Regal SMARTVALVES Training manual

As population increases, municipal water and wastewater
treatment facilities must also increase in size in order to supply
and treat the greater demand for water. As the plants increase
in size, so do the distribution and piping systems carrying this
water to and from the population. These piping systems cover
many, many miles making it difficult to maintain suitable
disinfection and stable residuals using manual chlorine and
sulfur dioxide gas feed systems.
The REGAL SMARTVALVES™ discussed in this bulletin
solve the problem whenever varying water flows and/or
varying water quality need to be controlled accurately and
automatically providing the correct ratio of chemical to
water at all times. NO WASTED C EMICAL. These REGAL
SMARTVALVES include an integral dedicated controller which
can be configured for Flow Proportional, Residual, Compound
Loop or Feed Forward Dechlorination control schemes.
Model 7009......................................................................................................................10 to 500 PPD
Model 7010....................................................................................................................1000/2000 PPD
REGAL SMARTVALVE™
Models 7009 and 7010
Flow Proportional Control, Residual Control, Compound Loop Control
and Feed Forward Dechlorination
INTRODUCTION
1. All software including design, appearance, algorithms, and source
codes are copyrighted and owned by Chlorinators Incorporated.
2. The entire contents of this manual MUST be read and under-
stood prior to installing and operating this equipment.
3. DO NOT discard this instruction manual upon completion of the
installa tion as this manual contains information essential to the
safe handling, operation, and maintenance of this equipment.
4. Additional instruction manuals are available at nominal cost
from Chlorinators Incorporated.
5. Plastic pipe or tubing connector fittings may be broken or
damaged if tightened excessively. AND TIG TEN ONLY.
6. For optimum operation, the installation should be indoors so
that the minimum and maximum temperature limitations as
listed in the “T CHNICAL SP CIFICATIONS” section of this
manual are not exceeded.
IMPORTANT NOTES
WARNINGS
INSTRUCTION BULLETIN 17009/17010
1. This equipment is suitable for use only with the gases specified.
DO NOT USE T IS EQUIPMENT WIT OT ER GASES. Such
use can result in failures having hazardous consequences.
2. This equipment is designed FOR VACUUM S RVIC ONLY.
3. To insure proper and safe operation of this equipment, use only
R GAL parts. The use of non-R GAL parts can result in equip-
ment failures having hazardous consequences and voids the
R GAL warranty and insurance coverage.
4. Maintenance should be performed by competent personnel
familiar with this type of equipment, such as Chlorinators
Incorporated themselves.
5. It is essential that all external wiring be done exactly as shown
on the wiring diagrams depicted in this manual. Incorrect wiring
or improper grounding of this equipment WILL cause improper
operation and presents a safety hazard.
6. Field wiring MUST conform to national and local electrical codes.
7. DISCONNECT POWER BEFORE removing the cover or
servicing this equipment.
8. ALWAYS make sure that the cover is in place and securely
fastened to prevent the entry of moisture, water, or corrosive
gases and also to eliminate the potential for electric shock.
9. Any equipment powered by AC line voltage presents a potential
shock hazard. Installation and servicing of this equipment
should only be attempted by qualified electronics technicians.
10. This non-metallic enclosure DOES NOT automatically provide
grounding between the conduit connections. Grounding MUST
be provided as part of the installation.
11. Damage to the circuit boards or internal components incurred
by drilling the enclosure for field wiring or connecting power
lines to low voltage signal terminals voids the warranty.
12. Changing parameter settings and selections WILL affect the
operation of this equipment. If unsure, consult Chlorinators
Incorporated BEFORE changing parameters or selections.
1044 S Dixie Cutoff Road, Stuart, Florida 34994 USA
Phone: [phone] Fax: [phone]
www.regalchlorinators.com mail: [email protected]

CHLORINATORS INCORPORATED
ONE (1) YEAR LIMITED WARRANTY
C lorinators Incorporated ( ereinafter called “C.I.”) sets fort
t e follow ing warranties wit respect to its REGAL Series
7000 SMARTVALVE™. T is war ranty does not apply to t e
purc ase of spare parts or ot er services performed by C.I. or
its aut orized dealers. T is represents t e entire agreement
between C.I. and Buyer (also referred to as “end-user”) and
s all apply unless modified in writing and signed by a
C.I. Officer, and t is warranty and its intended terms s all
supersede any prior negotiations, correspondence, understand ings,
or agreements, written or oral. T e Buyer agrees to and
accepts all terms of t is warranty by its contracting for or
acceptance of C.I.’s prod ucts, and forms or ot er documents or
statements issued by Buyer or any ot er person s all not modify
or ot erwise affect any of t e following terms. Buyer s ould be
aware t at reseller must rely entirely upon C lo rinators
Incorporated’s warranties, or assume t eir own responsibility.
Th following stat s C.I.’s ntir warranty and
r pr s nts Buy r’s xclu siv r m dy with
r sp ct to its product. Such warranti s ar
xpr ssly giv n in li u of any oth r warranty,
xpr ss d or impli d, including but not limit d
to thos of m rchantability and fitn ss for
a particular purpos . This xpr ss d warranty
or any oth r warranty impli d by law shall
not cov r d f cts du to accid nt, improp r us ,
or non-complianc with C.I.’s op rating and
main t nanc , ass mbly, installation manual
and instructions.
Recommendations and advice as to specifications, capabilities,
design, in stallation, engineering, application, and use of
products are provided as an accommodation and are intended
only as suggestions. C.I. assumes no lia bility for suc
recommendations and advice and t ey are not to be con strued
as constituting any warranty, expressed or implied.
TERMS OF WARRANTY
C.I. warrants its REGAL Series 7000 SMARTVALVE™ for
a period of one (1) year from date of s ipment from C.I. Date
of s ipment from t e factory s all be determined solely on
t e basis of t e serial code affixed to t e SMARTVALVE’s
enclosure. T e serial number contains a date code. All serial
numbers are also registered by C lorinators Incorporated as to
date of s ipment, model number, accessories, options, and
billing name. If t e serial number is missing, defaced, c anged,
or in any way ren dered un readable, C lorinators Incorporated
s all, at its option, ave t e rig t to declare t e warranty void.
If t e serial number does not matc t e regis tered model
number as to, but not limited to, suc items as accessories or
options, t e same s all apply.
T e warranty s all apply against material defects in
components and work mans ip occurring in t e course of
manufacture. Buyer’s sole remedy for breac of said warranty
s all be, at C.I.’s option, eit er repair or replace ment of any
unit w ic is received by C.I. at its plant in Stuart, Florida
(s ipping c arges prepaid by buyer), wit in t e time period set
fort above and w ic is found by C.I. to be defective by
reason of manufacture.
Not withstanding th for going, C.I. shall not
b liabl to Buy r for damag s, including
p rsonal injury or d ath to any p rson or
p rsons, or claims of any kind by a third party
or prop rty damag or loss of busin ss or
profits. In no v nt shall C.I. b liabl to Buy r
for cons qu ntial or accid ntal damag s of
any kind, v n if C.I. was awar of th
possibility of such damag s. Th r ar no
r m di s xc pt thos s t forth. Furth r, that
th r ar no oth r authoriz d warranty r pair
faciliti s oth r than thos at th Chlorinators
Incorporat d factory in Stuart, Florida.
EXCLUSIONS
The following are considered external environmental factors beyond
the control of C.I., and which may cause damage and/or need for
service which will be specifically excluded from this warranty (i.e., not
a material defect in components and workmanship occurring in the
course of manufacture).
1. Damage by extraneous causes such as fire, water, lightning,
chemical or galvanic attack, etc.
2. Damage to the circuit boards or internal components incurred by
drilling the enclosure for field wiring.
3. Damage due to the connection of power lines to low voltage signal
terminals.
4. Physical damage due to force, dropping, misuse or other abuse.
5. Use other than that as described in this Instruction Manual
(misapplication).
6. Repair by someone other than Chlorinators Incorporated.
7. Improperly installed.
8. This warranty DOES NOT cover wear items subject to periodic
replacement such as sensors, generating cells, fuses, batteries,
o-rings, gaskets, seals, packing, etc.
The exclusions listed above are provided for purposes of clarification,
and are not intended to, in any way, limit or eliminate other possible
exclu sions.
NO OTHER WARRANTIES
Unless otherwise explicitly agreed in writing, and signed by a C.I.
officer, it is understood that this is the only written warranty given by
C.I. for the systems and components stated.
Th d al rs or r pr s ntativ s of C.I. may not
mak v rbal r pr s ntations that add, modify
or chang th writt n warranti s contain d
h r in or chang th xt nt and natur of C.I.’s
liability. In no v nt shall C.I. b liabl for dir ct,
cons qu ntial, sp cial, incid ntal or punitiv
damag s of any kind with r sp ct to th product,
including but not limit d to thos which may
all g dly aris out of br ach of warran ty,
br ach of contract, n glig nc , strict liability,
or any oth r law, gov rnm ntal r gulation, or
court d cision, xc pt as provid d h r in.
2

