Walchem WBL400 Series, WBL410 Series Instruction Manual

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W A L C H E M

BL400/410 Controllers

WBL400/410 Series Boiler Controller

Instruction Manual

Walchem Corporation Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA

TEL: 508-429-1110 FAX: 508-429-7433 WEB: www.walchem.com

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Notice

Proprietary Material

The information and descriptions contained herein are the property of WALCHEM Corporation. 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 Corporation, 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 Corporation warrants equipment of its manufacture, and bearing its identification 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 Corporation and for the purposes disclosed in writing at the time of purcha se, if any. WALCHEM Corporation'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 Corporation, transportation charges prepaid, has been inspected and determined by WALCHEM Corporation 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.

180325.C Jul 2008

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TABLE OF CONTENTS

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

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

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

2.2 Electrical: Input/Output.............................................................................................................2

2.3 Mechanical...............................................................................................................................2

2.4 WBL Variables and their Limits................................................................................................3

3.0 UNPACKING & INSTALLATION..................................................................................................4

3.1 Unpacking the unit....................................................................................................................4

3.2 Mounting the electronic enclosure............................................................................................4

3.3 Installation................................................................................................................................4

3.4 Icon Definitions.........................................................................................................................8

3.5 Electrical Installation ................................................................................................................8

4.0 FUNCTION OVERVIEW ............................................................................................................13

4.1 Front Panel.............................................................................................................................13

4.2 Display ...................................................................................................................................13

4.3 Keypad...................................................................................................................................14

4.4 Access Code..........................................................................................................................14

4.5 Startup.................................................................................................................................... 14

4.6 Shut Down..............................................................................................................................14

5.0 OPERATION..............................................................................................................................15

5.1 Main Menu .............................................................................................................................15

5.2 Conductivity Menu..................................................................................................................17

5.3 Temperature Menu.................................................................................................................19

5.4 Blowdown Menu.....................................................................................................................20

5.5 Feed Menu.............................................................................................................................22

5.6 Time Menu .............................................................................................................................26

5.7 Alarm Menu (Only for WBL400 models).................................................................................27

5.8 4-20mA Menu.........................................................................................................................28

5.9 Access Code Menu................................................................................................................29

5.10 Datalog Menu.........................................................................................................................30

5.11 Config Menu...........................................................................................................................32

5.12 Upgrade Menu .......................................................................................................................33

6.0 MAINTENANCE.........................................................................................................................34

6.1 Electrode Cleaning.................................................................................................................34

6.2 Replacing the Fuses...............................................................................................................34

7.0 TROUBLESHOOTING...............................................................................................................35

7.1 Error Messages......................................................................................................................35

7.2 Conductivity Readout Does Not Change................................................................................36

7.3 Procedure for Evaluation of Conductivity Electrode...............................................................37

8.0 SERVICE POLICY .....................................................................................................................37

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1.0 INTRODUCTION

The Walchem WBL Series controllers offer conductivity control of boiler water and control of chemical feed. The WBL400 series controller has one feed/auxiliary relay available. The WBL410 series controller has four feed/auxiliary relays. The chemical feed pump may be selected to operate in one of the following modes:

Feed and Blowdown Feed and Blowdown with Lockout Feed as a percent of Blowdown Feed as a percent of Time Feed based on a Water Contactor input Feed based on a Paddlewheel Water meter input

The WBL series boiler controller is supplied with a temperature compensated stainless steel electrode with a cell constant of 1.0. The controller is a microprocessor driven industrial type with on/off control outputs. Timed sample or continuous modes may be selected. An optional isolated 4-20 mA output that is proportional to the conductivity reading is available for all models.

Any set point may be viewed without interrupting control. Each set point change will take effect as soon as it is entered. An access code is available to protect set point parameters, while still allowing settings to be viewed.

Our unique USB feature provides the ability to upgrade the software in the controller to the latest version.

An advanced USB capability option is available. The Config file feature allows you to save all the set points from a controller onto a USB flash 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 last months readings and events to a USB flash disk.

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2.0 SPECIFICATIONS

2.1 Measurement Performance

Conductivity Range 0 - 10,000 µS/cm (microSiemens/centimeter)

Conductivity Resolution 1 µS/cm

Conductivity Accuracy 10 - 10,000 µS/cm ±1% of reading

Temperature Range 32 - 392°F (0 - 200°C)

Temperature Resolution 0.1°C

Temperature Accuracy ± 1% of reading

2.2 Electrical: Input/Output

Input Power

Input Signals

Conductivity electrode 1.0 cell constant, Pt1000 RTD

Flow Meter (optional) Isolated, dry contact closure required (i.e. relay,reed switch)

Flow Switch (optional) Isolated, dry contact closure required (i.e. reed switch)

Outputs

Mechanical Relays Pre-powered on circuit board switching line voltage

4 - 20 mA (optional) Internally powered

Agency Approvals

UL ANSI/UL 61010-1:2004, 2

CAN/CSA C22,2 No.61010-1:2004 2

CE Safety EN 61010-1 2

CE EMC EN 61326 :1998 Annex A*

Note: For EN61000-4-6,-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.

0 - 10 µS/cm ±20% of reading

100-240 VAC, 50/60 Hz, 8A Fuse: 1.0 ampere, 5 x 20 mm

6 A (resistive), 1/8 HP All relays are fused together as one group, total current for this group must not exceed 6A. Two relays for WBL400 models, six relays for WBL410 models.

Fully isolated 600 Ohm max resistive load Resolution .001% of span Accuracy ± 1% of reading

Edition (2001)*

Edition*

2.3 Mechanical

Enclosure Material Polycarbonate

Operating Ambient Temp 32 – 122°F (0 – 50°C)

Storage Temperature -20 – 180°F (-29 – 80°C)

Electrode mounting ¾" NPTF

Electrode rating 250 psi at 392°F (17.2 bars at 200°C)

Electrode material 316 SS and PEEK

NEMA Rating NEMA 4X

Dimensions 8.5" x 6.5" x 5.5"

Display 2 x 16 character backlit liquid crystal

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2.4 WBL Variables and their Limits

Low Limit High Limit

Conductivity menu

Temperature Menu

BlowdownMenu

Set Point 0 µS/cm 10,000 µS/cm Dead Band 5 µS/cm 500 µS/cm Blowdown Limit Time (set in hours/minutes) 1 minute 8 hrs: 20 min

Feed Menu

Feed Lockout Timer (Mode A) 1 second 99 min: 59 sec Percent of Blowdown (Mode B) 5 % 99 % Feed Time Limit (Mode B) 1 minute 99 min: 59 sec Percent of Time (Mode C) 0.1 % 99 % Feed Cycle Time (Mode C) 10 minutes 59 min: 59 sec Time per Contact (Mode D) 1 second 59 min: 59 sec ÷ Contacts by (Mode D) 1 contact 100 contacts Time Limit (Mode D & E) 1 minute 99 min: 59 sec Time/Vol (Mode E) 1 second 59 min: 59 sec Vol to Initiate Feed (Mode E) 1 9,999 K Factor (Mode E) 1 pulse/vol 20,000 pulses/vol

4-20 mA Menu 4 & 20 mA Settings 0 µS/cm 10,000 µS/cm

Access Code Menu New Value 0 9999

Alarm Menu* High & Low (set to zero to disable) 1% 50%

Datalog Menu (Optional)

Config Menu (Optional)

Upgrade Menu

*Note: The Alarm relay is non-programmable. Refer to the Main Menu diagram on page 16 for the list of error conditions that trigger the alarm relay.

