ABCO plus

Automatic Blowdown Controller

Manufactured Marketed by :
Spirax Marshall Pvt. Limited
A Forbes Marshall Company
P. B. No. 29, Mumbai - Pune Road, Kasarwadi, Pune - 411 034. India.
Tel. : 91 (0) 020 27145595 Fax : 91 (0) 020 27147413, 27147593
URL : http://www.forbesmarshall.com/spirax
Branches
: Ahmedabad, Alibag, Bangalore, Bharuch, Chandigarh, Chennai,
Coimbatore, Delhi, Hyderabad, Jamshedpur, Kolkata, Mumbai, Nagpur,
Navi Mumbai, Pune, Surat, Vadodara, Visakhapatnam.

Dear User,
Thank you for purchasing the Automatic Blowdown Control System. To maximize your benefits from this
product, we request that you read these instructions thoroughly before using the Controller. If you
experience difficulty with the operation of this equipment, please contact our Customer Service
Representative.

Spirax Marshall Pvt. Ltd.

Index
1. The ABCO plus Controller
1.1. General description

04
04

1.2. Technical Specifications

1.2.1. Electrical
1.2.2. Mechanical
2. Getting Started
2.1. Included Items
2.2. What you need
2.3. Installation
2.3.1. Controller
2.3.2. Sensor
2.3.3. Wiring
2.4. ABCO plus Blowdown Controller
2.4.1. Safety
2.4.2. Description of the Controller
2.4.3. Blowdown operations
2.4.4. Display details
2.4.5. Programmable Parameters

04
04
05
06
06
06
06
06
08
09
13
13
13
14
15
16

2.4.6. Keyboard and Menu Navigation

2.4.7. Commissioning
2.4.8. Maintenance
2.4.9. Dos and Donts
2.4.10. Fault Finding
3. Detailed Keyboard Operation
3.1. PARAMETERS
3.1.1. START TIME
3.1.2. ENABLE BLR1/BLR2/BLR3
3.1.3. UNITS
3.1.4. DATA FOR BOILER 1/2/3
3.2. ALARMS
3.3. RESET TOTALIZERS
3.4. SERVICE/RTC/SP
3.4.1. SERVICE
3.4.2. RTC
3.4.3. SP
3.5. Determining K-Factor
4. Spares
5. Service
3

17
21
23
23
23
25
27
27
27
27
26
26
26
26
26
27
27
27
29
30

5.1. Field service

5.2. Field service record

30
30

1 The ABCO plus Controller

1.1. General description
ABCO plus is a micro-controller based Electronics device designed to maintain the
Boiler water TDS within the safe band as specified by the boiler manufacturer. This is
done by measuring the TDS value of boiler water continuously or periodically using
sensors mounted in-situ or externally on bottom-blowdown lines respectively.
Whenever the measured TDS exceeds the Set-point value, the boiler water is blown
down until the TDS value falls below the set-point value. The system is capable of
controlling the TDS of 1 boiler (Economy version) or up to 3 boilers (Standard version).
1.2. Technical specifications
1.2.1. Electrical
o

Number of boilers under TDS control

Economy version

Standard version

One
Up to three (max)

Sensors (per boiler) for

Conductivity
Bottom Blowdown measurement CP10, 2-wire
In-situ measurement
CP32, 4-wire (optional)

Temperature sensor
PT100 3-wire Class B DIN
43760

Sensor for feed water

with K=0.1
(Integrated temperature sensor)

o
o

TDS

o

Range for Blowdown

Range for feed water
Accuracy for Blowdown & feed water
value)
Resolution for Blowdown & feed water

Temperature

Accuracy for Blowdown & feed water

Resolution for Blowdown & feed water

Range for Blowdown
5

Feed Water Sensor

1 ppm to 9999 ppm

1 ppm to 1000 ppm
(+/- 5% of Actual
+/- 1ppm
1 ppm

+/- 1 deg C
0.1 deg C
0 250 deg C

Range for feed water

0 150 deg C

Relay output

For Blowdown valve

For BHRS valve
boiler

Contact rating
with RC

1 NO contact per boiler

1 NO contact per
230 VAC, 500mA
snubber

Re-transmission output 4-20 mA for Blowdown TDS per boiler

Accuracy
+/- 0.1% of FS (+/- 0.02mA)

Load
500

Load dependence
+/-0.002 mA

Isolated Test voltage
1KV DC for 1 minute

User interface

Display
(Red Color)

7 segment LED display

128x64 Dots Graphic LCD display
Bicolor Status LEDs

Keypad
keys

Membrane keypad with 4

Alarm signals

Continuous Green LED if no blowdown since 8 hours

Continuous Red in Failure Mode

Alarm messages in scrolling mode on LCD display

Feature in Run mode

Purge Cycle for currently displayed Boiler

Reset Totalizer feature resets

Blowdown totalizer

Heat Totalizer

Total Purge cycles

o
o
o

Operating voltage
Operating temperature
Storage temperature

85-260 VAC, 50/60Hz

-20 to +70 deg C
0 to +50 deg C

1.2.2. Mechanical
7

Wall Mounted version

o Enclosure
o Ingress protection
o Dimensions (in mm)
o Cable glands
Version

Aluminum die-cast housing

IP65
306(w) 273(h) 97(d)
11 (max) for Standard
07 (max) for Economy
version

Panel Mounted version

o Enclosure
coated
o Panel cutout (in mm)
o Front plate (in mm)

