AQUARIUS ULTIMA Series User Manual
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AQUARIUS ULTIMA Series User Manual

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ULTIMA SERIES
USER MANUAL
REVISION 0 - 1/08/2024

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  • Page 1 ULTIMA SERIES USER MANUAL REVISION 0 - 1/08/2024...

  • Page 2: Table Of Contents

    CONTENTS Water Meter ........... 38 Contents ........... 2 Level Switches and Sensors....39 Introduction ..........3 Timers ........... 40 Safety Information ........3 Accessory Timers ........41 Installation ..........4 Output Configuration ......42 Unboxing & Initial Inspection ....4 Test Outputs ..........

  • Page 3: Introduction

    Refer AS/NZS 3000 WIRING RULES when installing electrical equipment in and around operating area. Power cover to be removed by Aquarius Technologies Pty Ltd, an authorized service agent or licensed electrician only, and must be replaced before controller is connected to power supply.

  • Page 4: Installation

    In case of damaged or missing parts, take a photo while items are still in the box and report the fault to the Aquarius Technologies sales team (sales@aquariustech.com.au). HARDWARE SETUP COOLIN G TOWERS NOTE: when fitting pH/ORP probe, remove the protective cap from and fit it into the manifold.
  • Page 5 Flow cell inlet hose UNIQ ONLINE CORROSION MONITORING FOR COOLING TOWERS UNIQ Layout 1. UNIQ Controller 2. Aquarius CS/Cu corrosion sensor 3. Sample valve and tube 4. Inline flowmeter controls manifold flow and functions as flow switch 5. FCT sensor 6.
  • Page 6 Put the suction line of pumps to the chemical tanks as required and ensure each dose pump’s discharge tubing is connected to the injection points provided on the manifold. ULTIMA USER MANUAL REVISION 0 PAGE 6 OF 67...

  • Page 7: Mounting The Controller

    MOUNTING THE CONTROLLER Mount and secure the backboard, manifold and controller to designated area. Connect a 20 mm line from the circulating pump discharge line, or system common discharge header or condenser, to the inlet of the manifold. Connect a return line from the manifold outlet valve, preferably in PVC pipe to the pump suction or common suction header or to the tower basin.
  • Page 8 ULTIMA USER MANUAL REVISION 0 PAGE 8 OF 67...
  • Page 9 Typical Installation – Cooling Tower Note: If installing a BCD Feeder, assemble as per OEM instructions and floor mount in the vicinity of the system. Plumb from the BCD solenoid to the inlet of the BCD feeder and from feeder to the system. Typical Installation –...
  • Page 10 ULTIMA USER MANUAL REVISION 0 PAGE 10 OF 67...
  • Page 11 ULTIMA USER MANUAL REVISION 0 PAGE 11 OF 67...

  • Page 12: Ultima Overview

    ULTIMA OVERVIEW 1. Controller ID label 2. Controller casing seal + 9 x captive closing screws 3. Mother board 4. Modem mounting clip 5. Casing hinges (retaining clip on upper hinge) 6. Ribbon type connection cables 7. Electrical hazard/safety information 8.

  • Page 13: Mother Board

    MOTHER BOARD 1. Modem power supply/ data Rx/Tx connector 2. SD card slot 3. Isolation board (module) connectors 4. Battery 5. USB port 1 and 2 6. Power cable connector 7. Probe-board power and data cable connector 8. Expansion board cable connector ULTIMA USER MANUAL REVISION 0 PAGE 13 OF 67...

  • Page 14: Expansion Boards

    EXPANSION BOARDS Expansion boards may be plugged into the expansion board cable connector (see 8 above) to provide additional features. For configuration guidance, please refer to “Expansion Board Configuration” section under System Settings. MODBUS BOARD – HIGH LEVEL INTERFACE (HLI) PCB card to enable Modbus RTU capabilities to BMS/DDC systems.

