Axeon S-150 User manual

Reverse Osmosis
Process Controller
User Manual
Model S – 150

S – 150 Controller User Manual
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TABLE OF CONTENTS
INTRODUCTION................................................................................................................. 6
SPECIFICATIONS............................................................................................................... 6
FRONT PANEL CONTROLS AND INDICATORS................................................................. 7
INSTALLATION
Physical Installation ............................................................................................................. 8
Terminal Strip, Jumper and Adjustment Locations............................................................... 8
Power Wiring ....................................................................................................................... 8
Pump and Valve Relay Outputs........................................................................................... 8
Reverse Osmosis (RO) Pump Wiring................................................................................... 8
Inlet and Flush Valve Wiring ................................................................................................ 8
TDS / Conductivity Cell Wiring............................................................................................. 9
Switch Inputs ....................................................................................................................... 9
Pressure Fault Switch.......................................................................................................... 9
Pretreat Switch ................................................................................................................... 10
Tank Full Switch ................................................................................................................. 10
I/O Expander Board............................................................................................................ 10
Auxiliary Pump.................................................................................................................... 11
Boost Pump........................................................................................................................ 11
Divert Output ...................................................................................................................... 11
Alarm Output ...................................................................................................................... 11
Tank Low Switch................................................................................................................. 11
SETPOINTS
Standard Setpoints............................................................................................................. 15
Displaying or Changing Setpoints....................................................................................... 16
SYSTEM OPERATION
General Operation .............................................................................................................. 17
Display................................................................................................................................ 17
Operating Status Messages................................................................................................ 17
TDS / Conductivity.............................................................................................................. 17

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Operating Hours ................................................................................................................. 18
Temperature....................................................................................................................... 18
Warning Messages............................................................................................................. 18
Tank Full Operation ............................................................................................................ 18
Tank Full Restart ................................................................................................................ 18
Tank Full Override.............................................................................................................. 19
Pressure Fault .................................................................................................................... 19
Auto Reset.......................................................................................................................... 19
Alarm Silence ..................................................................................................................... 19
Pretreat............................................................................................................................... 19
Membrane Flush................................................................................................................. 20
Flush Mode......................................................................................................................... 21
High TDS / Conductivity Warning / Alarm............................................................................ 21
Operating Hours Exceeded................................................................................................. 21
I/O Expander ...................................................................................................................... 21
Auxiliary Output .................................................................................................................. 21
Tank Low............................................................................................................................ 22
Boost Pump Output ............................................................................................................ 22
Divert Output ...................................................................................................................... 22
Alarm Output ...................................................................................................................... 22
ADJUSTMENTS
TDS / Conductivity Calibration............................................................................................ 22
Display Adjustment............................................................................................................. 22
TROUBLESHOOTING
System Inoperative............................................................................................................. 23
Display Blank...................................................................................................................... 23
Inlet Valve Will Not Operate................................................................................................ 23
RO Pump Will Not Operate................................................................................................. 23
Unit Not Flushing or Not Flushing Correctly........................................................................ 23
No or Incorrect TDS / Conductivity Reading........................................................................ 23

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TDS / CONDUCTIVITY EXPANDER
Installation / Wiring ............................................................................................................. 24
Setpoints............................................................................................................................. 25
Operation............................................................................................................................ 25
Calibration .......................................................................................................................... 25
GENERAL WARRANTY ..................................................................................................... 26
FIGURES AND TABLES
Figure 1 – Front Panel Controls and Indicators.................................................................... 7
Figure 2 – Terminal Strip, Jumper Locations....................................................................... 12
Figure 3 – Sample Wiring ................................................................................................... 13
Figure 4 – Expander Board Terminal Strip, Jumper Locations............................................ 14
Figure 5 – TDS / Conductivity Cell Installation .................................................................... 14
Figure 6 – TDS / Conductivity Expander............................................................................. 24
Table 1 – Switch Select Programming ................................................................................. 9
Table 2 – Expander Mode Programming............................................................................. 10
Table 3 – Flush Type.......................................................................................................... 20
Table 4 – Flush Mode......................................................................................................... 21