Sheet metal, powder

262(w) x 164(h)
290(w) x 175(h)

2. Getting started
2.1. Included items
This product should come supplied with the following items:
o ABCO plus Blowdown Controller
1 nos.
o Conductivity Sensor for feed water K=0.1
1 nos. with 1.25 mtr cable
o User manual
1 nos.
Note: In case of the Panel Mount option, the Controller is delivered pre-mounted
on the Control Panel.
2.2. What you need
ABCO plus Blowdown Controller
Mechanical skid assembly that includes:
o Upstream & downstream isolation valves
o Blowdown valve with solenoid
o Downstream check valve
o Sensor chamber, etc
Set of spanners & screwdrivers
Air supply at a regulated pressure of 3 to 6 bar g
Single phase AC mains supply with proper Earth

2.3. Installation
2.3.1. Controller

For Wall Mount option, select a location which will keep the controller out of
direct sun and rain. Fix four M8 bolts into the wall with relative distances as shown
on the drawing. Using M8 plain washers and hex nuts, mount the controller onto
these bolts.

Wall Mount (dimensions in mm)

Panel Mount (dimensions in mm)

2.3.2. Sensors
CP10: Fit the joint gasket to the sensor and screw into the sensor chamber. A
graphite sealing compound is recommended to make subsequent removal
easier. PTFE tape sealing is not recommended.
CP32: This sensor type is supplied in nominal tip lengths of 300, 500 or 1000 mm,
and can not be cut to length. 300 mm and 500 mm probes can be installed
vertically or horizontally.
CAUTION: 1000mm probes must be installed vertically only.
WARNING:
Do not install the probe outdoors without additional weather protection.
The boiler must be depressurized and vented to atmosphere before
installation of the probe.
Wherever possible the boiler manufacturer must be consulted for advice on
the positioning of the probe and the optimum TDS level.
PT100: Mount the 1/8 BSP end of the Stud Coupling onto the sensor chamber.
Slide the Olive Nut over the sensor stem followed by the Olive. Tighten the Olive
Nut over the second end of the Stud Coupling such that the sensor tip does not
touch the opposite wall of the sensor chamber.
Feed Water Sensor: The sensor can be mounted either in-situ onto the feed water
tank such that the sensor is always below the minimum level of the feed water.
Alternatively it can be mounted downstream on the outlet pipe a shown.

10

Feed water tank

To ABCO plus
controller
S
To ABCO plus
controller

Mounting
option B
S

Mounting
option A

Feed water out

S: Feed water sensor (K=0.1) can be mounted at either location A or B

FEED WATER SENSOR: MOUNTING OPTIONS

2.3.3 Wiring
The detailed wiring connection schematics follow. These include the Sensor
connections, Solenoid Valve connections, 4-20 mA Output connections and
Mains connections. Please refer the following sheets for all the relevant details.

11

ABCO plus Terminal Connection Numbers

BOILER 1

10

11

32/40/
46

BOILER 2

33

34

35

36

41

42

43

40

BOILER 3

12

13

14

32

Shield

Shield

HANGING
CONNECTOR

A: Female

B: Male

CP10 Sensor

NOTES
A: IC2, 5/8-ST-5.08 connector screw type
B: MSTB2, 5/8-ST-5.08 connector screw type
C: 4 core shielded wire 16/2, 0.5 sq.mm.(16/0.2)
D: PTFE insulated SPC cable 24/7/32Ex3cores, twisted
PTFE isolated, SPC shielded, overall PTFE jacketed

12

Red

White

White

Blue

Red

NC

PT100 Sensor

BOILER SENSOR CONNECTIONS

ABCO plus Terminal Connection Numbers

28

29

30

31

37

38

Shield

46

Shield

A: Female

B: Male

Shield

White

Red

Red

Brown

Yellow

Blue

Orange

HANGING
CONNECTOR

39

C
NOTES
A: IC2, 5/8-ST-5.08 connector screw type
B: MSTB2, 5/8-ST-5.08 connector screw type
C: PTFE insulated SPC cable 24/7/32Ex7cores, twisted
PTFE sheathed with drainwire of 7/32, overall
PTFE jacketed
D: PTFE insulated SPC cable 24/7/32Ex3cores, twisted
PTFE isolated, SPC shielded, overall PTFE jacketed
E: 4 core shielded wire 16/2, 0.5 sq.mm.(16/0.2)