1. Read these and all related instructions thoroughly and follow
them carefully.
2. Make certain all required safety equipment is in place and
operational.
3. Whether it is required or not, a gas mask (D MAND TYP AIR
PACK) should be available in the immediate area of the gas
feed equipment and all operating personnel should be properly
trained in its use. OP RATORS SHOULD NOT NT R
AR AS WH R CHLORIN XISTS, UN SCORT D.
4. Chlorine, Sulfur Dioxide, and Ammonia gas or the fumes from
Chlorine, Sulfur Dioxide, and Ammonia solutions can be lethal
in large enough doses. Always have a coworker observe from
a safe location when you are working on any part or component
of the gas feed system.
5. Avoid breathing the gas fumes of Chlorine, Sulfur Dioxide, and
Ammonia solutions and AVOID contact with your skin. Work
only in a well ventilated area.
6. Before working on the gas feed system, make certain that the
cylinder/container/manifold valve(s) are shut off. If the
cylinder/container/manifold valve(s) seem to be shut off, open
them one quarter turn, and immediately close them again to
make certain they are not frozen in the open position. If you
cannot turn the valve(s) in either direction, ALWAYS ASSUM
TH Y AR OP N, and call your chemical supplier.
7. Do not use wrenches larger than the standard cylinder/container
wrench (approximately 8˝ long) and DO NOT hit the wrench
with a heavy object to open or close the valve.
8. Do not reuse lead gaskets. They may not seal properly thereby
permitting the release of gas.
9. Use only lead gaskets. Other types may contract with
temperature variations resulting in the escape of gas.
10.Check for gas leaks every time the vacuum regulator(s) are
connected or remounted onto the cylinder/container/manifold
valve.
11. The rate valve IS NOT a shut-off valve. To shut off the gas
supply, CLOS TH CYLIND R/CONTAIN R/MANIFOLD
VALV (S).
PRECAUTIONS FOR PERSONAL AND SYSTEM PROTECTION
IMPORTANT:
Please mail or fax this registration form
to establish your warranty.
REGAL REGISTRATION CARD
IMPORTANT: To further establish your warranty and to enable us to contact you should the
need arise, please fill out this card and return it promptly. Please do it now. Thank you.
Chlorinators Incorporated, Stuart, FL is the only authorized Warranty Repair facility for
R GAL GAS D T CTORS/SMARTVALV S.
PLEASE PRINT, T ANK YOU
Gas Detector/SMARTVALV Serial No.(s)* 1._________________ 2._________________
*Serial No. plate located inside unit on the right
Purchased From __________________________________________________________
Your Name ____________________________________________ Title_______________
Organization ______________________________________________________________
Mailing Address ___________________________________________________________
City _____________________________________ State _____________ Zip ___________
Phone (__________) _____________________________________ xt. ____________
REGAL Registration Card
3

A) Location of Components
B) Pipes, Tubing and Fittings
C) lectrical Interconnections
3.0 INSTALLATION
A) To nter the ngineering Mode
B) ngineering Parameters
C) To xit the ngineering Mode
5.0 ENGINEERING MODE
A) Linearizing (Calibrating) the SMARTVALV
B) Setting Control Parameters
C) Setting the Lag Time
7.0 SYSTEM START-UP
A) Flow Proportional Control
B) Residual Only Control
C) Compound Loop Control
D) Feed Forward Dechlorination
8.0 OPERATIONAL MODE
A) Calibrating the Analog Input(s)
B) Calibrating the Analog Output
C) Setting the Mechanical Zero
9.0 MAINTENANCE
10.0 SPECIFICATIONS
A) To nter the Configuration Mode
B) Configuration Parameters
C) To xit the Configuration Mode
6.0 CONFIGURATION MODE
A) The Importance of Mixing
B) The Importance of Lag Times
C) The Importance of Proper Sizing of
System Components
D) Transient Voltage Surge Suppression
2.0 DESIGN AND INSTALLATION
CONSIDERATIONS
A) Flow Proportional Control
B) Residual Only Control
C) Compound Loop Control
D) Feed Forward Dechlorination
) Chloramination
1.0 INTRODUCTION
4.0 GENERAL INFORMATION
PRIOR TO START-UP
IMPORTANT:
Fill out and mail or fax the form on the reverse side
to establish your warranty.
CONTENTS
PLAC
STAMP
H R
C LORINATORS INCORPORATED
1044 S Dixie Cutoff Road
Stuart, FL 34994-3436
4

Drawing No. 1 Typical Installation of Flow Proportional Control
Drawing No. 2 Typical Installation of Residual Only Control
Drawing No. 3 Typical Installation of Compound Loop Control
Drawing No. 4 Typical Installation of Feed Forward Dechlorination
Drawing No. 5 Typical Automatic System for Chloramination
Drawing No. 6 SMARTVALV Installation to Provide Both Manual and Automatic Operation
Drawing No. 7 Terminal Strip Designations
Drawing No. 8 Field Wiring Connections
Drawing No. 9 ngineering Data Sheet for SMARTVALV Dimensions
Drawing No. 10 Use of xternal Surge Suppressors
Drawing No. 11 Display Circuit Board (Part No. 7070) and Power Supply Circuit Board (Part No. 7071)
Drawing No. 12 Control Valve Assembly for 10 to 500 PPD (Part No. 7003)
Drawing No. 13 Control Valve Assembly for 1000/2000 PPD (Part No. 7004)
Drawing No. 14 7500 Remote Meter Panel Assembly for 10 to 500 PPD Systems
Drawing No. 15 Remote Meter Panel Assembly for 1000/2000 PPD Systems
Drawing No. 16 Signal Connection Scheme When Flowmeter and Analyzer
Provide Analog Loop Power
Drawing No. 17 Signal Connection Scheme When Flowmeter and Analyzer
DO NOT Provide Analog Loop Power
Drawing No. 18 Dosage xplanation
DRAWINGS AND PARTS LIST
5

