Walchem W100W Operating Manual

WCT/WBLW100 Series

Cooling Tower and Boiler Controller

Instruction Manual

Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA

TEL: [phone] WEB: www.walchem.com

Notice

© 2018 WALCHEM, Iwaki America Incorporated (hereinafter “Walchem”)
5 Boynton Road, Holliston, MA 01746 USA
[phone]
All Rights Reserved
Printed in USA

Proprietary Material

The information and descriptions contained herein are the property of WALCHEM. Such information and descriptions
may not be copied or reproduced by any means, or disseminated or distributed without the express prior written permis­sion of WALCHEM, 5 Boynton Road, Holliston, MA 01746.

This document is for information purposes only and is subject to change without notice.

Statement of Limited Warranty

WALCHEM warrants equipment of its manufacture, and bearing its identication to be free from defects in workmanship

and material for a period of 24 months for electronics and 12 months for mechanical parts and electrodes from date of
delivery from the factory or authorized distributor under normal use and service and otherwise when such equipment is
used in accordance with instructions furnished by WALCHEM and for the purposes disclosed in writing at the time of pur­chase, if any. WALCHEM’s liability under this warranty shall be limited to replacement or repair, F.O.B. Holliston, MA
U.S.A. of any defective equipment or part which, having been returned to WALCHEM, transportation charges prepaid,
has been inspected and determined by WALCHEM to be defective. Replaceable elastomeric parts and glass components
are expendable and are not covered by any warranty.

THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EITHER EXPRESS OR IMPLIED, AS TO DESCRIP­TION, QUALITY, MERCHANTABILITY, FITNESS FOR ANY PARTICULAR PURPOSE OR USE, OR ANY OTHER
MATTER.

180530 Rev. R September 2018

Contents

1.0 INTRODUCTION ................................................................................................................................ 1

2.0 SPECIFICATIONS ............................................................................................................................. 2

2.1 Measurement Performance ................................................................................................................ 2

2.2 Electrical: Input/Output ....................................................................................................................... 3

2.3 Mechanical ......................................................................................................................................... 4

2.4 Variables and their Limits ................................................................................................................... 5

3.0 UNPACKING & INSTALLATION ....................................................................................................... 6

3.1 Unpacking the unit .............................................................................................................................. 6

3.2 Mounting the electronic enclosure ...................................................................................................... 6

3.3 Installation .......................................................................................................................................... 6

3.4 IconDenitions ................................................................................................................................... 9

3.5 Electrical installation ......................................................................................................................... 10

4.0 FUNCTION OVERVIEW .................................................................................................................. 22

4.1 Front Panel ....................................................................................................................................... 22

4.2 Display .............................................................................................................................................. 22

4.3 Keypad ............................................................................................................................................. 22

4.4 Icons ................................................................................................................................................. 22

4.5 Startup .............................................................................................................................................. 24

4.6 Shut Down ........................................................................................................................................ 29

5.0 OPERATION .................................................................................................................................... 30

5.1 Alarms Menu .................................................................................................................................. 30

5.2 Inputs Menu ................................................................................................................................... 30

5.2.1 Contacting Conductivity ......................................................................................................... 32

5.2.2 Electrodeless Conductivity .................................................................................................... 32

5.2.3 Temperature ........................................................................................................................... 33

5.2.4 DI State .................................................................................................................................. 33

5.2.5 Flow Meter, Contactor Type ................................................................................................... 34

5.2.6 Flow Meter, Paddlewheel Type .............................................................................................. 34

5.3 Outputs Menu ................................................................................................................................. 35

5.3.1 Relay, Any Control Mode ........................................................................................................ 35

5.3.2 Relay, On/Off Control Mode ................................................................................................... 35

5.3.3 Relay, Flow Timer Control Mode ............................................................................................ 36

5.3.4 Relay, Bleed and Feed Control Mode .................................................................................... 36

5.3.5 Relay, Bleed then Feed Control Mode ................................................................................... 36

5.3.6 Relay, Percent Timer Control Mode ....................................................................................... 36

5.3.7 Relay, Biocide Timer Control Mode ........................................................................................ 37

5.3.8 Relay, Alarm Mode ................................................................................................................. 38

5.3.9 Relay, Time Proportional Control Mode ................................................................................. 38

5.3.10 Relay, Intermittent Sampling Control Mode ............................................................................ 39

5.3.11 Relay or Analog Output, Manual Mode .................................................................................. 40

