Neptune WATER TREATMENT SYSTEM Fourth & Fifth Pump Option (Sprite WT) Neptune Controller Reference Manual CM-700 Series Copyright 2004 Nova Controls, Inc. P/N 20-07788-00 Rev. H i P/N 20-07788-00 Rev. H ii P/N 20-07788-00 Rev. H Table of Contents 1 Theory of Operation Page Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Starting the Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 System Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Pump Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 Installation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Mounting the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Bulkhead Fitting Installation (3 Fittings) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Supply and Discharge Tubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Solenoid Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Trigger Output for Optional Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Probe Float Assembly Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Float Adjustment After Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Adjust Probe Floats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Adjust Water Tank Float Ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Probe Float Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Power On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Run a Test Cycle (after Set up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3 Description of Controls Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 4 Run Mode Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Run Mode Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Select Formula / Home Screen (Fr-A ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Prime Pump/Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Operating Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Tank at Low Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Tank Fill / Formula in Progress . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Pump(s) Running / Formula in Progress. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Error Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Time-To-Fill Error (t.Err) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 P/N 20-07788-00 Rev. H iii Formula Error (F.Err) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Calibration Error (C.Err) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Probe Float Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Setup Mode Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 5 Setup Mode Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Setup Mode Menu Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Password Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Prime Pump/Fill (Pr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 User Prime Enable (UPr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Installer Formula Select (Fr-A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 User Formula Select (UFr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Formula Time Edit (FE) -- (Create/Change a Formula) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Pump Volume vs. Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Fill Time Limit (FILL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 AutoStart on Power Up (ASt.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Fill Solenoid Type Identification (FC.AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Pump/Fill Sequence Edit (S.1-F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Password Edit (PASS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Exit Setup Mode (END) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 6 Troubleshooting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Power Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Calibrating the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Probe Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 In Tank Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Out of Tank Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 7 Maintenance and Service Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Every Maintenance Visit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Pump Tube Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Neptune Replacement Parts & Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Neptune System Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Probe Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 8 Specifications Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Index iv P/N 20-07788-00 Rev. H 1 Theory of Operation Overview This chapter describes the theory of operation and the features of the Neptune Water Treatment Controller. The Neptune, with probe, detects the tank solution level. When the probe indicates a low solution level in the tank, Neptune automatically doses up to three chemicals into the tank and fills it with water up to the appropriate level. When the probe indicates a high solution level in the tank, the solenoid closes and shuts off the water fill. In the unlikely event that the solenoid switch should fail, a tank float ball switch (positioned at the makeup waterline) mechanically stops the fill to prevent overflow. Once a high-level indication is reached, no programs can begin to run until a new, low-solution level signal is received. The three chemical pumps, and the solenoid water fill, can be set up to dispense in three different formulas (programs). An installer's test formula is shipped with all new Neptune units. The easy-to-read LCD screen displays information about the current cycle and any system errors in formula, fill or calibration that may occur. Starting the Cycle AutoStart--The Neptune is factory set to automatically begin probe float operation and run a formula­if the tank is low­when the power is turned on. It is recommended that the Neptune system be run in AutoStart mode. Manual Start--The installer can choose to disable AutoStart during setup. With AutoStart disabled, the display flashes "Fr-A" to indicate that the power is on but the system is not yet operational. (probe will not detect low or high water levels and no formula will run). To enable system operation, the operator must manually press and release the ENTER key to start functional operation of the unit. Normal Operation With AutoStart enabled (or after the operator has pressed and released ENTER in Manual Start), a cycle starts and runs the displayed formula if all of the following conditions are met: · At least one formula is programmed into the Neptune. On new Neptune units, the factory test formula displays as Formula A . · The probe senses a low solution level for 20 continuous seconds, indicating that the tank needs to be refilled. A low solution level is indicated by a "dot" added to the displayed formula . · No cycle is currently in progress. Chemical pumps run (either sequentially or simultaneously) and the solenoid initiates a water fill that remains on until the tank is full. After the selected formula has run and the tank has filled with water, the system resets itself automatically to the "ready" stage. P/N 20-07788-00 Rev. H 1 System Error A system error displays on the screen if there is a problem with the probe, the water fill solenoid, the formula, or system calibration. Based upon the Troubleshooting Guide and the error message displayed, the operator can correct the problem and restart the cycle. For more information, see "Error Messages" on page 24 of the Troubleshooting chapter in this manual. Note The error must be cleared before the next formula can be run. Pump Sequence When tank conditions trigger the start of a cycle, the unit dispenses a formula that causes the pumps and the water fill to run in a preset order. More than one pump, or the fill solenoid, can be set to run simultaneously. The last used formula will run, unless the user selects a different formula (only allowed when the installer has enabled User Formula Select). For more information on setting User Formula Select or the pump sequence, see "User Formula Select (UFr)" on page 19 or "Pump/Fill Sequence Edit (S.1-F)" on page 21. Features Additional Neptune features include: · Factory-Set Test Formula Neptune is shipped with a pre-programmed test formula that allows quick a ...