13

Feed Water Sensor (K=0.1)

with Temperature Sensor

FEED WATER SENSOR CONNECTIONS

14

4-20mA OUTPUT
CONNECTIONS

500 max

Solenoid
valve

Fuse 1A
slow blow

BOILER
BLOWDOWN VALVE
CONNECTIONS

Black

NEUTRAL

LIVE

Red

Solenoid
valve

Fuse 1A
slow blow

Red

BHRS VALVE
CONNE CTIONS

Black

NEUTRAL

LIVE

Red

52

51

27

26

45

44

B OILER 3

Red

50

49

25

24

18

17

BOILER 2

48

47

23

22

16

15

BOILER 1

ABCO plus Terminal Connection Numbers

57

MCB

Black

Green

3 core
Mains cable

Black Green

56

MAINS
CONNECTIONS

Red

Red

55

2.4. ABCO plus Blowdown Controller

2.4.1. Safety: Refer to the Terminal connection label pasted on the inside of the
Terminal box lid. Provide AC power line protectors & appropriate electrical
grounding to the Earth point on the Mains terminal and to the enclosure.
Isolate the Mains Supply voltage before disconnecting the controller. While
connecting or disconnecting any wires please switch off the supply to the
Controller.
2.4.2. Description of Controller: ABCO plus is a micro-controller based system
used to maintain the TDS of boiler water within the safe band as specified by
the boiler manufacturer. Normally this is done by periodically measuring the
TDS using sensors mounted on the bottom blowdown line external to the
boiler. Optionally this can be done by continuously measuring the TDS using
a sensor, which is mounted in-situ within the boiler shell.
In both cases whenever the measured TDS exceeds the Set-point value, the
boiler water is blown-down until the TDS value falls below the set-point value.
The system is capable of controlling the TDS of 1 boiler (Economy version) or
3 (Standard version) boilers.
In addition, the system measures the TDS of the feed water. This value is used
to compute the Heat Loss and Percentage Blowdown on a daily (24 hrs)
basis. In case of the Standard version, the feed water TDS measurement is
common to all the 3 boilers.
All TDS computations are temperature compensated and expressed in parts
per million (ppm).
The user interface is via a 4-key matrix and local display. A 7-segment LED
display array is used to display the Boiler Number and the corresponding TDS
value along with a relevant process message. A LCD module is used for
Parameter Programming and to display other data in Run mode including
feed water TDS, feed water Temperature, Boiler Set-point, Total Purge Cycles
and Blowdown Rate. The LCD also displays Total Heat Loss & Percentage
Blowdown on daily basis. The alarm messages like Boiler TDS High, Boiler TDS
Low, Feed water TDS High and % Blowdown High are displayed in scroll
mode on the same LCD screen.
A 4-20 mA output is provided for each boiler blowdown TDS and can be
used for remote display of the TDS or as an input to the Distributed Control
System.

15

Relay outputs are provided per boiler, to operate the respective Blowdown
valves and the Blowdown Heat Recovery System valves. Operation of the
relay contacts:
BHRS valve is activated first

After 15 seconds blow down valve will be activated

After completion of the blow down cycle blow down valve will be
closed

After 15 seconds BHRS valve will be closed

A two-level password-protected security feature prevents undesired or

accidental changes of the set-points.
Sensor cleaning feature is provided for periodic cleaning of the
Conductivity sensor for Boiler 1(and Boiler2 & Boiler3 for Standard version)
and Feed water once every 24 hrs. The sensor cleaning operation is active
for approximately 15 seconds per sensor. While this is in progress, any ongoing action is aborted, all measurements are put on hold and key inputs
are ignored.
2.4.3. Blowdown operations
In systems with the in-situ sensor the TDS measurement is continuous and the
ABCO plus causes to open the blowdown valve if the TDS exceed the setpoint. When the TDS falls below the set-point the controller closes the
blowdown valve.
For systems where the sensor is mounted in the blowdown line a set of timing
values comes into play. The controller periodically (time PA: Purge After)
opens the blowdown valve to refresh the boiler water around the sensor
before its TDS value is sampled. This is known as purging. At the end of the
purge duration (time PD), the blowdown valve is closed and the TDS value is
sampled. If the value is below the set-point, the blowdown valve remains
closed until the next purge cycle occurs (after time PA). If the TDS value
exceeds the set-point, the controller will cyclically open and close the
blowdown valve until the TDS falls below the set-point. Each such cycle will
repeat at certain short intervals (time BA) and for a certain duration (time
BD). The TDS is successively measured at the end of each BD time. All the
above timing values are programmable.

16

Typical operation
tPA
Valve
open

tPD

tPD

Purge

Purge

Valve
closed
Time

Purge cycles
High
Boiler water
TDS

Set
point

Low

Conductivity controlled around set point

tPA
tBHRS

15 sec
Valve
open

tBA

tPD

tBD

tBD

Purge

Blowdown

Blowdown

15 sec

Valve
closed
Blowdown

Purge

Blowdown

Blowdown Cycle
tPD: Purge Duration
tPA: Purge After

Time

tBD: Blowdown Duration

tBA: Blowdown After
tBHRS: Blowdown Heat Recovery System

Blowdown cycle

2.4.4. Display Details

7- Segment LED display:
Normally to display Boiler No. and corresponding TDS value with the
process message in Economy and Standard versions. In Standard version
the TDS value for 3 boilers is accessed in scrolled mode.
Alternatively to display process messages
For purge cycle: Prg
For Blowdown cycle: bLd
For Cleaning cycle: CLn
When sensor is open or short or coated: Err
In Program menu: to display the corresponding menu level

