Filter Control System

Installation and Operation Manual

Software Version 3.xx
P/N DOC-00136 | Rev D Printed 18 July 2017

Note: This manual is relevant only to the Jazz 20 controller and above.
This manual supports all zones (Safe and Ex) and all filters from single to 4 screen units.
 Copyright © 2015-2017 Filtersafe®, All rights reserved.
The data contained in this document is proprietary to Filtersafe®. It is disclosed to the receiving party only for
the sole purpose stated herein, and shall not be disclosed by the receiving party to any third party, and shall
not be duplicated, used or disclosed in whole or in part for any purpose other than the purpose specifically
stated.
This publication, or any parts thereof, may not be reproduced in any form without the express written
permission of Filtersafe®.
NOTE
All specifications in this manual are subject to change without notice.

P ublished by Filtersafe ®

M arch 2017

Contact Filtersafe®
To communicate with a Filtersafe® representative, use the following contact information:

Israel
Address: HaElla Street, P.O.B 23, Tefen Ind. Zone 2495900
Phone: +972-4-9873620/1
Fax: +972-4-9873617
Email: [email protected]
Web www.filtersafe.net

Germany
Address: Papenreye 55, Unit 11, 22453 Hamburg
Phone: +49-(0)151 5111 9622
Email: [email protected]

Singapore
Address: 56 Toh Tuck Road, #07-02 Signature Park, Singapore 596746
Phone: +65-8321-3739
Email: [email protected]

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 Authorization

Signature
Revision 02 Approval Name Date approved
Mark X

(HC only)

X System Engineer 01.12.2014

X Project Manager 01.12.2014
X QA Manager 01.12.2014

Revision History
Rev. Description of Revisions Changed by: Date/Sign

A Initial Release 01.12.2014

B Changing Modbus numbers, adding analog inputs 15.5.2015
Added new messages, Ver 3.3 info to the Alarm Event table, 26.7.2016
C
Messages and Indicators Logic annex, and Setup Values Form.
D Adding Jazz 20 battery replacement 20.03.2017

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 Table of Contents
1. Preface ..............................................................................................1-6
2. Safety ................................................................................................2-7
2.1 Cautions ....................................................................................................................... 2-7
2.2 General Safety Cautions .............................................................................................. 2-7
3. Introduction ......................................................................................3-8
3.1 System Overview ........................................................................................................ 3-8
3.2 System Purpose ........................................................................................................... 3-8
4. Operating Principles..........................................................................4-9
4.1 Filter Functions.......................................................................................................... 4-10
4.2 Active Components of the Filter ............................................................................... 4-11
4.3 Scanner Movement .................................................................................................... 4-13
4.4 Flushing Cycle ........................................................................................................... 4-13
4.5 Conditions that Initiate an Auto Flushing Cycle ....................................................... 4-14
4.6 Flushing Cycle Options ............................................................................................. 4-14
4.7 Manual Flushing ........................................................................................................ 4-15
4.8 Remote Flushing........................................................................................................ 4-16
5. Control Cabinet Overview .............................................................. 5-17
5.1 Control Panel ............................................................................................................. 5-18
5.2 Controller................................................................................................................... 5-19
5.3 Control Cabinet – Inside View .................................................................................. 5-20
6. Installation ..................................................................................... 6-21
6.1 Mounting ................................................................................................................... 6-21
6.2 Wiring ........................................................................................................................ 6-21
7. Setup .............................................................................................. 7-22
7.1 Introduction ............................................................................................................... 7-23
7.2 Displaying the Setup Menu ....................................................................................... 7-23
7.3 Flushing Parameters .................................................................................................. 7-24
7.4 Optional Flushing Pump Parameters ......................................................................... 7-26
7.5 IP Parameters ............................................................................................................. 7-27
7.6 Controller Name ........................................................................................................ 7-28
7.7 Pressure Transmitter Settings .................................................................................... 7-28
7.8 Analog DPT Settings ................................................................................................. 7-29
7.9 Minimum Flushing Time........................................................................................... 7-30
7.10 Exiting the Setup Menu ............................................................................................. 7-30
8. Service and Testing ........................................................................ 8-31
8.1 Displaying the Service Menu .................................................................................... 8-31
8.2 Returning to the Main Screen .................................................................................... 8-31
8.3 Service Menu Screens ............................................................................................... 8-32
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 8.4 Testing the Scanner Limit Sensors and Motors......................................................... 8-33
8.5 Testing the Pump ....................................................................................................... 8-36
8.6 Testing the Flushing Valve........................................................................................ 8-37
8.7 Testing the MPI Devices ........................................................................................... 8-37
9. Operation ....................................................................................... 9-38
9.1 Power Up ................................................................................................................... 9-39
9.2 Controller Operating Screens .................................................................................... 9-39
9.3 Messages and Indicators ............................................................................................ 9-40
10. Technical Specifications ............................................................... 10-45
10.1 Power Supply .......................................................................................................... 10-45
10.2 Control Panel Components ...................................................................................... 10-45
11. Annex A: Controller Inputs and Outputs ..................................... 11-46
11.1 Inputs ....................................................................................................................... 11-46
11.2 Outputs .................................................................................................................... 11-48
12. Annex B: Modbus Specifications .................................................. 12-49
12.1 Modbus Word Registers .......................................................................................... 12-49
12.2 Word Register Bit Map ........................................................................................... 12-52
13. Annex C: PLC Program Upgrade .................................................. 13-53
14. Annex D: Interface Logic ............................................................. 14-54
14.1 Pump Interface Logic .............................................................................................. 14-54
14.2 Filter Interface Logic ............................................................................................... 14-55
15. Annex: E: Setup Values Form ....................................................... 15-56
16. JAZZ 20 BATTERY REPLACEMENT ................................................ 16-57
17. User Notes .................................................................................... 17-60

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1. Preface
Manual Purpose
The Filter Control System Installation and Operation Manual is designed for the use of authorized operators
and technicians of the Filter Control System. This manual reviews the most common procedures required
during the operation and maintenance of the Filter Control System.
This manual is associated with Safe Zone, Ex d and Ex ia model filters. The Filter Control System is used to
control single filters and multi-filter systems. The images and illustrations are for demonstration only and may
not reflect the exact hardware included in your filter model.

Controller Model and Software Version

This manual is associated with the Unitronics© JazzTM 20 PLC controller with application version M5-1-00 or,
M5-XX-XX-V3.X.

Applicable Documents
 BS025-BS200 Operation Manual (P/N 00144)
 BS300/BS400 Automatic Screen Filter Operation Manual (P/N DOC- 00142)
 Compact Model Operation Manual (P/N DOC- 00157)
 Multi-Screen Filter Operation Manual (P/N DOC- 00141)
 Safe Zone Data Sheets (P/N DOC 00159)
 Ex d Model Operation Manual Appendix (P/N DOC- 00155)
 Ex ia-1 Appendix (P/N DOC-0000309)
 Ex ia-0 Appendix (P/N DOC-0000310)
Note:
Filtersafe® takes extreme care in packaging the equipment to protect it against damage during shipment.
Upon receipt, inspect all shipment contents and in case of damage, contact Filtersafe® immediately.

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2. Safety
This chapter contains an overview of the Filter Control System safety concerns and includes:
 Section 2.1: Cautions
 Section 2.2: General Safety Cautions

2.1 Cautions

CAUTION
CAUTION: Filters may flush automatically, without prior warning.

The following instructions and guidelines are necessary to ensure safe operation and long filter life.
Before performing any work on the filter, become familiar with the following safety sections:

2.2 General Safety Cautions

 Read the installation and the operation instructions prior to installation or before servicing the
filter.
 Before working on the filter, read all safety standards and instructions to avoid injury to the
operator or damage to equipment or property.
 The electrical connections must be connected or serviced by a qualified electrician, using certified
components only, and according to local regulations and standards.
 A main safety power cut-off switch must be installed near the control cabinet.
 Install a main power cut-off switch near the filter if the control cabinet is not visible from the filter.
 The control cabinet and other electrical devices must be installed so that they are not accidentally
exposed to water.
 If the filter is used in hot water applications (i.e. water temperatures up to 55⁰C), additional safety
devices must be installed to avoid injuries.

