Walchem WDB400 Series Instruction Manual

W

W A L C H E M

DB400 Controllers

WDB400 Series

Dual Boiler Controller

Instruction Manual

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

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

Notice

© 2008 WALCHEM Corporation
5 Boynton Road, Holliston, MA 01746 USA
[phone]
All Rights Reserved
Printed in USA

Proprietary Material

The information and descriptions contained herein are the property of WALCHEM 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 witho ut 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 purchase, 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 gla ss
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.

180328.D
Jul 2008

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 WDB 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 ......................................................................................................12

4.1 Front Panel.......................................................................................................................12

4.2 Display..............................................................................................................................12

4.3 Keypad .............................................................................................................................13

4.4 Access Code ....................................................................................................................13

4.5 Startup..............................................................................................................................13

4.6 Shut Down........................................................................................................................13

5.0 OPERATION........................................................................................................................14

5.1 Main Menu........................................................................................................................14

5.2 Conductivity (A or B) Menu...............................................................................................16

5.3 Temperature (A or B) Menu.............................................................................................18

5.4 Blowdown (A or B) Menu..................................................................................................19

5.5 Auxiliary Menu..................................................................................................................21

5.6 Time Menu........................................................................................................................24

5.7 4-20mA (A or B) Menu......................................................................................................25

5.8 Access Code Menu ..........................................................................................................26

5.9 Datalog Menu...................................................................................................................27

5.10 Config Menu.....................................................................................................................29

5.11 Upgrade Menu .................................................................................................................30

6.0 MAINTENANCE...................................................................................................................31

6.1 Electrode Cleaning...........................................................................................................31

6.2 Replacing the Fuses.........................................................................................................31

7.0 TROUBLESHOOTING.........................................................................................................32

7.1 Error Messages................................................................................................................32

7.2 Conductivity Readout Does Not Change..........................................................................34

7.3 Procedure for Evaluation of Conductivity Electrode.........................................................34

7.4 Procedure for Checking Relay Outputs............................................................................34

7.5 No Display........................................................................................................................35

8.0 SERVICE POLICY...............................................................................................................35

1.0 INTRODUCTION

The Walchem WDB400 Series controllers offer conductivity control of boiler water and control of
chemical feed of two separate boilers. 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

The WDB series boiler controller is supplied with temperature compensated stainless steel electrodes with
a cell constant of 1.0. The controller is a microprocessor driven industrial type with on/off control
outputs. Timed intermittent sample or continuous modes may be selected. One or two optional 4-20 mA
outputs that are proportional to the conductivity reading are 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.

An alarm relay is provided that is triggered by:
Low conductivity reading
High conductivity reading
No flow situation
Sensor error
Temperature sensor error
Blowdown timeout

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.

1

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

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.

4 - 20 mA (1 or 2 optional) Internally powered

Agency Approvals

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.

2.3 Mechanical

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

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

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*

Enclosure Material Polycarbonate

NEMA Rating NEMA 4X

Dimensions 8.5" x 6.5" x 5.5"

Display 2 x 16 character backlit liquid crystal

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

nd

Edition (2001)*

nd

Edition*

nd

Edition*

2

2.4 WDB Variables and their Limits

Low Limit High Limit

Conductivity menu

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
Hold Time 1 second 499 min: 59 sec
Blowdown Time 1 minute 8 hrs: 20 min
Max Proportional Time 1 minute 8 hrs: 20 min
Proportional Band 0 10,000 µS/cm
% Calibration Range -50% +50%

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 Blowdownd (Mode B) 5 % 99 %
Feed Time Limit (Mode B) 1 minute 99 min: 59 sec
Percent of Time (Mode C) 5 % 99 %
Feed Cycle Time (Mode C) 10 minutes 59 min: 59 sec
Time per Contact (Mode D) 1 second 59 min: 59 sec
Divider Count (Mode D) 1 contact 100 contacts
Feed Time Accumulate (Mode D) 1 minute 99 min: 59 sec
Time Limit (Mode D) 1 minute 99 min: 59 sec

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.

No variables

(enabled)
0=unlimited (disabled)

No variables

No variables

No variables

3

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

3.2 Mounting the electronic enclosure

The WDB 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 WDB series controller is mounted, the metering pumps may be located at any distance from the
controller. The conductivity electrodes 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.

4

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.

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 charts below.

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 charts below.

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.