  • Page 15: Probe Board

    PROBE BOARD 1. Power cable connector between Probe board and Motherboard 2. BNC location for external pH/ORP connectors (if fitted) 3. Combination Probe (PR_PHRG) connector 4. FAC* probe connector (default 3-pin type probe) 5. FCT probe (PR_FCT) connector 6. 12V DC and Ground (GND) port at TB2 7.
  • Page 16 CONNECTING STANDARD SENSORS/PROBES Standard ULTIMA controllers use two probes for measurement:  PR_FCT Probe: Flow switch/Conductivity/Temperature. Blue connection cable, RJ45 connector.  PR_PHRG Probe: pH/ORP/Ground Reference (note: for pool systems, use PR_PHRG_AU). Black connection cable, Molex 2x2 / Minifit JR 4-pin connector. Loosen the 9 captive casing crews on the front cover to open the controller.
  • Page 17 Free and total chlorine Fluorometers 2- and 3-wire sensors may be fitted. Please consult with the Aquarius Technical team so that we can assist in seamlessly integrating your chosen sensors with your ULTIMA controller. The ULTIMA can be specified to include facility for 6 x generic 4-20mA inputs within the firmware. These inputs may be configured to desired alarms and setpoints;...
  • Page 18 6 x 4-20mA inputs – Probe Board (PRO, UCT & UNIQ only) There are 6 available 4-20mA inputs available on the probe board: “CL1-5” at TB1 (12), and “4_20” at TB5 (7). To utilise “CL4” and “CL5”, ensure that corresponding dip switches (8) are turned to the “ON”...
  • Page 19 SETTING DIP SWITCHES The ULTIMA probe board contains two dip switches: Component Dip Switch (8) and Default FAC Gain Dip Switch (9). Component Dip Switch Use component dip switches to enable or disable component inputs. Left = disabled, right = enabled Symbol Component Conductivity...

  • Page 20: Gpo Outputs

    GPO OUTPUTS Match and connect power points for pumps and functions’ outputs by following below table: Allocated output’s function (By Default) Output pH pump (Acid or Base) ORP pump (eg. sodium hypochlorite) or BCD solenoid Inhibitor pump Bio B pump (can be accessed through “Timers”...

  • Page 21: No Volt (Dry Contact) Outputs

    NO VOLT (DRY CONTACT) OUTPUTS If using diaphragm pumps for chemical injection, it is recommended to run them using no volt (dry contact) outputs.  Plug diaphragm pump to a free 240V GPO socket inside the controller (outputs 1 – 4) ...

  • Page 22: Before First Startup

    BEFORE FIRST STARTUP  Ensure ribbon connection cables are connected securely.  Ensure solenoid plugs are electrically connected and secured with connecting screw.  Ensure all plumbing and tubing are connected securely and sealing. CONTROLLER SETUP POWER ON Plug the controller into compliant 240VAC power supply. Wait for 30-60 seconds until program is fully loaded, and front “Unlock”...
  • Page 23 Press on any panel, eg. to open up the corresponding screen. To exit a screen and return to the previous menu, press Alarms: menu screens display different parameters or functions. These are normally blue, but flash red when in the alarm state. On Menu Screen 3 above, the “Flow Off” alarm is active and so the “Flow”...

  • Page 24: Ph/Phb

    PH/PHB Select pH or pHB from the main menu. pHB appears on the second menu screen. pHB is a backup function to control pH between two limits using Acid and Base chemical dosing, or to provide secondary/backup dosing control. Ignore this function if not relevant. Set point: Manually enter target pH value.
  • Page 25 ADVANCED FEATURES Select from the function screen: Cycle Time (Dose Period): Time period whereby the controller decides whether and for how long to dose, to achieve set point. This decision occurs at the last second of every cycle time. If the decision is taken to run the pump at 20% duty, pump will run for 20% of the next cycle time, eg.

  • Page 26: Orp/Orpb

    ORP/ORPB Select ORP or ORPB from the main menu. ORPB appears on the second menu screen. ORPB may be configured to provide control for a secondary secondary/backup dosing output if required. Ignore this function if not relevant. Set point: Manually enter target ORP value. Pump duty: Use to regulate output capacity for ORP pump or chlorinator.
  • Page 27 ADVANCED FEATURES Select from the function screen: Dose Type: Select “Oxidising” or “Reducing”, depending on chemical type. Safety Min & Max: these functions are used only if ORP is set as an accessory timer. Note: Leave the safety limits on default if not sure. Fuzzy: see “pH/pHB”.

  • Page 28: Flow Settings

    (Flow OFF) The required flow rate to turn on the flow function depends on the flow switch type. By default, the flow signal comes from Aquarius flow switch (PR_FCT) which requires 12L/min flow to show Flow ON.