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3. Introduction
This manual describes installation and operation of the Filter Control System for Filtersafe automatic single
screen and multi-screen filters.

3.1 System Overview

The system includes:
 Control cabinet – controls the filter operation.
 Flushing pump – controls the operation of the optional flushing pump (see Section 4.2.5:
Optional Flushing Pump).
 Customer control system – main control communicates with the filter control via dedicated
inputs and outputs.
 SCADA – enables remote monitoring of the controller. Connected to the controller via Ethernet
communication (MODBUS TCP). The SCADA system is used by authorized service personnel only.
SCADA requires (optional) Ethernet adaptor to communicate with the filter control.
Figure 3-1: Filter Control System

3.2 System Purpose

The purpose of the Filter Control System is to:
 Control the filter operation
 Enable testing of the filter
 Signal alerts
 Communicate with the customer control system
 Provide communication with a SCADA control system

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4. Operating Principles
This chapter describes operating principles of the filter and control system and includes the following:
 Section 4.1: Filter Functions
 Section 4.2: Active Components of the Filter
 Section 4.3: Scanner Movement
 Section 4.4: Flushing Cycle
 Section 4.5: Conditions that Initiate an Auto Flushing Cycle
 Section 4.6: Flushing Cycle Options
 Section 4.7: Manual Flushing
 Section 4.8: Remote Flushing

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4.1 Filter Functions
The Filtersafe Automatic Screen Filter performs two primary functions:
 Filtering – raw water flows into the filter and comes out clean
 Flushing – the filter screens are cleaned
4.1.1 Filtering
During filtering:
 Raw water flows through the filter inlet pipe and through the filter screen.
 Solids and dirt particles are caught by the screen.
 Clean water exits the system through the filter exit pipe.
4.1.2 Flushing
During flushing:
 The Flushing Valve is open.
 The Flushing Pump is operating.
 The Scanner motor is operating.
 The screen is cleaned.
 Dirt is flushed from the system.

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4.2 Active Components of the Filter
Note: Components vary according to application.

4.2.1 Scanner
 The scanner is a set of nozzles rotated by a Drive Unit that cleans the filter screen during
Flushing.
 The scanner moves in a helical motion causing the nozzles to run back and forth across the
screen.
 See section 4.3: Scanner Movement.
4.2.2 Drive Unit
 The drive unit powers the Scanner operation.
 The different filter models have different types of drive units (motor + Gear):
• Safe zone – standard electric motor
• Ex d – Ex d electric motor
• EX ia – air operation motor
4.2.3 Limit Sensor
 A Scanner includes two limit sensors that control the Scanner Movement (see section 4.3).
 The limit sensors are normally closed (NC).
 The different filter models have different types of limit sensors:
• Safe zone – mechanical limit switches or proximity sensors
• Ex models – mechanical limit switches or proximity sensors
4.2.4 Flushing Valve
 The flushing valve is a normally closed valve and is opened during Flushing.
 The open valve creates a pressure differential between the filter inlet and the atmospheric
pressure at the flushing outlet. This differential creates suction at the scanner nozzles.
4.2.5 Optional Flushing Pump
 The flushing pump is connected to the flushing pipe.
 The flushing pump helps relieve water pressure head in the downstream flow.
 The flushing pump increases the suction pressure at the scanner nozzles.
 The flushing pump is powered and controlled from the Filtersafe control cabinet or the customer
control system.
4.2.6 Optional Flow Switch
 The optional flow switch indicates the water flow at the flushing water outlet.
 The flow switch sends a signal to the control cabinet.
 The flow switch provides pump protection in case of a valve fault.

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 4.2.7 DPT
The DPT (Differential Pressure Trigger) indicates the differential pressure between the filter upstream
(incoming) water and the downstream(outgoing) water. Dirt buildup on the screen changes the pressure
differential between the upstream raw water pressure and the downstream clean water pressure.
The filter includes one of the following DPT options:
 Differential Pressure Switch – default option
 Analog Differential Pressure Transmitter – provides an analog signal
 Analog Pressure Transmitters – includes two analog transmitters: one for upstream and one
for downstream
4.2.8 Optional Alert Switches
The following optional switches can be connected to the Controller:
 Differential Pressure Switch with Alarms –high DP outputs
 Pressure Switch – located in the upstream; alarm options:
• High upstream pressure
• Low upstream pressure (alert on low flushing pressure)
• Contact Filtersafe for additional options

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4.3 Scanner Movement
Scanner movement proceeds as follows (see Figure 4-1):
1. The Drive Unit starts, causing the Scanner to rotate in a spiral movement.
2. When the Scanner reaches the end of its travel, a disk on the Scanner shaft activates the Limit Sensor.
3. The motor changes direction, causing the Scanner to rotate in the opposite direction.
4. When the Flushing Cycle signal ends, the Scanner moves to the next Limit Sensor and stops.
5. After Remote Flushing the Scanner continues until it reaches the HOME position and then stops.
Note: The description is relevant to automatic mode flushing. In manual flushing (see section 4.7: Manual
Flushing), the Scanner stops moving as soon as the flushing is turned off, even if it did not reach a Limit
Sensor.
Figure 4-1: Scanner M ovem ent

4.4 Flushing Cycle

A Flushing Cycle refers to the period of time in which the system operates in Flushing. The following is the
workflow for a full Flushing Cycle from initiation to stopping:
1. A Flushing Cycle initiation condition occurs (see section 4.5: Conditions that Initiate an Auto Flushing Cycle).
2. The Flushing Valve opens.
3. The Flushing Pump starts.
4. The Scanner motor starts rotating and moving.
5. The trigger for stopping the Flushing Cycle is activated.
6. The Scanner reaches the nearest Limit Sensor.
7. The Scanner motor and the Flushing Pump stop.
8. The Flushing Valve closes.

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4.5 Conditions that Initiate an Auto Flushing Cycle
To configure Flushing Cycle settings, see chapter 7: Setup.
This section describes conditions that initiate an auto Flushing Cycle in filter automatic mode:
4.5.1 DPT Signal
The DPT (see section 4.2.7) indicates pressure
differential that requires a Flushing Cycle. The
Flushing Cycle starts after a predefined delay time.
The Flushing Cycle ends after meeting all of the
following conditions:
 DPT is off
 DPT Off delay timer exceeds its set point
 Minimum flushing time exceeds its set point
 Scanner reaches its stop position.

Note: There is a three second delay between reaching the pressure differential set point and initiation of the
Flushing Cycle.

4.5.2 Timer Operation

At the end of a Flushing Cycle, the timer starts
counting. When the preset time ends, the next
Flushing Cycle starts. This ensures a minimum time
lapse between Flushing Cycles.
The timer resets after any type of Flushing Cycle.

Note: When the system is at rest, timer operation is disabled until one DPT initiated Flushing Cycle occurs.
When performing Remote Flushing (see section 4.8) the timer goes into rest mode until one DPT initiated
Flushing Cycle occurs.

Note: It is recommended to set the timer to initiate a Flushing Cycle every 45 minutes.

4.6 Flushing Cycle Options

This section describes features that affect Flushing Cycle operation.
4.6.1 Minimum Flushing Time
Minimum Flushing Time maintains the Flushing
Cycle for a preset amount of time regardless of the
DPT . This is to prevent the Flushing Pump motor
from being rapidly turned on and off.
This feature is useful if the pump motor has a limit
on number of activations per hour.
To define the Minimum Flushing Time, see
section 7.9: Minimum Flushing Time.

