1

AV-100 Autovalve

Operation and Maintenance Manual

AV-100 Rev. 6/17/05

2

AV-100 AutovalveOperation & Maintenance

Manual

Table of Contents

Safety Concerns ............................................................................................................... 3

I. Overview.......................................................................................................................... 3

II. Control Features .............................................................................................................. 4

III. Configuration Mode ........................................................................................................ 4

IV. Advanced Calibration Mode ............................................................................................ 7

V. Operation Mode ............................................................................................................. 10

VI. Alarm & Output Features .............................................................................................. 12

VII. Reference Terms ............................................................................................................ 12

VIII. Troubleshooting ............................................................................................................. 14

Drawings

Circuit Board ............................................................................................................. 17

Valve Body ................................................................................................................ 18

Motor Assembly ........................................................................................................ 19

3

SAFETY CONCERNS

GENERAL: Be sure to follow all applicable and prudent safety precautions when working with chemicalsand electrical equipment.

ELECTRICAL: The circuit board and incoming A/C power line do include electrical shock risk. Take careto avoid electrical shocks and do not touch any part of the circuit board or A/C power line unless you arecertain that A/C power has been disconnected from the system.

I. OVERVIEW

1. Modes of the AV-100 – The AV-100 Automatic Control Valve has 3 modes that can be accessed. Thesemodes are as follows:

a. Configuration Mode – This mode is used to set up the control and display parameters. (Flow Meterrange, Control type, Display units, alarms, etc…)

b. Advanced Calibration Mode – This mode is used to electrically recalibrate the PV1 & PV2 inputsas well as the 4-20mA Output. It is also used to linearize the valve to a flow tube indicator.

c. Operation Mode – This is the mode used during automated operation of the AV-100 AutomaticControl Valve. It allows for Dosage and Set Point Adjustments as well as manual operation of thechemical feed rate.

2. Switching Between Modes – In order to enter and exit the three modes, the following steps must betaken. (Refer to Figure 4, page 17.)

a. Operation Mode – If Dip Switch S4 is OPEN then the device is in this mode.

b. Configuration Mode – To enter this mode, first be sure that the device is in Operation Mode. Thenclose Dip Switch S4. To return to Operation Mode, OPEN Dip Switch S4 again.

c. Advanced Calibration Mode – To enter this mode, first be sure that the device is in Operation Mode.Then depress and hold the “up arrow” key while closing Dip Switch S4. To return to Operation Mode,OPEN Dip Switch S4 again.

3. Menus & Display – Within each “Mode” there is a set of “Parameters”. Prameters are represented by theblocks in the following flow charts. To move between these parameters, use the “up arrow” and “downarrow” keys.

4. Control Methods – The AV-100 offers three different control methods. They are Flow Pacing (Propor-tional), Residual/ORP, and Compound Loop Control. The method is selected within the “ConfigurationMode”. (See Section III.)

5. Electrical Inputs – The AV-100 offers two input channels. Each channel can accept either 4-20mA or1-5V signals. (See Section II.2a. & II.2b.) The PV1 channel is used only for Flow (or Proportional)signals. The PV2 channel is used for Residual or ORP signals.

6. Electrical Outputs – The following outputs are available:

a. Alarm Contact Output – Each AV-100 includes a single (1) common alarm contact output (N/C or N/O.)

b. 4-20mA Output – The AV-100 can be equipped with a 4-20mA output which is proportional tochemical feed rate.

4

II. CONTROL FEATURES

1. Keypad Operation – The keypad is used in all three modes of the AV-100. Generally the keys are usedas outlined here below. However, detailed instructions will follow.

a. & keys – These keys are generally used to move through the available parameters. These keysare used to cycle through the various display screens. These keys will be referred toas “up arrow” and “down arrow”.

b. & keys – These keys are generally used to adjust settings and values within the screen beingdisplayed. These keys will be referred to as “plus” and “minus”.

2. Dip Switches – One dip switch block containing four switches is located on the circuit board inside theAV-100. (See Figure 4, page 17.) The block is red and the switches are white. These switches are used asfollows:

a. S1 – Used to select input type for PV1 input: Closed = 4-20 mA; Open = 1-5V.

b. S2 – Used to select input type for PV2 input: Closed = 4-20 mA; Open = 1-5V.

c. S3 – Not used. Position does not matter.

d. S4 – Used in switching between the three modes of AV-100. Refer to secton I.2 on page 3.