5

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

Use the following graphs to select a flow control device:

Flow Rate in Lbs/hr for Various Orifices

18000

16000

14000

12000

10000

Lbs/hr

8000

6000

4000

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

2000

25000

20000

15000

Lbs/hr

10000

5000

0

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

Pressure PSI

Flow Control Va lve

Maximum Fl ow Rate s in Lbs/hr

1/2" 150 P SI
1/2" 300 P SI
3/4" 150 P SI
3/4" 300 P SI

0

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

Pressure PSI

6

CO

UOUS S

G

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

FIGURE 1

RECOMMENDED INSTALLATION

INTERMITTENT SAMPLING

with minimal valv es, elbows & unions

Manual Blowdown
(Normally Closed)

Boiler Controller

PREV NEXT

ENTER

www.walchem.com

10 ft. max.

Full Port Block

Valve

TO

DRAIN

EXIT

CONDUCTIVITY

¾" TEE

2 ft.

minimum

ELECTRODE

1 to 3 ft.

maximum

Motorized

Ball

or Solenoid

Valve

Flow

Control

Valve or

Orifice Union

To Drain

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

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

Full Port Block

Valve

Manual Blowdown
(Normally Closed)

Motorized

Ball

or

Solenoid

Valve

CONDUCTIVITY

¾" TEE

To Drain

Flow
Control
Valve
or Orifice
Union

ELECTRODE

FIGURE 2

RECOMMENDED INSTALLATION

NTIN

AMPLIN

Flow
Control
Valve or
Orifice Union

To Drain

To Drain

7

3.4 Icon Definitions

Symbol Publication Description

IEC 417, No.5019 Protective Conductor Terminal

3.5 Electrical installation

The various standard wiring options are shown in figure 3, below. Your WDB 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 4 and 5 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 4 and 5).

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

IEC 417, No. 5007 On (Supply)

IEC 417, No. 5008 Off (Supply)

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

ISO 3864, No. B.3.1 Caution

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.

8

BLOWDOWN A

AUX B

SPARES

4-20mA 1
(OPTIONAL)

4-20mA 2
(OPTIONAL)

WATER METER B
(OPTIONAL)

CONDUCTIVITY
ELECTRODE A

CONDUCTIVITY
ELECTRODE B

POWER

AUX A

BLOWDOWN B

ALARM

SPARE

WATER METER A
(OPTIONAL)

Figure 3 Conduit/Wiring Configuration

FLOW SWITCH B
(OPTIONAL)

FLOW SWITCH A
(OPTIONAL)

9

SYSTEM B

T-T+

G

W

RE

H

E

I

T

N

E

R+R-

COND

R+R-

FEED

L2L2

FLOW SW 1

T-T+

COND

BLKRED

+5V

IN-IN+

FLOW MTR 1 FLOW MTR 2

IN+

IN-

FLOW SW 2

IN-IN+
IN+

T-T+

COND

BLKRED

+5V

F1

L1 L2/N

BLEED

N.C.

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

F2

GROUND
STUD

G

R

G

N

R

1

N

2

+5V

BLKRED

SHIELD

SHIELD

/

Y

0

V

E

L

2

4

0

V

L1 L2/N

B

B

L

R

K

N

1

2

2

4

0

0

V

V

WHT 120V
BLU 240V

Do not connect

shield drain wire

at this end!

GWR B

Conductivity

Electrode

SYSTEM A

FLOW SW 1

IN-IN+

Contact Closure:

Polarity not critical

Reed Switch

Polarity not Critical

FLOW MTR 1

IN-

IN+

Flow Meter

SYSTEM B

FLOW SW 2

IN-IN+

FLOW MTR 2

IN+

Hall Effect

Flow Meter

Figure 4 Inputs

T-T+

W

H

I

T

E

Do not connect

shield drain wire

at this end!

SYSTEM A

COND

BLKRED

G

R

E

E

N

GWR B

Conductivity

Electrode

+5V

Power Supply

(115 VAC or 230 VAC)

10

p

A

p

GRN 120V
GRN/YEL 240V

Chart
Recorder

T-T+

COND

BLKRED

+5V

Chart
Recorder

FLOW SW 1

IN-IN+

FLOW MTR 1 FLOW MTR 2

IN+

IN-

FLOW SW 2

IN-IN+
IN+

T-T+

COND

BLKRED

+5V

GROUND

STUD

L2 L2 L2 L2 L2 L2

L1 L2/N

BLEED

FEED

N.C.

N.O. N.C.

BOI 1

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

N.O.N.C.

