Installation and Operation Manual For Boiler-Feed Chemical Monitoring Applications Network Sensor 4VDC Power Source Meter 4 5 6 Network X X X LINE NEURAL GND 4-0mA Interface Warning his Heat-imer sensor is strictly for monitoring purpose; it should never be used as a primary limit or safety control. All equipment must have its own certified limit and safety controls required by local codes. he installer must verify proper operation and correct any safety problems prior to the installation of this Heat-imer sensor.
Overview Due to the nature of most steam boilers, their water must be chemically treated to increase their efficiency and protect the boiler and the steam system from the adverse effects of mineral deposits. he Heat-imer Network Sensor provides an easy way to measure the electric conductivity of the water which can be converted to the otal Dissolved Solids (DS) in the boiler water. hus, help to maintain proper chemical levels. See Converting Between µs/cm and DS (PPM) on page. During the operation of steam boilers, impurities from the boiler feed (oils, fats, high alkalinity, suspended solids, and dissolved solids) that do not boil off easily are left to concentrate in the boiler water. he dissolved and non-disolved solids in addition to other contaminants tend to have the highest concentration close to the water surface. As the contaminants concentrate in the boiler water, the boiler s steam producing capability is reduced. hat is due to the steam bubbles not bursting and instead produce foam. As more contaminants are added through the feed system, there comes a point at which the majority of the steam producing surface becomes filled with foam. Foam reduces the boiler s capability to produce steam. he steam produced will be wet and contains contaminants which are then carried over to valves, heat-exchangers, traps, and other parts of the steam system where they deposit. hat is the reason Heat-imer recommends installing the Network Sensor in the blowdown line or right below the skim line to provide the most accurate DS reading. Even though there are many causes of steam boiler water foaming (oils, fats, high alkalinity, suspended solids, and dissolved solids), the DS is the main indicator. he term otal Dissolved Solids (DS) represents the amount of contaminants that are dissolved in the water. DS is measured in many ways. he most common measurement is Parts-per-Million (PPM) which represents the ratio of the number of solid ions dissolved in one million parts of water. DS is also measured by electric conductivity which uses microsiemens (µs/cm) as the unit of measure. Since conductivity varies drastically with changes in temperature, the Heat-imer Network Sensor provides temperature-compensated conductivity reading. Steam boiler manufacturers instruct users to maintain their boiler water DS levels between 000 PPM (500 µs/cm) and 700 PPM (4000 µs/cm). Running the boiler at higher values for long periods will result in scale buildup on the heat-transfer surfaces reducing the overall boiler efficiency. Scale consist of Calcium Carbonate which is a great insulator, thus its surface accumulation reduces the heat transfer between the combustion surfaces and the boiler water. I.e., running a boiler with water DS of 500 PPM for 50 hours forms a /64 scale layer. his /64 of scale increases fuel usage by 8%. Moreover, excessive scaling can cause hot spots and premature tube failure. A scaled boiler may require acid cleaning or sometimes tube replacement. o manage the DS range within the manufacturer recommendations, use chemicals designed for the type of boiler used and perform boiler blowdown at the chemical company s recommended intervals. wo of the Heat-imer Network Sensor advantages are its monitoring and alarming capabilities. First, since it is connected to an Internet-ready Heat-imer Platinum control, its historical readings can be saved, graphed, and E-mailed as a report through the Heat-imer ICMS website (http://www.htcontrols.com). hat provides a great way to keep track of the boiler water health throughout its life. Second, the ICMS can be set to send an alarm as an E-mail, a cell phone text message, or both when the sensor is out of an adjustable range for an adjustable time period. his feature helps alert the responsible party to the need for boiler water chemical adjustment. he alarm incorporates the sensor value, thus making it easy to determine the amount of chemicals required and possibly the change in blowdown frequency. Network Sensor Manual
