Boiler Blowdown Controller

BBCS 485
User Manual
V1.2 August 2016

Forbes Marshall Pvt Ltd

85, Phase
B-85, Phase-II, Chakan Industrial Area,
Sawardari, Chakan,
Tal : Khed, District : Pune,
Maharashtra, India - 410501

1
Contents

1. WHO MUST READ THIS MANUAL? ...................................................................................................................................................... 3

2. INTRODUCTION ........................................................................................................................................................................................... 4

3. SPECIFICATIONS .......................................................................................................................................................................................... 5

4. DOs and DONTs ......................................................................................................................................................................................... 10

5. BEFORE INSTALLATION........................................................................................................................................................................ 11

6. INSTALLATION .......................................................................................................................................................................................... 12

7. ELECTRICAL CONNECTIONS ............................................................................................................................................................... 13

8. AFTER 1st POWERUP ............................................................................................................................................................................... 16

9. HUMAN MACHINE INTERFACE (HMI)............................................................................................................................................. 17

10. Operation: RUN mode .......................................................................................................................................................................... 18

11. Operation: CONFIG mode ................................................................................................................................................................... 20

12. Operation: SERVICE mode ................................................................................................................................................................. 23

13. Sensor Calibration: In-line calibration (to determine K factor) ......................................................................................... 28

14. Troubleshooting ..................................................................................................................................................................................... 29

15. Appendix 1: Modbus RTU related information ......................................................................................................................... 30

2
 1. WHO MUST READ THIS MANUAL?

This manual has information that is useful to personnel who have to interact with the BBCS 485 during
the following situations:
Installation and commissioning
Configuration
Operation
Maintenance
Service

Please note that there may be multiple chapters that could be useful during each of the above situations.
For example, the installation & commissioning person will primarily need to refer to the chapters BEFORE
INSTALLATION, INSTALLATION and ELECTRICAL CONNECTIONS. He/she may also refer to the chapter AFTER
1ST POWER UP.
Likewise, the user of BBCS 485 will normally need to refer to chapters HMI & OPERATION. He/she may also
refer to the chapter TROUBLE SHOOTING in case certain problems are noticed.

3
 2. INTRODUCTION

General description
BBCS is a micro-controller
controller based Electronic 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
periodically using sensor mounted d externally at bottom-blowdown
bottom line or level gauge. Whenever the measured
TDS exceeds the Set-point
point value, the boiler water is blown
blown down until the TDS value falls below the set
set-point
value. The system is capable of controlling
ling the TDS of one boiler.

High Temperature Conductivity Sensor (HTCS

HTCS) sensor is used to measure conductivity and temperature of
water sample collected in sensor chamber. TDS is calculated based on these measurements.

The user interface includes keypad with three tactile keys and Backlit LCD display. Two LED
LEDs indicate Mains
power (green), current status (red – steady)
teady) and error (red- blinking) respectively. It has a RS485
communication port over which all important parameter values are transmitted to a host computer
computer,
following Modbus RTU protocol.

The BBCS 485 has a wall mountable enclosure rated for IP65. The eenclosure
nclosure has two sections the upper
main section that houses the electronics and the lower smaller section that houses the user cable
terminations.

The BBCS 485 is mains power operated and is factory configurable to work on either 230 VAC (default) or 110
VAC supply.

4
 3. SPECIFICATIONS

System Components

BBCS 485 Control Unit

o Mains-powered: UPS recommended to avoid loss of run time data
o Communication: Modbus RTU over RS485
o Sensor inputs: Temperature and conductivity from a single sensor
o Relay outputs: Internally mains powered output to solenoid valves

HTCS Sensor (mounted on sensor chamber supplied from Forbes Marshall)

o Conductivity Sensor (K = 1)
o PT100 RTD
o Fixed length cable

Computed and displayed parameters

Parameter Description
TDS TDS value of water sample present in sensor chamber.
Set point TDS value to be maintained, configured by user.
Purge Totalizer Total numbers of Purge cycles that have occurred
Blowdown Totalizer Total numbers of Blowdown cycles that have occurred
Purge After Time to be elapsed before next purge
(Remaining time)

Details

Parameter Value Unit Updating Rate

Min Max
TDS 700 7000 ppm 1 sec
Set point 700 7000 ppm When changed by user
Purge Totalizer 0 4294967295 number As it occurs
Blowdown Totalizer 0 4294967295 number As it occurs
Purge After minutes
1 720 1 min
(Remaining time)

Configurable parameters

Configurable Purge Interval

Time Description
15 min Purge after 15 minutes
30 min Purge after 30 minutes
1 hour Purge after 1 hour (default)
2 hour Purge after 2 hours
4 hour Purge after 4 hours
8 hour Purge after 8 hours
12 hour Purge after 12 hours

