Walchem WTCW100 Series, WBLW100 Series Instruction Manual
WCT/WBLW100 Series
Cooling Tower and Boiler Controller
Instruction Manual
Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA
TEL: 508-429-1110 WEB: www.walchem.com
Notice
© 2018 WALCHEM, Iwaki America Incorporated (hereinafter “Walchem”)
5 Boynton Road, Holliston, MA 01746 USA
(508) 429-1110
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 identication to be free from defects in workmanship
and material for a period of 24 months for electronics and 12 months for mechanical parts and electrodes from date of
delivery from the factory or authorized distributor under normal use and service and otherwise when such equipment is
used in accordance with instructions furnished by WALCHEM and for the purposes disclosed in writing at the time of purchase, if any. WALCHEM’s liability under this warranty shall be limited to replacement or repair, F.O.B. Holliston, MA
U.S.A. of any defective equipment or part which, having been returned to WALCHEM, transportation charges prepaid,
has been inspected and determined by WALCHEM to be defective. Replaceable elastomeric parts and glass components
are expendable and are not covered by any warranty.
THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EITHER EXPRESS OR IMPLIED, AS TO DESCRIPTION, QUALITY, MERCHANTABILITY, FITNESS FOR ANY PARTICULAR PURPOSE OR USE, OR ANY OTHER
MATTER.
180530 Rev. Q January 2018
Contents
1.0 INTRODUCTION ................................................................................................................................ 1
2.0 SPECIFICATIONS .............................................................................................................................2
2.1 Measurement Performance ................................................................................................................ 2
2.2 Electrical: Input/Output ....................................................................................................................... 3
2.3 Mechanical ......................................................................................................................................... 4
2.4 Variables and their Limits ...................................................................................................................5
3.0 UNPACKING & INSTALLATION .......................................................................................................6
3.1 Unpacking the unit .............................................................................................................................. 6
3.2 Mounting the electronic enclosure ...................................................................................................... 6
3.3 Installation .......................................................................................................................................... 6
3.4 IconDenitions ................................................................................................................................... 9
3.5 Electrical installation ......................................................................................................................... 10
4.0 FUNCTION OVERVIEW .................................................................................................................. 22
4.1 Front Panel ....................................................................................................................................... 22
4.2 Display .............................................................................................................................................. 22
4.3 Keypad ............................................................................................................................................. 22
4.4 Icons ................................................................................................................................................. 22
4.5 Startup .............................................................................................................................................. 24
4.6 Shut Down ........................................................................................................................................ 29
5.0 OPERATION ....................................................................................................................................30
5.1 Alarms Menu .................................................................................................................................. 30
5.2 Inputs Menu ................................................................................................................................... 30
5.2.1 Contacting Conductivity ......................................................................................................... 32
5.2.2 Electrodeless Conductivity .................................................................................................... 32
5.2.3 Temperature ...........................................................................................................................33
5.2.4 DI State .................................................................................................................................. 33
5.2.5 Flow Meter, Contactor Type ................................................................................................... 34
5.2.6 Flow Meter, Paddlewheel Type .............................................................................................. 34
5.3 Outputs Menu ................................................................................................................................. 35
5.3.1 Relay, Any Control Mode ........................................................................................................ 35
5.3.2 Relay, On/Off Control Mode ...................................................................................................35
5.3.3 Relay, Flow Timer Control Mode ............................................................................................ 36
5.3.4 Relay, Bleed and Feed Control Mode ....................................................................................36
5.3.5 Relay, Bleed then Feed Control Mode ...................................................................................36
5.3.6 Relay, Percent Timer Control Mode ....................................................................................... 36
5.3.7 Relay, Biocide Timer Control Mode ........................................................................................ 37
5.3.8 Relay, Alarm Mode ................................................................................................................. 38
5.3.9 Relay, Time Proportional Control Mode ................................................................................. 38
5.3.10 Relay, Intermittent Sampling Control Mode ............................................................................39
5.3.11 Relay or Analog Output, Manual Mode .................................................................................. 40
5.3.12 Relay, Pulse Proportional Control Mode ................................................................................40
5.3.13 Relay, Dual Set Point Mode ...................................................................................................40
5.3.14 Relay, Probe Wash Control Mode ..........................................................................................41
5.3.15 Analog Output, Retransmit Mode ........................................................................................... 42
1
1.0 INTRODUCTION
The Walchem WCT/WBL100 Series controllers offer a high level of exibility in controlling cooling tower and boiler
water treatment applications.