  • Page 29: Temperature

    TEMPERATURE Select Temperature from main menu. Set point: Manually enter target temperature. Mode: Disabled: no temperature control Continuous: continual control of temperature, regardless of flow status Flow: control temp when Flow is ON (default). Control will be disabled when flow is OFF. Alarm mode: Disabled: no alarm mode Plus: triggers alarm when temp is above set point + alarm range, eg.

  • Page 30: Conductivity/Conductivity B

    CONDUCTIVITY/CONDUCTIVITY B Select Conductivity/TDS from the main menu. UCT controllers also have Conductivity B function available, to allow measurement of make-up water with separate conductivity probe. Control Mode: Allows you to select between Conductivity (µS/cm) and TDS (Total Dissolved Solids, ppm) to be shown on the main screen.
  • Page 31 ADVANCED FEATURES Safety Min: The minimum allowed Conductivity/TDS for pre-bleed function Safety Max: The maximum allowed Conductivity/TDS for bleed lockout Note: Safety Min and Safety Max must be at least 15% below or above the set-point. Set the safety limits before starting the controller. Otherwise, pre-bleed and bleed lockout functions may not work.

  • Page 32: Fac/Facb (Pro Models Only)

    FAC/FACB (PRO MODELS ONLY) Free Available Chlorine (FAC) is available for measurement and control on PRO-model ULTIMA controllers. Set point: Manually enter target FAC value. Pump duty: Use to regulate output capacity for FAC pump or chlorinator. See “pH/pHB”. Mode: Disabled: no FAC control Continuous: continual control of FAC, regardless of flow status...
  • Page 33 “Default” setting, at bottom right, is the 4-pin port for the PR_FAC probe. For PRO and ADVANCED models: Aquarius FAC Membrane sensors provide a superior method of measuring FAC, with high accuracy and simple maintenance requirements. These sensors are 2-wire generic sensors, and are configured to the FAC screen via Generic Inputs. See “Generic Inputs”...

  • Page 34: Inhibitor / Pretreat / Prechlor / Anti-Ox

    INHIBITOR / PRETREAT / PRECHLOR / ANTI-OX Inhibitor function enables dosing control, and has many applications for maintaining accurate concentrations of desired chemicals to your water treatment system. Here are the configuration options if applicable to your ULTIMA model: Mode: Disabled: no inhibitor dosing Continuous: continual dosing of inhibitor, regardless of flow...

  • Page 35: Dispersant

    DISPERSANT Dispersant configuration if applicable: Pump size: Set the size of dispersant pump (mL/hr) Dose rate: input the required dose rate Mode: Configure when to dose the entered “Dose Rate” of dispersant: Disabled: No dispersant control Continuous: Continual periodic dosing, regardless of flow status Bleed: Periodic dosing when bleed relay is ON.

  • Page 36: Generic Inputs

    GENERIC INPUTS ULTIMA controllers with ADVANCED firmware can accept up to 6 x generic input signals for data logging, monitoring and control. Wiring and installation  Ensure device is installed as per OEM instructions.  Wire sensor to any of the available 4-20mA inputs and 5/12/24VDC power ports inside the ULTIMA.
  • Page 37 3. Once you have named your Probe press ‘Calibration’ – ‘Setup’ – then select which input the cable has been wired into (i.e., M1, M2, 4-20mv, CL1 – CL5) 4. Enter your minimum range of the probe and press OK, then enter maximum range of probe and press OK.

  • Page 38: Water Meter

    6. Once this is done you should see readings from the probe, and corresponding mA reading between 4-20mA. Note: there may be a delay/ run-in period in achieving correct reading, depending on sensor type. Please refer to “Troubleshooting” section if any issues. 7.

  • Page 39: Level Switches And Sensors

    LEVEL SWITCHES AND SENSORS LOW LEVEL TANK SWITCH (FOR STANDARD ULTIMA MODELS) 0-5V low level tank switches are supplied in two sizes:  500mm with 3m pump suction tube and 3m lead/cable;  1000mm with 5m pump suction tube and 3m lead/cable. They come with the following items: ...

  • Page 40: Timers

    TIMERS ULTIMA controllers come with six 7-day timers, allowing for periodic activation of designated outputs. Example applications for the timer: Weekly superchlorination of cooling tower or pool; Periodic dosing of non-oxidising biocide to a cooling tower system. Set the timer Bio A/ORP and Bio B timers may already be labelled in the list of timers.

