By: 614-841-4650

Prepared in cooperation with the Ohio Department of Transportation and the U.S. Department of Transportation, Federal Highway Administration

By:

Sharp Technologies, Inc. December 1999 982 Crupper Avenue Columbus, Ohio 43229 614-841-4650

1. R.port No. 2. Gorsmmnt AcC.uion No. 3. R.clpient's Catalog No. 3 1980 00016 1477 FHWNOH-99/016

4. Tltle and Subtitle I Report Date

OHIO DEPARTMENT OF TRANSPORTATION WASTEWATER lgg9

TREATMENT PLANT TELEMETRY MONITORING PILOT PROJECT 6. performing Organiration code

8. Worming OrganhUon Repon No. r. Author(s) Raymond Bloch Eric Klintworth, PE 10. Work Unit No. (W)

1. Performing Oqanization Name and Addmu 11. Contract or Grant No. Sharp Technologies, Inc. (State Job No. 14657(0) 382 Crupper Avenue 2olurnbus, OH 43229 13. Type d Repod and Period Covered -Final Report 12 Sponsoring Agency Name and Address 3hio Department of Transportation 14. Sponsoring Agency Code 1600 West Broad Street Zolumbus, OH 43223

With the increased scrutiny placed on operators of road side rest stops to maintain system operation within environmental regulatory requirements and maintain low cost operations, the Ohio Department of Transportation in conjunction with the US.Department of Transportation, Federal Highway Administration, commissioned the implementation of a wastewater treatment plant telemetry monitoring pilot project. This project incorporated the implementation of a state-of-the-art SCADA (supervisory control and data acquisition) system providing ODOT operators and management the ability to remotely monitor and control operations of the Rt. 32 Rest Stop Wastewater Treatment plant. This rest stop is located in Pike County approximately 100 miles south of Columbus, Ohio.

The system was retrofitted with new analog and discrete instrumentation tied to a local programmable controller. The programmable controller was designed with the ability for remote operation by ODOT supervisory personnel to access information via phone modem.

The control scheme at the wastewater treatment plant was enhanced and modified to minimize ammonia discharge fiom the facility. This was accomplished by using the existing package treatment system and through software logic in the programmable controller modify the operation from a strictly timed operation into a sequencing batch reactor.

'. Key Wods ia Oistrlbutlon Statement SCADA, SuperVis~ryControl and Data Acquisition, No Restrictions. This document is Telemetry, Remote Monitoring, Sequencing Batch Reactor, Ammonia Control, Instrumentation, Remote Operatiom, available to the public through the Package Wastewater Treatment Plant National Technical Information Service, Springfield, Virginia 22161 s.Surlty Ctassif. (of thla repon) w.(Of w8 m) 21. No. of Pag.. 22 Rice nclassified Unclassified Fo~DOT F 1700.7 (8-72) -dcompl.t.dP.0.-

,. ..

OHIO DEPARTMENT OF TRANSPORTATION WASTEWATER TREATMENT PLANT TELEMETRY MONITORING PILOT PROJECT EXECUTIVE SUMMARY

One of the most appreciated amenities provided by the state for use by the motoring public are the little "comfort stops'' along the highway. As the interstate highway systems became a reality the need for rest areas on these super highways became apparent. Today there are 146 roadside rest areas throughout Ohio. A total of forty-eight are located on interstates with the remainder on primary and secondary highways. The Ohio Department of Transportation (ODOT) is responsible for the operation and maintenance of a network of watedwastewater treatment systems at rest areas throughout the State of Ohio. Presently, ODOT personnel must visit these sites on a daily basis due to permit requirements for maintaining system operation, process modifications, process information retrieval, and compliance to Ohio EPA regulatory requirements. With the geographic arrangement of the variousroad side rests, site visits have become expensive for ODOT in terms of personnel, scheduling, and routine maintenance activities. Environmental considerations including increased regulatory requirements by the Ohio EPA require a system solution that provides ODOT the ability to more closely control effluent discharge without large capital or manpower costs.

Present operations staff procedure requires that an individual visit the rest stop a minimum of four times per week. This is due to regulatory requirements associated with permit compliance. Contingent upon discussion and approval from the Ohio EPA our goal is have the daily site visits relaxed based upon implementation of a remote access, supervisory control system. This reduction of scheduled visits will allow ODOT increased flexibility with its manpower.

Operators of roadside rest stops are under increased scrutiny to maintain system operation within environmental regulatory requirements while maintaining low cost operations. The Ohio Department of Transportation in conjunction with the U. S. Department of Transportation, Federal Highway Administration, commissioned the implementation of a wastewater treatment plant telemetry monitoring pilot project. This project incorporated the implementation of a state-of-the-art supervisory control and data acquisition (SCADA) system providing ODOT operators and management the ability to remotely monitor and control operations of the Rt. 32 Rest Stop Wastewater Treatment Plant. This rest stop is located in Pike County approximately 100 miles south of Columbus, Ohio.

The system was retrofitted with new analog and discrete instrumentation tied to a local programmable controller. The programmable controller was designed with capability for ODOT personnel to access information and to operate the system remotely via phone modem.

The control scheme at the wastewater treatment plant was enhanced and modified to minimize ammonia discharge from the facility. This was accomplished by using the existing package treatment system and, through software logic in the programmable controller, modifying the operation of the treatment plant from a strictly timed operation into a sequencing batch reactor.

Ammonia control is the primary non-attainment concern in regards to permit requirements. The other areas monitored, carbonaceous biological oxygen demand (CBOD), dissolved oxygen (DO), and pH, were tracked during this study period. Data results show that the system has met the goals for maintaining system performance.

Sharp Technologies, Inc., 982 Crupper Ave., Columbus OH 43229, (614) 841-4650

____ ---~______- --- I TABLE OF CONTENTS

OHIO DEPARTMENT OF TRANSPORTATION

WASTEWATER TREATMENT PLANT TELEMETRY MONITORING PILOT PROJECT I

I i 1.0 Executive Summary

2.0 System Overview

3.0 System Implementation I

Appendix A - System User’s Guide

I Appendix B - Manufacturer’s Literature

THE CONTENTS OF THIS REPORT REFLECT THE VIEWS OFTHE AUTHORS WHO ARE RESPONSIBLE FOR THE FACTS AND THE ACCURACY OF THE DATA PRESENTED HEREIN. THE CONTENTS DO NOT NECESSARILY REFLECT THE OFFICIAL VIEWS OR POLICIES OF THE OHIO DEPARTMENT OF TRANSPORTATION OR THE FEDERAL HIGHWAY ADMINISTRATION. THIS REPORT DOES NOT CONSTITUTE A STANDARD, SPECIFICATION, OR REGULATION.

SECTION 1

EXECUTIVE SUMMARY

One of the most appreciated amenities provided by the state for use by the motoring public are the little "comfort stops" along the highway. Safety rest areas are not new to the American motorist. In the 1920s and 1930s, they were first seen as wayside rests and served as little more than pull-off spots along two- lane highways where travelers could stop and rest or perhaps, at best, have a picnic. Ohio was an early pioneer in roadside development. During the 1930s, a severe drought hit Ohio. Farmers were having a difficult time keeping their cattle alive. The Department of Transportation took it upon itself to drill wells along the highways to aid the farmers. Scioto 52 is believed to be where the first wells were drilled.

As more wells were drilled, shelters and benches were added. Not only did farmers take advantage of I these water sources, but the traveling public also began to use the water. The first roadside rest areas developed out of these well locations. In 1935, the first road-side rest was dedicated and in the next few years the number was rapidly expanded. These roadside rests were built on state lands. A lack of finding prompted the department to ask the public to donate land to develop additional roadside rests. Donors were honored with a plaque at each location. Today many of these rest areas are named for the original landowner. By 1940 there were 277 roadside rests available to motorists.

While the park system was evolving, interstate highway systems became a reality and the need for rest areas on these super highways became apparent. The Federal Highway Administration took an active role in rest area development during the mid-1960s. The need for these changes was brought about by a very mobile public demanding roadside facilities for the traveler. Today there are 146 roadside rest areas throughout Ohio. A total of forty-eight are located on interstates with the remainder on primary and secondary highways.'

1.1 RESEARCH OBJECTIVE I The Ohio Department of Transportation (ODOT) is responsible for the operation and maintenance of a network of watedwastewater treatment systems at rest areas throughout the State of Ohio. Presently, ODOT personnel must visit these sites on a daily basis due to permit requirements for maintaining system operation, process modifications, process information retrieval, and compliance to Ohio EPA regulatory requirements. With the geographic arrangement of the various road side rests, site visits have become expensive for ODOT in terms of personnel, scheduling, and routine maintenance activities. Environmental considerations including increased regulatory requirements by the Ohio EPA require a system solution that provides ODOT the ability to more closely control effluent discharge without large capital or manpower costs.

discussion and approval from the Ohio EPA our goal is have the daily site visits relaxed based upon I implementation of a remote access, supervisory control system. This reduction of scheduled visits will allow ODOT increased flexibility with its manpower.

A mechanism was required to provide ODOT the ability to remotely monitor and control rest areas remotely while maintaining effluent discharge within the Ohio EPA regulatory requirements. The , implementation of supervisory control and data acquisition (SCADA) and an improved on-site

' Home & AwayIOhio, JulyIAugust 1997, p 30A-31A. instrumentation system coupled with new process control strategies were recommended to meet the various project requirements.

Ammonia control is the primary non-attainment concern in regards to permit requirements. The other areas monitored, carbonaceous biological oxygen demand (CBOD), dissolved oxygen (DO), and pH, were tracked during this study period. Analysis and trend data is provided in Section 2, starting on page 18. Data results show that the system has met the goals for maintaining system performance. c

SECTION 2

SYSTEM DESIGN

2.1 SYSTEM OVERVIEW

Sharp Technologies, Inc. (SHARP) installed a state-of-the-art supervisory control and data acquisition system (SCADA) that provides ODOT the ability to remotely monitor and operate the Pike County roadside rest treatment facility from either the ODOT Central ofices in Columbus, Ohio or the local regional ODOT office. The Pike County roadside rest is located approximately ten miles west of State Route 23 on the south side of State Route 32 (Appalachian Highway). The installation included replacement or modification of existing on-site ODOT equipment including new instrumentation and enhanced control schemes. The enhanced control scheme is achieved by converting the existing timer-based flow-through plant configuration (as existed) to a Sequencing Batch Reactor (SBR) process with aerobic and anoxic treatment sequences for nitrification, denitrification, and ammonia stripping. The system design also provides flexibility to add Figure 1 - Pike County Rest Stop additional roadside rest sites from across the state over I time into the existing SCADA architecture. The implementation provides ODOT with the following capabilities:

0 instantaneous access to operational parameters, 0 improved environmental compliance to meet new standards, 0 ability to troubleshoot system operation remotely, 0 ability to better schedule maintenance activities based upon operational parameters, 0 ability to remotely store, retrieve and trend operational data, 0 ability to tune the process based on operational data, and; 0 reduce travel time by evaluating problem areas.

The SCADA system provides the ability to access operational process parameters via dial-up modems over phone lines. This requires an on-site process computer with software, enhanced process instrumentation, modem and phone line at Pike County. A personal laptop computer with process software and modem was provided at ODOT’s Columbus, Ohio central ofice location to access the remote site, as well as providing the ability to be upgraded to cover multiple future sites.

I. Figure 2 -Pike County Roadside Rest Treatment Facility The process controller is an Allen-Bradley I programmable logic controller (PLC) with sufficient capacity to support the process instrumentation and log operational data. This provides ODOT personnel the ability to monitor, control, and store process data. The PLC is configured so that the remote system is able to analyze system performance from the Windows based graphical interface software package residing on the central office computer. A process graphic representing the system schematic shows the status of all process equipment and provides the capability of remote site operation.

With the data storage capability provided in the PLC, operational data can be maintained. Typically, a rolling file is used to maintain eight days of operational data before old data is overwritten with new data. ODOT downloads this data once a week to maintain data integrity.

This provides ODOT with the ability to Figure 3 - Allen-Bradley PLC

Process improvements that were incorporated into the initial process improvements plan included:

0 Optimize flow equalization facilities by coordinating tank levels, process flow, and performance indicators; 0 Control blower output with electrically actuated valves; Monitor pump status and performance; 0 Pace process flow, blower rate, and sludge recycle rate as a function of dissolved oxygen concentration in aeration tank and performance indicators; 0 Pace sludge recycle rate to avoid clarifier overloading; 0 Monitor performance indicators in the aeration basin such as: dissolved oxygen, OW, and temperature; and, 0 Monitor and record flow in the effluent basin.

2.2 SYSTEM OPERATION

The system has four operating modes: Summer, Winter, Timer, and Test. The system will nomally be set to operate in either Summer or Winter modes.

Summer and Winter modes are true feedback control modes. In both modes, the system cycles through a series of steps, beginning with transfer of influent from the equalization basin. It is essentially a batch process. The subsequent steps are:

0 aerate (nitrification and BOD removal),

0 denitrify, and; 0 then aerate again to strip off ammonia.

The key to the improved performance of the system is the feedback control. A dissolved oxygen (D.O.) probe in the aeration basin provides the feedback to the PLC that determines the duration of certain steps. .. . ,.>,. .. . This optimizes the process, compensating for the effects of influent quality and temperature, weather conditions, and other variables.

Summer and Winter modes are similar, but each is optimized to accommodate the significant seasonal differences in oxygen uptake and loading. Timer mode controls the system based on a preset 24-hour timer. It emulates the plant operating scheme prior to installation of the feedback control system, and is only used in case of failure of the D.O. probe.

Test mode essentially turns the plant off, but allows for manual operator control of individual devices. It is used for system testing and for plant maintenance, such as transferring sludge to the holding tank.

The system mode must be changed by the operator, with one exception: the system will automatically change to Timer mode if the D.O. probe appears to have failed. This prevents the effective shutdown of the plant that would otherwise occur, and is further explained in the Timer Mode section.

The HandOfflAuto switches and indicator lights from the standard controls remain in service for each pump and blower. The switches must be in the Auto position for the system to control the plant, although only one pump or blower of a redundant pair is required to be in Auto. The Spray Pump is the only exception-it is left turned Off unless foaming is a problem. If it is in Auto it runs concurrently with the aerators.

The PLC is also used to log real time parameters on an hourly basis so that long term trend charts can be produced to evaluate system performance over time. Data is imported into Microsoft Excel and manipulated to present data in trend format. See Section 2.8, Report Generation.

2.3 ENHANCED INSTRUMENTATION SYSTEM

One of the first criteria in evaluating what could be accomplished was to analyze existing instrumentation and provide a list of new instrumentation to provide the ability to remotely monitor and control the system. Reviewing the existing instrumentation showed that there was little in the way of automation at the Pike County rest stop. Level and pressure switches were the primary means of control and were used to start and stop pumps and blowers with redundant level switches for high-high level alarm and shutdown.

We added the following instrumentation to the system (see Graphic 3 - Pike County Process Schematic):

0 Equalization Tank Level Sensor - used to measure the level in the equalization tank in feet and inches; 0 Temperature Sensor - used to measure the temperature in the Aeration Basin; 0 Dissolved Oxygen (DO) Sensor - used to 7igure 4 - Ultrasonic Level Transmitter in measure the amount of dissolved oxygen in the Sflluent Discharge Aeration Basin. A self-cleaning DO probe was ... /

. . .?I . , ..

...... ' L '. .. provided to eliminate the need for on-site maintenance to keep the probe working properly due to excess sludge buildup. The probe has not required any on-site maintenance due to sludge buildup; Oxygen Reduction Potential (OW) Sensor - used as in indicator of net oxidative or reductive conditions which is a controlling factor for nitrificatioddenitrification conditions; Effluent Discharge Flow Meter - used to measure the effluent flow from the system; and, Solenoid Valves - used to control air to the Aeration Basins and Clarifier Chambers.

The instrumentation was added to provide us the ability to evaluate site conditions in real time, both on- site and remotely. The real-time data was used by the programmable controller to institute the proper control algorithms.