III. CONFIGURATION MODE

How to Enter: See Section I.2b on page 3.

Overview: This mode is used to set permanent control parameters. With the exception of Dosage andResidual (or ORP) Set Point, all other parameters are set in this mode.

NOTE: The following is a flow chart showing each parameter in this mode. Notes follow the chart withexplanations of each parameter. The selection of “Control Type” in the first parameter will determine whichof the three branches below is followed.

5

Res/ORP CLCFlow Pace

Control Mode(Flow) or (Res/ORP) or (CLC)

PVx Failure(Signal Loss)2a

PV2 Units(Residual/ORP Display Units)2b

PV2 (Res/ORP) DisplayDecimal Location2c

PV2 (Res/ORP) InputFull Scale Value2d

PV2 (Res/ORP) InputMinimum Value2e

PV2 (Res/ORP)Input Filter2f

PV2 (Res/ORP)Low Level Setpoint2g

PV2 (Res/ORP)High Level Setpoint2h

PV2 (Res/ORP) DeviationDead Band2i

PV2 (Res/ORP)Integral Value2j

PV2 (Res/ORP)Lag Time2k

PO1 Display Unitsfor Gas Feed4a

PO1 Gas Feed DisplayDecimal Location4b

PO1 Gas FeedFull Scale Value4c

PO1 Gas Feed Type Skipped in Flow Mode

Skips 1e

5a

Return to Top

1a

1g

2b

2j

Fixed or Variable3a

Lag Time forRes/ORP3b

Maximum Lag Time3c

Flow/PV1at Variable Lag3d

PVx Failure(Signal Loss)1a

PV1 Units(Flow Input)1b

PV1 (Flow) DisplayDecimal Location1c

PV1 (Flow Input)Full Scale Value1d

PV1 Threshold Value(Flow Input)1e

PV1 (Flow)Signal Filter1f

PV1 (Flow) InputLow Level Set Point1g

FIGURE 1

CONFIGURATION MODE

6

CONFIGURATION MODE

I. Control Type: Select the control mode that will be used to operate the automatic valve.a. Flow Pace (PV1) ORb. Residual Control or ORP (PV2) ORc. Compound Loop (PV1 and PV2)

1. Flow Pace Setup (Flow Input/PV1): Calibrate PV1 input from Flow Meter.

1a. PVx Failure. (Signal Loss) Maintain Position/Close Valve. (Select One)

1b. Select the units for display. (%, GPM, MGD, LPM, MLD)

1c. Select Decimal Location. (0, 0.0, 0.00, 0.000)

1d. Enter Full Scale Flow Value. (xxxx)NOTE: Calibrates Flow Input signal from zero to this Full Scale value.

1e. Enter Threshold Value. (In the units from point b above.)NOTE: This parameter should be set at zero (0) unless you do not want the valve to respond until thisthreshold value is reached by the 4-20mA flow input signal. The valve will then scale the input fromthreshold to full scale as (0-100% of input signal).

1f. Select Flow Filter Time. (xxxx) (seconds)NOTE: Controller will average the input signal over this time span.

1g. Set Low Level Set Point. (in units chosen above)NOTE: When the flow signal drops below this level the Low Flow Alarm will trip.

2. Residual/ORP Control Setup (Residual/PV2): Calibrate PV2 input.

2a. PVx FAILURE. (Signal Loss) Maintain Position/Close Valve (Select One)

2b. Select PV2 units for display. (PPM, MG/L, mV)

2c. Select Decimal Location. (0, 0.0, 0.00, 0.000)

2d. Full Scale PV2 Value. (+ or - xxxx)

2e. Minimum PV2 Value. (+ or - xxxx)

2f. PV2 Filter Time. (xxxx) (seconds)NOTE: Controller will average the input signal over this time span.

2g. Low Set Point Limit. (xxxx)NOTE: Will trip Low Set Point Alarm if reading or Set Point becomes lower.

2h. High Set Point Limit (xxxx)NOTE: Will trip High Set Point Alarm if reading or Set Point becomes higher.

2i. PV2 Deviation (xxxx) (This is in PV2 units)NOTE: Controller will set a dead band this amount above and below set point.

2j. Select Integral Value. (xxx) (%) (0.0 to 100.0) (Default value 10.0)NOTE: Value used in PV2 and Compound calculation for control.

2k. Lag Time (xxxx) (seconds)NOTE: Lag time for obtaining accurate Residual/ORP readings after feed changes.