6
IMPORTANT: T E ENTIRE CONTENTS OF T IS
MANUAL MUST BE READ AND UNDERSTOOD PRIOR
TO INSTALLATION, STARTUP, AND OPERATION OF
T IS EQUIPMENT. ALSO, DO NOT DISCARD T IS
INSTRUCTION MANUAL UPON COMPLETION OF
T E INSTALLATION AS T IS MANUAL CONTAINS
INFORMATION ESSENTIAL TO T E SAFE ANDLING,
OPERATION, AND MAINTENANCE OF T E EQUIPMENT.
RGAL Series 7000 SMARTVALV S are used to AUTOMATICALLY
regulate the feed rate of a R GAL gas dispensing system. The
Models (7009 and 7010) covered in this manual can be used
to feed either chlorine (CL2) or sulfur dioxide (SO2) gas. These
models may be configured to control a variety of automatic
systems including: A) Flow Proportional Control, B) Residual
Only Control, C) Compound Loop Control, D) Feed Forward
De-chlorination or E) Chloramination. A brief description of
each of these systems is included below.
MODEL 7009 is used for 10 PPD (200 gm/hr)
to 500 PPD (10 kg/hr) systems.
MODEL 7010 is used for 1000 PPD (20 kg/hr)
and 2000 PPD (40 kg/hr) systems.
A) FLOW PROPORTIONAL CONTROL
(See Drawing No. 1)
Flow Proportional Control is used in systems where the water
flow varies but the quality of the water remains the same. In
this control scheme, a water Flow Meter, located in the main
water line, continuously transmits a 4-20 milliamp signal to the
SMARTVALV indicating variations in the water flow rate. The
SMARTVALV then responds by automatically adjusting the
chemical feed rate in direct PROPORTION to the water flow.
B) RESIDUAL ONLY CONTROL
(See Drawing No. 2)
Residual Only Control is used in applications where the water
flow remains constant but the quality of the water varies. In this
Control Scheme, a chlorine residual analyzer, located down-
stream from the SMARTVALV , transmits a 4-20 milliamp
signal indicating variations in the chlorine residual level. The
SMARTVALV responds by automatically adjusting the
chlorine feed rate to maintain the desired residual level.
C) COMPOUND LOOP CONTROL
(See Drawing No. 3)
Compound Loop Control is a combination of both Flow
Proportional and Residual Only control schemes. It is used
when both the water flow rate AND water quality vary. In this
control scheme, both a water flow meter and a chlorine residual
analyzer are used to signal the SMARTVALV to make any
necessary adjustment(s) to the gas feed rate. The initial signal
is transmitted from the upstream water flow meter to the
SMARTVALV which responds by adjusting the gas feed rate
in proportion to the water flow rate. The secondary signal is
transmitted from the downstream residual analyzer to the
SMARTVALV which responds by making further adjustment,
if necessary, to maintain the desired residual level.
D) FEED FORWARD DEC LORINATION
(See Drawing No. 4)
In this control scheme, two SMARTVALV S are used; one to
feed chlorine to disinfect the water; and one to feed sulfur dioxide
to remove any remaining chlorine residual from the treated
water. The SMARTVALV used for chlorination is located
upstream from the residual analyzer and the SMARTVALV
used for de-chlorination is located downstream. An upstream
flow meter sends a signal to both valves which regulate the
chemical feed rates in proportion to the water flow. The residual
analyzer signal is sent to the chlorination (upstream) valve to
make a more precise adjustment, if necessary, to maintain the
proper chlorine residual level. The dechlorination (downstream)
valve simultaneously receives the analyzer signal and then
adjusts the sulfur dioxide gas feed rate to reduce (or remove)
any remaining chlorine residual prior to discharge of the water.
E) C LORAMINATION
(See Drawing No. 5)
Although the R GAL Model 7009/7010 SMARTVALV does
not offer “CHLORAMINATION” as a specific, selectable Control
Scheme, the SMARTVALV is still a commonly used component
in this type of system. Therefore, we have included a basic
guideline to provide a better understanding of the chloramination
process and the installation of this type of system.
The Chloramination water disinfection process is becoming a
more common application in large water treatment facilities
where distribution may cover several square miles, thus requiring
water flow through long distances of pipeline(s). Due to chlorine’s
aggressive, rapid reaction with both organics and non-organics,
it can sometimes be difficult to maintain a FR chlorine
residual that lasts long enough to reach the point(s) of
distribution. In comparison, CHLORAMIN S offer an alternative,
less aggressive disinfectant that reacts more slowly and
remains in the distribution system longer. Chloramines also
help reduce the formation of disinfection by-products such as
trihalomethanes (THM).
Chloramines are formed during a reaction between chlorine
(CL2) and ammonia (NH3) which creates a combined residual
that consists predominantly of monochloramine. A Chloramination
system is used to promote the formation of chloramines by
combining the use of a R GAL chlorine (CL2) gas feed system
and a R GAL ammonia (NH3) gas feed system. The fully
automatic system illustrated in this bulletin, requires the use of
two R GAL SMARTVALV S, one for ammonia and one for
chlorine. The chlorination SMARTVALV adjusts its feed rate
based upon a signal(s) from either, or both, a water flow meter
and residual analyzer. The chlorine feed rate (output) signal is
then transmitted to the ammonia SMARTVALV (Model
7001A) which simultaneously adjusts its feed rate proportional
to a preset ratio of ammonia to chlorine.
A) T E IMPORTANCE OF MIXING
Complete and rapid mixing of the chemical solution at the point
of application CANNOT B OV RSTAT D. Without proper
mixing, control will be erratic and unacceptable due mainly to
the chemical’s tendency to stratify (horizontally and vertically),
even around bends and sharp corners. A quick, thorough mix
will enhance the chemical contact time resulting in more
constant, stable residual readings.
2.0 DESIGN AND INSTALLATION
CONSIDERATIONS
1.0 INTRODUCTION

In potable water applications, if the chemical solution is injected
into a full, turbulent flowing pipeline, a complete mix should
occur within a matter of seconds and a relatively short distance
(10-20 times the pipe’s diameter). It is very important that the
chemical solution be injected into the center one-third of the
pipeline. Under variable flow conditions such as open channels
or pipelines that are not flowing full, external mixing devices
(static mixers, mechanical mixers, flash mixers, propeller mixers,
etc.) are necessary to ensure a complete, thorough mix. These
devices should always be located just after the chemical
injection point and, to prevent off-gassing and corrosion, it is
SS NTIAL that the chemical solution be injected directly into
the water stream, NOT above it.
B) T E IMPORTANCE OF LAG TIMES
(See Drawing Nos. 2, 3, 4, and 5)
In a closed loop system, it is extremely important to keep the
total system hydraulic lag time within acceptable parameters,
resulting in slow, non-erratic deviations and a smooth
adjustment cycle for the SMARTVALV when responding to
the residual analysis. In systems with variable water flow, the
lag time will also vary. Under laminar flow conditions, such as
open channel wastewater applications, the TOTAL system lag
time should always be kept as short as possible (less than 5
minutes) when the system is operating at average (50 %) water
flow. Keep in mind that the lag time will increase as the water
flow decreases and vice versa.
The total system lag time is generally the sum of three individual
times (T1, T2, and T3) as illustrated in drawing Nos. 2, 3, 4,
and 5. T1 and T3 are FIX D lag times and T2 can be either
FIX D OR VARIABL .
1) T1 is the time it takes for the chemical solution to travel
from the throat of the ejector to the point of application.
Keep this time as short as possible by installing the ejector
close to the application point.
2) T2 is the time it takes for the chemical solution to mix
with the water and travel to the sampling point of the
analyzer. This time will vary ONLY if the water flow varies.
3) T3 is the time it takes for the water sample to travel from
the point it is drawn to the sampling cell of the analyzer.
This time should be kept as short as possible by
installing the analyzer close to the sample point.
NOTE: AN EFFECTIVE WAY OF MEASURING T E
SYSTEM LAG TIME IS EXPLAINED LATER IN T IS
BULLETIN UNDER SYSTEM STARTUP (SECTION 7.0).
C) T E IMPORTANCE OF PROPER SIZING
OF SYSTEM COMPONENTS
Use the following guideline to properly size the system components.
1) The R GAL Gas Feed System should be sized so the
average gas feed rate falls within the middle third of the
system’s capacity (maximum feed rate).
2) The Residual Analyzer should be sized so the established
set point falls as close as possible to the midpoint (12mA)
of a 4-20mA analog signal range. e.g. - If the residual
set point is 1.00 PPM, the best size analyzer would
have a range of 0 (4mA) to 2.00 (20mA) PPM.
3) The water flow meter and transmitter must be sized, or
scaled, so the maximum water flow coincides with the
maximum feed rate (capacity) of the SMARTVALV .
D) TRANSIENT VOLTAGE SURGE SUPPRESSION
(See Drawing No. 9)
In order for automatic control systems to operate properly, the
individual components must have “clean” signals that are free
of accumulated transients and protected against electrical
power surges. lectrical surges travel along AC lines, data
lines, analog signal lines, communication lines, and virtually
any conductor they can find. A powerful surge can totally
destroy solid state circuits and their components. Therefore, it
is essential to install external power conditioning equipment
such as surge suppressors and filters. R GAL SMARTVALV S
should be protected with suppression devices placed on the
incoming AC power line and on the incoming DC analog signal
lines. The analog signal lines for flow inputs and residual
analyzer inputs should provide a voltage clamp at a maximum
of 12 volts.
The R GAL Models 7009 and 7010 SMARTVALV S are just
one component in a R GAL complete gas feed system.
Therefore, it is essential for all other system components to be
in proper operating condition prior to installation. If the R GAL
SMARTVALV is being added to an existing gas feed system,
some changes to system components may be required to
ensure proper function. Refer to the Instruction Bulletin provided
with your R GAL gas feed system for more information. Also
feel free to contact your local R GAL dealer or Chlorinators
Incorporated directly.
IMPORTANT: When shipped from the factory, the REGAL
Model 7009 or 7010 SMARTVALVE will be sized to
the capacity specified by the customer at the time of
purchase. If the capacity needs to be changed for any
reason, the Valve Plug size, Remote Meter Panel, and
other system components may also need to be changed.
Consult your REGAL dealer or Chlorinators Incorporated
for further assistance.
NOTE: It is highly recommended to use exclusively REGAL
components to ensure proper, consistent function of
the system.
A) LOCATION OF COMPONENTS
(See Drawing Nos. 1, 2, 3, 4, and 5)
The R GAL SMARTVALV should be wall mounted at eye
level in an area where it is easily accessible and provides a
clear view for easy operation. For optimal performance, the
installation should be indoors so that temperature limitations
are not exceeded. S SP CIFICATIONS.
IMPORTANT: Make sure the enclosure cover is in place
and securely fastened to prevent the entry of moisture or
corrosive gases while also eliminating the possibility of
electric shock.
7
3.0 INSTALLATION