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INTRODUCTION
The S – 150 Series controller is a state of the art control system for commercial and industrial reverse
osmosis systems. The S – 150 Series controller combines features that have not previously been
available in one compact unit.
The S – 150 Series controller is a microprocessor controlled system that can monitor pressure and level
switches. A TDS / Conductivity monitor / controller with programmable Setpoints is an integral part of the
S – 150 Series controller. The S – 150 Series controller displays system status and sensor and switch
input status on an easy to read backlit display. User programmable Setpoints are provided that allow fast
and easy adjustment of system parameters.
SPECIFICATIONS
Power: 85 – 265VAC 50/60Hz, 25Watts
Environment: –22°F to 140°F, 0 – 95% RH, noncondensing
Enclosure: 8" x 6" x 4" (203mm x 152mm x 102mm) NEMA 4X
Display: 2 line x 20 character, alphanumeric backlit LCD
Front Panel: Overlay with LCD window, alarm lamp, 7 key membrane switch
Switch Inputs, Dry Contact: Pressure fault
Pretreat lockout
Tank full high
Tank full low
Relay Outputs: RO pump relay 120/240VAC, 1HP
Inlet valve relay 120/240VAC, 5A
Flush valve relay 120/240VAC, 5A
Relays supply same output voltage as board power (120 or 240 VAC)
Cell: TDS / Conductivity cell with digital display, permeate standard range,
0 – 250 PPM or uS.
Other ranges available:
Permeate: 50, 100, 500, 1,000, 2,500, 5,000.
Optional Feed: 50, 100, 500, 1,000, 2,500, 5,000, 10,000.
Wetted parts ABS and 316SS, 3/4" NPT, maximum 300 psi
Optional I/O expander: Auxiliary/divert/boost relay 120/240VAC, 1HP
Divert/alarm relay 120/240VAC, 5A
Tank low switch input, dry contact

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FRONT PANEL CONTROLS AND INDICATORS
DISPLAY: Shows status of system.
ALARM LAMP: Flashes when fault causes the RO system to shut down.
On steady when a Setpoint is exceeded that does not
cause the RO system to shut down.
POWER KEY: Places controller in operating or standby mode.
LEFT ARROW KEY: Scrolls through Setpoints starting with first Setpoint.
RIGHT ARROW KEY: Scrolls through Setpoints starting with last Setpoint.
UP ARROW KEY: Increases value of Setpoint.
DOWN ARROW KEY: Decreases value of Setpoint
ENTER KEY: Confirms entry of new Setpoint value
ALARM SILENCE/RESET KEY: Push once for alarm silence and twice to reset system
after a shutdown has occurred.
Figure 1

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INSTALLATION
Physical Installation
Mount the S –150 Series controller in a convenient location on the RO equipment using the four mounting
ears provided with the unit or the optional panel mounting bracket.
NOTE: All terminals on the board are labeled.
Terminal Strip, Jumper and Adjustment Locations
Refer to Figure 2 for the location of all terminal strips and connectors. Figure 2 also shows all jumper and
adjustment locations. Figure 3 shows a sample wiring diagram.
Power Wiring
Refer to Figure 2 and Figure 3 for the terminal strip locations. AC power for the unit is connected to
terminal strip P1. Connect the ground wire of the AC power to the terminal labeled GND. For AC power
with a neutral and hot wire, the hot wire connects to L1 and the neutral wire connects to L2. For AC power
with two hot wires, either wire can connect to L1 and L2. On ACpower with two hot wires, the wire jumper
between P6 and P7 should be removed and a fuse (GMA 1/4A) installed in F2.
Pump and Valve Relay Outputs
The S – 150 Series controller supplies relay outputs to control the RO pump and solenoid valves.
NOTE: The relays output the same voltage as the AC power to the board. If the pump and solenoids
operate on different voltages, a contactor will need to be supplied to operate the pump.
RO Pump Wiring
The RO pump connects to the L1 and L2 RO pump terminals of P1. This output can operate 120/240VAC
motors up to 1HP directly. For motors larger than 1HP or 3 phase motors, this output can be used to
operate a contactor.
Inlet and Flush Valve Wiring
The inlet and flush valves must operate at the same voltage as supplied to the board. These outputs can
supply 5A maximum and are not designed to operate pump motors directly. If these outputs are to be
used to operate a boost or flush pump, the output should be used to operate a contactor. The inlet valve
connects to the L1 and L2 inlet terminals of P1. The flush valve connects to the L1 and L2 flush terminals
of P1.