PPM Conversion Factor 0.200 ppm/µS/cm 1.000 ppm/µS/cm

Interval Time (sampling) 5 minutes 24:00 hours

Duration Time (sampling) 1 minute 59 min: 59 sec

% Calibration Range -50 +50

No variables

(enabled) 0=unlimited (disabled)

No variables

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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 WBL series controller and instruction manual. Any options or accessories will be incorporated as ordered.

3.2 Mounting the electronic enclosure

The WBL series 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 rated. The maximum operating ambient temperature is 122°F (50°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) Right: 4" (102 mm) Bottom: 7" (178 mm)

3.3 Installation

Once the WBL series controller is mounted, the metering pumps may be located at any distance from the controller. The conductivity electrode should be placed as close to the controller as possible, to a

maximum distance of 250 ft. Less than 25 ft is recommended. The cable MUST be shielded from

background electrical noise. (The standard cable length is 10 feet. Should you require longer cable, consult factory.)

Important Installation Notes: (see figure 1)

1. Make sure the minimum water level in the boiler is at least 4-6 inches 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 flow restrictions from the tap for the boiler skimmer blowdown line to the electrode. If the ID is reduced below 3/4 inch, then flashing 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 flow 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.

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

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6. There MUST be a flow restriction after the electrode and/or control valve in order to provide back pressure. This flow restriction will be either a flow control valve or an orifice union. The amount of the flow 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.

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

Guide to Sizing Blowdown Valves and Orifice 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 (fire-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

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 flow control valve or less than the flow through the smallest orifice. 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 flow control valve or orifice. See the graphs on the next page.

Use of a flow control valve will give you the best control of the process, since the flow rate can be easily adjusted. The dial on the valve also gives you a visual indication if the flow rate has been changed. If the valve clogs, it can be opened to clear the obstruction, and closed to the previous position.

If an orifice plate is used, you must install a valve downstream from the orifice in order to fine tune the flow 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 flow rate of the smallest flow control valve is 3250 lbs./hr. 3250 x 0.25 = 812.5 which is too high for continuous sampling. Using an orifice, the flow rate through the smallest diameter plate is 1275 lbs./hr. This is too high for continuous sampling.

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5. Determine the Orifice or Flow Control Valve Size for this Blowdown Rate

Use the following graphs to select a flow control device:

18000

16000

14000

12000

10000

Lbs/hr

8000

6000

4000

2000

Flow Rate in Lbs/hr for Various Orifices

1/8 inch dia 3/16 inch dia 1/4 inch dia 5/16 inch dia

25000

20000

15000

Lbs/hr

10000

5000

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

Pressure PSI

Flow Control Valve

Maximum Flow Rates in Lbs/hr

1/2" 150 PSI 1/2" 300 PSI 3/4" 150 PSI 3/4" 300 PSI

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

Pressure PSI

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Skimmer Blowdown Lin e 3/4" Min. up to Electrode

with minimal valves, elbows & unions

10 ft. max.

Full Port Block

Valve

minimum

Manual Blowdown (Normally Closed)

DRAIN

CONDUCTIVITY

¾"

Cross

2 ft.

ELECTRODE

1 to 3 ft.

maximum

Manual Clean-Out

(Normally Closed)

Motorized

Ball

or Solenoid

Valve

RECOMMENDED INSTALLATION INTERMITTENT SAMPLING

Flow

Control

Valve or

Orifice Union

To Drain

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

Skimmer Blowdown Lin e 3/4" Min. up to Electrode

Full Port Block

Manual Blowdown (Normally Closed)

Valve

Motorized

Ball

Solenoid

Valve

CONDUCTIVITY

ELECTRODE

¾"

Cross

To Drain

Flow Control Valve or Orifice Union

Manual Clean-Out (Normally Closed)

RECOMMENDED INSTALLATION

CONTINUOUS SAMPLING

Figure 1 Typical Installation

Flow Control Valve or Orifice Union

To Drain

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3.4 Icon Definitions

Symbol Publication Description

IEC 417, No.5019 Protective Conductor Terminal

IEC 417, No. 5008 Off (Supply)

3.5 Electrical Installation

The various standard wiring options are shown in figure 2. Your WBL series controller will arrive from the factory prewired or ready for hardwiring. Depending on your configuration of controller options, you may be required to hardwire some or all of the input/output devices. Refer to figures 3 and 4 for circuit board layout and wiring.

Notes:

1. When wiring the conductivity electrode, it is critical to use shielded 24 AWG cable. DO NOT

route the cable in the same conduit as any AC wiring. The shield must be terminated at the controller earth ground only. Make sure to cut off the shield wire at the electrode and to ensure

that it does not touch the grounded junction box.

2. When wiring the optional flow meter contactor input, the 4-20 mA output or a remote flow switch,

it is advisable to use stranded, shielded, twisted pair wire between 22-26 AWG. Shield should be terminated at the controller ground stud (see figures 3 and 4).

3. Always route low voltage (sensor) signals with at least 6” separation from AC voltage wiring.

IEC 417, No. 5007 On (Supply)

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

ISO 3864, No. B.3.1 Caution

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 specified by Walchem may impair the protection

provided by the equipment.

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CONDUCTIVITY ELECTRODE

FLOW SWITCH (OPTIONAL)

POWER

BLOWDOWN

FEED

BLOWDOWN

AUX1

SPARES

PLUG

Figure 2a WBL400 Conduit Wiring

AUX2

PLUG

AUX4/ALARM

SPARES

AUX3

Figure 2b WBL410 Conduit Wiring

4-20mA (OPTIONAL)

FLOW METER (OPTIONAL)

CONDUCTIVITY ELECTRODE

FLOW SWITCH (OPTIONAL)

FLOW METER (OPTIONAL)

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(

)

FEED

L2L2

BLEED

N.C.

N.O. N.C. N.O.

FLOW SW 1

IN-IN+

Contact Closure:

Polarity not critical

FLOW MTR 1

IN+

IN-

FLOW MTR 2

IN+ IN-

Hall Effect

Flow Meter

T-T+

GROUND STUD

COND

BLKRED

+5V

SHIELD

L1 L2/N

20V

WHT 120V BLU 240V

Reed Switch

Flow Meter

Polarity not Critical

Do not connect

shield drain wire

at this end!

Figure 3 Inputs

GWR B

Conductivity

Electrode

Power Supply

115 VAC or 230 VAC

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Chart Recorder

BLEED

N.C.

FEED

N.O. N.C. N.O.

BLOWDOWN

N.C.

N.O. N.C. N.O.

