meter from the flow cell by unscrewing the cap and pulling gently 5 Install the new meter in the flow cell 6 Route the wires back to the turbidity module and reconnect the 5 wires following the color coding on the module 7 Restart the flow and turn the power on 8 Confirm that proper operation has been restored Replacing Turbidity Input Module Disconnect the power supply to the unit before opening the control unit 1 Disconnect the flat cable plug from the card 2 Disconnect all terminal blocks 3 Unscrew the four 4 mounting screws 4 Putin the new card and tighten the 4 mounting screws 5 Connect the flat cable plug to the card
21. flow switch If an external switch is not connected a jumper must be installed for the analyzer to operate properly 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 17 OBluel e Flow Meter Connection for 2 or 3 wire flow meter The analyzer will not look for the flow meter connection unless the option is turned ON in the technician menu therefore no jumper is required if a meter is not installed Caution Electrical connections depicted in this section are ONLY recommendations All electrical connections should comply with National Electrical code NEC and all local regulations 5 First Time Operation and Calibration 5 1 Installing Additional Sensors and Meters Install all additional sensors and meters and connect to the HG 702 main system following the supplemental manuals for each sensor or meter 5 2 Installing Reagents For Free Chlorine Only measurements DPD1 reagent set will be used For Total Chlorine Only measurements DPD4 reagent set will be used For both Free and Total CI measurements DPD1 and DPD3 reagent sets will be used The reagents should be installed according to the labels located behind the reagent holder For systems ordered previously please refer to the following installation For Free Cl Only For Total CI Only 1 Free Chlorine Indicator DPD 1 1 Total Chlorine Indicator DPD 4 2 Free Chlorine Buffer DPD 1 2 Total Chlor
22. is reached b Press OK The parameter name and current setting appear in the LCD display Note The technician menu password is different from the Operator menu password The default Technician menu password is 456 and if lost can only be reset by replacing the chipset 4 Press OK again The LCD display shows the parameter and the current setting 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 52 5 Enter the new parameter setting a Press the up arrow or down arrow until the desired parameter value is reached according to the options listed in Table 13 b The second row of the menu display below the value that is being changed shows the current value 6 Press Enter to save the new setting or Esc to abort without saving the new setting 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 53 Table 12 Modbus Configuration Options Bit 4 EM 3 Bit 2 Bit 1 Bit 0 Parameters 2stop SE 19200bps Parity Even Parity 1 stop bit floating point 9600bps Odd No parity 0 0 0 0 0 0 1 0 0 0 0 1 2 0 0 0 1 0 3 0 0 0 1 1 4 0 0 1 0 0 5 0 0 1 0 1 6 0 0 1 1 0 7 0 0 1 1 1 8 0 1 0 0 0 9 0 1 0 0 0 10 0 1 0 0 1 11 0 1 0 1 0 12 0 1 0 1 1 B Ve Bit 4 pit 3 Bit 2 Bit 1 Bit 0 valu
23. is supplied from the factory However in addition to the standard free chlorine set up some additional steps are required 7 2 2 Installing DPD3 Reagent The DPD 3 reagent bottle is installed the same way as the DPD 1 and Buffer solution bottles The DPD 3 reagent will be in a 500 ml bottle labeled as DPD 3 1 Place the reagent bottle in position a Remove the cap from the reagent bottles Place the opening of the reagent bottle below the bottle siphon on the right Lift the bottle up until the opening reaches the bottle siphon cap ong Push the lever above the siphon cover away from you and push the reagent bottle up e Push the bottom of the bottle into position 2 Prime the reagent pump for ninety 90 seconds until the reagent drops are visible through the DPD 3 needles a Turn reagent pumps on from the operator menu 7 2 3 Additional Menus and First Time Set up In order to operate the free and total chlorine measurements a few additional menus are required The menus and their descriptions are listed below The settings in these menus will need to be configured before operation The tables below outline the menus specific to Total Chlorine monitoring in the operator and technician menu Table 10 Additional Menus in the Operator Menu Description Alarm when the Total Chlorine is above this value Alarm when the Combined Chlorine is above this value Table 11 Additional Menus in the Technician Menu Descript
24. is the new value which you want to set 9 Press the up arrow or down arrow until the value is the same as the value given by the digital photometer Note The HYDROGUARD will not allow calibration above 0 5ppm from the un calibrated sensor reading If the value given by the digital photometer is more than 0 5ppm from the currently calibrated value retest the water in the digital photometer If the value is still more than 0 5ppm above or below the calibrated value try testing the water with another device If there is still a deviation of more than 0 5ppm between the new digital photometer there may be a problem with the HYDROGUARD colorimeter which cannot be corrected by calibration alone 10 Press OK to save the new calibration or Esc to abort without saving 11 Press Esc to return to the main display 5 4 2 Calibrating other Sensors and Meters Calibration of other sensors and meters is similar to the chlorine calibration and requires the use of a reliable external testing device or standard solution See the supplemental manuals for each sensor or meter for specific information on calibration 5 5 Calibration and Initial Operation Checklist Before leaving the site perform the procedure in this section and record the requested values Calibrate the following HYDROGUARD parameters and enter the information into the table below If pH and ORP are reading slightly low do not calibrate as they will continue to increase for
25. main display 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 42 O Blue I Water Technologies ORP Redox Calibration ORP is calibrated using an ORP Standard Solution A standard closest to the normal operating value should be used for calibration 1 Shut off the water inlet and outlet from the flow cell 2 Remove the ORP sensor and PT 100 temperature probe from the flow cell 3 Wipe sensor probe with a dry cloth and submerge it and the temperature probe into a cup with the ORP Standard Solution and wait for the reading to stabilize Note The reading will not stabilize if the temperature probe is not also in the buffer solution 4 Press Menu until ORP Calibrated to appears in the LCD display 5 Press OK 6 Enter the password Press the up arrow or down arrow until the password is reached 7 Press OK 8 Press OK again 9 Press the up arrow or down arrow until the value is the same as the value printed on the label of the standard solution 10 Press OK to save the new calibration or Esc to abort without saving 11 Press Esc to return to the main display Note When the HYDROGUARD is initially turned on the pH and ORP readings will continue to rise for the first 24 48 hours If calibration is required it is best to wait until the readings have stabilized or recalibrate when the readings have stabilized Temperature Calibration Tak
26. point it will control the dosing systems to slow down to a lower speed i e 60 As chemical levels get even closer to the set point the dosing system will slow down even more i e 30 and so on until the chemical level gets to the set point Proportional Factor Proportional control of chemical dosing requires configuration according to various factors The primary factors are the ratio between the system size and the rate the chemical dosing systems can feed chemicals and the delay time between when the chemical level changes and when it is sensed by the controller In large systems changes in chemical levels occur slowly The dosing systems must feed large amounts of chemicals for a long period of time in order for a change to be noticed The chemicals also disperse slowly in larger systems Smaller systems on the other hand react much more quickly The length of time between the change and when the controller identifies the change also affects proportional control The controller can only identify water chemical levels after they have been distributed throughout the system and have returned to the analyzer This lag time varies for each system and in general systems with shorter lag times will operate better with high P factors and systems with longer lag times will operate better with low P factors The following figure explains the process of determining the chlorine P factor 18 Ha melacha St Rosh Ha ayin 4809148 Israel
27. the colorimeter assembly Make sure the The piston is not moving No chlorine colorimeter connection is Stuck piston A5 properly within the measurements No well connected to the colorimeter chlorine dosing mixer on the control panel The other possibility is that there is not enough flow to the colorimeter Increase the flow to the analyzer Clean the tube with a Impurities have accumulated No chlorine ER Unclean cell A6 in the pe analyzing jr ee AG enough flow to the colorimeter Increase the flow to the analyzer LED in colorimeter is not No chlorine Re solder LED Replace light A7 working Insufficient measurements No connection Change connection on the board chlorine dosing colorimeter assembly Reagents are below 20 Message only NOT an Bo A8 Notifies how many days until gd error Indicates reagents the reagents are depleted are needed soon Compare to manual f reading If normal at A9 STEE SEN DE OwO No chlorine dosing operation will be around 0 1 ppm range then disable alarm 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com O Blue I Water Technologies High ORP A10 Description ORP above upper limit No chlorine dosing as safety against over chlorination Solution Suggestion Compare to manual reading and recalibrate if necessary Check unstable reading due to poor grounding Increase high low ORP le
28. u la formation ad quate et d ment habilit 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 8 O Blue I Water Technologies 2 Preface 2 1 Intended Use This manual is for qualified and trained service technicians who will install and service the HYDROGUARD HG 702 Water Quality Analyzer It provides instructions on how to install the HYDROGUARD system how to integrate it with external chemical dosing systems and how to calibrate operate and maintain the system 2 2 Safety Precautions Warning Only properly trained and licensed electricians should attempt to wire or service the electronic components of the analyzer There is an Electrical Shock Hazard when servicing this system Always verify that all electrical power source s are off before opening the analyzer unit or attempting to service electronic components or wiring Caution Extreme caution should be used when installing operating and maintaining the HYDROGUARD HG 702 Water Quality Analyzer and Controller Only properly trained technicians are authorized to install and maintain the analyzer Only properly trained and licensed electricians should attempt any change to the system s electrical components Only properly trained and licensed operators should attempt to make any changes to chemical dosing levels Always follow local health and safety regulations when performing any service
29. 10 Module Software Update Each electronic module card has a microcontroller chip IC with its own unique software Whenever a module s software is updated its chip must be replaced by a new version with the new software 1 Turn OFF the power to HYDROGUARD Locate the chip that needs to be replaced 3 Remove the chip carefully by prying up each end a little at a time with a thin screwdriver Install the new chip in the same location Please note in the figure that the chip and the board each have a directional mark The chip must be positioned so that these directional marks are aligned The control panel has no IC it is necessary to replace the module electronics card Warning Installing the chip in the wrong direction will damage the system and can create an electrical fire hazard Directional Mark Figure 11 Installing new chipset 7 Additional Measurements and Features 7 1 Additional Measurements The following additional measurements may be added to the HG 702 e Free Total Chlorine monitoring instead of just free or total e Turbidity e Conductivity e Flow Rate e pH 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 39 O Blue I Water Technologies e Redox ORP e Temperature 7 2 Free Total Chlorine Measurements 7 2 1 Installation The Free Cl Total Cl measurements are an optional feature that