7

3. Compound Mode Only:

3a. Fixed or Variable Lag. Selecting Fixed lag will keep the lag time constant atall times. Selecting Variable lag will cause the program to constantly adjust the lag time based on thecurrent flow value and the FLOW/PV1 @ LAG TIME parameter. (Variable lag time increases as flowdecreases.)

3b. Lag Time. (xxxx) (seconds)NOTE: Lag time for obtaining accurate Residual/ORP readings after feed changes.

3c. Maximum Lag Time. Default/Max. Allowable is 1800 sec./30 min.

3d. Flow/PV1 @ Variable Lag Enter an average value for the Flow Meter in unitsabove. (Used as the base value to calculate/adjust the variable lag time.)

4. Display of Gas Feed Rate (Linearized): (Purpose) Calibrate for display purposes.

4a. Choose Units (%, PPD, GR/H, KG/H)

4b. Choose Decimal 0, 0.0, 0.00, 0.000

4c. Choose Full Scale xxxx

5. Gas Feed Type (Accounts for opposite effect of SO2 and Cl2 on Res/ORP)

5a. Select Feed Type (SO2 or Other) NOTE: Other for Chlorine.

IV. ADVANCED CALIBRATION MODE

How to Enter/Exit: See Section I.2c on page 3.

Overview: This mode is used for the following:

1. Input Electrical Type and Calibration: PV1 and PV2 are set as 4-20mA or 1-5V. Both are alsocalibrated electrically.

2. Output Electrical Calibration: PO1 (4-20mA) is electrically calibrated.

3. Valve Output Linearization: The gas feed rate is calibrated and linearized.

NOTE: The following flow chart shows the parameters of this mode. Explanation follows below.

8

Valve Hysterisis

0%

100%

4b

5a

5k

Accept Value6a

PV1 Input(4-20 mA) or (1-5V)1a

PV1 Calibration

PV2 Calibration

1b

PV2 Input(4-20 mA) or (1-5V)2a

2b

PO1 Calibration4 mA3a

20 mA3b

Shutoff Extend4a

1. Input PV1: (Purpose) Ensure the input channel PV1 is properly electrically calibrated.

1a. Select Input Type 1-5 Volts or 4-20 mA (Close(up) S1-1 if 4-20mA)

1b. Calibrate PV1 DIRECTIONS: Input a 4 mA (or 1 V) signal into PV1sockets. When satisfied that signal is exactly 4 mA, press the key. Then adjust input to 20 mA.When satisfied that signal is exactly 20 mA, press key.

2. Input PV2: (Purpose) Ensure the input channel PV2 is properly electrically calibrated.

2a. Select Input Type 1-5 Volts or 4-20 mA (Close(up) S1-2 if 4-20mA)

2b. Calibrate PV2 Input a 4 mA (1 V) signal into PV2 sockets.When satisfied that signal is exactly 4 mA, press the key. Then adjust input to 20 mA.

When satisfied that signal is exactly 20 mA, press key.

FIGURE 2

ADVANCED CALIBRATION MODE

9

3. Output PO1: (Purpose) Ensure the output channel PO1 is properly electronically calibrated.

3a. Calibrate 4 mA Read and adjust 4 mA output signal using & keys.

3b. Calibrate 20 mA Read and adjust 20 mA output signal using & keys.

4. VALVE CLOSURE: This parameter relates to fully closing the valve when the gas feed rate shouldbe zero. We recommend choosing YES if complete closure is desired.

4a. YES: Recommended. This will close the valve stem past the zero set point (determined in thecalibration procedure below) to ensure that the valve is closed.

NO: This will leave the valve at the exact zero point (as set below).

4b. (If YES Only) Valve Hysterisis: Select angle from 0 up to 45 degrees. This determines the exactangular distance past the zero set point for shut off extend.

5. Linearize (Calibrate Valve Position/Feed Rate): The chemical feed rate is not perfectly linear withvalve position. However, all valves are initially factory calibrated (linearized).

DIRECTIONS: Hook up the Automatic valve in the configuration in which it will be operated nor-mally. Read the physical chemical flow meter from your system to determine the actual chemical flowat a given valve position. For each point below, adjust the actual valve position with the and keysuntil the chemical feed rate for that point is achieved.

(i.e., for a 100 PPD gas system for the 10% point below adjust valve position manually until theremote meter reads 10 PPD) When you have obtained the correct feed rate for the point below, PRESSTHE UP ARROW to accept the position and move to the next point.

