Walchem WDIS Series Instruction Manual

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W A L C H E M

DIS Controllers

WDIS Series Disinfection Controller

Instruction Manual

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

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

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Notice

Proprietary Material

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

This document is for information purposes only and is subject to change 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 equipm ent 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 WA LCHEM Corporation to be defective. Replaceable elastomeric parts and glass components are expendable and are not covered by any warranty.

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

P/N 180318.D Feb 2008

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Table of Contents

1.0 Introduction.....................................................................................................................................1

2.0 Specifications..................................................................................................................................1

2.1 Measurement Performance (Sensors)..........................................................................................................1

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

2.3 Mechanical (Controller).................................................................................................................................2

3.0 Unpacking and Installation............................................................................................................3

3.1 Unpacking the unit.........................................................................................................................................3

3.2 Mounting the electronic enclosure...............................................................................................................3

3.3 Installation......................................................................................................................................................3

Assembling the Sensor....................................................................................................................................3

Flow Cell Placement ........................................................................................................................................4

Installing Sensor into Flow Cell........................................................................................................................4

3.4 Icon Definitions..............................................................................................................................................5

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

Initial Startup..................................................................................................................................................13

Normal Startup...............................................................................................................................................14

4.6 Shutdown......................................................................................................................................................14

5.0 Operation.......................................................................................................................................14

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

5.2 Sensor Menu ................................................................................................................................................16

Cal'd...............................................................................................................................................................16

Calibration......................................................................................................................................................16

Zero Calibration..............................................................................................................................................16

Days Btwn Cal ...............................................................................................................................................16

Input...............................................................................................................................................................18

Self Test.........................................................................................................................................................18

Sensor Type...................................................................................................................................................18

5.3 Control 1 and Control 2 Menus...................................................................................................................18

Hi/Lo Set Point...............................................................................................................................................18

Dead Band.....................................................................................................................................................18

Time Limit ......................................................................................................................................................18

Interlock .........................................................................................................................................................18

Control Dir......................................................................................................................................................19

HOA...............................................................................................................................................................19

5.4 Auxiliary 1 and 2 Menu................................................................................................................................ 21

Mode..............................................................................................................................................................21

Lo Alarm Pt ....................................................................................................................................................21

Hi Alarm Pt.....................................................................................................................................................21

Dead Band.....................................................................................................................................................21

Probe Wash Sched........................................................................................................................................22

Hold Time.......................................................................................................................................................22

HOA...............................................................................................................................................................22

5.5 4-20 mA Menu (Optional).............................................................................................................................24

4 mA Pt..........................................................................................................................................................24

20 mA Pt........................................................................................................................................................24

Calibrate.........................................................................................................................................................24

Fixed 4 mA Out..............................................................................................................................................24

Fixed 20 mA Out............................................................................................................................................24

5.6 Clock Menu...................................................................................................................................................25

Set Clock........................................................................................................................................................25

5.7 Access Code Menu......................................................................................................................................26

Enable Y/N.....................................................................................................................................................26

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New Access Code..........................................................................................................................................26

6.0 Maintenance..................................................................................................................................28

6.1 Sensor Maintenance....................................................................................................................................28

Cleaning the Membrane.................................................................................................................................28

Replacing the Membrane...............................................................................................................................28

6.2 Replacing the Fuses....................................................................................................................................29

7.0 Troubleshooting ...........................................................................................................................29

7.1 Error Messages............................................................................................................................................29

Calibration Time.............................................................................................................................................29

Cal Failed.......................................................................................................................................................29

Sens Low No Cal ...........................................................................................................................................29

Probe Error No Cal.........................................................................................................................................29

Bad Zero Cal Fail...........................................................................................................................................30

Output Timeout ..............................................................................................................................................30

High Alarm.....................................................................................................................................................30

Low Alarm......................................................................................................................................................30

Out Range Alarm ...........................................................................................................................................30

In Range Output.............................................................................................................................................30

Probe Error ....................................................................................................................................................31

Interlock .........................................................................................................................................................31

Check Set Points............................................................................................................................................31

8.0 Service Policy ...............................................................................................................................31

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1.0 Introduction

The Walchem WDIS Series controllers are wall mount disinfection controllers that provide two relays used to perform on/off control of chlorine, chlorine dioxide, ozone or Peracetic acid. Two additional relays are available for use as alarms or probe washing. A fifth output is used as a diagnostic alarm. An isolated 4-20 mA output is optional.

They are only compatible with Walchem sensors. The choice of the type of sensor is selected through the keypad. The sensors are temperature compensated internally; no temperature signal is transmitted to the controller. The controller will prompt you to calibrate the sensor at the desired frequency.