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 4.6.2 DPS Off Delay
When the DPT turns off, the DPS Off Delay
extends the Flushing Cycle for a preset amount of
time. This is to prevent rapid flushes in very dirty
water. It is recommend to set this delay preset to
half of the scan cycle.
To define the DPS Off Delay time, see DPS Off
Delay screen pg. 7-25.

4.7 Manual Flushing

Manual flushing is initiated and stopped manually.
Manual flushing is used to:
 initiate cleaning.
 During filter testing or service.
To initiate manual flushing:
Turn the flushing switch on the Control Panel to Manual (see section 5.1: Control Panel).
The system enters Flushing (see section 4.1.2).
To stop manual flushing:
1. Turn the flushing switch on the Control Panel to Off or Auto.return the Scanner to the HOME position
place the flushing switch at Auto position and perform one of the following:

• Remote Flushing (see section 4.8).

• Press and hold the 4 button on the Controller.
Note: The Scanner must be returned to the HOM E position after each Manual Flushing.

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4.8 Remote Flushing
Remote flushing is initiated manually using the customer controller. After the controller signal is terminated,
flushing stops when the Scanner reaches the HOME position (see section 4.3: Scanner Movement).
During the remote flushing procedure:
 The flushing switch on the Control Panel must be in Auto position.
 A command signal is sent from the central control system.
 The Timer Operation enters rest mode (see section 4.5.2).
 The filter enters Flushing (see section 4.1.2) until the flushing trigger is off.
 The Scanner reaches the HOME position.
 Flushing Cycle stops.
Note: Remote flushing can be initiated by pressing and holding the 4 button on the Controller or directly
from the I/O in the control cabinet (see electrical diagrams).

Note: Remote flushing must be initiated after each filtration session and after each Manual Flushing.

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5. Control Cabinet Overview
This chapter describes the parts of the control cabinet and includes:
 Section 5.1: Control Panel
 Section 5.2: Controller
 Section 5.3: Control Cabinet – Inside View

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5.1 Control Panel
The control panel includes:
 Main power switch (1) – turns ON and OFF the filter power.
 Controller (4)– see section 5.2
 Power indicator (6) – lights up when the main power switch is ON and power is present in the
system.
 Alarm indicator (5) – indicates alarm events and includes the following states:
• Blinking – alarm (view alarm message on the Controller display screen).
• Constant – attention is required (view alarm message on the Controller display screen).
 Flushing control switch (3) – includes the following settings:
• AUTO – Flushing Cycle activation is controlled by the control system.
• MAN – flushing operates continuously (see section 4.7: Manual Flushing).
• 0 – automatic and manual functions are disabled and alarm is reset.
 Flushing indicator (2) – includes the following states:
• Constant – the system is ready (standby).
• Blinking – the system is in Flushing.
 Pump control switch (8) – controls the Flushing Pump; includes the following states:
• AUTO – pump activation is controlled by the system.
• MAN – pump is activated continuously.
• 0 – pump is OFF.
 Pump indicator (7) – indicates the flushing pump status and includes the following states:
• Constant – pump is ready (standby).
• Blinking – pump is operating.
Figure 5-1: Control P anel

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5.2 Controller
The controller is used to perform Setup (see chapter 7) and Service and Testing (see chapter 8)) and displays
System Information Screens (see section 9.2.2). The controller includes:
 Display screen (3) – displays the current system procedure and alarm messages.
 Navigation buttons (1) – used to scroll through the controller menus.
 Number pad (2) – used to enter numeric settings.
 Enter button (4) – used to advance the screens and enter values.
Figure 5-2: Controller

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5.3 Control Cabinet – Inside View
The control cabinet inside view includes:
 Terminal blocks (1)
 Contactors (2)
 Overload switches (3)
 Power supply (4)
 Fuses (5)
 Relays (6)
Figure 5-3: Control Cabinet – Inside View

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6. Installation
6.1 Mounting
 Install the control cabinet in a dry, secured area.
 Fasten the control cabinet to a strong stable wall or other stable installation site.

6.2 Wiring

CAUTION
CAUTION: The control cabinet must be connected by a certified electrician.

CAUTION
CAUTION: The installation must meet or exceed all electrical codes.

 Refer to electrical diagrams.

 Connect a three-phase power source.
 Ground the control cabinet.
 Use 4 x 1.5 mm wires in conduit to connect the filter motor to the control cabinet.

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7. Setup
This section describes the tasks associated with using the controller for setting up the filter operation
parameters and includes:
 Section 7.1: Introduction
 Section 7.2: Displaying the Setup Menu
 Section 7.3: Flushing Parameters
 Section 7.4: Optional Flushing Pump Parameters
 Section 7.5: IP Parameters
 Section 7.6: Controller Name
 Section 7.7: Pressure Transmitter Settings
 Section 7.8: Analog DPT Settings
 Section 7.9: Minimum Flushing Time
 Section 7.10: Exiting the Setup Menu

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7.1 Introduction
7.1.1 Instruction Tables
The following sections contain tables that illustrate how to use the controller menus:
 The first column contains a Description of the function of the relevant controller screen.
 The second column contains an image of the screen as it appears on the controller and
Instructions for using the controller buttons for the relevant screen.
7.1.2 Entering Numeric Values
To enter a numeric value for one of the controller menus:
2. Press the  _ button to enter edit mode.
3. Use the number pad to enter a value.
4. Press the button  _ to set the value.

7.2 Displaying the Setup Menu

To display the setup menus on the controller screen:

1. Verify that the Flushing switch and Pump

switch are set to 0/RESET.

2. Press and hold the  _ button (1) on the

controller.

3. Turn the main power switch (2) to ON

(while holding the  _ button).
The Set–Up Menu screen is displayed on the
controller screen.

4. Press the  _ button (3) on the controller.

The Navigation screen is displayed.
5. Press the  button (4) to go to the next
screen OR press the  button to go to the
previous screen.
Use the following tables to navigate through the
setup screens.

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7.3 Flushing Parameters
The following table shows cycle times for different filter models.

Cycle time (sec) Default cycle

Filter Models Gear
50Hz 60Hz Pneumatics time setup
BS025/050 1:50 ~34 ~28 - 110
BS031/070/061/100 1:60 ~41 ~34 - 110
BS101/150/151/200/201/603/804/1004/1204/1206/1406 1:80 ~54 ~45 ~60 60
1:120 ~81 ~68 - 110
BS300/400 1:140 ~95 ~79 ~90 110
1:150 ~102 ~85 - 110

Description Instructions
Number of Screens – define the amount of
screen units used in the filter.

Note: The number is selectable only in controller Enter a value from 1 – 4 to define the
application version M5-4A-00. In version M5-1-00 number of filter screens.
only 1 screen is available.
Operation Mode Selection – select how many
screen units operate at one time during Flushing.
In multi-screen filters, Scanners can operate
sequentially. Each Scanner operates until it 1 – 1 Group Flush: all scanners
reaches the Limit Sensor (see section 4.3: operate together
Scanner Movement), and then the next Scanner in 2 – 2 Group Flush: the filter is divided
the sequence operates. into 2 groups –
Default setting: Safe Zone - 1 Group Flush  In filters with 2 screens, one
Exd - 1 Group Flush screen unit operates at a time.
Ex ia - 2 Group Flush In filters with 4 screens, 2
screen units operate at a
Note: This mode is selectable only with a multi time: first scanners 1 and 2,
controller with application version M5-4A-00. In then scanners 3 and 4.
version M5-1-00 only 1 group is available. 3 – Sequential Flush: one screen unit
operates at a time
Cycle Time – define the time it takes the Scanner
to move from one Limit Sensor to another (see
section 4.3: Scanner Movement).
This setting is required to measure Limit Sensor  _ – press once to edit the value; use
error. An error is a greater than 20% delay of a the press again to set the value
stroke.
Default setting: according to the filter model (see
above table).