5.3.12 Relay, Pulse Proportional Control Mode ................................................................................ 40

5.3.13 Relay, Dual Set Point Mode ................................................................................................... 40

5.3.14 Relay, Probe Wash Control Mode .......................................................................................... 41

5.3.15 Analog Output, Retransmit Mode ........................................................................................... 42

5.3.16 Analog Output, Proportional Control Mode ............................................................................ 42

5.4 Settings Menu .............................................................................................................................. 43

5.4.1 Global Settings ..................................................................................................................... 43

5.4.2 Security Settings .................................................................................................................. 44

5.4.3 Display Settings ................................................................................................................... 44

5.4.4 File Utilities ........................................................................................................................... 44

5.4.5 Controller Details .................................................................................................................. 44

6.0 MAINTENANCE ............................................................................................................................. 46

6.1 Conductivity Sensor Cleaning ........................................................................................................ 46

7.0 TROUBLESHOOTING ................................................................................................................... 47

7.1 Calibration Failure .......................................................................................................................... 47

7.1.1 Contacting Conductivity Sensors ........................................................................................... 47

7.1.2 Electrodeless Conductivity Sensors ...................................................................................... 47

7.2 Alarm Messages ............................................................................................................................. 48

8.0 SERVICE POLICY ......................................................................................................................... 51

9.0 SPARE PARTS IDENTIFICATION ................................................................................................. 52

1.0 INTRODUCTION

The Walchem WCT/WBL100 Series controllers offer a high level of exibility in controlling cooling tower and boiler

water treatment applications.

One sensor input is available that are compatible with a variety of sensors:

Cooling tower, boiler, and low cell constant condensate contacting conductivity
Electrodeless conductivity

Two digital inputs may be used for a variety of purposes:

State type: Flow switch or other Interlock to stop control, or drum level switch

Water meter contactor: To control a relay to feed a chemical based on ow total
Paddlewheel owmeter: To control based on ow total or ow rate

Three relay outputs may be set to a variety of control modes:

On/Off set point control

Bleed or Feed based on a Water Contactor or Paddlewheel ow meter input

Feed and Bleed
Feed and Bleed with Lockout
Feed as a percent of Bleed
Feed as a percentage of elapsed time
Daily, Weekly, 2-week or 4-week Biocide timers with pre-bleed and post-add lockout of bleed
Intermittent sampling for boilers with proportional blowdown, controlling on a trapped sample
Time Proportional control
Always on unless interlocked
Dual set point
Probe Wash timer
Diagnostic Alarm triggered by:
High or Low sensor reading
No Flow
Relay output timeout
Sensor error

An optional isolated analog output may be included to retransmit sensor input signals to a chart recorder, data logger,
PLC or other device.

Our unique USB features provide the ability to upgrade the software in the controller to the latest version.

1

2.0 SPECIFICATIONS

2.1 Measurement Performance

0.1 Cell Contacting Conductivity

Range 0-3,000 µS/cm

Resolution 0.1 µS/cm, 0.0001 mS/cm, 0.01 mS/m, 0.0001 S/m, 0.1 ppm

Accuracy ± 1% of reading

1.0 Cell Contacting Conductivity

Range 0-30,000 µS/cm

Resolution 1 µS/cm, 0.001 mS/cm, 0.1 mS/m, 0.0001 S/m, 1 ppm

Accuracy ± 1% of reading

10.0 Cell Contacting Conductivity

Range 1,000-300,000 µS/cm

Resolution 10 µS/cm, 0.01 mS/cm, 1 mS/m, 0.001 S/m, 10 ppm

Accuracy ± 1% of reading

Temperature

Range 23 to 500°F (-5 to 260°C)

Resolution 0.1°F (0.1°C)

Accuracy ± 1% of reading

Electrodeless Conductivity

Ranges Resolution Accuracy

500-12,000 µS/cm 1 µS/cm, 0.01 mS/cm, 0.1 mS/m, 0.001 S/m, 1 ppm ± 1% of reading

3,000-40,000 µS/cm 1 µS/cm, 0.01 mS/cm, 0.1 mS/m, 0.001 S/m, 1 ppm ± 1% of reading

10,000-150,000 µS/cm 10 µS/cm, 0.1 mS/cm, 1 mS/m, 0.01 S/m, 10 ppm ± 1% of reading

50,000-500,000 µS/cm 10 µS/cm, 0.1 mS/cm, 1 mS/m, 0.01 S/m, 10 ppm ± 1% of reading