2.0 Specifications

2.1 Measurement Performance (Sensors)

Chlorine Dioxide

Range 0-10 mg/l 0-1000 mg/l 0-10 mg/l 0-10 mg/l

Resolution 0.01 mg/l 1 mg/l 0.01 mg/l 0.01 mg/l

Cross Sensitivity Free Chlorine (5%),

Ozone

Flow Rate of Sample 30 to 100 liters/hour (0.13 to 0.44 gallons/minute) pH Range of Sample 1.0 – 14.0 6.8 – 8.0 (7.2 to 7.4 ideal)

Conductivity Range of Sample 50 to 10,000 μS/cm Up to 4% NaCl

Response Time 30 sec 3 min 30 sec 30 sec

Electrical

Power Requirements ± 5 VDC, 5 mA maximum

Signal 0 to -1000 mVDC

Maximum Cable Length 1000 ft (305 m)

Cable Required 2 twisted pair, 22 AWG, shielded, 35 pF/ft (Walchem 100084 or Belden 8723)

Mechanical

Peracetic

Acid Ozone Chlorine

Free Chlorine

(5%)

Bromine, Ozone, Iodine,

ClO2, Di-/Trichloramine, or

Bromamine

Operating Temperature 0 to 50°C (41 to 122°F) 0 to 45°C (41 to 113° F)

Operating Pressure 0 to 1 atm (0 to 14.7 psi)

Storage Temperature 0 to 50°C (41 to 122°F)

Shelf Life 1 year

Flow Cell Inlet ¼” NPTF

Flow Cell Outlet ¾” NPTF

Wetted Materials of Construction

Sensor Body PVC, Polycarbonate

Membrane Silicone PTFE

Flow Cell Body Isoplast

O-Ring FKM

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2.2 Electrical: Input/Output

Input Power (Controller)

Input Signal

Controller Sensor Input ±1400 mV

Interlock (optional) Isolated dry contact closure required (i.e., flow, level, etc.)

Output

Control 1/2 (ON/OFF)

Internally powered relays

110-120VAC or 220-240VAC 50/60 Hz, 10A or 50/60 Hz, 5A

@ 120 VAC, 10 A resistive, 1/8 HP @ 240 VAC, 6A resistive, 1/8 HP

AUX1, AUX2, Alarm

Dry contact relays

Note: The Alarm relay is non-programmable. Refer to the Main Menu diagram on page 14 for the list of error conditions that trigger the alarm relay.

4-20 mA (optional)

Sensor Power

(supplied by controller)

Agency Approvals

@ 120 VAC, 10A resistive, 1/8 HP @ 240 VAC, 6A resistive, 1/8 HP

Fully isolated, internally powered

600 Ω max. resistive load

Resolution .001% of span

Accuracy ±1% of reading.

±5 VDC, 5 mA

UL ANSI/UL 61010-1:2004, 2 CAN/CSA C22,2 No.61010-1:2004 2 CE Safety EN 61010-1 2 CE EMC EN 61326 :1998 Annex A* Note: For EN61000-4-6,-3 the controller met performance criteria B. *Class A equipment: Equipment suitable for use in establishments other than domestic, and those directly connected to a low voltage (100-240 VAC) power supply network which supplies buildings used for domestic purposes.

2.3 Mechanical (Controller)

Enclosure Material Polycarbonate

NEMA Rating NEMA 4X

Dimensions 8.5" x 6.5" x 5.5"

Display 2 x 16 character backlit liquid crystal

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

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

Shipping Weight 7 lbs (3kg) approximately

Edition (2001)*

Edition*

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3.0 Unpacking and 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 WDIS controller and instruction manual. Any options or accessories will be incorporated as ordered.

3.2 Mounting the electronic enclosure

The WDIS 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 4 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). The enclosure requires the following clearances:

Top: 2" Left: 8" Right: 4" Bottom: 7"

3.3 Installation

Once the enclosure is mounted, the metering pumps may be located at any distance from the controller. The sensor may be placed up to 1000 feet (305m) from the controller. Shielded cable with twisted pairs is required. Always route AC voltage wiring in conduit that is separated by 6 inches from low voltage DC signal lines (such as the sensor signal).

Assembling the Sensor

CAUTION: Wear gloves and safety glasses during assembly of the sensor since the electrolyte is a STRONG ACID. It is recommended to perform this operation over a sink with running water available. After using, re-cap any remaining electrolyte until the next use.

1. Remove the black protective tube from the electrode tip, and clean just the tip of the working

electrode with the special abrasive paper supplied. Avoid touching the electrodes! Hold the pad with the special abrasive paper and rub the electrode tip over it, holding the electrode at a slight angle. Repeat several times at different angles.

2. Open the vial containing the membrane cap. Empty out the water. Make sure that only one gray band is in the groove covering the vent hole in the membrane cap. Fill the membrane cap to the top with the electrolyte fill solution. (The free chlorine membrane cap is shipped dry, and has only one band)

3. Hold the sensor body vertically with the tip pointing down and SLOWLY screw on the membrane

cap until it is hand tight. Be prepared for some electrolyte solution to squeeze out from the vent hole in the cap.

4. Push the second gray band into the groove in the cap, making sure that the bands are smooth and flush.

5. Rinse your hands, the sensor, and all surfaces contaminated with electrolyte solution with running water. Check the sensor for leaks, especially at the membrane and the membrane cap threads. If any leaks are detected, tighten the membrane cap or replace it.

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6. Push the cable onto the end of the sensor, aligning the pins with the holes. Turn the connector until hand tight to seal the cable connection.

Flow Cell Placement

Instructions for mounting the sensor into the process can vary greatly with the circumstances that are encountered in your application. Here are some general guidelines to assist you. Refer also to the typical installation drawings.

The sensor should be mounted such that the measuring surfaces will always stay wet. If the membrane dries out, it will respond slowly to changing disinfectant values for 24 hours, and if dried out repeatedly, will fail prematurely.

