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Walchem WDP420 Instruction Manual

Wph series, wdp series, ph & orp controllers
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W A L C H E M
WPH/WDP Controllers
WPH/WDP Series
pH & ORP Controllers
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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  • Page 1 W A L C H E M WPH/WDP Controllers WPH/WDP Series pH & ORP Controllers 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...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION........................1 SPECIFICATIONS ........................2 Measurement Performance ........................2 Electrical: Input/Output .......................... 2 Mechanical............................. 3 WPH/WDP Variables and their Limits....................3 UNPACKING & INSTALLATION ....................4 Unpacking the unit ..........................4 Mounting the electronic enclosure ......................4 Installation..............................

  • Page 4: Introduction

    INTRODUCTION The Walchem WPH Series single sensor input and WDP Series dual sensor input controllers are wall mount pH/ORP controllers that are available in on/off or modulated pulse proportional versions. They are available with four on/off control relays (WPH410 or WDP410) with two modulated pulse proportional output and two dry contact relays (WPH420 or WDP420) or four modulated pulse proportional outputs (WDP340).

  • Page 5: Specifications

    WPH420 Pulse Pulse WDP410 Powered Powered Powered Powered Powered WDP420 Pulse Pulse WDP440 Pulse Pulse Pulse Pulse Note: The Alarm relay is non-programmable. Refer to the Main Menu diagram for the list of error conditions that trigger the alarm relay.

  • Page 6: Mechanical

    Mechanical 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) Flow switch manifold temperature rating 140°F (60°C) max Flow switch manifold pressure rating 150 psi...

  • Page 7: Unpacking & Installation

    UNPACKING & INSTALLATION 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 WPH/WDP series controller and instruction manual.

  • Page 8: Icon Definitions

    For submersion applications, mount the electrode below the minimum solution level. If the tank will be completely emptied, plan on removing the electrode and storing it in tap water (NOT DI water) or pH 4 buffer solution while the tank is empty. If this is not desirable, a recirculation loop may be installed with the electrode mounted in-line.
  • Page 9 Installation with Submersion Electrode pH/ORP Controller W A L C H E M FLOW IN FLOW OUT AC POWER SUBMERSION ELECTRODE ACID BASE PROBE COOLING TOWER SOLENOID VALVE WATER METER Flow Switch Flow switch pH/ORP Controller W A L C H E M Electrode Electrode CIRCULATING...

  • Page 10: Electrical Installation

    Proper grounding of this product is required. Any attempt to bypass the grounding will compromise the safety of persons and property. Operating this product in a manner not specified by Walchem may impair the protection provided by the equipment. ALARM...
  • Page 11 ALARM CTRL 1 CTRL 2 Figure 2c WDP410 Conduit Wiring FLOW SWITCH 2 4-20mA 1 ALARM pH/ORP 1 PLUG 4-20mA 2 FLOW POWER CTRL 2 CTRL 1 SWITCH 1 pH/ORP 2 CTRL 3 CTRL 4 Figure 2d WDP420 Conduit Wiring...
  • Page 12 FLOW SWITCH 2 4-20mA 1 ALARM pH/ORP 1 PLUG 4-20mA 2 FLOW POWER CTRL 2 CTRL 1 SWITCH 1 pH/ORP 2 CTRL 3 CTRL 4 Figure 2e WDP440 Conduit Wiring...
  • Page 13 BLEED FEED BOI 1 BIO 2 ALARM N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. L2/N GROUND STUD L1 L2/N DIG IN 2 DIG IN 3 DIG IN 4 DIG IN 5 DIG IN 1 IN+ IN- IN+ IN- IN+ IN- WHT 120V...
  • Page 14 BLEED FEED BOI 1 BIO 2 ALARM N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. L2/N GROUND STUD L1 L2/N DIG IN 2 DIG IN 3 DIG IN 4 DIG IN 5 DIG IN 1 IN+ IN- IN+ IN- IN+ IN- WHT 120V...
  • Page 15 BLEED FEED BOI 1 BIO 2 ALARM N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. L2/N GROUND STUD L1 L2/N DIG IN 2 DIG IN 3 DIG IN 4 DIG IN 5 DIG IN 1 IN+ IN- IN+ IN- IN+ IN- SYSTEM B...
  • Page 16 BLEED FEED BOI 1 BIO 2 ALARM N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. L2/N GROUND STUD L1 L2/N DIG IN 2 DIG IN 3 DIG IN 4 DIG IN 5 DIG IN 1 IN+ IN- IN+ IN- IN+ IN- SYSTEM A...
  • Page 17 Chart Recorder BLEED FEED BOI 1 BIO 2 ALARM N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. L2/N (WPH410 only) GROUND STUD GRN 120V GRN/YEL 240V Note: CTR3, CTRL 4 and Alarm are dry contact relays (polarity not critical). CTRL 1 CTRL 2 CTRL 3...
  • Page 18 “negative” terminal of the controller. Alarm GRN 120V GRN/YEL 240V FUSED EXTERNAL POWER SOURCE Pump(s) WHT 120V FUSED BLU 240V EXTERNAL EXTERNAL EXTERNAL AC POWER AC POWER POWER GRN 120V SOURCE GRN/YEL 240V Figure 4b WPH/WDP420 Outputs...
  • Page 19 Chart Chart Recorder Recorder BLEED FEED BOI 1 BIO 2 ALARM N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. L2/N GROUND STUD GRN 120V GRN 120V GRN/YEL 240V GRN/YEL 240V CTRL 3 CTRL 1 CTRL 2 CTRL 4 ALARM L2/N...
  • Page 20 Chart Chart Recorder Recorder BLEED FEED BOI 1 BIO 2 ALARM N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. N.C. N.O. L2/N GROUND STUD Note: Alarm is a dry contact relay (polarity not critical). CTRL 1 CTRL 2 CTRL 3 CTRL 4 ALARM...