30. 2 Mounting Panel ss 14 Figure 3 Flow Cell and Colorimeter Inlet and Outlet rannnnnonrnnnnrrnnnnrnnonrnnrnrrrnnnrnnnnnnnrenrenn 15 Figure A le e 15 Figure 5 115 120VAG E 16 Figure 6 200 230VAC setting iii 16 Figure 7 Flow cell and Colorimeter Inlet and outlet nna 18 Figure 8 Reagent handling avnarmervnaanines avmseubakvdnsdecnnmedvaveamnneennnn 19 Figure 9 HydroGuard Control Panel sisi 21 Figure 10 Replacing all types of electronic modules cards 38 Figure 11 Installing new chipset 39 Figure 12 Turbidity Sensor and Flow Cell 46 Figure 13 Connecting Turbidity Sensor to Turbidity Module 46 Figure 14 Relay positions on board nanten nant 60 Figure 15 Proportional Control of Chemical Dosing eesseesseesseeseesseseseerereennnsnnnsnnnsennsen nens 61 Figure 16 P factor computation example sss sessnssrsisnrsraaiannannninnns annann RNE 62 Table of Tables Table 1 Control panel structure 21 Table 2 Operator Menu Functions and Descriptions 22 Table 3 Operator s Menu amp variables limits rrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrrnrrrnrsrnnsnnnnrnrnrnnnrnnsnnse 23 Table 4 Technician Menu Functions and Descrptons 25 Table 5 Technician Menu and Variable Limits 0 0 0 0 ccc eeeceeeeeneeeeeeeneeeeeeaaeeeeeeaaeeeeeeaeeeeeeaas 26 Table 6 Calibration Table ivessceress ce secteces moment nn mms ner 28 Table 7
31. Alkalinity Manually entered for Langelier Index Total Hardness Manually entered for Langelier Index TDS Manually entered for Langelier Index T CI calibrated to sensor value was Most recent calibration amp sensor value at calibration for troubleshooting purposes Total Cl high alarm Initiates an alarm when Total Cl is above value Comb CI high alarm Initiates an alarm when combined Free amp total Cl is above value ORP Emergency mode Allows ORP mode to be used in case there is a CI measurement problem If a problem occurs with the colorimeter unclean cell stuck piston communication error or the customer runs out of reagents the analyzer may be temporarily operated in ORP Emergency Mode 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 22 Blue I Water Technologies Function Name Description This mode must be started manually by scrolling to the ORP Emergency Mode Menu entering the password and switching the mode to ON If no colorimeter problem is present the analyzer will not allow this mode to be entered When in ORP Emergency mode the ORP set point will be used to control Relay 1 primary Cl relay When the problem is corrected the analyzer will automatically resume operation in normal mode If not corrected after 3 5 days the analyzer will close Relay 1 Language Choice of la
32. HYDROGUARD is simple to use Its straight forward control panel and parameters menu make chemical balance control an easy task All basic information can be viewed at a glance and changing settings is as simple as scrolling through the menu and adjusting the current settings 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 9 O Blue I Water Technologies 3 2 Measurements and Features The HYDROGUARD 702 comes standard with chlorine measurement and can be configured to measure any combination of the following water quality parameters e Free Chlorine e Total Chlorine e Both Free Chlorine and Total Chlorine Optional Measurements e Turbidity e Temperature or Conductivity e ORP Redox and Temperature e Flow Rate Optional communication protocol e Modbus Protocol e Blue Protocol Communication options e Internal 4 to 20 mA outputs up to 6 channels e Wireless modem e Ethernet 3 2 1 Wireless Management Package An advanced and unique HYDROGUARD option is the wireless modem which provides web based monitoring of up to 5 analyzers This cellular communicator collects HYDROGUARD s alarms and readings and transmits them to a web based application server The information is easily accessed via the Internet or mobile phone The wireless modem is an optional module Note Not all cellular companies support this wireless modem Please contact Blue Water Techno
33. Low Flow Discrete Input 10033 No Reagents Discrete Input 10034 Table 13 continued on following page 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 55 O Blue I Water Technologies Table 13 Modbus Communications Options continued Parameter s Name Type Address Notes Chlorine lt 0 1 Discrete Input 10035 ORP gt XXX Discrete Input 10036 Unclean cell Discrete Input 10037 Replace light Discrete Input 10038 Low chlor Discrete Input 10039 High chlor Discrete Input 10040 Low Ph Discrete Input 10041 High Ph Discrete Input 10042 Low ORP Discrete Input 10043 High NTU Discrete Input 10044 External OFF Discrete Input 10046 Colorimetr comm error Discrete Input 10047 High total chlor Discrete Input 10048 High combine chlorine Discrete Input 10049 No DPD3 Discrete Input 10050 Chlor overfeed time Discrete Input 10051 Ph overfeed time Discrete Input 10052 Piston stuck Discrete Input 10053 Low temperature Discrete Input 10054 High temperature Discrete Input 10055 Low conductivity alarm Discrete Input 10056 High conductivity alarm Discrete Input 10057 Parameter s Name Type Address Notes Free chlorine Input Register 30000 Floating point IEEE 754 pH Input Register 30002 Floating
34. Measuring cell flow rate 35L h 60I h 0 3 bar 4 4 psi to 1 bar 14 5 Inlet pressure psi Outlet pressure closed cell Flow switch type FLOW MEASUREMENT Up to 0 9 bar 13 psi Rotary switch Frequency input via I O card or 4 20mA input via NTU card Measurement range 0 1 000 m3 hour pH VALUE CONTROL Control function Characteristics Relay function P or PI or On Off or frequency Normal Inverted Pulse Length proportional controller Pulse Frequency proportional controller ORP REDOX CONTROL Control function CHLORINE CONTROL 1 Control function PI or On Off or frequency Proportional band Yes Relay function Pulse Length proportional controller Pulse Frequency proportional controller High alarm as chlorine override CHLORINE CONTROL 2 Control function On Off Proportional band No Relay function Pulse Length proportional controller Pulse Frequency proportional controller Memory 256Kbit Lines 1000 Recording interval 1 360 min Event logger Yes Total relay on time Yes Operation password Yes Technician password Yes Optional Feature 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 64 O Blue I Water Technologies No part of this publication may be reproduced transmitted transcribed stored in a retrieval system or translated into any language or any computer language in any form or by any third party without the prior wr
35. Minutes 1 59 n a min Hour 0 23 n a hour Day 1 31 n a day Month 1 12 n a month Year 1 99 n a year Recording interval 1 240 0 03 min Tot chlor OFF ON OFF Chlor ratio 1 30 1 View free chlor OFF ON ON View pH OFF ON ON View ORP OFF ON ON View conductivity OFF ON ON Address 1 32 1 Ver n a n a n a Max flow range 9 200 999 200 M7 hour or GPM 4 20mA Output Settings Built in ch 1 2 1 4 10 NTU ch 1 4 1 Parameter F CL read or control Cl only Read Set value for 4mA 4 20 4 ppm Set value for 20mA 4 20 20 ppm Set Test channel 2 20 2 mA On alarm go to 2 20 2 mA Reagent pump time 0 8 2 5 1 1 sec Modbus com format 0 31 0 Operator password 1 999 123 Technical password 1 999 456 See Optional features 5 3 5 Configuring Settings in the Technician Menu Navigation within the Technician Menu is identical to the operator menu 1 To enter the Technician menu press Menu to enter the operator menu and then press the up arrow and down arrow simultaneously until the menu display changes 2 Locate the desired parameter in the menu 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 26 O Blue I Water Technologies a Press Menu until the desired parameter name appears in the LCD display b Press OK Enter Password 100 appears in the LCD display 3 Enter the Technician menu passw
36. OBluel HYDROGUARD HG 702 Water Quality Analyzer User Manual March 2015 Document ID HG702UM1 36 O Blue I Water Technologies No part of this publication may be reproduced transmitted transcribed stored in a retrieval system or translated into any language or any computer language in any form or by any third party without the prior written permission of Blue Water Technologies Ltd Disclaimer Blue Water Technologies Ltd does not accept any responsibility for any damage caused to its products by unauthorized personnel Use of non Blue Water Technologies reagents and or replacement parts will void all warranties Trademark Acknowledgements HG 702 is a registered trademark of Blue Water Technologies Ltd Copyright 2014 by Blue Water Technologies Ltd 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com ii Table of Contents 1 General Safety Precautions sisi 7 2 PROTACC EE EE ddan tse Bennet eege 9 2 1 Intended USE uns amis ane ein dene E 9 2 2 Safety Te E 9 Bi EE EES d 9 3 1 The HYDROGUARD Solution iii 9 3 2 Measurements and Features 10 3 2 1 Wireless Management Package AA 10 3 3 System Components sienne SEENEN 10 4 AMS TAN TOM ose 4425 E nn dits ee titane 13 4 1 Working Environment tssneienesisneihentsssntmiiaesdte aiment 13 4 2 Selecting a Location sii nm M ete Re ee me nt 13 4 3 Site Requirements and In
37. ally Troubleshooting Occasionally problems will occur with the analyzer readings or chemical dosing These problems are most often simple to correct The troubleshooting section provides an outline to follow to help correct the problems easily 6 1 Monitoring HYDROGUARD Alarms HYDROGUARD issues alarms when it detects chemical levels that are above or below the allowed range Every alarm is automatically displayed in the LCD status display and logged in the data logger Most deviations in chemical levels however are automatically corrected Thus the internal alarms do not immediately activate an external alarm A delay mechanism prevents false alarms from minor deviations that were automatically corrected The external alarm is only activated after an internal alarm has been continuously active for a certain period of time as defined by the operator The Alarm Delay command in the Operator menu sets the number of seconds HYDROGUARD waits before closing Relay 5 the relay that operates the external alarm Only one alarm is 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 29 O Blue I Water Technologies shown on the screen at a time based on importance and the order in which it should be fixed For example if the pH is high and the ORP is low only the pH alarm will be indicated since lowering the pH will likely also correct the low ORP All of the alarms are presen
38. arm Initiates an alarm when ORP is below value ORP high alarm Initiates an alarm when ORP is above value amp opens Cl relays 1 amp 2 Temp calibrated to sensor value was Most recent calibration amp sensor value at calibration for troubleshooting purposes Temp low alarm Initiates an alarm when Temp is below value Temp high alarm Initiates an alarm when Temp is above value Turbidity set point Controls Turbidity relay 4 optional module NTUI calibrated to sensor value was Most recent low NTU amp sensor value at calibration for troubleshooting purposes NTUh calibrated to sensor value was Most recent high NTU amp sensor value at calibration for troubleshooting purposes Turbidity high alarm Initiates an alarm when Turbidity is above value Conduc set point Controls Conductivity relay 6 when conductivity is available Conduc calibrated to sensor value was Most recent conductivity amp sensor value at calibration for troubleshooting purposes Conduc low alarm Initiates an alarm when Conductivity is below value Conduc high alarm Initiates an alarm when Conductivity is above value Conduc active time The activations duration of the coagulants pump Alarm delay Time delay before alarm relay 5 closes Flow low limit Low limit for external flow meter Flow k factor k factor for external flow meter Total
39. ary 6 Replace all additional sensors and meters close the sampling valve and turn on flow immediately to re wet any probes N Recalibrate the analyzer Note ORP and pH probes will likely require 24 48 hours to re stabilize and will require re calibration at that time 6 5 1 Replacing Reagent Pump Head and Tubes If the reagent pump head and or tubes are cracked appear significantly worn or are no longer functioning properly they should be replaced to ensure consistent operation and control 1 Turn off the power to the HYDROGUARD analyzer 2 Remove the tubes from the pump head and the needles in the colorimeter cap by holding the top of each needle and pulling the tube gently 3 Remove the tubes from the reagent bottles and wipe off any excess reagent the DPD will stain so be careful 4 Unscrew the two 2 screws on the face of the pump head Save the screws 5 Remove the pump head by pulling gently and sliding the pump head off of the motor assembly 6 Slide the new pump head onto the motor assembly ensuring that the slot in the pump head matches the notch in the motor shaft DO NOT force the pump head onto the motor assembly it should easily slide into place 7 Rotate the pump head and slide the alignment pins into the motor assembly 8 Replace the two 2 screws to reattach the pump head 9 Attach the new pump tubes by pressing the tubes onto the connectors on the end of the pump head 10 Insert the