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 Description Instructions
MPI 0 (Multi-Purpose Input 0) Function
Several optional devices can be connected to the
controller input # 0 (on single filter system) or input
#2 (on multi filter). 0 – Not Used: Function not used.
This option defines what is connected to this input 1 – Flow Switch: Flow Switch output
and enables the function of the selected device. contact.
Default setting: Not Used (0). 2 – High PR Alarm: connected to the
For more details, refer to the electrical drawings. Pressure Switch.
3 – High DP Alarm: connected to the
Differential Pressure Switch with
Alarms.
4 – Low Inlet Pressure Alarm:
connected to the Pressure Switch.
Flow Error Delay – when the flow switch is
connected to I2, the function delays activation of
the flow error alarm.
See section 4.2.6: Optional Flow Switch.  _ – press once to enter a value; press
Default setting: 10 again to set the value
MPI 1 (Multi-Purpose Input 1) Function
Several optional devices can be connected to the
controller input # 1 (on single filter) or input #0 (on
multi filter). 0 – Function not used.
This option defines what is connected to this input 1 – Flushing DPS: DPT output.
and enables the function of the selected device.
2 – High DP Alarm: connected to the
Default setting: Flushing DPS (1).
Differential Pressure Switch with
For more details, refer to the electrical drawings.
Alarms.
3 – High PR Alarm: connected to the
Pressure Switch
DPS Off Delay – defines the time that delays the
DPS output when it switches Off.
See section 4.6.2: DPS Off Delay.
Default setting: 20.  _ – press once to enter a value; press
again to set the value
Timer Operation – when activated, a maximum
time between Flushing Cycles can be defined (see
section 4.5.2: Timer Operation and next control).
Default setting: Not Used (0). 0 – Timer Operation is not used
1 – Timer Operation is used
Timer Interval – defines the maximum allowed
time without screen flushing. The Flushing Cycle is
initiated automatically after the interval has
passed.  _ – press once to enter a value; press
See section 4.5.2: Timer Operation. again to set the value
Default setting: 45
Timer Cycle Interval – defines the number of
Scanner Movement cycles for each flushing
initiated by a Timer Interval.
Default setting: 1 Enter a value from 1 – 9 .

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7.4 Optional Flushing Pump Parameters
Description Instructions
Pump Enabling – defines if the Flushing Pump is
used in the system.
Default setting: Used (1).
0 – flushing pump is not used
1 – flushing pump is used
Pump Ready Signal – defines if the Controller
receives a Flushing Pump ready signal input and
activates an alarm if this input is not received.
Default setting: Enabled (1) 0 – pump ready signal is disabled
1 – pump ready signal is enabled
Pump Run Signal – defines if the Controller
receives a Flushing Pump run signal input and
activates an alarm this such input is not received.
Default setting: Enabled (1) 0 – signal disabled
1 – signal enabled

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7.5 IP Parameters
7.5.1 Setting IP Parameters
Define the IP settings by selecting the relevant segment and editing the numbers in the selected segment.
The X represents the segment to be edited.
Note:
Each IP segment value must be between 000 and 255.

To define an IP setting:

1. Press the  button to select the relevant

segment (a).

The X (b) changes position each time the  button

is pressed. The relevant segment number (c) is
displayed.

2. Press the  _ button to edit the segment.

The Set value (d) is active.

3. Use the controller number pad to define up

to four digits for the selected segment (e).
4. Press the  button to clear a digit.
5. Press the  to return to the last saved
segment (all four digits).
6. Press the  _ button to save the selected
segment.

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 7.5.2 IP Parameters
The following table describes the different IP parameters.

Description Instructions
Local IP – defines in four segments the controller
IP address. Each segment is defined on a different
screen.
Sub Net Mask – defines the IP mask in four
segments.
Each segment is defined on a different screen.
Gateway IP – defines in four segments the
network gateway address.
Each segment is defined on a different screen.
ModBus Loc Port – defines the Local ModBus
TCP communication port.
(See chapter 12: Annex B: Modbus
Specifications.)
Default setting: 502

7.6 Controller Name

Description Instructions
PLC Name – defines the controller name. Only the
last digit can be changed.
Default value: FLSAFE0
Default value ver 3.1 and above: FLSAFE Type a number from 0 – 9 for the last
digit of the name.

7.7 Pressure Transmitter Settings

The following settings associated with the Analog Pressure Transmitters.

Description Instructions
PT0/PT1 Zero Set – type the zero set value found
on the Analog Pressure Transmitters label at 4ma.
Default setting: 0
1. Define the value for PT0.
2. Advance to the next screen to
define the value for PT1.
PT0/PT1 Span Set – type the span set value
found on the Analog Pressure Transmitters label at
20ma.
Default setting: 0 1. Define the value for PT0.
2. Advance to the next screen to
define the value for PT1.

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7.8 Analog DPT Settings
The following settings are associated with the DPT and optional alert switches with analog output.
All values are in millibar.

Description Instructions
Upstream Low Pressure Set Point – defines the
set point for the upstream low pressure alarm.
Default setting: 1600
Upstream High Pressure Set Point – defines the
set point for the upstream high pressure alarm.
Default setting: 6000
Differential Pressure Flush – defines the DPT set
point for initiating flushing.
Default setting: 400
Differential Pressure Hysteresis – defines the
defines the set point for stopping the DPT flushing
signal.
Example: if the Differential Pressure Flush is set
to 400 mb and the Hysteresis is set to 150 mb,
the request for flush starts when DP reaches 550
mb and will remain until DP falls below 250 mb.
Default setting: 150
Alarm Set Point – defines the high alarm set point
for the Differential Pressure Switch with Alarms.
Default setting: 1000
Zero 4ma – set the reading for the zero level of the
analog inputs. This setting is performed when all
analog inputs are at zero level only.
Note: Do not perform this function if the readings Press 1 to zero analog readings.
are accurate.
Sel. AN. (Select Analog) – defines analog
sensors used in the system.
Default setting: No analog sensors (0)
Enter on of the following values:
0 – no analog sensors
1 – PT0: upstream, PT1: disabled
2 – PT0: upstream, PT1: downstream
3 – PT0 is disabled, PT1 is connected
to the Analog Differential Pressure
Transmitter
4 – PT0 is upstream, PT1 is connected
to the Analog Differential Pressure
Transmitter
5 (for version 3.1) – Current - the
Flushing Pump motor current.

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7.9 Minimum Flushing Time
Description Instructions
Minimum Flushing Time – the minimum amount
of time to sustain a Flushing Cycle regardless of
the DPT signal.
See section 4.6.1: Minimum Flushing Time).
Default setting: 0

7.10 Exiting the Setup Menu

To exit the Setup Menu:
Turn the main power switch to OFF.

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8. Service and Testing
This section describes the controls for servicing and testing the system.
Note: The tasks in this section must be performed by an authorized Filtersafe technician.

8.1 Displaying the Service Menu

To display the service menu:

1. Verify that the flushing switch and pump

switch are set to 0.

2. Turn the main power switch (1) to ON.

The controller application version screen is
displayed and then the Main Screen is displayed
after a few seconds.

3. Press the  _ button (2) on the controller.

The Service Menu screen is displayed.
4. Press the  _ button again.
The Navigation screen is displayed.

5. Press the  button (3) to go to the next

screen OR press the  button to go to the
previous screen.
Use the following tables to navigate through the
service menu screens.

8.2 Returning to the Main Screen

To return to the Main Screen from the service menu:

1. Scroll one screen past the first or last

service menu screen.
The Exit screen is displayed.
2. Press the  _ button (2) on the controller.
The Main Screen is displayed.