17

LCD display:
To set different values via Program menu and display other parameters &
calculated parameters in Run mode
Password for programming: 4 digit sequence
DN > UP > PURGE> ENT
Parameters displayed in Run mode (for the selected boiler):
TDS set point of Blowdown & Blowdown temperature on LCD.
Feed water TDS & feed water temperature
Blowdown loss (Kg) for each boiler
Blowdown flow rate (Kg/Hr) (instantaneous)
Energy total (Kcal / KJ).
% Blowdown
Total Purge Cycles
Alarm Indications & Sensor Short, Sensor Open message in rolling
mode
Parameters displayed in the Program menu:
All the programming parameters are displayed in Program Menu.
Bicolor LEDs to indicate
Red Flashing Blowdown cycle active
Green Flashing Purge cycle active
Constant Red Failed status
Constant Green Blowdown cycle has not occurred for more than
8 hrs
2.4.5. Programmable parameters
Calibration:
Used to calibrate the K factor of the conductivity sensor per boiler
Parameters:
Start Time in Hrs & Mins
Boiler Status (Enable/Disable) of each boiler
Units (SI/MKS) for each boiler
Purge After, Purge Duration, Blowdown after, Blowdown Duration
Line, Pressure, Capacity, Input sensor (CP10 / CP32) for each boiler
(blowdown only, not feed water)
Alarms (per boiler):
18

Boiler TDS High, Boiler TDS Low, feed water TDS High, % Blowdown
High
Service:
Data retrieval* Date, Time & TDS Value after valve close event of
each boiler
Electronic calibration - Boiler TDS circuits, Blowdown Temperature
circuits, feed water TDS circuit, feed water Temperature circuit, 4
20 mA current output circuit of Blowdown TDS of each boiler, test
mode for 4-20 mA current output.
* Number of records limited to 600 records per boiler.

2.4.6. Keyboard and menu navigation

1) Prog displayed on 4 digits LED display, while user is in the Program Menu
options
1 to 4 and SERVICE/RTC options of 5.
2) SEtp displayed on 4 digits LED display, while user is in SET POINT Menu
(SP).
2.4.6.1.

Keyboard Matrix
Symbol of key

Description of key

PURGE

Purge

PROG /

Program / Enter
Up arrow
Down arrow

2.4.6.2.
Navigation
NOTE:
1. If BACK is selected and ENT key pressed then previous screen is displayed. While
on the PROGRAM menu screen, BACK is selected and ENT key is pressed then
the Controller will exit the program mode and the Run mode will be displayed.
2. In the LCD Screen Contents <v> is used to denote each numeral of the displayed
value.
19

3. When particular Boiler is not selected corresponding Boiler parameters cannot

be edited.
4. When the user is in the program menu on any screen & presses PURGE & PROG
keys simultaneously, the unit will exit from the program menu and goes to the run
menu.
5. If in Run mode ENT key is pressed,
i. PROGRAM ENTER PASSWORD **** screen will be displayed on
LCD display.
ii. To enter the Program Menu enter password sequence: DN > UP >
PURGE > ENT
6. Auto time out for each menu function is set for 1 minute, if user is in PROGRAM
MENU and no key is pressed for 1 minute, the controller returns to Run mode
automatically.

Key

Key Action

PROGRAM MENU
1 CALIBRATION 5(%
2 PARAMETERS
3 ALARMS
4 RESET TOTALIZER
5 SERVICE/RTC/SP
BACK

PURGE

No Action

UP

To select particular parameter in upward direction

CALIBRATION BLR<n>
CALIB VALUE
<vvvv> ppm
1.0

PURGE

Menu
Level

LCD Screen Contents

L1

L2

L3

<n>::boiler number
<v>::actual value

CALIBRATION BLR<n>
DONE/BACK
1.1

DN
ENT

To select particular parameter in downward

direction
To enter selected Menu option
Change between Boiler no.s and Feed water for
sensor calibration OR move to the next digit of
CALIB VALUE for changing its value

UP

Boiler selection or CALIB VALUE /

Increment the selected digit

DN

Boiler selection or CALIB VALUE /

Decrement the selected digit

ENT

Save parameter value

PURGE

Toggle between DONE & BACK.

UP

No Action

DN

No Action

ENT

Done is selected & ENT key pressed Compute

the K Factor, check if within range, save if valid,
displays the calculated K factor / Go to PROGRAM
MENU screen

20

L1

L2

PROGRAM MENU
1 CALIBRATION
2 PARAMETERS
3 ALARMS
4 RESET TOTALIZER
5 SERVICE/RTC/SP
BACK

Screen2
L2

Screen3

L1

L2

No Action

UP

To select particular parameter in upward direction

DN

To select particular parameter in downward

direction

ENT
PURGE

To enter selected Menu option

Select the option / boiler No./ next digit of start Hr &
Min

UP

Previous Parameter or increment the particular

digit.