Converting Between µs/cm and DS (PPM) he DS (otal Dissolved Solids) can be measured in Parts-per-Million (PPM). relation to DS varies by the water chemical composition. value is measured in microsiemens per centimeter (µs/cm). o convert the conductivity (µs/cm) reading to the DS (PPM) reading, the (µs/cm) must be multiplied by a Dissolved Solids Chemical Composition Factor. his factor can be acquired through the city s water department. he factor ranges between 0.55 to 0.80. A common 0.67 factor is used as an approximation if the factor for a location is not known. he following table converts the conductivity (µs/cm) value to DS (PPM) based on several Dissolved Solids Chemical Composition Factors including the default one (0.67). Recommended Boiler Water emperature Compensated (µs/cm) Dissolved Solids Chemical Composition Factor 0.55 0.6 0.67 0.7 0.75 0.8 DS measured in (PPM) 00 55 60 67 70 75 80 00 65 80 0 0 5 40 500 75 00 5 50 75 400 700 85 40 469 490 55 560 900 495 540 60 60 675 70 00 605 660 77 770 85 880 00 75 780 87 90 975 040 500 85 900 005 050 5 00 600 880 960 07 0 00 80 700 95 00 9 90 75 60 800 990 080 06 60 50 440 900 045 40 7 0 45 50 000 00 00 40 400 500 600 00 55 60 407 470 575 680 00 0 0 474 540 650 760 00 65 80 54 60 75 840 400 0 440 608 680 800 90 500 75 500 675 750 875 000 600 40 560 74 80 950 080 700 485 60 809 890 05 60 800 540 680 876 960 00 40 900 595 740 94 00 75 0 000 650 800 00 00 50 400 00 705 860 077 70 5 480 00 760 90 44 40 400 560 00 85 980 0 475 640 400 870 040 78 80 550 70 500 95 00 45 450 65 800 600 980 60 4 50 700 880 700 05 0 479 590 775 960 800 090 80 546 660 850 040 900 45 40 6 70 95 0 4000 00 400 680 800 000 00 400 0 50 84 940 50 60 emperature Compensated (µs/cm) Dissolved Solids Chemical Composition Factor 0.55 0.6 0.67 0.7 0.75 0.8 DS measured in (PPM) 4400 40 640 948 080 00 50 4600 50 760 08 0 450 680 4800 640 880 6 60 600 840 5000 750 000 50 500 750 4000 500 860 0 484 640 900 460 5400 970 40 68 780 4050 40 5600 080 60 75 90 400 4480 5800 90 480 886 4060 450 4640 6000 00 600 400 400 4500 4800 600 40 70 454 440 4650 4960 6400 50 840 488 4480 4800 50 6600 60 960 44 460 4950 580 6800 740 4080 4556 4760 500 5440 7000 850 400 4690 4900 550 5600 700 960 40 484 5040 5400 5760 7400 4070 4440 4958 580 5550 590 7600 480 4560 509 50 5700 6080 7800 490 4680 56 5460 5850 640 8000 4400 4800 560 5600 6000 6400 800 450 490 5494 5740 650 6560 8400 460 5040 568 5880 600 670 8600 470 560 576 600 6450 6880 8800 4840 580 5896 660 6600 7040 9000 4950 5400 600 600 6750 700 900 5060 550 664 6440 6900 760 9400 570 5640 698 6580 7050 750 9600 580 5760 64 670 700 7680 9800 590 5880 6566 6860 750 7840 0000 5500 6000 6700 7000 7500 8000 000 560 60 684 740 7650 860 0400 570 640 6968 780 7800 80 0600 580 660 70 740 7950 8480 0800 5940 6480 76 7560 800 8640 000 6050 6600 770 7700 850 8800 Network Sensor Manual
