Installation Guide DCM 200 series Aquatic Water Quality Controller ProMinent Fluid Controls p/n 7500612 136 Industry DrivePittsburgh, PA, USA 15275-1014 DCM 200 Installation Guide 02/12
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DCM 200 Installation Contents 1. Overview 2. Installation-Commissioning 2.1. 2.2. 2.2.1. 2.2.2. 2.3. 2.3.1. 2.3.2. 2.3.3. 2.3.4. 3. Calibrations 3.1. 3.2. 4. Safety Mounting Sample Connections Sensor Installation Wiring 120VAC Line Power and Feeder Wiring Pulse Controlled Pumps Flow switches, Contact Sets, and Water Meters Sensors Single Point Calibrations, 1 point or Standardization Two Point Calibration Password Security 4.1. Overview 4.2. Password Level Activities 4.3.
DCM 200 Installation Contents 6.8. Units for Volumes & Temperatures 6.8.1. Metric – US Units Selection 6.8.2. Water Meter Volumes 6.8.3. Rate-to-Volume 6.8.4. Copy Volume to 6.8.5. Pump Volumes 6.8.6. mL/Pulse Meters 6.8.7. Temperatures 6.8.8. User Assigned Units 7.
DCM 200 Installation 1. Overview 1.1. All ProMinent DCM 200 controllers have an integral web server with a CAT5 Ethernet connection, ready to communicate with any internet ready computer, regardless of operating system. This makes the ProMinent DCM 200 one of the easiest Aquatic controllers to allow you to network and remotely monitor and control your pool and spa chemistry parameters. 1.2. DCM 200 controllers are optimized for aquatic water disinfection control applications.
DCM 200 Installation Flow Switch Function NEVER OVERRIDE A FLOW SWITCH Uncontrolled feeding of concentrated chemicals can result in personal injury or death. Sample and recirculation flow switches are critical safety devices which prevent uncontrolled chemical feed. Follow Instructions Carefully. Flow switches are provided with all ProMinent pool controllers and are an integral safety device to prevent the uncontrolled feed of chemicals, which could cause personal injury or death.
DCM 200 Installation ALWAYS USE ANTI-SYPHON DEVICES Uncontrolled feeding of chemicals can result in injury or death. Anti-Syphon devices must be installed on chemical feeders to prevent uncontrolled feed of concentrated chemicals. If a vacuum is created in the water circulation line and no anti-siphon device is installed on the chemical feeders, potentially hazardous concentrations of chemicals can be drawn into pool or spa.
DCM 200 Installation 2.2 Mounting 1.1. 1.2. Fully Assembled System on Acrylic Backpanel 1.3. 1.4. Overall System Mounting • • • Locate an area on a flat wall large enough to accommodate the full size of the 22x22” system panel with enough extra room to accommodate flexible sample tubing. The controller is shipped with a 3 ft. power cord already installed, for easy connection to a close wall receptacle.
DCM 200 Installation DCM 200 Controller Enclosure Mounting (continued) • • • • • Individual DCM 200 controllers are shipped with mounting bracket (4) and mounting screws (1) to assist with wall mount installation. Snap the bracket off the back of the enclosure by pressing the release clip (4) at the bottom, and slide the enclosure off the bracket. The wall mounting bracket can then be used as a drilling template. Mount the bracket on a vertical wall at approximately eye level, within 3ft.
DCM 200 Installation 2.2.1. Sample Connections Modular Sensor Housing (DGMa) Mount white acrylic mounting plate within 60” of the DCM 200 controller, and allow at least 18” clearance above the top of the mounting plate. • Using the typical installation drawings on the following pages, connect sample tubing to the DGMa modular sensor housing and the main recirculation lines, using the fittings supplied. • Note that the default mounting of the modular housing is to flow from left to right.
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DCM 200 Installation 2.2.2. Sensor Installation ORP sensor pH sensor SGT sensor Aquatic Sensor Placement in DGMa Modular Sensor Housing • • • • • • Check that all fittings of the assembly have O-rings installed, and fittings are secure. Adjust flow switch shaft so the top of the ring at the bottom of the shaft is at the 12.5 gph mark, and tighten the compression nut to keep the shaft from leaking and secure the flow switch shaft in place.
DCM 200 Installation 2.3. Wiring Before beginning controller wiring, be sure power has been removed, locked out and tagged as under repair, before proceeding. Observe all national and local electrical codes during wiring and installation to best assure your safety and the safety of the pool operations staff and swimmers. Wiring Guidelines 1.6. AC Controller Power Power the controller using a dedicated, separate breaker in the local lighting-distribution panel.