The flow cell should be placed on the discharge side of a circulation pump or downhill from a gravity feed. Flow into the cell must come from the bottom side that has the ¾” x ¼” NPT reducing bushing

installed. The reducing bushing provides the flow velocity required for accurate readings and

must not be removed!

A “U” trap should be installed so that if the flow stops, the sensor is still immersed in the water. The outlet of the flow cell must be plumbed to open atmosphere unless the system pressure is at or below 1 atmosphere. If the flow through the line cannot be stopped to allow for cleaning and calibration of the sensor, then it should be placed in a by-pass line with isolation valves to allow for sensor removal. Install the sensor vertically, with the measuring surface pointing down, at least 5 degrees above horizontal. (Refer to Installation drawings)

Flow rate regulation must be done upstream from the sensor, because any flow restriction downstream can increase the pressure above atmospheric and damage the membrane cap!

The sensor should be installed in an area where there is good solution movement and where it will respond rapidly to chemical additions. The placement of the sensor relative to the placement of chemical replenishment, along with the quality of the mixing, and the replenishment chemical flow rate are critical to accurate process control.

Installing Sensor into Flow Cell

1. Assemble the flow cell as shown below from the top down. The reducer should already be installed in the flow cell body.

2. Slide the 102586 nut over the membrane end of the sensor, followed by the 103419 top washer, followed by the 103422 o-ring, followed by the 103419 bottom washer (concave side up), followed by the 103421 clip ring. The clip ring must be pushed up until it snaps into the groove in the sensor body.

3. Place the 102594 o-ring in the top o-ring groove of the 102881 flow cell body.

4. Place the sensor body into the flow cell body, and tighten the 102586 nut until it is hand-tight. Before tightening completely, pull the sensor up until the clip ring is up against the bottom washer.

5. Insert the 191303 cable into the connector at the top of the sensor. The connector is keyed and will only insert in one orientation.

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Sensor, P/N 191280 (WCDB) 191300 (WFCB) 191320 (WOZB) 191338 (WPAB)

Washer Set, P/N 103419

O-Ring, P/N 102594

Cable, P/N 191303

Nut, P/N 102586

Clip Ring Groove

Membrane Cap, P/N 103423 (WCDB) 103463 (WFCB) 103498 (WOZB) 103499 (WPAB)

O-Ring, P/N 103422

Clip Ring, P/N 103421

3.4 Icon Definitions

Symbol Publication Description

IEC 417, No. 5008 Off (Supply)

Body, P/N 191279-R

IEC 417, No.5019

Protective Conductor Terminal

IEC 417, No. 5007 On (Supply)

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

ISO 3864, No. B.3.1 Caution

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20 FT (6M)

10 9 8

PROCESS

ISOLATION

VALVE

(NORMALLY

OPEN)

3/4" NPT

1/4" NPT

ROTAMETER

7 6 5

30-100 LPH

4 3 2 1

RECIRCULATION PUMP

FROM

PROCESS

Figure 1 Typical Installation

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To Open Atmosphere

Water Out

Water In

Sensor

Rotameter

Flow Cell

Flow Switch

Flow Control Valve

Sample Valve

Typical Installation Using Walchem Manifold

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3.5 Electrical Installation

Based on the model number, the following voltages are required:

WDIS3xx-1xx 120 VAC, 50/60 Hz, prewired WDIS3xx-4xx 120 VAC, 50/60 Hz, hardwired WDIS3xx-5xx 240 VAC, 50/60 Hz, hardwired

The various standard wiring options are shown below. Your WDIS 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 output devices. Refer to figures 2, 3 and 4 for circuit board layout and wiring.

Note: When wiring the optional 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 figure 4).

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.

CAUTION

2. When mounting the controller, make sure there is clear access to the disconnecting device!

3. The electrical installation of the controller must be done by trained personnel only and

conform to all applicable National, State and Local codes!

4. Proper grounding of this product is required. Any attempt to bypass the grounding will

compromise the safety of persons and property.

5. Operating this product in a manner not specified by Walchem may impair the protection

provided by the equipment.

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Bottom View

Outputs

Inputs

Bottom View

Alarm AUX 1 AUX 2

Power CTRL 2 CTRL 1 Supply

Optional

Input

Optional Input

Side View

Hardwired Option WDIS

4-20 mA Output Optional Optional Sensor (optional) Input Input Input

Strain Reliefs (230 VAC) or Holes for Hardwiring of Input Power and Control Devices

WDIS Prewired Option

4-20 mA (optional)

Sensor Input

Figure 2 Conduit/Wiring Options

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To Grounding

Stud

FRONT PANEL

COM

INPUTS

-5

(Grounding

Stud)

FLOW

PH+

SWITCH

NEU

HOT

POWER SUPPLY

TB2

4-20mA

(Optional 4-20 mA Board)

TB3

NEUTRAL

RED

WHT

BLACK

WFCB WCDB WOZB WPAB

Figure 3 Wiring to Sensor

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Note: The Alarm relay is non-programmable. Refer to the Main Menu diagram on page 14 for the list of error conditions that trigger the alarm relay.

