Walchem W600 Series Instruction Manual

W600 Series

Metal Finishing Controller

Instruction Manual

Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA

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

Notice

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

Proprietary Material

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

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

Statement of Limited Warranty

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

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

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

180702 Rev. B June 2018

Contents

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

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

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

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

2.3 Mechanical .............................................................................................................................................................5

2.4 Variables and their Limits .......................................................................................................................................6

3.0 UNPACKING & INSTALLATION ...........................................................................................................................8

3.1 Unpacking the unit ..................................................................................................................................................8

3.2 Mounting the electronic enclosure ..........................................................................................................................8

3.3 Immersible Copper Sensor Installation ..................................................................................................................9

3.4 Flow Through Copper Sensor/Sample Loop Installation ........................................................................................9

3.5 Flow Through Nickel Sensor/Sample Loop Installation ..........................................................................................9

3.6 Other Sensor Installation ...................................................................................................................................... 11

3.7 IconDenitions .....................................................................................................................................................13

3.8 Electrical installation .............................................................................................................................................13

4.0 FUNCTION OVERVIEW.......................................................................................................................................31

4.1 Front Panel ...........................................................................................................................................................31

4.2 Touchscreen .........................................................................................................................................................31

4.3 Icons ....................................................................................................................................................................31

4.4 Startup ..................................................................................................................................................................33

4.5 Shut Down ............................................................................................................................................................40

5.0 OPERATION using the touchscreen .................................................................................................................40

5.1 Alarms Menu ......................................................................................................................................................41

5.2 Inputs Menu .........................................................................................................................................................41

5.2.1 Copper/Nickel ...........................................................................................................................................45

5.2.2 Contacting Conductivity ............................................................................................................................46

5.2.3 Electrodeless Conductivity ........................................................................................................................46

5.2.4 Temperature ..............................................................................................................................................47

5.2.5 pH ..............................................................................................................................................................47

5.2.6 ORP ...........................................................................................................................................................48

5.2.7 Disinfection ................................................................................................................................................48

5.2.8 Generic Sensor ........................................................................................................................................49

5.2.9 Transmitter Input and AI Monitor Input ...................................................................................................... 49

5.2.10 DI State .....................................................................................................................................................50

5.2.11 Flow Meter, Contactor Type ......................................................................................................................50

5.2.12 Flow Meter, Paddlewheel Type .................................................................................................................51

5.2.13 Feed Monitor .............................................................................................................................................51

5.2.14 Virtual Input – Calculation .........................................................................................................................53

5.2.15 Virtual Input – Raw Value .......................................................................................................................... 54

5.3 Outputs Menu .....................................................................................................................................................55

5.3.1 Relay, Any Control Mode ...........................................................................................................................55

5.3.2 Relay, On/Off Control Mode ......................................................................................................................56

5.3.3 Plating Control ...........................................................................................................................................56

5.3.4 Plating Follow ............................................................................................................................................57

5.3.5 Relay, Percent Timer Control Mode ..........................................................................................................57

5.3.6 Relay, Alarm Output Mode ........................................................................................................................58

5.3.7 Relay, Time Proportional Control Mode .....................................................................................................58

5.3.8 Relay, Manual Mode ................................................................................................................................... 58

5.3.9 Relay, Pulse Proportional Control Mode .................................................................................................... 59

5.3.10 Relay, PID Control Mode ............................................................................................................................ 59

5.3.11 Relay, Dual Set Point Mode ....................................................................................................................... 62

5.3.12 Relay, Timer Control Mode ......................................................................................................................... 62

5.3.13 Relay, Probe Wash Control Mode .............................................................................................................. 63

5.3.14 Relay, Spike Control Mode ......................................................................................................................... 64

5.3.15 Relay, or Analog Output, Lag Control Mode ............................................................................................... 66

5.3.16 Relay or Analog Output, Retransmit Mode ................................................................................................. 72

5.3.17 Analog Output, Proportional Control Mode ................................................................................................ 72

5.3.18 Analog Output, PID Control Mode .............................................................................................................. 73

5.3.19 Analog Output, Manual Mode .................................................................................................................... 76

5.3.20 Analog Output, Flow Proportional Mode .................................................................................................... 76

5.4 CongurationMenu ............................................................................................................................................... 76

5.4.1 Global Settings ...................................................................................................................................................... 77

5.4.2 Security Settings ........................................................................................................................................ 77

5.4.3 Network Settings ........................................................................................................................................ 77

5.4.4 Network Details .......................................................................................................................................... 77

5.4.5 Remote Communications (Modbus) ........................................................................................................... 78

5.4.6 Email Report Settings ................................................................................................................................ 78

5.4.7 Display Settings ......................................................................................................................................... 79

5.4.8 File Utilities ................................................................................................................................................. 80

5.4.9 Controller Details ........................................................................................................................................ 80

5.5 HOA Menu ........................................................................................................................................................... 81

5.6 Graph Menu ........................................................................................................................................................ 81

6.0 OPERATION using Ethernet ............................................................................................................................... 82

6.1 Connecting to a LAN ............................................................................................................................................. 82

6.1.1 Using DHCP ............................................................................................................................................... 82

6.1.2 UsingaxedIPAddress ............................................................................................................................ 82

6.2 Connecting Directly to a Computer ....................................................................................................................... 82

6.3 Navigating the web pages ..................................................................................................................................... 83

7.0 MAINTENANCE .................................................................................................................................................... 83

7.1 Copper or Nickel Sensor Cleaning ........................................................................................................................ 83

7.2 pH Electrode Maintenance .................................................................................................................................... 83

7.3 Replacing the Fuse Protecting Powered Relays ................................................................................................... 84

8.0 TROUBLESHOOTING .......................................................................................................................................... 84

8.1 Calibration Failure ................................................................................................................................................. 84

8.1.1 Copper or Nickel Sensors ............................................................................................................................. 84

8.1.2 pH Sensors ................................................................................................................................................... 85

8.1.3 Contacting Conductivity Sensors .................................................................................................................. 85

8.1.4 Electrodeless Conductivity Sensors .............................................................................................................. 85

8.1.5 ORP Sensors ................................................................................................................................................ 85

8.1.6 Disinfection Sensors ..................................................................................................................................... 86

8.1.7 Analog Inputs ...............................................................................................................................................86

8.1.8 Temperature Sensors .................................................................................................................................... 86

8.2 Alarm Messages .................................................................................................................................................... 86

8.3 Procedure for Evaluation of Conductivity Electrode .............................................................................................. 91

8.4 Procedure for evaluation of the pH/ORP electrode .............................................................................................. 91

8.5 Diagnostic Lights ................................................................................................................................................. 92

9.0 SparePartsIdentication ................................................................................................................................... 93

10.0 Service Policy ...................................................................................................................................................... 94

1.0 INTRODUCTION

The Walchem W600 Series controllers offer a high level of exibility in controlling metal nishing applications.