5
 Configurable Cable Length
Sensor Cable Length Description
5 meters Cable length = 5 meters (default)
10 meters Cable length = 10 meters

Baud rate
Baud Rate Description
1200 Baud rate for communication =1200
2400 Baud rate for communication =2400
4800 Baud rate for communication =4800
9600 Baud rate for communication =9600(default)
19200 Baud rate for communication =19200

Parity bits
Parity bits Description
None parity No parity bits, stop bits =2(default)
Odd parity Odd parity, stop bit =1
Even parity Even parity, stop bit =1
None parity: 1 stop bit No parity bits, stop bits =1

Purge location
Purge location Description
Bottom blowdown line Select when sensor is mounted on bottom blowdown line (default)
Level Gauge Select when sensor is mounted on level gauge

Other configurable parameters

Parameter Min Max Default Unit

TDS Setpoint 700 7000 3000 ppm

Purge time 05 60 05 seconds
Blowdown time 05 60 05 seconds
Modbus slave ID 1 247 1 number
TDS factor 0.1 0.9 0.7 number

Configurable TDS setpoint

TDS value of boiler water to be maintained, specified by boiler manufacturer. If measured TDS rises
above the setpoint, the boiler water is drained (blown down) till TDS falls below the setpoint.
Configurable Purge time
Duration for which Purge Valve is open, allowing fresh sample of water to be collected in sensor
chamber.
Configurable Blowdown time
Duration for which Blowdown valve is open, allowing water to drain in order to reduce TDS.
Configurable Device ID (Modbus)
In case one or multiple units of BBCS 485 have been installed in your plant and have been connected
to a host computer over Modbus, you need to assign a unique device ID to each.
Configurable TDS factor
Factor to convert conductivity to TDS, can be set as per customer's reference meter TDS factor.

6
Communication: with host computer via Modbus RTU over RS485

Human Machine Interface

Backlit LCD for display -Alpha numeric indications.
STATUS indicator LED: indicates status of purge or blowdown cycle
o (steady ON) when purge or blowdown is happening and
o (blinking) when an ERROR condition exists
POWER indicator LED: indicates presence of Mains power
3 keys with tactile feedback for menu navigation

Relay output
1 NO contact, internally powered with 230/110 VAC for solenoid valve operation
Contact rating: 230 VAC, 1A with internal RC snubber

Access passwords: separate for

Configuration mode
Service mode

7
Electrical Specifications
UPS supply strongly recommended to prevent loss of run time data.
Power Input
o Mains operated
• 230VAC +10% -15%, 50/60 Hz (default, factory set)
• 110VAC +10% -15%, 50/60 Hz (if specified, factory set)
o Consumption < 5VA
o Fuse 20x5mm glass 200mA slow blow(for MAINS and VALVE fuse)
Cable Glands
o Mains power, Blowdown valve, Purge valve, Modbus, Sensor: All type PG9
Cables
o Mains: 3 core 1.0 mm2 with pin type lugs, cable OD 4-8 mm
o Sensor: supplied with Sensor
o Modbus: shielded twisted pair, shield coverage better than 75%, cable OD 4-8 mm
o Valves: 2 core 1.0 mm2 with pin type lugs, cable OD 4-8 mm
Terminal Connections
o Screw type terminal blocks
o Suitable for 1 mm2 pin type lugs
o Housed in terminal section of enclosure

Mechanical Specifications
Mounting: wall mounted
Aluminum die cast enclosures
Dimension of the Unit (with cable glands)
o Height: 234 mm
o Width: 252 mm
o Depth: 086 mm

Environmental specification
EMI/EMC compliance
Ingress Protection IP65
Tolerable Operating temperature 0-70 °C

8
Dimensional Drawing

9
4. DOs and DONTs

Ensure that the wiring of the system is well protected from any physical damage.
The mounting location must be away from high capacity rotating equipment and welding
equipment.
The ambient temperature must be between 0 and 55 °C for best performance.
Do not extend the sensor cable length.
Do not attempt to repair the electronics.
While replacing the fuse switch off the mains power supply.
Use cables of only the specified type.
Ensure that firm Earth is provided to controller.

IMPORTANT
To ensure IP65 sealing of the enclosure ensure the following
o Fasten all the 8 screws of the enclosure – main and terminal sections.
o Use cables of only the specified type and outer diameter.
o Always block off unused cable glands with the blanking plugs provided.
o If the blanking plugs are misplaced, please use short lengths of insulated cable.
o Always tighten the cable gland nut over the cable outer sheath and ensure that it is properly
gripped.

