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Pulsafeeder PULSAblue 3300 Series Installation & Operation Manual

Microprocessor-based orp and conductivity controller
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PULSAFEEDER
MODEL 3323
MICROPROCESSOR-BASED
ORP AND CONDUCTIVITY CONTROLLER
INSTALLATION & OPERATION MANUAL
SERIAL #:_______________
0

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  • Page 1 PULSAFEEDER MODEL 3323 MICROPROCESSOR-BASED ORP AND CONDUCTIVITY CONTROLLER INSTALLATION & OPERATION MANUAL SERIAL #:_______________...

  • Page 2: Table Of Contents

    Table of Contents Quick Installation Sheet .................... 3 Cautions and Warnings ..................... 5 Contact Information ....................5 Introduction ......................6 Features, Benefits, Specifications ................7 Features ......................7 Benefits ......................7 Specifications ....................8 Unpacking, Mounting and Installation................9 Unpacking ...................... 9 Mounting .......................
  • Page 3 13.7 Configuring Relays 2,3 and 4 ................27 13.7.1 Disabled ....................28 13.8 By Setpoint ....................28 13.8.1 Setpoint ....................28 13.8.2 Deadband ....................29 13.8.3 Overfeed Time ..................29 13.8.4 When to Activate ..................29 13.8.5 By Water Meter ..................29 13.8.6 By percent of blowdown Time ...............

  • Page 4: Quick Installation Sheet

    Pulsafeeder™ Model 3300 Controller 1 Quick Installation Sheet 1. Attach the four (4) supplied mounting feet to the back of the controller enclosure either vertically or horizontally. Install the controller on a flat, non-vibrating surface. Do not mount the controller to a steel object that has a large temperature change (side of cooling tower, etc).
  • Page 5 FIGURE A...

  • Page 6: Cautions And Warnings

    DO NOT change the plug in any way. 3 Contact Information We thank you for your selection and purchase of a Pulsafeeder product. With proper care and maintenance, this device should give you many years of trouble-free service.

  • Page 7: Introduction

    4 Introduction The Model 3323 is a L Technology, microprocessor based, menu driven, ORP and conductivity ORKS water treatment controller designed for use in cooling towers. The Model 3323 provides for ORP and conductivity tracking and control, flow monitoring and chemical injection. The Model 3323 is CSA and ANSI/UL approved.

  • Page 8: Features, Benefits, Specifications

    5 Features, Benefits, Specifications 5.1 Features ORP input with ORP sensor diagnostics indicates fouled reference or open PT band. Conductivity input with fouling compensation and alarm. Integral flow sight & flowswitch lockout. Two (2) water meter inputs. Records both makeup (MTR1) and Blowdown (MTR2) water meter total gallons.

  • Page 9: Specifications

    Has expansion slots to add additional control, such as additional relay outputs, 4-20 mA outputs, remote sensor inputs, digital inputs, and 4-20 mA inputs. 5.3 Specifications Conductivity range Water meter inputs (2) 0-5000 µS Contact head, paddle wheel or turbine. Conductivity Accuracy Output relays 1 Bleed off...

  • Page 10: Unpacking, Mounting And Installation

    Use #10 mounting screws (4). Avoid drilling or punching additional holes in the controller enclosure. Damage incurred as a result of any alteration to the enclosure is not covered under the Pulsafeeder product warranty. The dimensions of the enclosure in inches are:...

  • Page 11: Plumbing Installation

    This line brings the sample water into the sensor plumbing for conductivity measurement. If the Pulsafeeder flow switch plumbing assembly is used, this flow of water also pushes the flow switch float up to activate the relay outputs of the controller.

  • Page 12: Electrical Installation

    WARNING: NEVER INJECT CHEMICALS UPSTREAM OF THE CONTROLLER FLOW CELLS!  If you have questions or need assistance, call Pulsafeeder Technical Service Department at (800) 333-6677, Monday-Friday, 8:00 a.m. - 5:00 p.m. EST. WARNING: SOME CHEMICALS MAY HAVE TO BE INJECTED DIRECTLY INTO THE COOLING SYSTEM WATER LINE AND NOT INTO THE SAMPLE LINE.

  • Page 13: Flow Switch Wiring

    Seametrics open collector output meters, Signet 2535 and 2540 paddle wheel meters, and the Autotrol 1 inch and 2 inch meters. Contact Pulsafeeder for other types of water meters. The water meters are wired to terminal block P1 which is the top terminal block on the I/O board.