Two sensor input slots are available to accommodate a variety of cards:
Single Copper or Nickel plus Single pH
Dual Analog (4-20 mA) Input
Single Analog Input + Single Sensor (Contacting Conductivity, pH, ORP, Disinfection or Generic linear voltage
between -2 and 2 VDC)
Sensor Input (Electrodeless Conductivity, Contacting Conductivity, pH, ORP, Disinfection or Generic linear
voltage between -2 and 2 VDC)

Six relay outputs may be set to a variety of control modes:
Plating Control
Plating Follow
Flow Timer
On/Off set point control
Time Proportional control
Pulse Proportional control (when purchased with Pulse solid state opto outputs)
PID control (when purchased with Pulse solid state opto outputs)
Lead/Lag control of up to 6 relays
Dual set point
Timer

Feed as a percent of elapsed time
Always on unless interlocked
Probe Wash timer
Spike to alternate set point on timed basis
Diagnostic Alarm triggered by:
High or Low sensor reading
No Flow
Relay output timeout
Sensor error

An option card with two isolated analog outputs may be installed to retransmit sensor input signals to a chart recorder,
datalogger, PLC or other device. They may also be connected to valves, actuators or metering pumps for linear propor­tional control or PID control.

An Ethernet option provides remote access to the controller’s programming via a PC connected directly, via a local

area network, or via Walchem’s VTouch account management server. It also allows emailing of datalog les (in CSV

format, compatible with spreadsheets like Excel) and alarms, to up to eight email addresses.

Our USB features provide the ability to upgrade the software in the controller to the latest version. The Cong le feature
allows you to save all the set points from a controller onto a USB ash disk, and then import them into another controller,

making the programming of multiple controllers fast and easy. The data logging feature allows you to save the sensor

readings and relay activation events to a USB ash disk.

1

2.0 SPECIFICATIONS

2.1 Measurement Performance

Sensor Specs

Copper

Range 0.10 to 99 g/l (varies with the chemical being measured)

0.10 to 5.50 g/l typical for electroless copper

Resolution 0.01 g/l

Accuracy ± 0.01 g/l

Nickel

Range 0.10 to 25 g/l (varies with the chemical being measured)

Resolution 0.01 g/l

Accuracy ± 0.01 g/l

0.01 Cell Contacting Conductivity

Range 0-300 µS/cm

Resolution 0.01 µS/cm, 0.0001 mS/cm, 0.001 mS/m, 0.0001 S/m, 0.01 ppm

Accuracy ± 1% of reading

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 0-300,000 µS/cm

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

Accuracy ± 1% of reading

pH ORP

Range -2 to 16 pH units
Resolution 0.01 pH units
Accuracy ± 0.01% of reading

Range -1500 to 1500 mV
Resolution 0.1 mV
Accuracy ± 1 mV

Disinfection Sensors

Range (mV) -2000 to 1500 mV Range (ppm) 0-2 ppm to 0-20,000 ppm

Resolution (mV) 0.1 mV Resolution (ppm) Varies with range and slope

2

Accuracy (mV) ± 1 mV Accuracy (ppm) Varies with range and slope

Temperature Analog (4-20 mA)

Range 23 to 500°F (-5 to 260°C) Range 0 to 22 mA

Resolution 0.1°F (0.1°C) Resolution 0.01 mA

Accuracy ± 1% of reading Accuracy ± 0.5% of reading

Electrodeless Conductivity

Range 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 on page 2 apply at 25°C. At higher temperatures, the range is reduced per the range multiplier
chart.

2.2 Electrical: Input/Output

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

Fuse: 6.3 A

Inputs

Copper/Nickel Sensor Signals (0, 1 or 2 depending on model code):

Copper Walchem 190787 immersible OR 190785, 190893, 191596 ow through

sensors

Nickel Walchem 190784 ow through sensor

Sensor Input Signals (0, 1 or 2 depending on model code):

Contacting Conductivity 0.01, 0.1, 1.0, or 10.0 cell constant OR

Electrodeless Conductivity (not available on the combination sensor/analog input card) OR

Disinfection OR

Amplied pH or ORP Requires a preamplied signal. Walchem WEL or WDS series recommended.

±5VDC power available for external preamps.

Each sensor input card contains a temperature input

3

Temperature 100 or 1000 ohm RTD, 10K or 100K Thermistor (For Cu/Ni card, only

1000 ohm RTD)

Analog (4-20 mA) Sensor Input (0, 1,
2 or 4 depending on model code):

2-wire loop powered or self-powered transmitters supported
3 or 4 –wire transmitters supported
Each dual sensor input board has two channels
Channel 1, 130 ohm input resistance
Channel 2, 280 ohm input resistance
The combination input board has one channel, 280 ohm input resistance
Available Power:
One independent isolated 24 VDC ± 15% supply per channel

1.5 W maximum for each channel
2W (83 mA at 24 VDC) total power consumption for all channels (four
total channels possible if two dual boards are installed; 2W is equivalent to
2 Little Dipper sensors)

Digital Input Signals (6):

State-Type Digital Inputs

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

Low Speed Counter-Type Digital
Inputs

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

High Speed Counter-Type Digital
Inputs

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

Outputs

Powered mechanical relays (0 or 6
depending on model code):

Dry contact mechanical relays (0, 2
or4 depending on model code):

Pulse Outputs (0, 2 or4 depending on
model code):

4 - 20 mA (0 or 2)

Ethernet

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

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

Opto-isolated, Solid State Relay
200mA, 40 VDC Max.
VLOWMAX = 0.05V @ 18 mA

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

10/100 802.3-2005
Auto MDIX support
Auto Negotiation

4

Agency Approvals:

Safety UL 61010-1:2012 3rd Ed.

CSA C22.2 No. 61010-1:2012 3rd Ed.
IEC 61010-1:2010 3rd Ed.
EN 61010-1:2010 3rd Ed.

EMC IEC 61326-1:2012

EN 61326-1:2013

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.

