Walchem W600 Series Instruction Manual
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Walchem W600 Series Instruction Manual

Water treatment controller
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W A L C H E M
IWAKI America Inc.
W600 Series Controllers
W600 Series
Water Treatment Controller
Instruction Manual
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 IWAKI America Inc. W600 Series Controllers W600 Series Water Treatment Controller Instruction Manual 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 and for the purposes disclosed in writing at the time of purchase, if any. WALCHEM's liability under this warranty shall be limited to replacement or repair, F.O.B. Holliston, MA U.S.A. of any defective equipment or part which, having been returned to WALCHEM, transportation charges prepaid, has been inspected and determined by WALCHEM to be defective.

  • Page 3: Table Of Contents

    Table of Contents 1.0  INTRODUCTION ........................2  2.0  SPECIFICATIONS ........................3    ..    Measurement Performance ......................3   ..    Electrical: Input/Output ........................4   ..    Mechanical ............................5   ..    Variables and their Limits ....................... 5 3.0 ...
  • Page 4     5.4.5 Display Settings ............................55     5.4.6 File Utilities ..............................56     5.4.7 Controller Details ............................57   ..    HOA Menu ............................ 58   ..    Graph Menu ..........................58 6.0  OPERATION USING ETHERNET ..................59   ...

  • Page 5: Introduction

    INTRODUCTION The Walchem W600 Series controllers offer a high level of flexibility in controlling water treatment applications. One or two sensor inputs are available that are compatible with a variety of sensors: Contacting conductivity Electrodeless conductivity Any Walchem disinfection sensor An analog (4-20 mA) sensor input card with two input circuits is also available for use with 2, 3 or 4- wire transmitters.

  • Page 6: Specifications

    SPECIFICATIONS Measurement Performance 0.01 Cell Contacting Conductivity Range 0-300 µS/cm Resolution 0.01 µS/cm, 0.0001 mS/cm, 0.001 mS/m, 0.0001 S/m, 0.01 ppm Accuracy ± 1% of reading 0.1 Cell Contacting Conductivity Range 0-3,000 µS/cm Resolution 0.1 µS/cm, 0.0001 mS/cm, 0.01 mS/m, 0.0001 S/m, 0.1 ppm Accuracy ±...

  • Page 7: Electrical: Input/Output

    Contacting Conductivity 0.01, 0.1, 1.0, or 10.0 cell constant OR Electrodeless Conductivity Disinfection Requires a preamplified signal. Walchem WEL or WDS series Amplified pH or ORP recommended. ±5VDC power available for external preamps. Each sensor input card contains a temperature input...

  • Page 8: Mechanical

    Ethernet 10/100 802.3-2005 Auto MDIX support Auto Negotiation Agency Approvals Safety UL 61010-1:2012 3rd Ed. CSA C22.2 No. 61010-1:2012 3rd Ed. IEC 61010-1:2010 3rd Ed. EN 61010-1:2010 3rd Ed. IEC 61326-1:2005 EN 61326-1:2006 Note: For EN61000-4-6, EN61000-4-3 the controller met performance criteria B. *Class A equipment: Equipment suitable for use in establishments other than domestic, and those directly connected to a low voltage (100-240 VAC) power supply network which supplies buildings used for domestic purposes.
  • Page 9 Relay output settings 86,400 seconds (0 = Output Limit Time 1 second unlimited) 86,400 seconds (0 = Hand Time Limit 1 second unlimited) Min Relay Cycle 0 seconds 300 seconds Set Point Low end of sensor range High end of sensor range Dead Band Low end of sensor range High end of sensor range...