200,000-2,000,000 µS/cm 100 µS/cm, 0.1 mS/cm, 1 mS/m, 0.1 S/m, 100 ppm ± 1% of reading

Temperature °C Range Multiplier Temperature °C Range Multiplier

0 181.3 80 43.5

10 139.9 90 39.2

15 124.2 100 35.7

20 111.1 110 32.8

25 100.0 120 30.4

30 90.6 130 28.5

35 82.5 140 26.9

40 75.5 150 25.5

50 64.3 160 24.4

60 55.6 170 23.6

70 48.9 180 22.9

Note: Conductivity ranges above apply at 25°C. At higher temperatures, the range is reduced per the range multiplier
chart.

2

2.2 Electrical: Input/Output

Input Power 100 to 240 VAC, 50 or 60 Hz, 7 A maximum

Fuse: 6.3 A

Input Signals

Contacting Conductivity 0.1, 1.0, or 10.0 cell constant OR

Electrodeless Conductivity

Temperature 100 or 1000 ohm RTD, 10K or 100K Thermistor

Digital Input Signals (2):

State-Type Digital Inputs

Low Speed Counter-Type
Digial Inputs

High Speed Counter-Type
Digial Inputs

Powered Mechanical Relays
(0 or 3 depending on model
code):

Dry contact Mechanical
Relays (0 or 3 depending on
model code):

4 - 20 mA (0 or 1 depending
on model code):

Agency Approvals

Safety UL 61010-1:2012 3rd Ed.

EMC IEC 61326-1:2012

Note: For EN61000-4-6, EN61000-4-3 the controller met performance criteria B.
*Class A equipment: Equipment suitable for use in establishments other than domestic, and those directly connected to
a low voltage (100-240 VAC) power supply network which supplies buildings used for domestic purposes.

Electrical: Optically isolated and providing an electrically isolated 9V power with a
nominal 2.3mA current when the digital input switch is closed
Typical response time: < 2 seconds
Devices supported: Any isolated dry contact (i.e. relay, reed switch)
Types: Interlock

Electrical: Optically isolated and providing an electrically isolated 9V power with
a nominal 2.3mA current when the digital input switch is closed 0-10 Hz, 50 msec
minimum width
Devices supported: Any device with isolated open drain, open collector, transistor or
reed switch
Types: Contacting Flowmeter

Electrical: Optically isolated and providing an electrically isolated 9V power with a
nominal 2.3mA current when the digital input switch is closed, 0-500 Hz,

1.00 msec minimum width
Devices supported: Any device with isolated open drain, open collector, transistor or
reed switch
Types: Paddlewheel Flowmeter

Pre-powered on circuit board switching line voltage
6 A (resistive), 1/8 HP (93 W) per relay
All three relays are fused together as one group, total current for this group must not
exceed 6A

6 A (resistive), 1/8 HP (93 W) per relay
Dry contact relays are not fuse protected

Internally powered
Fully isolated
600 Ohm max resistive load
Resolution 0.0015% of span
Accuracy ± 0.5% of reading

CSA C22.2 No. 61010-1:2012 3rd Ed.

IEC 61010-1:2010 3rd Ed.

EN 61010-1:2010 3rd Ed.

EN 61326-1:2013

3

2.3 Mechanical

Enclosure Material Polycarbonate

Enclosure Rating NEMA 4X (IP65)

Dimensions 8” x 8” x 3” (203 mm x 203 mm x 76 mm)

Display 128 x 64 graphic backlit display

Operating Ambient Temp -4 to 131 °F (-20 to 55 °C)

Storage Temperature -4 – 176°F (-20 – 80°C)

Mechanical (Sensors) (*See graph)

Sensor Pressure Temperature Materials

Graphite contacting
conductivity tower

316 SS contacting
conductivity tower

High pressure tower 0-300 psi (0-20 bar)*

Electrodeless tower

Low pressure manifold

High pressure manifold 0-300 psi (0-20 bar)*

Boiler/condensate
contacting conductivity

0-150 psi up to 100°F (38°C)*
0- 50 psi at 140°F (60°C)

0-150 psi up to 100°F (38°C) *
0- 50 psi at 140°F (60°C)

0-150 psi up to 100°F (38°C)*
0- 50 psi at 140°F (60°C)

0-150 psi up to 100°F (38°C)*
0- 50 psi at 140°F (60°C)