2.3 Mechanical

Enclosure Material Polycarbonate

Enclosure Rating NEMA 4X (IP65)

Dimensions 9.5” x 8” x 4” (241 mm x 203 mm x 102 mm)

Display 320 x 240 pixel monochrome backlit display with touchscreen

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 Process Connections

Immersible Copper Not applicable 32-200 F (0-93 C) Polypropylene, glass Not Applicable

Flow through Copper or
Nickel

Electrodeless conductivity 0-150 psi (0-10 bar)*

pH 0-100 psi (0-7 bar)* 50-158°F (10-70°C)* CPVC, Glass, FKM

ORP 0-100 psi (0-7bar)* 32-158°F (0-70°C)*

Contacting conductivity
(Condensate)

pH (High Pressure) 0-300 psi (0-21 bar)* 32-275°F (0-135°C)*

ORP (High Pressure) 0-300 psi (0-21 bar)* 32-275°F (0-135°C)*

Free Chlorine/Bromine 0-14.7 psi (0-1 bar) 32-113°F (0-45°C)

Extended pH Range Free
Chlorine/Bromine

Total Chlorine 0-14.7 psi (0-1 bar) 32-113°F (0-45°C)

Chlorine Dioxide 0-14.7 psi (0-1 bar) 32-131°F (0-55°C)

Ozone 0-14.7 psi (0-1 bar) 32-131°F (0-55°C)

Peracetic Acid 0-14.7 psi (0-1 bar) 32-131°F (0-55°C)

Hydrogen Peroxide 0-14.7 psi (0-1 bar) 32-113°F (0-45°C)

Flow switch manifold 0-150 psi (0-10 bar) up to 100°F (38°C)*

Flow switch manifold
(High Pressure)

0-14.7 psi (0-1 bar) 32-200 F (0-93 C) Polyethylene, glass, FKM

CPVC: 32-158°F (0 to 70°C)*
PEEK: 32-190°F (0 to 88°C)

0-200 psi (0-14 bar) 32-248°F (0-120°C) 316SS, PEEK 3/4” NPTM

0-14.7 psi (0-1 bar) 32-113°F (0-45°C)

32-140°F (0-60°C) GFRPP, PVC, FKM,

0-50 psi (0-3 bar) at 140°F (60°C)

0-300 psi (0-21 bar)* 32-158°F (0-70°C)*

CPVC, FKM in-line o-ring
PEEK, 316 SS in-line
adapter

o-rings, HDPE, Titanium

rod, glass-lled PP tee

Glass, Polymer, PTFE,
316SS, FKM

Platinum, Polymer, PTFE,
316SS, FKM

PVC, Polycarbonate,
silicone rubber, SS, PEEK,
FKM, Isoplast

Isoplast

Carbon steel, Brass,
316SS, FKM

3/8” OD tubing

compression ttings

1” NPTM submersion
2” NPTM in-line adapter

1” NPTM submersion
3/4” NPTF in-line tee

1/2” NPTM gland

1/2” NPTM gland

1/4” NPTF Inlet
3/4” NPTF Outlet

3/4” NPTF

3/4” NPTF

5

Bar

24.1

20.7

17.2

13.8

10.3

6.9

3.4

PSI

350

300

250

200

150

100

50

Pressure vs. Temperature

pH/ORP

LD2

Cond

HP Cond/Steel

HP pH/ORP/Steel

0

30

40

50

60

70

80

90

100

110

120

130

140

150

160

°F

170

180

-1.1

4.4

10.0

15.5

21.1

26.6

32.2

37.7

43.3

48.8

54.4

60.0

65.5

71.1

76.6

82.2

°C

2.4 Variables and their Limits

Sensor Input Settings Low Limit High Limit

Calibration Offset (Copper or Nickel only) -10 g/l or oz/gal 10 g/l or oz/gal

Stabilization Time (Copper or Nickel only) 0:00 minutes 59:59 minutes

Alarm limits Low end of sensor range High end of sensor range

Input alarm dead band Low end of sensor range High end of sensor range

Cell constant (conductivity only) 0.01 10

Smoothing Factor 0% 90%

Temp Comp Factor (conductivity linear ATC only) 0% 20.000%

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 -5 500

Deadband Low end of sensor range High end of sensor range

Calibration Required Alarm 0 days 365 days

Sensor Slope (Generic sensor only) -1,000,000 1,000,000

Sensor Offset (Generic sensor only) -1,000,000 1,000,000

Low Range (Generic sensor only) -1,000,000 1,000,000

High Range (Generic sensor only) -1,000,000 1,000,000

4 mA value (Transmitter, AI Monitor analog input only) 0 100

20 mA value (Transmitter, AI Monitor analog input only) 0 100

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 0.01 100,000

K Factor for units of m

Smoothing Factor 0% 90%

Set Flow Total 0 1,000,000,000

Feed Monitor Input Settings Low Limit High Limit

3

3

0.001 1,000

1 1,000,000

6

Totalizer Alarm 0 vol. units 1,000,000 vol. units

Set Flow Total 0 vol. units 1,000,000,000 vol. units

Flow Alarm Delay 00:10 Minutes 59:59 Minutes

Flow Alarm Clear 1 Contact 100,000 Contacts

Dead Band 0% 90%

Reprime Time 00:00 Minutes 59:59 Minutes

Volume/Contact 0.001 ml 1,000.000 ml

Smoothing Factor 0% 90%

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

Spike Set Point (Spike mode) Low end of sensor range High end of sensor range

Onset Time (Spike Mode) 0 seconds 23:59:59 HH:MM:SS

Duty Cycle Period (On/Off, Spike, Dual Setpoint modes) 0:00 minutes 59:59 minutes

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

On Delay Time (Manual, On/Off, Dual Setpoint modes) 0 seconds 23:59:59 HH:MM:SS

Off Delay Time (Manual, On/Off, Dual Setpoint modes) 0 seconds 23:59:59 HH:MM:SS

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

Turnover Volume (Plating Control, Plating Follow modes) 0 10,000

Turnover Limit (Plating Control, Plating Follow modes) 0 100

Pump Capacity (Plating Control, Plating Follow modes) 0 1,000

Pump Setting (Plating Control, Plating Follow modes) 0% 100%

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

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

Event duration (Timer modes) 0 30,000

Proportional band (Time/Pulse Proportional mode) Low end of sensor range High end of sensor range