  • Page 10: Unpacking & Installation

    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 W600 series controller and an instruction manual. Any options or accessories will be incorporated as ordered.
  • Page 11 Sensors should be located such that they respond rapidly to a well-mixed sample of the process water and the treatment chemicals. If they are too close to the chemical injection point, they will see spikes in concentration and cycle on and off too frequently. If they are too far away from the chemical injection point, they will respond too slowly to the concentration changes, and you will overshoot the set point.
  • Page 12 occur beyond that point and the conductivity reading will be low and erratic. Minimize the usage of tees, valves, elbows or unions between the boiler and the electrode. 3. A manual shut off valve should be installed so that the electrode can be removed and cleaned.
  • Page 13 If an orifice plate is used, you must install a valve downstream from the orifice in order to fine tune the flow rate and provide additional back pressure in many applications. Example: An 80 psi boiler has a Required Blowdown Rate of 383.33 lbs./hr. The maximum flow rate of the smallest flow control valve is 3250 lbs./hr.

  • Page 14: Icon Definitions

    National, State and Local codes! 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.
  • Page 15 Figure 1 Conduit Wiring...
  • Page 16 COOLING TOWER METERING PUMPS HEAT EXCHANGER 19.5" ¾“ NPTF FLOW SWITCH FLOW WEL pH/ORP ELECTRODE ¾“ NPTF FLOW 11.75" CONDUCTIVITY SAMPLE ELECTRODE VALVE 1/4" POLYPRO PANEL 19.5" x 11.75" Figure 2 Typical Installation – Cooling Tower...
  • Page 17 AC POWER FLOW IN FLOW OUT SUBMERSION ELECTRODE BASE ACID PROBE Figure 3 Typical Installation – Cooling Tower Submersion...
  • Page 18 RECOMMENDED INSTALLATION INTERMITTENT SAMPLING Skimmer Blowdown Line 3/4" Min. up to Electrode 10 ft. max. with minimal valves, elbows & unions CONDUCTIVITY ELECTRODE Flow Motorized Full Port Block Control Ball Valve Valve or or Solenoid ¾" TEE Orifice Union Valve 2 ft.
  • Page 19 SAMPLE RETURN 1 ATMOSPHERE MAXIMUM ROTAMETER SENSOR 30-100 LPH FLOW CELL ISOLATION FLOW VALVE SWITCH FLOW (NORMALLY CONTROL OPEN) VALVE SAMPLE VALVE RECIRCULATION PUMP PROCESS WATER Figure 5 Typical Installation – Disinfection Sensor...
  • Page 20 Figure 6 Parts Identification...
  • Page 21 POWER SWITCH FUSE TEMP– WHT TEMP+ GRN BLACK SHIELD SENSOR LABEL TB1 or 2 Conductivity Electrode Figure 7 Contacting Conductivity Sensor Input Wiring...
  • Page 22 POWER SWITCH FUSE TEMP – TEMP + RCV – RCV + SHIELD XMT + XMT – SENSOR LABEL TB1 or 2 Conductivity Electrode Figure 8 Electrodeless Conductivity Sensor Input Wiring...
  • Page 23 POWER SWITCH FUSE Optional Temperature Compensation TEMP– WHT/GRN TEMP+ GRN/WHT IN– WHT/ORN ORN/WHT SHIELD BLU/WHT -5V WHT/BLU SENSOR LABEL TB1 or 2 pH/ORP electrode Figure 9 pH/ORP Sensor Input Wiring...
  • Page 24 POWER SWITCH FUSE IN– SHIELD -5V BLK SENSOR LABEL TB1 or 2 Figure 10 Disinfection Sensor Input Wiring...
  • Page 25 POWER SWITCH FUSE Type of Transmitter 2 Wire 2 Wire 4 Wire 3 Wire Pin# Loop Powered +24V +24V +24V 24V(–) XMTR– XMTR– Little XMTR+ XMTR+ XMTR– XMTR+ Dipper COM(-) SHIELD SHIELD SHIELD SHIELD +24V +24V +24V POWERED 24V(–) 4-20mA SOURCE –...
  • Page 26 POWER SWITCH FUSE SIGNAL IN – POWER +9V FLOW SWITCH Contact Closure: Polarity not critical Hall Effect FLOW METER Reed Switch FLOW METER TB1, 2 OR 3 Polarity not Critical (TB 3 SHOWN) SAFETY COVER LABEL Figure 12 Digital Input Wiring...
  • Page 27 POWER SWITCH FUSE GRN 120V GRN/YEL 240V IF MOTORIZED BALL VALVE BLK 120V WHT 120V BRN 240V BLU 240V SOLENOID/ MOTORIZED BALL VALVE WHT 120V BLK 120V BLU 240V BRN 240V WHT 120V BLU 240V BLK 120V BRN 240V GRN 120V GRN/YEL 240V WHT 120V BLU 240V...
  • Page 28 POWER SWITCH FUSE If motorized ball valve GRN 120V GRN/YEL 240V WHT 120V BLU 240V BLK 120V BRN 240V WHT 120V BLK 120V BLU 240V BRN 240V GRN 120V GRN/YEL 240V GRN 120V Fused GRN/YEL 240V External BLK 120V WHT 120V BRN 240V BLU 240V Power...
  • Page 29 POWER SWITCH FUSE External Power External Power GRN 120V Fused GRN/YEL 240V External WHT 120V BLU 240V Power Source BLK 120V BRN 240V GRN 120V Fused GRN/YEL 240V WHT 120V External BLU 240V Power BLK 120V BRN 240V ALARM Source WHT 120V BLU 240V BLK 120V...
  • Page 30 POWER SWITCH FUSE External Power External Power External Power External Power GRN 120V Fused GRN/YEL 240V External WHT 120V WHT 120V BLU 240V BLU 240V Power ALARM BLK 120V Source BRN 240V BLK 120V BRN 240V Power Supply (115 VAC or 230 VAC) Figure 16 W640 AC Power &...
  • Page 31 POWER SWITCH FUSE – – SHIELD SHIELD Chart Chart Recorder Recorder SAFETY LABEL Figure 17 Analog Output Wiring...