2.4 AUTODIALER

One of the critical design criteria was the ability for the system to provide operations personnel notification of system or process upsets. Urgent alarms are sent from the PLC to a Sensaphone autodialer that is programmed to call the site operator, followed by ODOT operations staff in Columbus if no response is given within a predetermined amount of time. The alarming scheme is designed to warn operations staff of potential problems so that they can make the appropriate response. Figure 5 - SensaphoneAutodialer I The Sensaphone dials out based on the following parameters:

I Autodialer The Sensaphone also has the added Alarm feature of allowing personnel to listen to Condition Nature of Alarm system operation through an on-board 1 Serious malfunction: EQ Tank high level, microphone. system left in Test mode, or both pumps or blowers of a redundant pair are disabled. Another useful feature is that when the 2 Plant has switched to Timer mode because Sensaphone loses its power, it will revert D.O. didn’t change as it should in Step 1 or to battery backup power and provide lost Step 3. power annunciation. The lost power 3 A pump or blower is disabled, but plant is warning is especially helpful in providing still functional. mUnp or blower has a operations personnel the ability to backup still operating, or is not critical. determine a system problem without 4 PLC Battery Low-must be replaced within physically traveling to the site. When 1-2 weeks. power is lost to the site, on-site presence does not provide any tangible benefit. ,. . .

._ ......

.,. 2.5 ON-SITE OPERATOR INTERFACE

P Sharp designed, integrated and installed an additional control panel on-site, wired to existing ODOT control panels so that existing equipment could be reused. This panel included all Sharp provided hardware and was designed to control the existing ODOT pumps and blowers. For on- site operations, a oDerator interface panel Figure 6 - Sharp Supplied Control Panel with from ~11~~-Messageview Operator Display Bradley was provided.

Figure 7 - Allen-Bradley Messageview Operator Display

while on-site. All operational and alarm data that is available in the Fix is available to the on-site operator via the Messageview.

2.6 FUTURE CAPABILITIES

As part of the overall system design, future expandability was provided. Expansion is provided in the following areas:

0 Spare inputs for future analog instrumentation including temperature or pH in the effluent chamber; 0 Spare wiring to support future instrumentation in the effluent chamber; Spare PLC capacity for additional YO; 0 Spare PLC capacity for data recording; 0 Capability to support additional rest stops in the Intellution Fix software package; and, 0 Ability to directly transfer process data from the Fix system to the Ohio EPA SWIMware product (EPA reporting).

2.7 INTELLUTION FIX GRAPHICAL USER INTERFACE

Sharp provided a Windows based PC graphical user interface from Intellution Corporation. Intellution’s Fix software product allows remote access to the PLC in the Pike County rest stop and displays this information graphically for use by ODOT personnel from any properly configured personal computer. The Fix allows the ability to view process operation and upload data from the PLC. Ease of use was provided so that ODOT staff could quickly learn the system and use its capabilities. Appended to this section are the graphic screens that were provided. The Fix system was designed so that future ODOT sites can be added to the overall system architecture. --

I 1

Supplied with the Intellution Fix was a personal laptop computer with the following specifications:

Winbook XP5 Laptop Computer with: 100 Mhz Pentium Processor 16 Megabytes Main Memory 1.44 Megabyte Floppy Drive 8 10 Megabyte Hard Drive Docking Station with integral SX CDROM 10.4" Active Matrix Screen 0 28.8 Kbaud US Robotics External Modem Microsoft Windows 95 Operating System 0 Intellution Fix 75 Point Run-time License 3 year return to factory warranty

A total of ten graphic screens were provided and are provided in the following pages. The following is a description of each graphic page and their purpose.

Graphic 1 - State of Ohio Overview This graphic provides the user the ability to select which ODOT district they are interested in viewing by selecting the appropriate corresponding button.

Graphic 2 - Rest Stop Selection Once the district button has been selected, the District screen provides the user to select the proper rest area.

Graphic 3 - Pike County Process Schematic This screen shows the overall system process schematic. It is from this screen that the user dials into the site by clicking the green phone in the lower left comer. This will automatically launch the Autodial routine and the laptop will dial out to the remote site and connect to the site programmable controller. Once the system has connected, process information will displayed on this screen in real time.

Graphic 4 - Excel Report Options By selecting the Reports button on the Graphic 3, the user is given an option as to which Microsoft Excel report the user is interested in obtaining. By selecting a report option, the system will automatically start Excel and transfer data from the programmable controller to Excel. The user can then save this data for future review or trending. The following reports were provided:

0 Equalization Tank Level Profile 0 Temperature Profile 0 Dissolved Oxygen Profile

0 ORPProfile 0 Flow Profile 0 Daily Flows

0 Cycle Data

Graphic 5 - System Cycle Information This screen provides the user the ability to quickly determine how many cycles the system has gone through since the previous cycle clock started. Since the system is now being controlled as a Sequential Batch Reactor (SBR), it is important to know the amount of time that is being required for each of the various steps in the process.

Graphic 6 - System Flow Information System flow information is used to show the amount of flow that has gone through the system on a twenty-four hour period. This screen shows the last four days of total flow as well as total flow for the day. The PLC also records ninety days worth of this data and is reported through the Excel report options capability. .- Graphic 7 - System Alms The Fix system provides for the ability to provide alarm information based on process parameters set within the programmable controller. The following alarms are supported by the system:

Equalization Tank High Level PLC Battery Low Surge Pump #1 and #2 Fault DO Too Long To Rise in Step 1 DO Too Long to Rise in Step 3 System In Test Mode Too Long EQ Tank Level Didn’t Fall When Surge Pump #1 and #2 Running EQ Tank Level Didn’t Fall When Surge Pump #2 Running Equalization Basin Blower Fault Spray Pump Fault

Graphic 8 - Remote Telemetry Control This screen provides the ability to turn process equipment on and off remotely. This screen shows the status bit of each individual piece of equipment (on or off) and allows the user to toggle the bit when in test mode (mode select). The following equipment can be toggled remotely:

Equalization Tank Blower Surge Pump 1 Surge Pump 2 Blower Motor 1 Blower Motor 2 Spray Pump Aerators RAS & Skimmer DO Probe (Self cleaning)

Graphic 9 - PLC Clock Adjustment This screen allows the user to remotely adjust the internal clock of the programmable controller for daylight savings time. The internal clock is used to time and date stamp all acquired data.

Graphic 10 - System Settings This screen allows the user to modify specific parameters associated with the operation of the water treatment process. Depending upon the time of the season, this allows adjustments to be made remotely. , Graphic 1 - Overview of the State of Ohio

Graphic 2 - Rest Stop Selection i ~~ Graphic 4 - Excel Report Options , . .. ., :-...... c. : . . .. . ,. . ., . , . ... , .. I. I.

,..,z.. 7 , .I . . .,. . .., .. I

Graphic 5 - System Cycle Information

Graphic 6 - System Flow Information

Graphic 7 - System Alarms

Graphic 8 - Remote Telemetry Control ... I. .... ,

i...... J ,. .. .I .. ...

~ .,.. . ., Graphic 9-PLC Clock Adjustment

Graphic 10 - System Settings

2.8 REPORT GENERATION

Report generation is provided through the data collection capabilities of the programmable controller in conjunction with Intellution Fix. The Intellution Fix package supports dynamic data exchange (DDE) allowing the Fix to transfer data from the programmable controller through its database directly into an Excel spreadsheet. From the Excel spreadsheet, macros were developed to trend the data. Once the Fix system connects to the PLC, the user selects one of the report options from the Excel Report Option window (See Graphic 4 - Excel Report Options on Page 2-9). Selecting the button will automatically start Excel, open the appropriate Excel file, and transfer the data from the PLC, through Fix and into the spreadsheet.

The PLC is configured to store hourly snapshots for up to eight days for each of the instruments we are trending (equalization tank level, temperature, dissolved oxygen, OW, and flow). We have combined the weekly snapshots into a report showing approximately four months of system performance. We also store one hundred days of daily flow.

We also track process cycle times. The treatment system operates on a programmed cycle, initiated every several hours, depending on plant loading. The System Cycle Report indicates the starting date and time of each cycle, as well as the duration, in minutes, of certain steps. The other steps are of fixed duration, so they are not reported here.

Step 0 begins the cycle by filling the aeration basin from the equalization tank. Its duration varies with the inflow rate and with pump performance. Step 1 aerates the wastewater until a preset dissolved oxygen (DO) level is reached, as measured by the DO probe. Step 3 allows the wastewater to denitrifi until the DO falls below a preset level. The duration of steps 1 and 3 vary significantly, and are highly indicative ! of treatment system performance.

After completing the denitrification, the process cycle repeats from step 1 until the equalization tank level calls for another fill cycle. The Pusses column indicates the number repeats that were done during the process cycle. (Process step 7 is not used at present, so its duration is always zero.) I

I Equalization Sump Level September - December 1996

40 Syrtan down for final swtchovn automatic mnb-ol 30

20 , .I / , ,+. ,. ,. . .," , ,. / . .... Sptcm Con~olledbetween I / \ syjtm Confrdled bmvan 10 20 and 60 Inches Level in Le 20 and 40 Inches Levd in the Equalization Tank Equalization Tank

0 4::::::::': ': .'::::':::'

Temperature September - December 1996

sa a M n Sperm down for final switchover to 30 automatic aonvol

7.0

IO 7' Dissolved Oxygen September - December 1996

1800

16.00 ~

14.00 I I

I 12.00 4 i I0.W I

. -.

I Oxygen Reduction Potential September - December 1996 ,,.. ,,.. 550 , I

\ I

,..-

I , I

Houriy Flow September - December 1996 70 ____

601

1.. 1..

Thrcc Month Totalized Daily Flow

n E 3

L .

SYSTEM CYCLE INFORMATION

Y --.

2.9 SAMPLING DATA

ODOT personnel are responsible for sampling the wastewater treatment system on a monthly basis to determine its meeting the Ohio EPA discharge limits for pH, dissolved oxygen, ammonia, and CBOD (carbonaceous biochemical oxygen demand).

The ODOT permit limits as mandated by the Ohio EPA are:

Dissolved Oxygen: > 6 mg/l CBOD: < 10 mg/l pH: between 6.5 - 9.0 Ammonia: 4.5 mg/l summer <3 mg/l winter

One of the system implementation goals was to maintain the wastewater treatment system within EPA permit limits. The system did have an ammonia and dissolved oxygen excursion in the month of February 1997. A sludge bulking condition occurred in the clarifiers because of an inadequate quantity of sludge returned to the aeration basin. The previous rest stop process system had no ability to control return activated sludge (RAS) except during the aeration process. In the new process design, the ability to control when activated sludge was returned to the aeration basin was implemented. During the early months of system operation, process operation parameters were tested and different return activated sludge rates were tried. Following the high ammonia and low DO reading, adjustments were made to the RAS rate and ammonia and DO control were effectively maintained thereafter. The system has maintained permit limit levels on all other parameters.

Dissolved Oxygen

16.00

14.00

12.00

10.00 f g 8.00 I 8 6.00

System implemented - 4.00 October 1996

2.00

0.00 \

, .c CBOD

10.00

9.00

8.00

7 .PI

3 6.00 a-

System implemented - October 1996

1.80

7.60

7.40

7.20

6 40

System implemented - 6 20 October 1996

600 System implemented

5 80 ,’ Ammonia

__Ammonia

SECTION 3

SYSTEM IMPLEMENTATION

3.1 SUPPLIED HARDWARE AND SOFTWARE

The following hardware and software was provided on this project:

System Hardware and Software One (1) - Allen-Bradley Programmable Logic Controller System with: 1746-P2 Power Supply 1747-L532 SLC-YO3 Processor 1746-IA16 16 Point AC Input Module 1746-IA 16 16 Point AC Input Module 1746-OA8 8 Point AC Output Module 1746-0A8 8 Point AC Output Module 1746-OW4 4 Point Contact Output Module 1746-N14 4 Point Analog Input Module 1746-N14 4 Point Analog Input Module 1747-SN Remote VO Scanner Onc (1) - Allen-Bradley Messageview 421F One (1) - Phonetics Sensaphone 1 104 Voice Autodialer Seven (7) - Asco Solenoid Valves One (1) - Neles-Jamesbury Electric Actuator One (1) - Ametek Level Gauge (Equalization Tank) One (1) - Great Lakes Instruments Dissolved Oxygen Meter (Aeration Basin) One (1) - Great Lake Instruments OW Sensor (Aeration Basin) One (1) - RTD Sensor (Aeration Basin) One (1) - Drexelbrook Ultrasonic Open Channel Flow Meter (Effluent Basin) One (1) - Nema 4X System Enclosure Misc. - Wire, Conduit, etc.

System Engineering Project Management System Electrical Schematic Control Panel Layout Drawing PLC Programming and Documentation Telemetry System Programming and Documentation On-site System Installation, Test, and Commissioning Operations & Maintenance Manual Engineering ReviewEvahation and Report

Personal Laptop Computer for ODOT Central Headquarters Winbook Laptop Computer with: 100 Mhz Intel Pentium Processor with Active Matrix Screen 16 Megabytes Memory 850 Megabyte Hard Drive 1.44 Megabyte Floppy Drive Docking Station with CDROM Drive Microsoft Mouse 14.4K Baud Modem Windows 95 Operating System Intellution Fix 75 Point Run-Time License

The cost of this research project was $48,000 which included all on-site installation time, testing, debugging, commissioning, and all items listed in this section. Additional sites can be retrofitted in the $35,000 to $40,000 range using the same software and hardware design as that in Pike County.

3.2 ODOT PROJECT PERSONNEL EXPERIENCE

ODOT is divided into twelve districts covering the entire state. Within each district, ODOT has personnel assigned to maintain and operate the roadside rests within their jurisdiction. District 9, which includes the Pike County Rest Stop, has its district ofices located in Chillicothe, approximately twenty miles from the rest stop. The ODOT operator assigned to Pike County is also responsible for the following roadside rest stops:

0 Brown County on Route 32 (twenty miles west of the Pike County rest stop); 0 Jackson County on Route 35; and, 0 Scioto County on Route 23.

He is also responsible for the operations and maintenance at the following package treatment plants at the following ODOT garages:

0 Jackson County Garage;

0 Ross County Garage; 0 Scioto County Garage; and, 0 Wheelersburg Outpost.

The design for the rest stop treatment plants are virtually identical except for the modifications made to Pike County as part of this project. Present ODOT operational procedure is to visit each site as often as possible to confirm proper system operation and meet daily site visit requirements as dictated by the NPDES discharge permit. As time permits, each site is visited at a minimum four times a week. A typical site visit consists of assessing system operation, determining that water quality meets visual standards, and checking physical operation of the mechanical equipment. Site visits that must occur on a periodic basis include monthly sampling activities as required by the Ohio EPA.

The three non-automated sites have no alarming ability other than signaling high level in the equalization tank or dosing tank via an annunciator light on the control panel. Should an alarm occur the operator is not notified until physically on-site. Over the course of the implementation of this system, operations personnel have been notified of numerous system alarms. Power loss notification through the on-site autodialer has been helpful in alerting the ODOT operator that electric service has been compromised.

Previously, if power was lost at the plant, no mechanism was in place for the operator to be notified. This is especially helpful if the power outage is of long duration so that proper biological activity with the plant is not compromised. Also, this has minimized site trips during non-working hours, saving time and travel costs associated with alarm occurrences.

The Pike County system has been very effective in meeting the Ohio EPA’s discharge permit levels. Once operational issues were corrected, system reliability has been excellent. At this point in its operation, ODOT personnel feel very comfortable that the system is meeting discharge limits and are concentrating on improving system operation at the other sites.

The amount of data the system collects allows operations staff the ability to quickly see what is occurring at the plant and trend short and long term operational information. The ability to log in remotely and see instantaneous data without traveling to the site. provides access for the operator to quickly summarize system operation. The other area where this is extremely helpful is when an alarm condition occurs, remote access pinpoints the nature of the alarm condition and helps the operator determine where and what the problem may be. On the other sites, when operations staff are notified of a problem, they must travel to the site, diagnose the problem, and then if the tools or parts are not with them, make additional trips to retrieve the parts or tools to complete the repair.