NOTE: Begin by pressing the key.

IMPORTANT NOTE: When setting the 0% and 100% points, the display will show “WAIT” while holdingeither the or key and it will continue to show “WAIT” for a moment after releasing the key. You mayhold the or key to move the valve continuously. However, after you have pressed and releasedeither the or key you should wait until the display no longer shows “WAIT” before touching anyother key. Failure to follow this instruction can cause the calibration to be saved improperly.

5a. 0% Actual shut off point (Press Up Arrow )5b. 5% 5% of full scale for the system5d. 10% 10% of full scale for the system5e. 15% 15% of full scale for the system5f. 25% 25% of full scale for the system5g. 35% 35% of full scale for the system5h. 50% 50% of full scale for the system5i. 70% 70% of full scale for the system5j. 85% 85% of full scale for the system5k. 100% 100% of full scale for the system (Press Up Arrow )

6. SAVE CALIBRATION?:

6a. YES: If you are satisfied with the calibration choose YES.NO: If you choose NO, the controller will revert to the previous calibration.

10

Res/ORP Control CLC ControlFlow Pacing Control

2a

2b

2c

2d

3a

3b

Set Res/ORP Setpointxxx PPM3c

Set Dosage1.03d

Alarm Con

3e

3f

Auto PV1 xxx MGD PO1 xxx PPD

Auto PV2 xxx PPM PO1 xxx PPD

Auto PV1 xxx MGD PO1 xxx PPD

Auto PV2 xxx PPM PO1 xxx PPD

1a

Set Dosage1.01b

Set PO1 (valve)xxx PPD

Set PO1 (valve)xxx PPD

Set PO1 (valve)xxx PPD

Setpoint Res/ORPxxx PPM

1c

Alarm ConditionsNone

Alarm ConditionsNone1d

V. OPERATION MODE

How to Enter/Exit: See Section I.2a on page 3.

Overview: When the AV-100 is in use it should be in this mode. This mode displays input values, outputvalue and alarm conditions. This mode is used to set dosage, Residual (or ORP) setpoint and formanual override of chemical feed rate.

1. Flow Pacing Mode: Operation in direct proportion to a flow meter signal.

1a. Select Automatic or Manual Control Mode.Choose AUTO/MANLDISPLAY (PV1) H

2O Flow Rate (%, GPM, MGD, …)

DISPLAY (PO1) Chemical Feed Rate (%, PPD, …)

1b. Select the Dosage level which is desired.DOSAGE 0.1-10 adjustable with and keys

1c. In Manual Mode the feed rate will be displayed and can be adjusted with and keys.DISPLAY (PO1) Chemical Feed Rate (%, PPD, …)

1d. Alarm messages are also displayed.DISPLAY ALARMS (none, lost Flow, …)

FIGURE 3

OPERATION MODE

11

2. Residual/ORP Control Mode: Control by ORP or Residual input only.

2a. Select Automatic or Manual Control Mode.Choose AUTO/MANLDISPLAY (PV2) PV2 Reading (PPM, MGL, mV)DISPLAY (SV2) PV2 Set Point (PPM, MGL, mV)

2b. Select the Residual/ORP Set Point which is desired.PV2 Set Point (SV2) Adjustable with and keys

2c. In Manual Mode the feed rate will be displayed and can be adjusted with +- keys.DISPLAY (PO1) Chemical Feed Rate (%, PPD, …)

2d. Alarm messages are also displayed.DISPLAY ALARMS (none, lost Residual, …)

3. Compound Loop Mode: (PID Control by Flow and Residual/ORP inputs)

3a. Select Automatic or Manual Control Mode.Choose AUTO/MANLDISPLAY (PV1) H

2O Flow Rate (%, GPM, MGD, …)

DISPLAY (PO1) Chemical Feed Rate (%, PPD, …)

3b. Select Automatic or Manual Control Mode.Choose AUTO/MANLDISPLAY (PV2) PV2 Reading (PPM, MGL, mV)DISPLAY (SV2) PV2 Set Point (PPM, MGL, mV)

3c. Select the Residual/ORP Set Point which is desired.PV2 Set Point (SV2) Adjustable with and keys

3d. Select the Dosage level which is desired.DOSAGE 0.1-10 adjustable with and keys

3e. In Manual Mode the feed rate will be displayed and can be adjusted with and keys.DISPLAY (PO1) Chemical Feed Rate (%, PPD, …)

3f. Alarm messages are also displayed.DISPLAY ALARMS (none, lost Flow, …)

12

VI. ALARM & OUTPUT FEATURES

1. 4-20 mA Output – This optional feature allows for a 4-20mA signal at terminals PO1 & . Thesignal is proportional to chemical feed rate. Availability of this feature requires the chip shown onFigure 4, page 17.

