Walchem W100W Operating Manual

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Page 1

WCT/WBLW100 Series

Cooling Tower and Boiler Controller

Instruction Manual

Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA

TEL: 508-429-1110 WEB: www.walchem.com

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Notice

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

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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

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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

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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.

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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.

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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

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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)

0-250 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

Pressure vs. Temperature

pH/ORP

LD2

Cond

HP Cond/Steel

HP pH/ORP/Steel

-1.1

4.4

10.0

15.5

21.1

26.6

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

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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%

0.001 1,000

1 100,000

Low end of sensor

High end of sensor range

range

Page 10

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.

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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

Page 12

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

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

Pressure PSI

Page 13

25000

20000

Flow Control Valve

Maximum Flow Rates in Lbs/hr

15000

lbs/hr

10000

5000

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

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

Page 14

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

Page 15

HEAT EXCHANGER

�METERING PUMPS

COOLING TOWER

13"

11.75"

Figure 2 Typical Cooling Tower Installation

Page 16

1 2 3

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

with minimal valves, elbows & unions

10 ft. max.

Full Port Block

Valve

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

Page 17

1 2 3

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

Full Port Block

Valve

To Drain

Motorized

Ball

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

Figure 4 Typical Boiler Installation Continuous Sampling

Page 18

110 VOLT AC

OUTLET

1 2 3

TYPICAL INSTALLATION

SUBMERSION ELECTRODE

COOLING

TOWER

CHEMICAL

PUMP

CHEMICAL

TANK

XYZX

VALV E

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

CONTROLLER

1" PVC

1" NPTF PVC

COUPLING

(OPTION "B")

OPEN SUMP

X Y Z X

VALV E

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

Page 19

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)

SANITARY

SEWER

(A)

(D)

(B)

(F)

(C)

(E)

SPRAY TOWER

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

(B) ½" solenoid

(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

Page 20

RELAY OUTPUT

CONNECTOR

TERMINAL BLOCK

EARTH GROUND

TERMINAL BLOCK

POWER SUPPLY

DIGITAL INPUT & OPTIONAL

ANALOG OUTPUT TERMINAL BLOCK

POWER

TB3

1234567891011

SWITCH

TB6

NNN

TB4

TB2

1234567891011

FUSE

POWER

SWITCH

FUSE

TB5

TB1

–

TB7

SENSOR INPUT

AC POWER

TERMINAL

BLOCK

TERMINAL BLOCK

OPTIONAL NON-AMPLIFIED

PH/ORP INPUT TERMINAL

BLOCK

RIBBON CABLE

Figure7IdenticationofParts

MAIN CONTROLLER

BOARD

USB

Page 21

TB7

1 2 3 4 5 6 7 8 9

TB3

10 11 12

TB2

1 2 3 4 5 6

TB4

7 8 9 10 11

TB5

TB1

–

TB6

N N N

FUSE

POWER SWITCH

TB1 ECOND CCOND

XMT+ XMT

1 2

XMT–

3 X-SHLD

pH/ORP

SHIELD SHIELD SHIELD

4 5 RCV– 6 RCV+ 7 RCV IN+ 8 –5V

w/BNC

USE

BNC FOR

INPUT

SIGNAL

pH/ORP

DIS

+5V

9 TEMP– TEMP– TEMP– TEMP–

10 TEMP+ TEMP+ TEMP+ TEMP+ 11 IN–

R-SHLD

SAFETY COVER LABEL

TB2 FUNCTION

1 4-20 OUT– 2 4-20 OUT+ 3 SHIELD 4

DIG IN 2–

5 DIG IN 2+ 6 +9 VDC 7 SHIELD 8

DIG IN 1–

9 DIG IN 1+

+9 VDC

10 11 SHIELD 12

1 2 3

XMT RED

SHIELD

4 5 6 7 8 9

RCV BLK

TEMP– WHT TEMP+ GRN

TB1

WHT

RED

BLK

GRN

High Pressure

Conductivity

Electrode

Condensate Electrode

(wiring is typical of all three sensor options)

Figure 8 Contacting Conductivity Sensor Input Wiring

Conductivity

Electrode

Page 22

pH/ORP

TB1 ECOND CCOND

w/BNC

pH/ORP

DIS

1 XMT+ XMT 2

XMT–

3 X-SHLD 4 +5V 5 RCV– 6 RCV+ 7 RCV IN+ 8 –5V

SHIELD SHIELD SHIELD

USE

BNC FOR

INPUT

SIGNAL

9 TEMP– TEMP– TEMP– TEMP–

TEMP+ TEMP+ TEMP+ TEMP+

11 IN–

R-SHLD

TB2 FUNCTION

1 4-20 OUT– 2 4-20 OUT+ 3 SHIELD 4

DIG IN 2–

5 DIG IN 2+ 6 +9 VDC 7 SHIELD 8

DIG IN 1–

9 DIG IN 1+

+9 VDC

11 SHIELD 12

1 2 3 4 5 6 7 8 9

TB3

10 11 12

TB2

1 2 3 4 5 6

TB4

7 8 9 10 11

TB5

TB7

1 2 3 4 5 6

TB1

–

XMT + WHT XMT – BLK X-SHLD

RCV – BLK RCV + RED

TB6

N N N

FUSE

POWER SWITCH

7 8 9

TEMP - BLK TEMP + GRN

R-SHLD

SAFETY COVER LABEL

Figure 9 Electrodeless Conductivity Sensor Input Wiring

TB1

Page 23

TB7

1 2 3 4 5 6 7 8 9

TB3

10 11 12

TB2

1 2 3 4 5 6

TB4

7 8 9 10 11

TB5

TB1

–

TB6

N N N

FUSE

POWER SWITCH

–

SHIELD

TB1 ECOND CCOND

XMT+ XMT

XMT–

SHIELD SHIELD SHIELD

X-SHLD

pH/ORP

4 5 RCV– 6 RCV+ 7 RCV IN+ 8 –5V

SIGNAL

w/BNC

USE

BNC FOR

INPUT

pH/ORP

+5V

9 TEMP– TEMP– TEMP– TEMP–

TEMP+ TEMP+ TEMP+ TEMP+

R-SHLD

TB2 FUNCTION

DIS

IN–

4-20 OUT–

2 4-20 OUT+ 3 SHIELD

DIG IN 2–

4 5 DIG IN 2+ 6 +9 VDC 7 SHIELD 8

DIG IN 1–

9 DIG IN 1+

+9 VDC

11 SHIELD 12

Chart

Recorder

1 2 3 4 5 6 7

INPUT – SIGNAL +

POWER

SHIELD

8 9

SHIELD

TB2

Hall Effect

Flow Meter

Reed Switch, Relay

(Flow Switch, Water Meter)

Polarity not critical

Figure 10 Digital Input and Analog Output Wiring

Page 24

TB3

GRN 120V GRN/YEL 240V

TB7

1 2 3 4 5 6 7 8 9

TB3

10 11 12

TB2

1 2 3 4 5 6

TB4

TB5

N N N

7 8 9 10 11 12

TB1

–

IF MOTORIZED BALL VALVE

POWER

POWER SWITCH

SWITCH

TB6

FUSE

GRN 120V

TB5

GRN/YEL 240V

TB4

N N N

WHT 120V BLU 240V

BLK 120V BRN 240V

WHT 120V BLU 240V

SOLENOID/ MOTORIZED BALL VALVE

PUMP

ALARM

BLK 120V BRN 240V

TB6

Power Supply

(120 VAC or 240 VAC)

Figure 11 W100 AC Power & Relay Output Wiring

Page 25

TB3

Fused

External

Power

Source

GRN 120V GRN/YEL 240V

WHT 120V BLU 240V

TB7

1 2 3 4 5 6 7 8 9

TB3

10 11 12

TB2

1 2 3 4 5 6

TB4

7 8 9 10 11

TB5

TB1

–

TB6

N N N

FUSE

POWER SWITCH

PLC

GRN 120V

TB5

GRN/YEL 240V

Fused

External

Power

Source

WHT 120V BLU 240V

BLK 120V BRN 240V

GRN 120V GRN/YEL 240V

WHT 120V BLU 240V

Power Supply

(120 VAC or 240 VAC)

PUMP

ALARM

BLK 120V BRN 240V

TB6

Figure 12 W110 AC Power & Relay Output Wiring

Page 26

4.0 FUNCTION OVERVIEW

4.1 Front Panel

Figure 13 Front Panel

4.2 Display

A Home screen is displayed while the controller is on. This display shows the sensor readings, active alarms and a row of icons that are used to navigate to other screens.