40. balance in closed loop systems The Control Panel Module also provides data to external communication devices such as the 4 20mA outputs or the wireless communication package Keyboard Panel mounted on the cover of the control module it functions as HYDROGUARD s user interface The control panel displays current measurements and indicates alarms All settings and adjustments are performed through the control panel Colorimeter Module controls the colorimeter and associated components such as the reagent pumps and solenoid valve It accurately calculates the chlorine level pH Redox Temp Module receives the signal from the pH Redox and temperature probes Internal 4 20 Input Module contains connections for Turbidity Conductivity meter and the 4 20 Flow Meter Internal 4 20 Output Module provides up to four 4 20mA outputs for any measured variable Optional Module 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 11 Colorimeter water outlet Regent Injection View window Site t i Lil Pa Analyzing r Unit m5 I e dur KZ Solenoid valve Reagent Pumps NE Colorimeter Drain Control Unit Reagent Siphon Caps Reagent Bottles SET Water Intake Filter Temperature Module VO Module Figure 1 HYDROGUARD HG 702 Main Components 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fa
41. bar Hardware and Plumbing Installation 1 Mount the Turbidity Flow Cell using the supplied bracket or other mounting hardware as appropriate such that the inlet and outlet ports are horizontal and the flow tube extends down 2 Insert the sensor into the opening of the flow tube ensuring that the notch in the top of the opening matches the rod on the sensor 3 Hand tighten the connector to secure the sensor and seal the turbidity flow cell 4 Connect the water supply to the turbidity flow cell Follow the flow indicated by the arrow on the flow cell A Without bubble remover B With bubble remover 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 45 H Blue I Water Technologies Figure 12 Turbidity Sensor and Flow Cell The flow rate should be between 0 25 and 1 GPM 15 60 gal hr or 50 225 L hr and the pressure should not exceed 30psi 2 bar The inlet and outlet connections are FNPT Electrical Installation 1 Install the Turbidity Module electronics card on the inside bottom of the control panel door using the supplied screws 2 Connect the turbidity module to the UO module using the supplied ribbon cable and any open connector the connectors on both boards operate in parallel 3 Pass the sensor cable through an open tight Cable Gland Pg on the bottom of the analyzer 4 Connect the wires from the sensor cable to the terminal blo
42. ck on the lower left corner of the Turbidity Module following the color order indicated on the module Figure 13 Connecting Turbidity Sensor to Turbidity Module The sensor cable may be cut or extended up to a maximum distance of 650 feet 200m as needed If the turbidity relay is not going to be connected to any external equipment the installation is complete If the relay will be used to operate equipment based on the turbidity set point the following steps in Relay Wiring and Use will need to be followed 7 4 2 Relay Wiring and Use Wiring of the Turbidity Relay NTU relay is identical to wiring of all other relays and should be connected to a dependent interlocked power supply to prevent operation of equipment when the water supply is not active Likewise it operates based on closed loop control The line live wire of the pump dependent power source connects to the connection labeled Common C on the NTU relay The line wire of the controlled external turbidity equipment is connected to the normally open NO or normally closed NC connection of each relay as appropriate Normally Open means that the relay will be open i e no power from the relay until the analyzer calls for power Normally Closed means that the relay will be closed i e power from the relay until the analyzer calls to stop power 1 Turn OFF all power sources to the analyzer 2 Connect the earth ground wire of the power supply to the ground return wi
43. d the 4 20mA Control Output Cl relay 2 will still be controlled based on Cl Set Point 2 Once the Cl Shock Mode is turned ON the controller controls the Cl Shock Set Point for the user selected Duration and then automatically shuts Cl Chlorination Mode OFF Then the controller returns to operating the Cl Set Point 1 To turn on Cl Shock Mode 4 Enter the Cl Shock Set point then press OK 5 Enter the Duration then press OK 6 Turn Cl Shock Mode ON You will also need to adjust the Cl P factor technician menu A low P factor will make slower changes to Cl dosing a high P factor will make faster changes to Cl dosing If you have trouble reaching the Cl set point use a higher P factor If you greatly overshoot the set point use a lower P factor 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 59 O Blue I Water Technologies Appendix A Relays and Closed Loop Control There are 6 dry contact relays on the I O module Five of the relays may be used for direct control of closed loop systems All of the relays may be used as dry contacts and will operate based on the settings specifically the set points selected in the operator menu Connecting external equipment to the relays This is only required if the relays are being used to power and control external dosing equipment The relays will act as dry contacts if no power is supplied A dependent power sup
44. dures should only be performed by properly qualified and trained HYDROGUARD analyzer technicians Warning Disconnect all power supplies to the HYDROGUARD analyzer before opening the control unit door Replacing any parts of HYDROGUARD without the expressed written authorization of Blue Water Technologies Ltd or the qualified representative who supplied the product may void the warranty Blue Water Technologies Ltd takes no responsibility written or implied for installation or maintenance of HYDROGUARD that is not performed by a properly trained and certified HYDROGUARD technician 6 7 1 Replacing Flow Switch 1 6 0 Turn off the inlet and outlet water to the flow cell and the power to the analyzer Open the doors of both the analyzing module and the control module Locate the flow switch attached to the flow cell Disconnect the flow switch wires from the I O module Remove the inlet connection to the old flow switch Remove the flow switch from the flow cell Pull the flow switch wires gently to completely remove them from the analyzer Insert the new flow switch on the flow cell Insert the inlet connection on the flow switch 10 Route the flow switch wires back to the connection on the I O module and connect the wires to the input switch terminal block 11 Close the analyzer doors and turn on the water and power and ensure proper operation 6 7 2 Replacing Reagent Siphons 1 2 3
45. e 2StP T 19200bps Parity Even Parity 1 stop bit floating point 9600bps Odd No parity 13 0 1 1 0 0 14 0 1 1 0 1 15 0 1 1 1 0 16 0 1 1 1 1 17 1 0 0 0 0 18 1 0 0 0 1 19 1 0 0 1 0 20 1 0 0 1 1 21 1 0 1 0 0 22 1 0 1 0 1 23 1 0 1 1 0 24 1 0 1 1 1 25 1 1 0 0 0 26 1 1 0 0 1 27 1 1 0 1 0 28 1 1 0 1 1 29 1 1 1 0 0 30 1 1 1 1 0 31 1 1 1 1 1 Modbus communications mapping is detailed in Table 13 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 54 O Blue I Water Technologies Table 13 Modbus Communications Options Parameter s Name Type Address Notes Chlor main pump Coil 0 Chlor Addition pump Coil 1 Acid Base Pump Coil 2 Turbidity cleaner Coil 3 Temperature control Coil 4 Alarm Lamp Coil 5 Parameter s Name Type Address Notes Low Reagent Discrete Input 10015 Alkali Acid Discrete Input 10016 Flow sensor connection Discrete Input 10017 oc Discrete Input 10018 Chlorine averaging enable Discrete Input 10019 Chlorine lt 0 1 alarm enable Discrete Input 10020 Celsius Fahrenheit Discrete Input 10021 Total Chlorine On Off Discrete Input 10022 M3 H GPM Discrete Input 10023 Free chlorine On Off Discrete Input 10024 ORP On Off Discrete Input 10025 pH On Off Discrete Input 10026 Sul om ENN Discrete Input 10027 No Flow Discrete Input 10032
46. e a sample of water from the flow cell 1 Insert a digital thermometer into the sample N Wait for the thermometer reading to stabilize WK Press Menu until Temperature Calibrated to appears in the LCD display Press OK Enter the password Press the up arrow or down arrow until the password is reached O OO A Press OK The value that appears is the last calibrated value Co N Press OK again 9 Press the up arrow or down arrow until the value is the same as the independent digital thermometer 10 Press OK to save the new calibration or Esc to abort without saving 11 Press Esc to return to the main display 7 3 2 2 Replacing Sensors Replacing the pH or ORP sensor 1 Turn off the inlet and outlet water to the flow cell and the power to the analyzer 2 Open the doors of both the analyzing module and the control module 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 43 3 Locate the sensor in the flow cell that is to be replaced The specific sensor may be identified by the label on the wire or by tracing the wire from the control panel back to the sensor 4 Remove the old sensor from the flow cell a Unplug the sensor s wires from the sensor by grabbing the connector at the top end of the sensor and unscrewing the connector b Unscrew the sensor from the flow cell c Pullthe sensor up until its gla
47. esasine AS a aA 40 7 2 3 Additional Menus and First Time Set up cecccececeeeeeeeeeeeeeceeeeeeeaeeeeeeeeeeeeetes 40 7 2 4 Activate Total Chlorine Monitoring 40 7 2 5 Routine Maintenance ceiver cee tive atest een eee beate eiere 41 7 2 5 1 Reagent Replacement sissies serien ss 41 1 2 56 2 Gallbratloh un nike ditt ales esha th diedvedeneteahica eased usanne 41 7 3 pH ORP and Temperature Measurements nees 41 LCE Le TEE 41 7 3 2 Routine Maintenance sn 42 92 NEE ere Te 42 7822 Replacing Deeg oeatueeideer eiegegt name hu rente eg nende 43 7 3 3 Shut down and Wimtertzinmg 44 7 4 Turbidity Measurements serge NEESS EENS EES 45 ch INStANatiIQNE iere NE e dee eegene 45 7 4 2 Relay Wiring and Use ui 46 7 4 3 First Time Set up and General Operation ssseesseesseesrresrrssrnssrrssrnssrnssrnssrnssrns 47 7 4 4 Routine Maintenance ss 48 7 4 4 1 Turbidity CGalbration ss 48 7 4 4 2 Cleaning the Turbidity Sensor ccecceeeeeeceeeee cee eeeeaeeeeeeeseaeeesaeeeeeaesenneeeaas 48 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com iv 7 4 4 3 Replacing Components iii 48 7 4 5 Shut down and Wimtertzimg 49 7 5 Conductivity Measurements rrrannrnnnnnvnnnnrnnnnrrnannvnnrnvenrnrrnnnnrnnennnnrrrressnrnesnnnesennenenn 49 Poe gt Installations pvr Nene 49 7 5 2 First Time Set up and General Operation
48. ff No chemical dosing A18 Total CI high Total Cl above upper limit A19 Combine CI high Combined CI above upper limit A20 Replace DPD3 DPD3 low Total CI testing stops A21 Temp low alarm Temperature below lower limit A22 Temp high alarm Temperature above upper limit A23 e A24 A25 Conductivity low Conductivity below lower limit A26 Conductivity high Conductivity above upper limit N No problem to allow ORP emergency o emergency D mode Use with care This ORP Emergency Mode Problem with method has AO ORP Emergency Colorimeter reading ORP is now disadvantages and will Mode controlling until problem is resolved up to 3 5 days only not reflect same results as normal operational mode No dosing only affects the relay operation Alarm relay will close and all other relays will open Table 8 Alarm Description and Result 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 30 O Blue I Water Technologies 6 2 Replacing Reagents HYDROGUARD issues a LOW REAGENTS message when the float at the end of one of the reagent siphons detects that one or both of the reagents is approaching depletion After this time HYDROGUARD will count down internally until the reagents are expected to be completely depleted and the Cl analysis will stop and the analyzer will activate an alarm The blue LED lights in the flow