One sensor input is available that are compatible with a variety of sensors:
Cooling tower, boiler, and low cell constant condensate contacting conductivity
Electrodeless conductivity
Two digital inputs may be used for a variety of purposes:
State type: Flow switch or other Interlock to stop control, or drum level switch
Water meter contactor: To control a relay to feed a chemical based on ow total
Paddlewheel owmeter: To control based on ow total or ow rate
Three relay outputs may be set to a variety of control modes:
On/Off set point control
Bleed or Feed based on a Water Contactor or Paddlewheel ow meter input
Feed and Bleed
Feed and Bleed with Lockout
Feed as a percent of Bleed
Feed as a percentage of elapsed time
Daily, Weekly, 2-week or 4-week Biocide timers with pre-bleed and post-add lockout of bleed
Intermittent sampling for boilers with proportional blowdown, controlling on a trapped sample
Time Proportional control
Always on unless interlocked
Dual set point
Probe Wash timer
Diagnostic Alarm triggered by:
High or Low sensor reading
No Flow
Relay output timeout
Sensor error
An optional isolated analog output may be included to retransmit sensor input signals to a chart recorder, data logger,
PLC or other device.
Our unique USB features provide the ability to upgrade the software in the controller to the latest version.
5.3.16 Analog Output, Proportional Control Mode .......................................................................... 42
5.4 Settings Menu .............................................................................................................................. 43
5.4.1 Global Settings ..................................................................................................................... 43
5.4.2 Security Settings .................................................................................................................. 44
5.4.3 Display Settings ................................................................................................................... 44
5.4.4 File Utilities ........................................................................................................................... 44
5.4.5 Controller Details .................................................................................................................. 44
6.0 MAINTENANCE ............................................................................................................................. 46
6.1 Conductivity Sensor Cleaning ........................................................................................................ 46
7.0 TROUBLESHOOTING ................................................................................................................... 47
7.1 Calibration Failure .......................................................................................................................... 47
7.1.1 Contacting Conductivity Sensors ........................................................................................... 47
7.1.2 Electrodeless Conductivity Sensors ...................................................................................... 47
7.2 Alarm Messages ............................................................................................................................. 48
8.0 SERVICE POLICY ......................................................................................................................... 51
9.0 SPARE PARTS IDENTIFICATION ................................................................................................. 52
2
3
2.2 Electrical: Input/Output
Input Power 100 to 240 VAC, 50 or 60 Hz, 7 A maximum
Fuse: 6.3 A
Input Signals
Contacting Conductivity 0.1, 1.0, or 10.0 cell constant OR
Electrodeless Conductivity
Temperature 100 or 1000 ohm RTD, 10K or 100K Thermistor
Digital Input Signals (2):
State-Type Digital Inputs
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
Digial 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
Digial 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
Powered Mechanical Relays
(0 or 3 depending on model
code):
Pre-powered on circuit board switching line voltage
6 A (resistive), 1/8 HP (93 W) per relay
All three relays are fused together as one group, total current for this group must not
exceed 6A
Dry contact Mechanical
Relays (0 or 3 depending on
model code):
6 A (resistive), 1/8 HP (93 W) per relay
Dry contact relays are not fuse protected
4 - 20 mA (0 or 1 depending
on model code):
Internally powered
Fully isolated
600 Ohm max resistive load
Resolution 0.0015% of span
Accuracy ± 0.5% of reading
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.