4.3 Keypad

The keypad consists of 5 ATM type keys and a Home key used to return to the summary screen. The icon above the

ATM keys will dene its purpose on the current screen being displayed.

4.4 Icons

The following icons appear on the Home screen. Press the key below the icon to get to the main menu selections.

Alarm Menu

Inputs Menu

Outputs Menu

Conguration/Settings Menu

Page 27

Other icons may appear in the menu screens.

Alarm Menu

Inputs Menu

Outputs Menu

Conguration/Settings Menu

Calibration key appears in sensor input menus and brings up the calibration menu

Cancel key cancels any entry

The Page Down icon scrolls down to a new page in a list of options.

The Page Up icon scrolls up to a new page in a list of options.

The Conrm icon accepts a choice and advances to the next calibration step

The Back/Return icon returns the display to the previous screen

The Make Character Higher key is used when making an alphanumeric entry

The Make Character Lower key is used when making an alphanumeric entry

The Move Cursor key is used to scroll left to right within an alphanumeric entry

The ENTER key is used to nish entering data or enter a highlighted menu choice

Overview of the use of keys

Changing Numeric Values

To change a number, use the Move Cursor key to the digit to be changed. If the new number will be negative, start with the sign using the Make Character Higher key. Move the cursor to each digit and change the value using either the Make Character Higher or Lower keys. Once the value of the number is correct use the Enter key to store the new value into memory, or use the Cancel key to leave the number at its previous value and go back.

Changing Names

To change the name used to identify an input or output, use the Move Cursor key to the character to be changed and change it using either the Make Character Higher or Lower keys. Upper case and lower case letter, numbers, a blank space, period, plus and minus symbols are available. Move the cursor to the right and modify each character. Once the word is correct, use the Enter key to store the new value into memory, or use the Cancel key to leave the word at its previous value and go back.

Page 28

Choosing from a List

Selecting the type of sensor, the units of measure of an input, or the control mode used for an output, the selection is picked from a list of available options. Use the Page Up or Down keys to highlight the desired option, and then use the Enter key to store the new option into memory, or use the Return key to leave the option at its previous value and go back.

Hand-Off-Auto Relay Mode

Use the Left or Right Move Cursor keys to highlight the desired relay mode. In Hand mode the relay is forced on for

a specied amount of time and when that time is up the relay returns to its previous mode, in Off mode the relay is always off until taken out of Off mode, and in Auto mode the relay is responding to control set points. Use the Conrm

key to accept the option, or the Return key to leave the option at its previous value and go back.

Interlock and Force On Menus

To select which outputs to force on, or which outputs to be interlocked, use the Move Cursor key to highlight the output

to be selected, then use the Make Character Higher or Lower keys to check or uncheck that output. When nished, press the Conrm key to accept the changes or the Cancel key to leave the selections at the previous settings and go back.

4.5 Startup

Initial Startup

After having mounted the enclosure and wired the unit, the controller is ready to be started. Plug in the controller and

turn on the power switch to supply power to the unit. The display will briey show the model number and then revert

to the normal summary display. Press the Home key if necessary to get to the Home screen. Refer to section 5 below for more details on each of the settings.

Settings Menu (see section 5.4)

Choose language

Press the Conguration Settings key. Press the Enter key. Press the Scroll Down key until the English word “Language” is highlighted. Press the Enter key. Press the Scroll Down key until your language is highlighted. Press the Conrm key

to change all menus to your language.

Set date (if necessary)

Press the Scroll Up key until Date is highlighted. Press the Enter key. Press the Move Cursor key to highlight the

Day, and then use the Make Character Higher or Lower keys to change the date. Press the Conrm key to accept the

change.

Set time (if necessary)

Press the Scroll Down key until Time is highlighted. Press the Enter key. Press the Move Cursor key to highlight the HH (hour) and/or MM (minute), then use the Make Character Higher or Lower keys to change the time. Press the Con-

rm key to accept the change.

Set global units of measure

Press the Scroll Down key until Global Units is highlighted. Press the Enter key. Press the Scroll Down key until the

desired units is highlighted. Press the Conrm key to accept the change.

Set temperature units of measure

Press the Scroll Down key until Temp Units is highlighted. Press the Enter key. Press the Scroll Down key until the

desired units is highlighted. Press the Conrm key to accept the change.

Press the Home key. Press the Inputs key.

Page 29

CONFIG

Alarms (1)

Sensor (S1)

Temp (S2)

CONFIG

Global Settings

Security Settings

Additional Config Settings: Display Settings File Utilities Controller Details

Config > Global Settings

Date 2017-Mar-22

Time 15:49:16

Config > Security Settings

Controller Log Out

Security

Config > Display Settings

Home 1

Home 2

Additional Global Settings: Global Units Temperature Units Alarm Delay HVAC Modes Language

Additional Security Settings: Local Password

Additional Display Settings: Adjust Display Key Beep

Config > File Utilities

File Transfer Status

Export Event Log

Config > Controller Details

Controller

Product Name

Additional File Utilities: Import User Config File Export User Config File Export System Log Restore Default Config Software Upgrade

Additional Controller Details: Control Board Software Version Sensor Board Software Version Power Board Battery Power Internal Temp 1 Internal Temp 2

Page 30

Inputs

CCond (S1) 0 µS/cm

INPUTS

Temp (S2) 74.7 °F

> > CCond (S1) > Calibration

One Point Process Calibration

(All)

One Point Buffer Calibration (CCond,ECond,pH,ORP,Generic) Two Point Buffer Calibration (ECond,pH,ORP,Generic) Three Point Buffer Calibration (pH) Open Air Calibration

(Cond)

Zero Calibration (Disinfection,Linear Generic)

No Alarms (1)

CCond (S1) 0 µS/cm

Temp (S2) 74.7°F

Inputs>CCond (S1)

Details Screen

Content varies with

output type

>>CCond (S1)

Alarms

Deadband

>>ECond (S1)

Alarms

Deadband

>>Temperature (S2)

Alarms

Deadband

>>pH (S1)

Alarms

Deadband

>>ORP (S1)

Alarms

Deadband

Additional Settings for CCond:

Reset Calibration Values Cal Required Alarm Alarm Suppression Smoothing Factor Default Temp Temp Compensation Temp Comp Factor

Additional Settings for ECond:

Reset Calibration Values Cal Required Alarm Alarm Suppression Smoothing Factor Default Temp Installation Factor Range Temp Compensation

Additional Settings for Temperature:

Reset Calibration Values

Cal Required Alarm Alarm Suppression Smoothing Factor Name Element

Additional Settings for pH:

Reset Calibration Values Cal Required Alarm Alarm Suppression Smoothing Factor Buffers Default Temp

Additional Settings for ORP:

Reset Calibration Values Cal Required Alarm Alarm Suppression Smoothing Factor Default Temp Cable Length

Cell Constant Cable Length Gauge Units Name Type

Temp Comp Factor Cell Constant Cable Length Gauge Units Name Type

Cable Length Gauge Electrode Name Type

Gauge Name Type

>>Generic (S1)

Alarms

Deadband

>>DI State (D1-D2)

Open Message

Closed Message

Contactor Type

>>Flowmeter (D1-D2)

Totalizer Alarm

Reset Flow Total

Paddlewheel Type

>>Flowmeter (D1-D2)

Alarms

Deadband

Additional Settings for Generic:

Reset Calibration Values Cal Required Alarm Alarm Suppression Smoothing Factor Sensor Slope Sensor Offset Low Range High Range

Additional Settings for DI State:

Interlock Alarm Total Time Reset Total Time Name Type

Additional Settings for Flowmeter:

Set Flow Total Scheduled Reset Volume/Contact Flow Units Name Type

Additional Settings for Flowmeter:

Totalizer Alarm Reset Flow Total Set Flow Total Scheduled Reset K Factor Flow Units Rate Units Smoothing Factor Name Type

Cable Length Gauge Units Electrode (Linear or Ion Selective) Name Type

Only Available in some models

>>Disinfection (S1)

Alarms

Deadband

Additional Settings for Disinfection:

Reset Calibration Values Cal Required Alarm Alarm Suppression Smoothing Factor Cable Length Gauge

Sensor Name Type

Page 31

>>On/Off (R1)>Settings

HOA Setting

Setpoint

Outputs>On/Off (R1)

Details Screen

Content varies with

output type

Outputs

On/Off (R1) Off

Bleed (R2) Off

OUTPUTS

R1-R3

Only if HVAC mode is disabled

No Alarms (1)