Item List he complete sensor assembly comes with the following: Network Sensor Assembly (H# 90450-00) Required Add-ons Sensor Network Power Supply (H# 96670-00) Control with 4-0mA Network Interface he Control can be connected to an Internet-ready Platinum control. he sensor and its alarms must be configured on the web using the ICMS (http://www.htcontrols.com). Alarms will be in the form of viewable web alarm, E-mail, or text message to a cellular phone. Installation Steps Warning Network Sensor For Internet Communication Install the Sensor in the steam boiler (Less than 5 Psi Operating pressure). Wire the Sensor to the Control, Wire the Control to the Network terminals on the Platinum control, Configure the sensor on the ICMS site, Set alarm set point, delay and deliveries he Sensor is a sensitive device. It MUS NO be installed in an environment that is known to exceed the sensor s Maximum emperature or Operating Pressure ratings. See Sensor Specification on page 8. Installing Sensor he sensor can only be used in low pressure steam boiler (Less than 5 Psi Operating pressure). It must not be used on systems that are over 5 PSI. Choose a blowdown valve tapping location on the boiler that will be in the blowdown or right below the skimline. Right below the water skimline has the highest level of contaminants. hus, will give the most accurate conductivity reading. Plan ahead. urn off the boiler at least 4 hours prior to installing the sensor to guarantee working on a cold boiler. Drain the boiler water to a level just below the blowdown tapping used. If the sensor is installed horizontally below the skimline, its probe openings must be vertical for better accuracy and to allow for vertical flow. Warning Install the Sensor in the boiler when the boiler is COLD and water level has been drained below the taping used. DO NO INSALL IN A HO BOILER. Skimline Sensor Connect to Control Steam High Concentration of Contaminants Flow Direction Boiler Water Wiring Sensor to the Control he Sensor is equipped with 65 feet of cable. It can be extended up to 00 Ft. using a -conductor shielded or 4-conductor cable (Belden 9770 or equivalent). Connect all 4 sensor wires to the Control as indicated in the drawing (from left to right: Red, Black, White, Shield). o protect the equipment, disconnect the Control power before wiring the sensor. Warning he Control is calibrated to the Sensor used. DO NO Push the Calibration button or change the Dip Switch setting on the Control. As this may cause calibration loss. Calibration Button LED ON CS 4 V+ Dip Switches V- ON CS 4 emp. IN (WHIE) Sensr Gnd (SHIELD) Signal RN (BLK) Signal IN (RED) Sensor 4 Network Sensor Manual
ON CS ON CS Control Signal IN (RED) 4VDC Power Source Meter Calibration Button LED 4 V+ Dip Switches V- 4 emp. IN (WHIE) Sensr Gnd (SHIELD) Signal RN (BLK) 4 5 6 Network X X X Sensor LINE NEURAL GND 4-0mA Interface 0VAC L N Earth Ground C O R P O R A I O N R Platinum Control MPC Platinum MON /8/04 0:4Am Cycle Cut= 55 o F On Day INPUS DO NO APPLY ANY VOLAGE O SENSOR ERMINALS ALL SENSORS MUS BE GOLD SERIES SENSORS ADJUS PRESS O SELEC A A A A4 A5 A6 A7 A8 A9 A0 SYSEM EMP SHUDOWN PROVE INPU 0 Network Wiring Network Power Supply AUO OD= o F SYS= 48 o F BACK A A A A4 OU EMP EMP 0 BYPASS HELP PREV. (DEL) DAY NEX A5 A6 A7 A8 EMP EMP GND N L OUPU SYS CLOCK 4 5 6 7 8 9 0 4 5 6 7 8 LINE NEURAL B R W MOORIZED VALVE BURNER SYSEM CLOCK ROUE SENSOR AND ILIARY WIRES HROUGH HIS KNOCKOU ONLY Wiring Control to Platinum Connecting the Control Network erminals (5 and 6) to the Platinum Network Input terminals (A7 and A8). Connect the NPS Network terminals to the Platinum Network terminals. No polarity is observed. he NPS can power up to 5 Network sensors. Record the digit Control Device ID. his number is used to identify the Sensor on the ICMS. Wiring Control to Power Connect the Control s erminal () to the 0 VAC Line. Connect the Control s erminal () to the 0 VAC Neutral. Connect the Control s erminal () to an Earth Ground. Network Sensor Manual 5