10
 5. BEFORE INSTALLATION

You will need

The BBCS 485 package
HTCS sensor with cable
Mechanical skid assembly that includes:
o Upstream & downstream isolation valves
o Blowdown valve and Purge valve with solenoid
o Sensor chamber
o Water sample collection Valve
Set of spanners & screwdrivers
Air supply at a regulated pressure of 3 to 6 bar g
Mains supply: 230/ 110VAC nominal output voltage as required. UPS is recommended to avoid loss of
run time data
4 nos of bolts or screws suitable for hole size of 6mm diameter to mount the BBCS 485 control unit
3 core (R/B/G colours) insulated cable with 1mm2 pin-type terminating lugs for mains power, outer
diameter 4-8 mm
2 core insulated cable with 1mm2 pin-type terminating lugs for solenoid valves, outer diameter 4-8 mm
2 core twisted shielded cable for Modbus, outer diameter 4-8mm

11
 6. INSTALLATION

Unpacking
Open the BBCS 485 package. This includes the following –
BBCS 485 control unit
Mounting template
Spare fuse pack – keep this in a designated location immediately
User Manual - keep this in a designated location after each use

Mounting template
Unfold the A4-size sheet of the mounting template. Identify a wall / vertical surface that satisfies the following
requirements:
Is close enough to sensor chamber to allow sensor cable of specified length to be routed till the control
unit.
The complete A4-size template can be pasted without any physical hindrances.
Is at an operating height of between 4.5 and 5.5 feet.
For best performance the surrounding ambient temperature does not exceed 55 °C.
Peel off the release paper from the underside of the template. Paste the template properly onto the identified
wall / vertical surface that is free of oil, dust and dirt.

Mounting the BBCS 485

Follow the instructions provided on the template. Ensure that the BBCS 485 is mounted firmly.

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 7. ELECTRICAL CONNECTIONS

CAUTION!
UPS is recommended to avoid loss of run time data
First check the Mains operating voltage of the BBCS 485 received by you and as stated on the side label. This can
be either 230VAC (default) or 110VAC if specifically ordered by you. Confirm that the installation location has
the requisite voltage and is stable. In case there are occasional variations in the voltage these must be well
within the following range and never outside the range.
230VAC operation: 200 to 250 VAC
110VAC operation:100 to120 VAC

Keep the Mains power switched off before attempting connections.

Unscrew the lower terminal compartment lid which has the terminal connection details pasted on its inside.
Follow these details and the terminal numbers marked on each terminal block to make the necessary electrical
connections. Observe indicated polarity and wire colour codes.

Mains power (1, 2, 3)

Purge valve (4, 5)
Blowdown valve (6,7)
Modbus (8, 9, 10)
Sensor (11, 12, 13, 14, 15)

Connection details

Colour codes
YE: Yellow
RD: Red
WH: White
BK: Black

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Wiring Details

CONFIRM THE SPECIFIED OPERATING VOLTAGE

BEFORE CONNECTING MAINS SUPPLY.
THIS SHOULD BE EITHER 110 or 230 VAC ±10%.

M AINS Sh = Sh ield
F USE
BL OW
M AINS PURGE M ODBUS SENSOR
DOWN
VALVE
L N E P1 P2 F USE B1 B2 Tx- Tx+ Sh C1 C2 T1 T2 Sh
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Mains BK (Sh ield )

switch
Live L L WH

WH
Neutral E E 4 core shielded
RD
Earth N N sensor cable
YE
Purge Blowdown
valve valve
Sh ield

Indicates EARTH 2 core twisted pair

shielded cable

IMPORTANT NOTES
1. VOLTAGE BETWEEN Neutral 'N' and Earth 'E' MUST BE LESS THAN 1.2 Vrms.
2. FOR SENSOR, USE ONLY THE CABLE SUPPLIED ALONGWITH THE SENSOR.
DO NOT EXTEND THE CABLE LENGTH.
3. FOR MODBUS USE ONLY TWISTED PAIR CABLE WITH SHIELD.
4. ALWAYS TERMINATE THE SHIELDS AS SHOWN.
5. CONNECT THE VALVES ONLY BASED ON 'PURGE LOCATION' AS FOLLOWS.

'PURGE LOCATION' in Service Mode

VALVE BOTTOM BLOWDOWN LEVEL GAUGE
PURGE VALVE Do NOT connect Connect
BLOWDOWN VALVE Connect Connect

For Solenoid valve

CAUTION!
The relay outputs available are internally powered by Mains Power (230/110 VAC). So just connect Purge
valve's coil to P1 & P2 and/or Blowdown valve's coil to B1 &B2 respectively.
Ensure that correct purge location is selected in service mode menu.