CCond (S1) 0 µS/cm

Temp (S2) 74.7°F

>>Flow Timer (R1)

HOA Setting

Feed Duration

>>Bleed and Feed (R1)

HOA Setting

Feed Time Limit

>>Bleed then Feed (R1)

HOA Setting

Feed Percentage

>>Percent Timer(R1)

HOA Setting

Sample Period

>>Biocide Timer (R1)

HOA Setting

Bleed

>>Alarm (R1)

HOA Setting

Alarm Mode

Only if HVAC mode is enabled

>>Time Prop (R1)

HOA Setting

Setpoint

>>Int Sampling (R1)

HOA Setting

Setpoint

>>Manual (R1)

HOA Setting

Interlock Channels

>>Pulse Prop (R1)

HOA Setting

Setpoint

>>Dual Setpoint (R1)

HOA Setting

Setpoint

>>Probe Wash (R1)

HOA Setting

Input

>>Timer (R1)

HOA Setting

Add Last Missed

Only if HVAC mode is enabled

Only if model W120/power relay bd installed

Additional Settings for On/OFF:

Deadband Duty Cycle Period Duty Cycle Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels

Min Relay Cycle Hand Time Limit Reset Time Total Input Direction Name Mode

Additional Settings for Flow Timer:

Accumulated Volume Reset Timer Reset Output Timeout Interlock Channels Activate with Channels Min Relay Cycle

Hand Time Limit Reset Time Total Flow Input Name Mode

Additional Settings for Bleed and Feed:

Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels Min Relay Cycle

Hand Time Limit Reset Time Total Bleed Name Mode

Additional Settings for Bleed then Feed:

Feed Time Limit Reset Timer Reset Output Timeout Interlock Channels Activate with Channels Min Relay Cycle

Hand Time Limit Reset Time Total Bleed Name Mode

Additional Settings for Percent Timer:

Feed Percentage Interlock Channels Activate with Channels Min Relay Cycle

Hand Time Limit Reset Time Total Name Mode

Additional Settings for Biocide Timer:

Event 1 (through 10) Repetition Week Day Start Time Duration Prebleed Time Prebleed To Cond Input

Bleed Lockout Add Last Missed Interlock Channels Activate with Channels Min Relay Cycle

Hand Time Limit Reset Time Total Name Mode

Additional Settings for Alarm:

Output Interlock Channels Activate with Channels Min Relay Cycle

Hand Time Limit Reset Time Total Name Mode

Additional Settings for Time Prop:

Proportional Band Sample Period Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels Min Relay Cycle

Hand Time Limit Reset Time Total Input Direction Name Mode

Additional Settings for Int Sampling:

Proportional Band Deadband Sample Time Hold Time Maximum Blowdown Wait Time Trap Sample Output Time Limit Reset Output Timeout

Interlock Channels Activate with Channels Min Relay Cycle Hand Time Limit Reset Time Total Cond Input Name Mode

Additional Settings for Manual:

Min Relay Cycle Hand Time Limit Reset Time Total Name Mode

Additional Settings for Pulse Prop:

Proportional Band Min Output Max Output Max Rate Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels

Min Relay Cycle Hand Time Limit Reset Time Total Input Direction Name Mode

Additional Settings for Dual Setpoint:

Set Point 2 Deadband Duty Cycle Period Duty Cycle Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels

Min Relay Cycle Hand Time Limit Reset Time Total Input Direction Name Mode

Additional Settings for Probe Wash:

Input 2 Event 1 (through 10) Repetition Week, Day Events per Day Start Time Duration Sensor Mode Hold Time

Interlock Channels Activate with Channels Min Relay Cycle Hand Time Limit Reset Time Total Name Mode

Additional Settings for Timer:

Event 1 (through 10) Repetition Week, Day Events per Day Start Time Duration Interlock Channels Activate with Channels

Min Relay Cycle Hand Time Limit Reset Time Total Name Mode

Page 32

OUTPUT

Output>Retrans (A1)

Details on this page

vary with type of

output

Output

On/Off (R1) Off

Retrans (A1) 0.0%

No Alarms (1)

CCond (S1) 0 µS/cm

Temp (S2) 74.7°F

>>Retransmit (A1)

HOA Setting

4 mA Value

>>Proportional (A1)

HOA Setting

Setpoint

Only available if HVAC is disabled

>>PID (A1)

HOA Setting

Setpoint

Additional Settings for Retransmit:

20 mA Value Hand Output Interlock Channels Error Output

Reset Time Total Input Name Mode

Additional Settings for Proportional:

Proportional Band Min Output Max Output Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels Hand Output

Hand Time Limit Reset Time Total Off Mode Output Error Output Input Direction Name Mode

Additional Settings for PID:

Gain Proportional Gain Integral Time Integral Gain Derivative Time Derivative Gain Reset PID Integral Min Output Max Output Max Rate Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels

Hand Output Hand Time Limit Off Mode Output Error Output Reset Time Total Input Direction Input Min Input Max Gain Form Name Mode

>>Manual (A1)

HOA Setting

Interlock Channels

>>Flow Prop (A1)

HOA Setting

Target

Additional Settings for Manual:

Activate with Channels Min. Relay Cycle Hand Output Hand Time Limit Reset Time Total

Additional Settings for Flow Prop Control Mode: Pump Capacity Pump Setting Specific Gravity Output Time Limit Reset Output Timeout Interlock Channels Activate with Channels Hand Output

Name Mode

Hand Time Limit Off Mode Output Error Output Reset Time Total Flow Input Name Mode

Page 33

Inputs (see section 5.2)

Program the settings for each input

The S1 sensor input will be highlighted. Press the Enter key to get to the Details screen. Press the Settings key. If the name of the sensor does not describe the type of sensor connected, press the Scroll Down key until Type is highlighted. Press the Enter key. Press the Scroll Down key until the correct type of sensor is highlighted, then press the Conrm key to accept the change. This will bring you back to the Details screen. Press the Settings key again to nish the rest of the S1 settings. For disinfections sensors, choose the exact sensor in the Sensor menu. For contacting conductivity sensors, enter the cell constant. Select the units of measure. Enter the alarm set points and alarm deadband. Set the default temperature that will be used for automatic temperature compensation if the temperature signal becomes invalid.

When nished with S1, press the Return key until the list of inputs is displayed. Press the Scroll Down key and

repeat the process for each input.

The S2 temperature input Element should be set correctly once the S1 sensor type has been set. If not, select the correct temperature element and set the alarm set points and alarm deadband. ORP and disinfection sensors do not have temperature signals and are preset to No Sensor.

To calibrate the temperature, return to the S2 Details screen, press the Calibrate key, and press the Enter key to perform a calibration.

If a ow switch or liquid level switch is connected, D1 or D2 should be set to DI State type (if no switch is connected,

select No Sensor). Set the state that will possibly interlock control outputs (refer to the Outputs settings to program which outputs, if any, will be interlocked by the switch). Set the state, if any, that will result in an alarm.

If a contacting head or paddlewheel ow meter is connected, D1 or D2 should be set to that type (if no ow meter is

connected, select No Sensor). Set the units of measure, volume/contact or K factor, etc.

Calibrate the sensor

To calibrate the sensor, return to the list of inputs, highlight S1, press the Enter key, press the Calibrate key, and select one of the calibration routines. For disinfection sensors, start with the Zero Calibration. For electrodeless conductivity, start with the Air Calibration. Refer to section 5.2.

Press the Home key. Press the Outputs key.

Outputs (see section 5.3)

Program the settings for each output

The R1 relay output will be highlighted. Press the Enter key to get to the Details screen. Press the Settings key. If the name of the relay does not describe the control mode desired, press the Scroll Down key until Mode is highlighted.

Press the Enter key. Press the Scroll Down key until the correct control mode is highlighted, then press the Conrm key to accept the change. This will bring you back to the Details screen. Press the Settings key again to nish the rest

of the R1 settings.

If you want the output to be interlocked by a ow switch or by another output being active, enter the Interlock Channels

menu and select the input or output channel that will interlock this output. The default is for the output to be in Off mode, where the output does not react to the settings. Once all settings for

that output are complete, enter the HOA Setting menu and change it to Auto. Repeat for each output.

Normal Startup

Startup is a simple process once your set points are in memory. Simply check your supply of chemicals, turn on the controller, calibrate the sensor if necessary and it will start controlling.

4.6 Shut Down

To shut the controller down, simply turn off the power. Programming remains in memory.

Page 34

5.0 OPERATION

These units control continuously while power is applied. Programming is accomplished via the local keypad and display.