Figure 4 WDIS310 Output Wiring

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On/O

4.0 Function Overview

4.1 Front Panel

Backlit LCD Display

Output LEDs

Setting Adjustment Keys

Menu/Function Keys

ff Power Switch

4.2 Display

A summary screen is displayed while the WDIS controller is on. This display shows a bar graph of the oxidizer process value relative to the set points, a digital display of the process value, and the current operating conditions.

Towards the center of the bar graph are the (S)'s, which represent the set points. The bar graph grows from the left hand side, and the point furthest to the right indicates where the process value is relative to the set points.

The bottom line of the summary screen displays the following potential status messages: Probe Error, Calibration Time, Output Timeout, High/Low Alarm, Range Alarm, In Range Output, Output1 On, Output2 On, Probe Wash, Probe Wash Hold, Normal and Interlock.

DISINFECTION CONTROLLER

CTRL 1

CTRL 2

AUX 1

EXIT

AUX 2

Summary Screen

NEXTPREV.

ENTER

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4.3 Keypad

The keypad consists of 4 directional arrows and 4 function keys. The arrow keys 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

NEXT and PREV keys to scroll through the various menu choices. ENTER is used to enter a submenu

and to enter a value. will return you to the summary screen.

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 that menu screen.

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

EXIT is used to back up one menu level. If you are at the main menu level, EXIT

ENTER only when you have finished making ALL of the changes for

4.4 Access Code

The WDIS series controller is shipped with the access code disabled. If you wish to enable it, see Section 5.10 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 WDIS model number and then revert to the normal summary screen. Scroll through the menus and calibrate the sensor, and set the control parameters as detailed in Section 5, Operation.

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

Conditioning

The sensor requires conditioning to acclimate the electrodes prior to generating stable readings. Conditioning consists of installing the sensor in the flow cell, ensuring that the sensor remains wet at all times and supplying power to the sensor. The following conditioning times are recommended:

New Sensor: 12-24 hours After membrane or electrolyte replacement: 1 hour

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

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Normal Startup

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

4.6 Shutdown

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

The sensor must be stored with the measuring surfaces wet. If an extended shutdown will result in

the sensor dehydrating, it must be removed from its position in the process and stored in a clean, dry place, without electrolyte in the cap. To reinstall, follow the directions in section 3.3.

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 setup menu for calibration and unit of measure selection as needed. Each output has its own setup menu including set points, timer values, direction of control, etc. as needed. After 10 minutes of inactivity in the menu, the display will return to the summary screen. Keep in mind that even while browsing through the menus, the unit is still controlling.

5.1 Main Menu

The exact configuration of your WDIS 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:

Sensor Control 1 Control 2 Auxiliary 1 Auxiliary 2 4-20 mA (Only if 4-20 mA option circuit board is installed) Time Access Code

The

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

list. Pressing

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

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Possible Status Screens * Probe Error

Probe Wash

Normal

Probe Wash Hold * Interlock * Output Timeout * Calibration Time Range Alarm In Range Output High/Low Alarm Output 1 On Output 2 On Normal

* These status screens indicate that the diagnostic alarm relay is activated.

1.00

ENTEREXIT

NEXTPREV.

Main Menu

Cl2 1.00ppm Sensor

Cl2 1.00ppm Aux 2 A OFF

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

Cl2 1.00ppm Ctrl 1 A 11:40

Cl2 1.00ppm 4-20 mA 15.66 mA

Main Menu

Cl2 1.00ppm Ctrl 2 A 11:40

Cl2 1.00ppm Time Thu 9:12

Press Enter key to enter menu or submenu. Press Exit key to exit menu. After 10 minutes of inactivity the controller will automaticall

Cl2 1.00ppm Aux 1 A OFF

Cl2 1.00ppm Access Code DIS

OperationLegend

return to the summary screen.

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5.2 Sensor Menu

The sensor menu provides the following settings: Calibration history (informational only), 1 point calibration, zero calibration, sensor type selection, and other sensor setup menus. Each is discussed in detail below. Refer to the Sensor Menu chart on the next page.

Note: If you are programming the unit for the first time you must set the Sensor Type first, selecting

between Chlorine (CL2), Chlorine Dioxide (ClO2), Ozone, or Peracetic Acid. See below.

Cal'd

Displays the date of the last sensor calibration.

Calibration

Press ENTER to perform a 1 point process calibration of the sensor.

With the sensor installed in the flow cell, and a sample circulating at the normal flow rate, and the oxidizer concentration at the normal level, press show a ppm reading. If this does not match the known ppm as measured by a test kit or titration, use the arrow keys to change the displayed value and press

Cal Successful/Cal Failed

If the sensor response is good, then the display will read "Cal Successful". If the controller cannot calculate an acceptable slope from that mV reading, it will read "Cal Failed". A failure usually means that the sensor needs to be cleaned or replaced.

Zero Calibration

This menu is used to calibrate the sensor to read precisely zero in pure water. It should be set at installation with the sensor in air or pure water. This zero procedure should be repeated if a new sensor is installed.

Press

ENTER to start the zero adjust procedure. When asked “SnsrInPureWater?”, remove the sensor

from the flow cell and dry it off. Alternatively, supply the flow cell with a sample of water without any oxidizer in it. Use the arrow key to change the “N” to “Y” and press to press

ENTER when the mV reading on the top line is stable. If the sensor offset was less than ±100

mV, the display will flash “SensorCalSuccess” and return to the Zero Calibration display. You may now press

EXIT.