14
For Modbus RTU communication
If you have a single BBCS 485 unit connected for Modbus communication with a Host computer, slide both the
DIP switches on the Terminal PCB to ON position.
If multiple BBCS 485 units are used in multi-dropped mode for Modbus communication with a Host computer,
slide both the DIP switches on the Terminal PCB to ON position in only one (usually the physically farthest unit
on the multi-drop cable) of the BBCS 485.

ON
Modbus
OFF

Terminal PCB

For Sensor
Connect the 4 wires of sensor cable as per colour mentioned on terminal sticker. Also connect shield of cable at
connection number 15 (In older version 15 is not available hence connect shield at 10).
Ensure that correct cable length is selected in config mode menu.

Closing the lid

Re-check that the wiring has been correctly done. Replace the lid of the terminal compartment and fasten all the
4 screws tightly.

Powering up
Re-check that the external wiring has been correctly done. Switch on the Mains power. The display will show
the FM logo and the BBCS 485 model name for a few seconds before getting into the RUN mode which is the
default mode.

15
 8. AFTER 1st POWERUP

Please go through the following sequence of actions.

Understand the Human Machine Interface; see chapter BBCS HMI.
Understand the RUN Mode of operation. View the various parameters whose values get displayed on
screen.
Understand the Config Mode of operation. Check and set the values of the various configuration
parameters as applicable to your installation. Save and exit.
Controller executes boiler operative cycles (P, M, B) sequentially, is also indicated on display.
Controller turns valves ON/OFF during respective modes, check valve functioning during respective
modes.
Check that TDS and other parameters are updated.
If the BBCS 485 is connected to the host computer check the DIP switches are set as described earlier in
chapter ELECTRICAL CONNECTIONS.
Observe the functioning of the unit. In case you notice any problem, refer to chapter TROUBLE
SHOOTING and take appropriate action.
For further help, call Forbes Marshall Support at the address mentioned on the cover page.

16
 9. HUMAN MACHINE INTERFACE (HMI)

The HMI consists of a keypad with 3 keys providing a tactile feedback to the user when a key is pressed. A
backlit LCD is centrally placed for visual indication of the various parameters. The POWER LED indicates the
presence of mains power. The STATUS LED indicates the current process (steady) and error (blinking)

The keys have multiple functions. The function depends on the operational mode and the instantaneous
position within the Menu. A brief explanation follows.

ALL keys are used while entering the Password.

DOWN: Use this key to

o Scroll down multiple options on a screen. The selected option gets highlighted.
o Increment a selected digit while setting a specific numerical value.
o Switch from one screen to another of the same mode in when Run Mode.

ENTER: Use this key to

Select a highlighted option and move to next screen.
Save the numerical value being edited and move to next screen.

RIGHT: Use this key to

Go to the mode selection screen when in RUN mode.
Shift to the digit on the right of current digit in a ring fashion

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10. Operation: RUN mode

Operating Modes
The BBCS 485 is provided with following modes of operation.
RUN
Config
Service
When BBCS 485 is powered on, the FM logo is displayed for few seconds. The Unit then enters the RUN
mode.

RUN mode operations:

The RUN mode is the default mode; it displays run mode parameters.
It has three screens displaying a total four parameters and error messages.
Use DOWN key to roll the screen manually through the following 3 screens.
In case ERROR occurs, status LED blinks continuously and respective error is displayed on screen 3.

Text on display Key operational

TDS DOWN Key – Next screen: screen 2
. . . . ENTER Key - Not operational
Set Point
Run mode screen 1.1 RIGHT key – Moves to SELECT
3000 ppm
(PURGE CYCLE) Mode menu.
PURGE
TDS DOWN Key – Next screen: screen 2
2000 ppm ENTER Key - Not operational
Set Point
Run mode screen 1.2 RIGHT key – Moves to SELECT
3000 ppm
(MEASUREMENT CYCLE) Mode menu.
MEASUREMENT
TDS DOWN Key – Next screen: screen 2
3500 ppm ENTER Key - Not operational
Set Point
Run mode screen 1.3 RIGHT key – Moves to SELECT
3000 ppm
(BLOWDOWN CYCLE) Mode menu.
BLOWDOWN
TDS DOWN Key – Next screen: screen 2
Run mode screen 1.4 2900 ppm ENTER Key - Not operational
Set Point
(IDLE MODE) or (PURGE RIGHT key – Moves to SELECT
3000 ppm
INTERVAL MODE) Mode menu.
Purge after 60 min

TDS DOWN Key – Next screen: screen 2

700 ppm ENTER Key - Not operational
Set Point
Run mode screen 1.4 RIGHT key – Moves to SELECT
3000 ppm
(in case of ERROR) Mode menu.
Purge after 60 min
ERROR

18
 Press DOWN key for next screen

Text on display Key operational

Purge Totalizer DOWN Key – Next screen: screen 3
25 ENTER Key - Not operational
Blowdown Totalizer
Run mode screen 2 RIGHT key – Moves to SELECT
300
Mode menu.