B) PIPES, TUBING, AND FITTINGS
All R GAL SMARTVALV S from 10 to 500 PPD are furnished with
appropriate size connectors to match the capacity of the gas feed
system. The SMARTVALV S with capacities of 1000 and 2000
PPD are furnished with PVC unions to be used with 1- inch
Schedule 80 PVC piping (supplied by others). Larger size piping
may be required if long distances between components are necessary.
The SMARTVALV is connected to the vacuum tubing (or
piping) between the gas feed systems remote metering panel
assembly and the ejector as shown on the drawings in this manual.
NOTE: The following installation guideline is a very basic
description of how to interconnect all the system components.
A more efficient method that allows quick and easy
conversion of the system to full manual operation is
illustrated on drawing No. 6.
On a STANDARD (non-switchover) system:
1) Connect a suitable length of tubing (or pipe) from the
regulator’s VACUUM (outlet) fitting to the remote metering
panel assembly’s BOTTOM (inlet) fitting.
2) Connect another length of tubing from the TOP (outlet)
fitting of the remote metering panel to the SMARTVALV ’S
inlet fitting, located on the side of the valve plug enclosure.
3) Connect a length of tubing from the outlet (bottom) fitting
of the SMARTVALV to the vacuum fitting of the ejector
assembly.
4) Finally, connect a suitable length of tubing to the bottom
(vent) fitting of the vacuum regulator. Route the tubing
to a safe outdoor location with the end pointing down
and covered with bug screen.
On an automatic SWITC OVER system:
1) Connect a suitable length of tubing (or pipe) from each
regulator’s vacuum (outlet) fitting to the side fittings on
the pressure relief valve.
2) Connect a length of tubing from the top fitting of the
pressure relief valve to the remote metering panel
assembly’s BOTTOM (inlet) fitting.
3) Connect a length of tubing from the TOP (outlet) fitting
of the remote metering panel to the SMARTVALV ’S
inlet fitting located on the side of the valve plug enclosure.
4) Connect a length of tubing from the SMARTVALV ’S
bottom (outlet) fitting to the vacuum fitting on the ejector
assembly.
5) Finally, connect a length of tubing from the bottom
connection of the pressure relief valve, routing it outside
with the end facing down and protected with bug screen.
NOTES:
1) The inlet fitting of the SMARTVALV can be rotated, if
necessary, on 90 degree centers for proper alignment of
the vacuum fitting with the other system components.
2) Use Teflon tape on all threaded plastic connections to
prevent galling of the threads; provide a vacuum tight
seal; and facilitate easy removal when necessary.
3) DO NOT over tighten fittings as damage to the fittings
and system components could occur. HAND TIGHT N ONLY.
C) ELECTRICAL INTERCONNECTIONS
(See Drawing Nos. 7 and 8)
1) It is essential that all external wiring be done exactly as
shown on the wiring diagrams in the manual. Incorrect
wiring or improper grounding WILL cause operational
problems.
2) All wiring and fusing MUST conform to the National
lectric Code as well as any local codes.
3) AVOID L CTRICAL SHOCK. Do not connect power
wiring at the source distribution panel until ALL wiring
connections have been made in the SMARTVALV and
the cover is securely fastened in place.
4) Servicing of this equipment should only be done by
qualified electronics technicians or by Chlorinators
Incorporated.
5) XT RNAL surge suppression devices should also be
a normal part of all electronic component installations.
These devices should be placed on all incoming AC
power circuits and, where applicable, on all incoming
DC signal lines. They MUST be chosen and sized properly
(especially when used on 4-20mA DC signal lines) to
assure maximum protection while preventing the surge
suppressor itself from overloading the line resulting in
signal loss.
6) State-of-the-art voltage surge suppressor components
and RFI/ MI filtering circuits are integrated into the
electrical circuitry of each electronic device. However,
these internal components are in place only as a last
line of defense to absorb electrical surges and spikes
before they cause irreparable damage.
7) Power and signal lines MUST be run in separate
electrical conduits to prevent signal interference.
8) The branch circuit should be protected by a fuse or a
breaker with an accessible disconnect switch.
IMPORTANT: Once installation is complete and BEFORE
AC power is applied to the SMARTVALVE, make sure the
internal power switch located on the 7071 Power Supply
Board is in the ON (upward) position. Also confirm that the
voltage (115 vs. 230) switch is set to your specification.
See Drawing No. 11.
AFTER the power and voltage switch positions have been
confirmed, AC power may be applied to the SMARTVALV .
When first powered up, the SMARTVALV will be set in the
OP RATIONAL MOD of the Factory Default FLOW (Flow
Proportional) Control Scheme. Since the water flow input sig-
nal is not yet activated, the TOP LIN of the SMARTVALV
display screen will read: AIN1 (FLOW) LOSS
Simply press the far right keypad button (ACK) to acknowledge
the loss of signal.
8
4.0 GENERAL INFORMATION PRIOR
TO START-UP

The TOP LIN of the screen will then display: FLOW------%
MANL, which represents the water flow in percentage and also
indicates the SMARTVALV is set for Manual (MANL)
Operation.
The BOTTOM LIN of the screen will display: VALVE 0.0 PPD
MENU, representing the gas feed at zero PPD (lbs. per day)
along with the Operational Mode Menu button. If the valve is
factory set for metric scale, the feed rate will be in grams (g) or
kilograms (kg) per hour (h).
IMPORTANT: As previously mentioned, the SMARTVALVE
is in the OPERATIONAL MODE of the factory default FLOW
(Flow Proportional) Control Scheme. owever, since the
OPERATIONAL procedure varies depending on which
CONTROL SC EME the system requires, the FIRST step
necessary is to proceed to Section 5.0 (ENGINEERING
MODE) and select the proper Control Scheme for your sys-
tem. After making this selection, continue on to ALL
remaining Engineering parameters.
NOTE: The keypad buttons will sometimes be referred to in left
to right numerical order (#1, #2, #3, #4) for easy reference.
A) TO ENTER T E ENGINEERING MODE
1) Simultaneously press and hold the #3 and #4 keypad
buttons for approximately five seconds until the TOP
LIN of the display screen reads: ENT ENG PW 0 * * *
( nter ngineering Password).
2) Press the NEXT keypad button three times until the
factory default password (0 0 0 0) appears. Then press
ENT (enter) to accept.
3) The TOP LIN will now display the first ngineering
parameter: OPERATION---FLOW which is used to
select the preferred system Control Scheme.
NOTE: To properly set this and all remaining Engineering
parameters, proceed to the following list which includes a
full explanation with instructions for each parameter. The
parameters are listed in the order they appear while in the
Engineering Mode and they are applicable to all Control
Schemes, with two noted exceptions pertaining to para-
meters No. 2 and 3.
B) ENGINEERING PARAMETERS
1) OPERATION
OP RATION allows the user to choose the Control
Scheme appropriate for their system. The selections are:
a) FLOW (Flow Proportional Control)
b) RES (Residual Only Control)
c) CLC (Compound Loop Control)
d) FEED FWD (Feed Forward Dechlorination)
To make your selection, press ADJ (adjust). Use the UP
or DOWN buttons to scroll to the desired selection.
Press ENTER to accept. Then press NEXT to proceed
to the following parameter.
2) CAL AIN1 (FLOW)
CALIBRAT ANALOG INPUT NO. 1 is for the Water
Flow Meter Input. This input has been factory calibrated
and should not need adjustment prior to startup.
NOTE: This parameter is NOT available for R SIDUAL
ONLY Control.
3)CAL AIN3 (RES)
CALIBRAT ANALOG INPUT NO. 3 is for the Residual
(R S) Analyzer Input. This input has been factory
calibrated and should not need adjustment prior to
start-up.
NOTE: This parameter is NOT available for FLOW
PROPORTIONAL Control.
4) CAL AOUT
CALIBRAT ANALOG OUTPUT – The analog OUTPUT
may be used to transmit the SMARTVALV output
(Gas Feed Rate) signal to another device(s). The output
has been factory calibrated and should not need
adjustment prior to start-up.
NOTE: As mentioned, parameters No. 2, 3, and 4
have been factory calibrated and should not need
adjustment prior to startup. owever, if recalibration
should prove necessary in the future, refer to
Section 9.0 (Maintenance).
5) VALVE CAL PTS
VALV CALIBRATION POINTS refers to the number of
points (in percentage) used to Linearize (calibrate) the
SMARTVALV to coincide with the Remote Metering
Tube. The selections are: 2, 5, 6, 11, or 15. Factory
setting is 5, which represents: 0, 25, 50, 75, & 100 percent
of the system capacity. To change the setting, press
ADJ (adjust). Scroll UP or DOWN to the desired selection.
Press ENTER to accept. Press NEXT to proceed to the
following parameter.
6) CAL VALVE
CALIBRAT (LIN ARIZ ) VALV - The SMARTVALV
is linearized at the factory prior to shipment. HOW V R,
it is recommended to check the linearization when the
system is first started up. This will be covered in more
detail in Section 7.0 (SYST M STARTUP).
7) VALVE SPEED
VALV SP D allows the user to vary the speed of the
SMARTVALV stepper motor as it moves the position
of the Valve Plug to adjust the Gas Feed Rate. The
selections refer to seconds per revolution. Choices
are: 0.5, 1.0, 1.5, 2.0, 3.0, 5.0, 7.5, & 10.0. Factory setting
is 1.5.
NOTE: To change this and all remaining ngineering
parameters, simply press ADJ. Scroll UP or DOWN to
the desired value. Press ENTER to accept. Press NEXT
to proceed to the following parameter.
8) VALVE YS
VALV HYST R SIS places a “dead band” around the
input signal(s) to limit response to minor signal variations.
This helps prevent wear and tear on the stepper motor
and feedback potentiometer. Selections in percentage
are: Off, 0.06, 0.13, 0.25, 0.38, 0.50, 0.75, 1.00 and
2.00 %. Factory setting is 0.13 %.
9
5.0 ENGINEERING MODE