If the message “BadZero: CalFail” appears, the offset was too large for the software to compensate. Check to see that the sensor is out of the bath and is dry and that all wiring connections are correct. If none of these corrects the problem, install a new sensor.

Days Btwn Cal

Use the arrow keys to set the number of days that you would like to go by before recalibrating the sensor. The controller will prompt you to recalibrate when that time has expired. Setting the number of days to zero will disable this feature.

ENTER at the Calibration screen. The display will

ENTER.

ENTER. You will be asked

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1.00 ppm Sensor

Sensor Cal'd Mar/10/96

ENTEREXIT

1.00 ppm Sensor Calibrate

1.00 ppm Sensor

ENTER

EXIT

1.00 ppm

Zero Calibration

ENTER

EXIT

NEXTPREV.

Sensor

1.00 ppm

Days Btwn Cal 7

Sensor Menu

Sensor

1.00 ppm Sensor

Input -100 mV

Self Test

EXIT

1.00 ppm

ENTER

Sensor

1.00 ppm

Sensor Type Cl2

ENTER

EXIT

Caibrate ppm 1.00

ENTER

Zero Readn -5.0 mV Enter when Stable

ENTER

Legend

Menu choices that appear when Buffer Recognition is selected.

Menu choices that appear only when Auto Temperature Compensation is not recognized.

Sensor Menu

Self Test Pass S1130 mV T1368mV

Buffer Set DIN DIN 6.75, 9.23 . .

Sensor Type Cl2 Cl2

Sensor Type Cl2 ClO2

Sensor Type Cl2 Ozone

Sensor Type Cl2 Peracetic Acid

. . . . WARNING . . . .

Check Set Points

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 Main Menu Level.

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Input

This menu displays the mV from the sensor. It is useful for troubleshooting. The sensor should be around 0 mV at 0 ppm and –100 mV per ppm (if chlorine, chlorine dioxide or ozone) or –10 mV per ppm (if Peracetic Acid).

Self Test

Press ENTER to perform a self-test. If it says "FAIL" in the upper right hand corner, try again with

the sensor wires disconnected. If it still says “FAIL”, this indicates a problem with the controller which should be returned for repair. If it passes, and you have a problem calibrating, it is sensor problem.

Sensor Type

Press ENTER to set up the controller to match the type of sensor to be used. Use the Up and Down

arrows to toggle between Cl2 (chlorine), ClO2 (chlorine dioxide), Ozone and Peracetic Acid, then press

ENTER to make your selection. The controller will warn you to check your set points because

the acceptable range of set points may have changed.

Press any key to clear the warning message.

5.3 Control 1 and Control 2 Menus

The Control 1 and Control 2 menus are separate from each other but operate in exactly the same way. Each menu provides the following independent settings: Set Point, Dead Band, Time Limit, Interlock, Control Direction, HOA, Set Point, Dead Band, and Time Limit.

The top level menu status line may display the following messages: Off, Intrlck, Timeout, or a time. "Off" indicates that the output is off. "Intrlck" indicates that a signal from a flow switch or level switch is stopping control and has disabled the control outputs. "Timeout" indicates that the output has been on for longer than the maximum time programmed by the user. The time shows that the output is on, and has been for that amount of time. Refer to the Control 1 & 2 menus on the following pages.

Hi/Lo Set Point

Use the arrow keys to adjust the display to read the desired set point value. Press ENTER to accept the

change. To feed an oxidizer, select Low Set Point. To feed a reducing agent, select High Set Point. This selection is made in the Control Direction menu described below.

Dead Band

Use the arrow keys to set the desired dead band, then press ENTER. If the low set point is 1.00 ppm,

and the dead band is 0.05 ppm, then the relay will close at 1.00 ppm and open at 1.05 ppm.

Time Limit

Use the arrow keys to set the time limit in min:sec for the output to be active, then press ENTER. If it

is set for "0:00", no limit will be imposed, and the output could stay on forever.

Interlock

Use the Up and Down arrows to toggle between Y(Yes) and N(No). Choosing Y means that the output will deactivate if the device attached to the controller is open. For example, if the sensor is installed in a recirculating pipe line, a flow switch that is closed if flow is sufficient and open if flow

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is insufficient may be installed in the line, so that if flow past the sensor stops, the controller will not pump in chemicals based on a stagnant sample. Similarly, a level switch may be attached to prevent control of an empty batch tank.

Control Dir

Press ENTER to change the direction of control, then use the Up and Down arrows to toggle between

High Set Point and Low Set Point, and press on the relay when the process value goes below the set point value (to add an oxidizer, or as a low alarm). A high set point will turn on the relay when the process value goes over the set point value (to add a reducing agent, or as a high alarm).

HOA

Use the Left and Right arrows to move between Hand, Off and Auto. In Hand (Manual) mode, the output will be turned on immediately for a maximum of 10 minutes. In the Off mode, the output will be turned off indefinitely. In the Auto mode, the output turns on and off in response to changes in the process value relative to the set point. The letter inside the block on the status screen indicates which mode the output is in.

ENTER to make your choice. A low set point will turn

LOW SET POINT

DEAD BAND

LOW SET POINT

ppm

Pump Off

Pump On

TIME

ZERO DEADBAND: NOT RECOMMENDED

Pump On & Off rapidly, damaging relay

TIME

Pump Off

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Ctrl 1 1:01:15

Interlock N

Ctrl 1 & 2 Menu

Ctrl 1 1:01:15

Reset Timer N

Menu choice that appears when Control Direction High

is selected.