With the Pike County system, one can very quickly determine the general problem and be prepared when you arrive on-site. For example, the plant alarmed the operator via the autodialer. The alarm screen showed that the DO level was not falling fast enough in one of the process steps. When operations staff arrived on-site, the aeration basin was opened and it was determined that a rag was covering the DO probe not allowing it to properly read the DO level. Once the rag was removed, the DO level went to a correct reading and the problem was resolved very quickly. Under previous scenarios there would not have been the alarming function to notify operations staff of a potential system upset. This potentially could have affected water quality and would not have been corrected until operations personnel recognized the problem.

3.3 AREAS OF POTENTIAL COST SAVINGS

The following are areas of potential cost savings that ODOT could implement with this system:

0 Reduce site visits - one of the driving factors for the level of site visits is the requirement to have “daily” visits as dictated by the NPDES permit. With this system Ohio EPA should be notified of its capabilities and substitute daily monitoring coupled with autodialer alarm callouts to suffice for “daily” visits. This provides operations staff the ability to focus its

I efforts on maintenance rather than driving from site to site determining if the plants are up and running properly.

ODOT and the Ohio EPA are presently reviewing the system capabilities and determining the system’s ability to meet the requirements as dictated by the NPDES permit. The goal is to have the Ohio EPA substitute daily visits with computer monitoring and autodialer capability keeping ODOT staff informed of process operations.

0 Data integration - this system provides the ability to collect data and provide it in a variety of different formats. The Ohio EPA is beta testing its new reporting software, SWIMware that could be integrated with the data from this system.

0 Additional data points - presently this system has only one data point in the effluent basin - effluent flow. Additional monitoring instrumentation including DO, turbidity, pH, and temperature could be added to provide additional data to facilitate acceptance by the Ohio EPA.

ODOT has not had a history of paying Ohio EPA fines for notices of violation in conjunction with the operation of its wastewater treatment plants. However, the EPA regulatory permitting requirements are becoming more stringent. Thus putting present wastewater treatment plants into non-compliance. Present Ohio EPA regulations state that notice of violations carry a $10,000 per day fine andor six month imprisonment for violators.

I I

APPENDIX A

SYSTEM USER’S GUIDE

Ohio Department of Transportation

System User’s Manual

for the

Waste Water Treatment Plant

Feedback Control and Telemetry System

US Route 32 Pike County Rest Area

Pike County, Ohio

= A ’ Technologies, Inc. 982 Crupper Avenue Columbus, Ohio 43229 614l841-4650

January, 1997

Waste Water Treatment Plant Feedback Control and Telemetry System System User’s Manual Table of Contents

1 .0 ...... Control System User’s Manual ...... 1 1.1...... Introduction ...... 1 1.2...... System Operation ...... 1 1.3 ..... Messageview ...... 3 1.4 ...... Instrumentation ...... 4 \ 1.5...... Displays ...... 6 1.6...... System Controls and Mode Selection ...... 8 1.7...... Summer Mode ...... 9 1.8 ...... Winter Mode ...... 10 1.9 ...... Timer Mode ...... 11 1 .10 ..... Test Mode ...... 11 1.1 1..... Alarms ...... 12 1.12..... Autodialer ...... 15 2.0 ...... Telemetry System User’s Manual ...... 16 2.1 ...... Introduction ...... 16 2.2 ...... Telemetry System Operation ...... 16 2.3 ...... Site Selection and Dialup ...... 17 2.4 ...... Main Status Screen ...... 18 2.5...... Control Screen ...... 23 3 .0 ...... Instrument Tabulation ...... 26 4.0 ...... Modem Configuration ...... 27

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997

1.0 CONTROL SYSTEM USER’S MANUAL

1.1 Introduction The Waste Water Treatment Plant (WWTP) Feedback Control and Telemetry System provides enhanced control and remote monitoring of the standard ODOT roadside rest area WWTP. The system controls all pumps and blowers associated with the equalization tank and aeration basins. Several transducers are added to provide control and informational inputs to the system, and several air valves are added so that the aerators, return activated sludge pumps, and skimmers can operate independent of each other. The Sand Filter Dosing Pump panel is not modified and operates independently of the system. The system is controlled by an Allen-Bradley SLC-5/03 programmable logic controller (PLC) located in the system control panel at the aeration basin. It is powered from a circuit breaker in the Aeration Basin panel. The fiont of the system control panel houses an Allen-Bradley Messageview 421F operator interface terminal. It provides system status information and all controls which are in addition to the standard system selector switches and indicators. A Phonetics Sensaphone telephone autodialer is housed inside the panel. Two telephone lines from GTE are brought in to the control panel. Telephone number 493-2033 is connected to the autodialer, and can be used as a voice line. Telephone number 493-3569 is connected to the telephone modem used by the telemetry software to remotely access the PLC. The area code for these telephone numbers is 614 at this writing, but is expected to change to 740 in calendar year 1998. 1.2 System Operation The system has four operating modes: Summer, Winter, Timer, and Test. The system will normally be set to operate in either Summer or Winter modes. Summer and Winter modes are true feedback control modes. In both modes, the system cycles through a series of steps, beginning with transfer of influent from the equalization basin. It is essentially a batch process. The subsequent steps aerate, denitrify, then aerate again to strip off ammonia. The key to the improved performance of the system is the feedback control. A dissolved oxygen (D.O.) probe in the aeration basin provides the feedback to the PLC that determines the duration of certain steps. This optimizes the process, compensating for the effects of influent quality and temperature, weather conditions, and other variables. Summer and Winter modes are similar, but each is optimized to accommodate the significant seasonal differences in oxygen uptake and loading. The steps in each mode are completely detailed in their respective sections. Timer mode controls the system based on a preset 24-hour timer. It emulates the plant operating scheme prior to installation of the feedback control system, and is only used in case of failure of the D.O. probe. Test mode essentially turns the plant off, but allows for manual operator control of individual devices. It is used for system testing and for plant maintenance, such as transferring sludge to the holding tank. The system mode must be changed by the operator, with one exception: the system will automatically change to Timer mode if the D.O. probe appears to have failed. This prevents the effective shutdown of the plant that would otherwise occur, and is further explained in the Timer Mode section. The Hand/Off/Auto switches and indicator lights from the standard controls remain in service for

This document contains information proprietary to Sharp Technologies, lnc. It is not to be disclosed to third parties or used other than for which it is fbmished without prior written consent of Sharp Technologies, Inc.

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997

each pump and blower. The switches must be in the Auto position for the system to control the plant, although only one pump or blower of a redundant pair is required to be in Auto. The Spray Pump is the only exception-it is left turned Ofunless foaming is a problem. If it is in Auto it runs concurrently with the aerators.

This document contains information proprietary to Sharp Technologies, Inc. It is not to be disclosed to third parties or used other than for which it is furnished without prior written consent of Sharp Technologies, Inc. 01997, . - - P ’ Technologies, Inc. Page 2

WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User's Manual Sharp Technologies, Inc. January, 1997

1.3 Messageview

Figure 5: Allen-Bradley Messageview 421F Terminal The Messageview terminal utilizes a four-line alpha-numeric display to show instrument readings, system data, and alarms. The top three lines are used for display of operator-selected data, while the bottom line is reserved for alarm messages. The four columns of buttons on the left side of the Messageview are used to select Messageview displays and control system operation. The 0-9, ".", "+/-", ACK, enter (J), and arrow (A and V) keys are not used. The first column of buttons is used to select the data displayed on the top three lines of the Messageview, as detailed in the Displqs section. The second column of buttons is used to select the system operating mode. The illuminated LED indicates the current mode. Each mode is explained in its own section. The system mode should not be changed casually, so a safety feature is built in to the program to prevent accidental changes: the mode buttons must be held for two seconds to change the mode. An exception to this is explained in the System Controls and Mode Selection section. The third column of buttons is used to manually control the system when it is in Test mode. The fourth column of buttons is used to select the alarm displayed on the bottom line of the Messageview, as detailed in the Alarms section. The Alarm Active button is only an indicator; it has no control function. Blank buttons are not used, and pressing them has no effect. 1.4 Instrumentation The system utilizes the following instrumentation to control the process and to provide information to the operator. Details on specific instruments can be found in the Instrument Tabulation and in their respective manuals.

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997

EQ Tank Level Transmitter The EQ Tank Level Transmitter, tag LEYLT-I, is a self-contained submersible pressure transmitter. It is suspended in the EQ Tank at a known depth (near the bottom) and transmits an analog signal to the PLC that is proportional to the hydraulic head pressure on the transmitter. This is converted directly to level, and assumes a specific gravity of 1 .OO. The EQ Tank level initiates and terminates Step 0: Fill, the beginning of the process cycle. As such, it is critical for proper functioning of the cycle. Dissolved Oxygen Probe and Transmitter The Dissolved Oxygen Probe, tag DE-3, and transmitter, tag DT-3, sense the dissolved oxygen (D.O.) level in the aeration basin. The probe is suspended in the aeration basin, while the transmitter is enclosed in a small box mounted on the edge of the aeration basin. The D.O. level is critical in controlling the process cycle. Steps 1 and 3 are terminated when certain D.O. levels are reached, and the D.O. level also controls aeration in Step 2. The D.O. probe is equipped with an air purge attachment for automatic cleaning. Compressed air, supplied by the aeration blowers, is blown across the probe membrane to remove buildup. This greatly reduces the need for periodic manual cleaning. The cleaning cycle is initiated at the beginning of certain process steps, as detailed in the Summer Mode and Winter Mode sections. The cleaning cycle lasts four minutes: one minute for cleaning, and three minutes to allow the probe to stabilize. The D.O. reading is frozen just before the cleaning cycle begins and is not updated until the cleaning cycle finishes. ORP Transmitter The ORP (Oxygen Reduction Potential) Transmitter, tag OE/OT-4, is a self-contained submersible ORP transmitter. It senses OW in the aeration basin. This value is displayed and logged, but is not used to control the process cycle. Temperature Probe (RTD) and Transmitter The Temperature Probe, tag TE-5, and transmitter, tag TIT-5, sense the temperature in the aeration basin. The probe is suspended in the aeration basin, while the transmitter is enclosed the PLC panel. The temperature is displayed and logged, but is not used to control the process cycle. Flow Transmitter The Flow Transmitter, tag FEET-8, is an ultrasonic level transmitter which measures the water level behind the double V-notch weir in the chlorination basin and converts the level to flow. It transmits the instantaneous effluent flow rate to the PLC, where all totalizing is performed. The effluent flow is displayed, totalized, and logged, but is not used to control the process cycle. Air Valves Eight air valves are added to the system to segregate the output of the aeration basin blowers. This permits independent control of the aerators, return activated sludge (RAS) pump, and skimmers. These blowers also provide air for automatic cleaning of the D.O. Probe. Five valves directly control air to the utilization points. Valve FY-3A controls air to the aerators, valves FY-3BI and FY-3B2 control air to the RAS pump, and valves FY-3Cl and FY-3C2 control air to the skimmers. Valve FY-3D controls air to the D.O. probe air purge, which periodically cleans the D.O. probe. This is detailed in the D.0. Probe section above. The two other valves, FY-3E and FY-3F, are utilized to exhaust excess air when some combination of valves FY-3A, -3B and -3C are closed. These valves are necessary because the blowers are of the positive displacement type. The necessary combination of exhaust valves is

This document contains information proprietary to Sharp Technologies, Inc. It is not to be disclosed to third parties or used other than for which it is hrnished without prior written consent of Sharp Technologies, Inc.

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997 automatically activated by the PLC to avoid damaging the blowers.

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WWTP Feedback Control and Telemetry Systern-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997

1.5 Displays There are three data displays available to give the operator current and historic information about system operation: Status Display, Cycle Data Display, and Daily Flows Display. Select the desired display by pressing the corresponding button on the Messageview. The LEDs adjacent to the buttons indicate the selected display. Status Display The Status Display shows the current process step and StatusDisplay instantaneous process values, as measured by the instrumentation. The third line is extra long, so it scrolks across the screen. Its full text is: OW: 107mV Temp: 65.OF/18.3C Effluent: 1.6gpm The process step display on the first line shows the step number followed by a brief description of the step, as shown below. Note that Timer mode and Test mode are effectively steps of their own. 0: Fill 1 : Aerate, Raise DO 2: Aerate, Hold DO 3: Denitrify,Lower DO 4: Denitrify, Hold DO 5: Reoxygenate 7: Wait for Refill 8: * Timer Mode * 9: *** Test Mode ***

Cycle Data Display The Cycle Data Display shows the starting time and date for Cycle Data Display the process cycle and the duration of the variable length process steps. When this display is first selected, data for the current cycle is displayed. You can press the button repeatedly to display data for the four proceeding cycles, working backwards. When you press the button a fifth time, the current cycle data is again displayed. The cycle being displayed will be evident from the start time and date. The start of the process cycle is defined as the beginning of Step 0: Fill. The duration of a step is the total number of complete minutes spent in that step. (If you are patient, you can watch the value for the current step increment.) In Winter mode, the process may pass through steps 14 several times; when that occurs, the step time continues to accumulate every pass, so the value shown is the total time in that step, potentially the result of several passes.

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997

Daily Flows Display The Daily Flows Display shows the total daily effluent flow, Daily Flows Display as measured by FT-8 at the chlorination basin weir. The top Daily Eff Ttl: 259gal line displays the running total for the current day. The -lday:1109 -2:1313gal previous four days are shown on the middle lines, where -1 -3dys: 988 -4: 894gal day is the total for the previous day, and so forth. When the day begins at midnight, the totals all shift down by one day.

: ..

This document contains information proprietary to Sharp Technologies, lnc. It is not to be disclosed to third parties or used other than for which it is Furnished without prior written consent of Sharp Technologies, Inc.

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest AreeSystem User’s Manual Sharp Technologies, Inc. January, 1997

1.6 System Controls and Mode Selection The four system operating modes are described in detail in their respective sections below. This section covers issues that are common to several modes, and the ramifications of changing modes. Process Steps The system control scheme is based on stepping through a process cycle. Each step has a number, name, and a condition that ends the step, called the termination trigger. The status of each pump, blower, etc., is defined for each step. The applicable steps are depicted in the Process Step Descriptions in the Summer and Winter mode sections. When the termination trigger condition is satisfied for a step, the cycle advances to the next step. The next step is usually, but not always, the next in order. Again, see the Process Step Descriptions for details. Mode Selection Summer and Winter are the normal operating modes, and should be selected by the operator based on the season. It is probably desirable to change modes only once each spring and fall, so that the system remains stable (the Summer and Winter modes are significantly different). When either Summer or Winter modes are selected, the system defaults to process step 1 : Aerate to Increase D.O., so that it need not make any assumptions about the processing status of the aeration basin contents. There is one exception to this, so that Test mode can be used for routine maintenance to the plant without significantly disrupting the process cycle. If the system is put in Test mode, then returned to the same mode it was in (Summer or Winter), the cycle resumes at the beginning of the step in progress when Test mode was selected. When in Test mode, the Summer or Winter mode Messageview LED blinks quickly as a reminder. Further, Summer or Winter mode (as appropriate) can be selected by just pressing the Messageview button-it doesn’t have to be held for two seconds as is required for all other mode changes. Alternators The EQ Tank surge pumps and Aeration Basin blowers are both redundant pairs. The system automatically alternates starts between the paired pumps or blowers, provided the selector switches for both of them are in the Auto position. If only one of the paired pumps or blowers is in Auto, only it is used. The other can be left off, or run in hand, without affecting the process cycle.

01997, . 1 P Technologies, Inc. Page 8 I WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User's Manual Sharp Technologies, Inc. January, 1997

1.7 Summer Mode Summer mode is a straightforward progression through the cycle steps, as detailed in the table below. Steps 1 and 3 are terminated when certain D.O. levels are attained, and so their duration varies with process conditions. When processing is compete, the system waits in step 7 until sufficient influent accumulates in the EQ Tank for another batch. To maintain process consistency, the batch size is always the same, even during periods of heavy influent. This is accomplished by terminating step 0 is based on level change, not at specific level. For example, if the EQ Tank level is 63" at the end of step 5, step 7 will terminate immediately, beginning step 0. Then, step 0 will terminate when the level reaches 23".