  • Page 14: Node Wiring

    Refer to the drawing in the back of this manual for wiring instructions. 8.6 Node Wiring If optional nodes are ordered they must be wired to the controller before installation and programming can take place. Nodes require +24 VDC for operation and twisted pair wire for data transmission. The network interface option card can provide the +24 VDC for up to two nodes using non-twisted pair wire.

  • Page 15: Display

    16-BUTTON KEYPAD ENT = for Menu selection and/or acceptance ENCLOSURE INDICATOR LIGHTS of selected values. A sturdy NEMA 4X enclosure LEDs for Power, Alarm, Relay BACK = to exit a Menu protects your controller. Make sure status, and Flow selection and/or skip it is properly mounted on a flat, input options.

  • Page 16: Keypad

    9.3 Keypad The unit uses a 16-key numeric keypad for ease of programming. The keys have the following functions: To accept a setting or to enter a screen. BACK To exit a screen or to access the main menu. To calibrate the controller. LANG To change languages.

  • Page 17: Starting Up The Controller

    relays manually, view the process screens, and calibrate the controller. He cannot change any other settings. In the Technician mode the operator has full access to all of the menus. A password is required to change from a tight security level to a less restrictive security level. Each level has its own factory-preset password (2222 for Technician, 1111 for Operator).
  • Page 18 The screen that is used the most in the 3323 controller is the Process Screen. Below are the process screen views. The process screen has three sections. The top section shows the ORP and conductivity readings. The alarm bar is the middle section and appears between the top and bottom sections. It is solid in appearance and flashes showing the current active alarms in sequence if there are multiple alarms.

  • Page 19: Manual Operation Of The Relays

    The controller uses a single point calibration. A two point calibration is not necessary if using a Pulsafeeder conductivity sensor. Ensure that the controller is operating with good flow past the sensor. Take a sample of the water and measure with a hand-held conductivity tester.

  • Page 20: Calibration Check Of Conductivity In Buffer Solutions

    12.2 Calibration check of conductivity in buffer solutions To check the calibration of the sensor in buffer solutions, the sensor is placed in a container of the buffer solution. Ensure that the sensor tips are centered in the container away from the edges and the bottom of the container.

  • Page 21: Calibration Of Orp

    22.0 6500 4700 24.5 7000 5000 27.5 7500 5400 33.0 8000 5800 39.0 8500 6200 45.0 9000 6600 51.0 9500 7000 56.0 10,000 7400 12.4 Calibration of ORP The controller reads ORP in millivolts. To control free bromine or free chlorine pH and temperature must be maintained.

  • Page 22: Calibration Check Of Orp In Buffer Solutions

    To calibrate the sensor in buffer solutions, the sensor and a solution ground wire must be in the container of the buffer solution. Perform the two-point calibration as follows: Initialize the calibration. Shut the isolation valves to the controller plumbing assembly. Open the controller front panel.

  • Page 23: Configuring The Relays

    5 WATER METERS 6 4-20 MA IN/OUT 7 SYSTEM SETUP 8 CLOCK The MAIN MENU can be accessed from the PROCESS screen by pressing ―BACK‖. If ―BACK‖ is pressed and the MAIN MENU does not appear, the controller is probably in the VIEW ONLY or OPERATOR security mode.

  • Page 24: Disabled

    The blowdown relay can be configured to operate based on a setpoint or based on a water meter input. When the blowdown relay is selected for programming the following screen will appear. BLOW ========================= 1 DISABLED 2 *BY TOWER SETPOINT 3 BY MAKEUP VOLUME 4 CHANGE MY NAME 5 SCHEDULED LOCKOUT?

  • Page 25: Deadband

    The SETPOINT is the Conductivity value that you are trying to maintain. Check with your water treatment engineer to determine the Conductivity setpoint for your system needs. Follow these instructions to establish the controller's setpoint: Use the keypad numbers to enter the proper Conductivity setpoint and press ‖ENT‖. When finished, you will automatically be moved down to the deadband.

  • Page 26: Change A Relay Name

    There are two methods available to blowdown based on volume, FOR BLOWDOWN FLOW and FOR BLOWDOWN TIME. With FOR BLOWDOWN FLOW, the blowdown relay will be on until a specified amount of blowdown is met after a specified amount of make-up has been received. With FOR BLOWDOWN TIME, the blowdown relay will be on for a specified amount of time after a specified amount of make-up has been received.