FEED

GROUND

STUD

L2L2

L2/N

GRN 120V GRN/YEL 240V

WHT 120V BLU 240V

Bleed Solenoid/

Motorized B all Valve

Figure 4a WBL400 Outputs

BLK 120V BRN 240V

IF MOTORIZED

BALL VALVE

BLK 120 BRN 240V

PUMP

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Chart Recorder

GRN 120V GRN/YEL 240V

L2/N L2/N L2/N L2/N L2/N L2/N

WHT 120V

BLU 240V

WHT 120V

BLU 240V

L2 L2 L2 L2 L2 L2

L1 L2/N

BLEED

N.O. N.C.

N.C.

GROUND

STUD

BLOWDOWN

N.C.

N.O. N.C.

AUX 1

N.O.N.C.

BLK 120V BRN 240V

AUX 2

N.O. N.C. N.O.

N.C.

BLK 120V BRN 240V

AUX 3

FEED

N.O.N.C.

BLK 120V BRN 240V

BOI 1

N.C.

BIO 2

N.O. N.C. N.O.

AUX 4

N.O.

GRN 120V GRN/YEL 240V

N.O.

N.C.

ALARM

N.C.

ALARM

N.O.

IF MOTORIZED

Bleed Solenoid/

Motorized Ball Valve

BALL VALVE

GRN 120V GRN/YEL 240V TO GROUND STUD

Pump(s)

Figure 4b WBL410 Outputs

GRN 120V GRN/YEL 240V TO GROUND STUD

larm

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4.0 FUNCTION OVERVIEW

4.1 Front Panel

Setting Adjustment Keys

On/Off Power Switch

Figure 5 WBL410 Front Panel

Backlit LCD Display

Output LEDs (WBL400 only has

Blowdown and Feed LEDs)

Menu/Function Keys

USB LED

USB Connector

4.2 Display

A summary screen is displayed while the WBL controller is on. This display shows a bar graph of the conductivity relative to the set point, the actual conductivity value, and current operating conditions. The center of the bar graph is at the (S), which represents the set point. For each 1% rise above the set point a vertical bar appears to the right of the (S). For each 1% drop below the set point a vertical bar appears to the left of the (S). There are small breaks in the bars at each 5%. The bar graph is limited to displaying 20% above or below the set point. When these limits are reached an (L) or (H) may appear at the end of the bar graph to indicate a low or high alarm. The operating conditions that are displayed on the bottom line of this display are Blowdown, Chem Feed, Sampling, Waiting, Sensor Error, Blowdown Timeout, Holding, and Normal. Normal just means there is nothing unusual to report.

Normal

1546

1728

Normal

Figure 6 Summary Screen

2010

Normal

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4.3 Keypad

The keypad consists of 4 directional arrow keys and 4 function keys. The arrows are used to move the adjustment cursor and change settings, while the function keys are used to enter values, and navigate the various menu screens. The function keys are

PREV scroll through the various menu choices. ENTER is used to enter a submenu and to enter a value. EXIT is used to back up one menu level. If you are at the main menu level, EXIT will return you to the

Summary Display.

To change a value in a submenu, the left/right arrow keys move the cursor left and right to each digit or option that can be changed. The up/down arrows will change numeric values up or down, or scroll through option choices. Press menu screen.

4.4 Access Code

The WBL series controller is shipped with the access code disabled. If you wish to enable it, see Section

5.9 for operation. With the access code enabled, any user can view parameter settings, but not change

them. Note that this provides protection only against casual tampering. Use a lock on the cover latch if you need more protection.

ENTER, EXIT, NEXT, and PREV (previous). NEXT and

ENTER only when you have finished making all of the changes for that

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 briefly show the WBL model number and then revert to the normal summary display. Scroll through the menus and calibrate the conductivity reading, temperature, and set the control parameters detailed in Section 5, Operation.

To return to the summary display, press the automatically return to this screen after 10 minutes.

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 it if necessary and it will start controlling.

4.6 Shut Down

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

EXIT key until you return to this screen. The controller will

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5.0 OPERATION

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

To view the top level menu, press any key. The menu structure is grouped by inputs and outputs. 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. After ten minutes of inactivity in the menu, the display will return to the summary display. Keep in mind that even while browsing through menus, the unit is still controlling.

5.1 Main Menu

The exact configuration of your WBL controller determines which menus are available as you scroll through the settings. Certain menus are only available if you select certain options. All settings are grouped under the following main menu items.

Conductivity Temperature Blowdown Feed Only if model number is WBL400 Aux 1-4 Only if model number is WBL410 Time Alarm 4-20mA Only if 4-20mA option installed Access Code Datalog Only if advanced USB feature is in model code Config Only if advanced USB feature is in model code Upgrade

The

NEXT key travels forward through this list while the PREV key travels backwards through the list.

Pressing

ENTER will Enter the lower level menu that is currently displayed.

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ibl

1000 µs 77°F

upgrade

1000 µs 77°F

Aux 3 A OFF

1000 µs 77°F

Aux 2 A OFF

Config

1000 µs 77°F

Datalog

tion card is installed.

4-20mA menu appears only if

Only for WBL410 models

Only for WBL400 models

Main Menu

***

e status screens

HI ALARM

LOW ALARM

TEMP ERR

oss

COND ERR

1000 µs 77°F

Aux 1 A OFF

2 2 2

1000 µs 77°F

Feed A OFF

Trips diagnostic alarm relay

in WBL410 models

* Stops conductvity control

NO FLOW

BLOWDOWN

FEED TIMEOUT

FEED

BLODWN TIMEOUT

WAITING

SAMPLE

NORMAL

HOLDING

ENTEREXIT

1000 µs 77°F

NEXTPREV.

BloDwn A OFF

1000 µs 77°F

Temperature

Access Code DIS

1000 µs 77°F

4-20 mA 9.32 mA

1000 µs 77°F

Alarm Lo ALRM

1000 µs 77°F

Time : SUN 3:00

Legend

Operation

Press Enter key to enter menu.

Press Exit key to exit menu.

Blinking fields may be edited with the adjust arrows.

1000 µs 77°F

NORMAL

1000 µs 77°F

Conductivity

Figure 7 Main Menu

1000 µs 77°F

Aux 4 A OFF

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5.2 Conductivity Menu

The conductivity menu provides the following settings: Calibration, Self Test, Unit selection, and sampling mode setup. Additional settings are also discussed below. Refer to figure 8, Conductivity Menu Chrt.

Calibrate

Self Test

Units

ppm C.F. Sample

Mode C / I

To Calibrate the conductivity, use either a hand held meter, or a standard solution, and adjust the controller to match. Once Calibrate is entered, the unit continuously displays conductivity readings. Press an arrow key to change the value displayed to match the hand held meter or the buffer solution. You must press ENTER to activate the new

calibration. You must press the EXIT key to exit calibration. The Bleed output is unaffected until the calibration

menu is exited, so if it was ON when you entered calibration it will stay on until you exit. If you are using intermittent sampling, the bleed valve will open automatically when you enter the calibrate menu.