DCM 200 Installation There is not a Sensor transmitter (preamplifier) available for the DCM 200. Sensors, may be not be extended past the maximum available length of coaxial SN6 cable, 33 feet (10 meters). For applications where the distance from the controller to the sensors exceeds 33 feet, consult your ProMinent distributor for options available to you. Verify that the shields on water meters are also spliced if meter cables are extended.
DCM 200 Installation 1.12. Controller Wiring Terminals DCM 200 Controllers consist of two main circuit boards, a Main circuit board and an LCD driver board. The Main circuit board is located in the rear half of the enclosure and supports 3 analog sensor inputs, 2 digital inputs and 5 digital Outputs. The digital outputs consist of 3, 120VAC relays and 2, DC contacts. It is connected to a single 2 line x 16 character LCD driver board and backlit LCD display mounted on the back of the lid.
DCM 200 Installation 2.3.1. 120VAC Line Power and Feeder Wiring The factory pre-wired your controller with a power cord and two 120VAC receptacle cords, unless you requested otherwise. For conduit wiring configurations, remove the cords supplied and replace the cord wiring with the individual wires from the conduit. The same terminals are used and are shown in the diagram below for reference.
DCM 200 Installation 2.3.2. Pulse Controlled Pumps Pulsed controlled pumps can be connected to give more precise control options like PID control and use low voltage wiring to convey pumping signals to the feeders. These features are built into all DCM 200 controllers as a standard feature. Use the diagram below for connections to ProMinent pump universal control cable and similar cables for other pumps.
DCM 200 Installation 2.3.3. Flow switches, Contact Sets, and Water Meters 1.13. Water meters, flow switches and ‘dry’ contact sets are connected to input terminal ‘F’ and a ground terminal. 5VDC limited by 10KΩ puts 1/2mA through a closed contact set. Input ‘E’ is reserved for the sample flow switch function and cannot be changed. 1.14. Paddlewheel and Turbine water meters (HallEffect types) are powered by the 12VDC controller power supply, and thermally fused at 100mA.
DCM 200 Installation 2.3.4. Sensors pH and ORP Sensor Wiring DCM 200 controllers normally have the cables for the pH and ORP sensors pre-wired and marked on the cables for the appropriate sensor. The SGT (Solution Ground+Temp) sensor and flow switch are also pre-wired at the factory. If replacing these cables, connect the center pins on the coaxial cables to the positive [+] terminal and the metallic shield is connected to negative [-]. A solution ground reference is required for proper operation.
DCM 200 Installation 3. Calibrations 3.1. Single Point Calibrations, One-Point or Standardization The pH and Temperature inputs A and C, have single point (Offset only) calibrations. Input B is the ORP input and should never need field calibration. Calibration of contact set inputs “E and F” is blocked. 3.2. Two Point Calibration Two point calibration is limited to pH sensors. Sensor OFFSET is adjusted so the sensor value matches the user’s calibration value.
DCM 200 Installation US units Metric units Zener 0.18 0.1 -459.4 -273 -430 -253 -590 -293 4. Password Security 4.1. Overview DCM 200 controllers use 4 levels of password for controller access and to stamp the activity log: Public, Operator, Configuration, and Administrator Refer to Section 4.2 for default user IDs and passwords. Passwords are defaulted OFF for keypad users and ON for Browser users. Passwords cannot be turned OFF for Browser users.
DCM 200 Installation 4.3. Browser Passwords & Lockout After 5 unsuccessful attempts to log on, the controller locks out Ethernet and Keypad access Locked out users will see an Alarmed status message in place of Password Incorrect . Browser & modem resets at 7:00AM or when AC power OFF/ON. Therefore, the maximum lockout time is 24 hours and the minimum is less than a minute. This feature blocks scripting attacks on controllers and cannot be disabled.
DCM 200 Installation 4.5. Passwords Reset Contact ProMinent Technical Department, at (412) 787 – 2484, with the controller serial number to obtain a reset password which resets all passwords to the factory defaults shown above. Proof of controller ownership is understandably required. ProMinent controllers have no backdoor or super user password. If you forget the password, this is the only way to recover controller access. 5. Application Notes 5.1.