2.0 SPECIFICATIONS
2.1 Measurement Performance
0.1 Cell Contacting Conductivity
Range 0-3,000 µS/cm
Resolution 0.1 µS/cm, 0.0001 mS/cm, 0.01 mS/m, 0.0001 S/m, 0.1 ppm
Accuracy ± 1% of reading
1.0 Cell Contacting Conductivity
Range 0-30,000 µS/cm
Resolution 1 µS/cm, 0.001 mS/cm, 0.1 mS/m, 0.0001 S/m, 1 ppm
Accuracy ± 1% of reading
10.0 Cell Contacting Conductivity
Range 1,000-300,000 µS/cm
Resolution 10 µS/cm, 0.01 mS/cm, 1 mS/m, 0.001 S/m, 10 ppm
Accuracy ± 1% of reading
Temperature
Range 23 to 500°F (-5 to 260°C)
Resolution 0.1°F (0.1°C)
Accuracy ± 1% of reading
Electrodeless Conductivity
Ranges Resolution Accuracy
500-12,000 µS/cm 1 µS/cm, 0.01 mS/cm, 0.1 mS/m, 0.001 S/m, 1 ppm ± 1% of reading
3,000-40,000 µS/cm 1 µS/cm, 0.01 mS/cm, 0.1 mS/m, 0.001 S/m, 1 ppm ± 1% of reading
10,000-150,000 µS/cm 10 µS/cm, 0.1 mS/cm, 1 mS/m, 0.01 S/m, 10 ppm ± 1% of reading
50,000-500,000 µS/cm 10 µS/cm, 0.1 mS/cm, 1 mS/m, 0.01 S/m, 10 ppm ± 1% of reading
200,000-2,000,000 µS/cm 100 µS/cm, 0.1 mS/cm, 1 mS/m, 0.1 S/m, 100 ppm ± 1% of reading
Temperature °C Range Multiplier Temperature °C Range Multiplier
0 181.3 80 43.5
10 139.9 90 39.2
15 124.2 100 35.7
20 111.1 110 32.8
25 100.0 120 30.4
30 90.6 130 28.5
35 82.5 140 26.9
40 75.5 150 25.5
50 64.3 160 24.4
60 55.6 170 23.6
70 48.9 180 22.9
Note: Conductivity ranges above apply at 25°C. At higher temperatures, the range is reduced per the range multiplier
chart.
4
5
2.4 Variables and their Limits
Sensor input settings Low Limit High Limit
Conductivity alarm limits 0 30,000
Conductivity alarm dead band 0 30,000
Cell constant 0.01 10
Smoothing Factor 0% 90%
Comp Factor (conductivity linear ATC only) 0% 20%
Installation Factor (Electrodeless conductivity only) 0.5 1.5
Cable length 0.1 3,000
PPM conversion factor (only if units = PPM) 0.001 10.000
Default temperature -5 500
Calibration Required Alarm 0 days 365 Days
Flow meter input settings Low Limit High Limit
Totalizer alarm 0 100,000,000
Volume/contact for units of Gallons or Liters 1 100,000
Volume/contact for units of m
3
0.001 1,000
K Factor for units of Gallons or Liters 0.01 10,000
K Factor for units of m
3
1 100,000
Smoothing Factor 0% 90%
Set Flow Total 0 1,000,000,000
Relay output settings Low Limit High Limit
Output Limit Time 1 second 86,400 seconds (0 = unlimited)
Hand Time Limit 1 second 86,400 seconds (0 = unlimited)
Min Relay Cycle 0 seconds 300 seconds
Set Point Low end of sensor range High end of sensor range
Duty Cycle Period (On/Off, Dual Set-point modes) 0:00 minutes 59:59 minutes
Duty Cycle (On/Off, Dual Setpoint modes) 0% 100%
Dead Band Low end of sensor range High end of sensor range
Feed duration (Flow timer mode) 0 seconds 86,400 seconds
Accumulator volume (Flow timer mode) 0 1,000,000
Feed Percentage (Bleed then Feed mode) 0% 100%
Feed Lockout Time Limit (Bleed & Feed, Bleed then Feed modes) 0 seconds 86,400 seconds
Prebleed to Conductivity (Biocide mode) 1 (0 = no prebleed) High end of sensor range
Prebleed Time (Biocide mode) 0 seconds 86,400 seconds