DN

Next parameter or decrement the particular digit.

ENT

1) Particular option or Hr & Min gets set for that

parameter.
2) After selecting the Boiler No. 1, 2 or 3. Press
ENT key for entering the boiler parameters.

BOILER DATA BLR<n>:

PURGE

Go to the next digit of arrow-indicated number.

PURGE AFTER:<vvvv> m
DURATION
:<vv> S

UP

Previous Parameter / Increment the Particular

Digit.

BLD AFTER
DURATION

DN

Next Parameter / Decrement the particular Digit.

ENT

Entered value gets set for that selected parameter /

go to the next screen of the boiler data
Select the Line Size & Input sensor type / moves to
the next digit for changing the number

PARAMETERS
STRT TIME H:<vv> M:<vv>
ENABLE BLR 1:Y/N
ENABLE BLR 2:Y/N
ENABLE BLR 3:Y/N
UNITS
:MKS/SI
DATA FOR BLR:1/2/3
2.0

Screen1
L2

PURGE

BACK

2.1

:<vv> S
:<vv> S
BACK

BOILER DATA BLR<n>:

PURGE

LINE
PR
CAP
INPUT

UP

Previous Parameter / Increment the Particular

Digit.

DN

Next Parameter / Decrement the particular Digit.

ENT

Entered value gets set for that selected parameter

PURGE

No Action

UP

To select particular parameter in upward direction

2.2

:
:
:
:

0.5/1
<vv.v> kg/cm2
<vvvvv> kg/h
CP10/CP32
BACK

PROGRAM MENU
1 CALIBRATION
2 PARAMETERS
3 ALARMS
4 RESET TOTALIZER
5 SERVICE/RTC/SP
BACK
ALARMS

DN

To select particular parameter in downward

direction

ENT
PURGE

To enter selected Menu option

Select the boiler No. / Move to the next digit of
arrow-indicated number.

BLR
:1/2/3
BLR TDS HIGH:<vvvv>

UP

Previous parameter / Increment the Digit.

21

BLR TDS LOW :<vvvv>

FW TDS HIGH :<vvvv>
% BLD HIGH :<vvvv>
3.0
BACK

L1

L2

ENT

Entered value gets set for that selected parameter

of the boiler.

PURGE

No Action

UP

To select particular parameter in upward direction

DN

To select particular parameter in downward

direction

ENT
PURGE

To enter selected Menu option

Select the Boiler No.

BOILER 1/2/3

UP

Toggle between Boiler selection & BACK.

DN

Toggles between Boiler selection & BACK

ENT

Reset respective totalizer values.

PURGE

To select the options from PROGRAM MENU

point 5
To select particular parameter in upward direction

BACK

PROGRAM MENU
1 CALIBRATION
2 PARAMETERS
3 ALARMS
4 RESET TOTALIZER
5 SERVICE/RTC/SP
BACK

L2

SERVICE
ENTER PASSWORD
****

L1

PROGRAM MENU
1 CALIBRATION
2 PARAMETERS
3 ALARMS
4 RESET TOTALIZER
5 SERVICE/RTC/SP
BACK

L2

Next Parameter / Decrement the Digit.

PROGRAM MENU
1 CALIBRATION
2 PARAMETERS
3 ALARMS
4 RESET TOTALIZER
5 SERVICE/RTC/SP
BACK
TOTALIZER RESET

4.0

L1

DN

SET
SET
SET
SET

HRS
MIN
SEC
DAY

:<vv>
:<vv>
:<vv>
:<vv>

UP
DN

To select particular parameter in downward

direction

ENT

After selecting particular menu option it will enter in

to the selected option.
(Entering the valid password will take you through
the Service Menu. Invalid password will be
ignored.)
Service menu is password protected and can be
accessed only by FM Service Engineer

PURGE

To select the options from PROGRAM MENU

point 5

UP

To select particular parameter in upward direction

DN

To select particular parameter in downward

direction

ENT
PURGE

After selecting particular menu option it will enter in

to the selected option.
Moves to the next Digit of the selected parameter

UP

Previous parameter / Increment the Digit value

22

L1

L2

SET DATE :<vv>

SET MONTH:<vv>
SET YEAR :<vvvv>
BACK

DN

Next parameter / Decrement the Digit Value

ENT

Stores the selected Parameter value

PROGRAM MENU
1 CALIBRATION
2 PARAMETERS
3 ALARMS
4 RESET TOTALIZER
5 SERVICE/RTC/SP

PURGE

To select the options from PROGRAM MENU

point 5
To select particular parameter in upward direction

BACK
SET POINT BLR<n>

UP
DN

ENT

To select particular parameter in downward

direction
After selecting particular menu option it will enter in
to the selected option.