  • Page 27: Blowdown By Cycle Setpoint

    Press ―1‖ YES to lock out the relay during a scheduled feed or press ―2‖ NO to allow the relay to operate normally during a Calendar Timer. Note: This setting is only available and visible when the relay is set to operate based on SETPOINT, WATER METER, or PERCENT of TIME.

  • Page 28: Configuring Relays 2,3 And 4

    This option is only available if a conductivity node (NCON) is installed as the MAKEUP COND input. If the NIN is installed with a conductivity node installed as the MAKEUP COND input the BLOWDOWN relay can be configured to blow down based on multiple setpoints instead of a single tower setpoint. There are three different setpoints that can be established based on the value of the makeup water conductivity.

  • Page 29: Disabled

    RLY2 ============ 1*DISABLED 2 SETPOINT 3 WATER METER 4 PERCENT BLOWDOWN 5 PERCENT OF TIME 6 CALENDAR TIMER 7 ALARM RELAY 8 CHANGE MY NAME 9 SCHEDULED LOCKOUT? 13.7.1 Disabled Relays 2, 3, and 4 can be disabled. When a relay is disabled, it will not energize automatically. From the RELAY OPTIONS screen press ―1‖...

  • Page 30: Deadband

    13.8.2 Deadband After the setpoint is established, the relay's deadband must also be set. "Deadband" refers to the amount of conductivity or ORP above and below the setpoint—a range within which the controller will not react. Due to continuous fluctuations in the conductivity and ORP level, it is necessary to have this deadband range or stable readings will be difficult to obtain.

  • Page 31: By Percent Of Blowdown Time

    From the RELAY OPTIONS screen press‖3‖ WATER METER. Select either MTR1 or MTR2 or BOTH as the trigger for the relay. Use the keypad to enter the amount of flow before the relay is activated. Press ‖ENT‖. Enter the amount of time that the relay will be activated. Press ‖ENT‖. 13.8.6 By percent of blowdown Time Relays 2, 3, and 4 can be activated by a percent of the time that the blowdown was on.

  • Page 32: By Calendar Time

    We select 10% of the time, our controller operates 24 hours a day and our chemical pump flow rate is 1 gallon per hour. 10% x 24 hours x 1gallon = 2.4 Gallons Hour From the RELAY OPTIONS screen press‖4‖ PERCENT OF TIME. Use the keypad to enter the percentage of time desired.

  • Page 33: Change Relay Name

    9 ANALOG INPUTS (4) 10 ANALOG INPUTS (4) 11 DIGITAL INPUTS (4) 12 DIGITAL INPUTS (4) Select the alarms from this menu that will activate the relay. 13.8.10 Change Relay Name The name of each individual relay can be changed to any 4-character name. This is useful to designate the chemical name for each relay.
  • Page 34 From the MAIN MENU press‖3‖ CALENDAR TIMER. You will see the following screen: CALENDAR TIMER ============ 1*BY WEEKDAY 2 BY CYCLE CALENDAR 3 LIST SCHEDULE The Calendar Timer can be programmed to feed chemicals by either WEEKDAY or by a CYCLE CALENDAR basis.
  • Page 35 Inputting 0:00 will disable this feature. Pulsafeeder recommends that some time be entered if pre-bleed is used. FEED DURATION is the amount of time the Calendar Timer relay will be on.

  • Page 36: Alarms

    Seametrics open collector output meters, Signet 2535 and 2540 paddle wheel meters, and the Autotrol 1 inch and 2 inch meters. Contact Pulsafeeder for other types of water meters. Both water meter inputs are programmed in the same manner.
  • Page 37 WATER METER TYPES ================= 1 CONTACTING HEAD 2 PADDLE WHEEL 3 DATA INDUSTRIAL 4 SIGNET 5 AUTOTROL TURB 1 IN. 6 AUTOTROL TURB 2 IN. 7 CHANGE MY NAME Use the keypad to select the type of water meter that you are using. The next screen is the UNITS OF VOLUME screen.