To see the top level menu keys, press the Home key if not already there. The menu structure is grouped by Alarms, Inputs,

Outputs, and conguration Settings. Each input has its own menu for calibration and unit selection as needed. Each output

has its own setup menu including set points, timer values and operating modes as needed. Under Settings will be general settings such as the clock, the language, etc.

Keep in mind that even while moving through menus, the unit is still controlling.

5.1 Alarms Menu

Press the key below the Alarms icon to view a list of active alarms. If there are more than two active alarms, the Page Down icon will be shown, and this key press will bring up the next page of inputs. Press the Back/Return button to go back to the previous screen.

5.2 Inputs Menu

Press the key below the Inputs icon to view a list of all sensor and digital inputs. The Page Down icon scrolls down the list of inputs, the Page Up icon scrolls up the list of inputs, the Return icon brings back the previous screen. Press the Enter key with an input highlighted to access that input’s details, calibration (if applicable) and settings.

Sensor Input Details

The details for any type of sensor input include the current value read, alarms, the raw (uncalibrated) signal, the sensor type, and the calibration gain and offset. If the sensor has automatic temperature compensation, then the sensor’s temperature value and alarms, the temperature resistance value read, and the type of temperature element required are also displayed.

Calibration

Press the Calibration key to calibrate the sensor. Select the calibration to perform: One Point Process, One Point Buffer or Two Point Buffer Calibration. Not all calibration options are available for all types of sensor.

One Point Process Calibration

New Value

Enter the actual value of the process as determined by another meter or laboratory analysis and press Conrm.

Cal Successful or Failed

If successful, press Conrm to put the new calibration in memory.

If failed, you may retry the calibration or cancel. Refer to Section 7 to troubleshoot a calibration failure.

One Point Buffer Calibration, Conductivity Air Cal

Cal Disables Control

Press Conrm to continue or Cancel to abort

Buffer Temperature (only appears if no temperature sensor is detected for sensor types that use automatic temperature compensation)

Enter the temperature of the buffer and press Conrm.

Buffer Value (only appears for One Point Calibration except when automatic buffer recognition is used) Enter the value of the buffer being used

Page 35

Rinse Sensor

Remove the sensor from the process, rinse it off, and place it in the buffer solution (or oxidizer-free water for Zero Cal, or air for the conductivity open air cal). Press Conrm when ready.

Stabilization

When the temperature (if applicable) and signal from the sensor is stable, the controller will automatically move to the next step. If they don’t stabilize you may manually go to the next step by pressing Conrm.

Cal Successful or Failed

If successful, press Conrm to put the new calibration in memory.

If failed, you may retry the calibration or cancel. Refer to Section 7 to troubleshoot a calibration failure.

Resume Control

Replace the sensor in the process and press Conrm when ready to resume control.

Two Point Buffer Calibration

Cal Disables Control

Press Conrm to continue or Cancel to abort

Buffer Temperature (only appears if no temperature sensor is detected for sensor types that use automatic temperature compensation)

Enter the temperature of the buffer and press Conrm.

First Buffer Value (does not appear if automatic buffer recognition is used) Enter the value of the buffer being used.

Rinse Sensor

Remove the sensor from the process, rinse it off, and place it in the buffer solution. Press Conrm when ready.

Stabilization

When the temperature (if applicable) and signal from the sensor is stable, the controller will automatically move to

the next step. If they don’t stabilize you may manually go to the next step by pressing Conrm.

Second Buffer Temperature (only appears if no temperature sensor is detected for sensor types that use automatic temperature compensation)

Enter the temperature of the buffer and press Conrm.

Second Buffer Value

Enter the value of the buffer being used

Rinse Electrode

Remove the sensor from the process, rinse it off, and place it in the buffer solution. Press Conrm when ready.

Stabilization

When the temperature (if applicable) and signal from the sensor is stable, the controller will automatically move to

the next step. If they don’t stabilize you may manually go to the next step by pressing Conrm.

Cal Successful or Failed

If successful, press Conrm to put the new calibration in memory. The calibration adjusts the offset and the gain

(slope) and displays the new values. If failed, you may retry the calibration or cancel. Refer to Section 7 to troubleshoot a calibration failure.

Resume Control

Replace the sensor in the process and press Conrm when ready to resume control.

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5.2.1 Contacting Conductivity

Settings Press the Settings key view or change the settings related to the sensor.

Alarms

Deadband

Low-Low, Low, High and High-High Alarms limits may be set.

This is the Alarm Deadband. For example, if the High Alarm is 3000, and the deadband is 10, the alarm will activate at 3001 and deactivate at 2990.

Reset Calibration

Enter this menu to reset the sensor calibration back to factory defaults.

Values

Cal Required Alarm

To get an alarm message as a reminder to calibrate the sensor on a regular schedule, enter the number of days between calibrations. Set it to 0 if no reminders are necessary.

Alarm Suppression

If any of the relays or digital inputs are selected, any alarms related to this input will be suppressed if the selected relay or digital input is active. Typically this is used to prevent

alarms if there is no sample ow past the ow switch digital input.

Smoothing Factor

Increase the smoothing factor percentage to dampen the response to changes. For example, with a 10% smoothing factor, the next reading shown will consist of an average of 10% of the previous value and 90% of the current value.

Default Temp

If the temperature signal is lost at any time, then the controller will use the Default Temp setting for temperature compensation.

Cable Length

The controller automatically compensates for errors in the reading caused by varying the length of the cable.

Gauge

Cell Constant

Temp Comp

The cable length compensation depends upon the gauge of wire used to extend the cable

Change the cell constant to match the sensor connected.

Select between the standard NaCl temperature compensation method or a linear %/ degree C method.

Comp Factor

This menu only appears if Linear Temp Comp is selected. Change the %/degree C to match the chemistry being measured. Standard water is 2%.

Units

Name

Type

Select the units of measure for the conductivity.

The name used to identify the sensor may be changed.

Select the type of sensor to be connected.

5.2.2 Electrodeless Conductivity

Settings Press the Settings key view or change the settings related to the sensor.

Alarms

Deadband

Reset Calibration

Values

Cal Required Alarm

Alarm Suppression

Smoothing Factor

Cable Length

Low-Low, Low, High and High-High Alarms limits may be set.

This is the Alarm Deadband. For example, if the High Alarm is 3000, and the deadband is 10, the alarm will activate at 3000 and deactivate at 2990.

Enter this menu to reset the sensor calibration back to factory defaults.

To get an alarm message as a reminder to calibrate the sensor on a regular schedule, enter the number of days between calibrations. Set it to 0 if no reminders are necessary.

If any of the relays or digital inputs are selected, any alarms related to this input will be suppressed if the selected relay or digital input is active. Typically this is used to prevent

alarms if there is no sample ow past the ow switch digital input.

The controller automatically compensates for errors in the reading caused by varying the length of the cable.

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Gauge

Cell Constant

Range

Installation Factor

Default Temp

The cable length compensation depends upon the gauge of wire used to extend the cable

Do not change unless instructed by the factory. The default value is 6.286

Select the range of conductivity that best matches the conditions the sensor will see.

Do not change unless instructed by the factory. The default value is 1.000.

If the temperature signal is lost at any time, then the controller will use the Default Temp setting for temperature compensation.

Temp Comp

Select between the standard NaCl temperature compensation method or a linear %/ degree C method.

Comp Factor

This menu only appears if Linear Temp Comp is selected. Change the %/degree C to match the chemistry being measured. Standard water is 2%.

Units

Name

Type

Select the units of measure for the conductivity.

The name used to identify the sensor may be changed.

Select the type of sensor to be connected.

5.2.3 Temperature

Settings Press the Settings key view or change the settings related to the sensor.

Alarms

Deadband

Low-Low, Low, High and High-High Alarms limits may be set.

This is the Alarm Deadband. For example, if the High Alarm is 100, and the deadband is 1, the alarm will activate at 100 and deactivate at 99.

Reset Calibration

Enter this menu to reset the sensor calibration back to factory defaults.

Values

Cal Required Alarm

To get an alarm message as a reminder to calibrate the sensor on a regular schedule, enter the number of days between calibrations. Set it to 0 if no reminders are necessary.

Alarm Suppression

If any of the relays or digital inputs are selected, any alarms related to this input will be suppressed if the selected relay or digital input is active. Typically this is used to prevent

alarms if there is no sample ow past the ow switch digital input.

Smoothing Factor

Name

Element

The name used to identify the sensor may be changed.

Select the specic type of temperature sensor to be connected.