2. Contact Alarm Output – Each AV-100 is equipped with one common alarm relay output. The outputincludes both N/C and N/O options. Rating is 5 Ampere (resistive) and 250 V.A.C., 250 V.D.C.

NOTE: Any of the below contacts will activate this alarm relay.

Control Mode Alarm Condition Description Action

Flow Pacing Flow Signal Loss PV1 Signal below 4 mA Valve Close or Hold Position**

Flow Pacing Low Flow PV1 Signal below set point* None

Residual/ORP Res/ORP Signal Loss PV2 Signal below 4 mA Valve Close or Hold Position**

Residual/ORP Low Set Point PV2 Signal below set point*** None

Residual/ORP High Set Point PV2 Signal above set point*** None

Compound Loop Flow Signal Loss PV1 Signal below 4 mA Switch to Residual/ORP

Compound Loop Low Flow PV1 Signal below set point* None

Compound Loop Res/ORP Signal Loss PV2 Signal below 4 mA Switch to Flow Pacing Control

Compound Loop Low Set Point PV2 Signal below set point*** None

Compound Loop High Set Point PV2 Signal above set point*** None

* See Section III.1.g. – User defined flow signal level below which alarm is activated.** See Section III.1.a. and III.2.a – User selects this parameter in Configuration Mode.

*** See Section III.2.g & III.2.h – User selects an acceptable range for Residual/ORP.

VII. REFERENCE TERMS

1. Contact – On/off channel used as an alarm output.

2. Compound Loop Control – Refers to the P.I.D. control method. This method controls chemical feedrate using both flow and residual/ORP inputs. The method essentially reacts in proportion to the flowinput, while it also adjusts the chemical feed rate to maintain a residual/ORP set point.

3. Deviation – In the context of residual deviation this is a dead band around the set point. As long as theresidual/ORP reading is within (+ or -) this amount from the set point, the device will consider the systemto be at set point. This is used to avoid excessive, continual adjustment of the valve position that wouldreduce the life of the mechanical parts.

4. Dip Switch – A terminal of four (4) switches (white) located on a red block at the lower right hand side ofthe Circuit board. See Figure 4, page 17.

5. Dosage – In the context of flow control dosage this is a factor that is multiplied to the incoming flowsignal. For example, if incoming flow signal is at 50% (12 mA) and the dosage is set to 2.0 then the AV-100 will adjust chemical feed to 100% (in Flow Pacing Control) or in the same example if dosage is set to0.5 the AV-100 will adjust chemical feed to 25% (in Flow Pacing Control).

13

6. Filter – In the context of input signal (PV1 or PV2) filter time this is a time over which the signal will becontinually averaged. This is used to smooth out the input signal and reduce motion of the valve thatcould be caused by rapid fluctuations of the input signals (electrical noise or other rapid signal fluctua-tions).

7. Flow Pacing Control – Refers to the proportional control method. In this method the valve adjustschemical feed rate in proportion to input signal.

8. Full Scale (In terms of Input Full Scale) – The value (in %, Flow, Residual, or ORP expressed in appro-priate units) represented by a 20 mA (or 5 V) input signal.

9. Integral – A factor used in calculation of adjustments to chemical feed rate in both Residual/ORP andCompound Loop Control. This value ranges between 0 and 100%. Essentially the program makes acalculation of how much the chemical feed rate needs to be adjusted in order to reach set point and thisfactor. The integral setting determines what percentage of this adjustment will be done in each step (i.e.,if it is set to 15% then the valve will move 15% of the calculated amount). If the integral is set at 0% itwill never move. If the integral is set at 100% it will probably adjust too much each time and continuallyovershoot the set point.

10. Lag Time – In the context of Residual/ORP lag time this is the time that elapses between a change inchemical feed rate and the change in input signal PV2 from the Residual/ORP analyzer (considering aconstant water flow). This time is the sum of the time it takes the water to travel from the injection pointto the analyzer plus the time it takes the analyzer to react to a change.