Press ENTER to begin self test. Press any key to stop. Self Test internally simulates a conductivity sensor and

should always give the reading 1000 µS/cm ±100 μS/cm. If it does not, there is a problem with the electronics and the unit should be serviced. If the self-test is in the expected range, and there is a problem calibrating, then the sensor or its wiring is at fault.

You may choose to display conductivity in µS/cm or in ppm. Press ENTER and then use the Up and Down arrows to change the units. If you change the units, you will be warned to check your settings. This is important. Set points are not automatically translated from µS/cm to ppm. If you change the units you will need to change your Blowdown settings.

This is the ppm Conversion Factor (or multiplier). This is typically 0.666 but can be changed to accommodate various requirements.

Press enter to choose Continuous sampling or one of the types of Intermittent sampling. A 'C' at the end of the display means that sampling is continuous, an 'I' indicates Intermittent sampling, a “T” indicates Intermittent Sampling with Timed Blowdown, and a “P” indicated Intermittent Sampling with Time Proportional Blowdown.

Interval Duration Hold Time

Continuous

Continuous sampling installations allow the conductivity to be monitored continuously. If the conductivity rises above the set point, a valve is opened to drop the conductivity. No additional menus related to this blowdown mode are found in the Conductivity menu.

Intermittent

Intermittent sampling installations read the conductivity at set intervals for a given sample duration. If the conductivity is above the set point, the valve that controls the sampling will stay open until the conductivity falls below the set point. If the time the valve stays open goes beyond the sample duration, the controller will display Extend on the top status line, as well as the amount of time extended. A limit on this amount of time may be imposed; see Figure 10 Blowdown Menu.

In intermittent sampling mode, once the set point conductivity has been reached, and the valve is closed, the conductivity will be re-checked after a programmable Hold Time with the valve still closed. If it is still below set point, the interval between samples will begin. If the conductivity with the valve closed is greater than the set point, this indicates that flashing may have caused the blowdown to stop prematurely. In this case, the sampling duration will begin again. This cycle will repeat until the conductivity is below the set point when the valve is closed.

If any type of Intermittent sampling is chosen, the following settings will become available:

This sets the amount of time between samples. This is set in Hours:Minutes and can be set between 5 minutes and 24 hours.

This is the length of each sample. This is set in Minutes:Seconds and can be set from 10 seconds to 59 minutes: 59 seconds..

This is the amount of time that the sample will be trapped with the blowdown valve closed. The Hold Time should be set for the minimum amount of time required for the trapped sample to reach boiler pressure and rise to its maximum conductivity value. This is set in Minutes:Seconds and can be set from 1 second to 99 minutes: 59 seconds.

If the sample mode is Intermittent with Timed Blowdown, then the sampling sequence is a little different. The controller will open the blowdown valve at the programmed Interval, for the programmed sample Duration. At the end of the sample duration time, the blowdown valve will close, and the sample will be trapped for the Hold Time.

If the conductivity of trapped sample is greater than the set point, then blowdown valve will open for the amount of time programmed below:

Page 21

BlowTime (H)

Prop Band

Max P Time

This is the length of time of the blowdown used in Intermittent Sampling with Timed Blowdown sampling mode. This is set in Hours:Minutes and can be set from 1 minute to 8 hours 20 minutes.

At the end of the blowdown time, the controller will check the conductivity of a held sample once again. If the conductivity is still above the set point, another blowdown cycle will occur.

If the sampling mode is set to Intermittent with Time Proportional Blowdown, then the blowdown valve will open at the programmed Interval, for the programmed sample Duration. At the end of the sample duration time, the blowdown valve will close, and the sample will be trapped for the Hold Time. If the conductivity of trapped sample is greater than the set point, then blowdown valve will open for a variable amount of time, depending upon how far above the set point it is. The controller uses the menus below to determine the blowdown time.

This is the conductivity value above the set point at which the maximum blowdown time will occur. This may be set for any value between 1 and 10,000 μS/cm or ppm.

For example, if your set point will be 2000 μS/cm, and the Prop Band is 200 μS/cm, then if the conductivity is above 2200 μS/cm the blowdown valve will open for the Max P Time described below. If the conductivity of the trapped sample is 2100 μS/cm, the blowdown valve will open for half the Max P Time.

This is the maximum amount of blowdown time. This is set in Hours:Minutes and can be set from 1 minute to 8 hours 20 minutes. This should be set for the amount of time that it takes for the blowdown to drop the conductivity of the boiler water by the conductivity value of the Prop Band under normal loading conditions.

At the end of the blowdown time, the controller will check the conductivity of a held sample once again. If the conductivity is still above the set point, another blowdown cycle will occur, with a new blowdown time calculated.

Figure 8 Conductivity Menu

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5.3 Temperature Menu

The Temperature menu provides the following settings: Calibration, Unit selection. The Temperature menu will be indicated on the display by one of the following:

Temperature Normal operation

Temp 70°F Normal operation

Temp Error Indicates that there is a problem with the temperature input. See figure 9.

Calibrate

Man Temp Units

This menu only appears if a temperature element is connected at power-up.

To Calibrate the Temperature, use a thermometer to measure the fluid temperature and adjust the WBL controller to match. Once Calibrate is entered, the unit continuously displays temperature readings. Press the Up or Down arrow key to change the value displayed to match the thermometer. You must press ENTER to activate the new calibration. You must press the EXIT key to exit calibration.

This menu appears only if no temperature element is connected at power-up. Use the arrow keys to adjust the temperature displayed to match that of the boiler water.

You may choose to display temperature in °C or °F. Press ENTER and the Up or Down Arrow keys to change the temperature units for display.

2000 s/cm 68° F Temperature

ENTEREXIT

Temp 300°F Man Temp °F 300°F

NEXTPREV.

Temp 300°F Calibrate

ENTER

EXIT

Temperature Menu

Temp 300°F Units (°F)

ENTER

EXIT

Legend

Only appears if no temperature element is connected at power-up. Menu wordin

Calibrate Temp °F 32

Units °F °F

Units °C °C

that appears when C units are selected.

Figure 9 Temperature Menu

Page 23

5.4 Blowdown Menu

The Blowdown Menu provides the following settings: Set Point, Dead Band, Time Limit, Control Direction, HOA. The Blowdown menu will be indicated on the display by one of the following: (The 'A' indicates that the output is being controlled automatically.)

Blowdn A

OFF

Indicates that the blowdown output is currently OFF.

Blowdn A

Set Point Dead Band

Time Limit

Reset Timer Control Dir

H / L

H O A

Indicates the length of time that the Blowdown output has been ON.

10:00 TIMEOUT NO FLOW

SAMPLE

This is the conductivity value at which the bleed solenoid valve is turned ON. The factory default setting for the WBL controller is for the Blowdown output to turn on when the conductivity is higher than the set point.