  • Page 32: Function Overview

    FUNCTION OVERVIEW Front Panel Figure 18 Front Panel Touchscreen A Home screen is displayed while the controller is on. This display shows a user-defined list of input readings and the status of any outputs that are tied to that input. Touching any of the input readings will bring up that input’s Details screen, where you can access calibration and setting menus.

  • Page 33: Icons

    Icons The following icons appear on the Home screen. The Main Menu icon brings you to the list of menu options listed below. The following icons appear on the Main Menu screen. Touch the icon to get to the menu selections. Alarm Menu Inputs Menu Outputs Menu...
  • Page 34 The Character Delete icon deletes part of an alphanumeric entry The Shift icon switches between upper and lower case alpha entry screens The Next Screen icon moves to the next step in a calibration sequence. In a Graph it shifts the graph forward in time. The Previous Screen icon moves back a step in a calibration sequence.

  • Page 35: Startup

    Interlock and Activate with Channels Menus To select which digital inputs or relays will interlock this relay (Interlock Channels), or which digital inputs or relays will force this relay on (Activate with Channels), touch the input or relay number(s). The background of the selected item will turn dark. When finished selecting as many as needed, touch the Confirm icon to accept the changes or the Cancel icon to leave the selections at the previous settings and go back.
  • Page 36 Overview of the menu structure...
  • Page 38 Inputs (see section 5.2) Program the settings for each input The S11 sensor input will be displayed. Touch it to get to the Details screen. Touch the Settings icon. If the name of the sensor does not describe the type of sensor connected, touch the Scroll Down icon until Type is displayed.

  • Page 39: 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. It is important that the pH/ORP electrode remains wet.