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8.3 Service Menu Screens
Description Instructions
Ethernet Status – displays the connection status
of the Ethernet connection.
Three possible states:
Not Attached – no module installed
Attached – module installed and working
Connected – client connected to PLC

Motor Enabling and Test Selection – enable or

disable a Scanner motor and select a Scanner
motor to be tested.
Each motor is enabled on a separate controller 0 – disable relevant motor
screen. Controller screens are displayed according 1 – enable relevant motor
to the number of filter screens defined for the
 _ – select the displayed motor for
relevant filter model (see Number of Screens on
pg. 7-24). testing and advance to the Motor
Testing screen
 – advance to the next motor
Motor Testing – runs a test of the selected
Scanner motor and its Limit Sensors.
 MLS – Motor side Limit Sensor
 FLS – Filter side Limit Sensor  – moves the Scanner toward the
motor.
For full test instructions, see section 8.4: Testing
the Scanner Limit Sensors and Motors.  – moves the Scanner toward the
filter.
 – advance to the next motor
Pump Test Selection – only displayed when the
Flushing Pump is enabled.
See Pump Enabling screen pg. 7-26.
 _ – display the Pump Testing screen.
Pump Testing – tests the Flushing Pump.
For full test instructions, see section 8.5: Testing
the Pump.
View the following values: 0 – stop test
FS – flow switch status 1 – start test
Rdy – pump ready signal status
Fb – pump operating signal status
Valve Test Selection
.

 _ – display the Flushing Valve test

screen.

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 Description Instructions
Valve Test Results – tests the Flushing Valve
For full test instructions, see section 8.6: Testing
the Flushing Valve.
View the following values: 1 – test V1
FS – flow switch status 2 – test V2
V1 – flushing valve 1
V2 – flushing valve 2
Multi-Purpose Input A Staus – displays the
status of the optional device or function that is
connected to MPI . The top line of the screen
shows the name of the connected device or
function.
See section 8.7: Testing the MPI Devices
Multi-Purpose Input B Status – displays the
status of the optional device or function that is
connected to MPI . The top line of the screen
shows the name of the connected device or
function.
See section 8.7: Testing the MPI Devices
Analog Readings – view DPS readings for:
 Upstream pressure
 Downstream pressure
Press the  button to scroll through the
 Pressure Differential different readings.
 Current pump reading (for ver. 3.1)

8.4 Testing the Scanner Limit Sensors and Motors

This section describes the following testing:
 Limit sensors – verifies that the Motor Limit Sensor (MLS) and the Filter Limit Sensor (FLS) are
sending a signal for the correct side. The Limit Sensors are normally closed circuits. When
pressed, the relevant Limit Sensor shows a Controller readout of 0. When not pressed, the
relevant Limit Sensor shows a Controller readout of 1
 Motors – verifies that the scanner motors are rotating and moving the scanner in the correct
direction.
8.4.1 Navigating to the Motor Testing Screen
To display the Motor Testing screen:

1. Navigate to the Motor Enabling and Test Selection

controller screen (see pg. 8-32).
2. Verify that the relevant motor is enabled.
3. Press the  _ button on the controller.

The Motor Testing Screen is displayed.

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 8.4.2 Testing the Limit Sensors
To test the proper functioning of the Scanner Limit Sensors:

1. On the Motor Testing screen, verify that the MLS

value is 1.
 MLS – Motor side Limit Sensor
2. Activate the Limit Sensor on the motor side of the
Scanner.

3. On the Motor Testing Screen, verify that the MLS

value is 0.
4. Release the Limit Sensor.
 MLS – Motor side Limit Sensor
5. Verify that the FLS value is 1.
 FLS – Filter side Limit Sensor

6. Activate the limit sensor on the filter side of the

Scanner.

7. On the Motor Testing Screen, verify that the FLS

value is 0.
 FLS – Filter side Limit Sensor

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 8.4.3 Testing the Scanner Motors
To test the proper functioning of the Scanner motors:

1. When the Motor Testing screen is displayed, press

and hold the  button on the controller.
2. Verify that the Scanner limit disk is moving toward
the motor and the Motor Testing screen displays:
run to motor.
3. Continue to hold the  button until the limit disk
activates the Limit Sensor next to the motor and the
Motor Testing screen displays: MLS: 0.

4. Press and hold the  button on the controller.

5. Verify that the Scanner limit disk is moving toward
the filter and the Motor Testing screen displays:
run to filter.
6. Continue to hold the  button until the limit disk
activates the Limit Sensor next to the filter and the
Motor Testing screen displays: FLS: 0.

8.4.4 Correcting Scanner Motor Operation

If the motor travels in the wrong direction and the wrong Limit Sensor is activated, a Drive Dir. Error is
displayed. In this case:
1. Turn the Main Power switch to OFF.
2. Change the connection between two of the three phases of the motor.
3. Repeat Testing the Scanner Motors.

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8.5 Testing the Pump
Note: The Pump Test screen is only displayed when the Flushing Pump is enabled (see section 7.4: Optional
Flushing Pump Parameters).
To test the proper functioning of the Flushing Pump:

1. Navigate to the Pump Test controller screen (see

section 8.3: Service Menu Screens).
2. Press the  _ button on the controller.

The pump testing screen is displayed.

3. Press the 1 button on the controller.
4. Verify that On value changes to 1. Rdy - Pump Ready signal
5. Press the 0 button on the controller. Fb – Pump Running feedback
Fs – Flow switch signal
6. Verify that On value changes to 1.
On – Pump Run output

8.5.1 Correcting Flushing Pump Operation

Note: This procedure is relevant only for a flushing pump that is powered from the Filtersafe control cabinet.

If the flushing pump operates in the wrong order:

1. Turn the Main Power switch to OFF.
2. Change the connection between the two phases.
3. Repeat Testing the Flushing Valve.

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8.6 Testing the Flushing Valve
This section describes testing the proper functioning of the Flushing Valve and the Flow Switch. 0 indicates
the output is OFF and 1 indicates that the output is ON.
To test the proper functioning of the Flushing Valve and the Flow Switch:

1. Navigate to the Valve Test Selection screen (see

pg. 8-32).
2. Press the  _ button on the controller.

The valve testing screen is displayed.

3. Press and hold the 1 button on the controller to
open valve 1.
Fs – Flow switch
4. Verify that V1 value changes to 1. V1 – Flushing valve on group 1
5. Press and hold the 2 button on the controller to V2 – Flushing valve on group 2
open valve 2.
Verify that V2 value changes to 1.

8.7 Testing the MPI Devices

This section describes testing the proper functioning of the devices connected to MPI (see page 7-25) and
MPI (see page 7-25). The readout is 0 when not active and 1 when active.
To test the proper functioning of an MPI device:

1. Navigate to the relevant MPI status screen (see

page 8-33).
2. Verify that the Status value is 0.
3. Activate the device connected to the relevant MPI.
4. Verify that the Status value changes to 1 when
the pressure reaches the flushing initiation set
point.

If the above test is not possible, perform the following:

1. Initiate a shortcut or disconnect the two wires at the junction box.
2. Verify that the Status value changes.

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9. Operation
This section describes filter startup and operation. For more information, refer to the Startup and First
Operation section in the relevant filter operation manual.
 Section 9.1: Power Up
 Section 9.2: Controller Operating Screens
 Section 9.3: Messages and Indicators
For more information, refer to the Startup and First Operation section in the relevant filter operation manual.

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9.1 Power Up
To power up the filter in automatic mode:

1. Turn the flushing control switch (2)

to 0.
2. Turn the pump control switch (5)
(optional) to 0.
3. Turn the main power switch (1)
ON.
The power indicator (4) lights up.
The controller (3) turns on.
4. Turn the flushing control switch (2)
to Auto.
5. Turn the pump control switch (5)
to Auto. 0.
The filter operates in automatic mode.
Flushing Cycles are intiated by the Filter
Control System.