Bleed Lockout(Biocide mode) 0 seconds 86,400 seconds
Event duration (Biocide, Timer modes) 0 seconds 86,400 seconds
Proportional band (Time/Pulse Proportional mode, Intermittent
Sampling)
Low end of sensor
range
High end of sensor range
Sample period (Time Proportional mode) 10 seconds 3600 seconds
Sample Time (Intermittent Sampling mode) 0 seconds 3600 seconds
Hold Time (Intermittent Sampling mode) 0 seconds 3600 seconds
Maximum Blowdown (Intermittent Sampling mode) 0 seconds 3600 seconds
Wait Time (Intermittent Sampling mode) 0 seconds 86,400 seconds
Max Rate (Pulse Proportional mode) 10 pulses/minute 480 pulses/minute
Minimum Output (Pulse Proportional mode) 0% 100%
Maximum Output (Pulse Proportional mode) 0% 100%
Analog (4-20 mA) Output settings Low Limit High Limit
2.3 Mechanical
Enclosure Material Polycarbonate
Enclosure Rating NEMA 4X (IP65)
Dimensions 8” x 8” x 3” (203 mm x 203 mm x 76 mm)
Display 128 x 64 graphic backlit display
Operating Ambient Temp -4 to 131 °F (-20 to 55 °C)
Storage Temperature -4 – 176°F (-20 – 80°C)
Mechanical (Sensors) (*See graph)
Sensor Pressure Temperature Materials
Process
Connections
Graphite contacting
conductivity tower
0-150 psi up to 100°F (38°C)*
0- 50 psi at 140°F (60°C)
32-140°F *
(0-60°C)
GFRPP, Graphite, FKM 3/4” NPTF
316 SS contacting
conductivity tower
0-150 psi up to 100°F (38°C) *
0- 50 psi at 140°F (60°C)
32-140°F *
(0-60°C)
GFRPP, 316SS, FKM 3/4” NPTF
High pressure tower 0-300 psi (0-20 bar)*
32-158°F *
(0-70°C)
316SS, PEEK 3/4” NPTF
Electrodeless tower
0-150 psi up to 100°F (38°C)*
0- 50 psi at 140°F (60°C)
32-140°F *
(0-60°C)
PP, PVC, FKM 3/4” NPTF
Low pressure manifold
0-150 psi up to 100°F (38°C)*
0- 50 psi at 140°F (60°C)
32-140°F *
(0-60°C)
GFRPP, PVC, FKM,
Isoplast
3/4” NPTF
High pressure manifold 0-300 psi (0-20 bar)*
32-158°F *
(0-70°C)
Carbon steel, steel, brass 3/4” NPTF
Boiler/condensate
contacting conductivity
0-250 psi (0-17 bar)
32-401°F
(0-205°C)
316SS, PEEK 3/4” NPTM
pH/ORP
LD2
Cond
HP Cond/Steel
0
50
100
150
200
250
300
350
30405060708090
100
110
120
130
140
150
160
170
180
°F
Pressure vs. Temperature
PSI
-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
Bar
HP pH/ORP/Steel
24.1
20.7
17.2
13.8
10.3
6.9
3.4
6
7
Always route low voltage (sensor) signals with at least a 6” (15 cm) separation from AC voltage wiring.
The electrodeless conductivity sensor should be placed as close to the controller as possible, to a maximum distance
of 120 ft. (37 m). Less than 20 ft. (6 m) is recommended.. The cable must be shielded from background electrical noise.
Always route low voltage (sensor) signals with at least a 6” (15 cm) separation from AC voltage wiring. These sensors
are affected by the geometry and conductivity of their surroundings, so either maintain 6 inches (15 cm) of sample
around the sensor or ensure that any nearby conductive or nonconductive items are consistently positioned. Do not install
the sensor in the path of any electrical current that may be owing in the solution, as this will shift the conductivity reading.