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TDS / Conductivity Cell Wiring
For accurate TDS / Conductivity readings, the cell should be installed in a tee fitting where a continuous
flow of water passes over the cell and no air can be trapped around the cell. Refer to Figure 5 for example
installation. The cell is connected with five wires to terminal strip P10. Connect each colored wire to the
terminal labeled with the same color.
Switch Inputs
Switch inputs are connected to P9. The connections for these inputs are not polarity sensitive and can
be connected to either terminal. The switch inputs should be dry contact closures only.
NOTE: Applying voltage to these terminals will damage the controller. The switches can be either
normally open or normally closed in any combination. The switch connected to an input that is configured
as normally open must be open for the unit to run. The switch connected to an input that is configured
as normally closed must be closed for the unit to run. The Switch Select Setpoint allows each input to be
configured as normally open or normally closed. The Switch Select Setpoint is defaulted to zero, which
programs all inputs as normally open. This means that all switch inputs must be open for the unit to run.
Table 1 lists the values used to program the Setpoint to configure the inputs.
TABLE 1. Switch Select Programming
Select the type of switch used for each input and put that number in the value column. Add the values
and program the total in the Switch Select Setpoint. For example, if the pressure fault and tank low
inputs were normally closed and all others normally open, the value programmed in the Switch Select
Setpoint would be 17(1 + 16).
Pressure Fault Switch
On systems where a low feed pressure shutdown is required, a feed pressure switch can be connected
to the pressure fault input of P9. If a high pump pressure shutdown is required, a high pressure switch
can be connected to this input. If both low feed pressure and high pump pressure shutdown are
required, both switches can be connected to this input. Both switches must be either normally open or
normally closed to operate properly.
SWITCH
N.O.
N.C.
VALUE
PRESSURE FAULT
0
1
PRETREAT
0
2
TANK FULL HIGH
0
4
TANK FULL LOW
0
8
TANK LOW
0
16
TOTAL

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Pretreat Switch
In systems with pretreatment, a pretreat lockout switch can be connected to the pretreat input of P9.
This switch should operate when the pretreatment device is out of service.
NOTE: The output from the pretreatment device must be a dry contact and must not supply voltage.
Tank Full Switch
In systems with a single tank level switch for controlling the RO pump, the level switch connects to the
tank full high input of P9. If dual level switches are used for controlling the RO pump, the upper level
switch connects to the tank full high input of P9 and the lower level switch connects to the tank full low
input of P9.
I/O Expander Board
If the optional I/O expander board is installed, two additional relay outputs and one additional switch
input are provided. Refer to Figure 4 for the location of terminal strips, jumpers and wiring for this
board. AC power for the relays is connected to the L1 and L2 power terminals of P1. Relay 1 is
connected to this power input and will supply the same voltage. This relay is rated for 120/240VAC at
1HP maximum. Relay 1 can be configured to supply a dry contact by connecting a jumper wire
between the L1 and L2 power terminals of P1.
NOTE: If Relay 1 is configured as a dry contact, Relay 2 must be configured as a dry contact also. If
Relay 1 is configured to supply voltage, Relay 2 can be selected to supply voltage, 120/240, 5A
maximum, or as a dry contact output. Jumpers J1–J4 are used to select the Relay 2 output type. To
output voltage, a wire jumper is installed between J1 and J4 and a second wire jumper is installed
between J2 and J3. For a contact closure output, a single wire jumper is installed between J3 and J4.
Relay 2 outputs can be selected to operate as an auxiliary pump output, a divert output or an alarm
output by programming the Expander Mode Setpoint. Table 2 shows the values used to program the
relay outputs.
TABLE 2. Expander Mode Programming
EXPANDER MODE
RELAY 1
RELAY 2
0
AUXILIARY PUMP
DIVERT
1
AUXILIARY PUMP
ALARM
2
DIVERT
ALARM
3
BOOST
DIVERT
4
BOOST
ALARM