Purge Totalizer DOWN Key – Next screen: screen 3

25 ENTER Key - Not operational
Blowdown Totalizer
Run mode screen 2 RIGHT key – Moves to SELECT
300
(in case of ERROR) Mode menu.
ERROR

Press DOWN key for next screen

Text on display Key operational

Error Message: DOWN Key – Next screen: screen 1
- TEMP sensor open ENTER Key - Not operational
- COND Sensor Open
Run mode screen 3 RIGHT key – Moves to SELECT
(in case of ERROR) Mode menu.

Error Message: DOWN Key – Next screen: screen 1

Run mode screen 3 ENTER Key - Not operational
(in case of NO ERROR) RIGHT key – Moves to SELECT
Mode menu.
NO ERROR

Press RIGHT key to change MODE

SELECT MODE
Text on display Key operational
DOWN Key – Highlight the next
Select Mode choice
Select mode screen Run ENTER key – select the highlighted
Config
choice and move to next menu item
Service
RIGHT key – Not operational.

19
11. Operation: CONFIG mode
Switching to Config Mode
The Config Mode enables you to modify certain configuration settings appropriate to your installation
and process.
While in RUN mode, press RIGHT key to go to the Select Mode screen and select Config.

Menu Screen Text on display Key operational/Comments

parameter no.
Config Mode
1 PASSWORD: DOWN KEY hit 4
Password: _ _ _ _
times continuously.
If authentication is successful, next
screen of menu is displayed.
If authentication fails, an “Invalid
Config Mode
Password” message is displayed. To
2
Password: **** retry the password, the Enter key
Password Success!!! should be pressed by selecting “Retry”
choice which again prompts for
password.
Config Mode
3 To go back to SELECT MODE screen,
Password: **** the Exit choice should be highlighted
Invalid Password using Down key and then Enter key
Retry should be pressed.
Exit

Config Mode DOWN Key–Scrolls digits from 0 to 9

TDS ENTER key – Saves the current value on
Set Point
TDS 1 screen and moves to next menu.
3000 ppm
SET POINT RIGHT key – to highlight the digit by
Allowed range is moving to next location from left to
700-7000 ppm right
Config Mode DOWN Key–Scrolls digits from 0 to 9
Purge time ENTER key – Saves the current value on
05 seconds
1 screen and moves to next menu.
PURGE TIME RIGHT key – to highlight the digit by
Allowed range is
05 to 60 seconds moving to next location from left to
right.
Config Mode DOWN Key –Scrolls digits from 0 to9
Blowdown time ENTER key – Saves the current value on
05 seconds
BLOWDOWN 1 screen and moves to next menu.
TIME RIGHT key – to highlight the digit by
Allowed range is
05 to 60 seconds moving to next location from left to
right

20
 Config Mode
Select Purge Interval DOWN Key – Highlight the next choice
15 min
1
30 mins
ENTER key – select the highlighted
1 hour
2 hour choice and move to next menu item
PURGE
2 Config Mode
INTERVAL RIGHT key – Not operational
Select Purge Interval
2 hour
4 hour
8 hour
12 hour
Config Mode DOWN Key–Scrolls digits from 0 to 9
Set Device Modbus ID ENTER key – Saves the current value
001
1 on screen and moves to next menu
MODBUS ID RIGHT key – to highlight the digit by
Allowed range is
1 -247 moving to next location from left to
right

Config Mode
Select Baudrate
1200
1 DOWN Key – Highlight the next
2400
choice
4800
9600
BAUD RATE Config Mode ENTER key – select the highlighted
Select Baudrate choice and move to next menu item
2400
2
4800 RIGHT key – Not operational
9600
19200
Config Mode DOWN Key – Highlight the next
1 Select parity choice
None
ENTER key – select the highlighted
Odd
PARITY BITS choice and move to next menu item
Even
None:1 stop bit
RIGHT key – Not operational
1 Config Mode DOWN Key – Highlight the next
Select Cable length choice
5 metres
CABLE Length ENTER key – select the highlighted
10Meters
choice and move to next menu item

RIGHT key – Not operational

1 Config Mode DOWN Key - Scrolls digits from 0 to 9
Enter TDS factor ENTER key – Saves the current value
0.7
TDS factor on screen and moves to next menu.
RIGHT key – to highlight the digit by
Allowed range is
0.1 to 0.9 moving to next location from left to
right