5.2.4 DI State

Input Details

The details for this type of input include the current state with a custom message for open versus closed, alarms, and the status of the interlock.

Settings Press the Settings key view or change the settings related to the sensor.

Open Message

Closed Message

Interlock

The words used to describe the switch state may be customized.

Choose whether the input should be in the interlocked state when the switch is either open or closed.

Total Time

Choose to totalize the amount of time that the switch has been open or closed. This will be displayed on the input details screen.

Reset Total Time

Enter this menu to reset the accumulated time to zero. Press Conrm to accept, Cancel to

leave the total at the previous value and go back.

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Alarm

Choose if an alarm should be generated when the switch is open, or closed, or if no alarm should ever be generated.

Name

Type

The name used to identify the switch may be changed.

Select the type of sensor to be connected to the digital input channel.

5.2.5 Flow Meter, Contactor Type

Input Details

The details for this type of input include the total volume accumulated through the ow meter and alarms.

Settings

Press the Settings key view or change the settings related to the sensor.

Totalizer Alarm

Reset Flow Total

A high limit on the total volume of water accumulated may be set.

Enter this menu to reset the accumulated ow total to 0. Press Conrm to accept, Cancel to

leave the total at the previous value and go back.

Set Flow Total

This menu is used to set the total volume stored in the controller to match the register on

the ow meter. Enter the desired value.

Scheduled Reset

Volume/Contact

Choose to automatically reset the ow total, and if so, Daily, Monthly or Annually.

Enter the volume of water that needs to go through the ow meter in order to generate a

contact closure.

Flow Units

Name

Type

Select the units of measure for the water volume.

The name used to identify the sensor may be changed.

Select the type of sensor to be connected to the digital input channel.

5.2.6 Flow Meter, Paddlewheel Type

Input Details

The details for this type of input include the current ow rate, total volume accumulated through the ow meter and

alarms.

Settings Press the Settings key view or change the settings related to the sensor.

Alarms

Deadband

Totalizer Alarm

Reset Flow Total

Set Flow Total

Scheduled Reset

K Factor

Flow Units

Rate Units

Smoothing Factor

Name

Type

Low and High Alarm limits may be set.

This is the Alarm Deadband. For example, if the High Alarm is 100, and the deadband is 1, the alarm will activate at 100 and deactivate at 99.

A high limit on the total volume of water accumulated may be set.

Enter this menu to reset the accumulated ow total to 0. Press Conrm to accept, Cancel to

leave the total at the previous value and go back.

This menu is used to set the total volume stored in the controller to match the register on

the ow meter. Enter the desired value.

Choose to automatically reset the ow total, and if so, Daily, Monthly or Annually.

Enter the pulses generated by the paddlewheel per unit volume of water.

Select the units of measure for the water volume.

Select the units of measure for the ow rate time base.

The name used to identify the sensor may be changed.

Select the type of sensor to be connected to the digital input channel.

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5.3 Outputs Menu

Press the key below the Outputs icon to view a list of all relay and analog outputs. The Page Down icon scrolls down the list of outputs, the Page Up icon scrolls up the list of outputs, the Return icon brings back the previous screen. Press the Enter key with an output highlighted to access that output’s details and settings. NOTE: When the output control mode or the input assigned to that output is changed, the output reverts to OFF mode. Once you have changed all settings to match the new mode or sensor, you must put the output into AUTO mode to start control.

5.3.1 Relay, Any Control Mode

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings Press the Settings key view or change the settings related to the relay. Settings that are available for any control mode

include:

HOA Setting

Output Time Limit

Select Hand, Off or Auto mode (see section 4.4).

Enter the maximum amount of time that the relay can be continuously activated. Once the time limit is reached, the relay will deactivate until the Reset Output Timeout menu is entered.

Reset Output Timeout

Enter this menu to clear an Output Timeout alarm and allow the relay to control the process again.

Interlock Channels

Select the relays and digital inputs that will interlock this relay, when those other relays are activated in Auto mode. Using Hand or Off to activate relays bypasses the Interlock logic.

Activate With Channels

Select the relays and digital inputs that will activate this relay, when those other relays are activated in Auto mode. Using Hand or Off to activate relays bypasses the Activate With logic.

Min Relay Cycle

This menu allows for the use of a motorized ball valve that needs time to fully open and close. Enter the number of seconds that the valve needs to fully actuate.

Hand Time Limit

Reset Time Total

Name

Mode

Enter the amount of time that the relay will activate for when it is in Hand mode.

Press the Conrm icon to reset the total accumulated on-time stored for the output back to 0.

The name used to identify the relay may be changed.

Select the desired control mode for the output.

5.3.2 Relay, On/Off Control Mode

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay.

Set point

Deadband

Duty Cycle Period

Duty Cycle

Enter the sensor process value at which the relay will activate.

Enter the sensor process value away from the set point at which the relay will deactivate.

Using a duty cycle helps to prevent overshooting the set point in applications where the response of the sensor to chemical additions is slow. Specify the amount of time for the cycle, and the percentage of that cycle time that the relay will be active. The relay will be

off for the rest of the cycle, even if the set point has not been satised.

Enter the length of the duty cycle in minutes:seconds in this menu. Set the time to 00:00 if use of a duty cycle is not required.

Enter the percentage of the cycle period that the relay will be active. Set the percentage to 100 if use of a duty cycle is not required.

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Input

Direction

Select the sensor to be used by this relay.

Select the control direction.

5.3.3 Relay, Flow Timer Control Mode

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings Press the Settings key view or change the settings related to the relay.

Feed Duration

Enter the amount of time for the relay to activate for once the accumulated volume through the water meter has been reached.

Accumulated Volume

Flow Input

Reset Timer

Enter the volume of water to pass through the water meter required to trigger the chemical feed.

Select the input to be used to control this output.

Use this menu to cancel the current feed cycle.

5.3.4 Relay, Bleed and Feed Control Mode

ONLY AVAILABLE IF HVAC MODES ARE ENABLED IN CONFIG MENU – GLOBAL SETTINGS

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay.

Feed Time Limit

Bleed

5.3.5 Relay, Bleed then Feed Control Mode

Enter the maximum amount of feed time per bleed event

Select the relay to be used for Bleed/Blowdown

ONLY AVAILABLE IF HVAC MODES ARE ENABLED IN CONFIG MENU – GLOBAL SETTINGS

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay.

Feed Percentage

Feed Time Limit

Reset Timer

Bleed

Enter the % of bleed relay activation time to use for the feed relay activation time

Enter the maximum amount of feed time per bleed event

Use this menu to cancel the current feed cycle.

Select the relay to be used for Bleed/Blowdown

5.3.6 Relay, Percent Timer Control Mode

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, cycle time, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay.

Sample Period

Feed Percentage

Enter the duration of the sample period.

Enter the % of the sample period time to use for the feed relay activation time

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5.3.7 Relay, Biocide Timer Control Mode

ONLY AVAILABLE IF HVAC MODES ARE ENABLED IN CONFIG MENU – GLOBAL SETTINGS

Basic Biocide Operation

When a biocide event triggers, the algorithm will rst prebleed (if a prebleed is programmed) for the set amount of

prebleed time or down to the set prebleed conductivity. Then the biocide relay is turned on for the set duration. This is followed by a post-bio add lockout that blocks the bleed relay from turning on for a set amount of bleed lockout time.

Special Condition Handling Prebleed

If both a time limit and a conductivity limit are set, the time limit takes precedence. The bleed relay will turn off

once the time limit is reached or when the prebleed conductivity limit is reached (whichever occurs rst). If the

prebleed has a conductivity limit set, then the time limit can’t be set to zero, as this would allow the prebleed to last forever if the conductivity limit is never reached.

Overlapping biocide events

If a second biocide event occurs while the rst one is still active (in pre-bleed, biocide add or lockout), the

second event will be ignored. An Event Skipped alarm will be set. Interlock Conditions Interlocks override the relay control, but do not change the operation of the timer control.

A no-ow (or other interlock) condition does not delay a biocide add. The biocide add duration timer will continue even if the relay is locked out due to a no-ow or other interlock condition. This will prevent delayed

biocide adds which can potentially cause higher than expected biocide concentrations in the system when two biocides adds occur close to the same time. Not allowing delayed biocide adds will also prevent incompatible biocides getting added at close to the same time.

“Activate With” Conditions “Activate with channels” settings override the relay control, but do not change the operation of the timers or related bleed control. The biocide timer continues counting biocide add time when the biocide relay is forced

on, and ends at the expected time (biocide event start time plus duration). If the “activate with” condition continues after the end of the biocide feed time, the relay remains activated.