N.C.

BIO 2

ALARM

N.C.

N.O.

N.O.

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

WHT 120V

WHT 120V

BLU 240V

BLU 240V

IF MOTORIZED

BALL VALVE

Note: Dashed lines
indicate extra wire needed
for wiring to a motorized ball
valve. For pre-wired controllers,

Blowdown Solenoid/
Motorized Ball Valve

remove the pigtail outlet when
wiring a motorized ball valve.

BLOWDN A

N.C.

BLK 120V

BRN 240V

AUX A

N.O.N.C.

BLK 120V

GRN 120V
GRN/YEL 240V
TO GROUND
STUD

N.O.

Pum

Figure 5 Outputs

BLOWDN B

N.C.

BRN 240V

Blowdown

Ball Valve

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

BLK 120V

BALL VALVE

BRN 240V

GRN 120V
GRN/YEL 240V
TO GROUND
STUD

IF MOTORIZED

Solenoid/

Motorized

AUX B

Pum

BLK 120V

BRN 240V

GRN 120V
GRN/YEL 240V
TO GROUND
STUD

N.C.

WHT 120V
BLU 240V

ALARM

N.O.

BLK 120V

BRN 240V

larm

11

4.0 FUNCTION OVERVIEW

4.1 Front Panel

Menu/Function Keys

Backlit LCD Display

Output LEDs

Setting Adjustment Keys

On/Off Power Switch

4.2 Display

A summary screen is displayed while the WDB controller is on. The operating conditions that are
displayed on the bottom line of this display are Hi Alarm A, Hi Alarm B, Low Alarm A, Low Alarm B,
Temp Err A, Temp Err B, Cond Err A, Cond Err B, No Flow A, No Flow B, Blodown Timeout A,
Blodown Timeout B, Blowdown A, Blowdown B, Feed A Timeout, Feed B Timeout, Feed A, Feed B,
Waiting A/B, Sample A/B, Holding A/B, and Normal. Normal just means there is nothing unusual to
report.

2000 2010

Normal

USB LED

USB Connector

Figure 6 Front Panel

Figure 7 Summary Screen

12

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
screen.

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

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

4.4 Access Code

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

5.7 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.

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 WDB 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.

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

4.6 Shut Down

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

13

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 WDB 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: Boiler A, Boiler B and Access Code. Within the menu for
each boiler, the following menus are found:

Conductivity A or B
Temperature A or B
Blowdown A or B
Auxiliary A or B
Time
4-20mA A or B 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

Each of the following menu descriptions is used exactly the same way for either Boiler A or Boiler B.

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

14

P

ibl

A 100 B 100 µs

Upgrade

A 100 B 100 µs

Config

e status screens

* HI ALARM A

oss

Main Menu

* HI ALARM B

* LOW ALARM A

* LOW ALARM B

* TEMP ERR A

A 100 B 100 µs

Datalog

A 100 B 100 µs

Access Code

NOTE:

* TRIPS DIAGNOSTIC ALARM RELAY WHEN

AUX OUTPUT ASSIGNED TO ALARM FUNCTION.

A 100 B 100 µs

NEXTPREV.

* TEMP ERR B

* COND ERR A

* COND ERR B

* NO FLOW A

* NO FLOW B

BLOWDOWN A

BLOWDOWN B

* FEED A TIMEOUT

FEED A

FEED B

*BLODWN TIMEOUT A

*BLODWN TIMEOUT B

* FEED B TIMEOUT

WAITING A/B

SAMPLE A/B

HOLDING A/B

NORMAL

Time:Sun 3:00

Same as A

A 100 B 100 µs

Boiler B

A: 1000 µs 77°F

4-20 mA 9.32 mA

A: 1000 µs 77°F

Aux

A: 1000 µs 77°F

Blowdown

A: 1000 µs 77°F

Temperature

ENTEREXIT

A 100 B 100 µs

NORMAL

Figure 8 Main Menu

15

A 100 B 100 µs

Operation

Press Enter key to enter menu.

Press Exit key to exit menu.

Blinking fields may be edited with the adjust arrows.

ENTER

EXIT

A: 1000 µs 77°F

Boiler A

Conductivity

5.2 Conductivity (A or B) 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 9, Conductivity
Menu Chart.

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 Blowdown 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 Blowdown 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 ± 100µS/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 Figure11 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:

16

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 9 Conductivity (A or B) Menu

17

5.3 Temperature (A or B) 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 270°F Normal operation

Temp Error Indicates that there is a problem with the temperature input. See figure 10.