Process Step Description -Summer Mode-

EQ Tank Return D.O. Termination Surge Activated Probe Step@ Name Trigger Duration Pump Aeration Sludge@ Skimmers@ Clean EQ Level I lowered by About 4 0 Fill 40"8 hours On On - - - Varies- Aerate to D.O. rises to 3 minutes On 30 minutes On 30 minutes 1 increase D.O. 5 PPm m i n i mu m - On every hour every hour Cycle@ Aerate to Cycle maintain D.O. Timer - per On 30 minutes On 30 minutes 2 3-5 ppm finished 6 hours8 D.0.O every hour every hour Cycle@

Denitrification D.O. falls to On 10 minutes On 10 minutes 3 D.O. Falling 1 PPm Varies - - every 2 hours every 2 hours - Denitrification- maintain D.O. Timer On 10 minutes On 10 minutes 4 below 1 oDm finished 2 hours8 - - every 2 hours every 2 hours -

\ Ammonia Strip and Timer On 10 minutes On 10 minutes 5 Re-Oxygenation finished 2 hours8 - On every 2 hours every 2 hours Cycle@ Varies from EQ Level 0 to 48+ On 10 minutes On 10 minutes 7 Wait for Refill reaches 60"O hours - - every 2 hours every 2 hours -

0 Status of the Aeration Basin blowers is shown. The Equalization Basin blower is on 15 minutes every hour during all steps and is energized continuously in step 0. The Spray Pump, if in Auto mode, runs whenever aeration is on. It is not normally required and would be left in the Off position. (3 The on periods start at the beginning of steps 1 and 3, then repeat as required. 0 The aerators will cycle off at the beginning of step 2. If the D.O. falls to 3 ppm, the aerators will cycle on until the D.O. reaches 5 ppm, then cycle off, thus maintaining the D.0 between 3 and 5 ppm. @ The D.O. probe cleaning cycle occurs at the beginning of the step. The cleaning cycle consists of 1 minute of cleaning, then 3 minutes to allow the probe to stabilize until it is read again. The D.O. value measured just before cleaning is displayed throughout the cleaning cycle. 0 Unique to Summer mode. When Step 7 is complete, the cycle starts over at Step 0. @ Step 6 is not used in this version of the program. 8 Summer mode batch size and the duration of steps 2, 4, and 5 can be adjusted with the telemetry system, as detailed under the Process Settings heading in the Control Screen section.

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User's Manual Sharp Technologies, Inc. January, 1997

1.8 Winter Mode Winter mode is a variation on Summer mode. Steps 0 through 4 use some different setpoints, and steps 5 and above are omitted. The greatest difference is the sequence: when step 4 terminates, step 1 begins again. Steps 1 through 4 then repeat until the EQ Tank level triggers the start of step 0. Steps 1 through 4 can repeat several times if plant loading is light. Besides the different sequence, Winter mode uses a smaller batch size, different D.O. setpoints for steps 1 and 2, and a much shorter duration of step 2. Further, the return activated sludge pumps operate during step 0. These differences accommodate the increased oxygen uptake and loading.

Process Step Description

-Winter Mode- I

EQ Tank Return D.O. Termination Surge Activated Probe Step Name Trigger Duration Pump Aeration SludgeQ Skimmers@ Clean EQ Level lowered by About 2 0 Fill 2v0 hours On On Varies- Aerate to D.O. rises to 3 minutes On 30 minutes On 30 minutes 1 increase D.O. 4 PPmQ minimum - On every hour every hour Cycle@ Aerate to Cycle maintain D.O. Timer 15 minutes@ - Per On 30 minutes On 30 minutes 2 2-4 ppm finished@ D.0.O every hour every hour -

Denitrification D.O. falls to On 10 minutes On 10 minutes 3 D.O. Falling 1 ppm@ Varies - - every 2 hours every 2 hours - Denitrification- Maintain D.O. Timer On 10 minutes On IO minutes 4 below 1 ppm finished@ 2 hours0 - - every 2 hours every 2 hours -

0 Status of the Aeration Basin blowers is shown. The Equalization Basin blower is on 15 minutes every hour during all steps and is energized continuously in step 0. The Spray Pump, if in Auto mode, runs whenever aeration is on. It is not normally required and would be left in the Off position. Q The on periods start at the beginning of steps 1 and 3, then repeat as required. 0 The aerators will cycle off at the beginning of step 2. If the D.O. falls to 2 ppm, the aerators will cycle on until the D.O.reaches 4 ppm, then cycle off, thus maintaining the D.0 between 2 and 4 ppm. @ The D.O. probe cleaning cycle occurs at the beginning of the step. The cleaning cycle consists of 1 minute of cleaning, then 3 minutes to allow the probe to stabilize until it is read again. The D.O. value measured just before cleaning is displayed throughout the cleaning cycle. 0 Unique to Winter mode. When Step 4 is complete, the cycle jumps back to Step 1. When the EQ Tank level reaches 40", the cycle starts over at Step 0, regardless of the current step. Process conditions generally allow at least one pass through Steps 1-4 before the cycle starts over at Step 0. 0 Winter mode batch size and the duration of steps 2 and 4 can be adjusted with the telemetry system, as detailed under the Process Settings heading in the Control Screen section.

This document contains information proprietary to Sharp Technologies, lnc. It is not to be disclosed to third parties or used other than for which it is furnished without prior written consent of Sharp Technologies, Inc.

01997, . B Technologies, Inc. Page 10 ! WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997

1.9 Timer Mode Timer mode exists to provide a fallback control scheme in case the D.O. probe fails, since the D.O. level is required for the Summer and Winter mode cycles to function. Timer mode operates the aerators, return activated sludge pumps, and skimmers on a fixed schedule for a total of 3% hours per day, as follows: 2:30-3:00 6:00-6:30 11:oo-12:oo 15:OO-15:30 19:oO-19:30 23:30-0:00 The EQ Tank surge pumps operate identically to Winter mode. Timer mode can be selected manually, or can be selected automatically by the system as a result of a D. 0. Too Long to Rise in Step I or Step 3 alarm. More detail is given in the Alarms section. 1.10 Test Mode Selecting Test mode turns off all pumps and blowers which are in Auto. Test mode can be used to remotely control plant components with the telemetry computer, and is used at the plant for maintenance and system testing, such as transferring sludge to the holding tank. The third column of Messageview buttons is active only in Test mode. The Aerators Test button actives an aeration basin blower and opens the aerators air valve. The RAS & Skimmers Test button likewise activates an aeration basin blower and opens all of the return activated sludge and skimmers air valves. These buttons can be used aIone or simultaneously. The D.O. Probe Clean button opens the D.O. probe air purge valve, but does not activate a blower, so it must be used in conjunction with the Aerators Test button or RAS & Skimmers Test button. The extremely low air consumption of the D.O. probe air purge necessitates this arrangement. Test mode, these buttons, the pump and blower selector switches, and the various manual air valves can be used to perform any needed maintenance to the plant.

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I WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997

1.11 Alarms Q A system of alarms is implemented to alert the operator to abnormal operating conditions and equipment malfunctions. Once an alarm occurs, it is considered active until it is reset. An alarms is reset by removing the conditions that caused it. This requires manual action by the operator for most alarms, although a few can reset themselves. Most alarms are configured to disable some part of the system to protect against equipment damage or undesirable operation. Alarm messages are displayed on the bottom line of the Messageview. When all alarms have been reset, the message *No Active Alarms* is displayed, and the red Alarm Active LED is extinguished. When an alarms occurs, the Alarm Active LED will light, and the corresponding alarm message will scroll across the Messageview, preceded by ACTIVE:, and followed by the date and time (in 24 hour format) that the alarm occurred. For example: ACTIVE: EQ Tank High Level 8/02 20:25 When the alarm is reset, the message will change to: HIST: EQ Tank High Level 8/02 20:25.00 indicating the alarm is historical. If all alarms are reset, i.e. none active, then the Alarm Active LED will go out. The above paragraphs presume that only one alarm occurred, but they can often come in groups. If there are multiple alarms, the first (oldest) alarm message will be displayed on the Messageview until it is reset. Any other “ACTIVE” alarm messages will be displayed, in order of their occurrence, when the first alarm is reset. It is wise to pay particular attention to the first alarm, since it is usually the cause of the others. If you wish to check for other active alarms, or view historical alarms, the Show OZder Alarm and Show Newer Alarm Messageview buttons will step through the alarm log. The PLC logs the 80 most recent alarms, discarding the oldest. By pressing Show Older Alarm, you can see, in order, the newest through oldest active alarms, then the newest through oldest historical alarms. If there are no active alarms, the *No Active Alarms* message will be displayed at the top of this list.

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User's Manual Sharp Technologies, Inc. January, 1997

Alarm Summary The following table describes all possible alarms, the autodialer alarm condition (see next section), causes, effects, remedies, and how to reset the alarm. Discussion of the various types of alarms follows. Alarm Description Condition Cause Effect Remedy How to Reset EQ Tank High 1 Float switch tripped Alarm only Lower level in EQ Resets automatically Level (the highest switch) Tank System in Test 1 System was in Test Alarm only, but System would not Changesystemmode Mode Too Long mode for 2 hours system does not usually be left in Test continuously operate in Test except by accident mode DO Too Long to 2 System was in Process System switches Check D.O. probe or Change system mode Rise in Step 1 Step 1 for 9 hours to Timer mode processbiology continuously DO Too Long to 2 System was in Process System switches Check D.O. probe or Change system mode Fall in Step 3 Step 3 for 12 hours to Timermode processbiology continuously Surge Pump #1 3 (and 1) EQ Tank level fell less Pump disabled Check pump and Turn HandlOfflAuto Didn't Lower EQ that 1" in 2 hours with piping; check EQ switch Ofi or turn pump Tank Level pump running level sensor On with telemetry test bit Surge Pump #2 3 (and 1) EQ Tank level fell less Pump disabled Check pump and Turn HandOfflAuto Didn't Lower EQ that I" in 2 hours with piping; check EQ switch Ofi or turn pump Tank Level pump running level sensor On with telemetry test bit Surge Pump #1 3 (and 1) Starter did not pick up Pump disabled Check overload relay Turn HandlOfflAuto Fault when energized (Auto switch 08 or turn pump mode only) On with telemetry test bit Surge Pump #2 3 (and 1) Starter did not pick up Pump disabled Check overload relay Turn HandOfflAuto Fault when energized (Auto switch Olf;or turn pump mode only) On with telemetry test bit EQ Basin Blower 3 Starter did not pick up Blower disabled Check overload relay Turn HandOfflAuto Fault when energized (Auto switch Ofi or turn blower mode only) On with telemetry test bit Aeration Basin 3 (and 1) Starter did not pick up Blower disabled Check overload relay Turn HandlOWAuto Blower # 1 Fault when energized (Auto switch Ofi or turn blower mode only) On with telemetry test bit Aeration Basin 3 (and 1) Starter did not pick up Blower disabled Check overload relay Turn HandlOfflAuto Blower #2 Fault when energized (Auto switch Ofi or turn blower mode only) On with telemetry test bit Spray Pump Fault 3 Starter did not pick up Pump disabled Check overload relay Turn' HandlOfflAuto when energized (Auto switch Olf; or turn pump mode only) On with telemetry test bit PLC Battery Low 4 Battery is low None, but Replace battery Resets automatically impending failure promptly or program will be lost EQ Tank High Level The system controls EQ Tank level based entirely on level indication from level transmitter LT- 1. The EQ Tank High Level alarm is activated by the highest float switch in the EQ Tank. This level will never be reached in normal system operation, so the float serves only as a back up to the level transmitter. If this alarm trips, check the level transmitter and system status. The float switch which activates this alarm also activates the alarm light on the EQ Tank panel, along with the horn, if enabled. System in Test Mode Too Long The system is effectively disabled in Test mode, so an alarm is provided to alert the operator if This document contains information proprietary to Sharp Technologies, Inc. It is not to be disclosed to third parties or used other than for which it is f'umished without prior written consent of Sharp Technologies, Inc.

01997, . G ' Technologies, lnc. Page 13

WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997 the system is in Test mode for an unusually long time, potentially by accident. Further details on the Test mode are found in the Test Mode section. D. 0. Too Long to Rise.. . The system cycle stepping in both Summer and Winter modes depends on proper functioning of the D.O. Probe. To guard against the system getting “stuck” in step 1 or 3 waiting for the D.O. to change, a timer-based alarm is implemented for each of those steps. The time is selected so that the alarm trips only if the step lasts an unreasonably long time. If either of these alarms trips, the system switches to Timer mode, where it remains awaiting operator intervention. If one of these alarms trips, check the D.O. probe for fouling, etc., and check the process biological action. Surge Pump ...Didn’t Lower EQ Tank Level The surge pumps are relatively prone to plugging and other malfunction, so the system monitors the EQ Tank level to confirm that the operating surge pump is working effectively. The system expects the EQ Tank level to fall (as detailed in the table above) when a surge pump is running. If one of these alarms trips, the respective surge pump is disabled until the alarm is reset. You should check for obstructions or pump malfunction. If both surge pumps are simultaneously disabled by alarms, the system activates autodialer Alarm Condition 1, because the system is disabled. PumpBlower Fault The system monitors the motor starter auxiliary contacts of all the motors it controls. When it energizes a motor starter, the auxiliary contact should close immediately. If it does not (after a brief delay), the system trips the correspondingfault alarm. When afaulr alarm trip, the respective pump or blower is disabled until the alarm is reset. A fault alarm usually indicates a tripped overload relay. If both pumps or blowers of a pair are simultaneously disabled by alarms, the system activates autodialer Alarm Condition 1, because the system is disabled. .. PLC Battery Low The entire system is controlled by an Allen-Bradley SLC-5/03 programmable logic controller. It utilizes a lithium battery to retain its program and data when power is turned off. This battery requires replacement approximately every two years. Failure to replace the battery will result in loss of the PLC program, which would render the system inoperable. The alarm is provided to alert the operator that the PLC battery is nearly depleted and must be replaced. (It gives about two weeks warning.) The alarm is tripped by the Low Buttery bit in the PLC. (This bit also lights the “BATLED on the front of the front of the PLC.) See Chapter 9 of the Allen-Bradley SLC 500TMModular Hardware Style Installation and Operation Manual for detailed instructions on replacing the battery. 1.12 Autodialer A Phonetics Sensaphone 1104 voice telephone autodialer is installed in the PLC panel to provide remote notification of alarms. It is connected to telephone number 493-2033. Its four alarm inputs are connected to a PLC output card. The PLC outputs are programmed to activate the autodialer when various alarms occur. This is summarized below, while the detail is shown in the alarm table in the previous section. In addition to these four alarm conditions, the autodialer will dial out (after an adjustable delay) when a power failure occurs. Autodialer alarm messages must be acknowledged (reset) separately from the PLC system. The autodialer setup determines which telephone numbers are dialed in response to alarms, the time delay between calls, etc. This is detailed in the separate Sensaphone manual. Page 21 of that

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997 manual contains a brief summary of the dial-out process, while page 80 contains a more complete summary. The autodialer utilizes six size D alkaline batteries to operate and maintain its clock during power failures. It reports the condition of these batteries as part of its status report. The autodialer batteries and clock are completely independent of the PLC battery and clock.

Autodialer Alarm Condition Nature of Alarm 1 Serious malfunction: EQ Tank high level, system left in Test mode, or both pumps or blowers of a redundant pair are disabled. 2 Plant has switched to Timer mode because D.O. didn’t change as it should in Step 1 or Step 3 3 A pump or blower is disabled, but plant is still functional. Pump or blower has a backup still operating, or is not critical. 4 PLC Battery Low-must be replaced within 1-2 weeks

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User's Manual Sharp Technologies, Inc. January, 1997

2.0 TELEMETRY SYSTEM USER'S MANUAL

2.1 Introduction The WWTP Telemetry System provides the user the ability to access the control system without traveling on-site. The telemetry system consists of a laptop computer with the Microsoft Windows 3.1 operating system and Intellution Fix version 5.5 telemetry software. The laptop computer is equipped with a modem which is used to communicate with the control system via a standard dial-up telephone line 2.2 Telemetry System Operation Operation of the telemetry system requires that the user start the laptop computer and execute the Intellution Fix application. The Intellution Fix application automatically launches the WWTP telemetry application and the modem autodial program. The autodial program handles modem commands, modem initialization strings, and program parameters associated with communicating to the control system. The autodialer window, shown " ,. I below, will come to the foreground as the program initializes, which requires about 15 seconds. When the autodialer initialization is complete, click somewhere outside the autodialer window to move the task to the background. Do not close the autodial window, as it is required for communication with the control system.