Menu choice that appears when Control Direction Low

is selected.AOnly appears if time limit has expired.

Ctrl 1 1:01:15

Time Limit 0:00

Legend

NEXTPREV.

Ctrl 1 1:01:15

Dead Band 0.10

Ctrl 1 Intrlck

Ctrl 1 OFF

Possible status screens

A A A A A

Ctrl 1 1:01:15

Lo Set Point 6.00

ENTEREXIT

Cl2 1.00ppm

Ctrl 1 1:01:15

Hi Set Point 8.00

HAND OFF >AUTO

Ctrl 1 1:01:15

ENTER

Ctrl 1 1:01:15

Control Dir H

EXIT

Control 1 & 2 Menu

Control Dir L

Control Dir H

Low Set Point

High Set Point

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

Operation

to Main Menu Level.

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5.4 Auxiliary 1 and 2 Menu

The Aux 1 and 2 relays may be configured to operate in a number of ways. They may be a low alarm, high alarm, an out-of-range alarm, an in-range output, or a probe wash.

The Aux 1 and 2 menus provides the following settings, which only appear if the appropriate output mode is selected: Low Alarm Pt, High Alarm Pt, Probe Wash Sched, Hold Time, Mode. Refer to the Auxiliary 1 and 2 Menu chart.

Note: When programming the controller for the first time, set the Output Control Mode first in order to display the correct menus for that mode. Press then press

PREV twice to get to the Mode menu.

Mode

Press ENTER then use the Up and Down arrows to toggle between the various choices:

Low Alarm

Press

ENTER if you want the Aux relay to close if the process value goes below a certain value.

High Alarm

Press

ENTER when this is displayed if you want the Aux relay to close if the process value goes

above a certain value.

Out Range Alarm

Press

ENTER if you want the Aux relay to close if the process value goes either above or below

certain values.

In Range Output

Press

ENTER if you want the Aux relay to close if the process value is between two values. This is

useful to open a solenoid valve if the oxidizer concentration has been corrected and you want to empty a batch tank.

Probe Wash

Press

ENTER if you want to use the Aux relay to interrupt control and activate a pump or valve to

clean the sensor membrane.

ENTER to get into the Aux 1 or Aux 2 submenus,

Lo Alarm Pt

Only appears if either the low alarm, in range output, or out range alarm mode has been selected.

Use the arrow keys to adjust the process value below which the relay will close. (In the in-range mode, it is the process value ABOVE which the relay will close).

Hi Alarm Pt

Only appears if either the high alarm or in/out range mode has been selected.

Use the arrow keys to adjust the process value above which the relay will close. (In the in-range mode, it is the process value BELOW which the relay will close).

Dead Band

Use the arrow keys to set the desired dead band, then press ENTER.

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Probe Wash Sched

Only appears if the probe wash mode has been selected.

Press

ENTER to program the probe wash schedule. The display may read "Event A 12:00 20" which

indicates that the probe wash will start at noon and the pump will run for 20 seconds. Use the arrow keys to change the time of day or the pump on-time. The maximum wash time is 99 seconds. If the sensor needs to be cleaned more than once a day, as many as nine additional events may be accessed by pressing

NEXT. The time is Military time (1:00 PM = 13:00).

Press

EXIT to go back to the Aux 1 menu level

Hold Time

Only appears if the probe wash mode has been selected. Use the arrow keys to select the time delay in seconds between the probe wash ending and control beginning again. The hold time can be programmed for a maximum of 99 seconds.

HOA

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ode

ele

ENTER

EXIT

Mode

Aux 1 OFF

Mode

Aux 1 OFF

Hold Time 1:00

Mode

High Alarm

Low Alarm

Mode

In Range Output

Out Range Alarm

Mode

Probe Wash

Auxiliary 1 and 2 Menu

ENTER

EXIT

Aux 1 OFF

Probe Wash Sched

NEXTPREV.

Aux 1 OFF

Dead Band 0.05

Possible Status Screens

Aux 1 1:05

Aux 1 OFF

Aux 1 PW

Aux 1 OFF

Hi Alarm Pt 10.00

ENTEREXIT

A A A A A A

Probe Wash Sched

Event A 12:00 99

Probe Wash Sched

Event J 12:00 99

. t

Set Points appear as needed depending on

output mode. (i.e., the Low Alarm Point does not

appear if Hi Alarm mode is selected.) Neither

Alarm Point appears if the Probe Wash mode is

selected.

Menu choices that appear when Probe Wash

Cl2 1.00ppm

Aux 1 OFF

Lo Alarm Pt 2.00

Aux 1 OFF

HAND OFF >AUTO

Auxiliary 1 and 2 Menu

Legend

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5.5 4-20 mA Menu (Optional)

This menu will only appear if the optional 4-20 mA output board is installed. It is used to set the scale of the 4-20 mA output. It contains the following menu selections: 4 mA Point, 20 mA Point, and Calibrate.

4 mA Pt

Use the arrow keys to enter the process value, in ppm, that you want to correspond to a 4 mA output from the controller.