49. g up or down will advance the first digit Holding up or down for an extended period of time will proceed through the numbers more quickly The factory set operator password is 123 The operator password can only be changed by entering the current operator or technician password see Technician Menu Setup 5 Press OK to accept the password The parameter s name and current setting appear in the LCD display 6 Press OK again The LCD display shows the parameter and the current setting 7 Enter the new parameter setting a Press the up arrow or down arrow until the desired value is reached b The second row of the menu display below the value that is being changed shows the current value 8 Press Enter to save the new setting or Esc to abort without saving the new setting To change the settings of additional parameters press Menu until the desired parameter appears in the LCD display Repeat steps 6 8 above to set the new parameter Note The Menu button displays the next parameter in the list so that the operator can check every parameter in the menu There is no scroll back option To view or change a previous parameter in the menu you must exit the menu by pressing Esc and start the above procedure from the beginning 5 3 4 Technician Menu The Technician menu includes advanced parameter settings that are accessible separately from the Operator menu The operators menu settings can be viewed however changes require a
50. hat you record the values frequently so that the process is closely monitored a Ifthe values greatly exceed the set point you need to decrease the proportional factor b If it takes too long to get to the set point you need to increase the proportional factor Note In large systems the delay time between injection of the chemicals and receiving the change in the controller can be very long 80 minutes or more Setting Pump Period Pump period is a single cycle during which the dosing pump operates and then rests Proportional control divides the pump period into two distinct phases active and at rest In general it is recommended to operate in a short cycle i e 00 30 Sec For large systems or if you activate solenoid valves you may consider longer pump periods 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 63 Appendix B Technical Specifications MECHANICAL DATA Dimensions controller WxHxD Dimensions mounting board Cable entries Ingress protection Max ambient temperature Weight Approx ELECTRICAL CONNECTION 670 x 330 x 130mm 26 4 x 13 x 5 1 800 x 550 x 5 mm 31 5 x21 7 x0 2 Pg 9 Cable Glands IP 65 NEMA 4 equivalent 2 C to 50 C 35 6 F to 122 F 11kg 24 3 Ibs Power supply Power consumption Power supply for RTC 100 115VAC 1A 200 230VAC 0 5A 50Hz 60Hz Approx 60 VA 3 6V Lithium Battery me
51. hnologies com 13 Blue I Water Technologies 4 3 1 Mechanical Installation Illustrates steps 3 to 5 in the following procedure 1 HYDROGUARD is shipped pre mounted on a mounting panel along with a water filter The mounting panel includes four screw holes one in each corner 2 Determine the location of one hole on the HYDROGUARD unit or on the mounting panel Secure one corner of the HYDROGUARD unit or mounting panel to the wall Level the HYDROGUARD unit or mounting panel and mark the remaining three 3 screw holes 5 Secure the remaining corners to the wall using 5 16 8 mm screws Step 5 Step 3 Level HydroGuard unit and Mark first hole drill and screw mark the remaining 3 holes mounting panel to wall 7 al Step 6 Mounting Panel We gt Drill the 3 holes and screw mounting board to wall S Sg Ee Use 5 16 8 mm screws HydroGuard T Controller P or sa ei Figure 2 HydroGuard 702 Mounting Panel 4 4 Plumbing Requirements and Installation 4 4 1 Water Supply and Drainage 4 4 2 Water Supply HYDROGUARD requires a pressurized water supply to the flow cell An isolating valve must be installed between the main line and the pipe or tube to the HYDROGUARD The minimum inlet pressure should be 4 4 psi 0 3 bar and should not exceed 14 5 psi 1 bar using a pressure regulator attached to the outlet of the pre filter The distance from the main pipe to the HYDROGUARD should be a
52. hout output wires connected to an external system Set the multimeter to measure current and connect the multimeter to an active output an output is inactive if it does not have a chipset installed next to the terminal block Record the current in mA Confirm that the value is accurate using the following equation Repeat for each active output je 16 MeasuredValue MinValue 4 FullScale mA milliamp output value Full Scale Max Value Min Value in case of Min is zero it s the max value Connecting to an External Monitoring System Connect two wires from the active output to the appropriate connection on the external system Repeat for each active output If an active output output with a chipset installed is not to be used place a jumper wire between the contacts 7 9 Chlorine Shock Mode Chlorine shock mode is available to provide a high level of chlorine for a relatively short period of time 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 58 O Blue I Water Technologies Two menus control this feature 3 Shock Chlorination 4 CI Shock Set point a Duration During normal operation the analyzer controller operates Cl dosing systems based on Cl Set Point 1 When Cl Shock mode is turned ON the controller will automatically control the Cl dosing system based on the Cl Shock Set Point This will only affect Cl relay 1 an
53. ine Buffer DPD 4 For Free Cl Total Cl 1 Free Chlorine Indicator DPD 1 2 Free Chlorine Buffer DPD 1 3 Total Chlorine Indicator DPD 3 Figure 7 Flow cell and Colorimeter Inlet and outlet 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 18 O a Sei E g Blue I Water Technologies 1 Open the HYDROGUARD Chlorine Indicator and Buffer kit The following items should be in the box e 600 ml bottle of chlorine buffer with a white label e 600 ml bottle of chlorine indicator fluid with a blue label e Small bottle of chlorine indicator salt with a white label Remove the caps on both the indicator fluid and small indicator salt bottles Empty the entire contents of the indicator salt into the bottle of indicator fluid 4 Place the cap on the bottle of chlorine indicator fluid and close tightly Turn the bottle upside down slowly and carefully so that no bubbles form in the fluid 6 Repeat five 5 times until all the indicator salt is dissolved in the indicator fluid io e EN FIN FN 1 2 3 4 5 mr w Ny Sa C Figure 8 Reagent handling 7 Place the reagent bottles in position a Remove the cap from the reagent bottles Place the opening of the reagent bottle below the bottle siphons Lift the bottle up until the opening reaches the bottle siphon cap eeg Push the lever above the si
54. ing is still in place b Screw the Colorimeter to the HYDROGUARD analyzing module housing with the four mounting screws c Place the top cap on the Colorimeter unit 9 Re connect the outlet tube to the Colorimeter 10 Pass the wires from the new colorimeter through the gasket into the control module 11 Connect the wires to the MIXER and SENSOR terminal blocks as indicated on the colorimeter module 12 Recheck all connections 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 37 13 Close the HYDROGUARD analyzing module door 14 Turn on the power and restore flow to the flow cell 15 Confirm that the colorimeter is operating properly 6 7 6 Replacing Colorimeter Solenoid Valve 1 Turn the water inlet and outlet to the flow cell and turn off the analyzer power 2 Release the top union connecting the solenoid valve to the Colorimeter module 3 Detach the cable from the solenoid valve 4 Unscrew the solenoid valve intake tube 5 Unscrew and disconnect the sampled water supply pipe from the solenoid valve intake pipe at the bottom of the solenoid valve 6 Disconnect the valve from the unions above and below 7 Connect the new solenoid valve a Connect the bottom of the new valve to the intake pipe b Insert an o ring into the slot at the bottom of the intake pipe and turn until the intake tube is firmly connected to the new valve c
55. ion Tot Chlor Turns the total chlorine monitoring and display ON or OFF Chlor Ratio The ratio of Free Chlorine measurments to Total Chlorine Measurements 7 2 4 Activate Total Chlorine Monitoring 1 Enter the Operator Menu 2 Set the TC High Alarm Level Set the CC High Alarm Level Enter the Technician Menu by pressing up and down together a A Press Menu until Total Chlor ON OFF appears Change to ON the default is OFF Press Menu unit until Chlor Ratio appears O 7 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 40 O Blue I Water Technologies 8 Select the ratio of total chlorine measurements The frequency of total chlorine testing will be based on the chlorine interval and the chlor ratio If the Chlor Ratio is 1 the total chlorine will be tested every cycle If the Chlor Ratio is greater than 1 the Total chlorine will be tested every few cycles For example if the Chlor Ratio is 5 the total chlorine will be tested after every 5 Free chlorine test 9 Perform a system reset to start operating in TC mode 10 Locate the LCD displays in the HYDROGUARD control panel A number should appear in the display TCI 0 00 and will update after the first total chlorine test 7 2 5 Routine Maintenance 7 2 5 1 Reagent Replacement Reagent replacement should be done after the message Replace DPD3
56. ion Mode OFF Then the controller returns to operating the Cl Set Point 1 To turn on Cl Shock Mode 1 Enter the Cl Shock Set point then press OK 2 Enter the Duration then press OK 3 Turn Cl Shock Mode ON You will also need to adjust the Cl P factor technician menu A low P factor will make slower changes to Cl dosing a high P factor will make faster changes to Cl dosing If you have trouble reaching the Cl set point use a higher P factor If you greatly overshoot the set point use a lower P factor 4 5 3 Input Switches Flow input switch terminal blocks on the I O module allow for three input switches to be connected to the system as additional layers of security against accidental chemical additions when there is no flow If a connection is expected but not detected at each input the analyzer controller will indicate an alarm and will close all relays and open the alarm relay Therefore if a safety switch flow level etc will not be installed a fixed connection jumper wire is required to allow the controller to operate Two flow switches and one flow meter may be connected e Flow Switch internal Flow switch connected to the flow cell of analyzer Supports both 2 and 3 wire flow switches o If a 2 wire switch is used it should be connected to the In and Gnd connections If a 3 wire switch is used the VCC connection will also be used e External Flow Switch Connection for an external 2 wire
57. itten permission of Blue I Water Technologies Ltd Trademarks and Patents HYDROGUARD is the Registered trademark of Blue I Water Technologies Ltd Patents issued and pending at the time of this printing Disclaimer Blue I Water Technologies Ltd does not accept any responsibility for any damage caused to its products by unauthorized personnel Use of non Blue I Water Technologies reagents and or replacement parts will void all warranties Blue I Water Technologies Ltd www blueitechnologies com 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 65
58. lays and the dosing systems they control 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 60 Relay Relay name Control Main Chlorine system On Off or Proportional Proportional Table 14 Relays and their controlled dosing systems eo controls pulse length or pulse frequency PL PF Secondary Chlorine system On Off only no proportional 2 CL2 control 3 pH Acid or Base dosing On Off or Proportional Proportional controls pulse length or pulse frequency PL PF Nephelometric Turbidity Units Controls the injection of 4 NTU flocculants or coagulants Used only with the optional Turbidity module Activates an external alarm when certain alarm types are 5 Alarm registered and after the alarm delay time has expired 6 Conductivity Used only with the optional Conductivity module Proportional Control Overview HYDROGUARD controls dosing proportionally This method sets dosing rates in relation to how far current chemical levels are from the set point The dosing rates gradually decrease as chemical levels get closer to the set point Set Point Chemical Level Figure 15 Proportional Control of Chemical Dosing If water chemical levels are far below the set point HYDROGUARD will operate the dosing systems to operate at full speed 100 As the controller senses chemical levels rising and getting closer to the set