9) FAIL OPERATION
FAIL OP RATION allows the user to choose how the
SMARTVALV will respond to a loss of the analog input
signal(s). Selections are OLD or DROP. HOLD will
keep the Feed Rate at its current level and DROP will
lower the Feed Rate to Zero. NOTE: For compound
loop and feed forward control, both (Flow and Residual)
input signals must be lost for the Fail Operation
parameter to take effect. This will be explained in
greater detail in Section 8.0 (OP RATIONAL MOD ).
NOTE: FAIL OP RATION is the final parameter to
check/change before exiting the ngineering Mode.
C) TO EXIT T E ENGINEERING MODE
1) Press ESC ( scape).
2) After pressing scape, you will be asked if you would
like to ENTER NEW ENG PWD ( nter a new ngineering
Password?).
3) Press NO to keep the existing password and to return to
the Main Operating Screen.
4) Press YES to change the password. The TOP LIN of
the display will read: NEW ENG PW 0 ? ? ?
a) Press the UP or DOWN keypad button(s) repeatedly
until the preferred FIRST digit is displayed. Then
press NEXT to accept the new value.
b) The number 0 will appear as the second digit. Once
again, use UP or DOWN to scroll to the preferred
number. Then press NEXT to accept and continue to
the third digit.
c) Repeat the same steps to select the third and fourth
digit.
d) Finally, press ENT ( nter) to accept the New
Password and return to the Main Operating Screen.
NOTE: At this time, if any changes to the settings were
made while in the ngineering Mode, you will be asked
if you want to SAVE C ANGES? Press YES or NO
accordingly and you will return to the Main Operating
Screen.
IMPORTANT: Once all Engineering parameter settings
have been confirmed, proceed directly to the next section
(6.0 CONFIGURATION MODE) to check and/or change the
Configuration parameter settings.
The Configuration Mode is used to set the basic valve
parameters. ach parameter MUST be checked and/or
changed prior to placing the system into operation. Simply
enter the configuration mode as explained below and the para-
meters will be displayed individually in the order they are listed.
The list includes a detailed description of each parameter
along with the settings and control schemes that apply.
IMPORTANT: Only the configuration parameters that apply to
the selected Control Scheme will be accessible, therefore,
confirm that the proper Control Scheme has been chosen in
the ngineering Mode before proceeding with the configuration
parameter settings.
A) TO ENTER T E CONFIGURATION MODE
1) Press and hold the far right (#4) keypad button for
approximately five seconds and you will be asked to
enter the Configuration Password. The TOP LIN of the
screen will read: ENTER CFG PW 0 * * * .
2) Press the NEXT keypad button three times until the
factory default password (0 0 0 0) is displayed.
3) Press ENT ( nter) and the first Configuration Parameter
(FLOW UNITS) will appear.
B) CONFIGURATION PARAMETERS
(Page 11)
NOTE: The far right columns of the parameters list designate
the control scheme(s) that apply to each parameter.
The abbreviations are:
1) FP (Flow Proportional)
2) RO (Residual Only)
3) CL (Compound Loop)
4) FF (Feed Forward)
10
6.0 CONFIGURATION MODE

CONFIGURATION PARAMETERS
CONTROL SC EMES*
PARAMETER DESCRIPTION AND SETTINGS FPROCLFF
1) FLOW UNITS
2) FLOW RANGE
3) FLOW AVERAGE
4) RES UNITS
5) RES RANGE
6) RES AVERAGE
7) VALVE UNITS
8) VALVE FS
The Water FLOW UNITS are available in %(percent), GPM (gallons
per minute), MGD (million gallons per day), L/s (liters per second),
m3s (cubic meters per second), and m3d (cubic meters per day).
Factory set in %.
NOTE: To change this parameter and any other Configuration
parameter, simply press (ADJ) adjust. Use the UP and DOWN
buttons to scroll to the preferred selection. Press ENTER
to accept, then press NEXT (or LAST) to continue to the
following parameter.
Sets the maximum WAT R flow according to the selected FLOW
UNITS. Since the factory setting for Flow Units is percent, the
FLOW RANG is set to 100 (%).
Allows the Flow Signal to be averaged over a specific time period
before the SMARTVALV makes any adjustments. This helps
prevent wear and tear on the stepper motor and feedback
potentiometer. The settings available are 0.2, 0.4, 0.6, 0.8, 1, 2, 3,
5, 8 & 10 seconds. Factory set at 1.
Residual Units are measured in PPM (parts per million) or mg/L
(milligrams per liter). Factory set in PPM.
The Residual Range MUST be set identical to the range of the
chlorine residual analyzer. Factory set at 3.00 PPM.
Residual Average allows the residual analyzer signal to be
averaged over a specific time frame prior to any adjustment to the
gas feed rate. The available settings are 0.2, 0.4, 0.6, 0.8, 1, 2, 3,
5, 8, & 10 seconds. Factory set at 1.
Units used to monitor and regulate the gas feed rate. The choices
are PPD (lbs. per day), g/h (grams per hour) and kg/h (kilograms
per hour). Factory setting is PPD.
Valve Full Scale is the maximum gas feed rate (capacity) of the
SMARTVALV which must be identical to the capacity of the
overall system including the remote metering tube.
IMPORTANT: The SMARTVALV is sized to the customer’s
specification at the time of purchase. If the Full Scale of the
SMARTVALV needs to be changed, the valve plug and other
system components may also need to be changed.
YES
YES
YES
NO
NO
NO
YES
YES
NO
NO
NO
YES
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YES
YES
YES
YES
YES
YES
YES
YES
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YES
YES
YES
YES
YES
YES
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YES
YES
11

CONFIGURATION PARAMETERS
CONTROL SC EMES*
PARAMETER DESCRIPTION AND SETTINGS FPROCLFF
9) SP1 MODE
10) SP2 MODE
11) SP3 MODE
12) LOCK CTRL
PARM
S T POINT ON MOD refers to the first of THR available
alarm Set Points. The Set Point Mode is used to activate alarm
devices (if desired) and designate what condition the alarm
represents. The selections are: OFF, LOW, or IG . If the S T
POINT MOD setting is left in the factory default OFF position, no
additional parameters will be made available for that particular
alarm set point. However, if LOW or HIGH Mode is selected, the
alarm is activated and the first of four (A thru D) Set Point
parameters will be displayed as follows.
A) SP1 SRC (S T POINT ON SOURC ) refers to the source of
the alarm. The choices, depending on which Control Scheme is
active, will be FLOW (water flow level), VALV (gas feed rate) and
R S (Residual level).
NOTE: When using Feed Forward (FF) Control, alarm set points
are only available for the Chlorination (upstream) valve to eliminate
the possibility of conflicting settings with the De-chlorination
(downstream) valve.
B) SP1 RELAY (S T POINT ON R LAY). There are three (K1,
K2, and K3) relay switches available on the SMARTVALV ’s
Power Supply Board (7071). ach active alarm Set Point MUST
be assigned to one relay. ach relay may be used for more than
one set point.
C) SP1 DELAY (S T POINT ON D LAY) allows the user to set
a time delay from when the alarm set point level is reached until
the alarm actually turns on. The range available is 0 to 60 seconds.
Factory setting is 0.
D) SP1 YS (S T POINT ON HYST R SIS) allows the user to
set a level above (or below) the set point that the source must
return to before the alarm turns off. This setting is based upon the
units used to measure the alarm source. e.g.- If the water FLOW
level is the alarm source and the range is in percentage (%) with
a LOW level set point of 10%, a 2% hysteresis setting would
require the water level to reach 12% before the alarm turns off.
Factory setting is 0.
S T POINT TWO MOD is used to activate (or de-activate) alarm
Set Point No. 2. As is the case with Set Point No.1, the choices
are: OFF, LOW, or IG . The factory setting (OFF) will de-activate
the alarm and LOW or HIGH will activate it. If the alarm is activated,
follow the same steps explained for alarm Set Point No. 1.
S T POINT THR MOD . Follow the same steps as explained
for Set Points No. 1 and 2.
LOCK CONTROL PARAM T RS is the final parameter in the
Configuration Mode. It is used to allow (or deny) access to the
Control Parameters from the OP RATIONAL MOD . Selecting
NO (factory setting) allows access to the parameters. Selecting
YES denies access.
NOTE: The Control Parameters are used exclusively for systems
set up for Compound Loop OR Residual Only Control. They are
explained in detail in the next section (7.0 System Startup).
YES
YES
YES
YES
YES
YES
YES
NO
YES
YES
YES
YES
YES
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YES
YES
YES
YES
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YES
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YES
YES
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NO
NO
NO
NO
NO
NO
NO
12

