EVAPCO PulsePure Integrated Controller-2 Installation and operating instructions

E V A P C O
Integrated Controller
Evapco
Pulse~Pure® Integrated Controller-2
Instruction, Operation and
Installation Manual Addendum
EVAPCO, Inc. World Headquarters; PO Box 1300; Westminster, MD USA
Pulse~Pure® Integrated Controller Addendum Rev.2 TEL: [phone]

TABLE OF CONTENTS
1.0 INTRODUCTION...........................................................................................................................................1
2.0 SPECIFICATIONS.........................................................................................................................................2
2.1 Measurement Performance...................................................................................................................2
2.2 Electrical: Input/Output..............................................................................................................................2
2.3 Mechanical............................................................................................................................................. 2
2.4 Variables and their Limits.......................................................................................................................3
3.0 INSTALLATION..................................................................................................................................................4
3.1 Installation..............................................................................................................................................4
3.2 Icon Definitions ......................................................................................................................................4
3.3 Typical Mounting....................................................................................................................................4
3.4 General Panel Layout............................................................................................................................6
3.5 Conductivity Probe, Flow Switch and Water Meter Connections............................................................7
3.6 Blowdown Valve and Timer Connections..............................................................................................8
4.0 FUNCTION OVERVIEW....................................................................................................................................9
4.1 Front Panel ............................................................................................................................................ 9
4.2 Display...................................................................................................................................................9
4.3 Touch Screen Display..........................................................................................................................10
4.3.1 Icons...................................................................................................................................................10
4.4 Password.............................................................................................................................................11
4.5 Startup .................................................................................................................................................11
4.6 Shut Down ........................................................................................................................................... 11
5.0 OPERATION................................................................................................................................................12
5.1 Main Menu...........................................................................................................................................12
5.2 Configuration........................................................................................................................................13
5.2.1 Global Settings…………………………………………………………………………………..…………...13
5.2.2 Security Settings……………………………………………………………………………………………...13
5.2.3 Display Settings……………………………………………………………………………………..………..14
5.2.4 File Utilities …………………………………………………………………………………………………...14
5.2.5 Controller Details……………………………………………………………………………………………..15
5.3 Inputs...................................................................................................................................................16
5.3.1 Conductivity…………………………………………………………………………………………………..16
5.3.2 Temperature.…………………………………………………………………………………………………16
5.3.3 Flow Switch…………………………………………………………………………………………………...17
5.3.4 Water Meters…………………………………………………………………………………………………17
5.3.5 Other Inputs…………………………………………………………………………………………………..17
5.4 Outputs ................................................................................................................................................17
5.4.1 Bleed…………………………………………………………………………………………………………..17
5.4.2 Biocide Timer and Alarm…………………………………………………………………………………….18
6.0 MAINTENANCE..............................................................................................................................................21
6.1 Sensor Cleaning ..................................................................................................................................21
6.2 Replacing Fuse………………………………………………………………………………………………..21
7.0 TROUBLESHOOTING................................................................................................................................22
7.1 Alarm/Error Messages.........................................................................................................................22
7.2 Procedure for Evaluation of Conductivity Probe..................................................................................24

1
1.0 INTRODUCTION
The Evapco Pulse~Pure Integrated Controller offers conductivity control of evaporative cooling water
integrated into Evapco’s patented water treatment system. This addendum should be used in
conjunction with Evapco’s standard Pulse~Pure® Installation, Operation, and Maintenance Manual.
The Pulse~Pure Integrated Controller is microprocessor-driven with on/off control outputs. It is
supplied with a temperature compensated toroidal conductivity sensor and associated mounting
assembly for the sensor. Set points and operating parameters may be viewed without interrupting
control. Each set point change will take effect as soon as entered.
The Timer output is scheduled on a user selectable daily, weekly, two week or four week recurring
cycle. It may be programmed for one cycle per day (in weekly, two week or four week cycle) or up to
10 times per day (in daily cycle). The Timer output is equipped with a pre-bleed and bleed lockout
feature.
All control outputs are interlocked with a flow input via the X-1 connector on the Pulse~Pure circuit
board. An alternative arrangement allows only the blowdown and timer relays to be interlocked with
flow while the Pulse~Purechamber is continuously energized.
Our unique USB feature provides the ability to:
1. Export Config file to a standard USB flash stick to save all controller set points and load settings
into another controller.
2. Download the last 2 months of data including, conductivity, temperature, water use (if
equipped with optional water meters), and Pulse~Pure status onto a standard USB flash disk.