Dip Switch Settings he Control is designed to operate a variety of Sensors. And since conductivity values are temperature sensitive, the control dip switch setting is set to have the conductivity value temperature-compensated. he graphed Dip Switch settings represent the standard.0 Cell (0-0,000 µs/cm) Sensor with temperature compensation. Make sure to have the dip switches checked prior to powering the unit. (DIP = ON, DIP = ON, DIP = OFF, DIP 4 = OFF). If the Dip Switch settings were changed after the powering of the unit, it may take up to 0 seconds to see the change take effect. on on LED ON CS 4 Dip Switches ICMS Site Sensor Setup After physically installing and wiring the Sensor, configure the transducer on the ICMS site as a Network Sensor. Logon to http://www.htcontrols.com using a full rights user using the account number, user name and password. Select the building hosting the Platinum control by clicking on the Building Icon. Click the Add Device(s) button. hen, select the Network Sensors option. A list of all un-configured sensors will be available on the left. Select the sensor with the same Device ID. Its information will be copied to the ID#. Give it a name. hen, select 0-0,000 as the ype. Follow that by clicking the Configure Sensor button. ICMS Site Sensor Alarm Setup Alert o send an alarm as a text message to a cellular phone, use the 0 digit cellular number followed by @ and the cellular carrier MMS or SMS (ext) address. Contact the cellular carrier for details on their address format. After configuring the Sensor on the ICMS site, configure the alarm High Set Point and delay. hen, configure the deliveries to E-mail, cellular phone text message, and web deliveries. Logon to http://www.htcontrols.com as a full rights user. Select the Sensor List in the Live Session. hen, select the Sensor. Click the Alarm Delivery Setup button. Set the High to inches above the normal Clean-Filter Vacuum Reading as a starting point. If the Clean-Filter Vacuum Reading was 4 inches, then the High should be set to 7 inches. 6 Network Sensor Manual
Set the Delay to 00 seconds to reduce false alarms. Click the 0 - Sensor Above High Alarm button. It shall be shaded with Red. hen, click the Add Delivery button on the right. his will open a new page to enter the Alarm Delivery Setup. In the Delivery Method Select either Web or E-mail. he E-mail option is used for E-mail or cellular text message (contact your cellular phone carrier for text message address format. MPC Plat 0006 9756 0 Sensor Cleaning he Control is pre-calibrated to the.0 Cell Sensor. It should maintain its calibration throughout its life and power cycles. However, if the reading was incorrect (did not change significantly with added chemicals), contaminants deposit on the Sensor s probe or entrapped air bubbles may be the culprit. In this case the probe may require cleaning. Plan ahead. urn off the boiler at least 4 hours prior to removing the sensor to guarantee working on a cold boiler. Drain the boiler water to a level just below the blowdown tapping used. o clean the Sensor, use a mild detergent and a cotton swab to remove any coatings on electrodes or probe metal surface. If after the cleaning the sensor reading was not accurate, contact Heat-imer echnical Support. In this case, both the Control and Sensor may need to be re-calibrated at the factory. roubleshooting he Sensor is reading disconnected his means that the 4-0mA Network Interface is not communicating to the Platinum Control. Check the Interface wiring to the Platinum Network terminals. Also, check that the Network Power Supply (NPS) is connected to the Platinum Network terminals and that it is providing 4 VDC to the Network terminals. If not, it may be damaged. Also, make sure that the installation has a maximum of 5 network sensors per a single NPS. If more than 5 network sensors are used, an additional NPS may be required. he Sensor is reading Short or Open Check the wiring between the Control and the 4-0mA Network Interface. See Wiring Control to Platinum on page 5.. he Sensor reading is incorrect If the incorrect reading was persistent, the Sensor may need to be cleaned from deposits. See Sensor Cleaning on page 7.. Network Sensor Manual 7