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Auxiliary Pump
If the Expander Mode Setpoint is programmed to zero or one, Relay 1 operates as an auxiliary pump
output. This output is energized when the tank low input is not active. This output will supply power or
a contact closure determined by the connections L1 and L2 of the terminal strip P1.
Boost Pump
If the Expander Mode Setpoint is programmed to three or four, Relay 1 operates as a boost pump
output. This output is energized when the inlet solenoid output is active. This output will supply power
or a contact closure determined by the connections L1 and L2 of the terminal strip P1.
Divert Output
If the Expander Mode Setpoint is programmed to zero or three, Relay 2 operates as a divert relay and
will operate whenever the unit is in the divert mode. This output will supply voltage or provide a contact
closure based on the configuration of Relay 1 and on the position of jumpers J1–J4. If the Expander
Mode Setpoint is programmed to two, Relay 1 operates as a divert relay and will operate whenever the
unit is in the divert mode. This output will supply power or a contact closure determined by the
connections L1 and L2 of the terminal strip P1.
Alarm Output
If the Expander Mode Setpoint is programmed to one, two or four, Relay 2 operates as an alarm relay.
When an alarm or warning is active, this relay will supply voltage or provide a contact closure based on
the configuration of Relay 1 and the position of jumpers J1–J4.
Tank Low Switch
A tank low switch input can be connected to the tank low input of P2 on the expander board. This input
will provide a tank low warning on the unit and if the expander is programmed to provide an auxiliary
pump output, will provide low tank level protection for this pump.

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Terminal Strip, Jumper Locations
Figure 2

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Sample Wiring
Figure 3

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Expander Board Terminal Strip, Jumper Locations
TDS / Conductivity Cell Installation
Figure 5
Figure 4

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STANDARD SETPOINTS
SETPOINT DESCRIPTION RANGE DEFAULT
TDS / Conductivity
Limit
When this value is met or exceeded, the alarm lamp will light
and high TDS / Conductivity will show on the display. To
disable, set to zero.
0 – 999 uS
or ppm 100
TDS / Conductivity
Delay
When the limit Setpoint is exceeded, no alarm will be given
until this time has expired.
0 – 999
seconds
30
TDS / Conductivity
Shutdown
Once a TDS / Conductivity alarm is active, if the time in this
exceeded, a TDS / Conductivity shutdown will occur. To
disable, set to zero.
0 – 99
minutes 0
RO Start Delay
The amount of time between the inlet valve opening and the
RO pump start.
0 – 99
seconds
5
Press Fault Delay
The time a pressure fault must be active before a pressure
fault shutdown occurs.
0 – 99
seconds
5
Auto Reset
When a pressure fault shutdown is active, the system will
attempt to restart after this delay. If set to zero, system must
be manually reset.
0 – 99
minutes 60
Alarm Silence
If the audible alarm is silenced after this delay, the alarm will
resound. If set to zero minutes the alarm will remain silenced.
0 – 99
minutes
0
TF Restart Delay When a tank full condition clears, the system will restart after
this delay.
0 – 99
seconds/
minute
5
TF Restart
Selects whether the tank full restart delay is in seconds or
minutes. 0 = seconds, 1 = minutes.
0 – 1 0
TFO Time The amount of time that a tank full override lasts.
0 – 9
minutes
5
Tank Lo Restart
When a tank low condition clears, the auxiliary pump will
restart after this delay.
0 – 99
minutes
15
Flush Type Selects the type of flush. Set to zero to disable flush. 0 – 8 0
Flush Time
The length of time a membrane flush cycle will last when flush
is active.
0 – 99
minutes
5
Flush Interval
The interval between flush cycles. Only valid with op hour,
elapsed time or off flush types.
0 – 99 hours 24
Flush Mode Selects if the inlet and RO pump relays operate during flush. 0 – 3 0
Maximum Hours
If the current operating hours exceed this limit, the operating
hours warning will occur. To disable, set to zero.
0 – 65000
hours
0
Current Hours Current number of hours of RO system operation. 0 – 65000 0
Expander Mode Selects how the relays on the I/O expander board operate. 0 – 4 0
Temp Offset Allows adjustment of temperature reading by +–5 degrees. –5 – +5 0
Temp UOM Selects display of temperature in °F or °C. 0 – 1 0
Switch Select Selects if switch inputs are normally open or normally closed. 0 – 32 0
TDS / Conductivity
UOM
Selects display of water quality in uS or PPM.
NOTE: If this Setpoint is changed, the unit must be
recalibrated.
0 – 1 0
TDS / Conductivity
Range
Selects range of TDS / Conductivity monitor 0–50, 1–100, 2–
250, 3–500, 4–1000, 5–2500, 6–5000
NOTE: If this Setpoint is changed, the unit must be
recalibrated and may require some components be changed.
0 – 6 2
TF Delay Selects delay time for Tank Full
0 – 5
seconds
5

