Walchem WDIS Series Instruction Manual
W A L C H E M
W
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
Notice
©2008 WALCHEM Corporation
5 Boynton Road, Holliston, MA 01746 USA
(508) 429-1110
All Rights Reserved
Printed in USA
Proprietary Material
The information and descriptions contained herein are the property of WALCHEM
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
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
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
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
1
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
nd
nd
nd
Edition (2001)*
Edition*
Edition*
2
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.
3
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.
4
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
5
20 FT
(6M)
10
9
8
TO
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
6
To Open Atmosphere
Water Out
Water In
Sensor
Rotameter
Flow Cell
Flow Switch
Flow Control Valve
Sample Valve
Typical Installation Using Walchem Manifold
7
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