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 WDB 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.

Figure 10 Temperature (A or B) Menu

18

5.4 Blowdown (A or B) 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

Indicates that the blowdown output is currently OFF.

OFF

Blowdn A

Blowdn A

Blowdn A

Blowdn A

Set Point
Dead Band

Time Limit

Reset Timer
Control Dir

H / L

H O A

TIMEOUT
NO FLOW

SAMPLE

This is the conductivity value at which the Blowdown valve is turned ON. The factory default setting for the WDB
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 hours 20 minutes. 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. If the time
limit is set to zero, then the valve may be open indefinitely.

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 length of time that the blowdown output has been ON.

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

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

1:01

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.

19

Figure 11 Blowdown (A or B) Menu

20

5.5 Auxiliary Menu

The Auxiliary output may be used either to control a chemical feed pump or as an alarm.
When setting up the controller for the first time, the Output Mode should be selected first. Press
at the Aux menu, scroll to the Output Mode menu and press
press

ENTER again and use the UP or DOWN arrow keys to toggle between "Feed" and "Alarm." Press

ENTER when the correct choice is displayed.

5.5.1 Feed (A or B) Menu

This menu only appears if the Auxiliary output mode is set for "Feed."
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 12.

A Blowdown and Feed with

B Feed % of Blowdown

C Feed % of Time

D Feed based on Water Contactor

Optional Lockout

ENTER again . To change the output 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.

ENTER

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

Feed A

Feed A

Feed A

TIMEOUT
NO FLOW

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.

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.

Blowdown and
Feed Mode

Feed % of
Blowdown Mode

Feed % of Time
Mode

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.

% 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.

% 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.

21

Feed Based on
Water Contactor
Mode

Chem Feed Mode
A / B / C / D

H O A

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.

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.

5.5.2 Alarm (A or B) Menu

This menu only appears if theAuxiliary output mode is set for "Alarm"
The settings here determine when the (L) and (H) indicators appear on the summary screen. The Alarm
menu screen will appear as follows:

Alarm OFF
Alarm LOW ALRM
Alarm HI ALRM

Alarm % Low

Alarm % High

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. Entering zero will disable
the Low Alarm.

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. Entering zero will disable
the High Alarm.

22

Alarm A Menu and Submenus

appear only when AUX A outputis configured for use as

Alarm Output.

TIMEOUT

LOW ALRM

AUX

Alarm OFF

Alarm

Possible status screens

HI ALRM

AUX

Alarm % High 20

NEXTPREV.

HAND OFF >AUTO

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 Feed Menu Level.

Press Enter or Adjust arrow to turn on/off output

at Hand menu.

Feed (A or B) Menu

Alarms (A or B) Menu

HI ALRM

ENTEREXIT

μ

A: 2000 S 68° F

Alarm

HI ALRM

AUX

Alarm % Low 20

Aux LockoutA

Aux 21:05A

Aux OffA

Aux No FlowA

Aux TimeoutA

TIMEOUT

AUX

Chem Feed Mode

(Hint: program Mode first)

NEXTPREV.

Possible status screens

ENTER

EXIT

TIMEOUT

Chem Feed Mode D

Chem Feed Mode A

Bleed & Feed

Chem Feed Mode B

Feed % of Bleed

TIMEOUT

TIMEOUT

TIMEOUT

Max Time 99:00

Aux A Aux A

Cycle Time 10:00

Chem Feed Mode C

Feed % of Time

Time Limit 99:00

Contacts by 1

÷

Water Contactor

Menu choices that appear when Feed as % of

Bleed 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.

NEXTPREV.

Aux 2:05A

Aux OFFA

Aux LOCKOUTA

Aux HI ALRMA

Aux NO FLOWA

Aux LO ALRMA

Aux TIMEOUTA

Possible status screens

HI ALRM

μ

A

Auxiliary (A or B) Menu

A:2000 S 68° F

Aux

ENTEREXIT

Menu choices depend on feed mode

TIMEOUT

ENTEREXIT

A

Aux OFF

Feed Setup

ENTEREXIT

Aux

Output Mode FEED

Output Mode

FEED

Aux A

Output Mode

ALARM

Lockout 99:00

Figure 12 Auxiliary Menu

23

Aux A Aux A

TIMEOUT

% of BlowDn 10

Aux A Aux A

24:05

% of Time 10

TIMEOUT

Aux A

Time/cont. 1:00

Legend

Feed A Menu and submenus appear only when AUX A is

configured for use as FEED.