Sample period (Time Proportional mode) 0 seconds 3600 seconds

Hold Time (Probe Wash modes) 0 seconds 3600 seconds

Max Rate (Pulse Proportional, Pulse PID modes) 0% 100%

Minimum Output (Pulse Proportional, Pulse PID modes) 0% 100%

Maximum Output (Pulse Proportional, Pulse PID modes) 0% 100%

Gain (Pulse PID Standard mode) 0.001 1000.000

Integral Time (Pulse PID Standard mode) 0.001 seconds 1000.000 seconds

Derivative Time (Pulse PID Standard mode)us 0 seconds 1000.000 seconds

Proportional Gain (Pulse PID Parallel mode) 0.001 1000.000

Integral Gain (Pulse PID Parallel mode) 0.001 /second 1000.000 /second

Derivative Gain (Pulse PID Parallel mode) 0 seconds 1000.000 seconds

Input Minimum (Pulse PID modes) Low end of sensor range High end of sensor range

Input Maximum (Pulse PID modes) Low end of sensor range High end of sensor range

Wear Cycle Time (Lag mode) 10 seconds 23:59:59 HH:MM:SS

Delay Time (Lag mode) 0 seconds 23:59:59 HH:MM:SS

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

4 mA Value (Retransmit mode) Low end of sensor range High end of sensor range

20 mA Value (Retransmit mode) Low end of sensor range High end of sensor range

Hand Output 0% 100%

Set Point (Proportional, PID modes) Low end of sensor range High end of sensor range

7

Proportional Band (Proportional mode) Low end of sensor range High end of sensor range

Minimum Output (Proportional, PID modes) 0% 100%

Maximum Output (Proportional, PID modes) 0% 100%

Off Mode Output (Proportional, PID modes, Flow Prop
modes)

Error Output (not in Manual mode) 0 mA 21 mA

Hand Time Limit (not in Retransmit mode) 1 second 86,400 seconds (0 = unlimited)

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

Gain (PID, Standard mode) 0.001 1000.000

Integral Time (PID Standard mode) 0.001 seconds 1000.000 seconds

Derivative Time (PID Standard mode) 0 seconds 1000.000 seconds

Proportional Gain (PID Parallel mode) 0.001 1000.000

Integral Gain (PID Parallel mode) 0.001 /second 1000.000 /second

Derivative Gain (PID Parallel mode) 0 seconds 1000.000 seconds

Input Minimum (PID modes) Low end of sensor range High end of sensor range

Input Maximum (PID modes) Low end of sensor range High end of sensor range

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

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

Conguration settings Low Limit High Limit

Local Password 0000 9999

VTouch update period 1 minute 1440 minutes

VTouch reply timeout 10 seconds 60 seconds

Alarm Delay 0:00 minutes 59:59 minutes

SMTP Port 0 65535

TCP Timeout 1 second 240 seconds

Auto Dim Time 0 seconds 23:59:59 HH:MM:SS

Graph settings Low Limit High Limit

Low axis limit Low end of sensor range High end of sensor range

High axis limit Low end of sensor range High end of sensor range

0 mA 21 mA

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 W600 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)

8

3.3 Immersible Copper Sensor Installation

The immersible copper sensor is designed for direct in-tank monitoring of electroless copper and microetch solutions.
By monitoring the copper content directly in the solution, control lag and hydraulic problems are eliminated.

The sensor is constructed such that a constant path length exists between the ber optic light guides. The solution
between the light guides absorbs light at specic wavelengths in proportion to the copper concentration. The lamp and

electronics are located under the cover of the sensor. In order to avoid a shift in calibration due to condensation, the
sensor’s cover should NEVER be opened.

The immersible sensor is provided with a mounting plate and 20 feet of cable. Extension cable is available if the sen­sor cannot be mounted within 20 feet of the controller. The maximum cable length is 80 feet.

While the positioning of the sensor is not particularly sensitive to the tank layout, the following suggestions are given
to aid installation:

• Do not place the sensor beside heaters; if solution ow stops, the polypropylene guard may melt.

• Do not immerse the entire sensor, or the cable.

• Place the sensor where the loads of parts will not strike it.

• Place the sensor in an area of good solution movement, but not directly in the path of any air agitation.

• Mount the sensor securely to the rim of the tank using the holes provided. If the tank is rimless, use a block to
provide the support for the mounting plate.

• Attach the cable’s connector to the WCU controller. The connector is keyed, do not force! The sensor you
receive with the controller has already been calibrated.

3.4 Flow Through Copper Sensor/Sample Loop Installation

The copper ow through sensor is designed for out-of-tank monitoring of electroless copper and microetch solutions.

The sensor is designed with a glass tube that contains the copper solution that forms a xed path length between the
lamp and receptor module. The solution absorbs light at specic wavelengths in proportion to the copper concentra-

tion. In order to avoid a shift in calibration caused by condensation, the sensor cover should NEVER be removed!

The ow through sensor is provided with a mounting plate and 20 feet of cable. Extension cable is available if the

sensor cannot be placed within 20 feet of the controller. The maximum cable length is 80 feet.

The sample loop consists of a shut off valve, a cooling coil or plate, a sensor and a pump or any combination thereof.
The shut off valve is to quickly isolate the system if necessary. A cooling coil or plate is necessary to cool the cop­per solution down to a temperature acceptable to a sample pump. Cooling the solution is also recommended to help
reduce the amount of plate out which may form in the sample loop. The pump may be either a stand alone sample
pump (which typically have temperature restriction) or a high temperature pump (which is usually just a branch off
the recirculation pump).

3.5 Flow Through Nickel Sensor/Sample Loop Installation

The nickel ow through sensor is designed for out-of-tank monitoring of electroless nickel solutions.

The sensor is designed with a glass tube that contains the nickel solution that forms a xed path length between the
lamp and receptor module. The solution absorbs light at specic wavelengths in proportion to the nickel concentra-

tion. In order to avoid a shift in calibration caused by condensation, the sensor cover should NEVER be removed!

The ow through sensor is provided with a mounting plate and 20 feet of cable. Extension cable is available if the

sensor cannot be placed within 20 feet of the controller. The maximum cable length is 80 feet. Always route AC

9

voltage wiring in conduit that is separated a minimum of 6 inches from low voltage DC signal lines (such as the sensor
signal).

The sample loop consists of a shut off valve, a cooling coil or plate, a sensor, an optional pH adapter assembly, a pump,
or any combination thereof. The shut off valve is to quickly isolate the system if necessary. A cooling coil or plate is
necessary to cool the nickel solution down to a temperature acceptable to a sample pump and/or pH electrode (if appli­cable). Cooling the solution is also recommended to help reduce the amount of plate-out that may form in the sample
loop. The pH adapter assembly is used to mount an in-line pH electrode. It should be mounted such that the electrode is
always immersed in the ‘U’ trap. The pump may be either a stand-alone sample pump (which will typically have high
temperature restrictions), or a high temperature pump (which is usually a branch off of the recirculation pump).