9.2 Controller Operating Screens

9.2.1 Main Screen

Description Instructions
When in operating mode, the controller screen
displays:
 Filter Status (1) – displays the operating
status of the filter (see section 9.3.1: Filter
Status Messages and Indicators).
 Alarm Messages (2) – displays specific
information about alarm events (see section
9.3.2: Alarm Event Messages and Indicators).

9.2.2 System Information Screens

When in operation mode, use the navigation buttons on the controller to view the following screens.

Description Instructions
Flushing Cycle History – displays how long ago
the last flushing cycle occurred and how many
flushing cycle have occurred since the filter was
installed. Press the  button to display this
screen.
The display returns to the main screen
after a few seconds.

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 Description Instructions
Analog Readings – view DPS readings for:
 Upstream pressure
 Downstream pressure
Press the  button to display this
 Pressure Differential screen.
 Current pump reading (for ver. 3.1) Press the  button to scroll through the
different readings.

9.3 Messages and Indicators

This section explains:
 Controller messages – messages that are displayed on the Main Screen (see section 9.2.1)
 Indicators – Control Panel lights (see section 5.1) and signals from the control cabinet (see
section 5: Control Cabinet Overview).
 Resetting the System After an Alarm Event – clearing alarm event messages and indicators
and resuming normal operation (see section 9.3.3).
Note:
For system logic information see chapter 14: Annex D: Interface Logic.

9.3.1 Filter Status Messages and Indicators

The following table contains messages that are associated with the filter operating status and are displayed
on the upper line of the controller Main Screen.
Green Flushing

Flushing Relay
Status Relay
Green Pump

Description/
Red Alarm
Controller

DP Relay
Indicator

Indicator

Indicator
Display

Action
Couse
Signal
Alarm
Relay

AUTO - - Const Const Const ON OFF - - Control Panel -

READY selectors set to
Auto.
SYSTEM - - - - - - - - - -
NOT READY
SYSTEM OFF - - - - - - - - - -
MANUAL - Blink Blink Const - Const - - Manual -
FLUSHING Flushing is
active
AUTO DP - Blink Blink Const - Const - - Flushing Cycle -
FLUSHING triggered by
DPT Signal
REMOTE - Blink Blink Const - Const - - Remote -
FLUSHING Flushing cycle
is operating
TIMER - Blink Blink Const - Const - - Timer Operation -
FLUSHING flushing
(preset),
regardless of
the DPT signal

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 9.3.2 Alarm Event Messages and Indicators
The following table contains messages that are associated with alarm events and are displayed on the lower
line of the controller Main Screen.

Description/
DP Relay
Indicator

Indicator

Indicator
Flushing

Flushing
Display

Action
Status

Couse
Signal
Green

Green
Alarm

Alarm
Pump

Relay

Relay

Relay
Red

High DP Const N/R N/R ON Off N/R ON Warning Differential

(Ver. Pressure
3.2- Switch with
OFF) Alarms is
signaling
that the
pressure
differential
has reached
a critical
point.
High PR Const N/R N/R ON Off N/R N/R Warning Pressure
Switch is
signaling
that the
pressure in
one side of
the filter has
reached a
critical point.
HEAVY DIRT Const N/R N/R ON OFF N/R ON Warning Filter runs in Caution, the
LOAD (after 10 AUTO and system is
cycles) differential working hard.
(Ver. 3.3 pressure It resets
after 5 signal automatically
cycles) remains once DPS is
“ON” after released
10 cleaning
cycles (Ver.
3.3 after 5
cleaning
cycles).
CHECK Blink N/R N/R ON ON, N/R Off. Alarm Filter runs in Check proper
DPS/VALVE OFF- (after 20 AUTO and operation of
after 20 cycles) differential the system:
cycles (Ver. 3.3 pressure pressure,
(Ver. after 10 signal DPS, valves,
3.3 cycles) remains Scanner
after 10 “ON” after rotation.
cycles) 20 cleaning Cause could
cycles (Ver. be the result
3.3 after 10 of a heavy
cleaning load of dirt in
cycles). the water. It
resets
automatically
once DPS is
released

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 Description/
DP Relay
Indicator

Indicator

Indicator
Flushing

Flushing
Display

Action
Status

Couse
Signal
Green

Green
Alarm

Alarm
Pump

Relay

Relay

Relay
FLOW Red
Const Blink OFF ON OFF N/R N/R Warning Pump is on Check flow,
ERROR alarm, and Flow Flushing
pump Switch mode valve, pump,
shutdown. is “ON” Flow Switch
(Setup (if no flow
Menu). After switch is
preset used, make
seconds sure it is
(Setup “OFF” in the
Menu), the setup menu).
flow signal
remains
OFF.
PUMP IS Const N/R Off Off Off Off N/R Warning Remote Start Not
OFF alarm, Auto Pump Possible.
operation selected check Pump,
not (Setup connection or
possible. Menu) and change
pump switch selections
on the (pump switch
Control must be on
Cabinet is Auto)
not on “0”
MOTOR Const N/R N/R On Off N/R N/R Warning Filter Motor Check
OVERLOAD overload Motors and
protection drive
device goes mechanism/
OFF. Wiring. Reset
Mechanical and start the
overload, system
Defective
Motor,
Defective
Wiring
M1/M2/M3/ Const N/R N/R ON/ Off. N/R N/R Alarm + Relevant Check Limit
M4 Failed OFF relevant motor works, Sensors and
(Dir) Filter stops Limit Disk wiring.
when
all moves away If necessary,
motor from Limit switch
Sensor but connection
fail
the LS between 2
signal does phases, to
not change. change the
Also used to relevant
check the motor’s
relevant direction.
motor
connection/d
irection on
startup.
M1/M2/M3/M Const N/R N/R ON/ Off. N/R N/R Alarm + Relevant Check Limit
4 Failed (LS) OFF relevant motor’s Limit Sensors and
Filter stops Sensors wiring. Reset
when
all broke, or & Start
motor have wiring
fail problems.

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 Description/
DP Relay
Indicator

Indicator

Indicator
Flushing

Flushing
Display

Action
Status

Couse
Signal
Green

Green
Alarm

Alarm
Pump

Relay

Relay

Relay
M1/M2/M3/M Red
Const N/R N/R ON/ Off. N/R N/R Alarm + It takes the Check Limit
4 Failed OFF relevant Limit Disk Sensors and
(RunT) Filter stops more than Drive system.
when
all 15% longer Reset & Start
motor to reach a
Limit
fail
Sensor, than
the selected
Run Time
(Setup
Menu)
Low PLC Blink N/R N/R On Off. N/R N/R Warning Controller Change the
Battery backup backup
battery is battery
running low
Pump Not Blink N/R On On Off. On N/R Warning Ready Check pump
Ready Signal not functionality
received and wiring
from pump
controller.
Pump Not Const Const Off. Off. Off. N/R N/R Warning Run Signal Check pump
Run not received functionality
from pump and wiring
controller.
PT0/PT1 Out Blink N/R N/R Off. Off. N/R N/R Warning Relevant Check wiring
of Range analog or replace
pressure device.
transmitter
(see Analog
Pressure
Transmitters
)
malfunctioni
ng – output
is less than
4ma or
greater than
20ma.
US.PR. Too Const Blink N/R On Off. On On Warning Upstream
Low! pressure is
lower than
optimal
flushing
pressure.
US.PR.Too Const N/R N/R On Off. N/R N/R Warning Upstream
High!! pressure is
greater than
maximum
plate stated
working
pressure.
DP. Too Const N/R N/R On Off. N/R On Warning Differential
High!!! (ver. pressure is
3.1 Off) too high.
The filter
may become
damaged.