.

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

μ

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

ENTER

EXIT

Set Clock
Set Jan/ 3/98

ENTEREXIT

Set Clock
Set Thu 12:15

Figure 13 Time Menu

24

5.7 4-20mA (A or B) Menu

This menu is only available if the 4-20mA output board is installed in the controller. Installing this option
board on the lower power supply board in the controller will assign it to Boiler A. Installing a 4-20mA
option board on the top front panel assembly assigns the output to Boiler B. See Figure 4.

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

A: 2000 S 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.

μ

ENTEREXIT

4-20mA (A or B)Menu

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

NEXTPREV.

4-20mA 12.4mA
Set 20mA Pt 1000

Figure 14 4-20mA (A or B) Menu

4-20mA 12.4mA
Cal 4-20mA

ENTER

EXIT

Cal 4-20mA
4mA Output

ENTER

EXIT

Cal 4-20mA
20mA Output

25

y

5.8 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

Access Code

Access Code

Enable N / Y
New Value

Any Top Display
Access Code 0000

2000 S/cm 68° F

μ

Access Code DIS

ENTEREXIT

Access Code DIS
Disable N

Access Code DIS
Disable Y

REQ

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.

OK

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.

Access Code Menu

The Access Code prompt may appear at any screen in the entire menu
structure if the current access code has not been entered by the user.
Access code entries will be valid for 10 minutes from the most recent
key press.

Possible status screens

Access Code REQ

Access Code OK

NEXTPREV.

Access Code DIS
New Value 0

Access Code DIS
New Value 1234

Enter an

four digit code

Figure 15 Access Code Menu

26

5.9 Datalog Menu

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

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 Resetlog<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.

Transfer Success Transfer Fail 1

27

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

Next

Datalog
Backup DataLog

Prev

ENTER EXIT

Datalog
Transfer Success

Datalog Menu

Next

Datalog
Copy Event Log

Prev

Datalog
Transfer Success

Next

Prev

Datalog
Copy Reset Log

Datalog
Transfer Success

Figure 16 Datalog Menu

28

5.10 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 17 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.

29

5.11 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.

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.

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 18 Upgrade Menu

30

6.0 MAINTENANCE

The WDB 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 electrodes.

Frequency

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

1. Read and record the conductivity.

2. Remove, clean and replace the conductivity electrodes 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 electrodes cleaning. If there is less
than 5% change in the reading, the electrodes were not dirty and can be cleaned less often.

Cleaning Procedure

The electrodes can normally be cleaned using a cloth, toothbrush, cotton swab or paper towel and a mild
cleaning solution such as 409
substances which require a more vigorous cleaning procedure, such as immersion in dilute muriatic acid.
Usually the coating will be visible, but not always. If normal cleaning does not improve the performance,
try a 1% muriatic (hydrochloric) acid rinse.

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 is 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

®

cleanser. Occasionally electrodes may become coated with various

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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.

Possible Cause Corrective 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 Corrective 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 probe Correct wiring. (see Section 3.4)
Faulty Blowdown relay Replace relay. (Consult factory.)

TEMP ERROR

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

Possible Cause Corrective Action

Green or white electrode wire disconnected. Reconnect.
Faulty electrode Evaluate (see Section 7.3). Replace if necessary. Revert to manual temperature

compensation by cycling power off and on.

COND 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.

Possible Cause Corrective Action

Black or red electrode wire shorted. Disconnect short.
Faulty electrode Evaluate (see Section 7.3). Replace if necessary.
Faulty controller Verify via failed self-test.

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BLODOWN TIMEOUT

This error condition will stop conductivity control. It is caused by the blowdown 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. Check for clogged strainer.

Blowdown valve not opening. Check blowdown valve wiring. Check controller relay.

FEED TIMEOUT

This error condition will stop the feed pump for that particular feed cycle. If feed is initiated again, the feed pump will be allowed to
activate. The error condition is caused by the feed output being activated for longer than the programmed limit.

Possible Cause Corrective Action

Programmed value too low for normal conditions. Increase Feed Time Limit. (May also be called Max Time or Lockout)

Blowdown took too long. (Blowdown & Feed or Feed as
% of Blowdown only)

Pumping problem. Check chemical supply. Check pump for prime. Check tubing for blockage or

Controller problem. Check output wiring. Check controller relay.