59. licensed operators should attempt to make any changes to chemical dosing levels Always follow local health and safety regulations when performing any service on the analyzer controller unit or when changing chemical dosing settings The main power supply may be connected to either 110 120 or 220 240VAC 50 60Hz Switching between voltages is accomplished by changing two 2 jumpers located above the main power connection to the left of the transformer For 110 120VAC a 1amp fuse should be use for 220 240VAC a 0 5amp fuse should be used These changes must be completed prior to wiring Attention Seuls des lectriciens qualifi s ayant re u la formation ad quate peuvent entreprendre le branchement l entretien ou la r paration des composants lectroniques de l analyseur du contr leur Il existe un risque de choc lectrique lors de l entretien de ce syst me Ayez soin de toujours v rifier que la ou les source s d alimentation lectrique est ou sont bien d connect e s avant d ouvrir l unit ou d entreprendre toute op ration de service technique et tout branchement des composants lectroniques Attention Il y a lieu d agir avec une extr me prudence lors de l installation de la mise en uvre et de la maintenance du contr leur HYDROGUARD Seuls des techniciens d ment form s cet effet sont autoris s effectuer l installation et la maintenance de l analyseur du contr leur Seuls des op rate
60. logies or your supplier for details See the supplemental manual for instructions on installing and using the modem 3 3 System Components HYDROGUARD has two primary units the analyzing unit and the control unit The analyzing unit performs the actual measurements It contains the following components Colorimetric Reading Cell measures free or total and optionally both free and total chlorine levels in the water using DPD reagents and a closed cell digital photometer Flow Cell contains the sensors including the pH Redox ORP and temperature sensors Reagent Bottles contains the reagents used by the colorimeter to measure chlorine levels in the water Reagent Pumps and Solenoid Valve accurately controls the flow of water and reagents into the colorimeter making every measurement as accurate as possible The control units include all electronics the user interface and the software that controls the measurements performed in the analyzing unit It includes the following components I O Module Input Output Power Supply to the analyzer and contains the dry contact relays for direct control of external dosing systems 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 10 O Blue I Water Technologies Control Panel Module Calculates the measurement results and determines the required chemical dosing to maintain an appropriate chemical
61. lorimeter Check clean solenoid valve including spring Check water flow Verify piston movement mixing Check that dosing systems are operating properly Combine Cl high A19 Combined CI above upper limit Replace DPD3 A20 DPD3 low No reagent in the right bottle out of the three Replace Total Chlorine reagent Temp low alarm A21 Temperature below lower limit 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 34 OBluel Description Solution Suggestion Temp high A22 Temperature above upper x alarm limit a A25 Conductivity below lower limit Conductivity A26 Conductivity above upper 8 D high limit No No problem to allow ORP 7 emergency emergency mode ORP Emergency Mode Use with care This g method has Function may be ORR pen va neo meres disadvantages and will enabled after no Emergency ER reading ORP i Tow not reflect See results solution for alarms Mode controlling until problem is as normal operational A3 4 5 6 7 resolved up to 3 5 days only mode No dosing only affects the relay operation Alarm relay will close and all other relays will open Potential Cause Solution Suggestion Prime for 90 seconds confirm pumps work properly and droplets form and drop from each needle Dilute and test manually controller will ope
62. lorimeter module if present using the 4 supplied screws 3 Connect the flat cable to the pH ORP and Temp module to an open connector on the I O module 4 Install the temperature probe a Thread the 3 8 compression connector into the back of the flow cell 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 41 b Place the probe into the connector until and the connector is tighten c Route the temperature probe wires into the electronics box and connect to the pH ORP and Temp module following the color codes listed on the module 5 Install the pH and or ORP probes a Remove the sensor from its packing box and remove the plastic cover or plug from the end of the sensor and drain the solution from the tube Keep the plastic cover in a safe place for winterizing or storage of probes b Hold the sensor by its connector with the glass tube pointing down c Insert the sensor into 7 connector on the top of the transparent flow cell and thread in securely DO NOT OVERTIGHTEN d Route the pH and or ORP cables to the electronics box and connect to the pH ORP and temp module e Connect each cable to the appropriate sensor 6 Repeat step 5 for additional sensors If only 1 sensor is installed a Install a jumper between the inputs for the missing probe b In the menu set the low and high alarm limits at the minimum and maximum values respectively t
63. ment to take effect before making additional changes 7 5 3 2 Cleaning the Conductivity Meter Routine cleaning of the conductivity meter will ensure long term reliability The frequency of cleaning will depend on the water source being tested and should be conducted whenever there is significant visible dirt the measurement accuracy is affected or before the meter is calibrated 1 Shut off the flow of water to the conductivity flow cell and remove the meter 2 Wash the meter under a jet of water to remove the debris 3 Use a soft cloth to remove any additional debris and oil 4 Replace the meter and restore flow to the flow cell 7 5 3 3 Replacing the Conductivity Meter Turn off the inlet and outlet water to the flow cell and the power to the analyzer Open the door of the control module Remove the wires from the bottom of the Conductivity input module Remove the meter from the flow cell by unscrewing the cap and pulling gently Install the new meter in the flow cell 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 50 6 Route the wires back to the conductivity module and reconnect the wires to the 4 20 input module 7 Restart the flow and turn the power on 8 Confirm that proper operation has been restored Replacing the Conductivity Input Module Disconnect the power supply to the unit before opening the control unit 1 2 3 4 5 6
64. mory DATA SERIAL OUTPUT SIGNAL OUTPUT RS 485 4 20mA Standard 1 Optional 2 4 or 6 RELAYS CL Chlorine set point 1 CL Chlorine set point 2 pH1 Turbidity control 1 General Alarm Temperature control DISPLAY 250VAC DC 4A Max 250VAC DC 4A Max 250VAC DC Max 250VAC DC 4A Max 250VAC DC 4A Max 250VAC DC 4A Max 5 5 Large Graphic Monochrome Display CHLORINE MEASUREMENT Measurement Sensor Cell cleaning Mixing technology Measurement range Measuring interval Max inlet operating pressure Flow rate colorimetric cell Working temperature REAGENTS Reagent type Reagent consumption Shelf life Free and or Total chlorine Colorimetric multi spectrum sensor Automatic self cleaning mechanism patent Inner solenoid activated active mixer patent 0 to 10ppm 2 to 10 minutes 1 bar 14 5 psi 3 to 12 LPH 1bar 0 75 to 36 GPH 14 5 psi 1 C to 45 C 33 8 F to 113 F DPD1 DPD3 DPD4 Min 0 033 ml per sample Unmixed DPD1 amp DPD4 3 years DPD3 15 months Mixed Recommended 60 days pH MEASUREMENT Measurement range Sensor Input impedance Oto 14 Ceramic diaphragm and gel filling 0 5 10 0 ORP REDOX MEASUREMENT Measurement range 0 to 2000mV Sensor Ceramic diaphragm and gel filling TEMPERATURE MEASUREMENT PT 100 0 C to 100 C 320F to 2120F Sensor Measuring range MEASURING CELL Working temperature FLOW REQUIREMENTS 1 C to 45 C 33 8 F to 113 F
65. nduc high alarm 1 5000 4900 US Conduc active Time 0 180 0 01 min Alarm delay 0 10 0 30 min Flow low limit 0 200 or 999 0 off M7 hr or GPM 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 23 O Blue I Water Technologies Function Name Min Value EK AE Default Units Flow k factor 0 01 655 0 01 Total Alkalinity 0 600 0 ppm Total Hardness 0 600 0 ppm TDS 0 5000 0 ppm T Cl calibrated to 0 01 9 99 1 50 ppm sensor value was Total Cl high alarm 0 9 99 3 5 ppm Comb Cl high alarm 0 9 99 2 5 ppm ORP Emergency mode OFF ON OFF Language English SYSTEM RESET n a n a n a Optional features Note In a FOT Free or Total model choosing T CL in the menu will result in the disappearance of the F_CL from the screen and vice versa 5 3 3 Configuration Settings in the Operator Menu Each of the parameters in the operator menu is configured in the same way The following procedure describes how to configure a typical setting 1 Locate the desired parameter in the menu a Press Menu until the desired parameter name appears in the LCD display 2 Press OK Enter Password 100 appears in the LCD display 3 Enter the Operator password or technician password both are accepted 4 Press the up arrow or down arrow until the password number is reached Note Holding Menu while pressin
66. nguage SYSTEM RESET Restarts the controller a safer option than turning it off and on Optional features Table 3 Operator s Menu amp variables limits Function Name Min Value MENE Default Units Shock Chlorination OFF ON OFF Menu Relays OFF ON OFF Reagent pump OFF ON OFF Cl set pointi 0 9 99 1 5 ppm CI shock set point 0 9 99 3 ppm CI shock duration 0 00 24 00 2 00 hours CI set point2 0 9 99 0 5 ppm F Cl calibrated to sensor value was EN SE ma PRm CI low alarm 0 9 99 0 5 ppm CI high alarm 0 10 2 0 ppm CI interval 2 00 10 00 2 00 min pH set point 4 0 14 0 7 40 pH 7 calibrated to a sensor value was 0 aie na pH low alarm 4 0 14 0 6 90 pH high alarm 7 0 13 9 7 80 Ss pH 4 10 calibrated to 8 sensor value was ES E 740 ORP set point1 0 1200 600 mV ORP calibrated to sensor value was i Er ma my ORP low alarm 0 1200 600 mV ORP high alarm 0 1200 850 mV Temp calibrated to On 0 sensor valie was 1 34 49 9 121 9 n a C F Temp low alarm 1 34 49 9 121 9 18 C C F Temp high alarm 1 34 49 9 121 9 50 C C F Turbidity set point 0 40 0 60 NTU NTUI calibrated to sensor value was L ne bl NTUh calibrated to sensor value was J 1 ia MTU Turbidity high alarm 0 99 9 99 9 NTU Conduc set point 1 5000 1000 US Conduc calibrated to sensor value was 1 S008 E us Conduc low alarm 0 5000 0 US Co
67. nu until Flow Rate m3 hour m3 hr appears Select the flow units of m3 hr or GPM 6 Press Menu until Max flow Range appears Enter the maximum flow rate flow rate at 20mA output The minimum flow rate flow rate at 4mA output is assumed to be zero The flow meter should now be active Confirm that the flow rate appears on the LCD display If it is not active perform a system reset 7 6 2 Routine Maintenance and Troubleshooting Follow manufacture s recommendations for maintenance procedures and any troubleshooting issues 7 7 Modbus Communication Protocol Note If the HYDROGUARD analyzer is configured for Modbus over Ethernet communication please refer to the setup instructions for this configuration and how to find the HG s IP at http www blueitechnologies com products hydroguard hg 702 Modbus is a serial communications protocol which allows for communication between many devices connected to the same network Modbus is configured via the technician menus 1 To enter the Technician menu press Menu to enter the operator menu and then press the up arrow and down arrow simultaneously until the menu display changes 2 Locate the Modbus com format in the menu a Press Menu until the desired parameter name appears in the LCD display b Press OK Enter Password 100 appears on the LCD display 3 Enter the Technician menu password a Press the up arrow or down arrow until the correct password number
68. o prevent a false alarm for a measurement that is not connected 7 Switch the HYDROGUARD ON and verify that pH and or ORP readings appear on the display In some analyzers this may need to be turned on in the technical menu 8 Observe the pH and ORP Redox levels and wait several minutes until both readings stabilize a If either one or both indicators do not display a proper reading or are not stable confirm proper installation and then see the Troubleshooting section 7 3 2 Routine Maintenance 7 3 2 1 Calibration pH Calibration pH is calibrated using a Phenol Red or Buffer 7 solution 1 Shut off the water inlet and outlet from the flow cell 2 Remove the pH sensor and temperature probe from the flow cell 3 Wipe the sensor probe with a dry cloth and submerge it and the PT 100 temperature probe into a cup with the Phenol Red or Buffer 7 solution Wait for the reading to stabilize Note The reading will not stabilize if the temperature probe is not also in the buffer solution 4 Press Menu until pH Calibrated to appears in the LCD display 5 Press OK 6 Enter the password Press the up arrow or down arrow until the password is reached 7 Press OK 8 Press OK again 9 Press the up arrow or down arrow until the value is the same as the value printed on the label of the Phenol Red or Buffer 7 Solution 10 Press OK to save the new calibration or Esc to abort without saving 11 Press Esc to return to the