21
 Config Mode DOWN Key – Highlight the next
1 choice
Save Changes?
ENTER key – select the highlighted
Yes
Save changes choice and move to next menu item
No

RIGHT key – Not operational

Config Mode
1 Final Settings:
Set point 3000 ppm
Purge time 05 sec
DOWN Key – to view next screen of
Blowdown time 05 sec
Saved SETTINGS PurgeInterval 1 hour the same menu
Modbus ID 001
Config Mode ENTER key – exit to SELECT Mode
2 Final Settings: screen
Baud rate 9600
Parity None RIGHT key – Not operational
Cable length 5 metres
TDS factor 0.7

22
12. Operation: SERVICE mode

The Service Mode enables you to reset certain values, test the display, keypad and perform
electronic calibration, sensor calibration.
It enables to modify service mode settings like display view and purge location.
If you intend to perform electronic calibration, be prepared with the following
o Standard resistance decade box
o If decade box not available, use
Resistor 110 ohms, 0.1%, 500mW
Resistor 180 ohms, 0.1%, 500mW
Resistor 180 ohms, 0.1%, 500mW
Resistor 11 ohms, 0.1%, 500mW
Resistor 2000 ohms, 0.1%, 500mW
Resistor 155 ohms, 0.1%, 500mW
o Narrow tipped screw driver suitable for terminal connector
If you intend to reset, please be careful while selecting.
Following tables represent the values after reset.

Run time Values after reset

Purge totalizer 0
Blowdown totalizer 0

Config Values after reset

TDS Setpoint 3000
Purge time 05
Blowdown time 05
Modbus slave ID 1
Purge Interval 1 hour
Sensor cable length 5 meters
Baud rate 9600
Parity None
TDS factor 0.7

Service and calibration Values after reset

Display view User
Purge location Bottom blowdown line
Sensor calibration (K factor) 1
Also electronic calibration will be erased and default hard coded values will be assigned.

23
Menu Text on display Key operational/Comments
parameter
Service Mode
1 PASSWORD: RIGHT KEY hit 4
Password: _ _ _ _
times continuously.
If authentication is successful, next
screen of menu is displayed.
If authentication fails, an “Invalid
2 Service Mode
Password” message is displayed. To
Password Password: ****
retry the password, the Enter key
Success!!! should be pressed by selecting
“Retry” choice which again prompts
for password.
3 Service Mode
To go back to SELECT MODE screen,
Password: ****
Invalid Password
the Exit choice should be highlighted
Retry using Down key and then Enter key
Exit should be pressed.

1 Service Mode
Reset data Please be careful while resetting
Runtime
values. Refer tables which
Config
represent values after reset.
Service & calibration
Exit
2 Service Mode
Are you Sure? DOWN Key – Highlight the next choice
Reset Yes
No ENTER key – select the highlighted
choice and move to next menu item

3 Service Mode
Are you Sure?
RIGHT key – Not operational
Yes
No
Wait…. Exit :- moves to next menu

24
 1 Service Mode DOWN Key – Highlight the next choice
Perform Electronic ENTER key – select the highlighted
Calibration
choice and move to next menu item
Yes
RIGHT key – Not operational
No
NO:- moves to next menu
2 Service Mode
Temperature Sensor
Calibration
DOWN Key – Not operational
1. Connect 110 Ohm
Hit ENTER to continue
Or RIGHT to exit ENTER key – Assumes that resistor is
3 Service Mode connected and proceeds further.
Temperature Sensor
Calibration RIGHT key – forces to exit and
1. Connect 180 Ohm proceeds with screen 5.
Hit ENTER to continue
Or RIGHT to exit
If calibration is successful it will move
4 Service Mode
Temperature Sensor
to next screen else, it shows “error”
Calibration message and will show same screen
until you press RIGHT key to exit
Successful!!!

Electronic 5 Service Mode

calibration Conductivity Sensor
Calibration
1. Connect 180 Ohm
Hit ENTER to continue
Or RIGHT to exit
Service Mode DOWN Key – Not operational
Conductivity Sensor
6 Calibration ENTER key – Assumes that resistor is
1. Connect 11 Ohm connected and proceeds further.
Hit ENTER to continue
Or RIGHT to exit
RIGHT key – forces to exit and
7 Service Mode
Conductivity Sensor
proceeds with next menu screen
Calibration
1. Connect 2000 Ohm
Hit ENTER to continue If calibration is successful it will move
Or RIGHT to exit to next screen else, it shows “error”
Service Mode message and will show same screen
8 Conductivity Sensor until you press RIGHT key to exit
Calibration
1. Connect 155 Ohm
Hit ENTER to continue
Or RIGHT to exit
9 Service Mode
Conductivity Sensor
Calibration

Successful!!!