IMPORTANT: To avoid damaging the female pipe threads on the supplied plumbing parts, use no more than 3 wraps
of PTFE tape and thread into the pipe FINGER tight only! DO NOT use any pipe dope, plumber’s putty or other
sealing products that containdiacetone alcohol, as these attack the ow switch plastic! Use PTFE tape ONLY!
Boilers:
The conductivity sensor should be placed as close to the controller as possible, to a maximum distance of 250 ft.
(76m). The cable MUST be shielded from background electrical noise. Use 24 AWG cable.
Important Boiler Installation Notes: (see gures 3 and 4)
1. Make sure the minimum water level in the boiler is at least 4-6 inches (10-15 cm) above the skimmer blowdown
line. If the skimmer line is closer to the surface, it is likely that steam will be drawn into the line instead of boiler
water. The skimmer line must also be installed above the highest tube.
2. Maintain a 3/4 inch minimum pipe ID with no ow restrictions from the tap for the boiler skimmer blowdown
line to the electrode. If the ID is reduced below 3/4 inch, then ashing will occur beyond that point and the conductivity reading will be low and erratic. Minimize the usage of tees, valves, elbows or unions between the boiler
and the electrode.
3. A manual shut off valve should be installed so that the electrode can be removed and cleaned. This valve must be
a full port valve in order to avoid a ow restriction.
4. Keep the distance between the tap for the boiler skimmer line to the electrode as short as possible, to a maximum
of 10 feet (3m).
5. Mount the electrode in the side branch of a tee in a horizontal run of pipe. This will minimize entrapment of
steam around the electrode and will allow any solids to pass through.
6. There MUST be a ow restriction after the electrode and/or control valve in order to provide back pressure. This
ow restriction will be either a ow control valve or an orice union. The amount of the ow restriction will
affect the blowdown rate as well, and should be sized accordingly.
7. Install the motorized ball valve or solenoid valve per the manufacturer’s instructions.
For best results, align the hole in the conductivity electrode such that the direction of water ow is through the hole.
Guide to Sizing Blowdown Valves and Orice Plates
1. Determine the Rate of Steam Production in Pounds per Hour:
Either read off the boiler name plate (water-tube boilers) or Calculate from horsepower rating (re-tube boilers):
HP x 34.5 = lbs./hr. Example: 100 HP = 3450 lbs./hr
2. Determine the Concentration Ratio (BASED ON FEEDWATER)
A water treatment chemical specialist should determine the desired number of cycles of concentration. This is the
ratio of TDS in the boiler water to TDS in the feedwater. Note that feedwater means the water that is fed to the
boiler from the deaerator and includes makeup water plus condensate return.
Example: 10 cycles of concentration has been recommended
3. Determine the Required Blowdown Rate in Pounds Per Hour
Blowdown Rate = Steam Production / (Concentration Ratio –1)
4 mA Value 0 30,000
20 mA Value 0 30,000
Hand Output 0% 100%
Set Point 0 30,000
Proportional Band 0 30,000
Minimum Output 0% 100%
Maximum Output 0% 100%
Off Mode Output (Proportional, PID, Flow Prop modes) 0 mA 21 mA
Pump Capacity (Flow Prop mode) 0 gal/hour or l/hour 10,000 gal/hour or l/hour
Pump Setting (Flow Prop mode) 0% 100%
Specic Gravity (Flow Prop mode) 0 g/ml 9.999 g/ml
Target (Flow Prop mode) 0 ppm 1,000,000 pm
Error Output 0 mA 21 mA
Conguration settings Low Limit High Limit
Local Password 0000 9999
Alarm Delay 0:00 minutes 59:59 minutes
3.0 UNPACKING & INSTALLATION
3.1 Unpacking the unit
Inspect the contents of the carton. Please notify the carrier immediately if there are any signs of damage to the
controller or its parts. Contact your distributor if any of the parts are missing. The carton should contain a W100
series controller and an instruction manual. Any options or accessories will be incorporated as ordered.