  • Page 41: Accessory Timers

    ACCESSORY TIMERS Each timer comes with 4 “Accessory Timers” allowing users to plan other functions related to that timer. Set the Accessory Timers Accessory Timers allow 4 other outputs to be interlocked with each main timer. Select an Accessory Timer to get into the settings page.

  • Page 42: Output Configuration

    OUTPUT CONFIGURATION ULTIMA series controllers have 14 outputs: Outputs 1 to 4: 240V output; wired to GPOs 1 to 4 inside the controller box. Output 5: 240V spare output Outputs 6&7: 240V output via relay, screw terminal available on the power board. Bleed solenoid cable is wired into the output 6 for conductivity control Output 8: optional 240V, 10-15A relay;...

  • Page 43: Test Outputs

    TEST OUTPUTS On the second screen of the controller, click on “Outputs” and then “Test Output” button, as shown. The following message will appear on the screen: “Press an output to activate it for 10 seconds”. ALL OUTPUTS ARE “FORCED OFF” NOW. Press outputs one by one and check the associated device is working correctly.

  • Page 44: Alarm Settings

    ALARM SETTINGS Alarm settings are available under Alarm page: Alarm filter: The delay to send an alarm after happening. This is to avoid unnecessary alarms in case of spikes. Default filter: 5 minutes. Mode: o Once only: When alarm happens o At time: Set a time to receive alarm if it is still active o Every: Set how often the same alarm to be repeated if still active...

  • Page 45: System Settings

    SYSTEM SETTINGS To access controller settings, press The system menu screen appears: ULTIMA USER MANUAL REVISION 0 PAGE 45 OF 67...

  • Page 46: Network Settings

    IP to connect. Local Network Requirements:  DHCP enabled, or contact Aquarius for a custom static IP to be set  If a firewall present: o reserve an IP for the MAC address on the network screen of the controller o Open TCP port 8883 to comms.aquareporter.com.au (currently 13.75.248.255) for reserved IP...
  • Page 47 NETWORK INTERFACE: WI-FI Plug a Wi-Fi adapter to either USB port. Click System, then Network Settings. Select Wi-Fi from Net Interface list.  Click Advanced;  Turn ON Wi-Fi and wait until Wi-Fi is found;  Select your Wi-Fi, input password and Connect; ...
  • Page 48 Fail = check location/better antenna/modem, send debug file to Aquarius Read Sim (check sim card details) Fail = check/replace sim card, send debug file to Aquarius Carrier/Carrier1/Carrier 2 (Connecting to network) Fail = check/replace sim card, send debug file to...

  • Page 49: Import/Export Settings And Export Data

    Set Static IP: assign IP address via particular network connection. Selecting this with no connection, will clear the Static IP address. Contact Aquarius to generate Static IP file. Select Exp Debug to export a debug data file for further investigation on issue and troubleshooting.

  • Page 50: Advanced Settings

    “Automatic Time Zone” must be ticked. No other changes in settings are required. o For non-web controllers: the time zone to be “Casablanca”. IMPORTANT: THE ABOVE SETTINGS ARE SET FROM FACTORY. CONTACT AQUARIUS PRIOR TO CHANGING. DO NOT SET DATE & TIME SETTINGS VIA “ADVANCED” SETTINGS MENU.

  • Page 51: Expansion Board Configuration

    EXPANSION BOARD CONFIGURATION Configure Modbus Refer to “ULTIMA MODBUS Manual” for minimum system requirements. Ensure that MODBUS PCB card is installed and wired as per “Expansion Boards” section of this manual, and “ULTIMA MODBUS Manual”. From the main screen, Select “System” then “Expansion Board”: In the Expansion Board dialog, you can see three settings.