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TO DISPLAY OR CHANGE SETPOINTS
1. Refer to Figure 1 for the location of the keys used to display or change the Setpoints
and Figure 2 for the location of the write protect jumper, J3. For the unit to be able to
accept a change in a Setpoint, the shorting jumper must be in the off position (center
and left pins).
NOTE: Setpoints cannot be changed if the write protect jumper is in the ON position.
2. Use the Left and Right arrow keys to display the Setpoints. Each press of an arrow
key will advance the display to the next Setpoint. The Left arrow key starts with the
beginning Setpoint and the Right arrow key starts with the last Setpoint.
3. The Up and Down arrow keys are used to increment or decrement the Setpoint value.
The value will change by one count each time a key is pressed. If the key is pressed
and held for less than one second, the Setpoint value will change at a fast rate. When
the key is released, the fast rate will be reset. Pressing both the Up and Down arrow
keys together will reset the Setpoint value to zero.
4. Pressing the Alarm Silence / Reset key at any time will cancel the operation and
return the display to the main screen.
5. To accept the new Setpoint value, press the Enter key.
6. The unit will beep twice if the change is accepted. If the write protect jumper is on, the
unit will show WRITE PROTECTED on the display and one long beep will sound.
7. When finished changing Setpoints, the write protect jumper should be placed in the
on position (center and right pins).

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SYSTEM OPERATION
General Operation
The unit has two modes of operation, a standby mode and an operating mode. In the standby mode, the
unit is effectively off. All outputs are turned off and the display shows STANDBY. In the operating mode,
the unit operates automatically. All inputs are monitored and the outputs are controlled accordingly.
Pressing the Power key will toggle the unit from standby to operate, or from operate to standby. If power
is removed from the unit, when power is reapplied, the unit will restart in the mode it was in when power
was removed.
Display
The display is a 2 line x 20–character backlit liquid crystal display. System operating status and sensor
readings are shown on this display. Setpoint information is also shown on this display.
Operating Status Messages
The operating status of the unit is shown on the top line of the display. The following list describes the
items shown for the operating status.
STANDBY: The unit is in the standby mode.
DELAY 99: The unit is in the RO start delay. The number is the seconds remaining before the
RO pump starts.
OPERATING: The RO unit is operating.
TANK FULL: The unit is shut down due to a tank full condition.
TANK FULL 99: The unit is shut down due to a tank full condition. If the number is blinking, the tank
full high switch has cleared, but the tank full low switch is still active. If the number
is on steady, both tank levelswitches have cleared andthe delay is counting down.
PRETREAT: The unit is shut down due to a pretreat lockout condition.
PRESS FAULT: The unit is shut down due to a pressure fault condition.
MEMB FLUSH 99: Membrane flush is active. The number is the minutes remaining in the flush
cycle.
TDS / Conductivity
The TDS / Conductivity is shown on the top line after the unit operating status. When the unit is offline
because of a shutdown condition, the reading is replaced with ‘––––’ If the reading is over range, the
reading is shown as ‘^^^^’.