  • Page 40: Operation Using The Touchscreen

    OPERATION using the touchscreen These units control continuously while power is applied. Programming is accomplished either via the touchscreen or the optional Ethernet connection. See section 6.0 for Ethernet instructions. To view the readings of each sensor, or whatever user-defined list of parameters that has been set, touch the Home icon if not already there.
  • Page 41 Cal Successful or Failed If successful, touch Confirm to put the new calibration in memory. If failed, you may retry the calibration or cancel. Refer to Section 8 to troubleshoot a calibration failure. One Point Buffer Calibration, Disinfection Sensor Zero Cal, Electrodeless Conductivity Air Cal Cal Disables Control Touch Confirm to continue or Cancel to abort Buffer Temperature (only appears if no temperature sensor is detected for sensor types that...
  • Page 42 Cal Successful or Failed If successful, touch Confirm to put the new calibration in memory. The calibration adjusts the offset and the gain (slope) and displays the new values. If failed, you may retry the calibration or cancel. Refer to Section 8 to troubleshoot a calibration failure. Resume Control Replace the sensor in the process and touch Confirm when ready to resume control.

  • Page 43: Contacting Conductivity

    5.2.1 Contacting Conductivity Settings Touch the Settings icon to view or change the settings related to the sensor. Alarms Low-Low, Low, High and High-High Alarms limits may be set. Deadband This is the Alarm Deadband. For example, if the High Alarm is 3000, and the deadband is 10, the alarm will activate at 3001 and deactivate at 2990.

  • Page 44: Temperature

    5.2.3 Temperature Settings Touch the Settings icon to view or change the settings related to the sensor. Alarms Low-Low, Low, High and High-High Alarms limits may be set. Deadband This is the Alarm Deadband. For example, if the High Alarm is 100, and the deadband is 1, the alarm will activate at 100 and deactivate at 99.

  • Page 45: Disinfection

    5.2.6 Disinfection Settings Touch the Settings icon to view or change the settings related to the sensor. Alarms Low-Low, Low, High and High-High Alarms limits may be set. Deadband This is the Alarm Deadband. For example, if the High Alarm is 7.00, and the deadband is 0.1, the alarm will activate at 7.01 and deactivate at 6.90.

  • Page 46: Flow Meter, Contactor Type

    5.2.9 Flow Meter, Contactor Type Input Details The details for this type of input include the total volume accumulated through the flow meter, alarms, and the current type of input setting. Settings Touch the Settings icon to view or change the settings related to the sensor. Totalizer Alarm A high limit on the total volume of water accumulated may be set.

  • Page 47: Outputs Menu

    Outputs Menu Touch the Outputs icon from the Main Menu to view a list of all relay and analog outputs. The Page Down icon pages down the list of outputs, the Page Up icon pages up the list of outputs, the Main Menu icon brings back the previous screen.

  • Page 48: Relay, Flow Timer Control Mode

    Set point Enter the sensor process value at which the relay will activate. Enter the sensor process value away from the set point at which the relay Deadband will deactivate. Input Select the sensor to be used by this relay. Direction Select the control direction.

  • Page 49: Relay, Bleed Then Feed Control Mode

    5.3.5 Relay, Bleed then Feed Control Mode ONLY AVAILABLE IF HVAC MODES ARE ENABLED IN CONFIG MENU – GLOBAL SETTINGS Output Details The details for this type of output include the relay on/off state, HOA mode or Interlock status, accumulated on-time, remaining feed time, the accumulated bleed time, alarms related to this output, and the current control mode setting.
  • Page 50 Interlock Conditions Interlocks override the relay control, but do not change the operation of the timers or related bleed control. A no-flow (or other interlock) condition does not delay a biocide add. The biocide add duration timer will continue even if the relay is locked out due to a no-flow or other interlock condition. This will prevent delayed biocide adds which can potentially cause higher than expected biocide concentrations in the system when two biocides adds occur close to the same time.

  • Page 51: Relay, Alarm Output Mode

    Bleed Select the relay to be used for Bleed/Blowdown If lowering the conductivity prior to feeding biocide is desired using a fixed Prebleed Time time instead of a specific conductivity setting, enter the amount of time for the prebleed. Also may be used to apply a time limit on a conductivity based prebleed.

  • Page 52: Relay, Time Proportional Control Mode

    5.3.9 Relay, Time Proportional Control Mode Output Details The details for this type of output include the relay on/off state, HOA mode or Interlock status, the current % on time calculated for the cycle, the current point in the cycle time, accumulated on-time, alarms related to this output, and the current control mode setting.