C) TO EXIT T E CONFIGURATION MODE
Follow the same steps as explained in Section 5C (TO EXIT
T E ENGINEERING MODE).
After all wiring and plumbing has been completed, and the
ngineering and Configuration parameters have been
confirmed, the system is ready for startup. After exiting
the Configuration Mode, the SMARTVALV will be in the
OP RATIONAL MOD of the selected Control Scheme.
Once the system is up and running, the TOP LIN of the
SMARTVALV display screen will read either the water FLOW
rate or the chlorine residual (RES) level, depending on the
active Control Scheme. The ball float in the remote metering
tube should read the same gas feed rate as shown on the
bottom line of the SMARTVALV display screen. ALWAYS
R AD TH C NT R OF TH BALL FLOAT.
IMPORTANT: The R GAL 7500 Remote Meter Panel MUST
be configured for AUTOMATIC control.
A) LINEARIZING (CALIBRATING) T E
SMARTVALVE
IMPORTANT: As previously mentioned, the SMARTVALV
has been calibrated (linearized) at the factory, however, it is
still recommended that the user/installer checks and becomes
familiar with the linearization process at startup, especially if all
system components HAV NOT been supplied by Chlorinators
Incorporated. To check the linearization, proceed as follows:
1) NT R TH NGIN RING MOD as explained in
Section 5.0.
2) Once in the ngineering Mode, scroll to the CAL VALVE
parameter.
NOTE: This Linearization process will be based upon
the factory set, 5-point linearization curve. To confirm
this setting, check the previous ngineering parameter,
VALVE CAL PTS (Valve Calibration Points).
3) While observing the ball float in the Remote Metering
Tube, press the ADJ (adjust) keypad button and the
SMARTVALV will start to drive to the Z RO feed rate
position. The ball should come to rest on the bottom
stop of the metering tube at exactly the same time the
motor stops driving.
4) The Top Line of the SMARTVALV display screen will
show a Z RO VOLTAG reading of 0.45 V.
NOTE: A voltage reading from 0.41 to 0.49 is acceptable.
IMPORTANT: If for some reason the voltage reading
falls outside of the acceptable range, contact
Chlorinators Incorporated for assistance.
5) Once the correct Z RO voltage reading has been
confirmed, press the NEXT keypad button and the
SMARTVALV will automatically open to the second
linearization point which represents 25% of the system’s
Full Scale (capacity). e.g.- For a 50 PPD system, 25%
would be 12.5 PPD.
6) If the reading on the metering tube panel equals the
reading on the SMARTVALV display screen, press
ENTER and proceed to step 8.
7) If the readings DO NOT match, press ADJ (adjust). Use
the UP and DOWN keypad buttons to move the ball float
to the correct (12.5 PPD) reading on the metering tube.
Once the value matches the reading on the display,
press ENTER to accept.
8) Press NEXT and the SMARTVALV will automatically
open to the third linearization point representing 50% of
the valve’s capacity. e.g.- 50% of a 50 PPD system
equals 25 PPD.
NOTE: Follow the same procedure described in steps 6
and 7 to complete the 50% point. Then continue on to the
fourth linearization point (75%) and the fifth linearization
point (100%).
9) Linearization is now complete. Press ESC (escape)
which accepts the Linearization and returns you to the
ngineering parameter, CAL VALVE. Press ESC
(escape) a second time to exit the ngineering Mode.
IMPORTANT: IF T E SYSTEM IS BEING USED FOR
FLOW PROPORTIONAL CONTROL OR FEED
FORWARD DEC LORINATION, ALL NECESSARY
STEPS AVE BEEN COMPLETED TO START
OPERATING T E SMARTVALVE. PROCEED TO
SECTION 8.0 (OPERATIONAL MODE). OWEVER, IF
T E SYSTEM IS TO BE USED FOR RESIDUAL ONLY
OR COMPOUND LOOP CONTROL, T E CONTROL
PARAMETERS LISTED BELOW MUST BE SET
PRIOR TO OPERATION.
B) SETTING CONTROL PARAMETERS
As mentioned, the Control Parameters are used exclusively for
system’s using COMPOUND LOOP (CL) or R SIDUAL ONLY
(RO) Control and are accessible from the OP RATIONAL
MOD of either of these Control Schemes. To access these
parameters, proceed as follows:
Press and hold the far left (#1) keypad button for approximately
5 seconds until the first Control Parameter, RES CTRL GAIN
(Residual Control Gain), is displayed. NOTE: Make sure you
have UNLOCK D the Control Parameters in the Configuration
Mode.
Use the following list to view and/or make changes to this and
all other Control Parameters. They are listed in the order they
will appear with a complete explanation including the settings
and applicable Control Scheme(s). ONLY the parameters for
the active Control Scheme will be accessible. Setting these
parameters is done the same as described for the
Configuration parameters: Press ADJ (adjust). Scroll UP or
DOWN to the desired selection. Press ENTER to accept.
13
7.0 SYSTEM START-UP

CONTROL PARAMETERS
CONTROL SC EMES*
PARAMETER DESCRIPTION RO CL
1) RES CTRL GAIN
2) RES CTRL LIM
3) FIXED LAG TIME
4) VAR LAG TIME
5) FLOW @ VAR LAG
Residual Control Gain establishes how aggressively the controller
responds when making corrections to maintain the residual Set
Point level. The higher the gain is set, the larger and more
frequent the corrective action will be. Too high a setting may lead
to excess “up and down” adjustments to the feed rate, whereas,
too low a setting may cause slow, insufficient adjustments. The
setting is in percentage (0.1 to 100). Factory set at 20%.
Residual Control Limit places a “band” around the waterflow
(primary) signal to prevent the over (or under) feeding of gas due
to a possible drifting, inaccurate, residual (secondary) signal.
e.g. - Using a 50 PPD system. If the water flow units are in
percentage and the present water flow is 40 %, the primary feed
rate would be 20 PPD. Therefore, a 10% residual control LIMIT
will restrict the OV RALL gas feed rate to +/- 10% of the primary
feed rate. Since 10% of the valve’s 50 PPD capacity is 5 PPD, the
output would be limited to a range of 15 to 25 PPD.
NOTE: The setting range is 0 to 25%. Factory set at 20%.
IMPORTANT: As explained in Section 2B, the TOTAL system
lag time (T1 + T2 + T3) refers to the time from when the chemical
solution exits the ejector assembly until the time that the
residual water sample reaches the wet cell of the residual
analyzer. Depending on the Control Scheme, the lag time will
be either FIXED or VARIABLE. The final three Control
Parameters listed below are used to provide the necessary
data for the controller to calculate, and compensate for the
lag time prior to making adjustments. NOTE: An effective and
relatively easy method of setting these parameters is
explained in detail in the next section (SETTING T E LAG
TIME).
The total system lag time becomes FIX D when there is no
variation in the water flow (T2). Therefore, this parameter applies
strictly to Residual Only Control which has a FIX D water flow.
The time setting is in seconds.
Variable Lag Time. The total system lag time is variable only when
the water flow (T2) is variable. Compound Loop Control systems
have variable water flow, therefore,variable lag time. The time
setting is in seconds.
Flow at Variable Lag refers to the rate the water is flowing when
the total lag time is measured. This value sets the necessary
“span” to establish the range of minimum to maximum lag times.
The value MUST be set based on the Flow UNITS and Flow
RANG selected in the Configuration Mode.
YES
NO
YES
NO
NO
YES
YES
NO
YES
YES
14