PURGE

Select Boiler no. / move to the next digit of Boiler

TDS value

UP

Select Boiler selection or Boiler TDS value /

Increment the Digit of Boiler TDS value

DN

Select Boiler selection or Boiler TDS value /

Decrement the Digit of Boiler TDS value

ENT

Store the set point for selected boiler

BLR TDS: <vvvv> ppm

BACK

2.4.7. Commissioning
Ensure that the Mains, Input and Output connections to ABCO plus
Controller are done as per the wiring diagram. Ensure that proper Earth
connection is provided to the ABCO plus Controller.
The ABCO plus Controller is despatched with the following factory-set
values. The settable Min & Max values of the programmable parameters are
also mentioned. User-specific changes can be done via the Program mode.

23

Table of programmable ranges and factory-set values:

Sr. Parameter Name
No
1
Cell constant for Boiler
Blowdown conductivity sensor
2
Cell constant for Feed water
conductivity sensor
3
Blow Down TDS Set Point
4
Blow Down Total
5
Heat Total
6
7

Calibration Value
Purge After (tPA)

0 ppm
1 minute

8
9
10
11
12

Purge Duration (tPD)

Blow Down After (tBA)
Blow Down Duration (tBD)
Line Size (options: 0.5, 1)
Pressure

5 seconds
5 seconds
5 seconds
0.5 inch
2 kg/cm2

13
14
15
16
17

Capacity
Boiler TDS High Limit
Boiler TDS Low Limit
Feed water TDS High Limit
% Blow Down High Limit

0 kg /h
0 ppm
0 ppm
0 ppm
0

24

Min Value

Max Value

K = 0.2

K = 0.8

Factory-set
Value
K = 0.5

K = 0.08

K = 0.12

K = 0.1

0 ppm
0 kg
0 kJ/KCal

9999 ppm
9999999 kg
9999999
kJ/KCal
9999 ppm
1440
minute
60 seconds
60 seconds
60 seconds
1.0 inch
32 kg /
cm2
99999 kg/h
9999 ppm
9999 ppm
1000 ppm
100

3500 ppm
3500 ppm
30 minute
30 seconds
60 seconds
30 seconds
0.5 inches
9 kg / cm2
2000 kg/h
4000 ppm
3000 ppm
200 ppm
3

Please refer DOS and Donts section 2.4.9. For commissioning of the
Controller please follow the steps as given below after switching on the
ABCO plus Controller.
Normally, you will need to set the following parameters specific to the
installation. For the setting procedure please refer to the section 3. Please
set 1. The TDS set point as per the value specified by the boiler
manufacturer, per boiler.
2. The other parameters
i. Start time of the first shift for the daily basis calculation of
the heat loss and % blow down
ii. Boiler Enable / Disable option
iii. MKS / SI units option
iv. Purge After and Purge Duration
v. Blow Down After and Blow Down Duration
vi. Line size of the bottom blow down skid
vii. Pressure: Normal operating pressure of the boiler
viii. Capacity: Normal operating capacity of the boiler
ix. Input: Type of the sensor
3. The Alarms for each boiler
i. Boiler TDS High
ii. Boiler TDS Low
iii. Feed water TDS High
iv. % Blow Down High
All the modified values will be saved in the non-volatile memory and will remain
unchanged until re-programmed.
2.4.8. Maintenance
It is necessary to clean the CP10 sensor at regular intervals depending on
the installation.
2.4.9. Dos and Donts
Dos

Ensure that the wiring of the system is correct.

Ensure that the wiring is protected from any damage.

25

Ensure that the Controller is mounted at a visible distance, away from

electrical rotating and welding equipments and where the ambient
temperature is below 55 deg C.
Check that all the parameter settings are done correctly.
Switch off the mains power before checking or replacing the fuse.
Sensors are installed properly.

Donts

Do not try to repair the electronics on your own, contact your nearest
Spirax Marshall Service Centre for help.

Do not connect or disconnect any of the wires while the Controller is
in a powered up state.

Do not change any of the set parameters or perform calibration
without help of trained professionals or authorized personnel.
2.4.10. Fault finding
1. Controller does not Power On: Check power supply connection and
cable. Use a multimeter to check 230VAC at L-N-E terminals of the
Controller as mentioned in the wiring diagram.
2. Display shows fluctuating/unstable reading: check proper Earth to the
Controller. Check that the voltage across Neutral & Earth is within 8 VAC.
3. Temperature value not displayed / appears incorrect: check the
temperature sensor connections.
4. TDS value not displayed / appears incorrect: check the conductivity
sensor & temperature sensor connections.
5. Blowdown Valve Solenoid not operating: check the connections and
mains supply to the solenoid.
6. In case the RESET RTC message appears on the LCD display in scrolled
mode, please refer Section 3.2.2 for action to be taken.