This is the conductivity value that when combined with the set point determines when the blowdown output turns OFF. The blowdown output will turn off when the conductivity drops below the set point minus the Dead Band. For example: The set point is 1500 µS/cm and the Dead Band is 200 µS/cm. The blowdown output turns ON when the conductivity reading is greater than 1500 but does not turn OFF until the conductivity drops below 1300. This setting is not used when intermittent Sampling has been selected.

This menu allows you to set a maximum amount of time for the blowdown. The limit time is programmed in hours and minutes and can be set between 1 minute and 8:59 hours. If the time limit is set to zero, then the valve may be

open indefinitely. If the maximum time is exceeded, the blowdown valve will close and will not re-open until the "Reset Timer" menu is reset by an operator.

Only appears if the time limit above has been exceeded. Use the up or down arrow to change "N" to "Y", then press ENTER.

This allows you to set the Normal (High Set Point) or Inverse (Low Set Point) operation of the blowdown output. When set to High, the output turns on when the conductivity is higher than the set point. When set to Low, the output turns on when the conductivity is lower than the set point.

Indicates that the output has been on longer than the programming time limit.

Indicates that bleed control has been suspended because there is presently no flow past the flow switch.

Indicates the relay is in sampling stage of Intermittent Sampling

High Set Point Low Set Point

The "Hand Off Auto" screen allows you to select the operating mode of the blowdown output. In Hand (manual) mode, the output is turned on immediately for a maximum of 10 minutes. If you walk away the output will return to Auto mode at the end of that time. In Off mode the output will stay Off indefinitely. In Auto mode the blowdown output will respond to changes in conductivity based on the set point. The HOA mode of the blowdown output is indicated on the blowdown status lines.

Page 24

BloDwn Menu

Possible status screens

2000 S/cm 68° F

BloDwn 1:01:15

ENTEREXIT

BloDwn OFF BloDwn Sample BloDwn Timeout BloDwn No Flow

NEXTPREV.

BloDwn 1:01:15 Set Point 2000

BloDwn 1:01 Dead Band 200

BloDwn 1:01 Time Limit 1:15

Legend

Appears only if limit timer has expired.

Appears only if continuous sampling has been selected in Conductivity Menu..

Operation

Press Enter key to enter menu. Press Exit key to exit menu. Blinking fields may be edited with the adjust arrows. Press Enter when modification is complete to return to Blodwn Menu Level.

BloDwn 1:01 Reset Timer N

BloDwn 1:01 Control Dir H

ENTER

EXIT

Control Dir H High Set Point

Control Dir L Low Set Point

BloDwn 1:01:15 HAND OFF > AUTO

Figure 10 BloDown Menu

Page 25

5.5 Feed Menu

The Chemical Feed Menu adapts to the selected Feed output mode.

Note: When programming the unit for the first time, it is recommended that the Chemical Feed Mode Menu be chosen first, then step through the rest of the Feed Menu indicated in Figure 11. The modes

are defined as follows:

A Blowdown and Feed with

Optional Lockout

B Feed % of Blowdown

C Feed % of Time

D Feed based on Water Contactor

E Feed based on Paddlewheel Input

The Feed menu will be indicated on the display by one of the following: (The 'A' indicates that the feed is being controlled automatically.)

Feed A

Blowdown and Feed Mode

Blowdown and Feed Mode turns the Feed output On and Off at the same time as the Blowdown output. The lockout setting determines the maximum allowable time for the Feed output. If this time is exceeded the Feed output is turned off and Locked out until the Blowdown output turns off.

Feed % of Blowdown Mode tracks the length of time that the Blowdown output is on. When the blowdown turns off the feed output is energized for a user defined proportion of the blowdown time.

Feed % of Time Mode turns on the Feed output for a user definable % of a timed cycle. The time cycle length is adjustable from 10 to 60 minutes.

Feed based on Water Contactor Input Mode turns on the Feed output for a user definable time each time a water contactor pulse is detected. This contactor input can be divided to

Input

accommodate a large variety of water meters. Contacts will accumulate feed time so that all contacts are accounted for.

Turns on the Feed output for a user definable time each time a defined volume of flow is detected. This paddlewheel input has a programmable K Factor to work with a large variety of

Mode

Hall Effect (square wave, not sine wave) flow meters.

Indicates that the Feed output is currently OFF.

OFF

Indicates the length of time that the Feed output has been ON or the length of time that the

10:00

Feed output will be ON.

TIMEOUT NO FLOW

Indicates that the feed relay has been on longer than the programmed maximum time.

Indicates that Feed control has been suspended because there is presently no flow past the flow switch.

Lockout

Set this for the Feed Lockout Time. The lockout time is the maximum length of time that the feed output can be on. If the lockout time is set to 0:00, the lockout timer is no longer used and the feed output will be on for as long as the blowdown is on.

Feed % of Blowdown Mode

% of Blowdown

This is the % value that is multiplied times the accumulated bleed time to determine how long the feed will be. For example, if the bleed was on for 10 minutes and this setting was 50%, the feed output would be on for 5 minutes.

Max Time

This is similar to the lockout time above in that the feed output will not exceed this maximum length.

Feed % of Time Mode

% of Time

This is the % value that is multiplied times the cycle length to determine the length of time that the feed output is ON. If the cycle length were 10 minutes and this setting was 40%, the feed output would be on for 4 minutes, then off for 6 minutes and then repeat the cycle.

Cycle Time

This determines the length of the cycle to be used.

Page 26

Feed Based on Water Contactor Mode

Time/Cont.

(Time per contact.) This determines the length of time that the feed pump should be on for each contact that is received.

÷ Contacts By

This setting allows a divider to be entered. The divider will count actual contacts from the meter until the setting is reached before a contact is considered to be received. For example, if the divider is set to 10 and the Time/Cont is set to 5:00, then the feed output would turn on for 5:00 minutes after 10 contacts were received.

Time Limit

This setting puts a limit on the amount of time that can be accumulated by the water meter input. Once this setting has been reached, all contacts will be ignored until the accumulated feed time expires. By setting Time Limit = Time/Cont., the accumulation of contacts can be disabled. Hint: Program this first when initially setting up the Feed and Blowdown additions.

Feed Based on Paddlewheel Mode

Chem Feed Mode A / B / C / D / E

H O A

Time/Vol

This setting determines the pump on-time once a given volume of water has passed through the paddlewheel sensor. The volume required to initiate feed is set below.

Vol to Init.

This setting determines the volume of makeup water that will initiate chemical feed.

K Factor

Enter the number of pulses per unit volume that the paddlewheel sensor sends out. This value is usually printed on the sensor’s flow cell or in its instructions.

Time Limit

This setting puts a limit on the amount of time that can be accumulated by the water meter input. Once this setting has been reached, all contacts will be ignored until the accumulated feed time expires. By setting Time Limit = Time/Vol., the accumulation of contacts can be disabled. This is set in minutes and seconds.

The following settings are for all feed modes.

This allows the user to select the chemical feed mode as described above.

This sets the Hand Off Auto for the feed output. This was explained in the Bleed Menu section and functions similarly. In Off position, the output will not turn ON regardless of the feed mode selected.