69. on the HYDROGUARD unit or changing chemical dosing settings 3 Overview The HYDROGUARD HG 702 Water Quality Analyzer continuously monitors chemical levels in a process water application HYDROGUARD automates free chlorine total chlorine pH ORP Redox temperature turbidity conductivity and or flow rate administering chemicals as required according to the results of these tests closed loop 3 1 The HYDROGUARD Solution Various methods have been developed over the years to monitor the concentration and balance of chemicals used in water treatment The older manual methods of monitoring chemical balance are neither objective nor effective HYDROGUARD measures free or total and optionally both free and total chlorine levels with a digital photometer which has many advantages over other types of sensors Digital photometer testing is completely objective It is not dependent on lighting conditions or the operator s eyesight and is far more accurate It does not require frequent calibration and is compatible with all types of disinfectant systems HYDROGUARD performs colorimetric testing in a closed reading cell It is the only system that automatically and accurately measures free chlorine using small amounts of reagent Once installed and calibrated HYDROGUARD is fully automatic It will monitor and can control dosing systems directly or indirectly releasing the proper quantity of chemicals based on frequent automatic measurements
70. ord a Press the up arrow or down arrow until the password number is reached b Press OK The parameter name and current setting appear in the LCD display Note Technician menu password is different from the Operator menu password The default Technician menu password is 456 and if lost can only be reset by replacing the chipset 4 Continue changing the parameter setting as described in the Operator menu 5 4 Calibration Parameters must be calibrated with measurements taken with external testing devices Always use digital calibration devices not the less accurate visual test kits Alternatively standard solutions may be used Make sure the standard solution is not expired or contaminated prior to using Follow the procedures below EXACTLY as instructed ALWAYS take water for calibration from the sampling valve NOT from the process line directly The analyzer should always be calibrated with water from the same source Note Chlorine calibration is only required every 6 to 12 months in most cases Minor deviations will exist between all testing equipment These minor differences do not warrant the calibration of the colorimeter 5 4 1 Chlorine Calibration Note Chlorine calibration should always be performed at the 5 measurement cycle in order to enable stabilization of the conditions 1 Open the water sampling valve Let water flow while observing the colorimeter countdown timer in the LCD display 2 Fill the sampling
71. phon cover away from you and push the reagent bottle up e Push the bottom of the bottle into position Caution Do not refill the reagent bottles Do not mix or add reagent from other bottles Do not use any non Blue I Water Technologies reagents 8 Prime the reagent pumps a Press Menu on the control panel keypad until the Reagent Pump menu appears b Press OK c Enter password 123 is default using the up or down arrows 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 19 d Press OK OFF will appear on top line e Press OK again OFF will appear on the top and bottom lines f Press UP to turn the reagent pumps ON 9 Press OK when the water flowing from the colorimeter has a red tint or reagent drops are being formed at the needle tips h Press Escape twice 2x to return to the main screen Note If outside of the range of 0 2 to 10 ppm remove the colorimeter cap and confirm that reagents are being pumped 5 3 First Time Menu Setup This section describes how to configure the settings set points alarms and calibrations through the HYDROGUARD control panel Caution HYDROGUARD s control board unit should not be opened except for initial installation and troubleshooting and should only be opened by a trained and approved technician 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies
72. place if any part of the filter fabric is torn 6 Return the filter into place making sure that the gaskets and o ring are in place 7 Open the water supply valve 8 Press the air relief valve to remove the air from the filter 9 Confirm that the water is flowing and the filter is properly sealed 6 4 Shut Down and Winterizing The HYDROGUARD analyzer is designed to keep the probes submerged even if there is no flow to the analyzer However if the analyzer is going to be offline for an extended period of time and or exposed to freezing temperatures it must be winterized to prevent damage to the analyzer and the probes Note Before powering off the unit please make sure that the analyzer s timer is set to 20 sec enabling the analyzer to finalize the cleaning process The timer option can be viewed by pressing the up arrow from the control panel 1 Store all probes by following directions in the supplemental manuals for each sensor 2 Drain the flow cell completely by opening the sampling valve on the bottom Leave the valve in the open position to allow air to completely dry the cell 3 Remove the reagent bottles and flush each pump tube by inserting the pump tube in a container of fresh water and turning the reagent pumps ON for at least 90 seconds 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 31 Op Blue I Water Technologies Remove the pump
73. ply should be used such that no equipment will be activated unless the process line has flow Wiring to Dosing Systems HYDROGUARD controls chemical dosing systems using a series of electronic relays that start and stop the dosing pumps Each relay opens and closes a switch that activates a separate pump or piece of equipment The line live wire of the dependent power source connects to the connection labeled Common on each relay The line wire of each controlled system is connected to the normally open NO or normally closed NC connection of each relay as appropriate Normally Open means that the relay will be open i e no power from the relay until the controller calls for power Normally Closed means that the relay will be closed i e power from the relay until the controller calls to stop power 1 Verify that the power switch or circuit breaker to the dependent power source is off 2 Connect the earth wire to the ground return wire from each of the external dosing systems 3 Connect the neutral wire to the return wire from each of the external dosing systems 4 Connect the line live wire to the connector marked Common of each active relay Caution Each relay connection is limited to 4 amps to prevent overheating The relays may show a higher rating but do not connect equipment exceeding 4 amps JED CL1 CL2 pH NTU Alarm Temp Conductivity Figure 14 Relay positions on board The following table lists the re
74. point IEEE 754 Redox Input Register 30004 Floating point IEEE 754 Temperature Input Register 30006 Floating point IEEE 754 Flow Input Register 30008 Floating point IEEE 754 Turbidity Input Register 30010 Floating point IEEE 754 Total chlorine Input Register 30012 Floating point IEEE 754 Combine chlorine Input Register 30014 Floating point IEEE 754 Conductivity Input Register 30016 Floating point IEEE 754 bitO Low Reagent bit1 No Reagents bit2 No DPD3 bit3 No Flo bit4 External OFF Colorimeter alarms Input Register 30018 bit5 Unclean cell bit6 Replace light bit7 Colorimeter communication Error bit8 Piston stuck Controller ID Input Register 30019 16 bit serial number Modbus connection details Holding 40000 bitO parity noparity Register bit1 parity even odd bit2 19200bps 9600bps bit3 floating point swapped floating point bit4 2 stop 1 stop bit Chlor measures interval Holding 40001 sec Register 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 56 7 8 Communication Options 7 8 1 Internal 4 to 20mA Output 7 8 1 1 Installation Required Parts e Internal 4 20mA Module electronics card e 250mm Flat Cable ribbon cable To complete the installation a 2 wire cable for each output channel parameter will also be required Hardware Installation 1 Attach the 4 to 20 module to the inside of the con
75. pump tube leading to the bottom of the pump head into the appropriate reagent bottle 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 32 11 Attach the pump tube from the top of the pump head to the needle on the colorimeter cap by holding the needle and gently pressing the tube onto the connector 6 6 Troubleshooting The following procedures instruct how to locate evaluate and fix a problem when HYDROGUARD issues an alarm or indicates suspect chemical levels Table 9 Troubleshooting Table Alarm Description Symptom Solution Suggestion Increase flow and check There is not enough water No chlorine flow switch wire reaching the controller Stop No flow Al all chemical dosing all relays measurements No connection on board are open dosing Check that the switch is i not stuck The water flow rate in the main circulation pipe is lower Check the circulation Low flow A2 than the flow limit Stop all No dosing pipes It is nota chemical dosing all relays controller problem are open Check wiring between Check Communication error between rar Se A3 ee ie No Cl measurements Change colorimeter sensor in case of continued problem Check reagent level and change bottle if needed No reagents A4 Reagents are empty No reading Make sure the sensor not stuck Wait for the second measurement and check visually Clean
76. rate fine once back in normal level confirm that water stops flowing when reading starts timer gets to zero Unscrew solenoid and clean the tip check filter for holes make sure reagent are in good conditions replace if needed Turn reagents pumps ON Problem Symptoms Reagent Pumps not Primed or broken Chlorine too high gt 10ppm and is bleaching reagents Solenoid not shutting completely Using wrong or not original reagents or reagents have passed expiration date forming as expected Check Clean valve and Valve malfunctioning spring Add grease Replace Valve if necessary Needle will be black on outside DPD occasional does not drop properly b c not flowing through needle Check if CI averaging on in CI averaging on Tech menu turn off it not wanted Enter calibration enter password and press enter to accept reading from colorimeter Check Clean valve and Valve malfunctioning spring Add grease Replace Valve if necessary 9 j D Needs Calibration near set point EA a Fer pantie calibrate Chlorine Measurement is Zero or Low Needle is cracked or tube split at needle Chlorine Measurement Calibrated at wrong level Inconsistent 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 35 6 7 Replacing Components The following procedures describe how to replace certain HYDROGUARD components Caution The following proce
77. ravity drain without creating an obstacle i e no pipe across walkway The flow cell may be pressurized to allow for return to the system under pressure Freezing Temperatures The analyzer should be installed in a location that is not susceptible to freezing temperatures The reagents can freeze preventing accurate readings even when thawed and parts may be damaged due to expansion when ice forms 4 3 Site Requirements and Installation The HYDROGUARD assembly is wall mounted It should be located on a wall where operators and service technicians can easily access it for normal operation and maintenance It is also advisable to install it wnere the operators can easily view the readings and alarms The complete unit with all connections weighs 18 lbs 8 kg so it must be mounted securely on a stable wall The HYDROGUARD unit measures 26 3 x 13 1 66 8 cm x 33 2 cm The base of the complete HYDROGUARD assembly should be mounted at least 24 60 cm above the floor preferably at eye level The HYDROGUARD unit and its mounting panel are not shipped with mounting screws or anchors The installer must provide screws and anchors that can hold the weight of the HYDROGUARD unit mounting panel intake filter and electrical outlets and junction boxes The screws and anchors must be compatible with the wall where it will be installed 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitec