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Operating Hours
The current operating hours are shown on the bottom line.
Temperature
The current water temperature is shown on the bottom line after the operating hours. When the unit is
offline because of a shutdown condition, the reading is replaced with ‘–––’.
Warning Messages
Warning messages are also shown on the second line. If any warnings are active, the active warnings
will alternate with the normal displays for the bottom line. The following lists the warning messages.
HI TDS / Conductivity: The TDS / Conductivity reading has exceeded the programmed limit.
TANK LOW: The tank low input is active.
TANK LOW 99: The tank low input has cleared, but the tank low restart delay is active.
The number reflects the minutes left in the delay.
OP HOURS EXCEEDED: The current operating hours have exceeded the programmed limit.
Tank Full Operation
The unit can be operated with 1 or 2 level switches. With 1 level switch, the switch is connected to the
tank full high input. When this switch has been active for five seconds, the unit will shut down on tank
full. TANK FULL will show on the display. When the tank full condition clears, the display will show
TANK FULL 99. The number is the tank full restart time and the unit will restart when this delay times
out.
For 2 level switch operation, the upper switch is connected to the tank full high input and the lower
switch is connected to the tank full low input. When both switches are clear, the RO unit will run. The
RO unit will continue to run when the water level rises and the lower switch becomes active. When the
upper switch becomes active, after the five second delay, the RO unit will shut down. TANK FULL will
show on the display. When the tank level drops and the upper level switch clears, the display will show
TANK FULL 99 and the RO unit will remain off. The number is the tank full restart time and the number
will blink until the lower level switch clears. When the lower level switch clears, the number will remain
steady and the RO will restart when the delay times out.
Tank Full Restart
The tank full restart is the delay before the RO unit starts when a tank full condition clears. This delay
can be in minutes or in seconds. The TF Restart Setpoint selects seconds or minutes.

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Tank Full Override
A timed tank full override can be initiated when the RO unit is shut down due to a tank full condition.
Pressing the Alarm Silence/Reset key for three seconds during a tank full condition will enable the tank
full override. The RO will start and TF OVERRIDE 9 will show on the display. The number is the
minutes remaining in the override timer. When the override times out, the unit will return to the tank full
shutdown condition.
Pressure Fault
If the pressure fault input becomes active and stays active for the delay programmed in the PF Delay
Setpoint, the unit will shut down for a pressure fault. The display will show PRESS FAULT, the alarm
lamp will flash and the audible alarm will sound. The pressure fault can be cleared by pressing the
Alarm Silence/Reset key twice.
Auto Reset
If a pressure fault shutdown occurs and the Auto Reset Setpoint is programmed to zero, the unit will
remain shut down until manually reset. If the Auto Reset Setpoint is programmed to a value greater
than zero, the unit will automatically clear the pressure fault and attempt to restart after this delay times
out.
Alarm Silence
When a shutdown occurs that causes the audible alarm to sound, the alarm can be silenced by
pressing the Alarm Silence/Reset key once. The alarm will remain silenced if the Alarm Silence
Setpoint is programmed to zero. If the Alarm Silence Setpoint is programmed to a value greater than
zero, the alarm will resound after this delay times out. Pressing the Alarm Silence/Reset key will silence
the alarm and reset this delay.
Pretreat
If the pretreat input becomes active and stays active for two seconds, the unit will shut down in a
pretreat lockout condition. PRETREAT will show on the display and the unit will remain shut down as
long as the pretreat input is active.

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Membrane Flush
If the Flush Type Setpoint is programmed to zero, flush is disabled. If membrane flush is desired, several
types of flush are available. When the unit enters a flush cycle, the flush relay will activate. The flush
cycle will last for the time programmed in the Flush Time Setpoint. Table 3 shows the value that must be
programmed in the Flush Type Setpoint for each type of flush.
TABLE 3. Flush Type
TANK FULL: The RO unit will flush each time a tank full condition occurs.
OPERATING HOURS: A flush will occur when the RO pump has operated for the number of
hours programmed in the Flush Interval Setpoint.
ELAPSED TIME: A flush will occur after the number of hours programmed in the Flush
Interval Setpoint has passed.
OFF HOURS: A flush will occur when the RO has been shut down due to a tank full
condition for the number of hours programmed in the Flush Interval
Setpoint.
RO START/STOP: A flush will occur each time the RO starts or stops.
The tank full flush can be combined with any of the three interval flush
types. A manual flush can be initiated by pressing the Alarm
Silence/Reset key for three seconds.
FLUSH TYPE
DESCRIPTION
0
NO FLUSH
1
TANK FULL
2
OPERATING HOURS
3
OPERATING HOURS AND TANK FULL
4
ELAPSED TIME
5
ELAPSED TIME AND TANK FULL
6
OFF HOURS
7
OFF HOURS AND TANK FULL
8
RO START/STOP