PHI 310 Series Manual
phi
PHI 310 SERIES CONTROLLER
Operations & Maintenance Manual
1-800-641-1726
15 Oro Beach Drive
Oroville, WA 98844
www.phiwater.com
5/9/18
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PHI 310 SERIES CONTROLLER
TABLE OF CONTENTS
INTRODUCTION
Scope of Manual .................................................................................. 3
Safety Information ................................................................................ 4
GENERAL DESCRIPTION
System Operation................................................................................. 5
How the PHI System Mixes.................................................................. 6
Mixing Zones/Area of Influence............................................................ 7
INSTALLATION
Bubble Forming Plate Mounting ........................................................8-9
Piping ................................................................................................. 10
SYSTEM SET-UP & ADJUSTMENTS
Electronics.......................................................................................... 11
Controller Overview.......................................................................12-13
Mixing Mode Functional Description................................................... 14
Series 310 Controller HMI Programming.......................................15-20
EQUIPMENT MAINTENANCE AND REPAIR
Regulator & Filter ..........................................................................21-23
Ross Poppet Valve(s)....................................................................24-33
TROUBLESHOOTING GUIDE......................................................34-35
MAINTENANCE LOG........................................................................ 37
WARRANTY ...................................................................................... 39
DRAWINGS ..........................................................................Addendum
MAJOR PARTS ....................................................................Addendum
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PHI 310 SERIES CONTROLLER
SCOPE OF MANUAL
This manual contains information concerning the installation, operation,
and maintenance of the PHI 310 mixer. To ensure proper performance
of the mixer, the instructions given in this manual should be thoroughly
understood and followed.
KEEP THE MANUAL IN A READILY ACCESSIBLE LOCATION FOR
FUTURE REFERENCE.
Changes and additions to the original edition of this manual will be
covered by a “CHANGE NOTICE” supplied with the manual. The
change notice will explain any changes made to the product described
in this manual.
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PHI 310 SERIES CONTROLLER
SAFETY INFORMATION
WARNING
DO NOT REMOVE VALVE OR DO ANY MAINTENANCE IN THE
PHI VALVE ENCLOSURE OR ON ANY PART OF THE PHI MIXING
SYSTEM UNTIL ELECTRICAL POWER IS TURNED OFF AND
LOCKED OUT FOR BOTH THE COMPRESSOR AND THE VALVE
PANEL. AIR PRESSURE TO CONTROLLER AND ALL PIPING
SHOULD BE AT 0 (ZERO) PSI TO PROCEED.
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PHI 310 SERIES CONTROLLER
SYSTEM OPERATION
Simplicity in design, effective mixing, and the low power requirement
makes the PHI 310 an ideal solution for any mixing application found in
a wastewater and water treatment plant.
The key to its effective mixing is achieved by proper sequencing of very
large air bubbles. Each bubble contains 2-4 cubic feet of air and
requires approximately ½ to 1 hp of energy. Depending on the
application the system will generate 2-6 bubbles per minute.
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PHI 310 SERIES CONTROLLER
HOW THE PHI SYSTEM WORKS
The air pulse is approximately ½ second in duration and is injected
through the forming plate. The forming plate distributes the air equally
around its circumference creating a large flat bubble mass that rises at
a rate of approximately four feet per second. This rapid rise of the large
bubble mass pulls liquid and solids up behind it as it rises. When the
bubble breaks the surface and exits from the liquid, the water continues
to rise to the surface. A second bubble is released after 10 to 60
seconds which continues the water flow from the bottom to the top of
the tank. When the water reaches the surface, it flows outward. As it
encounters a fixed wall or a virtual wall (formed when flow from multiple
bubbles come together), there is only one way the water can travel, and
that is down. The water flows down the tank and when it reaches the
bottom flows back toward the forming plate. This circular flow is what
creates the effective mixing currents. This can be observed by watching
the underwater video found at www.phiwater.com.