C) SETTING T E LAG TIME
IMPORTANT: For best results with Compound Loop
Control systems, the lag time should be measured when
the water is at its AVERAGE daily flow rate.
1) Press ESC (escape) to exit the Control Parameters and
return to the Main Operating Screen.
If the SMARTVALV is configured for COMPOUND
LOOP CONTROL, the TOP LIN will display the water
FLOW rate and also indicate if the valve is set for automatic
(AUTO) or manual (MANL) operation. Press the select
(SEL) keypad button, then press RES (residual) to
display the residual reading (PPM) in place of the water
flow reading. Also, if it is set for AUTO operation, press
SEL a second time, then press MANL (manual).
OR
If the SMARTVALV is configured for R SIDUAL ONLY
CONTROL, the TOP LIN will display the residual (RES)
level in PPM (parts per million) and indicate if the valve
is set for automatic (AUTO) or manual (MANL) operation.
If set for AUTO, press the MENU button, then press
MANL (manual).
2) Based upon the Residual Range (RES RANGE) that
was set in the Configuration Mode, a residual level Set
Point (SP) must be established. Press the SEL (select)
button, then press the MENU button. Press SP (set
point), scroll UP or DOWN to the preferred set point
value, then press ENT (enter) to accept. Finally, press
ESC (escape) to return to the main operating screen.
3) The next step is to “balance” the system by manually
adjusting the gas feed rate until the displayed residual
reading matches the residual S T POINT value. Start
by pressing the VALVE button. Then use the OPEN and
CLOSE buttons to gradually adjust the system into
balance. NOTE: This process may take a significant
amount of time, depending on the size of the system.
4) For Residual Only Control systems, proceed to step
No. 5. HOW V R, for Compound Loop Control systems,
the water FLOW rate must also be recorded prior to
proceeding to the next step. To do so, press the MENU
button, then press FLOW and the water level will be
displayed in the selected Flow Units. Record the level.
Then press MENU a second time and press RES to
display the residual reading again. Proceed IMM DIAT LY
to step 5.
5) While observing the displayed residual reading, “upset”
the system by manually increasing or decreasing the gas
feed rate by a substantial amount while simultaneously
starting an accurate timing using a stop watch.
6) Closely observe the residual reading on the screen until
it begins to reflect the upset condition. At that point,
immediately record the timed value in seconds. Once
recorded, manually adjust the gas feed rate again to get
the system back into balance.
7) Once the system is in balance, press and hold the No. 1
keypad button to access the Control Parameters again.
For Residual Only Control. ENTER the recorded time as
the FIXED LAG TIME. For Compound Loop Control,
ENTER the recorded time as the VARIABLE LAG TIME.
8) Finally, for Compound Loop Control, proceed to the
FLOW @ VAR LAG parameter and ENTER the previously
recorded water flow rate. NOTE: Also, check the current
water flow rate to make sure it has not varied much (+/- 5%)
during the timing process. If so, the process must be
repeated.
NOTE: Relocation of the sample point to achieve accurate
results is not uncommon and may require significant
time and trial.
Once all control parameters have been set and
produce the necessary results, proceed to section
8.0 (OPERATIONAL MODE).
NOTE: At this time, it is also recommended to
re-enter the configuration mode and lock the control
parameters to prevent unauthorized access.
ach of the four Control Schemes available for the Model 7009
and 7010 SMARTVALV S has separate OP RATIONAL
MOD PARAM T RS and settings which are explained
below. These parameters may be changed by the operator at
any time, regardless if the valve is set in the MANL (manual) or
AUTO (automatic) operational mode. The currently active
mode (AUTO or MANL) will always be indicated on the far
right, TOP LIN of the display.
To change the operational mode, simply press the MENU or
SEL (select) button. ONLY the mode which is not in use will be
shown on the BOTTOM LIN of the display. Press the keypad
button (No. 3) of the displayed mode to make the change. The
main operating screen will now show the selected mode on the
TOP LIN .
IMPORTANT: When the valve is set in the manual (MANL)
operational mode, the gas feed rate may be adjusted in one of
the four following ways, depending upon the condition.
1) Fully Electric – In the event of loss of the analog input
signal(s), use the keypad buttons and the digital display.
Simply press the VALVE button. Then use the OPEN and
CLOSE buttons to adjust the gas feed rate accordingly.
2) Electric Manual – If the remote meter assembly is
temporarily out of service, use the thumbwheel and
digital display. IMPORTANT: To avoid gear damage
and possibly upset the electrical zero setting, it is
SS NTIAL to place the valve in MANL operation
PRIOR to turning the thumbwheel. Also, be sure to
bypass the remote meter assembly by connecting the
vacuum tubing from the vacuum regulator directly to the
SMARTVALV inlet fitting.
3) Manual – In the event of power loss, use the thumb-
wheel and remote metering tube. To adjust the feed rate,
simply turn the thumbwheel while using the remote
meter ball float as a guide.
15
8.0 OPERATIONAL MODE

4) Fully Manual – To temporarily bypass the SMARTVALV
entirely, use the remote meter rate valve assembly.
NOTE: The remote meter rate valve assembly MUST
first be changed to manual operation. See drawing No. 6.
OPERATIONAL MODE PARAMETERS
A) FLOW PROPORTIONAL CONTROL
The Dosage and Alarm Set Point(s) are the only Operational
parameters for Flow Proportional Control.
1) DOSAGE – The dosage setting allows the user to adjust
a ratio of the gas feed rate with respect to both the
VARIABL water flow and the NON-VARIABL water
quality. Settings are 0.0 to 4.0. Factory setting is 1.0.
NOTE: For a better understanding of DOSAGE, refer
to page 35 and drawing No. 18.
a) To view or change the Dosage setting, press the
MENU button, then press DOSE.
b) Use the UP and DOWN buttons to reach the
preferred value. Press ENTER to accept and auto-
matically return to the Main Operating Screen.
2) ALARM Set Point(s) – If any alarms were activated in
the Configuration Mode, the alarm Set Point Levels
MUST then be set (or changed) in the Operational
Mode. If no alarms have been activated, the ALARM
selection will not appear when the MENU button is
pressed. The alarm set points available for Flow
Proportional Control are VALVE (gas feed rate) or
FLOW (water flow).
a) To set, or change, the active alarm levels, press the
MENU button, then press ALARM. The display will
read the set point number (SP1, SP2 or SP3);
followed by the source (FLOW or VALVE); followed
by the level (LOW or IG ) in the applicable units.
b) To change the level, press ADJ (adjust). Use the UP
and DOWN buttons to display the preferred value.
Then press ENTER to accept.
c) Press NEXT to proceed to any additional activated
Set Points.
d) Follow the same instructions for all Set Points. Then
press ESC (escape) to return to the main operating
screen.
B) RESIDUAL ONLY CONTROL
The Residual Set Point (SP) and ALARM Set Point(s) are the
only Operational parameters available for Residual Only Control.
1) RES SP (Residual Set Point) is the preferred level of
chlorine residual to be maintained by the system. To set
the value, press MENU, then press SP. The TOP LIN
will read RES SP (residual set point) and the present
value. Use the UP and DOWN buttons to set the desired
level. Press ENTER to accept and automatically return
to the main operating screen.
2) ALARM Set Point(s) – The available Alarm Set Points
for Residual Only control are VALVE (gas feed rate)
and/or RES (residual level). To set or make changes,
follow the steps explained for the Flow Proportional
Control alarm set points.
C) COMPOUND LOOP CONTROL
Compound Loop Control provides the option to monitor either
the water FLOW rate or the residual level (RES) on the TOP
LIN of the main operating screen. To select the preferred
display, simply press SEL (select) followed by RES or FLOW.
The additional Operational Mode parameters for Compound
Loop Control are the residual level set point (RES SP) and any
active ALARM set point(s).
1) RES SP (residual set point) – To change the chlorine
residual set point (SP), simply press SEL followed by
MENU. Then press the SP (set point) button. RES SP
and the current value will appear. Use the UP and
DOWN buttons to set the desired level. Press ENTER to
accept and return to the main operating screen.
2) ALARM Set Point(s) – The available Alarm Set Points
for Compound Loop Control are VALVE (gas feed rate),
FLOW (water flow), and RES (residual level). To set or
make changes, follow the same steps explained for the
Flow Proportional Control alarm set points.
IMPORTANT: The dosage is automatic when the
system is set up for Compound Loop Control.
owever, if the signal from the chlorine residual
analyzer should be lost, the SMARTVALVE will auto-
matically convert the system to operate exclusively
in Flow Proportional Control, at which time, the
dosage (DOSE) parameter will be made available for
the operator. Likewise, if the signal from the water
flow meter is lost, the system will automatically be
converted to Residual Only Control and the applicable
parameters will be made available. In either case,
the active Control Scheme (RES or FLOW) will be
displayed on the TOP LINE of the screen, flashing
repeatedly to indicate the loss of signal.
D) FEED FORWARD DEC LORINATION
Feed Forward Dechlorination also provides the option of
monitoring either the water FLOW rate or the residual (RES)
level on the TOP LIN of the main operating screen. To select
the preferred display, simply press SEL (select) followed by
RES or FLOW. The only additional Feed Forward dechlorination
parameter is the multiplier (MULT).
1) MULT (multiplier) – The multiplier setting allows the
user to adjust the gas feed rate with respect to BOTH
the variable water flow and the variable residual level.
The setting is in percentage ranging from 0 to 400 %.
The factory setting is 100%. To adjust the value, press
SEL (select) followed by MULT. Use the UP and DOWN
buttons to set the preferred value. Press ENTER to accept
and automatically return to the main operating screen.
NOTE: No ALARM set points are made available for the
dechlorination (downstream) SMARTVALVE to prevent
settings which may conflict with the chlorination
(upstream) SMARTVALVE.
IMPORTANT: As explained for compound loop control, if
the input signal from either the flow meter or the residual
analyzer is lost, the system will automatically be convert-
ed to the alternate control scheme.
16