0-250 psi (0-17 bar)

32-140°F *

(0-60°C)

32-140°F *

(0-60°C)

32-158°F *

(0-70°C)

32-140°F *

(0-60°C)

32-140°F *

(0-60°C)

32-158°F *

(0-70°C)

32-401°F

(0-205°C)

GFRPP, Graphite, FKM 3/4” NPTF

GFRPP, 316SS, FKM 3/4” NPTF

316SS, PEEK 3/4” NPTF

PP, PVC, FKM 3/4” NPTF

GFRPP, PVC, FKM,
Isoplast

Carbon steel, steel, brass 3/4” NPTF

316SS, PEEK 3/4” NPTM

Process

Connections

3/4” NPTF

Bar

24.1

20.7

17.2

13.8

10.3

6.9

3.4

PSI

350

300

250

200

150

100

50

Pressure vs. Temperature

pH/ORP

LD2

Cond

HP Cond/Steel

HP pH/ORP/Steel

0

30

-1.1

40

4.4

50

10.0

60

15.5

70

21.1

80

26.6

90

32.2

100

37.7

110

43.3

120

48.8

130

54.4

140

60.0

150

65.5

160

71.1

170

76.6

180

°C

82.2

°F

4

2.4 Variables and their Limits

Sensor input settings Low Limit High Limit

Conductivity alarm limits 0 50,000

Conductivity alarm dead band 0 50,000

Cell constant 0.01 10

Smoothing Factor 0% 90%

Comp Factor (conductivity linear ATC only) 0% 20%

Installation Factor (Electrodeless conductivity only) 0.5 1.5

Cable length 0.1 3,000

PPM conversion factor (only if units = PPM) 0.001 10.000

Default temperature -20 500

Calibration Required Alarm 0 days 365 Days

Flow meter input settings Low Limit High Limit

Totalizer alarm 0 100,000,000

Volume/contact for units of Gallons or Liters 1 100,000

Volume/contact for units of m

K Factor for units of Gallons or Liters 0.01 10,000

K Factor for units of m

Paddlewheel rate alarm limits 0 High end of sensor range

Paddlewheel rate alarm deadband 0 High end of sensor range

Smoothing Factor 0% 90%

Set Flow Total 0 1,000,000,000

Relay output settings Low Limit High Limit

Output Limit Time 1 second 86,400 seconds (0 = unlimited)

Hand Time Limit 1 second 86,400 seconds (0 = unlimited)

Min Relay Cycle 0 seconds 300 seconds

Set Point Low end of sensor range High end of sensor range

Duty Cycle Period (On/Off, Dual Set-point modes) 0:00 minutes 59:59 minutes

Duty Cycle (On/Off, Dual Setpoint modes) 0% 100%

Dead Band Low end of sensor range High end of sensor range

Feed duration (Flow timer mode) 0 seconds 86,400 seconds

Accumulator volume (Flow timer mode) 0 1,000,000

Feed Percentage (Bleed then Feed mode) 0% 100%

Feed Lockout Time Limit (Bleed & Feed, Bleed then Feed modes) 0 seconds 86,400 seconds

Prebleed to Conductivity (Biocide mode) 1 (0 = no prebleed) High end of sensor range

Prebleed Time (Biocide mode) 0 seconds 86,400 seconds

Bleed Lockout(Biocide mode) 0 seconds 86,400 seconds

Event duration (Biocide, Timer modes) 0 seconds 86,400 seconds

Proportional band (Time/Pulse Proportional mode, Intermittent
Sampling)