3.2 Mounting the electronic enclosure
The controller is supplied with mounting holes on the enclosure. It should be wall mounted with the display at eye level,
on a vibration-free surface, utilizing all four mounting holes for maximum stability. Use M6 (1/4” diameter) fasteners
that are appropriate for the substrate material of the wall. The enclosure is NEMA 4X (IP65) rated. The maximum
operating ambient temperature is 131°F (55°C); this should be considered if installation is in a high temperature
location. The enclosure requires the following clearances:
Top: 2” (50 mm)
Left: 8” (203 mm) (not applicable for prewired models)
Right: 4” (102 mm)
Bottom: 7” (178 mm)
3.3 Installation
Once the controller is mounted, the metering pumps may be located at any distance from the controller.
Plumbing
The W100 series controllers can be supplied with a ow switch manifold designed to provide a continuously owing
sample of cooling water to the sensors. Please refer to Figures 2 through 6 below for some typical installation drawings.
Cooling Towers:
Tap off the discharge side of the recirculation pump to provide a minimum ow of 1 gallon per minute past the sensor.
The sample must ow into the bottom of the manifold in order to close the ow switch, and return to a point of
lower pressure in order to ensure ow. Install an isolation valve on both sides of the manifold to stop ow for
sensor maintenance.
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.
8
9
0
5000
10000
15000
20000
25000
20 30 40 50 60 70 80 90 100 150 200 300
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
lbs/hr
3.4 IconDenitions
Symbol Publication Description
IEC 417, No.5019 Protective Conductor Terminal
IEC 417, No. 5007 On (Supply)
O
IEC 417, No. 5008 Off (Supply)
ISO 3864, No. B.3.6 Caution, risk of electric shock
ISO 3864, No. B.3.1 Caution
Example: 3450/(10-1) = 383.33 lbs./hr.
4. Determine if Continuous or Intermittent Sampling is Required
Use intermittent sampling when the boiler operation or loading is intermittent, or on boilers where the required
blowdown rate is less than 25% of the smallest available ow control valve or less than the ow through the
smallest orice. See the graphs on the next page.
Use continuous sampling when the boiler is operating 24 hours per day and the required blowdown rate is more
than 25% of the smallest applicable ow control valve or orice. See the graphs on the next page.
Use of a ow control valve will give you the best control of the process, since the ow rate can be easily
adjusted. The dial on the valve also gives you a visual indication if the ow rate has been changed. If the valve
clogs, it can be opened to clear the obstruction, and closed to the previous position.
If an orice plate is used, you must install a valve downstream from the orice in order to ne tune the ow
rate and provide additional back pressure in many applications.
Example: An 80 psi boiler has a Required Blowdown Rate of 383.33 lbs./hr. The maximum ow rate of the
smallest ow control valve is 3250 lbs./hr. 3250 x 0.25= 812.5 which is too high for continuous sampling.
Using an orice, the ow rate through the smallest diameter plate is 1275 lbs./hr. This is too high for continuous
sampling.
5. Determine the Orice or Flow Control Valve Size for this Blowdown Rate
Use the following graphs to select a ow control device:
lbs/hr
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
10 20 30 40 50 60 70 80 90 100 200 300
Pressure PSI
Flow Rate in Lbs/hr for Various Orifices
1/8 inch dia
3/16 inch dia
1/4 inch dia
5/16 inch dia
10
11
HEAT
EXCHANGER
COOLING TOWER
�METERING
PUMPS
13"
11.75"
Figure 2 Typical Cooling Tower Installation
3.5 Electrical installation
The various standard wiring options are shown in gure 1 below. Your controller will arrive from the factory prewired
or ready for hardwiring. Depending on your conguration of controller options, you may be required to hardwire some
or all of the input/output devices. Refer to gures 7 through 13 for circuit board layout and wiring.
Note: when wiring the optional ow meter contactor input, the 4-20 mA outputs or a remote ow switch, it is advisable
to use stranded, twisted, shielded pair wire between 22-26 AWG. Shield should be terminated at the controller (see
gure 10).
CAUTION
1. There are live circuits inside the controller even when the power switch on the front panel is in the OFF position!
The front panel must never be opened before power to the controller is REMOVED!