78. re from the controlled external turbidity equipment 3 Connect the neutral wire of the power supply to the neutral wire from the controlled external turbidity equipment 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 46 Ort Blue I Water Technologies Connect the line live wire of the power supply to the connector marked C common on the NTU terminal block 5 Connect the line live wire of the controlled external turbidity equipment to the normally open NO or normally closed NC connection on the NTU terminal block Caution Each relay connection is limited to 4 amps to prevent overheating The relays may showa higher rating but do not connect equipment exceeding 4 amps Relay and External Equipment Operation The relay will operate in an ON OFF mode Whenever the measured turbidity is below the set point the relay will remain open no power to normally open the connection Whenever the measured turbidity is above the turbidity set point the relay will close power will be supplied to the normally open connection If the measured turbidity is above the turbidity high alarm the alarm on the analyzer will be activated The NTU relay will remain closed power to the normally open connection even during the alarm 7 4 3 First Time Set up and General Operation Although the turbidity unit is connected it will not operate until it is set up in
79. right corner of the I O Module Although the flow meter is connected it will not operate until it is set up in the analyzer menu 4 Press Menu until Flow Low Limit appears Enter the low flow value the flow value which will cause an alarm and will disable any direct chemical dosing 5 Change to Flow Sensor on 6 Press Menu again and K factor appears Enter the k factor for the flow meter being used should be on paperwork with flow meter 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 51 O Blue I Water Technologies 7 Press Up Down arrows together and then press Menu until Flow Rate m3 hr appears Select the flow units of m3 hr or GPM 4 20 Output Flow Meter Any flow meter with a 4 20mA output can be connected to the analyzer s internal 4 20 input module 1 Install the flow meter as per the manufacturer directions 2 Pass the flow sensor cable through an open glad on the bottom of the analyzer 3 Connect the 4 20mA output wires from the flow meter to the middle 4 20mA Input connection on the input module Although the flow meter is connected it will not operate until it is set up in the analyzer menu 4 Press Menu until Flow Low Limit appears Enter the low flow value the flow value which will cause an alarm and will disable any direct chemical dosing 5 Press Up Down arrows together and then press Me
80. s in place 1 Verify that the power switch or circuit breaker to the non dependent power source is OFF 2 Connect the line live wire to the I O board connector marked Line 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 16 O Blue I Water Technologies 3 Connect the neutral wire to the I O board connector marked Neutral 4 Connect the earth wire to the I O Module connector marked Ground 5 Continue with the other electrical connections 6 Turn on electrical power only after all electrical connections have been completed For information on wiring and using the relays as dry contact or for control see chlorine shock mode 4 5 2 Chlorine Shock Mode Chlorine shock mode is available to provide a high level of chlorine for a relatively short period of time Two menus control this feature 1 Shock Chlorination 2 Cl Shock Set point a Duration During normal operation the analyzer controller operates Cl dosing systems based on Cl Set Point 1 When Cl Shock mode is turned ON the controller will automatically control the Cl dosing system based on the Cl Shock Set Point This will only affect Cl relay 1 and the 4 20mA Control Output Cl relay 2 will still be controlled based on Cl Set Point 2 Once the Cl Shock Mode is turned ON the controller controls the Cl Shock Set Point for the user selected Duration and then automatically shuts Cl Chlorinat
81. s short as possible in order to minimize the delay time between the water being sampled and HYDROGUARD measurement 4 4 3 Drainage A pressurized vacuum or gravity connection is required from the outlet of the flow cell to return water from the flow cell to the water supply A FNPT fitting is supplied for the flow cell drain connection A gravity drainage connection is required for the water coming out from the colorimeter The length of the colorimeter drain line should be as short as possible and must have a constant downward slope to prevent a backflow of water A drain cap is located on the colorimeter outlet to prevent the backup of water into the colorimeter if the drain line is blocked A 12 MNPT fitting is supplied for the colorimeter drain connection 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 14 O Blue I Water Technologies Flow Cell Outlet Colorimeter Outlet Sample Valve Water Inlet Rotating Flow Switch Figure 3 Flow Cell and Colorimeter Inlet and Outlet Note The HYDROGUARD colorimeter drains water at zero 0 pressure The drainage pipe should be as straight as possible and have a constant downward slope and should not have any bends where water flow can be restricted If the colorimeter drains to a bucket or basin the end of the drainage pipe should terminate above the bucket or basin rim 4 5 Electrical Requirements
82. se chemicals that reduce the surface tension When using hydrochloric acid observe all safety regulations Caution HYDROGUARD s control board unit should not be opened except for initial installation and troubleshooting and should only be opened by a trained and approved technician Attention Avant de relier l appareil une quelconque alimentation lectrique v rifiez que les deux cavaliers sont situ s sur les valeurs correctes de tension et que c est le bon fusible qui est en place Chaque connexion relais est limit e a 4 Amp afin d viter toute surchauffe M me si les relais affichent ventuellement une valeur sup rieure ils ne se connecteront pas a un l ment d passant 4 Amp Tous les branchements lectriques doivent tre conformes au Code Electrique National NEC National Electrical Code ainsi qu a toutes les consignes locales M langes r actifs Attention Utilisez l quipement de protection pr conis dans la fiche de donn es de s curit MSDS Attention N utilisez pas de produits chimiques susceptibles de r duire la tension superficielle Lors de l utilisation d acide chlorhydrique appliquez scrupuleusement toutes les consignes pertinentes Attention Le tableau de commandes de HYDROGUARD ne doit en aucun cas tre ouvert si ce n est lors de l installation initiale et en cas de d pannage auquel cas son ouverture ne doit tre effectu e que par un technicien ayant re
83. special password allowing only qualified personnel to change the analyzer s 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 24 O Blue I Water Technologies advanced settings These settings do not require frequent changes after the initial installation and set up Table 4 Technician Menu Functions and Descriptions Function Name Description Cl P factor Proportional Factor for Cl Relay 1 Cl pump period 1 Pump cycle on off time for Cl relay Cl pump freq Cl pump max pulses min 0 for on off pump Cl averaging Displays an average of the last 4 Cl readings This feature will only affect the displayed value not the action of the analyzer This feature is intended primarily to prevent operators from making changes due to minor normal fluctuations in the measured chlorine level The averaging is done on the last 4 readings displayed on the screen and the result will be displayed in the next measurement The analyzer will always act based on the last reading and not according to the averaging value Cl lt 0 1 alarm Initiates an alarm and opens Cl relays 1 2 If Cl drops below this level Whenever the CI measurement is lt 0 1 ppm the analyzer will disable relay 1 and relay 2 This alarm is provided as an extra level of safety against over chlorination due to bleaching of reagents However it complicates the start up of the analyzer when the Cl is
84. ss than 15m 45 feet from the HYDROGUARD analyzer Connect a water supply of no greater than 2 bar 30 psi to the inlet fitting using 6mm tubing It may be a new separate water supply or a line tapped from the main analyzer water supply before the pre filter Larger tubing may be used if the fitting is replaced to accept the new tubing Connect a 6mm water outline line to the outlet fitting and connect to a The water system at least 5 psi 0 3 bar lower than the inlet water supply or b The pre filter of the HYDROGUARD analyzer Route the conductivity meter wire through an open gland on the bottom of the analyzer Connect the wires to an open 4 20mA input on the bottom of the 4 20 module Connect 24V from the meter to 24V on the module Connect mS from the meter to IN on the module 10 Connect GND from the meter to ground symbol on the module 7 5 2 First Time Set up and General Operation For Output of the conductivity measurement see internal or external 4 20mA module sections to configure the output in your specific HYDROGUARD analyzer 7 5 3 Routine Maintenance 7 5 3 1 Conductivity Calibration Must be conducted when the process is stable specifically the temperature should be within normal operating range 1 2 3 Test a sample of water with an accurate external conductivity meter Use the calibration adjustment screw to increase or decrease the conductivity making very small changes Wait for the adjust
85. ss tube clears the hole 5 Install the new Sensor a Open the replacement sensor s box and remove the sensor by the metal connector b Remove the plastic cap on the glass end of the probe c Hold the sensor by its metal connector with the glass tube pointing down and insert the glass tube into a hole in the flow cell d Screw the probe into place DO NOT OVERTIGHTEN e Attach the sensor wire onto the probe Replacing the Temperature Probe 1 Turn off the inlet and outlet water to the flow cell and the power to the analyzer 2 Open the doors of both the analyzing module and the control module 3 Remove the four 4 wires from the temperature probe in the control module 4 Remove the old sensor from the reading cell a Unscrew the compression fitting from the temperature probe b Pull the probe up until it clears the fitting 5 Install new sensor a Insert the temperature probe into the fitting b Screw the compression fitting around the probe c Connect wires to pH ORP and the Temp module following color coding Replacing pH Redox and Temperature Module Disconnect the power supply to the unit before opening the control unit 1 Disconnect the flat cable plug from the card 2 Unscrew the four 4 mounting screws 3 Putin the new card and tighten the 4 mounting screws 4 Connect the flat cable plug to the card 7 3 3 Shut down and Winterizing 1 Remove the probe from the flow cell 2 Fill the rubber caps
86. stallation 13 4 3 1 Mechanical Installation eonnronnronnrrnnronnrrnnnnnnrrnnnonnrrnnrrnnrrnnrennrrnnrennrrnnsennrrnnsenn 14 4 4 Plumbing Requirements and Installation 14 4 4 1 Water Supply and Drainage renses 14 4 42 E Tee EE 14 443 El E EE 14 4 5 Electrical Requirements and Installation soornronnrrnnnnnnrrvnnnnnvrnnnrnnrrnnnrnnvrnnnnnnrrnnenn 15 4 5 1 Connecting the Main Electrical Power 15 4 5 2 Ghl rine Shock Mode tn mines nent 17 4 5 3 Input SWICNES wradnsansuamnmurnsedennkbi anus a aa aa 17 5 First Time Operation and Calibration eoonrrnrnrrnnnnvnnonnvnrnnrennnrnnnnnnnnrnnenrnrreennrnnsnnnnnennenenn 18 5 1 Installing Additional Sensors and Meters sessssesesssrssrresrissrrssrissrissriesrinsrrnsrnee 18 5 2 deiten 18 5 3 First Time Menu Setup lt s siis ecient desi 20 5 3 1 HYDROGUARD Control Panel sus 21 5 32 Operator Men s a satin bhai tendres eme ein een Mt eee 21 5 3 3 Configuration Settings in the Operator Menu 24 534 Technician Menu eme Ae ege EE ete 24 5 3 5 Configuring Settings in the Technician Menu 26 5 4 CETTE NE re I LE 27 5 4 1 Chlorine Calibration sisi 27 5 4 2 Calibrating other Sensors and Meiers 28 5 5 Calibration and Initial Operation Checklist sseesseesseesseesseeeseeeeresnnnrennsrn nern nennen 28 6 Routine Operation and Maintenance cccccecceeeeeceeeeeeeeeeeeaeeeeaeeseeeeeseeeetaeeeeeeeeeneess 28 6 1 Monitoring HYDROGUARD Alams cece is
87. ted in Table 8 along with a description and resulting action of the analyzer controller Alarm Alarm Description Result A1 No flow There is not enough water reaching the Stop all chemical dosing controller all relays are open A2 L The water flow rate in the main circulation Stop all chemical dosing ow flow SE Ge pipe is lower than the flow limit all relays are open Check CLRMTR Communication error between NG ENGANG sendi ia A3 optional ORP connect colorimeter and colorimeter board emergency mode No chlorine dosing A4 No reagents Reagents are empty optional ORP emergency mode No chlorine dosing A5 Stuck piston The piston is not moving properly optional ORP emergency mode No chlorine dosing A6 Unclean cell The glass in the colorimeter is dirty optional ORP emergency mode No chlorine dosing A7 Replace light LED in colorimeter is not working optional ORP emergency mode A8 Low reagents Reagents are below 20 Bue ED asna message only A9 Chlorine lt 0 1 Chlorine unusually low No chlorine dosing A10 High ORP ORP above upper limit No chlorine dosing A11 Low chlorine CI below lower limit Ss A12 High chlorine Cl above upper limit A13 Low pH pH below lower limit A14 High pH pH above upper limit Ss A15 Low ORP ORP below lower limit A16 High NTU Turbidity above upper limit A17 EXTERNAL OFF External flow switch is o