11. Minimum (In terms of Input Minimum) – The value (in %, Flow, Residual, or ORP expressed inappropriate units) represented by a 4 mA (or 1 V) input signal.

12. Mode – In terms of the three modes of the AV-100. (See Section I.1)

13. ORP – Oxidation Reduction Potential. The units of measure are mV. It can be + and -. In terms of theAV-100, discussion is focused on the 4-20mA or 1-5V signal representing the ORP value. This signalmust originate from an ORP Analyzer.

14. Parameter – In this manual, this term refers to that which is shown on the display screen simultaneously.The AV-100 is moved from one parameter to the next using the “up arrow” and “down arrow” keys.

15. Proportional – Equivalent to Flow Pacing. The valve reacts in proportion to the incoming signal onchannel PV1.

16. Relay – In this manual, this refers to the alarm output contact. When an alarm condition is satisfied thecontact (relay) will close the N/O (Normally Open) relay and open the N/C (Normally Closed) relay.

17. Residual – Refers to either Free or Total Chlorine Residual reading. The units of measure are either mg/lor PPM and it must be a positive number or zero. In terms of the AV-100, discussion is focused on the 4-20mA or 1-5V signal representing the Residual value. This signal must originate from a Chlorine Re-sidual Analyzer.

18. Residual/ORP Control – Refers to the Set Point control method. In this method, the user indicates thedesired Residual or ORP set point and the AV-100 will automatically adjust chemical feed rate to maintainthat set point.

19. Set Point – In this manual, this refers to a desired value for the Residual or ORP reading. It is the specificResidual or ORP reading that is chosen by the user and that the user would like the system to maintain.

20. Threshold – In this manual, this refers to the parameter selected in PV1 input setup (See Section III.1.e.).This is the value of PV1 that will be considered as zero PV1 input for control purposes. For PV1 betweenminimum and threshold, the control calculations will consider PV1 to be zero. For control purposes, theAV-100 will rescale the PV1 input (linearly from 0 – 100%) from PV1 Threshold to PV1 Full Scale. Thethreshold value is expressed in the units used to display the PV1 input.

14

VIII. TROUBLESHOOTING

A. FACTORY DEFAULT – If there is an electronics problem that cannot be solved by any of the belowefforts, then you might consider performing a factory default. However, when this is done all calibrationdata is lost and must be reset. Therefore it is best to try other steps first because you will have to gothrough both the Advance Calibration Mode and the Configuration Mode to enter all control and calibra-tion settings. The factory default can eliminate glitches that may arise in the software by erasing allsettings and entering the factory default settings. In order to perform a factory default follow these steps:

1. Turn off the power to the AV-100.

2. Hold the “minus” key on the front panel.

3. While holding the “minus” key, turn on the power to the AV-100.

NOTE: You should see a message reading “factory default”. Then you can release the “minus” key.

B. POSSIBLE PROBLEMS and Recommended Steps to take:

1. Display Value of Chemical Feed does not agree with flow meter measured value – If your systemchemical flow meter indicates a different value than the AV-100 display check the following items inthe following order:

a. Vacuum Leaks – If there is a vacuum leak in the system (especially between the flow indicatorand the AV-100) then this could be the source of the problem.

b. Manual Rate Valves – If any manual rate valve is partially closed (not fully open) then this willcause the AV-100 display to be inaccurate. Typically the AV-100 will indicate a higher value thanthe flow indicator in this case.

c. Empty chemical supply or obstructed lines – If the chemical supply is obstructed or empty thiswill cause the AV-100 to display (generally) a higher value than the flow indicator.

d. Lost or reduced vacuum – If the vacuum source (Venturi, ejector, or induction pump) is notproviding a full vacuum (i.e., if the vacuum level produced has reduced since installation) then thiswill generally result in the AV-100 indicating a higher feed rate than the flow indicator.

e. Feedback Pot Failure – If the feedback potentiometer is damaged, disconnected electrically to thecircuit board, or disconnected from the gearing this will cause the AV-100 to display inaccuratechemical feed rates.

f. Incorrect Setup of Chemical Feed Rate Display – See Section III.4.a-III.4.c. Ensure that thesesettings match your system.

g. Incorrect Valve Calibration – After checking all of the above considerations, if the valve is not inagreement with the flow indicator, then see Section IV to carry out a linearization of the valveposition.