Alarms An Event Skipped alarm is set when a second biocide event occurs while one event is still running (either in prebleed, biocide add or post-biocide add lockout). An Event Skipped alarm is also set when the biocide add

relay never turns on during a biocide add because of an interlock condition. The alarm is cleared when the relay is next activated for any reason (the next timer event or HAND mode or “activate with” force on condition).

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type. The current week number and day of the week is displayed (even if there is no multi-week repetition event programmed). Cycle Time shows the time counting down of the currently active part of the biocide cycle (pre-bleed, biocide feed, or post biocide feed lockout of the bleed).

Settings

Press the Settings key view or change the settings related to the relay.

Event 1 (through 10)

Repetition

Enter these menus to program timer events via the menus below:

Select the time cycle to repeat the event: Daily, 1 Week, 2 Week, 4 Week, or None. An event means that the output is turned on at the same time of day, for the same amount of time, and except for the Daily cycle, on the same day of the week.

Week

Only appears if Repetition is longer than 1 Week. Select the week during which the event will occur.

Day

Only appears if Repetition is longer than Daily. Select the day of the week during which the event will occur.

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Start Time

Duration

Bleed

Prebleed Time

Enter the time of day to start the event.

Enter the amount of time that the relay will be on.

Select the relay to be used for Bleed/Blowdown

If lowering the conductivity prior to feeding biocide is desired using a xed time instead of a specic conductivity setting, enter the amount of time for the prebleed. Also may be

used to apply a time limit on a conductivity based prebleed.

Prebleed To

If lowering the conductivity prior to feeding biocide is desired, enter the conductivity value. If no prebleed is required, or if a time-based prebleed is preferred, set the conductivity value to 0.

Cond Input

Bleed Lockout

Add Last Missed

Select the sensor to be used to control the prebleed relay selected above.

Enter the amount of time to lockout bleed after the biocide feed is complete.

Select Enabled if the controller should delay start the most recent Biocide cycle until immediately after an Interlock clears, or Disabled if all Biocide feed should be skipped if there is an Interlock condition at the time the add was due to start.

5.3.8 Relay, Alarm Mode

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay.

Alarm Mode

Select the alarm conditions that will put the relay into the alarm state:

All Alarms

S1 Low Alarms (+LoLo Alarm, Sensor Range Error, or Sensor Fault)

S1 High Alarms (+HiHi Alarm, Sensor Range Error, or Sensor Fault)

S2 (Temperature) Low Alarms (+LoLo Alarm, Sensor Range Error, or Sensor Fault)

S2 (Temperature) High Alarms (+HiHi Alarm, Sensor Range Error, or Sensor Fault)

D1 Alarms (Flowswitch/State, Flow Total, Flowmeter Range)

D2 Alarms (Flowswitch/State, Flow Total, Flowmeter Range)

Relay Alarms (Output Timeout, Control Failure, Event Skipped) for ALL relays

Output

Select if the relay will be active when in the alarm state (Normally Open) or if the relay will be active when not in the alarm state (Normally Closed).

5.3.9 Relay, Time Proportional Control Mode

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay.

Set point

Proportional Band

Sample Period

Input

Direction

Enter the sensor process value at which the relay will be off for the entire Sample Period.

Enter the distance that the sensor process value is away from the set point at which the relay will be on for the entire Sample Period.

Enter the duration of the sample period.

Select the sensor to be used by this relay.

Select the control direction.

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5.3.10 Relay, Intermittent Sampling Control Mode

ONLY AVAILABLE IF HVAC MODES ARE ENABLED IN CONFIG MENU – GLOBAL SETTINGS In an Intermittent Sampling with Proportional Blowdown control mode, the controller reads an analog input on a

timed schedule, and the relay responds to maintain the conductivity value at the set point by activating for a programmable amount of time that varies with the deviation from the set point.

The relay goes through a sequence of activation/deactivation as described below. The intended purpose of this algorithm is boiler blowdown. A sample cannot be supplied to the sensor continuously in many boilers because a recirculating loop is not possible, and it would be a waste of hot water to constantly run a sample to a drain. A valve is opened intermittently to supply a sample to the sensor.

Where a non-ideal installation of the sensor can cause the sample to ash to steam, and give a false low reading, this

can be corrected by taking the reading with the sample held in the pipe with the sampling valve closed, so the sample is at boiler pressure and therefore back in the liquid state. Enable Trap Sample if this is the case. Because the conductivity reading cannot be trusted while the valve is open, the blowdown is timed rather than in direct response to a

sensor reading. Rather than relying upon a xed time, where the blowdown could be much longer than necessary if

the reading is just barely off the set point value, proportional blowdown adjusts the time appropriately.

If Trap Sample is Disabled, then the blowdown is not timed, and the Hold Time and Maximum Blowdown time are not used. The blowdown valve will stay open until the conductivity is below set point. In this case the Output Time Limit menu is available to stop the blowdown if the sensor is unresponsive.

Note that the software will not allow two relays using Intermittent Sampling to be assigned to the same sensor input; the previous relay set up will change to Off mode.

Output Details

The details for this type of output include the relay on/off state, relay status (HOA mode, Interlock status, Intermittent Sampling cycle step, etc.), time remaining for the active Intermittent Sampling cycle step, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay.

Set point

Proportional Band

Enter the conductivity value below which the controller will not start a blowdown cycle.

(only shown if trap sample is enabled) Enter the conductivity value above the set point at which the maximum blowdown time will occur. For example, if the Set point is 2000 uS/ cm, and the Proportional Band is 200 uS/cm, then if the conductivity is above 2200 uS/ cm the blowdown valve will open for the Maximum Blowdown time described below. If the conductivity of the trapped sample is 2100 uS/cm, the blowdown valve will open for half the Maximum Blowdown time.

Deadband

(only shown if trap sample is disabled) Enter the sensor process value away from the set point at which the relay will deactivate.

Sample Time

Enter the length of time the blowdown valve will be open in order to capture a fresh sample of boiler water.

Hold Time

(only shown if trap sample is enabled) Enter the length of time the blowdown valve will be closed in order to ensure that the captured sample is at boiler pressure.

Maximum Blowdown

(only shown if trap sample is enabled) Enter the maximum length of time that the blowdown valve will be open, when the conductivity of the captured sample is above the set point plus the proportional band.

Cond Input

Wait Time

Trap Sample

Select the sensor to be used by this relay.

Enter the time to wait to sample the water again once the captured sample is below set point.

Enable or disable trapping of the sample.

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5.3.11 Relay or Analog Output, Manual Mode

Output Details

The details for this type of output include the relay on/off state or analog output %, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

A Manual relay will activate if the HOA mode is Hand, or if it is Activated With another channel. There are no additional programmable parameters.

5.3.12 Relay, Pulse Proportional Control Mode

ONLY AVAILABLE IF W120 MODEL/POWER RELAY BOARD IS INSTALLED

Output Details

The details for this type of output include the relay pulse rate, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay.

Set point

Proportional Band

Minimum Output

Maximum Output

Maximum Rate

Input

Direction

Enter the sensor process value at which the output will pulse at the Minimum Output % set below.

Enter the distance that the sensor process value is away from the set point beyond which the output will be pulsing at the Maximum Output % set below.

Enter the lowest possible pulse rate as a percentage of the Maximum Stroke Rate set below (normally 0%).

Enter the highest possible pulse rate as a percentage of the Maximum Stroke Rate set below.

Enter the maximum pulse rate that the metering pump is designed to accept (10 - 360 pulse/minute range).

Select the sensor to be used by this relay.

Set the control direction.

5.3.13 Relay, Dual Set Point Mode

Output Details

The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the relay.

Set point

Set point 2

Deadband

Duty Cycle Period

Duty Cycle

Input

Enter the rst sensor process value at which the relay will activate.

Enter the second sensor process value at which the relay will activate.

Enter the sensor process value away from the set point at which the relay will deactivate.

off for the rest of the cycle, even if the set point has not been satised.

Enter the length of the duty cycle in minutes:seconds in this menu. Set the time to 00:00 if use of a duty cycle is not required.

Enter the percentage of the cycle period that the relay will be active. Set the percentage to 100 if use of a duty cycle is not required.

Select the sensor to be used by this relay.

Page 45

Direction

Select the control direction. In Range will activate the relay when the input reading is between the two set points. Out of Range will activate the relay when the input reading is outside the two set points.