20 mA Pt

Use the arrow keys to enter the process value, in ppm that you want to correspond to a 20 mA output from the controller.

Calibrate

This menu is used to calibrate instruments connected to the mA output. The 4-20 mA output is extremely accurate and stable and therefore will never need calibration. This feature allows other devices to be calibrated at the 4 and 20 mA points. Press

Fixed 4 mA Out

The controller will output 4.00 mA. Adjust the chart recorder or data logger per its instruction so that the process value displayed is what is expected for a 4.00 mA input.

Fixed 20 mA Out

As above, except that the controller will output 20.00 mA. The design of the 4-20 mA output is such that it should never need calibration. If the mA signal is not what it should be, call the factory for service.

ENTER to start the calibration.

4-20mA Menu

Cl2 1.00ppm 4-20mA 12.4mA

ENTEREXIT

4-20mA_1 12.4mA Set 4mA Pt 0

4-20mA_1 12.4mA Set 20mA Pt 0

4-20mA menu is only pres ent if 4-20mA hardware is installed.

NEXTPREV.

4-20 mA Menu

4-20mA_1 12.4mA Calibrate 4-20mA

ENTER

EXIT

Calibrate 4-20mA Fixed 4mA Output

ENTER

EXIT

Calibrate 4-20mA Fixed 20mA Output

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5.6 Clock Menu

The clock menu is used to set the date and time that the controller uses to schedule probe washing and calibration prompts. There is only one menu selection: Set Clock.

Set Clock

Press ENTER to set the clock. Use the arrow keys to change the year, date, and month, then press

ENTER. Use the arrow keys again to set the day of the week and the time. Use military time (for

example, 1:00 PM is 13:00). Press

10.00 pH 68° F Time Thur 12:15

ENTEREXIT

Time 1Sat 12:15 Set Clock

ENTEREXIT

ENTER to return to the top level clock menu.

Clock Menu

Set Clock Set Apr/04/96

ENTEREXIT

Set Clock Set Thu 12:15

Set Clock Menu

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5.7 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 code is entered, the parameter can be changed. (If the cursor is blinking, a change will be allowed; if the number or words are not blinking, they can't be changed). Once the correct access code has been entered, it will remain valid until there is a period of 10 minutes without a key being pressed.

Possible status screens are: Access Code REQ, Access Code OK, and Access Code DIS.

The first indicates that the access code is required to alter settings. The second indicates that the access code is required and has been entered correctly, and the last indicates that the access code has been disabled.

Enable Y/N

Use the arrow keys to select Y(Yes) or N(No) and press ENTER to enable or disable the access code.

If the code was enabled, you must enter the access code in order to disable it.

New Access Code

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.

The factory default access code is 1995.

If you change the access code and can't remember it, follow this procedure:

1. Turn off the 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 arrow keys and the code will disappear.

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Access Code Menu

Any Top Display Access Code 0000

Cl2 1.00ppm Access Code DIS

Access Code DIS Enable N

Access Code DIS Enable Y

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

ENTEREXIT

NEXTPREV.

Access Code DIS New Access Code 0

Access Code DIS Value 1234

Enter an

four digit code

Access Code Menu

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6.0 Maintenance

The WDIS control module itself needs very little maintenance. Clean the outside of the controller enclosure with a damp cloth. Do not spray down the controller unless the enclosure door is closed and latched. "Pigtails" should be protected from spray or wash-down. Check the cords and cables for damage.

6.1 Sensor Maintenance

Cleaning the Membrane

Instructions for cleaning the membrane vary depending upon the type of contamination. Follow the directions for replacing the membrane shown below, replacing step 3 with one of these cleaning methods:

For general deposits: Rinse in clear cold water.

For calcium scale: Soak in dilute (1% by volume) hydrochloric acid, then rinse in clear cold water.

For oils: Rinse in isopropyl alcohol. DO NOT use cleaners or detergents containing surfactants, as these will reduce the life of the membrane.

If the sensor still cannot be calibrated after cleaning, replace the membrane cap as described below.

Replacing the Membrane

CAUTION: Wear gloves and safety glasses during assembly of the sensor since the electrolyte is a

STRONG ACID. It is recommended to perform this operation over a sink with running water available. After using, re-cap any remaining electrolyte until the next use.

1. Hold the sensor vertically with the membrane facing down and carefully unscrew the membrane cap. Always move the gray bands to uncover the vent hole before removing the cap!

2. Rinse the electrolyte fill solution off the cap and electrodes with cold water.

3. Discard the old membrane cap.

4. Unpack the new membrane cap, taking care not to touch the membrane or get it dirty.

5. Fill the membrane cap to the top with the electrolyte fill solution.

6. Hold the sensor body vertically with the tip pointing down and SLOWLY screw on the membrane

cap until it is hand tight. Be prepared for some electrolyte solution to squeeze out from the cap

7. Rinse your hands, the sensor, and all surfaces contaminated with electrolyte solution with running water.

8. Check the sensor for leaks, especially at the membrane and the membrane cap threads. If any leaks are detected, tighten the membrane cap or replace it.