The ow through sensor/sample loop must be installed according to the following guidelines:

• Mount the sensor on a vibration-free, vertical surface so that the sensor tubing inlet connection is at the bottom and the
outlet is at the top. The vertical orientation will prevent air bubbles from being trapped in the sensor.

• Install a shut-off valve at the beginning of the sample loop so that the system may be shut off quickly if necessary.

• If a sample pump is to be used, it must be installed last, after the cooling coil or cooling plate, the ow through sensor,

and the pH adapter assembly, if applicable.

• If a high temperature recirculation pump is to supply ow, adjust ow rate through the sample loop between 400 - 500
mL/min (approx. 0.11 - 0.13 gal/min). This ow rate will help ensure adequate cooling of the solution while maintain

ing a reasonable lagtime in longer runs of tubing. If this is not possible or is undesirable, see Application Notes below.

Other installation guidelines that may be helpful in the overall system:

• Mount the sensor as close to solution as possible. Keep tubing distances to the sensor inlet as short as possible to avoid
hydraulic lag time. Maximum recommended length of tubing from solution to sensor is 25 feet. If this is not possible,
see Application Notes below.

• The solution inlet should draw sample from an area of good solution movement in order to respond quickly to
chemical additions. However, the solution inlet should not draw too near to where the chemistry is added to avoid

articial ‘spikes’ in concentration.

• The solution discharge should be open to atmospheric pressure in order to ensure proper ow.

• The cable connector to the controller is keyed, do not force!

Application Notes

If the distance from the solution to the sensor is further than the recommended length of 25 feet, the maximum lagtime

must be calculated from the desired control band to determine a pump ow rate based on a given distance of standard,

uniform tubing. The maximum lagtime is the maximum allowable time for the solution to continuously get to the sensor
in order to achieve the desired control band.

To calculate maximum lagtime:

Max. Lagtime = Desired Control Band*
4 x Depletion Rate
where Control band = Maximum deviation of concentration
Depletion rate = Rate at which the bath will deplete per unit of time

The deadband should be adjusted so that it is 1/4 the desired control band.

For Example: The set point is 4.00 g/L.

10

If the desired control band is 0.20 g/L (± 0.10 g/L or 2.5%) and the bath is depleting at a rate of 1.25 g/L every
15 minutes (0.08333 g/L every minute),

then Max. Lagtime = 0.20 g/L = 0.60 minutes
4 x (0.08333 g/L /min)

So, 0.60 minutes is the maximum time it should take for the solution to reach the sensor.

To calculate pump ow rate:

Minimum Pump Flow Rate = Volume of System*

Maximum Lagtime

where Volume of system = π ( Tubing I.D.) 2 x Length of tubing

2
Maximum lagtime = Previously calculated time to get solution to sensor.

* Volume is based on length from solution to sensor, not the return.

For Example: If the system parameters are: Tubing is 3/8” O.D. ‘ 1/4” I.D.
Length is 30 feet (360 inches)

then the volume of the system = π ( 0.25 in )2 x (360 in)

2
= 17.7 in3

Note: 1 U.S. Gallon = 231 U.S cubic inches 1 Liter = 61.03 U.S. cubic inches

Note: Volume of Cooling Coil: 0.018 Gallons

0.068 Liters

Volume of 3/8” O.D. x 1/4” I.D. (0.59 in3/ft): 0.00255 Gallons/linear ft

0.00965 Liters/linear ft

Volume of Cooling Plate: 0.023 Gallons

0.088 Liters

Volume of the system = 17.7 in3 = 0.0765 gallons
231 in3 / gallon

Maximum lagtime = 0.60 minutes (previously calculated)

So, the minimum pump ow rate = 0.0765 gallons = 0.127gal/min (483 mL/min)

0.60 minutes

Caution: The calculated pump ow rate is the minimum required to obtain the desired control band, however, if the
ow rate increases over the recommended rate of 500 mL/min (approx. 0.13 gal/min) the rate of cooling will decrease.

This may be compensated for by re-evaluating the system criteria: length / desired control band or to double up on the
cooling plate/coil.

Consult factory with any further installation questions.

3.6 Other Sensor Installation

Refer to the specic instructions supplied with the sensor being used, for detailed installation instructions.

General Guidelines

11

Locate the sensors where an active sample of water is available and where the sensors can easily be removed for
cleaning. Position the sensor such that air bubbles will not be trapped within the sensing area. Position the sensor
where sediment or oil will not accumulate within the sensing area.

In-Line Sensor Mounting

In-line mounted sensors must be situated so that the tee is always full and the sensors are never subjected to a
drop in water level resulting in dryness. Refer to Figure 3 for typical installation.

Tap off the discharge side of the recirculation pump to provide a minimum ow of 1 gallon per minute through
the ow switch manifold. 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.

IMPORTANT: To avoid cracking the female pipe threads on the supplied plumbing parts, use no more than 3

wraps of Teon tape and thread in the pipe FINGER tight plus 1/2 turn! Do not use pipe dope to seal the threads
of the ow switch because the clear plastic will crack!

Submersion Sensor Mounting

If the sensors are to be submersed in the process, mount them rmly to the tank, and protect the cable with

plastic pipe, sealed at the top with a cable gland, to prevent premature failure. Place the sensors in an area of good
solution movement.

Sensors should be located such that they respond rapidly to a well-mixed sample of the process water and the
treatment chemicals. If they are too close to the chemical injection point, they will see spikes in concentration
and cycle on and off too frequently. If they are too far away from the chemical injection point, they will respond
too slowly to the concentration changes, and you will overshoot the set point.

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 non-conductive 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.

The pH/ORP electrode should be placed as close to the controller as possible, to a maximum distance of 1000 feet
(305 m) from the controller. A junction box and shielded cable are available to extend the standard 20 foot (6 m)
length. pH and ORP electrodes must be installed such that the measuring surfaces will always remain wet. A U-trap

provided in the manifold design should achieve this, even if the sample ow stops. These electrodes also must be

installed with the measuring surfaces pointing down; that is 5 degrees above the horizontal, at a minimum.

The disinfection sensor should be placed as close to the controller as possible, to a maximum distance of 100
feet (30 m) from the controller. A junction box and shielded cable are available to extend the standard 20 foot (6
m) length. The sensor should be mounted such that the measuring surfaces will always stay wet. If the membrane
dries out, it will respond slowly to changing disinfectant values for 24 hours, and if dried out repeatedly, will fail
prematurely. The ow cell should be placed on the discharge side of a circulation pump or downhill from a grav­ity feed. Flow into the cell must come from the bottom side that has the ¾” x ¼” NPT reducing bushing installed.