In the video, the red streamers show the actual water flow. This
substantiates Dr. Arnold’s CFD modeling that shows that the energy is
additive and achieves a steady state in approximately 30 minutes
First Pulse Energy Builds Steady State
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PHI 310 SERIES CONTROLLER
MIXING ZONES
When mixing requires solids to be suspended, as found in wastewater
treatment plants the effective mixing area is 1:1.2 ratio. This means for
each foot of water depth the effective mixing zone is a 1.2’ radius from
the center of the forming plate. Thus a forming plate in 10 feet of water
will have a radius of influence of 12’ (24’ in diameter). The practical
placement of the bubble forming plates is at a 1:1 ratio as shown below:
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PHI 310 SERIES CONTROLLER
BUBBLE FORMING PLATE MOUNTING
To mount the stainless steel bubble forming plate on a concrete
surface, two concrete anchors are used as shown in the following
diagram:
For a steel tank there are two ways to install the bubble forming plate:
The first option is to purchase a PHI magnetic mounting kit. These
powerful stainless steel magnets will hold the plate to the bottom of a
flat carbon steel surface. The second option is to weld 1/4” bolts or
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PHI 310 SERIES CONTROLLER
BUBBLE FORMING PLATING MOUNTING —
cont’d
all-thread to the tank floor, being careful to match the hole pattern of the
plate (See Addendum 4). If the surface is not flat, then use leveling nuts
to square the plate and then bolt the plate in place (make sure to use all
three holes).
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PHI 310 SERIES CONTROLLER
PIPING
The plate connection is a 1” NPT pipe nipple and all piping coming from
PHI controller must be 1” and leak free! Choose the material for the
piping or the tubing/hose that best fits the environment that it will be
used in. It is recommended to use only NSF 61 approved material for
potable water. For corrosive environments use only the material that will
sustain in the environment. PVC piping is not recommended for
compressed air; however, it can be used on the output side of the PHI
controller as the bubble forming plate end is not sealed, so the air in the
pipe is not compressed. (Use CPVC as the higher temperature rating is
required.)
You must use piping or hose that is approved for compressed air (125
psi) from the compressor to the PHI controller. Do not undersize the
pipe. The supply pipe size will increase in size with the number of
controllers connected to it. (Please contact PHI for sizing.) The piping to
the controller must be a minimum of 1” and the same 1” size to the
plate(s).
If two bubble forming plates are connected from one valve, then
the pipe distance from the “T” to each plate must be equal in
length for air balance. Bubble forming plates must be level and
equal height from the tank bottom when in a “T” configuration to
assure an even distribution of air.
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PHI 310 SERIES CONTROLLER
ELECTRONICS
The PHI controller is housed in a NEMA-4X enclosure. If the controller
is mounted outside, it must have the optional heater. If it is not heated,
the valves will freeze due to the moisture in the compressed air. If
mounted inside; the area must not go below freezing if the optional
heater is not included.
The only maintenance required is the air filter to be checked, cleaned or
replaced quarterly.
The valves are rated for 20 million cycles, and if the air supply is kept
clean and free of excessive moisture, they will rarely fail. If the valve
fails, it can be field repaired by installing a rebuild kit (See instructions
provided with the kit.) The valves can be replaced by undoing the
unions and then removing and replacing the failed valve.
The air regulator is not a repairable part. If it should fail, it will require
replacement. This is done by undoing the unions and replacing the
regulator assembly.
Contact your local PHI representative for information on these products.
WARNING
DO NOT REMOVE VALVE OR DO ANY MAINTENANCE IN THE
PHI VALVE ENCLOSURE OR ON ANY PART OF THE PHI MIXING
SYSTEM UNTIL ELECTRICAL POWER IS TURNED OFF AND
LOCKED OUT FOR BOTH THE COMPRESSOR AND THE VALVE
PANEL. AIR PRESSURE TO CONTROLLER AND ALL PIPING
SHOULD BE AT 0 (ZERO) PSI TO PROCEED.
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PHI 310 SERIES CONTROLLER
CONTROLLER OVERVIEW
The system has three parameters that control mixing efficiency:
1) Air Pressure
2) Pulse Duration
3) Pulse Frequency
The system is shipped preset with the air regulator at 50 psi, pulse
duration at 0.5 seconds, and pulse frequency of four pulses per minute.
Increasing the pulse size (bubble) will lift more liquid to the top; this is
done by increasing the air pressure. To increase Air Pressure, unlock
regulator adjustment knob by pulling up and turning clockwise. View
pressure gauge and do not exceed 80 psi. To reduce pressure, turn
counter-clockwise. (System needs to be operating to adjust pressure).
The HMI system has two adjustments to control mixing: Pulse Duration
(milliseconds) controls the duration of the pulse adding more air mass
to the bubble. For effective mixing, the duration should not exceed one
second. Pulse rate controls the number of valve firings per minute; the
maximum rate should allow one pulse of air to exit the liquid before a
second is created.
CAUTION: DO NOT EXCEED AIR COMPRESSOR CAPACITY.
Optimum system results are obtained by all parameters set at the
minimum settings required to perform the necessary task.
NOTE: SYSTEM OPERATION SHOULD BE OBSERVED BETWEEN
EACH ADJUSTMENT.