26

3. Detailed Keyboard Operation

3.1. PARAMETERS: Various parameters related to the boiler are entered in this menu.
A description follows.
3.1.1. START TIME: The start time of the first shift of the days operations is required
to be entered. This will be used for the calculation of the Heat Loss Total
and the % Blowdown on a daily basis. The time is in terms of Hours and
Minutes. Use PURGE, UP and DN keys for changing the start time. The
procedure for changing the start time is as follows:
1 Go to the PARAMETER menu in the PROGRAM MENU screen.
2 Press ENT key to enter the PARAMETER menu.
3 Select STRT TIME using the UP or DN keys.
4 Press PURGE key for editing the Hour time. Set the time by using UP, DN &
PURGE keys.
5 Press ENT key which saves the entered Hour time.
6 Press PURGE key for editing the Minute time. Set the time by using UP, DN
& PURGE keys.
7 Press ENT key which saves the entered Minute time.
After entering the correct START TIME press ENT key. The 24hrs calculation will
start immediately. The Heat Loss Total and % Blowdown will be calculated at
the end of every 24 hrs period after the START TIME. This value will be
retained until the end of the next 24 hrs period and then refreshed.
3.1.2. ENABLE BLR 1 / BLR 2 / BLR 3: This option can be used for enabling or
disabling the measurement and TDS control of a particular boiler. If the user
selects Y and presses the ENT key the corresponding boiler is enabled. If
the user selects N and presses the ENT key the corresponding boiler is
disabled. Depending on this selection the LCD screens for the respective
boiler are displayed in RUN mode. Also depending on this selection
particular boiler related settings will be enabled or disabled.
3.1.3. UNITS: This option is used to select between MKS or SI units. The MKS/SI
parameter details follow.
Sr. No.

Parameter

SI Unit

MKS Unit

Energy

Kg

KCal

Temperature

Flow rate

Kg/h

Kg/h

Total

Kg

Kg

27

3.1.4. DATA FOR BOILER 1/2/3: Individual boiler parameters are entered in this
mode. Select boiler 1/2/3 by using PURGE key. Press ENT key to enter
parameter setting mode for the corresponding boiler. Following are the
parameters that can be set.
3.1.4.1.
PURGE AFTER: PURGE AFTER is the time between two purge cycles.
This can be considered as the Purge Frequency. The settable range is 1
min to 1440 min.
3.1.4.2.
DURATION (Purge): This time is the time duration for which the purge
cycle is active. The settable range is 5 sec to 60 sec.
3.1.4.3.
BLD AFTER: Repetitive Blowdown cycles will occur until the boiler
TDS value is above the SET POINT. This time is the time between two
successive Blowdown cycles. The settable range is 5 sec to 60 sec.
3.1.4.4.
DURATION (Blowdown): This time is the time duration for which the
Blowdown cycle is active. The settable range is 5 sec to 60 sec.
LINE: This is used for the selection of boiler Blowdown line size. The
3.1.4.5.
selection is either 0.5 or 1.
3.1.4.6.
PR: The user has to enter the maximum pressure value at which the
boiler runs normally and not the maximum operating pressure of the
boiler. The settable range is 2 kg/cm2 to 32 kg/cm2.
3.1.4.7.
CAP: This is the capacity of the boiler at which the boiler operates
normally but NOT the maximum capacity. The user has to enter the
capacity value in kg/h. The settable range is 0 kg/h to 99999 kg/h.
3.1.4.8.
INPUT: The user has to select the sensor type for the Boiler from
which the input is taken. There are two types of the sensors - CP10 and
CP32.
3.2. ALARMS:
3.2.1. To meet the safety and efficiency requirements of the boiler we have to
apply certain limits for Boiler TDS, feed water TDS and % Blowdown. These
limits are set through the ALARMS menu. The user has to specify the Boiler
TDS high level, Boiler TDS Low Level, FW TDS High Level & % Blowdown High
Level. All these alarm values are programmable. Blowdown TDS HIGH and
LOW limits are programmable from 0 to 9999. FW TDS HIGH limit is
programmable from 0 to 1000. % Blowdown high limit is programmable from
0 to 100. All these parameters are to be set individually for each boiler. If the
measured value crosses the programmed ALARM value then the respective
alarm message for the particular boiler is displayed on the LCD display in
scrolling mode. Once the value comes within the alarm limit the message
will disappear.

28

3.2.2. A status message RESET RTC is displayed on the LCD display in scrolling
mode, alongwith other alarm messages under the following two conditions

3.2.2.1.
There is an internal RTC mismatch. The User must reprogram the RTC
values as explained under Section 3.4.2 RTC. Once reprogramed, the
RTC status message will disappear.
3.2.2.2.
The internal Battery voltage has dropped below operational level.
Please call FM Service Engineer.
3.3. RESET TOTALIZER: This function is used for resetting the Blowdown Totalizer, Heat
Totalizer, Number of Purge Cycles and % Blowdown of the selected boiler. Use
the PURGE key to select the boiler. Once selected, press the ENT key for resetting
the corresponding boiler data. After completion of the reset process RESET
COMPLETE message is displayed on LCD display.
3.4. SERVICE/RTC/SP: This has 3 options 3.4.1. SERVICE: Service menu is password protected and can be accessed only
by FM Service Engineer.
3.4.2. RTC (REAL TIME CLOCK): This parameter is used to set the RTC related
parameters. When the Controller is switched on for the first time the user has
to set the RTC. Later, the user can set the RTC parameters whenever
required. For setting the RTC please follow these steps.
1 Select SERVICE/RTC/SP option from the main programming
parameters menu & press ENT key.
2 Select RTC by PURGE key and press the ENT key. RTC parameter
screen will be displayed on the display.
3 Select the parameter by UP or DN key and press ENT key for
changing the particular parameter.
4 After pressing the ENT key use PURGE or Up or DN key to set the
value for that parameter.
5 After setting the value press ENT key, the entered value will get set
for that parameter.
6 Set Hours, Minutes, Seconds, Day, Date, and Month & Year by
following the above procedure.
3.4.3