2
2.0 SPECIFICATIONS
2.1 Measurement Performance
Conductivity Range
0 - 12,000 µS/cm (microSiemens/centimeter)
Conductivity Resolution
1 µS/cm
Conductivity Accuracy
500 - 12,000 µS/cm ±1% of reading
Temperature Range
32 - 158°F (0 - 70°C)
Temperature Resolution
0.1°F or oC
Temperature Accuracy
± 1% of reading
2.2 Electrical: Input/Output
Input Power
115 or 460 VAC 60 Hz
230 VAC 50 Hz (Europe)
Input Signals
Conductivity probe
Passive Electrodeless, RTD, PT1000 Temp. Element
Flow Switch (if equipped)
Isolated, dry contact closure required (i.e. relay, reed
switch)
Water Meter (optional)
Digital 0-10 Hz, 50 msec minimum width
Outputs
Mechanical Relays
Two - 6 Amp Total 115/230 VAC (resistive) fused
One mechanical relay assigned to blowdown valve
2.3 Mechanical
Enclosure Material
Stainless Steel
NEMA Rating
NEMA 4X
Dimensions
16” x 16” x 9”
Display
320 x 240 pixel monochrome backlit display
with touchscreen
Operating Ambient Temperature
32 –122°F (0 –50°C)
Storage Temperature
-20 –180°F (-29 –80°C)
Electrodeless Sensor Pressure Rating
140 psi (9.7 Bar)

3
2.4 Variables and their Limits
Low Limit
High Limit
Default
Conductivity Menu
Units
µS/cm, mS/m, S/m
µS/cm
Bleed Menu
Set Point
0 µS/cm
15,000 µS/
1000
Dead Band
Low end of range
High end of range
50
Water Meter Menus
Units
Gallons, Liters, Cubic Meters
Gallons
Gallons per Contact
1 gal/contact
500 gal/contact
100
Liters per Contact
1 L/contact
500 L/contact
Not set
Cubic Meters per contact
0.001 cu. meters/contact
1000 cu. meters/contact
Not set
Timer Menu
Pre-Bleed (0 disables pre-bleed)
1µS/cm
99 µS/cm
0
Lockout
0 minutes
9 hrs:59 min
0
Add Time
Mode
Daily, weekly, two-week, four-week
Not Set
Daily Adds
0 minutes
144 minutes
0
All other modes
0 minutes
1440 minutes
0
Time of Day (Military)
0:00:00
23:59:00
0:00
Password Menu
New Value
0000
9999
Not Set

4
3.0 INSTALLATION
3.1 Installation
Once the Pulse~Pure Integrated Controller panel is mounted, the blowdown valve may be located at any
distance from the controller. The conductivity probe should be placed as close to the panel as possible.
For field installed integrated controllers the probe and flow switch assembly must be located within 20
ft. of the integrated controller. Sufficient flow to the probe assembly should be ensured by piping supply
from the discharge side of recirculating pump and return to either the basin or the suction side of
recirculating pump. Always route low voltage (sensor) signals with at least a 6” separation from AC
voltage wiring.
Locate the probe assembly where an active sample of cooling tower water is available. The probe and
flow switch (system dependent) must be located where they can easily be removed for cleaning and
inspection. They must be situated so that the assembly is always full of water when the tower is
operating. Refer to Figure 1 and Figure 2 for typical installations.
IMPORTANT: To avoid cracking the female pipe threads on the supplied plumbing parts, use no
more than 3 wraps of Teflon tape and thread in the pipe FINGER tight plus 1/2 turn! Do not use
pipe dope to seal the threads of the flow switch because the clear plastic will crack!
3.2 Icon Definitions
3.3 Typical Mounting
Mount the Pulse~Pure Integrated Controllerpanel so that the Chamber cable will reach the bottom
connector. It is advisable to mount the Pulse~Pure Purification Chamber before mounting the
panel to ensure that the shielded cable reaches the bottom of the panel without stress. The panel
should be mounted at a height and location that allows operators to fully open the panel door for routine
access. Locate the conductivity probe in side stream piping which supplies a representative portion of
evaporative cooling water and is within 20 feet of the panel. Install side stream piping with isolation
valves so that the probe and flow switch (system dependent) can be easily removed for periodic cleaning
and inspection. See Figure 1 and Figure 2 for typical mounting options. Contact your Evapco
representative for specific installation recommendations.
Symbol
Publication
Description
IEC 417, No.5019
Protective Conductor Terminal
IEC 417, No. 5007
On (Supply)
IEC 417, No. 5008
Off (Supply)
ISO 3864, No. B.3.6
Caution, risk of electric shock
IEC 3864, No. B.3.1
Caution