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 Description/
DP Relay
Indicator

Indicator

Indicator
Flushing

Flushing
Display

Action
Status

Couse
Signal
Green

Green
Alarm

Alarm
Pump

Relay

Relay

Relay
High Red
Const N/R N/R On Off. N/R N/R Warning Pressure in
Pressure!!! the filter is
greater than
maximum
plate stated
working
pressure.
No DPT Const Off N/R Off Off. N/R N/R Fatal Error No
selected! Filter differential
operation pressure
trigger
Not
(DPT)device
possible
selected at
setup.
Leakage Const N/R N/R On Off. N/R N/R Warning Flow Switch
Detected detected
flow while
flushing
valve
closed.
Replace
Flushing
Valve or
faulty Flow
Switch.
Err. Power Blink Off Off Off Off Off Off Fatal Error All Setup Check PLC
Down Filter parameters battery;
Run Setup operation have been replace if
first Not lost. PLC faulty and run
battery low Setup.
possible
OR no setup
done during
installation.
Pump N/R N/R Blink N/R N/R N/R N/R Indication Pump run
Run Ext from
V3.2

Cab external
pump
cabinet.

Man. Const Off. Off. Off. Off. Off. N/R Warning Power Up Reset -
Power while filter In Change
V3.3

Up Manual Flushing
Restart Mode. Selector to 0.

9.3.3 Resetting the System After an Alarm Event

After investigating the cause of the alarm and performing any necessary actions the reset the system to clear
the alarm message and resume normal operation.
To reset the system after an alarm event:
Turn the Flushing switch to Manual or Auto and
then to 0.

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10. Technical Specifications
10.1 Power Supply
10.1.1 Line voltage
 Type A – 190 ÷ 220 V 50/60Hz (3~)
 Type B – 380 ÷ 480 V 50/60Hz (3~)
10.1.2 Control voltage
24 VDC

10.2 Control Panel Components

 Motor Overloads – Q11-Q14
 Contactors – K11.X - K14.X operate the Filter Motor and K17 operates the Pump Motor
 Switching Modulation Power Supply (U5) – Power Supply for 24VDC control voltage
 2 x 6 Amp (Q5) – -protect the power supply input
 1.0 Amp Fuses (F16-17-18) – -protect the control circuits.
 Analog circuits protection – F7-F8, 32 mA
 Controller type – JZ20-T40/JZ20-R31

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11. Annex A: Controller Inputs and Outputs
11.1 Inputs
11.1.1 Analog Inputs

Input Name Normal State Notes

A0 Upstream Analog Pressure OPTIONAL K
Transmitters
A1 Downstream Analog Pressure OPTIONAL K
Transmitters/ Analog Differential
Pressure Transmitter / pump current
transmitter

11.1.2 Single Filter

Input Name Normal State Notes

0 MPI Function (see page 7-25) NO/NC
1 MPI Function (see page 7-25) NO/NC
2 Limit Sensor #1 (Motor Side) NC
3 Limit Sensor #2 (Filter Side) NC
4 Screen Motor Auto Mode NO
5 Screen Motor MAN Mode NO
6 Screen’s Motor O.L / Pump Motor NO Control Panel wiring diagram:
O.L
7 Pump Auto Mode NO OPTIONAL D / J
8 Pump MAN Mode NO OPTIONAL D / J
9 Old pump Motor O.L / Reserved NO
10 Run Flushing Remote NO
11 Pump Ready (external) NO OPTIONAL D / J
12 Pump Run (external) NO OPTIONAL D / J

11.1.3 Multi-Filter

Input Name Normal State Notes

0 MPI Function (see page 7-25) NO/NC
1 External Pump Run NO OPTIONAL J
2 MPI Function (see page 7-25) NO/NC
3 External Pump Ready NO OPTIONAL J
4 Filter Flushing MAN Mode. NO
5 Filter Flushing Auto Mode NO
6 Filter’s Motor O.L NO
7 Pump Motor MAN Mode NO OPTIONAL J
8 Pump Motor Auto Mode NO OPTIONAL J
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 Input Name Normal State Notes
9 Run Flushing Remote NO
10 Screen 1 Limit Sensor (Motor Side) NC
11 Screen 1 Limit Sensor (Filter Side) NC
12 Screen 2 Limit Sensor (Motor Side) NC
13 Screen 2 Limit Sensor (Filter Side) NC
14 Screen 3 Limit Sensor (Motor Side) NC
15 Screen 3 Limit Sensor (Filter Side) NC
16 Screen 4 Limit Sensor (Motor Side) NC
17 Screen 4 Limit Sensor (Filter Side) NC

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11.2 Outputs
11.2.1 Single Filter

Output Name Notes

0 Screen Motor A (to filter) (K11.1)
1 Screen Motor B (to motor) (K11.2)
2 Filter Status Lamp (L12)
3 Solenoid Valve (SV1)
4 Pump Motor (K17) OPTIONAL D / J
5 Pump Status Lamp (L13) OPTIONAL D / J
6 Alarm Lamp (L14)
7 System Filter Status Relay (K15)
8 Fault Relay (K16)
9 System Flushing (K18)
10 Continuous Flushing/ Very High DP (K19)

11.2.2 Multi-Filter

Output Name Notes

0 Free
1 Free
2 Filters Status Lamp (L12)
3 Pump 1 - Status Lamp (L13) OPTIONAL J
4 Screen 1 Motor (K11.1)
5 Screen 1 Motor (K11.2)
6 Screen 2 Motor (K12.1)
7 Screen 2 Motor (K12.2)
8 Screen 3 Motor (K13.1)
9 Screen 3 Motor (K13.2)
10 Screen 4 Motor (K14.1)
11 Screen 4 Motor (K14.2)
12 System Status (K15)
13 System Fault Relay (K16)
14 Run Pump 1 (K17) OPTIONAL J
15 Alarm Lamp (L14)
16 Solenoid Valve Group 1 (SV1)
17 Solenoid Valve Group 2 (SV2)
18 System Flushing (K18)
19 Continuous Flushing/Very High DP (K19)

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12. Annex B: Modbus Specifications
12.1 Modbus Word Registers
Register Access Name Limits Units Data Function
number Type Code
40210 Read Only Motor Alarms bit high = in alarm Bit Mask signed 03
16-bit
integer

40211 Read Only System Alarms bit high = in alarm Bit Mask signed 03
16-bit
integer
40212 Read Only System Status bit high = active Bit Mask signed 03
16-bit
integer

40213 Read Only Cycles Totalizer 0-32000 signed 03

16-bit
integer
40214 Read Only Last Cycle (MM 0-60 Minutes signed 03
Ago) 16-bit
integer
40215 Read Only Last Cycle (HHH 0-999 Hours signed 03
Ago) 16-bit
integer
40216 Read Only PT0 Analog 0-16000 millibar signed 03
Rearding (mbar) 16-bit
integer
40217 Read Only PT1 Analog 0-16000 millibar signed 03
Rearding (mbar) 16-bit
integer
40218 Read Only DP Rearding (mbar) 0-1000 millibar signed 03
16-bit
integer
40219 Read Only Pump Current 0-20000 miliAmper signed 03
16-bit
integer
40220 Read Only Reserved signed 03
16-bit
integer
40221 Read Only Reserved signed 03
16-bit
integer
40222 Read Only Const Value 32767 None signed 03
16-bit
integer
Function Bits
208 Read/Write Reset Alarms 1 = reset None Bit 06
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 Register Access Name Limits Units Data Function
number Type Code
209 Read/Write Start Remote 1 = Flush None Bit 06
Flushing
Motor Alarm Bits
210 Read Only Motor 1 bit high = in alarm None Bit 01
Limit Switch Error
211 Read Only Motor 1 bit high = in alarm None Bit 01
Direction Error
212 Read Only Motor 1 bit high = in alarm None Bit 01
Run Time Error
213 Read Only Motor 2 bit high = in alarm None Bit 01
Limit Switch Error
214 Read Only Motor 2 bit high = in alarm None Bit 01
Direction Error
215 Read Only Motor 2 bit high = in alarm None Bit 01
Run Time Error
216 Read Only Motor 3 bit high = in alarm None Bit 01
Limit Switch Error
217 Read Only Motor 3 bit high = in alarm None Bit 01
Direction Error
218 Read Only Motor 3 bit high = in alarm None Bit 01
Run Time Error
219 Read Only Motor 4 bit high = in alarm None Bit 01
Limit Switch Error
220 Read Only Motor 4 bit high = in alarm None Bit 01
Direction Error
221 Read Only Motor 4 bit high = in alarm None Bit 01
Run Time Error
222 Read Only Reserved bit high = in alarm None Bit 01
223 Read Only Reserved bit high = in alarm None Bit 01
224 Read Only Motor OverLoad bit high = in alarm None Bit 01
225 Read Only 1 Second Blink Bit Not applicable None Bit 01
System Alarms Bits
226 Read Only Pump Switch Is Off bit high = in alarm None Bit 01
227 Read Only No Run Signal From bit high = in alarm None Bit 01
Pump
228 Read Only No Ready Signal bit high = in alarm None Bit 01
From Pump
229 Read Only Flow Error bit high = in alarm None Bit 01
230 Read Only Leakege bit high = in alarm None Bit 01
Detected
231 Read Only Heavy Dirt bit high = in alarm None Bit 01
Load Warning
232 Read Only Check bit high = in alarm None Bit 01
DPS Or Valves