15:38:22 AutoDialer Started. 15:38:22 Node Name: PRDUCAH ..retrieued from Windows' registry. 15:38:22 Scanning configuration file 'fiUTODIAL.CFG'. 15:38:22 Creating Group List 15:38:22 Initializing serial port. 15:38:22 Shutting Down Driuer.. I

01997, . 4 ' Technologies, Inc. Page 16 I WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Areasystem User’s Manual Sharp Technologies, Inc. January, 1997

2.3 Site Selection and Dialup

‘The first Intellution Fix screen is a map of Ohio from which you select the ODOT district you wish to monitor (above, left). Only District 9 is implemented at this time. Click District 9 to select the next screen. The second screen lists sites within District 9 (above, right). Only the Pike County Rest Stop is implemented at this time. Click the Pike button to select the next screen, which is site-specific for the Pike County Rest Area. The above screen selection steps may be made while the autodial program is starting. They do not involve communication, so they do not require that the autodial program be operating.

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2.4 Main Status Screen

The main status screen, shown above, shows an overview of the system status. All numerical data will display as asterisks and all devices will show as off until communication with the control system is established. Click the green telephone icon to dial the modem and establish communications with the control system. The autodialer initialization must be complete and the autodialer task running in the background. You will hear the laptop modem connect to the PLC modem at the control system. After fifteen to twenty seconds, the laptop will begin receiving data from the control system PLC and will display the real-time system status and process parameters. Analog process values and the PLC time and date are displayed throughout the screen, along with the system mode and current process step at the bottom. The status of each monitored pump, blower, and valve is indicated by its color: red signifies that the equipment is off or closed, while green signifies on or open. Click on the Reports, Cycle, Flow, and Alarms buttons to select the corresponding sub-screen. Each is described below. Click the Control button to select the Control screen, described in the following section. When you have finished monitoring the control system, click the red telephone icon to hang up the telephone modem. Click the District 9 icon to return the District 9 screen. From there, click the Ohio Map button to return to the Ohio Map screen. From there, click the Exit button to shut down the Intellution Fix and autodial sobare.

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997

Excel Trend Reports The Excel Reports sub-screen allows you to compile several Select Rishbutton to reports of system data utilizing Microsoft Excel. Each report loads data from the system PLC in to an Excel spreadsheet. The first five reports provide profiles of process parameters for the preceding ten-day period at 30-minute intervals. They all provide “snapshots” of the process values, except the FZow Profile, which provides 3Gminute effluent flow totals (since instantaneous flow has little meaning). The Daily Flows report provides the totalized effluent flow for the current day and each of the last 99 days. The Cycle Data report provides the cycle start time, duration of the variablelength steps, and number of cycle passes for the current and previous 99 process cycles. The number of cycle passes is the number of times cycle step 4 has been completed. It will always be zero or one in Summer mode, but can be larger in Winter mode, as explained in the Winter section. Selecting any of the buttons will automatically open Microsoft Excel and the spreadsheet for the selected report. When the spreadsheet opens, the document contains links dialog box shown below will appear. Select Yes and the spreadsheet will update with real time data from the system PLC. Once Excel has been opened, you do not need to return to the Telemetry system to open the other report files. From within Microsoft Excel, go to the C:\WDMACS\TREND directory and open the .XLS files in that directory. You will prompted again with the document contains linh dialog box; select Yes and the spreadsheet will update.

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997

System Cycle Datu

The System Cycle Information sub-screen shows the cycle start time and duration of the variablelength steps for the current and previous process cycles. This is the same data shown on the Messageview Cycle Data Display screen. Additionally, this screen displays the number of cycle passes for the current and previous cycle. This is the number of times cycle step 4 has been completed. It will always be zero or one in Summer mode, but can be larger in Winter mode, as explained in the Winter section. This data is available for the last 100 cycles using the Cycle Data report. Click the Close button to close the sub-screen.

This document contains information proprietary to Sharp Technologies, Inc. It is not to be disclosed to third parties or used other than for which it is hmished without prior written consent of Sharp Technologies, Inc. 01997, . - B Technologies, Inc. Page 20

W~TPFeedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997

System Flow Data

The System Flow Information sub-screen shows the totalized effluent flow for the current day and each of the last four days. This is the same data shown on the Messageview Daily Flows Display screen. This data is available for the last 100 days using the Dairy Flows report. Click the Close button to close the sub-screen.

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Alarm Status

The System Alarms screen shows the status of all system alarms. The alarm text turns red if the alarm is active, and returns to gray when the alarm resets. Click the Close button to close the sub-screen.

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997

2.5 Control Screen

The Remote Telemetry Confrol screen provides the ability to remotely control the WWTP system. The WWTP can be effectively shut down from this screen, so the screen should be well understood before it is used. The screen includes system mode selection and indication, process step indication, test bits for various plant equipment, and equipment status and selector switch position indication. The mode selection buttons on this screen duplicate the buttons on the Messageview at the WWTP. Like the Messageview buttons, they must be held for at least two seconds to change the mode. Point the mouse to the desired mode button, then click and hold the mouse button. Changing the mode from this screen has the same very significant effects as changing the mode at the plant. The nine sets of On and 0)buttons turn the associated equipment test bit on and off. The main use for these equipment test bits is to remotely turn on the associated plant equipment. This only occurs when the system is in Test mode, however. As a safety feature, these bits are all turned off when Test mode is first selected. Further, these bits only work if the selector switch for that particular piece of equipment is in Auto mode. The system cannot control a particular piece of equipment, either with the test bits or automatically, if it is not in Auto mode. The Aerators, RAS & Skimmers, and D.O. Probe cleaning do not have selector switches, and are effectively always in Auto mode. The status indicators show the state of the equipment as best as it is known to the control system PLC, red for off or closed, green for on or open. Keep in mind, though, that a device can fool the PLC. For the pumps and blowers, the motor starter status is indicated. The circuit breaker can be

WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997 tripped, or the wiring failed, and the status indicator still show the motor as on. For the solenoid valves, the status of PLC output is indicated. The output, wiring, or the valve itself can fail and cause status indicator to give a false indication. Generally, you would select Test mode, turn on a piece of equipment, then return to the main screen to observe changes to process parameters. The process parameters can then give clues about whether the equipment is functioning properly. You would not generally leave the system in Test mode for any length of time, since process cycle stepping and all automatic control is disabled in this mode. The test bits have one additional function. Toggling a test bit on, then off, regardless of the system mode, will reset alarms associated with that pump or blower. It is important to turn the test bit off when performing this procedure-failure to do so will disable the associated alarms. Click on the Clock and Settings buttons to select the corresponding sub-screens, which are described below. Click the Main button to return the Main Status screen. PLC Clock Setting The PLC Clock Adjustment sub-screen allows you to set the PLC clock. This is necessary during the semi-annual change for daylight savings time. The PLC Clock is used to record cycle start times, alarm trip times, and to initiate all 30 minute and daily trending and logging, so it is important to set the clock correctly. It is recommended that the clock not be set at exactly 0 or 30 minutes past the hour, since this can sometimes cause a data logging event to be skipped or duplicated. Double-click the parameter you wish to change. An entry box will be displayed showing the allowable range for the parameter. Enter the new value, and click the OK or Cancel button as desired. Click the Close button to close the sub-screen.

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User's Manual Sharp Technologies, Inc. January, 1997

Process Settings

The System Settings sub-screen allows you to change several of the process step parameters. The settings are detailed in the Summer and Winter sections. Double-ciick the parameter you wish to change. An entry box will be displayed showing the allowable range for the parameter. Enter the new value, and click the OK or Cancel button as desired. Click the Close button to close the sub-screen.

WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest ArertSystem User’s Manual Sharp Technologies, Inc. January, 1997 tripped, or the wiring failed, and the status indicator still show the motor as on. For the solenoid valves, the status of PLC output is indicated. The output, wiring, or the valve itself can fail and cause status indicator to give a false indication. Generally, you would select Test mode, turn on a piece of equipment, then return to the main screen to observe changes to process parameters. The process parameters can then give clues about whether the equipment is functioning properly. You would not generally leave the system in Test mode for any length of time, since process cycle stepping and all automatic control is disabled in this mode. The test bits have one additional function. Toggling a test bit on, then off, regardless of the system mode, will reset alarms associated with that pump or blower. It is important to turn the i test bit off when performing this procedure-failure to do so will disable the associated alarms. Click on the CZock and Settings buttons to select the corresponding sub-screens, which are described below. Click the Main button to return the Main Status screen. PLC Clock Setting The PLC Clock Adjustment sub-screen allows you to set the PLC clock. This is necessary during the semi-annual change for daylight savings time. The PLC Clock is used to record cycle start times, alarm trip times, and to initiate all 30 minute and daily trending and logging, so it is important to set the clock correctly. It is recommended that the clock not be set at exactly 0 or 30 minutes past the hour, since this can sometimes cause a data logging event to be skipped or duplicated. Doubleslick the parameter you wish to change. An entry box will be displayed showing the allowable range for the parameter. Enter the new value, and click the OK or Cancel button as desired. Click the Close button to close the sub-screen.

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W~TPFeedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997

Process Settings

The System Settings sub-screen allows you to change several of the process step parameters. The

I settings are detailed in the Summer and Winter sections. Double-click the parameter you wish to change. An entry box will be displayed showing the allowable range for the parameter. Enter the new value, and click the OK or Cancel button as desired. Click the Close button to close the sub-screen.

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User's Manual Sharp Technologies, Inc. January, 1997

3.0 INSTRUMENT TABULATION

Tag Number Instrument Type Manufacturer Model Number Settings Range LELT-1 Submersible Ametek, US Gauge 575- Mounted 9" from 0 to 166.244 Pressure/Level Division SB0006RLS(20) bottom of EQ inchesofwater Transmitter Tank DE-3 Dissolved Oxygen Great Lakes 5440D w/15' cable Probe Instruments & MS connector DT-3 Dissolved Oxygen Great Lakes 697D2RO with 0 to 10 ppm Transmitter Instruments 10WB4A3 0 13 D.O. enclosure OE/OT-4 Oxygen Reduction Great Lakes 2428RO with -500 to +500 Potential Instruments 60A2F 1278 mV Transmitter protector TE-5 RTD Temperature JMS Southeast 3ESBK48"BWPP- a=0.003 85 Probe, 48" long 3 00"ZY PZA WW"C TIT-5 Temperature Moore Industries SPT/TPRG/PRG/U To match TE-5, 0 to 100 OF Transmitter /DIN 3-wire RTD FY-3A Motor Operated Neles-Jamesbury 2" 21- Ball Valve, 2" 1 1OOTTEL20 1 1WAC wheater FY-3Bl Solenoid Valve Asco 82 lOG95 FY-3B2 Solenoid Valve Asco 8210695 FY-3Cl Solenoid Valve Asco 8210635 FY-3C2 Solenoid Valve Asco 8210635 FY-3D Solenoid Valve Asco 8210694 FY-3E Solenoid Valve Dayton 1 A577 FY-3F Solenoid Valve Dayton 1A577 FEET-8 Ultrasonic Level Drexelbrook Y505-1300-2 Weir = 90" 0 to 68.4 gpm Transducer w/ GIDU Range = 3.0" (for the two Integral Flow See note notches) Computation

Note on FERT-8 settings: set DIP switch SW8 positions 1-4 all down (level mode). Set first column of rotary switches (span) at 030 (top to bottom) for 3.0 inches. Set second column of rotary switches (zero) at the distance measured from the bottom of transducer to the water level at zero flow, i.e. at bottom of weir notch. This is set in tenths of inches, e.g. 185 for 18.5 inches. Set third column of rotary switches at 590: 5 for V-notch weir, 90 for 90 degree notch. For best accuracy, perform Optimal Calibration procedure described in section 4.3 of Drexelbrook manual. This must be performed when there is no flow, but with the chlorination basin level at the bottom of the weir notches, almost ready to flow. Since this procedure is performed at the actual zero level, no change in the zero switches (dials) is necessary (as mentioned in the first step of the procedure).

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997

4.0 MODEM CONFIGURATION The modems used at the Telemetry PC and PLC are US Robotics External Sportster 14400 Fax Modems. Standard PC modem cables are used to connect the modems to the PC and PLC respectively. The PC modem requires no special configuration beyond DIP switch settings, as the necessary setup commands are sent to the modem by the telemetry software each time it dials the modem. The DIP switch I settings for the PC modem are shown in the table below. The only difference from the standard factory settings is switch 1, which is set to DTR override. The PLC modem is specially configured to communicate with the PLC. The configuration settings are stored in the non-volatile RAM of the modem, and thus remain in place without power. They would only have to be reentered if the modem were replaced. The DIP switch settings for the PLC modem are shown in the table below. The only difference from the standard factory settings is switch 5, which is set to Auto Answer. Switch 1 2 3 4 5 6 7 8 PC Modem Down Up Down Up Down Up Up Down PLCModem Up Up Down Up UP UP UP Down Description UP=DTR UP= DOWN= UP=echo UP= UP=CD UP=load DOWN= normal verbal display.- offline auto normal NV RAM smart result result commands answer defaults mode codes codes DTR DOWN= override do not answer

PLC Modem Setup Strings Should it be necessary to configure a modem for the PLC, use a dumb terminal program (such as Windows 95 Hyperterminal) on a PC connected to the modem to send the following command strings to the modem. (Press the enter key after each line.) The modem should reply to each line with “OKy.You may use all lower case or all caps, but not a mixture. All of the 0 characters are zeros, not 0’s. AT&FO ATYO AT&Bl&Cl&D2&Hl &KO&MO&N6&RI&Sl&WO ATBO&WO ATSO=I&WO I Using PLC Programming Software with a Modem If it is desired to use PLC programming software over a modem, the following configurations can be used. DIP switch settings identical to the PC modem can be used, although switch 1 can be in either position. Interface Hardware Type: 5/03 CHO Baud Rate: 9600 Parity: None Error Checking: BCC Protocol: Full Duplex Dial Modem: Yes Modem Dial String: atsO=Osl3=1 s19=1 &bl&cl&dO&h l&kO&mO&n6&rl&s1dt916144933569 The last command in the modem dial string (dt916144933569) dials the modem number including the 9 prefix. You may need to insert a comma after the 9 if your phone system requires a delay, or delete the 9 This document contains information proprietary to Sharp Technologies, Inc. It is not to be disclosed to third parties or used other than for which it is furnished without prior written consent of Sharp Technologies, Inc.

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WWTP Feedback Control and Telemetry System-US Route 32 Pike County Rest Area-System User’s Manual Sharp Technologies, Inc. January, 1997

if it isn’t required. Depending on the software you use, you may need to enter the number separate from the modem initialization string, and the software may dial the “dt” (dial tone) command for you.

###

01997, . A B ’ Technologies, Inc. Page 28 I APPENDIX B

MANUFACTURER’S LITERATURE

i / 4. .ES-S (ONE EXTRA SPDT SWITCH) LK-SO34 (LK-5079 for x) a. &move the two fillister head screws (7) and two lockwashers (8) holdiag switches 1 and 2. Refer to Pig. 1. b. place the additional switch insulator on top of svitch 2 and the additional switch on top of the insulator. Refer to Pig. 3.

c. Fasten using the 2 original lockwashers and ae 2 Longer fillister head screvs provided in the option kit. d. Lead vires colored yellow and red may be placed on the terminals desired. Route lead vires through the conduit.

e. Place the third cam on the cam shaft and adjust Cor desired switch indication. C. Switches S1 and 52 may have to be readjusted for propar opening and closing of the valve per -ST- EXT 1:lSTRUCTIONS. 5. HEATER AND THERnOSWITCIl LX-SO60 - 1 a. munt the thenaoswitch on top of the limit switch uring the Cillister head screws (7) that hold the L' witches in place. Refer to Fig. 3. I b. Place the heater aroud the inside of the bare so thdt the end of the heater wit!! the lead wires is near the conduit hole. Re5er to Pig. 2.