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PHI 310 SERIES CONTROLLER
CONTROLLER OVERVIEW —cont’d
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PHI 310 SERIES CONTROLLER
MIXING MODE FUNCTIONAL DESCRIPTION
The PHI 310 controller is a Unitronics Model V 120 PLC. It provides a
simple method for operating personnel to change parameters of the
mixing system without the need to learn computer codes or follow
complicated programming maps.
If the PLC’s display is dark when you approach the PHI 310, either the
mixer has been powered down or the PLC has defaulted into a power
saving mode. By simply depressing any key on the front of the PLC,
the display will activate and programming can proceed. The last screen
viewed before the PLC goes into the power saving mode will reappear
once the PLC is activated again.
CAUTION: DO NOT EXCEED AIR COMPRESSOR CAPACITY
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PHI 310 SERIES CONTROLLER
PROGRAMING —MAIN SCREEN
One Main screen serves as the hub from which all function screens can
be reached. Each function screen has instructions regarding how to
change operational parameters, save them and escape back to the
Main screen. Escaping from any function screen always returns to the
Main screen.
The main screen provides a quick overview of the PHI 310’s operational
status.
In the upper right corner, is a space where either “VLV 1” or
“VLV 2” will flash when either valve is pulsed.
In the upper left corner, three functional programming menus are
display: 1-Time/Mode, 2-Valve Select, 3-Settings. By depressing
the number key below the display, the desired programming
menu will appear.
In the lower half of the main screen, the current program settings
for pulses per minute (PPM), pulse duration (DUR) and operating
mode (MODE) are indicated.
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PHI 310 SERIES CONTROLLER
PROGRAMING —TIME/MODE SCREEN
Once you have navigated to this screen from the Main screen by
depressing the numbre “1”key, you can set the current time on the
PLC, set the “intermittent time”or select between operating the mixing
system in a continuous mode or intermittent mode.
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PHI 310 SERIES CONTROLLER
PROGRAMING —TIME/MODE SCREEN —
cont’d
In the continuous mode, the mixing system will operate as configured
24 hours per day / 7 days per week.
In the intermittent mode, the mixing system will only start mixing at the
time set and for the amount of time set for each start time.
Programming the intermittent mode establishes the same start and stop
times for all seven days of the week.
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PHI 310 SERIES CONTROLLER
PROGRAMING —TIME/MODE SCREEN —
cont’d
When entering the start time, you need to enter values for a 24-hour
clock. For example, a start time for 3 am would be entered as 0300
and a start time for 3 pm would be 1500. It is possible program 24 start
times during the course of one day. To navigate from hour “0” through
hour “23” just depress the backward arrow key to the left of the display
screen repeatedly. Follow the instructions on the screen to make
changes and exiting.
To make the number of start / stop times used during the day simpler to
program, the Set Intermittent Time screen has a line (ON/OFF
STATUS) that lets you turn on or turn off set times quickly. Just select
the desired START HOUR at the top of the screen and, then, go down
to the ON/OFF STATUS line and change between on or off by
depressing the +/- CHANGE STATUS key. Again, each screen in this
PLC’s control program provides instructions for that screen.
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PHI 310 SERIES CONTROLLER
PROGRAMING —VALVE SELECT SCREEN
The PHI 310 can have one or two pulsing valves. In order to determine
if one or both pulsing valves are to operate, you navigate to this screen
by depressing the number “2” when in the Main Screen. Once the
Valve Select Screen is displayed, you need to place a number (1, 2 or
0) in the boxes SEQ1 and SEQ2. If both valves are to be in use, enter
the number 1 to activate valve one and enter the number 2 to activate
valve two. By leaving the number as 0 in either box, that valve is turned
off.
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SERIES 360 CONTROLLER
HMI PROGRAMING —SETTINGS SCREEN
By depressing the number 3 key while in the Main screen, you navigate
to the Setting Screen. Here the number of pulses that each valve will
pulse per minute is set and the length of time that the valve will remain
open during each pulse is set. Pulse rates from 1 to 6 can be selected.
Pulse durations from 0.2 seconds to 0.8 seconds can be selected.
There is one other control line in this screen and this is named SWITCH
(1-0). This is only applicable to existing models of PHI 300 mixers that
have hand switches on the outer door of the mixing valve enclosure.
When the Switch (1-0) setting is set at “1” then control of the pulse rate
is made from the LO –MED –HI three position switch on the door.
When the setting is at “0”, then control of the pulse rate is made from
the PLC and the door switch is de-activated.
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Table of contents