Control Specification Operating emperature.................................... 4 F/-0 C to 85 F/85 C Operating Humidity...................................... 0 to 95%, non-condensing Control Power............................ 0 VAC (4V Power Supply included and wired) Communication to 4-0mA ransmitter................................ (-wire) 4-0mA Dip Switches................... to 4 to match Sensor and emperature Compensation Dimension.............................................. 7-⅛ x 7-⅛ x 4-¼ Weight...................................................... Pound s Sensor Specification Power.......................................... hrough controller Cell.................................0 cell (0 to 0,000 µs emperature Compensated Accuracy............................................... ±% of full range. Maximum emperature........................................... 48 F/0 C Fitting.............................................. / NP Stainless Steel Operating Pressure........................................... Less than 5 Psi Maximum Pressure................................................ 00 Psi Dimension................................................ 6 x ½ - ½ NP Weight...................................................... Pound Warranty WARRANIES AND LIMIAIONS OF LIABILIY AND DAMAGE: Heat-imer Corporation warrants that it will replace, or at its option, repair any Heat-imer Corporation manufactured product or part thereof which is found to be defective in material workmanship within one year from the date of installation only if the warranty registration has been properly filled out and returned within 0 days of the date of installation. Damages to the product or part thereof due to misuse, abuse, improper installation by others or caused by power failure, power surges, fire, flood or lightning are not covered by this warranty. Any service, repairs, modifications or alterations to the product not expressly authorized by Heat-imer Corporation will invalidate the warranty. Batteries are not included in this warranty. his warranty applies only to the original user and is not assignable or transferable. Heat-imer Corporation shall not be responsible for any maladjustments of any control installed by Heat-imer Corporation. It is the users responsibility to adjust the settings of the control to provide the proper amount of heat or cooling required in the premises and for proper operation of the heating or cooling system. Heat-imer Corporation shall not be required to make any changes to any building systems, including but not limited to the heating system, boilers or electrical power system, that is required for proper operation of any controls or other equipment installed by Heat-imer Corporation or any contractor. hird Party products and services are not covered by this Heat-imer Corporation warranty and Heat-imer Corporation makes no representations or warranties on behalf of such third parties. Any warranty on such products or services is from the supplier, manufacturer, or licensor of the product or service. See separate erms and Conditions of Internet Control Management System ( ICMS ) services, including warranties and limitations of liability and damages, for ICMS services. HE FOREGOING IS IN LIEU OF ALL OHER WARRANIES, EXPRESS OR IMPLIED AND HEA-IMER CORPORAION SPECIFICALLY DISCLAIMS ANY AND ALL WARRANIES OF MERCHANABILIY FOR A PARICULAR PURPOSE. UNDER NO CIRCUMSANCES SHALL HEA-IMER CORPORAION, IS AUHORIZED REPRESENAIVES, AFFILIAED OR SUBSIDIARY COMPANIES BE LIABLE FOR SPECIAL, CONSEQUENIAL OR INCIDENAL DAMAGES, EXCEP AS SPECIFICALLY SAED IN HESE ERMS AND CONDIIONS OF SALE. HE SOLE REMEDY WIH RESPEC O ANY PRODUC OR PAR SOLD OR INSALLED BY HEA-IMER CORPORAION SHALL BE LIMIED O HE RIGH O REPLACEMEN OR REPAIR F.O.B. FAIRFIELD, NJ. HEA-IMER CORPORAION SHALL NO BE LIABLE OR RESPONSIBLE FOR LOSS OR DAMAGE OF ANY KIND RESULING FROM DELAY OR INABILIY O DELIVER FOR ANY REASON, INCLUDING BU NO LIMIED O FIRE, FLOOD, LIGHNING, POWER FAILURE OR SURGES, UNAVAILABILIY OF PARS, SRIKES OR LABOR DISPUES, ACCIDENS AND ACS OF CIVIL OR MILIARY AUHORIIES. 000 0 New Dutch Lane, Fairfield, NJ 07004 Ph: (97) 575-4004 Fax: (97) 575-405 http://www.heat-timer.com