C. Route one lead vire through t!!e conduit.

d. Cut the second lead wire to approximately 4. long (save Cle remaining wire) such that it reaches one of t!!e terminals on the the-msvitch. Aasenble a connector and insulator to it and connect it to the thermasvitch. e. Assenble a connector and insulator to one end of the remaining wire from Ste? d and connecz it to the remaining tfiermswi:ctr terminal. Route it through the conduit. f. Bend ehe tabs on the therzosvitch to approxinately 4s. toward the center of %%eactuator to insure clearance for the cover, aefer to Pig. 3. 6. Readjust L4e switches if necessary per ADJUST.%NT IN- STWCZIONS. I MA1NTENANCE The unit is perzanently lubricated at the factory. Figure 1 Under normal operating conditions %?e actuator requires only periodic observation to veri>/ proper switch adjustment. I ITEM NO. i For repair or replacement of limit switches follow the PART NAME I precautions listed in the WARNILG Section (Fig. 1). -NO. REQD. 1. Remve the cover. 1 1 1. Renova the lead vires from G!e switch to be repaired. 2 1 Cover 3. Remove the fillister head screws (7) and lockvashers 5 1 Switch Bracket sub-assembly I (8) holding the switches and remove .the affected switch. 6 2 Switch 4. Reassemble in reverse order and readjust per XDJUST.~(ENT 7 2 Cap Screw 1NSTRUCIU:IS. Refer to Fig. 4 for wiring diapram. 8 2 SOTE: Ths unit is themally protected. If unit will not 10 2 run, allow to cool before operatiap. 11 2 12 4 16 1 21 1 22 2 30 a 48 2 i 58 2

Figure 3

MOTOR TMERMAL PROTECTOR COMMON LEA0 -- WHITE 1115 VACI BLACK I230 VACI

POWER I SUPPLY 2

N.O. I i

BLUE-OPEN

ORANGE Wl8LUE 11 I YELLOW I I ACTUAToR ESl LEADS IOPTIONAL) I-,,,,, ACTUATOR ENCLOSURE OC MOTOR +Iv IRmrriblel KS-1 onnot b* dl

I ACTUATOR ENCLOSURE-U ON.0. I

HEATER

IOPTIONALI I - -- I OPTIONS

ELECTRIC RATING OF ES-1 AN0 ES-5 IN AMPERES I

! 125 & 250 VAC I 15 ' 125 VDC I 8.5

WIRING DIAGRAM (ACTUATOR SHOWN IN THE CLOSED POSITION1

Figure 4

c @!A@ 6 ellAutomation AllemBradley

Control the Future Today with Allen-Bradley's SLC 500TMProcessors: Small Controllers for Big Applications 5/01,5/02,5/03,5/04,5/05 Processors

The SLC 500 line of small programmable controllers are some of the most powerful and flexible processors available. The SLC family offers a wide range of communications, features, and memory options. W The 5/05 processor includes built-in 10Base-T Ethernet@. W Communications enhancements enable the 5/03, 5/04, and 5/05 to provide master control of SCADA networks. W Powerful features including indirect addressing, high-level math capability, and a compute instruction. W The 5/04 and 5/05 processors provide 3 memory size options: 16K, 32K, and 64K. W The 5/03 processor provides 2 memory size options: 8K and 16K. W The 5/02 is available with 4K; the 5/01 is available with 1K or 4K. Capacity to do More, Flexibility to Cost Less With up to 64K of configurable datdprogram memory available, the SLC 500 line has the power, flexibility, and expanded I/O selection to take on applications that previously required larger, more expensive control solutions. The 5/02, 5/03, 5/04, and 5/05 processors can address up to 4,096 input points and 4,096 output points. And, if less than 64K of memory will get your job done, you can take cost out of your project by using one of the many other memory sizes available. Versatility for Stand-alone Control or Distributed Stand-alone applications from Agriculture to Zinc mining are ideal Arch itecures for the SLC 500 because of: W Cost effectiveness W Wide variety of I/O available Small size W Ease of expansion to include up to 30 slots of local YO Distributed applications can take advantage of six networking options: Ethernet W RemoteVO W Data Highway Plusm W DeviceNetTh' DH-485 RS-232 ___- --- Communication Allen-Bradley gives you choices of built-in communications. The SLC 5/05 Choices processors support 10 Mbps Ethernet communications with a built-in 10 Base-T Ethernet channel. The SLC 5/04 processors include built-in Data Highway Plus (DH+) for high-speed peer-to-peer communications, or , if your application doesn't need the full performance of Ethernet or DH+, you can choose the 5/01, 5/02, or 5/03 processors with built-in DH-485 communications.

Peer-To-Peer Network options include Ethernet on the 5/05 processor, Data Highway Communications Plus (DH+)on the 5/04 processor, as well as the DH-485 network built into all SLC processors. E&er.net communications, built into all SLC 5/05 processors, features TCP/IP protocol. Built-in Ethernet communication - not an add on module - means faster throughput because of no backplane delays. The 10 Base-T Ethernet connection provides an economical

means of connecting to an Ethernet network. Communication takes I place at 10 Mbps, providing high performance networking for program upload/download, online editing, and peer-to-peer messaging. Data Highway Plus (DH+) communications, built-in to 5/04 processors, provide a high-speed peer-to-peer communication network and seamless connection to Allen-Bradley PLC-5 programmable controllers. DH+ is similar in nature to DH-485, but can support up to 64 devices (nodes) and operates up to 230.4K baud. Remote I/O passthrough is now available, enabling personal computers on the DH+ network to upload or download applications to MMI devices on the Remote YO network, such as PanelViewnl Operator terminals and Dataline?' Message Displays. Other DH+ features in the 5/04, include: I Global Status flags for high-speed broadcast to all processors W DF1 Bridging which enables users to access an entire DH+ network through the RS-232port, even through a modern connection. DH-485 Bridging which enables users to bridge one DH-485 network with one DH+ network. DH-485 capability on all the SLC processors provides communications .with up to 32 devices on a single network. This network allows monitoring of data and processor status, along with program uploading and downloading to any SLC on the network from one location. SLC I processors are also able to pass data to each other on DH-485, and operator interface devices on the network may access data from any SLC processor on the network. The RS-232port can also be configured as a second DH-485 port, enabling the 5/03 to connect to two DH-485 networks simultaneously, or enabling the 5/04 and 5/05 processors to connect to one DH-485 network. Remote I10 Remote UO (RIO) options abound when the 1747-SN RIO scanner module is added to an SLC System. It allows users to take advantage of 1746 UO, Flexn' UO, Block YO, and 1771 I/O devices. SLC 5/02, 5/03,5/04, and 5/05 processors can address up to 4,096 input points and 4,096 output points, which includes all local and RIO points. The 5/01 can address up to 3,940 input points and 3,940 ouput points. The 1747-SN RIO scanner module and the 1747-ASB RIO adapter module both support discrete and block transfer options, which enables the use of the SLC 5/03,5/04, and 5/05 processors with drives, operator interface, third party devices, evice Level Control The SLC programmable controller family can connect to the popular DeviceNet device network with the 1747-SDN DeviceNet Scanner module. DeviceNet is an open, global industry standard communication network based on the proven Controller Area Network (CAN) technology with more than 150 companies worldwide developing “smart” products. It is designed to provide an interface through a single cable from a programmable controller directly to “smart” devices such as sensors, push buttons, motor starters, simple operator interfaces, and drives. Low node cost and ease of integration Reduced installation costs and wiring Additional diagnostics from intelligent devices Rapid troubleshooting

S-232 A built in Rs-232 port on the 5/03,5/04, and 5/05 processors provides communication flexibility. It can be used for ASCII, modem communications (DF1) and an operator interface/programming port. ASCII capability of the RS-232 port provides direct connection to bar code decoders, serial printers, weigh scales or any device that uses ASCII to communicate. This advantage eliminates the need for additional modules. Instructions in ladder logic are also provided, allowing you to read, write and manipulate ASCII strings. Direct connection to a modem enables the 5/03,5/04, and 5/05 processors to act as remote terminal units (R’IZTs) or as master terminal units (MTUs), communicating with up to 254 other devices. The 5/03, 5/04,and 5/05 processors have the ability to report by exception, which means you can keep your SCADA system’s response high. You can select the RS-232 port to run the Allen-Bradley DF1 protocol. The DF1 protocol allows transmission of information across modems (dial-up, leased line and radio), and permits communication between I, Allen-Bradley products and third-party products. : Direct personal computer connection to the programming port, without the need for interface products, or use the port for an operator interface.

ange of The SLC 500 uniquely combines the ability to address high speed discrete Applications applications and process control applications from a single platform.

igh Speed Discrete Extensive features in the SLC 5/03,5/04, and 5/05 processors are ideal for high speed applications like bottling lines and packaging. These features include: Throughput time of less than 1msK of program is typical for 5/03,5/04, and 5/05 processors. Advanced instructions like immediate Inputloutput and Service Communications process your most critical tasks. Built-in communications eliminate backplane delays. High speed discrete and analog YO complement the high speed processor functions. Selectable timed interrupt function allows you to interrupt the scan of the main program automatically, on a periodic basis, to execute a specified subroutine file as often as every millisecond. Event-driven interrupt, called Discrete Input Interrupt, is for use in any application that needs to respond to an event quickly. Process Control Process applications and complex math are supported by a wide range of specialized instructions, such as: W Compute Instruction, which minimizes ladder programming and provides users with the ability to develop their own complex mathematical expressions within one ladder rung instruction. W Floating Point Math W Built-in PID Trigonometric Functions W Exponential Math Other process and math oriented features include: Multiple Data File Types (String, Integer, ASCII, Floating Point) Dynamically Allocated Memory which allows the programmer complete control over how memory resources are used for either ladder program or data, even down to what data types are used in each program. 1 Real Time Clock, Year 2000 and Leap Year ready. W Wide variety of analog modules, including Thermocouple and RTD to meet your exact process requirements.

Security Features Hardware and software security features enable you to protect your system from undesired or unauthorized changes to the program or data. W Key switch security Communication port protection Global password protection W Selectable protection of programs and data files

Programming RSLogix 5oOm, a MicrosofP 32-bit Windows 95" and Windows NTTM Features programming software package, supports Allen-Bradley SLC 500 and MicroLogixM families of processors. RSLogix 500 is designed to offer you powerful functionality, superior diagnostics, reliable communications, and an easy-to-use interface. RSLogix 500 provides you everything you expect in a programming software package, from consolidated project view to drag-and-drop editing. Plus RSLogix 500 is part of the RSLogix family of products that share: A common user interface and feature set Flexible, easy-to-use Editors Point-and-click YO configuration Powerful database editor Diagnostic and troubleshooting tools Dependable communications Notebook Computer __ with d

Workstation PLCS

SLC yo4 SLC yw-

1746 DenceS

SLC-5/04 Processor wim 1747-s~~ DeviceNet vo

SLC 50011Xed

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MlmLogix TermlnalOperator SLCYOl". PWSSOK

.I,..%. ' I Specifications SLC 5/01 SLC 5/02 SLC 5/03 SLC 5/04 SLC 5/05 IK (1747-fill) 4K (17174.524) 8K (17474.531) lM(1747-l.541) 16K(1747-L551) 4K (17474514) 1M (1747-L532) 32K (17474542) 3% (17474552) WK(1747W) 64K (17474.553) ~;ol.YO Capacity bndud~ngNO) 3940 irJ3960 oul 4096w4096out 4096irJ4096Wt 4096 in14096 out 4096irJ4096Wt btaL Racwslots 3/30 3/30 3/30 3/30 3130 Rph( Mem. Backup Cap 2 weekson 17474.511 Lithium Battery 2 years Lithium Battery 2 yean Lithium Battery 2 years LithiumBattery2yearS Lithium Battery, 2 yean MI 17471514 Memory Back-up Options EEPROM M W PROM EEPROM 01 W PROM flash EPROM Rash EPROM Aash EPROM LED indicators Run, CPU,Forced VO. RM, m,Forced uo fhm,cpu~ForcedVO Run. CPV Fault, Forced VO RM. cw Fault, Forced VO Battery Low Battery Low, Comm aaawy Low, w,Rs-232 Battery h,DHt. RS-232 Bakry LOW. ENET, 8-232 programming RsLogu 500,PI 500, RELogu 500,PI 500, (81QRsLogu500~1.26.03 RSl&X NOV. 124.04 RsLogix 500 V. 2.0 8 above; Aps Aps &above:Al500 (lwfWga 8 above;PI5OOV. 8.10 500 V. 1.24.04 8 abme; 8ahw ApsV 6D & above PI500V. 810 8 above; APS V 6.0

BltEX~onWc) 41s 24ys 0.W 0.371s 0.371s Communlcabon Buinmpeer-topeer OH45 receive only DH-485 DIi-485 DHt. OH4 Ethernet OH485 NO WA 1746 VO. 1794 Rex'" VO, 1791 1746 VO. 1794 Flex* VO, 1791 1746 UO. 1794 flex* UO,1791 1746 VO, 1794 flexTYVO, BlockVO,61771 UOw/the Bkk U0,81771 vOw/the Block UO,8 1771 UO wkhe 1791 BW VO, B 1771 VO 1747-94 Scanner 1747-94 Scanner 1747-94 ScaMler w/the 1747-94 ScaMer WeLevel NIA DenceNet w11747-sDN Scanner DenceNet W1747-SON Scannec Devicdlet ~11747-SDNScanner DeviceNet wl1747-SON S~~IIRY Built in 6-232 NlA WA W1 funldupl~OF1 half-duplex OF1 fullduplex, OF1 halfduplex DF1 MldUPfex, DF1 half- mfigurabk for master or slave. nsai OH* mrtster or slave,ASCII. DH-485 . duplex master ca slave, ASCII. DH-485 Real meClock N/A WA yes Yes Yes Key switch PosiUons WA NM Remote. Rogram, Run Remote, Program, Run Remote, Program, Run Operaling Temperature O'tO t60'C(t32"tot140'F) WbtW°C(t3TtotlQo"F) Wto+6o"C(t37to t1409) Wto+6o"C(t32"tot14O"F) Oo~+6(pC(t32'l~t140"F) storage Tempetature 4O0tot85"C(-4O"tot165'F) 404tO+85"C(-40'tOt185"FJ -4o"to t8S"C(WIOt185'F) -4Q'tot85'C(-40'to tl85'F) -4O'tot85%(-4O'to+185"F) Humidity Rating 5 to 95% (non condensing) 5 to 95% (non condensing) 5 to 95% (non mnd@ng) 5 to 95% (non condensing) 5 to 95% (nm condensing) CertiFmtiOn UL IiidlCsA approved, CE UL IiWW appmved. CE UL IistedGA appmved. ff UL liappmved, CE UL IistedlCSAapproved, CE Mass 1, Grwps A B.C. or D. a% I, ~mupsqB. C, or D. aasS 1. GrwpsA B.C.or 0. aass i,~rwps~~.c,orD. am 1,~mups~~,c.or D. Division 2 ff mmpknt for an Division 2 Cf mmprifor all Diion2 E compliant fw all Division 2 CE compliant for all Division 2 Cf compliant for all aDpliable directives apdicable directives amlieable direebves aoolimble directives amlikable directives

I Throughput time is typal for a 1K ladder logic program consisting of simple ladder logic and communications servicing. Actual scan times depend on your program size, instructions used and communicatrons. SLW05, SLC 5/04,SLC 5/03, SLC 5/02, SLC 5/01, SLC 500, Data Highway Plus, INTERCHANGE, Encompass, ControlLcgix, MC6OO0, PaneMew, Dataliner, DTAM, FLEX UO,Messageview, AdaptaScan, ArmorBlock and MicroLogix are trademarks of RockwellAutomation. PLC-5 IS a registered trademark of Rockwell Automation. Ethernet IS a registered trademark of Digital Equipment Corporation, Intel, and Xerox Corporation. Microsoft and Windows 95 are registered trademarks of Micmft Corporation. Mndaws NT is a trademark of Microsoft Corporation. DeviceNet is a trademark of Open DeviceNet Vendor Asxiition. ContmlNet is a trademark of ConbnlNet International Ltd. Una is a registered trademark of WOpen Company Limited. ELinx, RSLoguc 500 and fWew are Wemarks of Rockwell software, Inc. R 'I Automation Rockwell Automation helps its customers receive a superior retum on their investment by bringing together leading brands in industrial automation, creating a broad spectrum of easy-to-integrate products. These are supported by local technical resources available worldwide, a global network of system solutions providers, and the advanced technology resources of Rockwell.