5.3.14 Relay, Probe Wash Control Mode

Basic Timer Operation

When a Probe Wash event triggers, the algorithm will activate the relay for the programmed time. The relay will activate a pump or valve to supply a cleaning solution to the sensor or sensors. The output of the selected sensors will either be held or disabled during the cleaning cycle, and for a programmable hold time after the cleaning cycle.

Special Condition Handling

Overlapping timer events

If a second timer event occurs while the rst one is still active, the second event will be ignored. An Event

Skipped alarm will be set. Interlock Conditions Interlocks override the relay control, but do not change the operation of the timer control. A digital input or output interlock condition does not delay the relay activation. The relay activation duration

timer will continue even if the relay is deactivated due to an interlock condition. This will prevent delayed events which can potentially cause problems in they do not occur at the correct time.

“Activate With” Conditions “Activate with channels” settings override the relay control, but do not change the operation of the timer

control. The relay activation duration timer continues counting when the timer relay is forced on, and ends at the expected time (event start time plus duration). If the “activate with” condition continues after the end of the event time, the relay remains activated.

Alarms An Event Skipped alarm is set when a second timer event occurs while one event is still running. An Event

Skipped alarm is also set when the timer relay never turns on during an event because of an interlock condition. The alarm is cleared when the relay is next activated for any reason (the next timer event or HAND mode or

“activate with” force on condition).

Output Details

Settings

Press the Settings key view or change the settings related to the relay.

Event 1 (through 10)

Repetition

Enter these menus to program timer events via the menus below:

Select the time cycle to repeat the event: Hourly, Daily, 1 Week, 2 Week, 4 Week, or None. An event means that the output is turned on at the same time of day, for the same amount of time, and except for the Daily cycle, on the same day of the week.

Week

Only appears if Repetition is longer than 1 Week. Select the week during which the event will occur.

Day

Only appears if Repetition is longer than Daily. Select the day of the week during which the event will occur.

Events Per Day

Only appears if Repetition is Hourly. Select the number of events per day. The events occur on the Start Time and then evenly spaced throughout the day.

Start Time

Duration

Input

Input 2

Enter the time of day to start the event.

Enter the amount of time that the relay will be on.

Select the sensor that will be washed.

Select the second sensor, if applicable, that will be washed.

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Sensor Mode

Select the effect that the probe wash event will have on any control outputs that use the sensor(s) being washed. The options are to either Disable the sensor readings (turn the control output off) or Hold the sensor reading at the last valid sensor reading prior to the start of the probe wash event.

Hold Time

Enter the amount of time needed to hold the sensor reading after the event has nished, in

order for the wash solution to be replaced by process solution.

5.3.15 Analog Output, Retransmit Mode

Output Details

The details for this type of output include the output %, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type

Settings

Press the Settings key view or change the settings related to the analog output.

4 mA Value

20 mA Value

Hand Output

Input

Error Output

Enter the process value to correspond to a 4 mA output signal.

Enter the process value to correspond to a 20 mA output signal.

Enter the output % desired when the output is in Hand mode.

Select the sensor input to retransmit.

Enter the output mA desired when the sensor is not giving the controller a valid signal. The acceptable range is 0 to 21 mA.

5.3.16 Analog Output, Proportional Control Mode

Output Details

The details for this type of output include the output %, HOA mode or Interlock status, accumulated on-time, alarms, current cycle on time and relay type.

Settings

Press the Settings key view or change the settings related to the analog output.

Set point

Proportional Band

Minimum Output

Maximum Output

Hand Output

Input

Direction

Off Mode Output

Error Output

Enter the sensor process value at which the output % will be the programmed minimum %.

Enter the sensor process value away from the set point at which the output % will be the programmed maximum %.

Enter the lowest output %. If the output should be off at the set point, this will be 0%.

Enter the highest output %.

Enter the output % desired when the output is in Hand mode.

Select the sensor input to use for proportional control.

Select the control direction.

Enter the output mA value desired when the output is in Off mode, or being Interlocked, or during a calibration of the sensor being used as an input. The acceptable range is 0 to 21 mA.

Enter the output mA desired when the sensor is not giving the controller a valid signal. The acceptable range is 0 to 21 mA.

5.3.17 Analog Output, Flow Proportional Mode

Overview

In Flow Proportional control mode, the controller monitors the rate of ow through a digital ow meter, and continuously adjusts the analog (4-20 mA) output proportional band to achieve a target PPM level.

The user enters the target PPM and the data necessary to calculate the proportional band (the water ow rate at which the maximum pulse rate will occur) required to maintain the target PPM with that ow rate of water.

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% output = Target PPM x Water Flow Rate (liter/min or gal/min)

Pump Capacity (liter/hr) x Pump Setting (%) x Specic Gravity x 0.16667

Pump Capacity (liter or gal/hr) x Pump Setting (%) x Specic Gravity x 166.67

% output = Target PPM x Water Flow Rate (m3⁄min)

Control Operation

If the output is continuously on for longer than the Output Time Limit, then output will deactivate.

Output Details

The details for this type of output include the output %, HOA mode or Interlock status, alarms related to this output, current cycle on time, total accumulated on-time, mA output, and the current control mode setting.

Settings

Touch the Settings icon to view or change the settings related to the relay.

Target

Pump Capacity

Pump Setting

Specic Gravity

Hand Output

Off Mode Output

Error Output

Flow Input

Enter the desired PPM set point for the product.

Enter the maximum ow rate for the metering pump.

Enter the stroke length setting for the metering pump, in percent.

Enter the specic gravity of the product to be added.

Enter the output % desired when the output is in Hand mode.

Enter the output mA value desired when the output is in Off mode, or being Interlocked, or during a calibration of the sensor being used as an input. The acceptable range is 0 to 21 mA.

Enter the output mA desired when the sensor is not giving the controller a valid signal. The acceptable range is 0 to 21 mA.

Select the ow meter to be used as an input for this control relay.

5.4 Settings Menu

The conguration Settings Menu is used for settings and activities that are not tied to Inputs or Outputs.

5.4.1 Global Settings

Date

Time

Global Units

Temperature Units

Alarm Delay

HVAC Modes

Language

Enter the current year, month and day.

Enter the current hour (military time), minute, and second.

Select the units to be used for cable length and wire gauge settings, metric or Imperial.

Select between Fahrenheit and Celsius.

Enter how much time to wait after powering up the controller before alarm conditions are considered valid.

Enable HVAC modes for cooling tower and boiler applications where the relay control modes for Biocide timer, Bleed and Feed, Bleed then Feed, and Intermittent Sampling are required. Disable HVAC Modes if these control modes are not necessary and a more generic timer control mode will replace the Biocide timer.

Select the language the software will use

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5.4.2 Security Settings

Controller Log Out

When Security is Enabled, and after the password has been entered, the controller requires

immediate use of a password to calibrate or change settings. Once nished making changes,

log out to prevent unauthorized changes by someone else. If not manually logged out, the controller will automatically log out after 10 minutes of inactivity.

Security

Select Enable to require a password in order to calibrate or change settings, or Disable to allow calibration and set point changes without a password. In order to Enable security, the

default password must be entered rst, then select Enable, then press the Conrm key.

Local Password

Used to change the password needed for full conguration capability if Security has been

enabled. The default local password is 5555. This can and should be changed using this menu if Security is enabled.

5.4.3 Display Settings

Home 1

Home 2

Adjust Display

Key Beep

Select the input or output to display on the 1

Select the input or output to display on the 2

Change the contrast using the arrow keys.

Select enable to hear a beep when a key is pressed, or disable for silence

5.4.4 File Utilities

File Transfer Status

Export Event Log

Export System Log

Import User Cong

File

Export User Cong

File

Restore Default Cong

Software Upgrade

NOTE: Remove power before inserting or removing the USB stick!

Displays the status of the last attempt to export a le

Save the Event Log le to a USB stick. This records set point changes, user calibrations, alarms, relay state changes, le exports, etc.

Save the System Log le to a USB stick. This records hardware changes, software

upgrades, automatic calibrations, power loss, system-level issues, etc.

Remove power from the controller and insert a USB stick that contains the settings that

you want to import to this controller (see Export User Cong le below). Press the Enter key and then press the Conrm key to transfer those settings to this controller.

The User Conguration le contains all settings for the controller. Enter this menu to

save the controller’s settings to a USB stick for using later to restore settings to this controller, or to program additional controllers with the same settings as this one. It

takes several minutes to create the le and transfer it to the stick. Remove power from the controller and insert a USB stick. Press the Enter key and then press the Conrm key to transfer a le containing the controller’s settings to the USB stick.