25
 1 Service Mode DOWN Key – Highlight the next choice
Sensor calibration
Enter K factor
Sensor ENTER key – select the highlighted
In-line calibration
calibration choice and move to next menu item
Exit
RIGHT key – Not operational
Exit :- moves to next menu
1.1 Service Mode DOWN Key – Scrolls digits from 0 to 9.
Enter K value Enter K factor ENTER key – Saves the current value
1.1000
manually on screen and moves to next menu.
(if required) RIGHT key – to highlight the digit by
Allowed range is
0.5000 to 1.5000 moving to next location from left to
right
2.1 Service Mode
In- line calibration

Hit ENTER to continue

DOWN Key – Scrolls digits from 0 to 9.
Or Right to exit ENTER key – Saves the current value
2.2 Service Mode on screen and moves to next menu.
In- line calibration RIGHT key – to highlight the digit by
PURGE cycle moving to next location from left to
Wait… right

In line Sensor Service Mode

2.4
Calibration In- line calibration
(Refer MEASUREMENT cycle
Chapter 13 for Wait…
detail
procedure)
2.3 Service Mode
In- line calibration
Controller will display previous saved
Enter TDS value TDS value, please enter TDS value
3000 ppm measured by reference meter or in
Allowed range is laboratory
700-7000 ppm
2.4 Service Mode
If calibration is successful (i.e. K value
K= 1.0000
is between 0.5 to 1.5 ) it will move to
next menu else, it shows “error” and
Ok . . .
will move back to screen 2.1
1 Service Mode DOWN Key – Highlight the next choice
Purge location
Select PURGE at
ENTER key – select the highlighted
Purge Location choice and move to next menu item
Bottom blowdown line
Level Gauge
RIGHT key – Not operational
1 Service Mode DOWN Key – Highlight the next choice
Select Display View ENTER key – select the highlighted
Service engineer
Display View choice and move to next menu item
User

RIGHT key – Not operational

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 1 Service Mode DOWN Key – Highlight the next choice
Test BBCS 485
Status LED
ENTER key – select the highlighted
Purge Relay
choice.
Blowdown relay
Exit
2 Service Mode RIGHT key – Not operational
Test BBCS 485 For Relay and LED test, select the
Display option using DOWN key and press
Keys ENTER key, it will turn ON for few
Status LED seconds and then turn OFF.
Purge Relay
Exit :- moves to select mode menu
Test BBCS 485
3 Display test

4 Keypad test – Press all keys to test

Hit DOWN Key
OK
Hit DOWN Key
OK
Hit DOWN Key
OK

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13. Sensor Calibration: In-line calibration (to determine K factor)

This menu in service mode is used to calibrate the conductivity sensor and determine its ‘K’ factor.
Please refer “Chapter 12.Operation: Service Mode” for Menu navigation. The procedure is as follows:
Go to service mode > sensor calibration > In-line calibration > press ENTER key
Wait till completion of Purge cycle and measurement cycle. After completion it will display
“Enter TDS value” message.

Service Mode
In- line calibration
Enter TDS value
3000 ppm
Allowed range is
700-7000 ppm

Now, let water sample in sensor chamber cool down for at least 30 minutes. Collect the sample
from sampling point at top piping and measure it by reference meter or in laboratory. During
this period controller will display same screen until you press ENTER key.
Controller will display previous saved TDS value, please enter measured TDS value and press
ENTER key. The controller will compute the K factor depending on the entered TDS value.
If the computed K factor is within the limit (0.5to 1.5) then “Calibration done” message will be
displayed on the display else “Calibration Error” message will be displayed.
In case of calibration error, repeat the procedure again. If still the error persists, contact
service engineer.
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.

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14. Troubleshooting

POWER LED is not lit, LCD is blank

o Check Mains connections are proper done.
o Check Mains voltage is within +10% and -15% of rated voltage.
o Check fuse link is intact. If not, replace with 20x5 glass fuse 200mA slow blow
o Open the lid and check internal PCB to PCB connector are intact.

STATUS LED blinks continuously:

While in RUN mode, using the DOWN key change screens until an error message is displayed.
o Temperature Error:
• Disconnect terminals T1, T2 (13, 14). Measure the resistance across the open sensor
wires. This must be between 100Ω and 195Ω. If not, replace sensor.
• Check temperature calibration. Perform temperature calibration if found necessary. See
section Service Mode in chapter OPERATION: Service mode.
o Conductivity Error:
• Disconnect terminals C1, C2 (11, 12). Measure the resistance across the open sensor
wires. This must be infinite, if not, replace sensor.
• Also check continuity between sensor electrodes and wire ends, if not, then check
connections at sensor head.
• Check conductivity calibration. Perform conductivity calibration if found necessary. See
section Service Mode in chapter OPERATION: Service mode.
o TDS Error:
• Take sample of boiler water from sensor chamber and measure it by reference meter,
should be within specified TDS range for controller.