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6.2 Replacing the Fuses

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

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

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

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

Controller Rating 120VAC 5x20mm,0.125A,250V 102369 5x20mm,10A,125V 102432 240VAC 5x20mm,0.063A,250V 103363 5x20mm,5A,250V 102370

F1 Walchem P/N F2 Walchem P/N

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

Calibration Time

This message appears to prompt you to perform the routine maintenance of cleaning and calibrating the sensor. It does not appear based upon any analysis of the condition of the sensor. The frequency of calibration is set by the user in the "Days Between Cal" menu found in the "Sensor" menu. If you do not want to be prompted to perform a calibration, set this menu to "0".

Cal Failed

The expected response is –100 mV/ppm for Cl2, ClO2, and Ozone, or –1 mV/ppm for Peracetic Acid. The acceptable range is for –100 mV (or –1 mV for PAA) to equal 0.5 to 2.0 ppm. If the sensor response is outside the acceptable range, refer the sensor’s instruction manual for troubleshooting.

Sens Low No Cal

The Calibrate menu will not allow a calibration if the concentration is too close to zero ppm. If the sensor input is above –5 mV (approximately 0.05 ppm), this message will appear. If the actual concentration is actually higher, refer to the sensor’s instruction manual for troubleshooting.

Probe Error No Cal

The Calibration menus will reject the calibration if the sensor is in a Probe Error condition. Refer to the troubleshooting for Probe Error below.

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Bad Zero Cal Fail

The Zero Calibration will fail if the mV reading from the sensor is outside of the range –100 to 100 mV. If the actual concentration is actually zero, refer to the sensor’s instruction manual for troubleshooting.

Output Timeout

This error message appears if one of the control outputs has been on longer than the maximum amount of time programmed in the "Time Limit" menu found in the "Control 1" or "Control 2" menus. It is reset by answering "Yes" to the "Reset Timer" prompt that will appear. There are a number of possible reasons that the output could go on for longer than normal:

Possible Causes Corrective Action

1. The process went further out of control than normal. Increase time limit or reset timer.

2. The chemical supply has run out. Replenish the chemical supply.

3. The pump or valve or supply line is faulty. Repair or replace the control device.

4. Wrong chemical is being controlled. Replace with correct chemical.

5. The sensor is not responding to changes. Repair or replace sensor or cable.

High Alarm

This error message appears if the reading exceeds the set point for one of the AUX outputs that has been configured as a high alarm output. There are a number of possible causes for this condition:

Possible Causes Corrective Action

1. The process went further out of control than normal. May have to increase chemical flow rate.

2. The chemical supply has run out. Replenish the chemical supply.

3. The pump or valve or supply line is faulty. Repair or replace the control device.

4. Wrong chemical is being controlled. Replace with correct chemical.

5. The electrode is not responding to changes. Repair or replace sensor or cable.

6. The pump is siphoning, valve leaking. Repair or replace the control device or re-route tubing.

7. Control output has been left in "HAND" mode. Switch back to "AUTO".

8. It may be a normal part of the process. None required.

Low Alarm

As above for "High Alarm", except that the reading is below the set point of one of the AUX outputs that has been set up as a low alarm output. Refer to the possible causes and corrective actions listed above for the "High Alarm" error message.

Out Range Alarm

This error message appears if the reading is outside of the range selected for one of the AUX outputs that has been programmed as an "Out of Range Alarm". Refer to the possible causes and corrective actions listed above for the "High Alarm" error message.

In Range Output

This error message appears if the reading is inside of the range selected for one of the AUX outputs that has been programmed as an "In Range Alarm". Refer to the possible causes and corrective actions listed above for the "High Alarm" error message.

Refer to sensor instructions. Evaluate mixing or recirculation.

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Probe Error

This error message appears if the sensor input signal is outside of the normal range. This usually indicates that the sensor has been disconnected or is faulty. It could appear under normal conditions if the Cl2, ClO2 or Ozone is outside of the operating range of 0 to 10 ppm, or if the Peracetic Acid is outside of the normal range of 0 to 100 ppm.

Possible Causes Corrective Action

1. Controller is faulty; fails self test(see section 5.2) Re-check sensor self test with the sensor cable disconnected.

2. Sensor has no power to it. Check +5V, -5V terminals vs COM terminal. Should read

3. Sensor is faulty. Indicated if ±5VDC power out of spec w/sensor attached, but

4. Sensor is faulty. Repair or replace sensor or cable.

Interlock

This error message indicates that control has been stopped because the dry contact signal from a flow switch or level switch is now open and one or more control outputs have been programmed to interlock.

Possible Causes Corrective Action

1. Flow has stopped, level too low. May be a normal condition, if not, restore flow or level.

2. Flow, level switch disconnected. Reconnect.

3. Flow, level switch faulty. Verify that switch closes using an ohmmeter. If not, repair

4. Controller faulty. Check the flow switch input by removing the switch wires

Check Set Points

This is a normal display if you have changed the type of sensor from one type of sensor to another. The default set points for each choice is different, and will not match what you need for your application. Always select the sensor type before setting the control or auxiliary output set points.

If it still fails, send controller back for repair. If it passes, sensor is faulty.

+5VDC ±5% and -4.6 VDC ±-5%.

in spec without sensor attached. Repair or replace sensor.

Refer to sensor instructions.

or replace.

and manually shorting the input using a short piece of wire. If the Interlock condition persists, repair the controller. If it goes away, problem is in the switch or cable.

8.0 Service Policy

The WDIS Series Disinfection 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 repaired 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.