The reducing bushing provides the ow velocity required for accurate readings and must not be removed! A “U”
trap should be installed so that if the ow stops, the sensor is still immersed in the water. The outlet of the ow
cell must be plumbed to open atmosphere unless the system pressure is at or below 1 atmosphere. If the ow

through the line cannot be stopped to allow for cleaning and calibration of the sensor, then it should be placed in
a by-pass line with isolation valves to allow for sensor removal. Install the sensor vertically, with the measuring
surface pointing down, at least 5 degrees above horizontal. Flow rate regulation must be done upstream from the

sensor, because any ow restriction downstream can increase the pressure above atmospheric and damage the

membrane cap!

12

3.7 IconDenitions

Symbol Publication Description

IEC 417, No.5019 Protective Conductor Terminal

|

O

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

3.8 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 6 through 17 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 advis-

able to use stranded, twisted, shielded pair wire between 22-26 AWG. Shield should be terminated at the controller at
the most convenient shield terminal.

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 an 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 equip-
ment.

CAUTION

13

Ethernet

4-20 mA Outputs

Sensor 1

Power In

Power Switch

Digital Inputs

Sensor 2

Figure 1 Conduit Wiring

Relays Relays

14

IMMERSIBLE
SENSOR

20 FT

(80 FT MAX.)

PLATING BATH

(TYPICAL ELECTROLESS COPPER APPLICATION)

CONVEYORIZED SPRAY EQUIPMENT

W A L C H E M

POWER

COPPER

WCU WITH IMMERSIBLE SENSOR

80 FT. MAX.

CAUSTIC

METERING PUMPS

FORMAL­DEHYDE

STABILIZER

TO

WASTE

TREATMENT

CIRCULATING

PUMPS

MANUAL

VALV E

3/8" TUBING

(< 20' PERFERRABLE)

WCU WITH FLOW-THROUGH SENSOR

(TYPICAL MICROETCH APPLICATION)

FLOW

THROUGH

SENSOR

POWER

Figure 2

15

SODIUM
PERSULFATE

"BLEED"

pH ELECTRODE

(recommended)

Copper/Nickel

Bath

pH ADAPTER

FLOW

THROUGH

SENSOR

MAX 80 FT

(24m)

OPTIONAL pH

REPLENISHER

REDUCER

NICKEL

Back to the bath

Shut-off valve

DEGASSER

FLOW ADJUSTMENT

VALV E

COIL

Filter

Pump

Rinse

COOLING

Warm

0

2

out

H

Sample

COOLING

COIL

Cool

0

2

in

H

WNI with Flow through Sensor and Degasser

(Typical Electroless Nickel Application)

Figure 3

16

pH ELECTRODE

Copper/Nickel

pH ADAPTER

MAX 80 FT

(24 m)

OPTIONAL pH

REPLENISHER

REDUCER

NICKEL

Warm

0

2

out

H

Sample

COOLING

COIL)

FLOW

SENSOR

Cool

THROUGH

0

2

in

H

Shut-off valve

(recommended)

FLOW

ADJUSTMENT

VALV E

COOLING

COIL

Filter

Pump

Rinse

Bath

Figure 4

WNI with Flow Through Sensor, without Degasser

(Typical Electrodless Nickel Application)

17

FUSE

ANALOG

OUTPUT

OPTION

ETHERNET

EARTH GROUND

TERMINAL BLOCK

RELAY OUTPUT

TERMINAL BLOCK

NEUTRAL

TERMINAL

BLOCK

AC POWER

TERMINAL

BLOCK

POWER SUPPLY

RIBBON CABLE

MAIN CONTROLLER BOARD

POWER

RELAY

BOARD

I/O SLOT 2

OPTION BOARD

I/O SLOT 1

BOARD

SENSOR, DIGITAL INPUT

AND ANALOG OUTPUT

TERMINAL BLOCKS

OPTION

DUAL

Figure5PartsIdentication

18

USB PORT

Sensor 2

pH Cu/Ni

1

TEMP–

2

TEMP+

3
4
5
6
7
8

9
10
11
12

Cu/Ni SHIELD USE TB3 #12

IN–
IN+
–5V

+5V

COM

VM

VR

+5V

+2.5V

SHIELD

Sensor 1

1
2
3
4
5
6
7
8
9

10

11
12
18

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

9

9

10

10

11

11

12

12

13

13

14

14

15

15

16

16

17

17

18

18

TB1

TB3

TEMP– WHT/GRN

TEMP+ GRN/WHT

IN– WHT/ORN

IN+ ORN/WHT

–5V WHT/BLU

+5V BLU/WHT

COM WHT/BLU

VM ORN/WHT

VR GRN/WHT

+5V BLU/WHT

+2.5V WHT/GRN

SHIELD

1
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16
17
18

TB4 TB6

TB2

POWER
SWITCH

FUSE

R1

R2

N

N

R3

N

N

N

N

N

N

R4

N

N

N

N

R5

TB5

R6

N

L

TB7

Optional Temperature
Compensation

pH electrode

Shield
to TB

3#12

Figure 6 - Copper/Nickel + pH Board Sensor Input Wiring

TB1 (for Sensor 1) or
TB2 (for optional Sensor 2)

19

Sensor 1

Sensor 2

SENSOR INPUT CARD LABEL

ECOND CCOND

1

TEMP– TEMP– TEMP–

2

TEMP+ TEMP+ TEMP+

3

R-SHLD

4

RCV–

5

RCV+

6
7

X-SHLD SHIELD SHIELD

8
9

10

XMT+ XMT

XMT–

11
12

pH/ORP

DIS

IN–

RCV IN+

+5V

–5V

10

11

12

1
2
3
4
5
6
7
8
9

TB1 (for Sensor 1) or
TB2 (for optional Sensor 2)

18

CCOND

1

TEMP– TEMP–

2

TEMP+ TEMP+

3

SHIELD

4

RCV IN+

5

XMT

6
7

8
9

10

11
12

pH/ORP

DIS

IN–

–5V

+5V

SHIELD or use DI SHIELD (TB3 7-12)

2 Wire

Loop

+24V

XMTR–

2 Wire

Pwrd

3 Wire 4 Wire

COM(–)

+24V

24V(-)