COND HIGH ALARM

This error message indicates that the conductivity is above the programmed percentage above set point. The conductivity will continue to be
monitored, and the blowdown and feed outputs will be allowed to be activated.

Possible Cause Corrective Action

Fouled conductivity electrode. See Conductivity Electrode Troubleshooting section.
Blowdown flow rate too low. Check for clogged strainer. Check for insufficient pressure differential.
Blowdown valve not opening. Check for faulty blowdown valve. Check blowdown valve wiring. Check

Conductivity rose over alarm limit while biocide lockout
occurred.

Check for insufficient pressure differential.

See Blowdown Timeout Troubleshooting.

leaks.

controller relay.
Allow normal blowdown to occur.

COND LOW ALARM

This error message indicates that the conductivity is below the programmed percentage below set point. The conductivity will continue to be
monitored, and the blowdown and feed outputs are allowed to be activated.

Possible Cause Corrective Action

Fouled conductivity electrode. See Conductivity Electrode Troubleshooting section. (sections 6.1 and 7.3)
Electrode disconnected. Reconnect.
Electrode dry. See "No Flow" Troubleshooting section.

Blowdown valve stuck open. Check for faulty blowdown valve. Check blowdown valve wiring. Check

Flashing. Remove flow restriction upstream from electrode. Increase flow restriction

controller relay.

downstream from electrode.
Install sample cooler.
Move skimmer line below water level or raise water level.

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7.2 Conductivity Readout Does Not Change

If the readout is stuck at or near zero:

Possible Cause Corrective Action

1. Dry electrode Check for flow through system.

2. Electrode is disconnected. Check wiring to electrode. Go to self-test menu, as

described in section 5.2 If readout changes to 900­1100, the problem is with electrode or connections.
(see section 7.3) If still at zero, problem is with

controller. Consult the factory.

If the readout is stuck at another number:

Possible Causes Corrective Action

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

2. Stagnant sample Check system for proper flow.

7.3 Procedure for Evaluation of Conductivity Electrode

Can be used for troubleshooting a sensor error message, low conductivity, high conductivity, conductivity
stuck at 0, cal failure, 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 probe or its connections. If it does not read 1000 ± 100 µS/cm, 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.

7.4 Procedure for Checking Relay Outputs

If any pre-wired output is not activating the device (pump, valve, etc.) attached to it:

Verify that the pump or valve is not faulty by plugging it directly into a wall socket.
In some controllers, certain relays are NOT internally powered. Check the instruction manual to determine
if the relay is a dry contact type. If so, make sure that external power (115 VAC) has been connected to
the relay. In most cases, this will be a jumper wire from the large screw labeled “HOT” to one of the relay
terminals.
Manually activate the relay using the hand-off-auto menu. Verify that the LED on the front panel lights
up. If the device turns on, there must be a problem with the set points if the device doesn’t turn on when it
should.

With power removed
loose, that they are not connected by the wire’s jacket, and that they are connected to the correct terminal.
Also check the removable terminal block where the black (hot) wires attach (TB2) to see if it has pulled
loose. Restore power and manually activate the relay.

, check the wiring of the pigtail to the terminal strips. Make sure that they are not

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With power removed
(TB2). This simply pulls up off some metal pins. Check these pins for corrosion. If they seem coated with
anything, scrape off the coating by replacing and removing the terminal block several times. Restore
power and manually activate the relay.

With power removed
that lines up with the wire for the relay in question, and the other lead on the other side of the relay (this
will be an adjacent pin for a dry contact relay, or neutral at TB3 for a powered relay). Set the meter to read
resistance. Restore power and verify that the meter reads infinite ohms with the relay off (open) and very
low ohms with the relay on (closed). If it always reads infinite ohms, the controller is faulty.

7.5 No Display

Verify that the controller has power. Check F1 fuse.

If a 4-20 mA output option board has been installed, make sure that it is not installed crooked (off by one
pin on the connector).

Make sure that the ribbon cable has not been removed and re-installed backwards. See Figure 4.

, remove the terminal block that has the black (hot) wires from all of the pigtails

, remove the TB2 terminal block again, and attach one lead of a multimeter to the pin

8.0 SERVICE POLICY

The WDB 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.

5 BOYNTON ROAD HOPPING BROOK PARK HOLLISTON, MA 01746 USA

WALCHEM CORPORATION

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TEL: [phone] FAX: [phone] WWW.WALCHEM.COM

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