Argentina Ausbalii Austria Bahmin Be!gium Bolivia Brazil* Bulgaria Canada Chile China, People's Republic of Colombia Costa Ri Croatia Czech Republic * Denmark Dominican Republic Ecuador Egypt * El Salvador Finw France 0 Germany Ghana Greece * Guatemala Honduras Hong Hungary Iceland 0 India Indonesia Iran * Ireland-Eire Israel Italy Jamaica Japan JOII~~~Korea * Lebanon Macau * Malaysia * Malta MdW ~roccoThe Netherlands * New Zealand Nigeria Nomay * Oman Pakistan Panama Phfippis Portugal Puerto Rico * Qatar Romania Russia Saudi Arabia Singapore Slovakia Slovenia South Africa, Republic of Spain Sweden s&zed& =land Triniid Tunisia Turkey United Arab Emirates United Kingdom *United states Uruguay *Venezuela

Rodnvea Autmatbn Headquatten, 1201 South second Sbeet. Mihnaukee, WI 53204 USA, Tek (1) 414 382-2ooo Fax: (1) 414 382-4444 Rtblication 1747-1.6- November, 1997 SllPeMdeS FlJCJbl!UI 1747-1.6 -May. 1997 I

Message Displays MessageView Interactive Message Display Terminals (Cat. No. 2706 Series)

0 Communicate with slave message displays across an RS-23242 link

0 Operating system using 128K bytes of Flash EPROM internal memory capable of storing 4096 messages including run-time variables and application program,code for quick and easy on-site programming Compatibility Messageview terminals can be used in networks hosting a wide range of devices. Some representative examples include:

0 Multiple MessageView terminals

0 PLC/SLC controllers ASCII Input Devices

0 1747-SN Remote I/O scanners The MessageView family of products includes flexible, lowcost, interactive display devices for both text and graphic 0 Bulletin 2711 PanelViewTMproducts

characters. Messageview terminals provide a high-level 0 Bulletin 2706 Datalinerm message displays (DL10, DL40, operator interface to logic controllers and other peripherals, DL50) as slave devices and are designed to meet a variety of machine control and monitoring applications. Versions available include display-only, display plus numeric input, and display with Specifications @ @* numeric input plus programmable function keys. c Messageview terminals can store 4,000 message entries VFD Graphic Display including variable and time/stamp data with its Historical Size (all terminals) 26.9 mm (H) x 108.5 mm (w) 1.06 in (H) x 427 in (w) Event Stack Memory. The terminals can view and sort Characters 21 x4;10x2;7xl historical data by frequency and chronological order of occurrence, providing a highly diagnostic operator interface Pixels 128 x 32 device. In addition, the Historical Event database can be LED Indicators COMM Green FAULT Red imported into programs such as Microsoft Excel@,Microsoft Access@, Lotus@,and other Windows based applications. Terminal Memorv Application Memory 4096 messages x 21 characters All MessageView terminals offer an RS-232 communication Historical Event Stack Memory 4OOO messages x 21 characters port on the main logic board. This port can be used for Communication uploading and downloading application programs, uploading Universal Remote UO Supports PLC and SLC controllers the Historical Event Stack, communicating with ASCII Input ASCII Triggering Supports PLC and SLC controllers devices, or with controllers using serial communication via Electrical ASCII Triggering. In addition, Messageview terminals can Supply Voltage 18 to 30V dc (24V dc nominal) accept a communication DaughterBoard with an adapter port Power Consumption 20 W maximum (833mA @ 24V dc) , for a Universal Remote I/O link. Environmental Temperature range: Features Operating 0 to 55" C (32 to 131' F) Text dispray using the industry standard Code Page 850 Storage 410850 c (4to 1850 F) alphanumeric character set and ISA graphic symbols on a Humidity rating - 5 to 95% (without condensation) blue-green 128 x 32 dot matrix Vacuum Fluorescent Ratings UI Listed, CSA Certified, CE Marked Display NEMA Type 12,13,4X (indoor use only) and Class I Division 2 fight brightness settings ranging from 12 to 100% Dimensions Chasis: Terminals D and 91 mm (H) x 202 mm (W) x 65 mm (D) 0 Special text formatting effects, including centering, N 3.6 in (H) x 8.0 in (w) x 4.0 (D) scrolling, blinking, and inverse text Terminal F 138 mm (H) x 202 mm (w) x 65 mm (D) Date and time data displayfrom the on-board 5.5 in (H) x 8.0 in 0 x 4.0 in (D) battery-backedReal Time Clock Front BezekTerminals D and N 130 mm (H) x 240 mm (w) x 16 mm (D) 5.1 in (H) x 9.5 in (w) x 0.6 (D) Insertion of ASCII and Numeric Entry, Display Variables Terminal F 177 mm (H) x 240 mm (WJ x 16 mm (D) 7.0 in (H) x 9.5 in Wl x 0.6 in (D) Historical f vent Stack logging of up to 4,000 message entries including variables, time data, and message ACK Weight Terminals D and N 1.45 kg (3.2 Ibs) with time duration Terminal F 1.72 ka (3.8 lbsl 0 Communicate with PLC and SLC processors across a Universal Remote I/O or RS-232-Clink For ordering information, see page 7-7.

7-6 Allen-Bradley ...... 5 8 Desktop onitoring System EnvironmentaVProcess monitoring over telephone lines with full I programming capabilities

0 The versatile Model 1104 is designed for programming flexibility

0 Variable alarm recognition and "listen-in" time, with alarm disable, security code access, remote sensing, and other programming features

0 Monitors power, temperature, and other important environmental conditions to protect computers, equipment, and processes

0 Automatically contacts you at up to 4 locations if unsafe conditions occur I

0 Allows you to contact your system using any telephone, to receive status reports and listen-in to on-site sounds P-CI- I// I PA L 0 Helps you detect problems before they I I turn into disasters UP TO 4 DIAL-OUTNUMBERS: I CONDITIONS If unsafe conditions occur, the Sensaphone MONITORED: I will automatically dial up to four numbers I PJ~-~rnent and Drocesses . I in sequence to advise y& of the problem. I gven when vou c an't be there -The Sensaphone 1104 Temperature Numbers may be up to 32 digits each, with monitors your computer rooms, equipment centers, Humidity I your choice of puke or tone dialout. I offices, or any unattended facility to detect power fail- Electricity *rnIIrnIIrnI IId ures, temperature extremes, intrusions, water incur- Water Incursion sion, sounds such as smoke and burglar alarms, and other conditions of your choice. Smoke - The Sound COMMUNICATES OVER Sensaphone 1 104 automaticallycontacts you by phone Windows & STANDARD PHONE at up to four different phone numbers, to alert you of LINES: Doors Call-in for periodic status reports on all unsafe conditions. The system communicates in ... and more! monitored conditions, using any telephone. voice-synthesized English, and even lets you "listen- The Sensaphone communicates in simple in" to actual on-site sounds. voice-synthesized English.

See reverse side for a list of the I tics, Sensaphone's outstanding features 901 Tryens Road, Aston, PA 19014 610-558-2700 FAX: 610-558-0222 and capabilities. http://www.sensaphone.com

- _.

.. ..

. ..

.I - a. Sensaphone@ll04 I

Ideal for a variety of applications - The 1 I Sensaphone is useful wherever there is a need VERSATILE DW~T~APABILITIES I= for monitoring of temperature, humidity, or other 0 Alert sensors trigger pulse or tone conditions. Sensors and input devices are avail- dialout automatically able to suit a wide range of applications. 0 Dials up to 4 numbers, up to 32 digits each 0 HVAC Equipment Continues dialing numbers in sequence, 0 Computer rooms until acknowledged 0 Refrigeration and freezers 0 Call Progress: Intelligently detects 0 Health care centers ringing or busy signal Offices Intelligent dial out to beepers and 0 Warehouses pagers 0 Livestock and egg/poultry 0 Home & property EASY CONTROL ACCESS: Greenhouses 0 Keypad for local programming and ... and many others! status report Unit can be called from any phone to I verify status of all monitored conditions BUILT-IN FEATURES I Local or remote enablinddisabling of 4 User-selectable inputs, temperature or 0 0 all dial-out conditions dry-contact I Can share a single phone line with Microphone monitors high sound alarms 0 an answering machine, allowing full and enables remote listen-in AC Power failure sensing with variable operation of both units 0 0 Programmable security code access recognition time 0 Battery condition monitor 0 Clock SPECIFICATIONS

Size: 1'/2'' W, 2" H, 8%'' D ADVANCED CAPABILITIES Batteries: (6) 1.5 Volt "D"cell alkaline (not included) User Programmable: Alarm recognition Telephone Interface: FCC approved RJ-11 plug-in modular connector with 6' cord time, Call delay, Inter-call delay, Message Operating Range: Unit should be kept between 32" F repetitions and 120° F. Temperature sensing in Fahenheit (-20°F Temperature Sensing Range: -20" F to 150" F with to 150°F), or Celsius (-29"C.?O65°C) remote temperature sensor. 0 Individual temperature input calibration Shipping Weight: 4 Ibs NRTL listed for compliance with U.L. Standard 1459. 0 Nonvolatile memory for all prograhed Technical data subject to change without notice. parameters

We'd like to show you how the Sensaphone 1104 can help you monitor your equipment and facilities. Give us a call to find out more! Or listen to an actual Sensaphone report by calling 610-558-4591.

(B 1995 Phonetics, Inc. Sensaphone03 is a registered tic I I trademark of Phonetics, he. 901 Tryens Road, Aston, PA 19014 610-558-2700 FAX: 610-558-0222 http ://www.sensap hone. com

INSTALLATION AND BULLETINS I 8210 I MAINTENANCE INSTRUCTIONS 8211 2-WAY INTERNAL PILOT OPERATED SOLENOID VALVES HUNG DIAPHRAGM - 3/8, 1/2 AND 3/4 N.P.T. NORMALLY CLOSED OPERATION Form NO. v-5825

DESCRIPTION Catalog Maximum Muimam Constructton Coll Number Amblent fld! Bulletin 8210’s are 2-way. normally closed, internal pilot operated sole- Class Temp.OF. Temp. noid valves. Valve body and bonnet are of brass construction. Standard Prefix F. ! valves have a General Purpose. NEMA Type 1 Solenoid Enclosure. A-C Constmion - A NoneorDA 77 180 Bulletin 8211‘s are the same as Bulletin 8210’s except the solenoids are (Alternating Current) F DFor FT 122 180 quipped with an enclosure which is designed to meet NEMA Type 4 HT 140 180 Watertight. NEMAType7(CorD) HazardousLocations-ClassI.GroupC H or D. and NEMA Type 9 (E. F or G) Hazardous Locations - Class 11. Group D-C Construction A, F None, FT 77 150 E. For G. The explosion-p~f/watmightsolenoid enclosure is shown on (Direct Current) or H or HT a separate sheet of Installation and Maintenance Instructions, No. ~ ~~~ Form A Noneor 77 210 v-5380. Catalog Numbers DA suffixed ‘Hw’ Bulletin 8210 and 821 1 valves with suffu ‘HW’ in the catalog number are DForFT 77 210 A-C Construction , F specifically designed for hot water service. (Alternating Current) HT 122 210 I

OPERATION POSlTl ONIHG/MOUNTING Normally Closed: Valve is closed when solenoid is de-energized and opens when solenoid is energized. Valve may be mounted in any position. For mounting bracket (optional feature) dimensions, refer to Figure 1. I PIPING MANUAL OPERATOR (Optional) Connect piping to valve according to markings on valve body. Apply pipe Valves with suffix ‘MO’ in catalog number are provided with a manual compound sparingly to male pipe threads only; if applied to valve threads, operator which allows manual operation when desired or during an inter- it may enter the valve and cause operational difficulty. Pipe strain should ruption of electrical power. To operate valve manually. push in knurled be avoided by proper support and alignment of piping. When tightening cap and rotate clockwise 180: Disengage manual operator by rotating the pipe do not use valve as a lever. Wrenches applied to valve body or knurled cap counterdockwise l80O before operating electrically. piping are to be located as close as possible to connection point. IMPORTANT: Valves wltb suffix ‘EM” in the dognumber bve a spectal dlapbrsgm mated wbkh Is speciacdy compounded for hot water service. This material can be attacked by oil and grease. Wipe the MANUAL OPERATOR LOCATION (Refer to Figure 3) pipe threads clean of cutting oils and use teflon tape to seal pipe Joints. Manual operator (when shipped from factory) will be located over the valve outlet. Manual operator may be relocated at Woincrements by 1-0- ~~o,R~~l~~~~~~~~~~~~~~~~~id~~cl~~~~~ tating valve bonnet. Remove bonnet screws (4) and rotate valve bonnet valve as POsslble’ cleanlng reqw dependdlng On the with solenoid to desired position. Replace bonnet screws (4) and torque in conditions. See Bulletins 8600, 8601 md 8602 for strdners. a crisscross manner to 110 2 10 inch pounds. WIRING If valve is installed in system and is operational, proceed in the following manner: Wiring must comply with Local and National Electrical Codes. Housings for all solenoids are provided with connections for 112 inch conduit. WARNMG: Deprreearlze valve .nd power ,upply. The - general purpose solenoid enclosure may be rotated to faditate wiring by 1. Remove retaining cap or clip and slip the mtirc solenoid enclosure off removing the retaining cap or clip. CAUTION: When metal retaining clip the solenoid base sub-assembly. CAUTION: When metal retaining clip disengages it will spring upwards. Rotate to desired position. Replace disengages. it will spring upwards. retaining cap or clip before operating. I 2. Remove bonnet screws (4) and rotate valve bonnet to desired position. 3. Replace bonnet screws (4) and torque in a crisscross manner to 110 AlternatfngCmat(A-o and Dm Clvrent(D-C)So’eno1ds I IO inch pounds. built differently. To convert from one to the other, It Is necessary to chge 4. Replace solenoid enclosure and retaining clip or cap. the complete solenoid including the solenold b‘pse sub-assembly and core assembly.

INSTA LLATION SOLENOID TEMPERATURE Standard catalog valves are supplied with coils designed for continuous CheFk nameplate for correct catalog number, pressure. Voltage and duty service. When the solenoid is energized for a long period. the sole- service. noid enclosure becomes hot and c3n be touched with the hand for only an instant. This is a safe operating temperature. Any excessive heating will be indicated by the smoke and odor of burning coil insulation. TEMPERATURE LIMITATIONS MAINTENANCE For maximum valve ambient and fluid temperatures refer to chart. The temperature limitations listed are for UL applications. For non UL WARNING: Turn off eleclrlcal power and depressurize valve before applications. higher ambient and fluid temperature limitations are making repairs. It Is not necessary to remove valve from plpe line for available. Consult factory. Check catalog number on nameplate to repalrs. determine maximum temperatures.