+24V

XMTR– XMTR–

XMTR+ XMTR+ XMTR+

COMBINATION SENSOR/ANALOG CARD LABEL

1

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

9

9

10

10

11

11

12

12

13

13

14

14

15

15

16

16

17

17

18

18

TB1

TB3

TEMP– WHT

TEMP+ GRN

RCV BLACK

SHIELD

XMT RED

1
2
3
4
5
6
7
8
9

10

11

12

TB1 (for Sensor 1) or
TB2 (for optional Sensor 2)

1
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16
17
18

TB4 TB6

TB2

POWER
SWITCH

N

N

N

N

N

N

N

N

N

N

N

N

TB5

N

L

TB7

General Purpose

(wiring is typical of all
three sensor options)

TEMP– WHT

TEMP+ GRN

SHIELD

RCV BLACK

XMT RED

FUSE

R1

R2

R3

R4

R5

R6

Conductivity

Electrode

GRN

WHT

High Pressure

RED

BLK

Conductivity

Electrode

Figure 7 Contacting Conductivity Sensor Input Wiring

20

Sensor 1

Sensor 2

TB1

POWER
SWITCH

FUSE

R1

R2

1

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

TB3

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

9

9

10

10

11

11

12

12

13

13

14

14

15

15

16

16

17

17

18

18

TB2

N

N

N

N

N

N

N

N

N

N

N

N

TB5

N

L

TB7

TB4 TB6

R3

R4

R5

R6

ECOND CCOND

1

TEMP– TEMP– TEMP–

2

TEMP+ TEMP+ TEMP+

3

R-SHLD

4

RCV–

5

RCV+

6
7

X-SHLD SHIELD SHIELD

RCV IN+

8
9

10

XMT+ XMT

XMT–

11
12

SENSOR LABEL

pH/ORP

DIS

IN–

+5V

–5V

10

11
12
13
14
15
16
17
18

1
2
3

TEMP – BLK

TEMP + GRN

R-SHLD (SHIELD)

4
5
6
7

RCV – BLK

RCV + RED

X-SHLD (SHIELD)

8
9

XMT + WHT

XMT – BLK

Figure 8 Electrodeless Conductivity Sensor Input Wiring

TB1 (for Sensor 1) or
TB2 (for optional Sensor 2)

ELECTRODELESS
CONDUCTIVITY
SENSOR

21

Sensor 1

Sensor 2

SENSOR INPUT CARD LABEL

ECOND CCOND

1

TEMP– TEMP– TEMP–

2

TEMP+ TEMP+ TEMP+

3

R-SHLD

4

RCV–

5

RCV+

6
7

X-SHLD

SHIELD SHIELD

8
9

10

XMT+ XMT

XMT–

11
12

pH/ORP

DIS

IN–

RCV IN+

+5V

–5V

10
11
12
18

POWER
SWITCH

1

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

TB1

1
2
3
4

TEMP– WHT/GRN

TEMP+ GRN/WHT

IN– WHT/ORN

IN+ ORN/WHT

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

9

9

10

10

11

11

12

12

13

13

14

14

15

15

16

16

17

17

18

18

TB4 TB6

TB2

TB3

FUSE

R1

R2

N

N

R3

N

N

N

N

N

N

R4

N

N

N

N

R5

TB5

R6

N

L

T

B7

Optional Temperature
Compensation

5
6
7
8
9

SHIELD

+5V BLU/WHT

-5V WHT/BLU

TB1 (for Sensor 1) or
TB2 (for optional Sensor 2)

pH/ORP electrode

CCOND

1

TEMP– TEMP–

2

TEMP+ TEMP+

3

SHIELD

4

RCV IN+

5

XMT

6
7

8
9

10

11
12

pH/ORP

DIS

–5V

+5V

SHIELD or use DI SHIELD (TB3 7-12)

IN–

2 Wire

Loop

+24V

XMTR–

2 Wire

Pwrd

3 Wire 4 Wire

COM(–)

+24V

24V(-)

+24V

XMTR– XMTR–

XMTR+ XMTR+ XMTR+

COMBINATION SENSOR/ANALOG CARD LABEL

Figure 9 pH/ORP Sensor Input Wiring

1
2
3
4
5
6
7
8
9

10

11

12

TB1 (for Sensor 1) or
TB2 (for optional Sensor 2)

SHIELD

TEMP– WHT/GRN

TEMP+ GRN/WHT

IN– WHT/ORN

IN+ ORN/WHT

-5V WHT/BLU

+5V BLU/WHT

pH/ORP electrode

Optional Temperature
Compensation

22

Sensor 1

Sensor 2

POWER
SWITCH

FUSE

R1

1

1

1

2

2

2

3

3

3

4

4

4

5

5

5

6

6

6

7

7

7

8

8

8

9

9

9

10

10

10

11

11

11

12

12

12

13

13

13

14

14

14

15

15

15

16

16

16

17

17

17

18

18

18

TB1

TB3

TB4 TB6

TB2

R2

N

N

R3

N

N

N

N

N

N

R4

N

N

N

N

R5

TB5

R6

N

L

B7

T

SENSOR LABEL

pH/ORP

CCOND

1

TEMP– TEMP–

8
9

10

11
12

CCOND

1

8
9

pH/ORP

TEMP– TEMP–

10

11
12

pH/ORP

CCOND

1

TEMP– TEMP–

8
9

10

11
12

2 Wire

2 Wire

DIS

Loop

Pwrd

3 Wire 4 Wire

COM(–)

+24V

+24V

XMTR– XMTR–

XMTR–

XMTR+ XMTR+ XMTR+

SHIELD or use DI SHIELD (TB3 7-12)

2 Wire

2 Wire

DIS

Loop

Pwrd

3 Wire 4 Wire

COM(–)

+24V

+24V

XMTR– XMTR–

XMTR–

XMTR+ XMTR+ XMTR+

SHIELD or use DI SHIELD (TB3 7-12)

2 Wire

2 Wire

DIS

Loop

Pwrd

3 Wire 4 Wire

COM(–)

+24V

+24V

XMTR– XMTR–

XMTR–

XMTR+ XMTR+ XMTR+

SHIELD or use DI SHIELD (TB3 7-12)

24V(-)

+24V

24V(-)

+24V

24V(-)

+24V

TB1 (for Sensor 1) or
TB2 (for optional Sensor 2)

1

8

9
10
11
12

1

8
9

10

11

12

1

8

9
10
11
12

GROUND

POWER

-

+

–

+

SHIELD

+

–

SHIELD

POWERED

4 WIRE

TRANSMITTER

POWERED 2 WIRE

4-20mA SOURCE

•SIMULATOR

•POWERED 4-20mA

OUTPUT

(e.g. W100)

UNPOWERED

2 WIRE

LOOP POWERED

TRANSMITTER

CCOND

1

TEMP– TEMP–

pH/ORP

DIS

2 Wire

Loop

8
9

+24V

10

11
12

XMTR–

SHIELD or use DI SHIELD (TB3 7-12)

NOTE: To program the combination card analog input, you must go to Inputs menu, then enter the analog input

(S13 or S23), scroll down to Transmitter, and select the type of transmitter from the list.