Sample period (Time Proportional mode) 10 seconds 3600 seconds

Sample Time (Intermittent Sampling mode) 0 seconds 3600 seconds

Hold Time (Intermittent Sampling mode) 0 seconds 3600 seconds

Maximum Blowdown (Intermittent Sampling mode) 0 seconds 3600 seconds

Wait Time (Intermittent Sampling mode) 0 seconds 86,400 seconds

Max Rate (Pulse Proportional mode) 10 pulses/minute 480 pulses/minute

Minimum Output (Pulse Proportional mode) 0% 100%

3

3

0.001 1,000

1 100,000

Low end of sensor

High end of sensor range

range

5

Maximum Output (Pulse Proportional mode) 0% 100%

Analog (4-20 mA) Output settings Low Limit High Limit

4 mA Value 0 30,000

20 mA Value 0 30,000

Hand Output 0% 100%

Set Point 0 30,000

Proportional Band 0 30,000

Minimum Output 0% 100%

Maximum Output 0% 100%

Off Mode Output (Proportional, PID, Flow Prop modes) 0 mA 21 mA

Pump Capacity (Flow Prop mode) 0 gal/hour or l/hour 10,000 gal/hour or l/hour

Pump Setting (Flow Prop mode) 0% 100%

Specic Gravity (Flow Prop mode) 0 g/ml 9.999 g/ml

Target (Flow Prop mode) 0 ppm 1,000,000 pm

Error Output 0 mA 21 mA

Conguration settings Low Limit High Limit

Local Password 0000 9999

Alarm Delay 0:00 minutes 59:59 minutes

3.0 UNPACKING & INSTALLATION

3.1 Unpacking the unit

Inspect the contents of the carton. Please notify the carrier immediately if there are any signs of damage to the
controller or its parts. Contact your distributor if any of the parts are missing. The carton should contain a W100
series controller and an instruction manual. Any options or accessories will be incorporated as ordered.

3.2 Mounting the electronic enclosure

The controller is supplied with mounting holes on the enclosure. It should be wall mounted with the display at eye level,
on a vibration-free surface, utilizing all four mounting holes for maximum stability. Use M6 (1/4” diameter) fasteners
that are appropriate for the substrate material of the wall. The enclosure is NEMA 4X (IP65) rated. The maximum
operating ambient temperature is 131°F (55°C); this should be considered if installation is in a high temperature
location. The enclosure requires the following clearances:
Top: 2” (50 mm)
Left: 8” (203 mm) (not applicable for prewired models)
Right: 4” (102 mm)
Bottom: 7” (178 mm)

3.3 Installation

Once the controller is mounted, the metering pumps may be located at any distance from the controller.

Plumbing

The W100 series controllers can be supplied with a ow switch manifold designed to provide a continuously owing
sample of cooling water to the sensors. Please refer to Figures 2 through 6 below for some typical installation drawings.

Cooling Towers:

Tap off the discharge side of the recirculation pump to provide a minimum ow of 1 gallon per minute past the sensor.
The sample must ow into the bottom of the manifold in order to close the ow switch, and return to a point of
lower pressure in order to ensure ow. Install an isolation valve on both sides of the manifold to stop ow for

sensor maintenance.

6

The contacting conductivity sensor should be placed as close to the controller as possible, to a maximum distance of
250 ft. (76 m). Less than 25 ft. (8 m) is recommended. The cable must be shielded from background electrical noise.
Always route low voltage (sensor) signals with at least a 6” (15 cm) separation from AC voltage wiring.

The electrodeless conductivity sensor should be placed as close to the controller as possible, to a maximum distance
of 120 ft. (37 m). Less than 20 ft. (6 m) is recommended.. The cable must be shielded from background electrical noise.
Always route low voltage (sensor) signals with at least a 6” (15 cm) separation from AC voltage wiring. These sensors
are affected by the geometry and conductivity of their surroundings, so either maintain 6 inches (15 cm) of sample
around the sensor or ensure that any nearby conductive or nonconductive items are consistently positioned. Do not install

the sensor in the path of any electrical current that may be owing in the solution, as this will shift the conductivity reading.

IMPORTANT: To avoid damaging the female pipe threads on the supplied plumbing parts, use no more than 3 wraps
of PTFE tape and thread into the pipe FINGER tight only! DO NOT use any pipe dope, plumber’s putty or other

sealing products that containdiacetone alcohol, as these attack the ow switch plastic! Use PTFE tape ONLY!

Boilers:

The conductivity sensor should be placed as close to the controller as possible, to a maximum distance of 250 ft.
(76m). The cable MUST be shielded from background electrical noise. Use 24 AWG cable.

Important Boiler Installation Notes: (see gures 3 and 4)

1. Make sure the minimum water level in the boiler is at least 4-6 inches (10-15 cm) above the skimmer blowdown
line. If the skimmer line is closer to the surface, it is likely that steam will be drawn into the line instead of boiler
water. The skimmer line must also be installed above the highest tube.

2. Maintain a 3/4 inch minimum pipe ID with no ow restrictions from the tap for the boiler skimmer blowdown
line to the electrode. If the ID is reduced below 3/4 inch, then ashing will occur beyond that point and the con­ductivity reading will be low and erratic. Minimize the usage of tees, valves, elbows or unions between the boiler
and the electrode.