2. Insufficient or Excessive Chemical Feed in Proportional/Flow Pacing Control.

a. Adjust Dosage Level – See Section V.1.b. Increase dosage for more chemical feed and decreasedosage for less.

b. Check Items 1.a. – 1.d. above – If actual chemical feed remains low, then check the suggestionsin item 1.a. through 1.d. above.

3. Failure to reach set point in Residual/ORP or Compound Loop Control.

a. Lag Times – The lag times set in section III.2.k or III.3.a through III.3.d may be too long for thesystem.

15

b. Integral – The integral value set in section III.2.j may be too low. If it is too low then the AV-100will not react quickly enough to reach set point.

c. Dead Band – The “deviation” or dead band set in section III.2.i may be too large. The valve willconsider set point met if Residual/ORP remains within this amount of set point.

4. Repeated Overshooting of Set Point in Residual/ORP or Compound Loop Control.

a. Lag Times – The lag times set in section III.2.k or III.3.a through III.3.d may be too short for thesystem.

b. Integral – The integral value set in section III.2.j may be too high. If it is too high then the AV-100will react too quickly and it will repeatedly drive the Residual/ORP reading below and above setpoint.

c. Dead Band – The “deviation” or dead band set in section III.2.i may be too small. The valve willonly consider set point met if Residual/ORP remains within this amount of set point. If it is set tozero the AV-100 will almost never be satisfied and will continue to adjust the valve position.

5. AV-100 will not remain in Automatic Control – If the AV-100 will not remain in AUTO control andthe “MANL” is flashing when the user attempts to enter AUTO control, then check the alarm messages(press “down arrow” key) (See Section V.1.d, V.2.d, or V.3.f).

a. Signal Loss – If all input control signals are lost, then this should be indicated in the alarm mes-sage screen (parameter). If all input signals are lost then the valve will switch to Manual control.

SERVICE & UPGRADES

SAFETY NOTE: Be sure to follow all safety precautions before attempting to service the AV-100. Be sure todisconnect power from the AV-100 before servicing electronics.

1. Upgrade to 4-20mA Output – If the AV-100 was not ordered with the 4-20mAoutput-option then itwill require the addition of two items to the circuit board. (See Figure 4, page 17)

a. 4-20mA I.C. (U17) – (Disconnect A/C power before this step.) A chip must be inserted into theport shown on Figure 4 to enable this option. NOTE: This chip can be obtained from the factory.Also, it must be installed with the notch to the left (as indicated on the printed circuit board).

b. Output Connector – A plug in connector must be added to the PO1+ and PO1- ports shown onFigure 4.

2. EEPROM Upgrade or Replacement – If an EEPROM must be replaced then follow these points.(Disconnect A/C power before this step.)

a. Location U8 – (See Figure 4) The EEPROM is located on the left side of the circuit board. It isthe third chip from the bottom along the left side.

b. Removal of existing EEPROM – Carefully use a small flathead screwdriver to pry up each end ofthe EEPROM slightly (several times each end) until it becomes loose enough to easily remove.

c. Orientation – Notice that there is a notch on the top of one side of the EEPROM. Also, there is amarking on the printed circuit board towards the right side of the EEPROM port. Be sure to installwith the notch to the right.

d. Insertion – Be sure that all of the pins of the EEPROM are straight and intact before attempting toinsert. Gently start all pins into the ports. Be sure that all pins are aligned and started. Thengently and evenly press in the chip until it is fully inserted.

16

3. Feedback Potentiometer Replacement (FBP) – (See Figures 4 and 6) Due to the fragile nature ofpotentiometers they will require replacement from time to time. For that same reason great careshould be taken upon installation. It is important to know that each potentiometer has a finite numberof turns within its range and that if it is turned past either end of this range it will be broken and use-less. Also, it does not take much force to push it past the end of its range. Therefore, the potentiom-eter must be selected with the proper range and it must be installed so that the stepper motor will notturn it past the end of its range.

a. Turn off Power – The first thing to do is to turn off the A/C power to the AV-100.

b. Close Valve – Close the valve by turning the Brass Coupling by hand. NOTE: Do not use exces-sive force, you will feel increased resistance at the bottom, but do not try to go beyond this point.(This is done by turning the Brass Coupling clockwise if looking down into the valve.) Notice thatthe FBP shaft turns in the same direction as the drive shaft (and Brass Coupling).

c. Remove Gear from FBP – Loosen the setscrew holding the gear onto the shaft of the existingFBP. Then loosen the nut holding the FBP to the mounting plate. Remove the FBP.

d. Attach new FBP – In the same fashion, connect the new FBP to the mounting plate. BUT NOTTO THE GEAR.

e. Adjust FBP Position – Gently turn the shaft of the FBP (counter clockwise if looking up at thebottom of mounting plate) until you reach the end of the range. Then turn it back in the otherdirection by 1/4 turn.

f. Attach the Gear – Keeping the FBP shaft in this position, attach the gear and tighten its setscrew.

g. Open Valve One Turn – Before turning on the power, open the valve one full turn by turning theBrass Coupling by Hand. (Counter Clockwise if looking down at the valve body.)