Enter this menu to restore all of the settings to the factory default values. Any changes to settings that were previously made will be lost!

Remove power from the controller and insert an USB stick that has the upgrade le stored in the root directory into the USB connector (see gure 7). Press the Enter key, and then press the Conrm key to start the upgrade.

line of the display Home screen.

5.4.5 Controller Details

Controller

Product Name

Control Board

Software Version

Sensor Board

Software Version

Displays the name for the group of default settings used as built

Displays the model of the controller as built

Displays the revision number of the front panel circuit board

Displays the software version on the control board

Displays the revision number of the sensor board

Displays the software version on the sensor board

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Power Board

Battery Power

Processor Temp

Sensor Temp

Displays the revision number of the power/relay board

Displays the VDC output of the battery that is used to hold the date and time. The acceptable range is 2.4-3.2 VDC.

Displays the temperature of the main processor. The acceptable range is -10 to 65 C.

Displays the temperature of the sensor input processor. The acceptable range is -10 to 65 C.

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6.0 MAINTENANCE

The controller itself requires very little maintenance. Wipe with a damp cloth. Do not spray down the controller unless the enclosure door is closed and latched.

6.1 Conductivity Sensor Cleaning

NOTE: The controller must be recalibrated after cleaning the sensor.

Frequency

The sensor should be cleaned periodically. The frequency required will vary by installation. In a new installation, it is recommended that the sensor be cleaned after two weeks of service. Electrodeless conductivity sensors are much less sensitive to coatings and should go longer between cleanings. To determine how often the sensor must be cleaned, follow the procedure below.

1. Read and record the conductivity.

2. Remove, clean and replace the conductivity sensor.

3. Read conductivity and compare with the reading in step 1 above.

If the variance in readings is greater than 5%, increase the frequency of sensor cleaning. If there is less than 5% change in the reading, the sensor was not dirty and can be cleaned less often.

Cleaning Procedure

The sensor can normally be cleaned using a cloth or paper towel and a mild detergent. If coated with scale, clean with a dilute (5%) solution of hydrochloric acid solution.

Occasionally an electrode may become coated with various substances that require a more vigorous cleaning procedure. Usually the coating will be visible, but not always.

To clean a severely coated electrodeless conductivity sensor, scrub with a toothbrush or stiff bottlebrush. Soap or hand cleaner may help. If coated with scale, clean with a dilute (5%) hydrochloric acid solution. Harsh abrasives should be avoided. Rinse the sensor thoroughly before returning to service.

To clean a severely coated at surface cooling tower electrode, use ne grit abrasive, such as emery paper. Lay the paper on a at surface and move the electrode in a back and forth motion. The electrode should be cleaned parallel to the carbon

electrodes, not perpendicular.

Clean in this

direction

Replacing the Fuse

CAUTION: Disconnect power to the controller before opening front panel!

Figure14Cleaningaatcontactingconductivityelectrode

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Models that include powered relays have a fuse to protect the controller from devices connected to the relays that draw excessive current. Locate the fuse on the circuit board at the back of the controller enclosure, underneath the

clear cover (see gure 7). Gently remove the old fuse from its retaining clip and discard. Press the new fuse into

the clip, replace the clear cover, secure the front panel of the controller and return power to the unit.

Warning: Use of non-approved fuses can affect product safety approvals. Specications are shown below. To insure product safety certications are maintained, it is recommended that a Walchem fuse be used.

F1 Fuse Walchem P/N

5 x 20 mm, 6.3A, 250V 102834

7.0 TROUBLESHOOTING

CAUTION: Disconnect power to the controller before opening front panel!

Troubleshooting and repair of a malfunctioning controller should only be attempted by qualied personnel using caution

to ensure safety and limit unnecessary further damage. Contact the factory.

7.1 Calibration Failure

Calibrations will fail if the adjustments to the reading are outside of the normal range for a properly functioning system.

Refer to the instruction manual for the specic sensor being used for further information.

7.1.1 Contacting Conductivity Sensors

The calibration will fail if the adjustment to the gain is outside of 0.5 to 2.0.

Possible Cause Corrective Action

Dirty electrode Clean electrode

Improper wiring of sensor to controller Correct wiring

Wrong cell constant entered Program the controller cell constant setting at the value

that matches the electrode being used

Incorrect temperature reading or setting Ensure that the temperature is accurate

Incorrect cable length or wire gauge setting Set to the correct values

Faulty electrode Replace electrode

7.1.2 Electrodeless Conductivity Sensors

The calibration will fail if the adjustment to the gain is outside of 0.2 to 10, or the offset is outside of -10,000 to 10,000.

Possible Cause Corrective Action

Dirty sensor Clean sensor

Improper wiring of sensor to controller Correct wiring

Sensor placed too close to container walls Relocate sensor

Sensor placed in the direct path of electrical current ow Relocate sensor

Incorrect temperature reading or setting Ensure that the temperature is accurate

Incorrect cable length or wire gauge setting Set to the correct values

Faulty sensor Replace sensor

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7.2 Alarm Messages

Alarm messages will include the Name of the input or output as dened in the Settings menu, the hardware identifying

type and number (S for sensor input, D for digital input, R for relay output, A for analog output), and the type of alarm.

HIGH or HIGH-HIGH ALARM

Occurs if the conductivity rises above the high conductivity alarm set points. If your unit is programmed for an alarm relay output, the alarm relay will activate. The controller will continue to check the conductivity, and any outputs using the conductivity sensor will remain active.

Possible Cause Corrective Action

Dirty sensor Clean sensor (see Section 6.1)

Faulty bleed solenoid valve Repair or replace solenoid valve

Faulty sensor Replace sensor

Improper wiring of valve or controller Correct wiring

Conductivity rose over alarm limit while biocide lockout occurred

Clogged Y-strainer in bleed line Clean Y-strainer

Infrequent intermittent sampling Sample more often

Faulty bleed relay Replace power relay board

LOW or LOW-LOW ALARM

Occurs if the conductivity drops below the low conductivity alarm set points. If your unit is programmed for an alarm relay output, the alarm relay will activate. The controller will continue to check the conductivity, and any outputs using the conductivity sensor will remain active.

Possible Cause Corrective Action

Sensor disconnected Reconnect. Check cable for continuity.

Sensor dry Check tee for obstruction. Verify ow. Change location of elec-

Pre-bleed set too low Check pre-bleed setting

Solenoid valve stuck open Repair or replace solenoid valve

Faulty electrode Replace sensor

Improper wiring of electrode Correct wiring

Faulty bleed relay Replace relay

In boilers, ashing to steam Make sure plumbing is done according to the recommended

Too frequent intermittent sampling Sample less often

DI STATE CUSTOM MESSAGE

A digital input that is a DI State type can be set such that either the open or closed state generates an alarm.

The alarm message may be customized. The most common use for this will be a Flow Switch.

Possible Cause Corrective Action

No ow Check piping for closed valves, blockage, etc. Check recirculation

Faulty ow switch/cable Check with ohmmeter.

Faulty controller Check by shorting digital input in controller.

TOTAL ALARM

Occurs if the owmeter totalizer alarm limit is exceeded.

Possible Cause Corrective Action

Normal operation Reset the total to clear alarm

AC coupled onto owmeter cable Route cable at least 6 inches (150 mm) away from any AC voltage

Allow normal bleed to occur

trode.

installation diagram

pump.

Page 53

Noise coupled onto owmeter cable Shield cable

OUTPUT TIMEOUT

This error condition will stop control. It is caused by the output (either relay or analog) being activated for longer than the programmed Time Limit.

Possible Cause Corrective Action

Programmed value too low for normal conditions Increase Time Limit.

Bleed ow rate too low Check for clogged strainer. Check for insufcient pressure diffe-

rential.

Bleed valve not opening Check for faulty bleed valve. Check bleed valve wiring. Check

controller relay.

Sensor not responding Clean sensor, check wiring, replace sensor

RANGE ALARM

It indicates that the conductivity signal from the sensor is out of the normal range of 0-30,000. This error condition will stop conductivity control. This prevents controlling based upon a false conductivity reading. If the temperature sensor goes into range alarm (outside -5 to 90 C for tower, -5 to 220 C for boiler), then the controller will go into manual temperature compensation using the Default Temperature setting.

Possible Cause Corrective Action

Sensor wires shorted Disconnect short

Faulty sensor Replace sensor

Faulty controller Replace or repair controller

SENSOR FAULT

This error indicates that the signal from the sensor is no longer valid at all. This error condition will stop conductivity control.