3. A manual shut off valve should be installed so that the electrode can be removed and cleaned. This valve must be
a full port valve in order to avoid a ow restriction.

4. Keep the distance between the tap for the boiler skimmer line to the electrode as short as possible, to a maximum
of 10 feet (3m).

5. Mount the electrode in the side branch of a tee in a horizontal run of pipe. This will minimize entrapment of
steam around the electrode and will allow any solids to pass through.

6. There MUST be a ow restriction after the electrode and/or control valve in order to provide back pressure. This

ow restriction will be either a ow control valve or an orice union. The amount of the ow restriction will

affect the blowdown rate as well, and should be sized accordingly.

7. Install the motorized ball valve or solenoid valve per the manufacturer’s instructions.

For best results, align the hole in the conductivity electrode such that the direction of water ow is through the hole.

Guide to Sizing Blowdown Valves and Orice Plates

1. Determine the Rate of Steam Production in Pounds per Hour:

Either read off the boiler name plate (water-tube boilers) or Calculate from horsepower rating (re-tube boilers):

HP x 34.5 = lbs./hr. Example: 100 HP = 3450 lbs./hr

2. Determine the Concentration Ratio (BASED ON FEEDWATER)

A water treatment chemical specialist should determine the desired number of cycles of concentration. This is the
ratio of TDS in the boiler water to TDS in the feedwater. Note that feedwater means the water that is fed to the
boiler from the deaerator and includes makeup water plus condensate return.

Example: 10 cycles of concentration has been recommended

7

3. Determine the Required Blowdown Rate in Pounds Per Hour

Blowdown Rate = Steam Production / (Concentration Ratio –1)
Example: 3450/(10-1) = 383.33 lbs./hr.

4. Determine if Continuous or Intermittent Sampling is Required

Use intermittent sampling when the boiler operation or loading is intermittent, or on boilers where the required

blowdown rate is less than 25% of the smallest available ow control valve or less than the ow through the
smallest orice. See the graphs on the next page.

Use continuous sampling when the boiler is operating 24 hours per day and the required blowdown rate is more

than 25% of the smallest applicable ow control valve or orice. See the graphs on the next page.

Use of a ow control valve will give you the best control of the process, since the ow rate can be easily
adjusted. The dial on the valve also gives you a visual indication if the ow rate has been changed. If the valve

clogs, it can be opened to clear the obstruction, and closed to the previous position.

If an orice plate is used, you must install a valve downstream from the orice in order to ne tune the ow

rate and provide additional back pressure in many applications.

Example: An 80 psi boiler has a Required Blowdown Rate of 383.33 lbs./hr. The maximum ow rate of the
smallest ow control valve is 3250 lbs./hr. 3250 x 0.25= 812.5 which is too high for continuous sampling.
Using an orice, the ow rate through the smallest diameter plate is 1275 lbs./hr. This is too high for continuous

sampling.

5. Determine the Orice or Flow Control Valve Size for this Blowdown Rate

Use the following graphs to select a ow control device:

Flow Rate in Lbs/hr for Various Orifices

18000

16000

14000

12000

10000

lbs/hr

8000

6000

1/8 inch dia

3/16 inch dia

1/4 inch dia

5/16 inch dia

4000

2000

0

10 20 30 40 50 60 70 80 90 100 200 300

Pressure PSI

8

25000

20000

Flow Control Valve

Maximum Flow Rates in Lbs/hr

15000

lbs/hr

10000

5000

0

20 30 40 50 60 70 80 90 100 150 200 300

3.4 IconDenitions

Symbol Publication Description

1/2" 150 PSI

1/2" 300 PSI

3/4" 150 PSI

3/4" 300 PSI

Pressure PSI

O

IEC 417, No.5019 Protective Conductor Terminal

IEC 417, No. 5007 On (Supply)

IEC 417, No. 5008 Off (Supply)

ISO 3864, No. B.3.6 Caution, risk of electric shock

ISO 3864, No. B.3.1 Caution

9

3.5 Electrical installation

The various standard wiring options are shown in gure 1 below. Your controller will arrive from the factory prewired
or ready for hardwiring. Depending on your conguration of controller options, you may be required to hardwire some
or all of the input/output devices. Refer to gures 7 through 13 for circuit board layout and wiring.

Note: when wiring the optional ow meter contactor input, the 4-20 mA outputs or a remote ow switch, it is advisable

to use stranded, twisted, shielded pair wire between 22-26 AWG. Shield should be terminated at the controller (see

gure 10).