Page 27

Feed Menu

ONLY FOR WBL400 MODELS

TIMEOUT

HAND OFF >AUTO

Feed

Operation

TIMEOUT

Feed

Chem Feed Mode A

(Hint: program Mode first)

NEXTPR EV.

ENTER

EXIT

Chem Feed Mode D

Water Contactor

Chem Feed Mode E

Chem Feed Mode A

BloDwn & Feed

Chem Feed Mode B

Feed % of BloDwn

Chem Feed Mode C

Feed % of Time

Paddlewheel

Feed No Flow

Feed Timeout

Feed Lockout

Feed 21:05

Feed Off

Possible status screens

2000 S/cm 68° F

Feed 21:05

Press Enter key to enter menu.

Press Exit key to exit menu.

Blinking fields may be edited with the adjust arrows.

Press Enter when modification is complete to return

to Feed Menu Level.

Press Enter or Adjust arrow to turn on/off output

at Hand menu.

TIMEOUT

Feed

TIMEOUT

Feed

TIMEOUT

Max Time 99:00

Feed

TIMEOUT

Cycle Time 10:00

Feed

Menu choices depend on feed mode

TIMEOUT

ENTEREXIT

Feed

Lockout 99:00

TIMEOUT

Feed

% of BloDwn 10

TIMEOUT

Feed

% of Time 10

TIMEOUT

Feed

TIMEOUT

Time Limit 99:00

Feed Timeout

Feed

Time Limit 99:00

Contacts by 1

Vol to Init 5:00 K Factor 256

444

Time/cont. 1:00

Time/Vol 5:00

Legend

Menu choices that appear when Feed as % of

BloDwn mode is selected.

Menu choices that appear when Feed as % of

Time mode is selected.

Menu choices that appear when Feed based

on water contactor input is selected.

ut is selected.

addlewheel in

Menu choices that appear when Feed based

Figure 11 Feed Menu

Page 28

Alarm A Menu and Submenus

appear only when AUX A output

is configured for use as

Alarm Output.

Alarms (1-4) Menu

Possible status screens

Chem Feed Mode

Water Contactor

TIMEOUT

Time Limit 99:00

Feed Timeout

Feed

Time Limit 99:00

Operation

Chem Feed Mode

Press Enter key to enter menu.

Press Exit key to exit menu.

Blinking fields may be edited with the adjust arrows.

Press Enter when modification is complete to return

to Feed Menu Level.

Press Enter or Adjust arrow to turn on/off output

at Hand menu.

Paddlewheel

TIMEOUT

LOW ALRM

HAND OFF >AUTO

(Hint: program Mode first)

Aux

TIMEOUT

Aux

Chem Feed Mode

ENTER

EXIT

Chem Feed Mode

Bleed & Feed

Chem Feed Mode

Feed % of Bleed

Chem Feed Mode

Feed % of Time

TIMEOUT

Time Limit 99:00

Aux

TIMEOUT

Aux

TIMEOUT

Cycle Time 10:00

Contacts by 1

Aux

3 3

Feed

Max Time 99:00

Aux

Alarm

Alarm OFF

HI ALRM

AUX

Alarm % High 20

NEXTPREV.

Feed (1-4) Menu

HI ALRM

ENTEREXIT

A: 2000 S 68° F

Alarm

HI ALRM

AUX

Alarm % Low 20

NEXTPREV.

Aux LockoutA

Aux 21:05A

Aux OffA

Aux No FlowA

Aux TimeoutA

Possible status screens

ONLY FOR

WBL410 MODELS

NEXTPREV.

Aux 2:05A

Aux LO ALRMA

Aux NO FLOWA

Aux OFFA

Aux HI ALRMA

Aux TIMEOUTA

Possible status screens

HI ALRM

Auxiliary (1-4) Menu

A:2000 S 68° F

Aux

ENTEREXIT

Menu choices depend on feed mode

TIMEOUT

ENTEREXIT

Aux

Aux OFF

Feed Setup

ENTEREXIT

Output Mode FEED

Aux

Output Mode

FEED

Output Mode

ALARM

% of BloDwn 10

Lockout 99:00

Figure 12 Auxiliary (1-4) Menu

Vol to Init 5:00 K Factor 256

4 4 4

24:05

TIMEOUT

% of Time 10

Aux

2 2

Time/cont. 1:00

Aux

Time/Vol 5:00

Menu choices that appear when Feed as % of Time mode

is selected.

Menu choices that appear when Feed as % of BloDwn mode

is selected.

Legend

Menu choices that appear when Feed based on wat er contactor input is selected.

Menu choices that appear when Feed based on pad dlewheel input is selected.

Feed A Menu and submenus appear only when AUX A is

configured for use as FEED.

Page 29

5.6 Time Menu

This menu has only one choice, to set the Time used for Datalogs. This menu will appear as follows:

Time: Mon 10:20

Set Time

2000 S 68° F

Time Sat 12:15

EXIT

Time Sat 12:15 Set Clock

Press ENTER to set the Time. Use the arrow keys to adjust the day and time and then press ENTER to store or EXIT to discard.

Time Menu

ENTER

EXIT

Set Clock Set Jan/ 3/98

ENTEREXIT

Set Clock Set Thu 12:15

Figure 13 Time Menu

Page 30

5.7 Alarm Menu (Only for WBL400 models)

The possible status screen for this menu are shown below. Note: Alarms produce a top level status message only. There is no alarm relay available.

Alarm OFF Alarm LOW ALRM Alarm HI ALRM

Alarm % Low Alarm % High

2000 S/cm 68° F Alarm

Alarm Alarm % Low 20

HI ALRM

ENTEREXIT

HI ALRM

This is the % below the blowdown set point that the LOW ALARM will activate. If the set point is 1000 and the % Low setting is 20 then the Low alarm will activate at 800.

This is the % above the blowdown set point that the HIGH ALARM will activate. If the set point is 1000 and the % Low setting is 20 then the High alarm will activate at 1200.

Possible status screens

Alarm OFF Alarm

NEXTPREV.

Alarm Alarm % High 20

HI ALRM

Figure 14 Alarm Menu

Alarm Menu

LOW ALRM

Page 31

5.8 4-20mA Menu

This menu is only available if the 4-20mA output is installed in the controller. This menu provides for scaling and calibrating the output. The 4-20mA menu screen appears as follows:

4-20mA 9.20mA

This indicates that the current output of the 4-20mA card is 9.20 mA.

Set 4mA Pt Set 20mA Pt Calibrate

2000 S/cm 68° F 4-20mA 12.4mA

4-20mA 12.4mA Set 4mA Pt 0

This conductivity setting will correspond to a 4 mA output from the controller.

This conductivity setting will correspond to a 20mA output from the controller.

This will provide fixed 4mA and fixed 20mA outputs to allow you to calibrate connected equipment.

ENTEREXIT

NEXTPREV.

4-20mA 12.4mA Set 20mA Pt 0

4-20mA 12.4mA Calibrate 4-20mA

EXIT

Calibrate 4-20mA 4mA Output

ENTER

EXIT

Calibrate 4-20mA 20mA Output

Figure 15 4-20 mA Menu

4-20mA Menu

4-20mA menu is only present if 4-20mA hardware is installed.