ASCO Valves A orm No. Vas PRINTED U.S.A. 1975 Swltch CU. FLORHAM PARK, NEWJERSEY 07932 CLEANING VALVE REASSEMBLY A periodic cleaning of all Solenoid valves is desirable. The time between 1. Reassemblein reverse order of disassembly paying careful attention to deanings will vary. depending on media and service conditions. In gen- exploded views provided for identification and placement of parts. eral. if the voltage to the coil is correct. sluggish valve operation. aces- 2. Replace body gasket and corddiaphragm sub-assembly. Locate the sive leakage or noise will indicate that cleaning is required. bleed hole in coreldiaphragm sub-assembly approximately 45' from the valve outlet. . PREVENTIVE MAINTENANCE 3. Replace core spring with wide end in cure first: closed end protrudes from top of core. 1. Keep the medium flowing through the valve as free from dirt and 4. If removed. replace manual operator stem. stem spring, stem gasket foreign material as possible. and stem pin. 2. While in service. operate valve at least once a month to insure proper 5. Replace valve bonnet and bonnet screws (4). Torque bonnet mews (4) opening and closing. in a crisscross manner to 110 2 IO inch pounds. 3. Periodic inspection (depending on media and service conditions) of in- 6. Replace bonnet gasket and solenoid base sub-assembly. Put solenoid ternal valve parts for damage or excessive wear is recommended. Thor- base sub-assembly to 175 2 2.5 inch pounds. ougly clean all parts. Replace any pans that are worn or damaged. 7. Replace solenoid enclosure and retaining cap or clip. 8. After maintenance. operate the valve a few times to be sure of proper IMPROPER OPERATION . opening and closing. 1. Faulty Control Clreoit: Check electrical system by energizing solenoid. A metallic click signifies the solenoid is operating. Absence of the click SPARE PARTS KITS indicates loss of power supply. Check for looseor blown-out fuses. open circuited or grounded coil. broken lead wires or splice connections. Spare Parts Kits and Coils are available for ASCO valves. 2. Burned-Out 611: Check for open circuited coil. Replace coil if neces- Parts marked with an asterisk(+) are supplied in Spare Parts Kits. =rY. 3. low Voltage: Check voltage across coil leads. V6ltage must be at least 85% of nameplate rating. ORDERING INFORMATION 4. Incorrect Pressure: Check valve pressure. Pressure to the valve must FOR SPARE PARTS KITS, be within range specified on nameplate. 5. Excessive Leakage: Disassemble valve and clean all parts. Replace When Ordering Spare Pam Kin or Coils Specify Valve Catalog Number, worn or damaged parts with a complete Spare Parts Kit for best results. Serial Number and Voltage. COIL REPLACEMENT (Refer to Figure 2) Turn off electrical power supply and disconnect coU Id.Romd In the following manner: 1. Remove retaining cap or clip, nameplate and cover. CAUTION: When metal retaining clip disengages, it will spring upwards. 2. Remove spring washer, insulating washer and coil. Insulating washers are omitted when a molded coil is used. 3. Reassemble in reverse order of disassembly paying careful attention to exploded view provided for identification and placement of parts. PARTIAL VIEW OF CAUTION: Solenoid must be fplly reassembled Y the housing and In- ternal parts are part of ead complete the nuguetk drc91t. PIace fnsuhthg MOUNTING BRACKET washer at each end of coil if required. (OPTIONAL 1 VALVE DISASSEMBLY (Refer to Figures 2 and 3) Depressurize valve and turn off electrical power sopply. Proceed In the following manner: 1. Remove retaining cap or clip and slip the entire solenoid enclosure off the solenoid base sub-assembly. CAUTION: When metal retaining dip disengages, it will spring upwards. 2. Unscrew solenoid base sub-assembly and remove bonnet gasket. 3. Remove valve bonnet screws (4) and valve bonnet. 4. For normal maintenance, it is not necessary to disassemble the manual operator (optional feature) unless external leakage is evident. To ds- assemble remove stem pin. manual operator stem, stem spring and stem gasket. 5. Remove core spring, core/diaphragm sub-assembly and body gasket. CAUTION: Do not damage or distort hanger spring between core/ diaphragm sub-assembly. 6. All parts are now accessible for cleaning or replacement. Replace worn or damaged parts with a complete Spare Parts Kit for best results. p7-g / .281 DIA. 2 MOUNTING HOLES n

Dlmcnstons For Mounthg Bdet Flpn 1. (Optlond Featare)

ASCO Valves 'a SMEh CO. FLORHAM PARK, NW JERSEY 07932 ~orm~o.V-5825 PRINTED IN USA 1975 SPARE PARTS KITS*

SPRING WASHER

NSULATING WASHER

SUB -ASSEMBLY TO

lNSULATINGWASHER IN A CRISSCROSS MANNER TO 1lOflO INCH POUNDS.

BONNET SCREWS (4) SOLENOID BASE SUB - ASSEMBLY OUNTING BRACKET TWO POSITIONS (OPTIONAL) BONNET GASKET

VALVE BONNET

LOCATE BLEED HOLE IN CORE SPRING+ CORUDIAPHRAGM SUB - (WIDE END IN CORE FIRST,CLOSED END ASSEMBLY APPROXIMATELY PROTRUDES FROM TOP OF CORE.) 450 FROM VALVE OUTLET CORE/DIAPHRAGM SUB -ASSEMBLY* BLEED HOLE

0-BODY GASKET*

VALVE BODY NOTE: INSULATING WASHERS (2) ARE OMlITED WHEN A MOLDED COIL IS USED. PARTS INCLUDED IN

SUB -ASSEMBLY TO

SOLENOID BASE SUB- ASSEMBLY IN A CRISSCROSS MANNER TO 110 5 10 INCH POUNDS.

BONNET GASKE

VALVE BONNET

MANUAL OPERATOR STEM

(SEE NOTE) 1

0 R E/D IAP H RAGM

LOCATE BLEED HOLE IN CORE/DIAPHRAGM SUB- Ass EM B LY APPROXIMATELY 45O FROM VALVE OUTLET 0-BODY GASKET*

VALVE BODY

NOTE: WIDE END OF CORE SPRING IN CORE FIRST, CLOSED END PROTRUDES FROM TOP OF CORE.

Bdetln 8210 - Mmud Operator -~~edparpose solenold enclosure down. gum 3. Forexplooion-proof/waterttgbtsolenold endormre donBIllletla 821 I, m Form No. V-SSO.

ASCO Valves 'A &itmUUt S h CU. FLORHAMPARK, NEW JERSEY 07932 F- No-V-25 PRINTED IN U.S.A 1975

, Specifications

Model 69702 Tmnsmitter Operational: Measunng Ranges ...... 0-2 ppm. 0-5 ppm. 0- IO ppm or 0:20 ppm; switch selecuble (and facrory-sec to specified range) . Ambient Condiuons ...... -22 to + I 40cF (-30to +60°C); 0 to 9596 relative humidity. non-condensing Temperature Compensation ...... Automatic 32- 122°F (0-50°C) Sensor-to-Transmitter Distance ...... loo0 ft. (305 m) maximum Output Transmission Distance ...... Limited only by wire resistance and power supply voltage Power Requirements ...... I I to 35 voits Dc

Pcrfonnance (Electrical, 4-20 mA Output): Sensitivity ...... 0. 1% of span Scability...... 0. I96 of span per 24 hours. non-cumulative Non-Linearity ...... 0.1% of span Repeatabiliry...... 0.025% of span or beccer

Temperature Drift ...... Zero: 0.01 5% of span per OC; Span: 0.0 I 5% of span per "C Response Time ...... i.... 3 minutes to 9096 of value upon step change lnserdon Loss at 20 mA ...... 9.5 volts DC (475 ohm maximum inserrion loss in the 4-20 mA loop)

Mechanical: Endosure (optional) ...... NEMA 4X; potycarbonare: surface mount Nec Weight (less optional endosure) ...... 0.6 Ibs. (0.27 kg) approximately

Model 5440D Membme D.O. Sensor

Weaed Materials ...... Polyoxymethylene (POM) membrane head assembly and loddng q.fluorinated ethylene propylene (FE?) membrane. and stainless steel sensor body Elemcde Farerids ...... Cathode: Gold Anode: Silver Reference: Silver Temperature Range ...... 32- I2ZCF(0-SOOC) Minimum 8ow Rare ...... 0.01 6 feet (0.5 centimeten) per second Maximum Pksure...... 145 psi (I 0 bar) .' Measuring Range ...... 0.0-20.0 ppm Response Tirne.(20"C);...... 3 minutes to 9096 of value upon step change Membrane ,nic!aess ...... 50 microns Sensor Cable ...... Integral IS ft. (4.6 m) long cable. terminated with an. MS-type quickdixonnedplug Measuring Prinaple ...... Porentiostatic polarographic three-elemde system

Ordering Information

era .* *I era .. -I -. -. =%e' =. r *a r e *. Interconnect Cable 99x1 W0980 This non-mdicaang, LWO-~~Etrammutter is This msmmer IS the same as Model This three-wire cable (two conductors plus fully encapsulated and provides a non- 697DZAO except it IS mounted to a meral shield) is used for power and output signal isolated 4-20 mA ouput Specify the plate for use wlth the opoonal transmission. Specify required length in measunng range as 0-20-5.0- IO. or 0-20 100084A30 I 3 endosure. Speafy the whole foot increments. PPm. measuring range as 0-2.0-5.0-10. or 0-20 ppm. NEMA 4X Endosure IOOO~~O13 This surface-mount. polycarbonate endosure indudes one bulkhead fining and one MS-cype quickdisconnect receptacle. Dam Shm 69702/396 Replaces 69701292 Model 697D2/5440D Membrane Dissolved Oxygen System (w it h no n- in d ic at in g two- w ire t rans mit t e r)

Converts/Transrnits Measured = Switch-selectable Measuring Values To a Standard 4-20 mA = Replaceable Membrane Head. Ranges. output; The sensor features a disposable The mnsrniixer includes a range The cransrniner provides a standard membrane head assembly. simplifying selector switch to provide measuring 4-20 mA output signal representing the delicate and ume-consuming task ranges of 0-2.0-5.0-10 and 0-20 the measured value within the of installing a new membrane. Each ppm to fit your application needs. selected mevuring range. assembly’s semi-permeable membrane is pre-installed to ensure Calibration Adjustment Simplified Hookup. a precise and consistent fit. Capability. Only a common two-wire wisced Offset and span controls calibrate the pair is required for power input and Rugged, Foul-resistant oansminer 4-20 mA output to output signal transmission. Membrane. z compensate for sensor aging. eliminating the need for special An extremely durable 50 micron ; (Transmitten are supplied factory- cabling. thick hydrophobic membrane calibrated to your specified ensures that the 0.0. sensor resists measuring range -- see above.) Optional NEMA 4X Protection. fouling and withstands che harsh 2 Optional enclosures are avalable for environmencs found in wastewater 3 Automatic Temperature applications requiring complete treatment plants. 3 Compensation. environmental protection. Refer to Y Automatic 0-50°Ctemperature page 3 for derails. 3 compensation msures accurate 3 dissolved oxygen i.-easurement. n n I 3 Ordering Information (continued)

*D **ID damp assembly, and surface-mount Electrolyte Solution 25M7AI 002- IO5 :-r e. junction box with quickdisconnect One 50 ml bode of electrolyte solution to The sensor includes: recep tact e. ,. replenish the membrane head assembly. Replaceable membrane head assembly Flotation M%. Hardware with a factory-installed, semi-permeable MH276J00F Cleaning Solution 25M9AI 004- IO7 membrane This hardware is the same as MH276HOOF One so bode of soludonfor deaning SO ml bode of electrolyte listed above but also includes a ball float the membrane 0.0.sensor's silver SO ml bode of cleaning solution assembly. and a 4S'-angled PVC coupling co elemode. Abrasive cleaning paper connect the floac assembly to the pipe. I2 disposable calibration bags for highly Abrasive Cleaning Paper 99XZAI 0 I4 accurate -Saturation Mechod" air 76A3A9902 Flotation Extension Pipe One abrasive deaning paper to dean the di bration For use with only the MH276JWFflotation membrane 0.0.sensor's gold demode. mounting hardware. This pipe extends the The sensor has an integrd 15 k (4.6 m) membrane end of the 0.0.sensor I foot Membrane D.O. Sensor long cable. terminated with an MS-me (0.3 m) below the bdl float for applications Maintenance Kit 676M4G IO50 quickdisconnect plug. that connects to a where greater submersion depth is desired. mating receptade on the junction box The kit indudes: ! lnduded with any of GU's optional MH276ROOF Submenion Mtg. Hdwe. Replacement membrane head assembly membrane sensor mounting hardware. SO ml bode of electrolyte Hardware consists of I I/2 inch dia. by 5 fr. - SO ml bode of silver elemode deming (I .5 m) long WCpipe. and a surface- NOTE A sensor ordered with a non- solution mount juncrion box with quickdisconnect standard cable /en$h must be specified by its e One abrasive deaning paper for deaning receptacle. model number fillowed by 'OOO" and the the gold electrode required length ofcable in whole fiot Carrying case. a e-. mi~e-x increments. Ltample: "5440000025"for a sensor with a 25 foot cable. Replacement Membrane Head Spare Calibration Bags 276A3M1210 Assembly 676- I030 A packass of I2 disposable bags for The assembly indudes a pre-installed. semi- "Saturation Method" air ulibration use MH276HOOF Handail Mounting permeable membrane. only. The bags provide a stable atmosphere Hardware (non-float qpe) around the membrane for highly accurate Hardware consists of I- 1/2 inch dia. by 7.5 calibration. ft. (2.3 m) long WCpipe. swivel/ pivodpipe

Engineering Specification

Model 697D2 Transmitter

I I. The mmershall be fully epoxy 3. The cnrmnmer shall be acwo-wire. Ioop- Opctonal: enapsulared. powend deslgn and shall dtWXcePc the 5. A shemom NEMA 4X enclosure shvl be sensor inpcx. 2. line non-tndtcartng trwmmer shall haw an 0.0. prowded co pmrect rhe cmsnmer imm the tnherendy isolzzed 4-20 mA ourpa signal thac 4. Themmmershall be GLI Incemanonal. Inc. enwmm. npmenrs che selmed measuring nnge. Modd 69702.

1 Model 54400 Membane 0.0. Sensor

I. The sensor shall be a thdecvode 5. The sensor shall have an imegral IS fe. (4.6 rn) sensor. swWptvodpipe bpassembly. and potennoscaw. polamgnphu sensor conststing long able tvrmnared wtrh an MS-cype qutck- surface-mornIWKnO" box WKh qutck- I of a silver reference. silver mode. and agold disconnm plug. disconnecc t-eceptade: &ode. 6. The sensor shall be provided wich a dozen Z The elemodes shall be covered by a SO disposable dihonbags to perform b) Flocarion Mounting Hard- MH276jOOF micron thick hydrophobtc membrane which is %on Mechod' air calibmciom. These consisting of I - I/2 inch dia by 7.5 f~.(2.3 rn) pre-~dledin a membrane head asembly. special bags provide a &le amospherc long WC pipe. WC-le coupling for sensar. The membrane md membran head assembly around the sensor membrane for highly ba~lflop. mivdpivodpipe Jamp bly. swfaccmom jllllcdon box wkh quick- shall be comrructed of flwriwed ethylene acmecdibAon. disconnect mewe:or propylene and polyoxymdd- 7. The sensor shall be GLI Irxem;lEiod. Inc rerpecclwly. Modd 54400. c) Submersion Mouraing HYdwve The sensor body shall be comrm~redof 3. owonal: MH276ROOF co&ng Of I-IR inch dh by 5 nunless adand polyoxymerhylene. 8. Hvdmre co mum the sensor shall be: fr. (I S m) iong PVC pipc and ~cmourr~ 4. The sensor shall z*~omzcidkycornpunare for a) Hd~ailMountinn Hardware MH276HOOF jdonbox with quick-diim changes in talpe- comiscing of I -1/2 ikhdir by 7.5 k (23 rn) KCpCk. long WCpipe. WC stnight coupling for ..3'

Model 697DZRO Transmitter Optional IOOOB4A3013 Surface-mount Endosure

MH276HOOF Handrail and MH276jOOF Rotation Mounting Hardware

Worldwide bkr Eu-n bkr CU lnternatimd Inc. ELE International Ltd Great Lakes Intscuments Eastmy Way. Hund HunpSd 9020 WmDean Road Hercfordshii HPZ 7H6 @m Milwaukee. Wscomin 53224. USA. phonc:O1442 229310 phone: (4 I41 355-3601 far01442 229311 fax (4 141 355-8346 mil: [email protected]

h the interest ofimpmng and uphnr IOequipment. GU rrrencr -+ qht to dtu speafcaaonr to cgurpmnt at any time. A Member d che EL€ Group -