CAUTION

1. There are live circuits inside the controller even when the power switch on the front panel is in the OFF position!
The front panel must never be opened before power to the controller is REMOVED!
If your controller is prewired, it is supplied with a 8 foot, 18 AWG power cord with USA style plug. A tool (#1
Phillips driver) is required to open the front panel.

2. When mounting the controller, make sure there is clear access to the disconnecting device!

3. The electrical installation of the controller must be done by trained personnel only and conform to all applicable
National, State and Local codes!

4. Proper grounding of this product is required. Any attempt to bypass the grounding will compromise the safety of
persons and property.

5. Operating this product in a manner not specied by Walchem may impair the protection provided by the equipment.

Digital Inputs
& Analog Output

Optional pH/ORP/ISE
Sensor BNC

Figure 1 Conduit Wiring

Sensor

Power
Switch

Relay
Outputs

AC Power

10

HEAT
EXCHANGER

�METERING
PUMPS

COOLING TOWER

13"

11.75"

Figure 2 Typical Cooling Tower Installation

11

1
2
3

Skimmer Blowdown Line
3/4" Min. up to Electrode

with minimal valves, elbows & unions

10 ft. max.

Full Port Block

Valve

TO

DRAIN

¾" TEE

2 ft.

minimum

Manual Blowdown
(Normally Closed)

CONDUCTIVITY

ELECTRODE

1 to 3 ft.

maximum

Motorized

Ball

or Solenoid

Valve

Flow
Control
Valve or

Orifice Union

To Drain

Install accessories
either vertically or
horizontally, per
manufacturer's
instructions.

Figure 3 Typical Boiler Installation Intermittent Sampling

12

1
2
3

Skimmer Blowdown Line
3/4" Min. up to Electrode

Full Port Block

Valve

To Drain

Motorized

Ball

or

Solenoid

Valve

CONDUCTIVITY

ELECTRODE

¾" TEE

Manual Blowdown
(Normally Closed)

Install accessories
either vertically or
horizontally, per
manufacturer's
instructions.

Flow

Control

Valve

or Orifice

Union

Flow
Control
Valve or

Orifice Union

To Drain

To Drain

Figure 4 Typical Boiler Installation Continuous Sampling

13

TO

110 VOLT AC

OUTLET

1
2
3

TYPICAL INSTALLATION

SUBMERSION ELECTRODE

COOLING

TOWER

CHEMICAL

PUMP

CHEMICAL

TANK

XYZX

VALV E

TO

SANITARY

SEWER

(OPTION "A")

CIRCULATION

PUMP

(X) Unions; installed for replacement of
solenoid or strainer
(Y) ½" Y-strainer

(Z) ½"solenoid

DETAIL OF

PROBE ASSEMBLY

CLIP PROBE
ASSEMBLY TO
SUMP WALL FOR
EASY REMOVAL
FOR CLEANING

PROBE

TO

CONTROLLER

1" PVC

1" NPTF PVC

COUPLING

(OPTION "B")

OPEN
SUMP

X Y Z X

VALV E

TO

SANITARY

SEWER

NOTE: LOCATION OF SOLENOID VALVE
USING OPTION "A" OR OPTION "B"
DEPENDS ON SYSTEM CONFIGURATION.

PIPE

INSTALL APPROXIMATELY
HALF-WAY IN SUMP VOLUME

AVOID INSTALLATION NEAR
PUMP SUCTION INLET

¾" PROBE
IN TEE

Figure 5 Typical Cooling Tower Installation Submersion Sensor

14

TO

CONSTANT

110 VOLTS

1
2
3

TYPICAL INSTALLATION

INTERMITTENT SAMPLING

TO ELECTRODE

TO SOLENOID

SHUTOFF
VALV E

PE DISCHARGE

CHEMICAL

PUMP

TUBING

CHEMICAL

TANK

(A)

TO

SANITARY

SEWER

(A)

(D)

(B)

(F)

(C)

(E)

SPRAY TOWER

(A) Unions; installed for replacement of
solenoid, strainer or probe

(B) ½" solenoid

(C) ½" Y-strainer

(D) Conductivity sensor in ¾" NPTF tee
(supplied with controller)

(E) ½" PVC bulkhead fitting

(F) winter drain

CITY WATER

MAKEUP

SPRAY
PUMP

Figure 6 Typical Cooling Tower Installation Intermittent Sampling

15