  • Page 52: Aquareporter

    AQUAREPORTER Aquarius ULTIMA controllers with remote web access are monitored online via AquaReporter. Once your controller is connected to the internet, contact your Aquarius Sales representative to assign the controller to appropriate users. When a controller is assigned to you, you will receive an invitation via email to access AquaReporter.
  • Page 53 In the “Status” view, the controller component functions are mirrored from the controller to your computer screen. Connection status and “Last Comms” time and date are visible as highlighted. In this view, select “Filter Parameters” drop-down to show/hide parameters as desired. Click on any parameter in the “Status”...
  • Page 54 Navigate to the “Chart” view to create, display and download custom charts. Select desired parameters from the right hand column to display and compare trends. Start and end date can be adjusted from the top drop downs. Hit “Refresh” to update the chart. Sliders to the left and right of the graphs will adjust the zoom of the y-axes.
  • Page 55 Select “Event Log” view to view and download event messages. Messages can be filtered according to type eg. Comms, power, alarms, calibration, other. Use the “Report Period” function to filter event messages within a specific date range. The “Auto Report” function allows users to create and schedule customisable periodic reports, which are sent to designated email recipients.
  • Page 56 The “Auto Report” function allows users to create and schedule customisable periodic reports, which are sent to designated email recipients. To view, edit or create a new report schedule, access “Auto Report” view. Click on “New Schedule” to build a new report, or click on an existing listed report to edit details including scheduling frequency and day of the week and report content.
  • Page 57 “Profiles” function allows multiple controller settings .JSON files to be saved and pushed to your controller as needed. This feature is helpful for cases where multiple control modes are required for one controller. Contact Aquarius team to discuss optimal advice for your application. ULTIMA USER MANUAL...

  • Page 58: Maintenance

    MAINTENANCE CLEANING Refer to separate “Aquarius Controller Maintenance and Parts List” manual for further details.  All sensors should be inspected, cleaned and calibrated as necessary every month.  Fouling of sensors can lead to inaccurate readings. Sensors should be cleaned and calibrated regularly using the following procedures.

  • Page 59: Calibration

    40% away from the current reading at each stage.  Stability for calibration’s test normally takes minimum 15 seconds.  Contact the Aquarius team to order relevant calibration and cleaning solutions. Calibration Procedure Temperature 1. Apply cleaning Flow/Conductivity/Temp probe procedure.

  • Page 60: Recommended Maintenance Schedule

    1. Apply cleaning pH/ORP probe procedure, also use a mild acid for better cleaning and rinse well 2. Put the probe in the solution and wait until measurements is stable 3. Go to ORP page, select “Calibration” button . Select from the following options: a) Single: Input pre-measured solution value and press OK.

  • Page 61: Troubleshooting

    3. Disconnect modem power/comms plug 4. Replace blown fuse/s 5. Power on controller. If fuse continues to blow, power board may have an issue. Contact Aquarius for further assistance. 6. Go to Outputs  Test Outputs. Whilst “Test Outputs” mode is selected, this will hold off all outputs until selected.
  • Page 62 Check if 150mA fuse is blown. If 150mA fuse blows, power will not be supplied to the mother board, core board and probe board. If issue persists after powering on, contact Aquarius for Screen locked Core board further assistance.
  • Page 63 If output/s stay ON during “Test Output” mode, relays may be faulty requiring power board replacement. Contact Aquarius for further assistance. 1. For Aquarius Peristaltic pumps: pump may be faulty. Outputs Pump/ Consult Contact Aquarius for further assistance.
  • Page 64 Verify that all three LEDs on the probe board have equal brightness. If the brightness of the LEDs on the probe board is not equal, there may be an issue with the probe board. Contact Aquarius for further assistance. 1. Ensure cables connecting mother board and probe Probe error Signal to board are checked.
  • Page 65 Location Issue Possible Action Cause 1. Check the mother board power LED is turned on. If the Modem Modem problem Modem power LED on the motherboard modem does not light power up, it indicates that the mother board needs to be replaced.

  • Page 66: Manufacturer's Product Warranty

    This warranty does not include removal or installation costs and in no event shall the manufacturer’s liability exceed its selling price of such equipment or part. Aquarius Technologies Pty Ltd disclaims all liability for damage to its products through improper installation, maintenance, corroded items or boards due to improper tightening of controller lid, use or attempts to operate such products beyond their functional capacity, intentionally or otherwise, or any unauthorised repair.

  • Page 67: Technical Support & Contacts

    TECHNICAL SUPPORT & CONTACTS MAIN OFFICE: 19 OVERLORD PLACE, ACACIA RIDGE, QLD, AUSTRALIA 4110 PHONE: +617 3274 4750 FAX: +617 3274 4736 EMAIL: SALES@AQUARIUSTECH.COM.AU CONTACT AQUARIUS TECHNOLOGY SERVICE TEAM FOR FURTHER ASSISTANCE. ULTIMA USER MANUAL REVISION 0 PAGE 67 OF 67...

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