  • Page 21: Function Overview

    FUNCTION OVERVIEW Front Panel Backlit LCD Display Output LEDs Setting Adjustment Keys Menu/Function Keys USB LED On/Off Power Switch USB Connector Figure 5 Front Panel Display A summary screen is displayed while the WPH/WDP controller is on. If you have a single sensor (WPH), this display will show a bar graph of the pH/ORP relative to the set point, the numeric sensor reading, and current operating conditions.

  • Page 22: Keypad

    10.00 Normal 7.0 pH 10.00 pH Normal Figure 6 Summary Screens 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.

  • Page 23: Shut Down

    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. Shut Down To shut the controller down, simply turn off the power. Programming remains in memory. The electrode must be stored with the measuring surfaces wet.
  • Page 24 Figure 7 Main Menu...

  • Page 25: Sensor Menu

    Sensor Menu The sensor menu provides the following settings: Calibration history (informational only), 2 point calibration, 1 point calibration, pH/ORP selection, and other calibration 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, press the key once, and set the "Sensor PREV...
  • Page 26 Continue Y The controller will hold this display until you have replaced the electrode in the process, and press ENTER. Control will not begin until ENTER is pressed, or 10 minutes go by. If calibration failed, control will begin using old calibration setpoints. 2 Pt Calibration for pH If using manual temperature compensation, the first display will be: electrodes, not using...
  • Page 27 Second Buffer This is a prompt to place the electrode in the second buffer. Again, in a few seconds the controller will automatically go to the next step. Input XXX mV The display will show the mV reading from the electrode. The entire number will blink until the reading is stable, then the display will change to: Buffer XXX Now you can change the mV value of the buffer, by using the arrow keys and pressing ENTER...
  • Page 28 1 Pt Calibration for pH If using manual temperature compensation, the first display will be: electrodes, not using Cal Temp °F/C 68 Auto Buffer Recognition Use the arrow keys to enter the actual temperature of the buffer solutions. Press ENTER to go on to the next step.
  • Page 29 Sensor mV This menu displays the mV from the electrode. It is useful for troubleshooting. Self Test Press ENTER to perform a self-test. If it says "FAIL" in the upper right hand corner, this indicates a problem with the controller which should be returned for repair. If it passes, and you have a problem calibrating, it is an electrode or preamp problem.
  • Page 30 Figure 8 Sensor Menu...

  • Page 31: Temperature Menu (This Menu Does Not Appear If An Orp Sensor Has Been Selected)

    Temperature Menu (this menu does not appear if an ORP sensor has been selected) The temperature menu contains the following settings: Calibrate and Units (if the Pt100 or Pt1000 sensor is detected when the unit is powered on) or Manual Temp and Units (if no Pt100 or Pt1000 sensor is detected at power-up).

  • Page 32: Control 1 - 4 Menus (For On/Off Controllers)

    The description of the menus for relay outputs will apply to Control 1 2, 3, and 4 for WPH410 and WDP410 models, and to control 3 and 4 for WPH420 and WDP420 models. The Control 1 - 4 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, Output Mode, Assign Input, HOA, Set Point, Dead Band, and Time Limit.
  • Page 33 Mode Time Prop Hi (Continued) Press ENTER when this is displayed to use time proportional control with a high set point. In Time Proportional Mode, the farther away from the set point the system is, the longer the ON time. Refer to the drawings below for an illustration of Time Proportional Mode.
  • Page 34 Proportional This menu only appears if Time Proportional control mode is selected. Band The proportional band menu sets the deviation from set point at which the control output will be on for the entire sampling period. The volume added at the worst case deviation can be calculated by multiplying the pump flow rate by the sample period time (for example, 1 gal per minute flow rate x 2 min sample period = 2 gal of chemical added).
  • Page 35 Reset Timer This menu only appears if the output mode has been selected as a Low Set Point, or a High Set Point and the time limit has expired. Determine the reason that the output stayed on too long, and once the problem has been solved, press ENTER to reset the timer.
  • Page 36 Ctrl 1 - 4 Menu Possible status screens Ctrl 1 ON/OFF CONTROL OUTPUTS Ctrl 1 Intrlck Ctrl 1 TIMEOUT Ctrl 1 1:01:15 10.00 pH 68° F CTRL 1-4 for model WPH410 Ctrl 1 Ctrl 1 1:01:15 CTRL 3-4 for model WPH420 Ctrl 1 80% On EXIT...