SP (TDS SET POINT): It is recommended that the TDS value specified by the
boiler manufacturer is set from Boiler Efficiency perspective. The Blowdown
action takes place based on this set value. The procedure for boiler set
point is as follows:
1 Select SERVICE/RTC/SP option from the main programming
parameter menu.
2 Select SP option by using PURGE key and press ENT key. Set point
screen will be displayed on the display.
29

3
4
5
6

First check for arrow which should be at boiler selection option. If

not then use UP or DN key for boiler selection option.
Press PURGE key for selection of the boiler and press ENT key.
Press DN key to select TDS set point mode.
Press PURGE key for editing the TDS value. Set the TDS value by
using PURGE, UP & DN key. After setting the correct value press
ENT key. The entered TDS value will get saved as the set point for
the selected channel.
Repeat steps 3 to 6 for other channels.

3.5 Determining K factor: of blowdown & feed water conductivity sensors

This mode is used to calibrate the conductivity sensors and determine their K
factor. This is done by using a solution whose TDS value is known. The procedure is
as follows.
1 Firstly ensure that the temperature circuit calibration of the corresponding
channel is done & the Controller is displaying the correct temperature
reading as per the input connected. Likewise ensure that the conductivity
circuit calibration of the corresponding channel is done.
2 Select the CALIBRATION option from the PROGRAM MENU and press ENT
key. The Controller will go into sensor calibration mode and the calibration
screen will be displayed on the LCD display.
3 When the Controller enters the calibration mode the current TDS value of
the respective channel is displayed on the display as CALIB VALUE in terms
of ppm.
4 Select the channel number whose sensor needs to be calibrated, by using
the PURGE key when the cursor is at the channel selection
(BLR1/BLR2/BLR3/FW).
5 After selecting the channel, press the ENT key for further processing of the
calibration of the selected channel.
6 Ensure that the sensor is connected to the appropriate channel and
properly dipped into the solution whose TDS value is known.
7 Enter the known TDS value of the solution at the ppm line by using
PURGE, UP and DN keys. Press ENT key after entering the exact TDS value.
8 The Controller will go to DONE/BACK screen. Select DONE /BACK by using
PURGE key & press ENT key. If user selects BACK and presses the ENT key
the Controller will go back to the Calibration Screen, but if user selects
DONE and presses ENT key then the entered TDS value will be considered
for the calculation of K factor.
9 The Controller will compute the K factor depending on the entered TDS
value by using the following formula:
K = TDS * R * (1 + 0.02(T 25))
----------------------------

30

(10)6 * 0.5

10 If the computed K factor is within the limit (0.2 to 0.8 for Boiler Blowdown &
0.08 to 0.12 for Feed water) then CALIBRATION VALID message will be
displayed on the display else CALIBRATION INVALID message will be
displayed. In both the cases the calculated K factor is displayed on the
display. If calibration is valid then new calibrated value will be saved into
the non-volatile memory and considered for further processing. If the
calibration is invalid the last calibrated value will be considered for the
further processing. If the user is doing the calibration for the first time,
default K values of 0.5 for Boiler Blowdown and 0.1 for feed water are
considered for the calculations respectively.
11 If calibration is valid, please mark the channel details clearly on the
respective Sensor. Mentioning the channel name on the sensor in
mandatory.
12 Repeat the steps 1 to 11 for all channels (BLR1, BLR2, BLR3, and FW) as
necessary.

31

4 Spares
We recommend you the following spares for uninterrupted performance.
1) CPU PCB assembly
2) SMPS PCB assembly
3) Terminal PCB assembly
4) Fuse 500 mA Slow Blow 20mm glass cartridge for F1 on Terminal PCB
5) Fuse 1 A Slow Blow 20mm glass cartridge for Blowdown and BHRS
solenoid
6) Feed water Sensor
7) CP10 Sensor
8) PT100 Sensor

32

5 Service
5.1 Field service
In most of the cases, the problems can be identified by following the
instructions in the troubleshooting section. If ABCO plus Controller is still
not functioning to your complete satisfaction please contact your
nearest FM representative.
ABCO plus system is sold with 1 year warranty period for manufacturing
defects or malfunctions. During this period all the spares will be
replaced free of charge. In cases where damage has been caused
due to improper use of the product, Spirax Marshall can not be
responsible for the replacement.
Please ensure that the records of all service calls are maintained by
our service personnel in the Field Service Record section of this
manual.
5.2 Field service record
This record must be updated by the FM Service Engineer for all instances
of the field service problems and actions taken.
Date

Reported problem

Action taken

33

FM Engineer

34

Field service record (continued)

Date

Reported problem

Action taken

35

FM Engineer