ENTER

Page 32

5.9 Access Code Menu

This menu determines whether the access code feature of the controller is enabled or disabled and allows you to customize the access code to your own value. The access code controls whether or not you are allowed to change the parameters in the controller. With the access code disabled, any user may change any parameter. With the access code enabled, any user can view any parameter, but cannot change them. Once an attempt is made to change a parameter, the display will prompt the user to enter the access code. If the correct access code is entered, the parameters can be changed. If the wrong access code is entered the parameters cannot be changed. Once the access code has been correctly entered, it will remain valid until there is a period of 10 minutes without a key being pressed. The access code menu will appear as shown below:

The access code menu will appear as shown below:

Access Code

REQ

Enable N / Y New Value

Indicates that the access code is disabled. No access code is required to change any setting.

DIS

Indicates that the access code is required to alter settings.

Indicates that the access code is required and has been entered correctly.

Press the Up or Down arrow key to change the N to Y and press ENTER to enable the access code feature. If the access code is enabled you must first enter the access code to disable it.

Press ENTER to display the current access code value and use the arrow keys to change it to any value between 0 and 9999. If the access code has been enabled, you will be prompted to enter the current access code before being allowed to change it. You must remember the access code if you enable it.

The Factory default Access code is 1995. If you change the access code and can't remember it follow this procedure:

1. Turn off power to the controller.

2. Wait 10 seconds.

3. Press and Hold the UP and DOWN arrow keys while turning on the power.

4. Read the access code on the display.

5. Release the keys, and the access code will disappear.

Figure 16 Access Code Menu

Page 33

5.10 Datalog Menu

This menu is available if the data logging option has been purchased. This is indicated in the model code by the letter U at the end of the model code. This menu allows you to save data from the controller to a USB flash drive.

The controller has four logs, the Current Datalog, the Backup Datalog, the Event Log, and the Reset Log. All files are in a CSV format that may be opened in a spreadsheet such as Microsoft Excel.

Current Datalog

Backup Datalog

Event Log

Reset Log

Current or Backup Datalog

Copy Event Log

Contains the following data taken at 10 minute intervals:

Conductivity Temperature Water Meter Total

When the current datalog is downloaded to a USB stick, it is erased and a new log file is started.

If the current datalog is not downloaded before it reaches its maximum size (at least 60 days of data) the oldest data is overwritten by the newest data.

Contains the same data as the current log but it is never erased. When the backup log reaches its maximum size (at least 60 days of data), the oldest data is overwritten by the newest data.

Contains columns for each relay and flow switch input, as well as the date and time. Each time any of these change state, the date and time is updated and it will show a 1 if the relay is on and 0 if it is off, and a 1 if the flow switch indicates no flow, 0 if there is flow. Tens of thousands of events will be recorded before the oldest data is overwritten by the newest, the number varying with the controller’s configuration.

Consists of time stamps of when power was lost, when it was returned, and the cause of the reset.

Place a USB flash drive with at least 10 MB capacity into the USB port on the front panel of the controller. Press the Enter key to download the file from the controller to the disk. The file name for the Current Datalog will be Datalog<serial number><date><time>.csv using the date and time it was downloaded. The file name for the Backup Datalog will be Datalog<serial number><date><time> .csv using the date and time it was created.

The controller will display the progress of the file download process. If the file was successfully copied to the USB disk the controller will display Transfer Success.

Place a USB flash drive with at least 10 MB capacity into the USB port on the front panel of the controller. Press the Enter key to download the file from the controller to the stick. The file name will be Eventlog<serial number><date><time>.csv.

The controller will display the progress of the file download process. If the file was successfully copied to the USB disk the controller will display Transfer Success, otherwise Transfer Fail 1.

Transfer Success Transfer Fail 1

Copy Reset Log

The controller will display the progress of the file download process. If the file was successfully copied to the USB disk the controller will display Transfer Success.

Transfer Success Transfer Fail 1

Page 34

Possible Status Screens

Transfer Success Transfer Fail 1

2000 µS

Datalog

ENTER EXIT

Datalog Current Datalog

ENTER EXIT ENTER EXIT ENTER EXIT

Datalog Transfer Success

67° F

Datalog Backup DataLog

ENTER EXIT

Datalog Transfer Success

Datalog Menu

Datalog Copy Event Log

Datalog Transfer Success

Datalog Copy Reset Log

Datalog Transfer Success

Figure 17 Datalog Menu

Page 35

5.11 Config Menu

This menu allows you to export a file that contains all of the set points in the controller to a USB flash disk drive, and then later import the set points into another controller.

Export Config

Import Config

Figure 18 Config Menu

Place a USB flash drive with at least 10 MB capacity into the USB port on the front panel of the controller. Press the Enter key to export the configuration file from the controller to the stick. The file name will be UCF.ini. If you are exporting files with different set points you may rename the file to something that describes it, as long as it has an ini extension.

The controller will display the progress of the file download process. If the file was successfully exported to the USB disk the controller will display Transfer Success, otherwise Transfer Fail 1.

Transfer Success Transfer Fail 1

Place a USB flash drive that contains only one configuration file stored on the root directory of the stick into the USB port on the front panel of the controller. Press the Enter key to import the configuration file from the stick to the controller. The file name must have an ini extension in its name.

The controller will display the progress of the file import process. If the file was successfully imported from the USB disk the controller will display one of the messages below:

Import Failure

Import Success: Any key to reboot

File Open Failed

File Read Failed Invalid CFG File Invalid Model Wrong SW Version

Corrupt CFG File Wrong file Size

Indicates that there were problems connecting to or accessing the USB stick.

The configuration file import succeeded and will be ready for use after reboot.

A config file could not be found on the USB stick or the USB stick file system could not be accessed.

The config file is too short (incomplete) or empty.

The imported file is not a valid config file.

The imported config file is not for this controller model.

The version of the imported config file is not compatible with this controller software version.

The imported config file is corrupt. (The checksum failed.)

The size of the imported config file is wrong.

Page 36

5.12 Upgrade Menu

This menu is used to upgrade the software to a newer version. If a new version of the software is available, an upgrade file will be posted on our web site. Save this file to a USB flash disk drive. It needs to be the only executable (.exe file extension) file stored on the root directory of the stick. Press the Enter key to import the software upgrade file from the stick to the controller.

The controller will display the progress of the file import process. If the file was successfully imported from the USB disk the controller will display Transfer Success. The controller will automatically reboot and come up with the new software installed.

Upgrade

To check that it was successful, turn off power to the controller, then press the Enter key while turning power on. The controller will show the software version, which should match the name of the upgrade file that you used.

If the software upgrade fails, you will see one of the following messages:

UpgradFileInvald

No Upgrade File

CorrptUpgradFile Flash Failure

The file found on the USB stick is for the wrong product, or is corrupt. Try getting the correct upgrade file and make sure it’s the only upgrade file on the stick.

There is no upgrade file stored on the stick, or the file is named incorrectly.