4. Servicing the Valve Body – (See Figures 5 and 6) If the valve becomes difficult to turn or for thepurpose of periodic maintenance (recommended every 18-24 months) the valve body should beserviced.

NOTE: Fully close the valve before removal. Failure to do this could damage the FBP.

a. Removal – The valve body can be removed from the enclosure simply by removing the three (Hexkey) screws located at the top (inside the enclosure). The complete valve can then be maneuveredout without removal of other parts.

b. Disassembly – The valve body can be disassembled by removal of the lower three (Hex Head)screws located at the lower end of the valve.

c. Maintenance – All parts should be inspected for damage, cleaned, and lubricated* before reas-sembly. Generally O-Rings should be replaced if in use for more than 12 months. The AV-6Teflon Valve Seat may require replacement if there are any cuts or burrs noticed.

NOTE: Fully close the valve before removal. Failure to do this could damage the FBP.

* Use appropriate lubrication for your chemical application. Contact your local representative ofthe factory if there is any uncertainty.

d. Reinstallation – Before installation after service, ensure that the valve will turn freely by manu-ally turning the Threaded Stem at the top using the cross bar.

17

FIGURE 4

A

UTO

VALV

E

Dat

e:

Feb

ruar

y 20

03

CIR

CU

IT B

OA

RD

D

wg.

No.

A

V-P

CB

-1

OP

EN

1

2 3

4

Rib

bon

Cab

leto

Key

pad

Dip

Sw

itche

s(S

1 -

S4)F

use

GM

C 5

00m

A, 2

50V

4-20 mA I.C.

Not

ch

Rib

bon

Cab

leto

Dis

play

EE

PR

OM

RO

M

RA

M

U8

U17

U9

HO

TN

TL

GN

D N

.C.

AR

MN

.O.

ØZ

ØY

ØX

ØW

CM

CW W

CC

W P

O1+

PO

1– P

V1+

PV

1– P

V2+

PV

2–

L1 L2

P

ower

GN

D

Con

tact

Out

put

Gre

enR

edB

lue

S

tepp

erB

lack

Whi

teW

hite

Red

Whi

te

Whi

te

Fee

dbac

k P

otB

lack

+

4-20

mA

DC

Out

put (

Gas

Fee

d)– +

4-

20 m

AD

C In

put (

Flo

w)

– (1

-5 V

DC

) +

4-

20 m

AD

C In

put (

Res

idua

l)–

(1-5

VD

C)

18

FIGURE 5

Date: December 1999 Scale: 100% AUTOMATIC VALVE Dwg. No.: AV-100

Item Part Item Part No. Description Quantity No. No. Description Quantity No.

1 Set Screw 1 10-24 x 5/16" 2 Torque Arm 1 AV-24 3 Threaded V-Stem 1 AV-2 4 Upper Body 1 AVB-10 5 Intermediate V-Stem 1 AV-1 6 Small Disc 1 AV-4 7 O-Rings 2 108 8 Large Disc 1 AV-3 9 NPT Fitting 1 Elbow 90° 10 Middle Body 1 AV-11 11 Lower Body 1 AVL-9 12 NPT Fitting 1 13 Bolts 3 1/4"-20 x 4" 14 Valve Stem Seat 1 AV-6

15 O-Ring 1 124 16 O-Ring 1 116 17 Valve Stem 1 AV-7 18 Pin* 1 19 O-Ring 1 124 20 O-Ring 1 116 21 Stem Seal 1 AV-5

* Tantaloy Wire – Do not substitute

19

FIGURE 6

Date: June 2005 AUTOMATIC VALVE (AV-100) Scale: 50% FEATURING MOTOR ASSEMBLY Dwg. No.: AV-100-MA

CouplingValveBody

StepperMotor

FeedbackPotentiometer

FeedbackPotentiometerGear

TorqueArm