If your controller is prewired, it is supplied with a 8 foot, 18 AWG power cord with USA style plug. A tool (#1
Phillips driver) is required to open the front panel.
2. When mounting the controller, make sure there is clear access to the disconnecting device!
3. The electrical installation of the controller must be done by trained personnel only and conform to all applicable
National, State and Local codes!
4. Proper grounding of this product is required. Any attempt to bypass the grounding will compromise the safety of
persons and property.
5. Operating this product in a manner not specied by Walchem may impair the protection provided by the equipment.
AC Power
Power
Switch
Relay
Outputs
Digital Inputs
& Analog Output
Optional pH/ORP
Sensor BNC
Sensor
Figure 1 Conduit Wiring
12
13
Install accessories
either vertically or
horizontally, per
manufacturer's
instructions.
To Drain
Skimmer Blowdown Line
3/4" Min. up to Electrode
Full Port Block
Valve
Manual Blowdown
(Normally Closed)
Motorized
Ball
or
Solenoid
Valve
Flow
Control
Valve
or Orifice
Union
CONDUCTIVITY
ELECTRODE
¾" TEE
Flow
Control
Valve or
Orifice Union
To Drain
To Drain
1
2
3
Figure 4 Typical Boiler Installation Continuous Sampling
Install accessories
either vertically or
horizontally, per
manufacturer's
instructions.
To Drain
Skimmer Blowdown Line
3/4" Min. up to Electrode
Full Port Block
Valve
Manual Blowdown
(Normally Closed)
Motorized
Ball
or Solenoid
Valve
Flow
Control
Valve or
Orifice Union
CONDUCTIVITY
ELECTRODE
¾" TEE
2 ft.
minimum
1 to 3 ft.
maximum
10 ft. max.
with minimal valves, elbows & unions
TO
DRAIN
1
2
3
Figure 3 Typical Boiler Installation Intermittent Sampling
14
15
TO ELECTRODE
TO SOLENOID
TO
CONSTANT
110 VOLTS
PE DISCHARGE
TUBING
CHEMICAL
PUMP
TO
SANITARY
SEWER
SPRAY TOWER
SPRAY
PUMP
CITY WATER
MAKEUP
SHUTOFF
VALVE
(A)
(D)
(A)
(B)
(F)
(C)
(E)
(A) Unions; installed for replacement of
solenoid, strainer or probe
(B) ½" solenoid
(C) ½" Y-strainer
(D) Conductivity sensor in ¾" NPTF tee
(supplied with controller)
(E) ½" PVC bulkhead fitting
(F) winter drain
TYPICAL INSTALLATION
INTERMITTENT SAMPLING
CHEMICAL
TANK
1
2
3
Figure 6 Typical Cooling Tower Installation Intermittent Sampling
TO
110 VOLT AC
OUTLET
TO
SANITARY
SEWER
COOLING
TOWER
OPEN
SUMP
CIRCULATION
PUMP
(X) Unions; installed for replacement of
solenoid or strainer
(Y) ½" Y-strainer
(Z) ½"solenoid
TYPICAL INSTALLATION
SUBMERSION ELECTRODE
(OPTION "A")
VALVE
XYZX
VALVE
X Y Z X
(OPTION "B")
TO
SANITARY
SEWER
PROBE
NOTE: LOCATION OF SOLENOID VALVE
USING OPTION "A" OR OPTION "B"
DEPENDS ON SYSTEM CONFIGURATION.
DETAIL OF
PROBE ASSEMBLY
CLIP PROBE
ASSEMBLY TO
SUMP WALL FOR
EASY REMOVAL
FOR CLEANING
TO
CONTROLLER
1" PVC
PIPE
1" NPTF PVC
COUPLING
¾" PROBE
IN TEE
INSTALL APPROXIMATELY
HALF-WAY IN SUMP VOLUME
AVOID INSTALLATION NEAR
PUMP SUCTION INLET
CHEMICAL
PUMP
CHEMICAL
TANK
1
2
3
Figure 5 Typical Cooling Tower Installation Submersion Sensor
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