Try getting a new copy of the file.

The flash memory on the processor board has a problem. Repair or replace the front panel assembly.

Figure 19 Upgrade Menu

Page 37

6.0 MAINTENANCE

The WBL 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 Electrode Cleaning

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

Frequency

The electrode should be cleaned periodically. The frequency required will vary by installation. In a new installation, it is recommended that the electrode be cleaned after two weeks of service. To determine how often the electrode must be cleaned, follow the procedure below.

1. Read and record the conductivity.

2. Remove, clean and replace the conductivity electrode in the process.

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 electrode cleaning. If there is less than 5% change in the reading, the electrode was not dirty and can be cleaned less often.

Cleaning Procedure

The electrode can normally be cleaned using a cloth, toothbrush, cotton swab or paper towel and a mild detergent. Occasionally an electrode may become coated with various substances which require a more vigorous cleaning procedure. Usually the coating will be visible, but not always. If the electrode is coated with scale, this can be chemically removed using a dilute acid solution.

6.2 Replacing the Fuses

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

Locate the fuses on the circuit board at the back of the controller enclosure. (See figure 3) Gently remove the old fuse from its retaining clip and discard. Press the new fuse into the clip, secure the front panel of the controller and return power to the unit.

Warning: Use of non-approved fuses can affect product safety approvals. Fuse ratings depend on

controller power rating. Specifications are shown below. To insure product safety certifications are maintained, it is recommended that a Walchem fuse be used.

F1 Fuse Walchem P/N F2 Fuse Walchem P/N 5 x 20 mm, 1.0A, 250V 103163 5 x 20 mm, 6A, 250V 102864

Page 38

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 qualified personnel using caution to ensure safety and limit unnecessary further damage. Contact the factory.

7.1 Error Messages

HIGH ALARM - (main summary screen only)

The summary screen will display an H at the right end of the bar graph if the conductivity rises above the high conductivity alarm set point. The controller will continue to check the conductivity, and the blowdown and/or feed outputs will be allowed to be activated.error condition will stop both conductivity and pH control. It indicates that the temperature signal from the conductivity electrode is no longer valid. This prevent controlling based upon a false pH or conductivity reading.

Possible Cause Correction Action

Dirty electrode Clean electrode (see Sect. 6.1)

Faulty solenoid valve Repair or replace solenoid valve.

Faulty electrode Evaluate (see Sect. 7.3). Check Temp display.

Improper wiring of valve or controller Correct wiring. (see Section 3.4)

Faulty blowdown relay Replace relay. (Consult factory.)

LOW ALARM

The summary screen will display an L at the left end of the bar graph. The controller will continue to check the conductivity and feed inhibitor as programmed.

Possible Cause Correction Action

Sensor disconnected Reconnect. Check cable for continuity. Sensor dry Check tee for obstruction. Verify flow. Change location of electrode. Solenoid valve stuck open Repair or replace solenoid valve. (Consult your distributor). Faulty electrode Evaluate (see Section 7.3). Replace if necessary. Improper wiring of electrode Correct wiring. (see Section 3.4) Faulty blowdown relay Replace relay. (Consult factory.)

TEMP ERROR

This error condition will stop both conductivity and pH control. It indicates that the temperature signal from the conductivity electrode is no longer valid. This prevent controlling based upon a false pH or conductivity reading.

Possible Cause Correction Action

Green or white electrode wire disconnected. Reconnect.

Faulty electrode. Replace electrode. Revert to manual temperature compensation by

SENSOR ERROR

This error condition will stop conductivity control. It indicates that the conductivity signal from the electrode is no longer valid. This prevents controlling based upon a false conductivity reading.

cycling power off and on.

Possible Cause Correction Action

Back or red electrode wire shorted. Disconnect short.

Faulty electrode. Replace electrode.

Faulty controller. Verify via failed self test.

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BLOWDOWN TIMEOUT

This error condition will stop conductivity control. It is caused by the bleed output being activated for longer than the programmed Blowdown Time Limit.

Possible Cause Corrective Action

Programmed value too low for normal conditions. Increase Blowdown Time Limit.

Blowdown flow rate too low.

Blowdown valve not opening. Check for faulty blowdown valve.

NO FLOW

This error message will appear if the flow/no flow switch closure is opened. The error message will be displayed and the alarm relay will trip. The conductivity is updated but all outputs are deactivated.

Possible Cause Corrective Action

No flow Check recirculating pump, valves, etc.

Faulty flow switch/cable Check for open circuit. Disconnect flow switch and short the input

Insufficient pressure drop through sample stream Check piping.

CAL FAIL

The controller allows a maximum of ±50% correction to the conductivity reading. This is a cumulative correction factor which means that if at one time the electrode is calibrated by 30%, the next time it is calibrated it will only accept an adjustment of +20% before reporting a Cal Fail.

The most likely problem is that the electrode needs to be cleaned. Refer to section 6.1.

Check for clogged strainer. Check for insufficient pressure differential.

Check blowdown valve wiring. Check controller relay.

with a piece of wire. If "no flow" message disappears, then switch or cable may be faulty.

7.2 Conductivity Readout Does Not Change

If the readout is stuck at or near zero:

Possible Cause Correction Action

Dry electrode

Electrode is disconnected.

If the readout is stuck at another number:

Dirty or faulty electrode Evaluate electrode (see Section 7.3).

Stagnant sample Check system for proper flow.

Check for flow through system.

Check wiring to electrode. Go to self-test menu, as described in section 5.2 If readout changes to 900-1100,the problem is with electrode or connections. (see section 7.3) If still at zero, problem is with controller. Consult the factory.

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7.3 Procedure for Evaluation of Conductivity Electrode

Can be used for troubleshooting low conductivity, high conductivity, conductivity stuck at 0, and/or conductivity stuck at a number other than 0.

Try cleaning the electrode first (refer to Sect. 6.1).

To find out if the electrode or the controller is faulty, step through the Self-Test menu, as described in section 5.2. The display should read 1000 ± 100µS/cm. This indicates that the controller is OK and the problem is in the electrode or its connections. If it does not read 1000 ±100 µS, return the control module for repair.

To check the electrode, check the electrode connections to the terminal strip (refer to Figure 3). Make sure that the correct colors go to the correct terminals, and that the connections are tight. Restore power and see if the conductivity is back to normal. If not, replace the electrode.

8.0 SERVICE POLICY

The WBL series Boiler Conductivity Controller has a 2-year warranty on electronic components and a 1year warranty on mechanical parts (keypad, terminal strip and relays).

We stock circuit boards for immediate exchange after we have isolated the cause of the problem.

Factory authorized repairs that are received by next-day-air will be returned within 24 hours. Normal priority for returns is two weeks.

Out of warranty repairs or circuit board exchanges are done on a flat fee basis after the warranty is expired.

WALCHEM CORPORATION

5 BOYNTON ROAD HOPPING BROOK PARK HOLLISTON, MA 10746 USA

TEL: 508-429-1110 FAX: 508-429-7433 WEBSITE: www.walchem.com