Figure 10 Combination Card 4-20mA Dual Sensor Input Wiring

2 Wire

3 Wire 4 Wire

Pwrd

COM(–)

24V(-)

+24V

+24V

XMTR– XMTR–

XMTR+ XMTR+ XMTR+

10
11
12

1

UNPOWERED

8
9

– GROUND

24V POWER

+ SIGNAL

SHIELD

3 WIRE

TRANSMITTER

23

TB

Pin#

1
2
3
4
5
6
7

8

9

10

11
12

TB

Pin#

1
2
3
4
5
6
7

8

9

10

11
12

2 Wire

Loop

+24V

XMTR–

SHIELD

+24V

XMTR–

SHIELD

2 Wire

Loop

+24V

XMTR–

SHIELD

+24V

XMTR–

SHIELD

Type of Transmitter

2 Wire

Powered

XMTR–
XMTR+

SHIELD

XMTR–
XMTR+

SHIELD

3 Wire

+24V

XMTR+

COM(-)

SHIELD

+24V

XMTR+

COM(-)
SHIELD

Type of Transmitter

2 Wire

Powered

XMTR–
XMTR+

SHIELD

XMTR–
XMTR+

SHIELD

3 Wire

+24V

XMTR+

COM(-)

SHIELD

+24V

XMTR+

COM(-)
SHIELD

4 Wire

+24V

24V(–)

XMTR–
XMTR+

SHIELD

+24V

24V(–)

XMTR–

XMTR+

SHIELD

4 Wire

+24V

24V(–)

XMTR–
XMTR+

SHIELD

+24V

24V(–)

XMTR–

XMTR+

SHIELD

AI#

1

2

AI#

1

2

1

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

TB1

1
2
3

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

TB3

Power

Ground

–

1
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16
17
18

TB2

+

4
5
6
7
8
9

10

11

–

+

Shield

12

TB1 (for Sensor 1) or
TB2 (for optional Sensor 2)

1
2
3

Jumper
wire

4
5

Shield

6
7
8
9

10

11

12

24V Power

Jumper
wire

+ Signal

– Ground

Shield

TB1 (for Sensor 1) or
TB2 (for optional Sensor 2)

POWER
SWITCH

N

N

N

N

N

N

N

N

N

N

N

N

TB5

N

L

TB7

TB4 TB6

POWERED

4-20mA SOURCE

•SIMULATOR

•POWERED 4-20mA

OUTPUT

(i.e. W100)

+

–

FUSE

R1

R2

R3

R4

R5

R6

UNPOWERED

2 WIRE

TRANSMITTER

UNPOWERED

3 WIRE

TRANSMITTER

POWERED

4 WIRE

TRANSMITTER

Figure 11 Dual 4-20mA Sensor Input Wiring

24

TB1

POWER
SWITCH

FUSE

R1

R2

1

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

TB3

1

2

2

3

3

4

4

5

5

6

6

7

7

8

8

9

9

10

10

11

11

12

12

13

13

14

14

15

15

16

16

17

17

18

18

TB2

N

N

N

N

N

N

N

N

N

N

N

N

TB5

N

L

TB7

TB4 TB6

R3

R4

R5

R6

1

2

3 3 +9 VDC

4 4

5 5

SEE

6 6 +9 VDC

SENSOR 1

7 7

LABEL

8 8

9 9

1

2

DIG IN 3+

DIG IN 3–

DIG IN 4+

DIG IN 4–

DI

SHIELD

1

2

3

4

5

6

7

8

9

SEE

SENSOR 2

LABEL

10 10 10

11 11 11

12 12 12

13 DIG IN 1+ 13 DIG IN 5+ 13 DIG IN 2+

14 DIG IN 1– 14 DIG IN 5– 14 DIG IN 2–

15

+9 VDC

16

4-20 OUT1+

17

4-20 OUT1–

18

SHIELD

15

+9 VDC

15

16 DIG IN 6+ 16

17 DIG IN 6– 17

18

+9 VDC

18

+9 VDC

4-20 OUT2+

4-20 OUT2–

SHIELD

TB1 TB3 TB2

SAFETY COVER LABEL

1
2
3
4
5
6
7
8
9

10

11
12
13
14
15
16
17
18

TB1, 2 OR 3

(TB 3 SHOWN)

SIGNAL

IN –

POWER +9V

Hall Effect

FLOW METER

Reed Switch

FLOW METER

Polarity not Critical

FLOW SWITCH

Contact Closure:

Polarity not critical

Figure 12 Digital Inputs

25

N
N
N
N
N
N

TB5

WHT 120V
BLU 240V

WHT 120V
BLU 240V

WHT 120V
BLU 240V

WHT 120V
BLU 240V

WHT 120V
BLU 240V

PUMP

GRN 120V

TO

TB4

SOLENOID/
MOTORIZED
BALL VALVE

GRN 120V
GRN/YEL 240V

GRN 120V
GRN/YEL 240V

GRN/YEL 240V

TO

TB4

TO

TB4

TB1

POWER
SWITCH

FUSE

R1

R2

1

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

2
3
4
5
6
7
8
9
10

10

11

11

12

12

13

13

14

14

15

15

16

16

17

17

18

18

TB3

IF MOTORIZED
BALL VALVE

1
2
3
4
5
6
7
8
9

TB2

BLK 120V
BRN 240V

N

N

N

N

N

N

N

N

N

N

N

N

TB5

N

L

TB7

TB4 TB6

R3

R4

R5

R6

NC

NO

R1

NC

BLK 120V
BRN 240V

NO

R2

NC

BLK 120V
BRN 240V

NO

R3

NC

BLK 120V
BRN 240V

NO

R4

NC

BLK 120V
BRN 240V

NO

R5

NC

R6

TO

TB4

TB6

WHT 120V
BLU 240V

BLK 120V
BRN 240V

NO

N

L

Figure 13 W600 AC Power + Relay Output Wiring

PUMP

ALARM

GRN 120V
GRN/YEL 240V

26

TO

TB4

GRN 120V

GRN/YEL 240V

Power Supply

(115 VAC or 230 VAC)

TB7