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 Register Access Name Limits Units Data Function
number Type Code
233 Read Only PT0 Out Off Range bit high = in alarm None Bit 01
234 Read Only PT 1 Out Off Range bit high = in alarm None Bit 01
235 Read Only Upstream Pressure bit high = in alarm None Bit 01
Too Low
236 Read Only Upstream Pressure bit high = in alarm None Bit 01
Too High
237 Read Only High Pressure Alarm bit high = in alarm None Bit 01
238 Read Only Differential Pressure bit high = in alarm None Bit 01
To High
239 Read Only PLC Battery LOW bit high = in alarm None Bit 01
240 Read Only Reserved bit high = in alarm None Bit 01
241 Read Only 1 Second Blink Bit Not applicable None Bit 01
System Status Bits
242 Read Only Pump Status bit high = ON None Bit 01
243 Read Only System Ready bit high = Ready None Bit 01
244 Read Only System Alram bit high = Alarm None Bit 01
245 Read Only Flushing Relay bit high = Flushing None Bit 01
246 Read Only High DP Relay bit high = OK None Bit 01
247 Read Only Valve 1 bit high = Open None Bit 01
248 Read Only Valve 2 bit high = Open None Bit 01
249 Read Only Home Return bit high = None Bit 01
Returning
250 Read Only Remote Flushing bit high = Flushing None Bit 01
251 Read Only DP Flushing bit high = Flushing None Bit 01
252 Read Only Timer Flushing bit high = Flushing None Bit 01
253 Read Only Run To Home bit high = Flushing None Bit 01
254 Read Only Scanner Home bit high = Home None Bit 01
255 Read Only 1 Second Blink Bit Not applicable None Bit 01

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 1 Second Blink Bit 1 Second Blink Bit
Bit 15
Motor OverLoad Reserved
Bit 14

Page 52 of 60
Reserved PLC Battery LOW 1 Second Blink Bit
Bit 13
Reserved Differential Pressure Fliter Home
Bit 12 To High
Motor 4 Run Time High Pressure Alarm Run To Home
Bit 11 Error
Motor 4 Direction Error Upstream Pressure Timer Flushing
Bit 10 Too High
Motor 4 Limit Switch Upstream Pressure DP Flushing
Bit 9 Error Too Low

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Motor 3 Run Time PT 1 Out Off Range Remote Flushing
Bit 8 Error
Motor 3 Direction Error PT0 Out Off Range Home Return
Bit 7
Motor 3 Limit Switch Check DPS Or Valves Valve 2
Bit 6 Error
Motor 2 Run Time Heavy Dirt Load Valve 1
Bit 5 Error Warning
Motor 2 Direction Error Leakege Detected High DP Relay
Bit 4
Motor 2 Limit Switch Flow Error Flushing Relay
Bit 3
Word Register Bit Map

Error
Motor 1 Run Time No Ready Signal From System Alram
Bit 2 Error Pump
Motor 1 Direction Error No Run Signal From System Status
Bit 1 Pump
Motor 1 Limit Switch Pump Switch Is Off Pump Status
Bit 0 Error
Register Number

40210

40211

40212
12.2
13. Annex C: PLC Program Upgrade
1. Open the side cover of the controller and push in the PLC programmer (CLONER) until it snaps into place.

2. Press and hold the i button for 5 seconds.

The PROGRAM CLONER (PLC programmer) screen is displayed.

3. Press the  _ button.
The CLONER (PLC programmer) TO PLC screen is displayed.
4. Press the  _ button.
The IMPORT screen is displayed.
5. Press the  _ button.
The PLC WILL STOP! CONTINUE screen is displayed.
6. Press the  _ button.
The upgrading process takes about one minute.
When the process is finished The PLC WILL RESET & RUN CONTINUE screen is displayed.
7. Press the  _ button to restart the controller.
The controller is back in operating state.
8. Remove the PLC programmer (CLONER) and close the side cover of the controller.
9. Restart the control cabinet and verify that the PLC displays the updated version on the Start Up screen.

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14. Annex D: Interface Logic
14.1 Pump Interface Logic

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14.2 Filter Interface Logic

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15. Annex: E: Setup Values Form
The following form is used by the client to define setup values for the controller.

No Parameter Name Controller Display Setup Value Comments

1 Numbers of screens Num.Of Screens
2 Flushing Operation Mode OP Mode Sel(1-3)
3 Cycle Time Cycle Time
4 MPI0 Function MPI Function(0-4)
5 Flow Error Delay Flow Error Delay
6 MPI2 Function MPI Function(0-3)
7 Differential Pressure Switch Off DPS. Off Delay
Delay
8 Timer Operation (Enabling) Timer Operation:
9 Timer Interval Timer Interval:
10 Cycles Per Interval (Timer Mode) Timer Cyc/inter
11 Pump (Enabling) Pump: Used Sel
12 Pump Ready Signal Pump Ready Sig.
13 Pump Running Signal Pump Run Sig.
14 IP Address Loc. IP X.X.X.X
15 Subnet Mask SubN.M. X.X.X.X
16 Gateway G.Way IP X.X.X.X
17 Modbus Port Modbus Loc Port
18 PLC Name PLC Name:FSM54A_
19 Analog Transmitter "'0" Zero (4ma) PT0 Zero Set
20 Analog Transmitter "'0" Zero (4ma) PT0 Span Set
21 Analog Transmitter "'1" Zero (4ma) PT1 Zero Set
22 Analog Transmitter "'1" Zero (4ma) PT1 Span Set
23 Upstream Low Pressure Alarm SP U.S. Low PR SP
24 Upstream High Pressure Alarm SP U.S. High PR SP
25 Differential Pressure Flushing SP DP. Flush SP
26 Differential Pressure Hysteresis DP. Hysteresis
27 High Differential Pressure Alarm SP HDP. Alarm SP
28 Analog Sensor Selection Sel.AN. OP (0-4)
29 Minimal Flushing Duration Min. Flush Time

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16. JAZZ 20 BATTERY REPLACEMENT
Note:
 Once the battery is disconnected, all setup values will be lost. It is highly important to copy (or
photo) all setup values, for setup process see Chapter 7.
 Disconnect all plugs from the OPLC.
 Make sure to replace the battery with battery model CR2032.
 Before opening the controller, touch a grounded object to discharge any electronic charge.
 Avoid touching the PCB board directly by holding the PCB board by its connectors.

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17. User Notes

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