88. ter is sampled The two 500 ml bottles last approximately 4 to 8 weeks depending on the measurement interval selected A Low Reagents alarm is issued when either one of the reagent bottles approaches depletion and should be replaced If the reagents are not replaced before the reagents are depleted the testing and chlorine dosing will stop and a No Reagents alarm will be displayed Therefore it is important to replace reagents before this occurs Filter Cleaning The HYDROGUARD unit has a filter installed in its water supply pipe which collects particles and impurities It should be cleaned or replaced periodically depending on water quality The clear filter cover allows a quick visual inspection to determine if cleaning is required Shut down and Winterizing If the analyzer will not be operating for an extended period of time or in areas where temperatures drop below freezing all water must be removed from the analyzer to prevent components from breaking The probes must be removed and stored in a warm area and kept wet at all times Start up and Preventive Maintenance A preventative inspection and cleaning of components should be completed whenever the analyzer is restarted after a long gt 2 weeks downtime or at least annually if the analyzer is operating constantly Likewise the analyzer has several mechanical components that will wear out over time To prevent future problems these components should be checked and or replaced periodic
89. the analyzer menu Operator Menu If the NTU relay is connected to external equipment 1 Press Menu until Turbidity Set Point appears on the display and press OK 2 Enter the operator or technician password and press OK 3 Enter the turbidity set point value and press OK With or without the NTU relay connected to external equipment 4 Press Menu until Turbidity High Alarm appears on the display and press OK 5 Enter the operator or technician password and press OK 6 Enter the turbidity high alarm value and press OK Technical Menu 1 Press Menu to enter the Operator Menu and then Press up and down together to enter the technical menu 2 Press Menu until Turbidity ON OFF appears in the display and press OK QD Enter the technician password and press OK o A Press UP to turn the turbidity sensor ON and then press OK Press Menu until Turbidity Wiper Interval appears in the display and then press OK O Enter the technician password and press OK 7 Enter the wiper interval 2 minutes is recommended and press OK The turbidity unit should now be active Confirm that the turbidity value appears on the LCD display If it is not active perform a system reset 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 47 O Blue I Water Technologies 7 4 4 Routine Maintenance 7 4 4 1 Turbidity Calibration 1 Take
90. the first 24 48 hours Table 6 Calibration Table Date Site Technician s Name Parameter Analyzer Readinc External Device or Standard Value Free Cl Total Cl Flow Rate 6 Routine Operation and Maintenance Once installed by a qualified technician HYDROGUARD can begin monitoring and controlling water quality HYDROGUARD is specifically designed for easy operation however some periodic maintenance is still required Basic guidelines are provided in Table 6 however the actual schedule may vary depending on conditions and use 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 28 O Blue I Water Technologies Table 7 Maintenance Table Service Required Expected Frequency 1 ta 2 months 1 month fclean when visible dirt oil 12 months Basic Operation involves setting the desired parameters and monitoring the system for alarms When operating normally HYDROGUARD demands very little operator involvement Calibration Sensor sensitivity and accuracy can degrade or drift over time For this reason HYDROGUARD settings must be periodically recalibrated and compared with measurements from other measuring devices such as electronic photometers pH sensors and thermometers or compared to standard solutions like pH buffers or ORP standards Reagent Replacement HYDROGUARD uses a very small amount approximately 0 03 ml of chlorine reagents each time wa
91. to be removed and reattached Please refer to 6 5 1 Replacing Reagent Pump Head and Tubes 6 7 5 Replacing Colorimeter The HYDROGUARD water quality analyzer s colorimeter is a self contained chlorine analyzing cell to determine the chlorine concentration in the water Follow the procedure below to replace the colorimeter 1 Turn off the water inlet and outlet from the flow cell and turn off the analyzer power 2 Open the doors of both the analyzing module and the control module 3 Locate the colorimetric cell unit in the analyzing sets 4 Disconnect the existing Colorimeter a Remove the top cap from the colorimetric unit i Make sure not to touch the reagent injection needles in the cap b Disconnect the outlet tube from the colorimetric unit c Unscrew the union between the solenoid valve and the Colorimeter d Unscrew the four 4 mounting screws that hold the Colorimeter to the HYDROGUARD housing 5 Open the control module door 6 Trace the wires from the Colorimeter to the colorimeter control module connector A total of four wire pairs 2x4 are connected to the control module 4 connected to the MIXER terminal block and 4 to the SENSOR terminal block 7 Disconnect the Colorimeter s wires from the Colorimeter module 8 Connect a new Colorimeter unit a Hand tighten the union between Colorimeter and the solenoid valve until the Colorimeter is tightly connected to the valve Check that the O r
92. trol panel door below the control panel module using the 4 supplied screws 2 Attach the ribbon cable from the 4 to 20 module to any open connector on the 1 0 module Electrical Installation The 4 to 20 mA module is powered through the ribbon cable and does not require a separate electrical supply as the external module Configuration For Free CI Only the 4 20mA output may be set to Read or Control e Read Mode will operate like the standard 4 20mA output and send an output related to the measured value See Internal 4 to 20mA Output e Control Mode will send an output to control the feed system based on o Measured value o F Cl set point 1 o Cl P factor The Control Mode has 2 options normal and inverted Invert in the menu e Normal o 4mA No CI Dosing o 20mA Max Cl Dosing e Inverted o 20mA No CI Dosing o 4mA Max Cl Dosing The menu for 4 20mA output settings is found on the technician menu 1 Set the 4 20mA outputs a Enter the technician menu and scroll until 4 20mA output settings appears in the LCD b Press OK i Enter the technician password and press OK c Select Channel i Select Built in ch 1 2 and press OK ii Select 4 10 NTU ch 1 4 and press OK d Select Parameter F CL pH ORP Temp Flow NTU T CL C CL Cond and press OK 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 57 O
93. tubes from the water containers and turn the pumps ON for an additional 90 seconds to remove any water 5 With the solenoid valve in the open position turn off the power to the analyzer If the solenoid is in the closed position the unions at the top and bottom of the solenoid should be loosened to allow the colorimeter and solenoid to completely drain 6 Check the security of the analyzer doors to ensure a weatherproof seal 6 5 Start up and Preventive Maintenance After the analyzer or flow has been off for a long period of time gt 2 weeks a few simple checks should be done during the initial start up Several components may need to be cleaned and some mechanical parts may be replaced as preventative maintenance 1 Remove the colorimeter cap and clean the quarts glass using a cotton swab 2 Remove the solenoid and check the tip for corrosion this may occur if shut down improperly and check the stop for deterioration or signs of wear The corrosion can usually be cleaned away and the solenoid will continue to work properly After start up confirm that the water is completely stopped when the solenoid shuts If it is not shutting properly it must be cleaned or replaced 3 Inspect the pump tubes for cracks or signs of significant wear and replace if necessary 4 Install new reagents and prime the tubes 5 Inspect the needles in the colorimeter cap to ensure that droplets are forming and falling properly Replace if necess
94. urs qualifi s ayant re u la formation ad quate sont habilit s modifier les dosages des produits chimiques utilis s Conformez vous sans exception aux consignes locales de sant et de s curit lorsque vous effectuez toute op ration technique sur l analyseur le contr leur ou lorsque vous modifiez les param tres de dosages chimiques L alimentation g n rale peut tre branch e sur 110 120 ou sur 220 240VAC 50 60Hz Pour basculer d une tension l autre il suffit de changer les deux 2 cavaliers situ s au dessus de la principale connexion lectrique gauche du transformateur Une tension 110 120VAC requiert un fusible de 1 Amp une tension 220 240VAC requiert un fusible de 0 5 Amp Ces modifications doivent tre accomplies avant le branchement lectrique 18 Ha melacha St Rosh Ha ayin 4809148 Israel Tel 972 9 7680004 Fax 972 9 7652331 www blueitechnologies com 7 Blue I Water Technologies Caution Before connecting to a power source confirm that both jumpers are located on the correct voltage and that the appropriate fuse is in place Each relay connection is limited to 4 amps to prevent overheating The relays may show a higher rating but do not connect equipment exceeding 4 amps All electrical connections should comply with National Electrical Code NEC and all local regulations Mixing reagents Caution Use protective gear as recommended in MSDS Caution Do not u
95. vel if operation is normal Replace probe if needed Low chlorine A11 CI below lower limit High chlorine A12 CI above upper limit Message Only Compare to manual reading Check reagent flow from bottle to colorimeter Check clean solenoid valve including spring Check water flow Verify piston movement mixing Check that dosing systems are operating properly Low pH A13 pH below lower limit High pH A14 pH above upper limit Compare to manual reading and recalibrate if necessary Check if unstable reading is due to poor grounding Increase high low pH level if operation is normal Replace probe Low ORP A15 ORP below lower limit Compare to manual reading and recalibrate if necessary Check if unstable reading is due to poor grounding Increase high low ORP level if operation is normal Replace probe High NTU A16 Turbidity above upper limit Check constant reading Compare to manual reading Check wiper movement Clean sensor window Change if necessary External Off alarm A17 External flow switch is off No chemical dosing all relays are open Make connection on UO board with flow sensor on connections 5 6 or with jumper wire to complete circuit Not recommended to operate with jumper only Total CI high A18 Total CI above upper limit Compare to manual reading Check reagent flow from bottle to co
96. x 972 9 7652331 www blueitechnologies com 12 O Blue I Water Technologies 4 Installation 4 1 Working Environment Pollution Degree 2 Installation Category 2 Altitude 2 000 m Humidity 1 to 90 non condensing Electrical Supply 100 115Vac 1 0A or 200 230Vac 0 5A 50 60Hz Temperature 5 C to 45 C 4 2 Selecting a Location Take extra time in selecting a location since the installation location will determine the ease of the installation and future operation and maintenance The location where HYDROGUARD is installed is dependent on various considerations Convenient Access The HYDROGUARD should be installed where it can easily be viewed and operated Dry Area The HYDROGUARD handles electricity and includes electronic circuitry that is susceptible to short circuiting and or corrosion when exposed to water or high ambient moisture levels Away from Chemicals Many water treatment chemicals can be corrosive to HYDROGUARD s electronic circuitry It is highly recommended that HYDROGUARD is not installed adjacent to a storage area for chemicals or the dosing systems themselves Minimum Distance from Supply Pipe The water sampling line that is connected to the main pipe and that feeds the HYDROGUARD should be as short as possible A long sample creates an unnecessary delay between supply measurement analysis and chemical dosing Drainage The location should easily allow the outlet of the colorimeter to g

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