A) CALIBRATING T E ANALOG INPUT(S)
IMPORTANT: The preferred Flow and/or Residual Units
and Ranges MUST be preset in the Configuration Mode
prior to calibrating the analog input(s).
As explained in Section 5.0 ( ngineering Mode), the two 4-20
mA analog Inputs (AIN 1 and AIN 3) have been factory
calibrated. If re-calibration becomes necessary, an accurate
4-20 mA signal generator is required. To begin calibration,
enter the ngineering Mode and proceed as follows:
1) In the Junction Box located on the left side of the Main
nclosure, connect the 4-20 mA signal generator to
Terminals #1 (positive) and #2 (negative) for AIN1
(FLOW) or to Terminals #6 (positive) and #7 (negative)
for AIN3 (RES).
2) Scroll to the appropriate calibration parameter, CAL
AIN1 (FLOW) or CAL AIN3 (RES).
3) Apply 4.0 milliamps to the input terminals and then
press the ADJ (adjust) button.
4) The displayed value should be 0.00, representing either
zero water flow (AIN1) or zero chlorine residual level
(AIN3). Press ZERO which will then establish the 4mA
signal as the zero value.
5) Now apply 20.0 milliamps to the terminals. To set the
maximum Water Flow (AIN1) OR maximum Chlorine
Residual Level (AIN3) equal to 20 mA, press the SPAN
button. Use the UP and DOWN buttons to set the true
value based on the applicable units. Then press ENTER.
6) This completes the calibration process.
7) After both (if applicable) analog inputs have been
calibrated, press ESC (escape) to return to the ngineering
parameter list. Press ESC a second time and SAVE
C ANGES to return to the main operating screen.
B) CALIBRATING T E ANALOG OUTPUT
The analog output has been factory calibrated. If re-calibration
proves necessary, an accurate digital VOM (volt ohm meter) is
required. Proceed as follows:
1) In the junction box located on the left side of the Main
nclosure, connect the VOM to Terminals #4 (positive)
and #5 (negative).
2) Scroll to the CAL AOUT (calibrate analog output)
parameter and press ADJ (adjust).
3) Press the 4mA keypad button and the digital display on
the VOM should also read 4.00 mA.
4) If the values do not match, use the UP and DOWN
buttons until the VOM displays 4.00 mA. Then press
ENTER to accept.
5) Press the 20 mA keypad button and the VOM digital
display should read 20.0 mA.
6) If values do not match, use the UP and DOWN buttons
until the VOM displays 20.0 mA. Then press ENTER to
accept. Calibration is complete.
7) Press ESC (escape) to return to the ngineering
parameters list. Press ESC a second time and SAVE
C ANGES to return to the main operating screen.
C) SETTING MEC ANICAL ZERO
(See Drawing Nos. 12 & 13).
The mechanical zero valve plug position has been set at the
factory and should not need resetting unless the SMARTVALV
is being serviced or a change in the system capacity is necessary.
NOTE: An 11/32” open end wrench is needed to set the
mechanical zero valve plug position.
To change the valve plug position, enter the ngineering Mode
as explained in Section 5.0 and then proceed as follows:
1) Scroll to the CAL VALVE parameter and press the ADJ
(adjust) button.
2) After the motor stops turning and the SMARTVALV
displays a “0” PPD gas feed rate, the metering tube ball
float will still be floating or fully rested on the bottom float
stop.
NOTE: Confirm that the Zero Voltage reading on the
TOP LIN of the display falls in the acceptable range of
0.41 to 0.49 volts. If it falls outside the range, do not
proceed further. Contact Chlorinators Incorporated.
3) After the zero voltage has been confirmed, loosen the
lock nut (#7139) that is holding the valve plug (#7105 or
7506) in position on the lead screw shaft (#7109).
NOTE: The top of the valve plug is also squared to
accommodate the 11/32” wrench.
4) IF TH BALL IS FLOATING, use the wrench to turn the
valve plug to the L FT which will move it DOWN the
lead screw shaft. The ball will begin to drop slowly. Just
as it touches and comes to rest on the bottom stop of
the metering tube, STOP turning the valve plug. This is
the mechanical zero valve plug position. Carefully hold
the valve plug in position and secure it using the lock nut.
OR
IF TH BALL IS ALR ADY R STING on the bottom
float stop, turn the valve plug to the RIGHT to move it
UP the lead screw shaft. Keep turning it until the ball
begins to lift off of the bottom stop. Then slowly turn the
valve plug back to the L FT until the ball just touches
and comes to rest on the float stop. Carefully hold the
valve plug and tighten the lock nut. Mechanical zero is
now set.
5) After mechanical zero is set, follow the remaining steps
under CAL VALVE to complete LIN ARIZING TH
SMARTVALV as explained in Section 7.0 (System Startup).
17
9.0 MAINTENANCE

Maximum Gas Feed:
10-2000 PPD for Chlorine
10-500 PPD for Sulfur Dioxide
Power Requirements:
Field selectable 115/230 VAC ±15%, Single Phase
Operating frequency 50/60 Hz
Fusing:
1/4 A @ 230V, 1/2A @ 115V (Time Delay, 250V)
Power Consumption:
45 Watts absolute.maximum
Input Signals:
4-20 milliamps DC
Input Impedance:
250 Ohms
Output Signals:
4-20 milliamps DC, 12 Volt compliance (600 Ohms)
isolated and powered
Micro-Controller:
MC9S12 with 128kB F PROM, 2kB PROM, 8kB SRAM,
16 Bit
Display:
20-character, 2-line, LCD
Decimal Point Setting:
0, 0.0, 0.00
Operator Interface:
Four button keypad integrated into overlay
Relays:
Three (3) each, 10A 250 VAC
Calibration Accuracy:
±0.25% from zero
Speed of Response:
Variable and field selectable between 0.5 and 10.0 seconds
per revolution of motor
Control Modes:
Automatic, manual electric and manual
Operating Range:
10:1
Environmental Limits:
32 to 120°F (0 to 50°C)
Serial Communications:
OPTIONAL Isolated RS232/RS422/RS485 (2/4-Wire) module
Stepper Motor:
Unipolar (5/6-Wire), 12 Volt, 1 A/winding, Size 23
Gain Setting:
0.1 to 100
Lag Time Setting:
1 - 7200 seconds
Residual Full Scale Setting:
0.1 to 100 PPM
Residual Input Signal Filtering:
0.0 to 20.0 seconds
Shipping Weight:
18 Lbs.
10.0 SPECIFICATIONS
18

DRAWING NO. 1 — TYPICAL INSTALLATION
Flow Proportional Control System
Flow Recorder
(BY OTH RS)
4-20 Milliamp Analog Output Signal
Vacuum Tubing
GAS FLOW from
Vacuum Regulator
R GAL 7500 Remote Meter
Assembly
Isolation Valve (Typ.) (BY OTH RS)
Booster Pump (BY OTH RS)
R GAL jector
Assembly
Y-Strainer
(BY OTH RS)
Pipe Union (Typ.) (BY OTH RS)
Gauge for Supply Pressure (Ps)
Gauge for Back Pressure (Pb)
R GAL Model CRA-5000 Residual Analyzer
R GAL VAC-1000
Vacuum Monitor
Static Mixer (BY OTH RS)
Chlorine Solution Injection into Center of Main Line
Residual
Sample Line
(BY OTH RS)
120/240 VAC
50/60 Hz
120/240 VAC
50/60 Hz
120/240 VAC
50/60 Hz
120/240 VAC
50/60 Hz
REGAL SMARTVALVE™
Model 7009
Residual Recorder
(BY OTH RS)
Water Flow Meter
(BY OTH RS)
Flow Analog Input Signal (4-20mA DC)
NOTE: The sole purpose of this drawing is to show the gas flow path through the R GAL System components
and the order in which these components are connected.
19

DRAWING NO. 2 — TYPICAL INSTALLATION
Residual Only Control System
4-20 Milliamp Analog Output Signal
Residual Analog Input Signal (4-20mA DC)
Vacuum Tubing
GAS FLOW from
Vacuum Regulator
R GAL 7500
Remote Meter
Assembly
Isolation Valve (Typ.) (BY OTH RS)
Booster Pump (BY OTH RS)
R GAL jector
Assembly
Y-Strainer (BY OTH RS)
Pipe Union (Typ.) (BY OTH RS)
Gauge for Supply
Pressure (Ps) Gauge for
Back Pressure
(Pb)
R GAL Model CRA-5200
Residual Analyzer
R GAL VAC-1000
Vacuum Monitor
Static Mixer (BY OTH RS)
Lag Time (T2)
Lag Time (T1) Lag Time
(T3)
Chlorine Solution Injection into Center of Main Line
120/240 VAC
50/60 Hz
120/240 VAC
50/60 Hz
120/240 VAC
50/60 Hz
REGAL SMARTVALVE™
Model 7009
Residual Recorder
(BY OTH RS)
NOT : When using Residual Only Control, the total lag time (T1 + T2 + T3) is Fixed
since water flow does not vary.
NOTE: The sole purpose of this drawing is to show the gas flow path through the R GAL System components
and the order in which these components are connected.
Residual Sample Line
(BY OTH RS)
20