Modbus communication does not occur

o Check the wiring.
o In case of a single BBCS 485 connected to the Host computer, confirm that DIP switches on the
Terminal PCB are set to ON position and an appropriate Device ID has been assigned at BBCS
485 and Host ends respectively.
o In case of multi-drop configuration, confirm that
• DIP switches on the Terminal PCB are set to ON position in only the last/ farthest of the
multi-dropped BBCS 485 devices.
• Unique Device ID has been assigned to each BBCS 485 at BBCS 485 and Host ends
respectively.

Valve is not operating

o Check if valve fuse link is intact.
o Check the wiring.
o Check resistance of coil, if short/ open then replace solenoid coil.
o Check air pressure is within operable range of the valve.

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 15. Appendix 1: Modbus RTU related information

Modbus RTU communication settings

Baud rate As per selection in CONIG Mode

No of bits 8
Parity As per selection in CONIG Mode
Stop bits As per selection of Parity in CONFIG mode
Supported function Read holding register
Data format Modbus -RTU

MODBUS Address details

Parameters/variables Data type Endianness Modbus Unit

address
TDS Float Highest byte 40001 ppm

40002
Lowest byte
Temperature Float Highest byte 40003 °C

(only for service

engineer) 40004
Lowest byte
Purge Totaliser Unsigned long integer Highest byte 40005

40006
Lowest byte
Blowdown Totaliser Unsigned long integer Highest byte 40007

40008
Lowest byte
Purge status Unsigned integer 0x00 40009
Lowest byte
Blowdown status Unsigned integer 0x00 40010
Lowest byte
Purge After Unsigned integer Highest byte 40011 minutes
(Remaining time) Lowest byte
30
Error Flag Unsigned integer 0x00 40012 Table
12
Lowest byte
Setpoint Unsigned integer 0x00 40013 ppm
Lowest byte
Purge time Unsigned integer 0x00 40014 seconds
Lowest byte
Blowdown time Unsigned integer 0x00 40015 seconds
Lowest byte
Purge interval Unsigned integer 0x00 40016 Table
Lowest byte 12

Modbus Slave ID Unsigned integer 0x00 40017

Lowest byte
Baudrate Unsigned integer 0x00 40018 Table
12
Lowest byte
Parity Unsigned integer 0x00 40019 Table
Lowest byte 12

Cable length Unsigned integer 0x00 40020 Table

Lowest byte 12

TDS factor Float Highest byte 40021

40022
Lowest byte
Temperature slope Float Highest byte 40023
(calibration parameter)

40024
Lowest byte
Temperature constant Float Highest byte 40025
(calibration parameter)

40026
Lowest byte
Range 1 slope Float Highest byte 40027
(calibration parameter)

40028
Lowest byte
31
Range 1 constant Float Highest byte 40029
(calibration parameter)

40030
Lowest byte
Range 2 slope Float Highest byte 40031
(calibration parameter)

40032
Lowest byte
Range 2 constant Float Highest byte 40033
(calibration parameter)

40034
Lowest byte
K factor Float Highest byte 40035
(calibration parameter)

40036
Lowest byte
Calibrated TDS Unsigned integer Highest byte 40037 ppm
(calibration parameter)
Lowest byte
Purge location Unsigned integer 0x00 40038 Table
Lowest byte 12

Display View Unsigned integer 0x00 40039 Table

Lowest byte 12

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Parameter string versus numerical values

Table 12
Purge interval Time Numerical value
15 min 0
30 min 1
1 hour 2
2 hour 3
4 hour 4
8 hour 5
12 hour 6

Baud Rate Numerical value

1200 0
2400 1
4800 2
9600 3
19200 4

Parity Numerical value

None 0
Odd 1
Even 2
None:1 stop bit 3

Cable Length Numerical value

5 meters 0
10 meters 1

Purge location Numerical value

Bottom Blowdown line 0
level gauge 1

Display view Numerical value

Service engineer 0
User 1

Error Flag Hex value (check corresponding binary bit only)

TEMPERATURE high 0x01
TEMPERATURE low 0x02
TDS high 0x04
TDS low 0x08
COND sensor short 0x10
COND sensor open 0x20
TEMP sensor open 0x40
Temp sensor short 0x80

33