  • Page 38: Set-Up The 4-20Ma Output

    If the AUTOTROL TURB 2 IN. is selected: The controller will confirm that the AUTOTROL TURB 2 IN. has been selected and you will be asked if you want to reset the total count for that meter to zero. Press ‖1‖ for YES or press ‖2‖ for NO. 17 Set-up the 4-20mA Output If the 4-20mA option is ordered the controller will have two channels of 4-20 mA outputs.

  • Page 39: Manual Control

    17.3 Manual Control Manual control is used to temporarily change the 4-20 mA output. From the 4-20 mA Setup screen, press ‖2‖ MANUAL CONTROL. Use the up and down arrow keys to raise or lower the 4-20 mA output. To exit this screen and restore automatic control of the 4-20 mA output press ‖BACK‖.

  • Page 40: Damping

    Use the arrow keys to change the characters, use the ENT key to move the cursor to the next character. 18.3 Damping The rate of change of the ORP value can be slowed down using DAMPING. If the ORP value is changing quickly you can slow it down by: From the Main Menu press‖7‖...

  • Page 41: Change The Security Passwords

    If you lose your password, contact Pulsafeeder for assistance. 18.8 Diagnostics The diagnostics screen is used for troubleshooting purposes. Contact Pulsafeeder for assistance. 18.9 Communications The controller has an option for remote communications, the RS-232 option. If this option is installed the communications option is configured from this screen.

  • Page 42: Initialize Modem

    If the modem fails to initialize, check the 25-pin connector, the phone cable, the modem, and the RS- 232 option card. 18.12 Remote Password Remote communications to the Pulsafeeder 3300 series controllers is protected with an 8-digit password. The remote password is required to make changes to the controller using the communications option card.

  • Page 43: Node Installation

    18.13 Node Installation The node installation menus is used to install new nodes and to de-install installed nodes. Please refer to your node manual for information on node installation. 19 Setting the Clock The clock uses the 24 hour or military time. 06:00:00 is 6 a.m. 18:00:00 is 6 p.m. To set the clock: From the Main Menu press ‖8‖...

  • Page 44: Maintenance

    To return to the Technician security level: Press the numeric password from the Process screen: TECHNICIAN PRESS ANY KEY Remember that following the first power-up the Technician password is 2222 and the Operator password is 1111. You may change the passwords in the SYSTEM SETUP menu. 21 Maintenance Periodic maintenance is required to ensure trouble free operation of the controller.

  • Page 45: Flow Switch Maintenance

    21.2 Flow Switch Maintenance If you have the flow switch plumbing assembly, you may need to periodically clean the wetted parts in this assembly. Shut off the inlet flow and the power to the controller. Turn the coupling nut for the flow switch counterclockwise. Pull out the red shuttle with your fingers.

  • Page 46: Replacing The Fuses

    This section discusses some of the more common questions. These notes are not intended to be all-inclusive—only to cover the most common situations. If you have other questions or need support, contact the Pulsafeeder Technical Service Department toll free at (800) 333-6677. PROBLEM...
  • Page 47 If there is power to terminals LINE and NEUTRAL on TA, call Pulsafeeder Technical Service for more information.
  • Page 48 PROBLEM WHAT THIS MEANS CORRECTIVE ACTION Check for proper operation of pump or valve. Use the manual relay control to help. Check that the chemical drum is not empty. This indicates that the controller has been trying {Alarm Flashing} Check for power to the chemical pump. to feed chemical for longer than the user- “RLY: TIME EXCEEDED”.
  • Page 49 PROBLEM WHAT THIS MEANS CORRECTIVE ACTION You are trying to perform a span calibration of the Check wiring. “SENSOR READS conductivity and the conductivity sensor reads ZERO” zero. Ensure sensor is full immersed in water. 3. The model 3323 for cooling towers will not accept a span calibration below about 200 µS.

  • Page 50: Factory Service

    Any modifications or out-of-warranty repairs will be subject to bench fees and costs associated with replacement parts. Warranty Pulsafeeder, Inc. warrants control systems of its manufacture to be free of defects in material or workmanship. Liability under this policy extends for 24 months from date of shipment.
  • Page 51 When calling Pulsafeeder, please have your controller‘s complete model number and serial number available, together with the firmware version so that the Technician can better assist you. Refer to the Ordering Information section of this manual for part numbered replacement parts.

  • Page 52: Drawings

    24 Drawings...
  • Page 55 Prewired...
  • Page 56 Prewired...

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Pulsablue 3323

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