DCM 200 Installation 5.2. Communications 5.3. Ethernet LAN TCP-IP: The DCM 200 controller contains a 10 Base T, RJ45 Ethernet port with a Fixed IP address assigned by the administrator. Additional parameters adjustable are Netmask, Gateway and Primary DNS. The controller operates as an HTML micro-server for command & control using Microsoft Windows IE7 and Mozilla’s Firefox internet browsers available on most computers. Logged data is served as an XML file in response to an HTML request.
DCM 200 Installation 5.7. Frequency Controlled Pumps, Contacts 4 & 5 Sets the variable frequency control range for pumps controlled by sensors A..C. Not applicable to pumps controlled by volume meters or contact set F. Method Function Examples Always Frequency varies proportional to sensor value when value between Turn ON and Turn OFF setpoints. Proportional acid or oxidant controls. Substitutes for more expensive 4-20mA controlled pumps.
DCM 200 Installation PID Time Modulation: Relays 1-5 Application: Time Modulation applications where additional variable loading control is needed like extremely variable bather loading. Setup: User selects a relay & selects Special Control = PID Control User sets Relay Period in seconds, as in Time Modulated control, minimum 60 (recommended), default= 120, maximum is 600 seconds. User sets Kp Proportional factor for correction to deviation from setpoint.
DCM 200 Installation 6.3. Contact Set, Flow Switch F Switching from Water Meter to Contact Set clears log. Type Setup Notes Contact Set User selects Contact Set Contact sets are ON when closed and OFF when open. ON time is logged. Contact sets used for interlocking, prevent relays from turning ON when contact set is OFF, or open.
DCM 200 Installation 6.5. Technical: Pump Frequency-Stroke Controls 1 Gallon = 3785 mL. Set pump frequency control to External & Stroke to 100% GPH = Gallons per hour GPD = Gallons per day Pump Defaults – User Adjustment Range & Resolution Pump default mL/stroke is set for a 25psi head, typical for chemical injection piping. The user mL/stroke adjust is limited to +25% and –70% for ProMinent pumps. The user mL/stroke adjust is limited to 0.01mL/stroke and 10ml/stroke for ‘Other’ type pumps.
DCM 200 Installation 6.6.2. Frequency Controls : P4 to P5 pulse outputs control pump frequency. The pump is always plugged into an AC supply and the pumping rate is set by the frequency of pulses from the controller. Modes Control Setpoints Timed Events Data Logging Feed Limits Control Method Blocking [not typical in pools and spas] Interlocking Frequency Controls Sensors: Control Range Setpoints are TurnOFF & 100%ON Proportional variable frequency control. Meters: Setpoints are ppm & volume.
DCM 200 Installation Relay & Frequency Controls Comparison (cont.) Notes 1. Contact Sets Runs once per controlling contact closure. In addition to being able to use Contact sets to turn ON & OFF relays and frequency controls, contact sets can have the following compensation: Invert ON/OFF: Switches the logical sense of the contact set so you can control on contacts opening or closing. Applications: Allows a control only when relay changes state Surge tank fill, remote disable, second flow switch 2.
DCM 200 Installation 6.8. Units for Volumes & Temperatures 6.8.1. Metric – US Units Selection Controller units are selected by the Metric/US Units keypad and/or browser switch. Although the increasing use of ppm controls and frequency controlled pumps moves more sites to Metric units, the familiarity with GPH, GPD, and GPM recirculation rates indicates that sites will continue to use both unit systems. This application note details how the controller applies the Metric/US Units switch setting.
DCM 200 Installation 6.8.4. User Assigned Units User assigned units have no effect on controller temperature compensation calculations. You are free to assign whatever units you wish and to mix unit types in any one controller bearing in mind how the controller handles unit conversions in Metric & US Units modes. If you need to override the units on any input, you can edit the OFFSET & GAIN that’s applied to the target input.
DCM 200 Installation 7. Spare Parts DCM 200 SPARE PARTS Part Number Description Sensors 7500441 pH sensor, Aquatic, Industrial Grade, 38.9mL Inorganic gel, 25mm with SN6 connector ORP Sensor, Aquatic, Industrial Grade, 38.
DCM 200 Installation DCM 200 SPARE PARTS (Continued) Accessories and Replacement Parts (Continued) Part Number Description Documents 987356 DGMa In-line sensor housing, Operating Instructions G/GB/F/E 7500608 Quick Start Guide DMC200 Browser Manual DCM200 Keypad User’s Manual (O&M) – DCM200 CD – DCM200 Manuals Page 34
