Axeon S-150 User manual

Reverse Osmosis
Process Controller
User Manual
Model S – 150

S – 150 Controller User Manual
MKTF – 429-A 2 09/16
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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