  • Page 37: Control 1-4 Menu (For Proportional Controllers)

    The description of the menus for pulse outputs will apply to Control 1 2, 3, and 4 for WDP440 models, and to control 1 and 2 for WPH420 and WDP420 models. The Control menus are separate from each other but operate in exactly the same way. Each menu provides the following independent settings: Set Point, Prop Band, Control Direction, Min SPM Rate, Max SPM Rate, Time Limit, Interlock and HOA.
  • Page 38 Reset Timer This menu only appears if the output mode has been selected as a Low Set Point, or a High Set Point and the time limit has expired. Determine the reason that the output stayed on too long, and once the problem has been solved, press ENTER to reset the timer.

  • Page 39: Interlock A Menu

    Interlock A Menu This menu only appears in WDP models. The Interlock A menu is used to assign an interlock device to the appropriate sensor. An interlock device is an external monitoring sensor like a flow or level switch that serves to deactivate control outputs when activated.

  • Page 40: Ma 1 And 2 Menus (Optional)

    4-20 mA 1 and 2 Menus (Optional) These menus will only appear if the optional 4-20 mA output board(s) is installed. They are used to set the scale of the 4-20 mA output. It contains the following menu selections: Assign Inputs, 4 mA Point, 20 mA Point, and Calibrate.

  • Page 41: Time Menu

    Time Menu The time 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. Press ENTER to set the clock. Use the arrow keys to change the year, date, and month, then press ENTER. Set Clock Use the arrow keys again to set the day of the week and the time.

  • Page 42: Access Code Menu

    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.

  • Page 43: Datalog Menu

    5.10 Datalog Menu This menu is available if the data logging option has been purchased. This is indicated in the model code by the letter U at the end of the model code. This menu allows you to save data from the controller to a USB flash drive.
  • Page 44 Datalog Menu 7.00 pH 67° F Datalog ENTER EXIT Next Next Next Datalog Datalog Datalog Datalog Backup DataLog Copy Event Log Copy Reset Log Current Datalog Prev Prev Prev Possible Status Screens ENTER EXIT ENTER EXIT ENTER EXIT ENTER EXIT Transfer Success Datalog Datalog...

  • Page 45: Config Menu

    5.11 Config Menu This menu allows you to export a file that contains all of the set points in the controller to a USB flash disk drive, and then later import the set points into another controller. Export Config Place a USB flash drive with at least 10 MB capacity into the USB port on the front panel of the controller.
  • Page 46 Config Menu 67° F 7.00 pH Config EXIT ENTER Next Config Config Import Config Export Config Prev Possible Status Screens ENTER EXIT ENTER EXIT Transfer Success Config Config Transfer Success ENTR selects cfg Transfer Fail 1 Possible Status Screens Import Failure ENTER EXIT Import Success...

  • Page 47: Upgrade Menu

    5.12 Upgrade Menu This menu is used to upgrade the software to a newer version. If a new version of the software is available, an upgrade file will be posted on our web site. Save this file to a USB flash disk drive. It needs to be the only upgrade file stored on the root directory of the stick.

  • Page 48: Maintenance

    MAINTENANCE The WPH/WDP 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.

  • Page 49: Replacing The Fuses

    Warning: Use of non-approved fuses can affect product safety approvals. Fuse ratings depend on controller power rating. Specifications are shown below. To insure product safety certifications are maintained, it is recommended that a Walchem fuse be used. F1 Fuse Walchem P/N F2 Fuse (WPH410 &...
  • Page 50 High Alarm This error message appears if the pH/ORP reading exceeds the set point for one of the Control outputs that has been configured as a high alarm output. There are a number of possible causes for this condition: Possible Cause Corrective Action The process went further out of control than normal.

  • Page 51: Service Policy

    Out of warranty repairs or circuit board exchanges are done on a flat fee basis after the warranty is expired. WALCHEM CORPORATION 5 BOYNTON ROAD HOPPING BROOK PARK HOLLISTON, MA 01746 USA TEL: 508-429-1110 FAX: 508-429-7433...

This manual is also suitable for:

Wph420Wph410Wdp340Wdp410

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