5
Figure 1 Typical Installation –Closed-Circuit Cooler or Condenser (self-draining sidestream)
Figure 2 Typical Installation –Single Tower

6
3.4 General Panel Layout
Figure 3 PPIC2 General Panel Layout
Figure 4 Interface Board Located on Left Side of Panel
Pre-wired Display Board
Pulse~Pure Board –X-1
Terminal is located here
DIN Rail to connect
blowdown valve and
timer
Interface Board –Connect
conductivity probe, flow switch
and water meters here
FLOW SW
H20 METER #1
H20 METER #2
Conductivity Probe connections
(Position #1 at top)
JP1 For Alternate Procedure
Move JP1 Jumper to center and
“COND ONLY” pins
If using alternate procedure
connect flow switch leads
to terminals shown.
Connect water meters to
terminals as shown.

7
3.5 Conductivity Probe, Flow Switch and Water Meter Connections
3.5.1 Conductivity Probe
The conductivity probe contains eight wires. Lace conductivity probe wires through the
probe’s locking nut before wiring into panel. Bring wire into panel through supplied
waterproof strain-relief cord grip located on the bottom of Integrated Panel.
Connect wires to connector on Interface Board located on the left-hand side of panel door. Be
sure to connect the named, color-coded wires to the proper connector. See door label or Figure
5for wiring sequence. From top of connector the sequence is:
Position
Wire Label
Wire Color
1
TEMP -
BLACK
2
TEMP+
GREEN
3
R-SHLD
CLEAR
4
NOT USED
5
RCV -
BLACK
6
RCV+
RED
7
X-SHLD
CLEAR
8
NOT USED
9
NOT USED
10
XMT+
BLACK
11
XMT-
WHITE
12 - 18
NOT USED FOR CONDUCTIVITY PROBE
Figure 5 Conductivity Probe Wiring Connections
3.5.2 Flow Switch (System Dependent)
In the preferred configuration, a secondary contact (dry) from the tower recirculating water
pump-starter is wired into the X1 connection on the main Pulse~Purecircuit board. (See the
Pulse~PureIOM for details of this connection). For an installation with multiple pumps where it
is impractical to connect the Pulse~PureIntegrated Controller Panel in this manner, the alternate
procedure should be used.
3.5.2.1 Alternate Procedure
A flow switch is used to control the conductivity-actuated blowdown-relay and
timer-relay while the Pulse~Pure Chamber operates continuously. Flow
switches require regular maintenance and may fail in the open (No Flow)
position. For the alternate procedure, jumper the X1 terminal on the Pulse~Pure
circuit board and move jumper JP-1 on the Interface Board from “PP +
COND” and center pins to center and “COND ONLY” pins. Connect a dry-
contact flow switch to the “FLOW SW” terminals on the Interface Board. See
Figure 4.
3.5.3 Water Meters (Optional)
Water meter totalizers are digital counters designed to operate with a contacting head water
meter. Two water meters can be connected to the Pulse~Pure® Integrated Controller. See
Figure 4.

8
3.6 Blowdown Valve and Timer Connections
The Pulse~Pure Integrated Controller allows 5 Amps of current for incoming power of
120V, 230V or 460V for operatingaconductivity-actuated blowdown valve and timer-
actuated device.
Make all connections to the DIN rail located inside the Pulse~Pure Panel at the bottom.
Feed wires from the devices through waterproof stress-relief cord grips provided.
Connect the HOT lead from blowdown valve to the BLDN terminal and NEUTRAL to #2
terminal. Connect the HOT lead from a timer-actuated device, to the TMR terminal and
NEUTRAL wire to #2 terminal. See Figure 6.
Figure 6 DIN Rail Connections for Blowdown
Valve and Timer-Actuated Device
Connect HOT lead from Timer-
Actuated Device to TMR terminal.
Connect HOT lead from Blowdown
Valve to BLDN terminal.
Connect NEUTRAL leads
from Blowdown Valve and
Timer-Actuated Device to
#2 terminals.