  • Page 53: Relay Or Analog Output, Manual Mode

    Settings Touch the Settings icon to view or change the settings related to the relay. Set point Enter the conductivity value below which the controller will not start a blowdown cycle. Proportional Band Enter the conductivity value above the set point at which the maximum blowdown time will occur.

  • Page 54: Relay, Dual Set Point Mode

    Set point Enter the sensor process value at which the output will pulse at the Minimum Output % set below. Proportional Band Enter the distance that the sensor process value is away from the set point beyond which the output will be pulsing at the Maximum Output % set below.
  • Page 55 “Activate With” Conditions “Activate with channels” settings override the relay control, but do not change the operation of the timer control. The relay activation duration timer continues counting when the timer relay is forced on, and ends at the expected time (event start time plus duration). If the “activate with” condition continues after the end of the event time, the relay remains activated.

  • Page 56: Analog Output, Retransmit Mode

    5.3.15 Analog Output, Retransmit Mode Output Details The details for this type of output include the output %, HOA mode or Interlock status, accumulated on-time, alarms related to this output, and the current control mode setting. Settings Touch the Settings icon to view or change the settings related to the relay. 4 mA Value Enter the process value to correspond to a 4 mA output signal.

  • Page 57: Configuration Menu

    Configuration Menu The configuration Settings Menu is used for settings and activities that are not tied to Inputs or Outputs. 5.4.1 Global Settings Date Enter the current year, month and day. Time Enter the current hour (military time), minute, and second. Name Enter the name to help identify the controller when it connects to VTouch.

  • Page 58: Network Settings

    5.4.3 Network Settings DHCP Setting Select Enabled to get an IP address from the LAN or Disabled to use a fixed IP address. Controller IP Enter the default IP address to use if a network is not available or if DHCP is Address disabled.

  • Page 59: File Utilities

    5.4.6 File Utilities File Transfer Status Displays the status of the last attempt to export a file Export Daily Data Save the Daily Data Log file to a USB stick. This records all inputs’ data from the last 24 hours in 10 second intervals. Export Weekly Save the Weekly Data Log file to a USB stick.

  • Page 60: Controller Details

    5.4.7 Controller Details Controller Displays the name for the group of default settings used as built Product Name Displays the model of the controller as built Serial Number Displays the serial number of the controller Controller Board Displays the revision number of the front panel circuit board Software Version Displays the software version on the controller board Power Board...

  • Page 61: Hoa Menu

    HOA Menu The HOA (Hand-Off-Automatic) Menu is used to quickly and easily test all relay outputs, and to stop or enable automatic control. Touch the relay number in order to change the HOA state of that relay. The relay number will be shaded dark, and its current HOA state will be shaded dark.

  • Page 62: Operation Using Ethernet

    The resolution of the screen only allows for 84 data points per graph, so not all data points in each time range can be shown. For finer resolution, download the data log CSV file from the Config – File Utilities menu and graph the data in Excel or equivalent spreadsheet application. Time Range Time between data points Datalog file used...

  • Page 63: Connecting Directly To A Computer

    Connecting Directly to a Computer Connect the controller’s network card to the computer using a CAT5 cable with RJ45 connector. Follow the instructions above to give the controller a fixed IP address that is compatible with the network settings of the computer. Open a browser and type the numeric Controller IP address in the web page address field.

  • Page 64: Maintenance

    MAINTENANCE The controller itself requires very little maintenance. Wipe with a damp cloth. Do not spray down the controller unless the enclosure door is closed and latched. Electrode Cleaning NOTE: The controller must be recalibrated after cleaning the electrode. Frequency The electrode should be cleaned periodically.

  • Page 65: Replacing The Fuse Protecting Powered Relays

    Warning: Use of non-approved fuses can affect product safety approvals. Specifications are shown below. To insure product safety certifications are maintained, it is recommended that a Walchem fuse be used.

  • Page 66: Electrodeless Conductivity Sensors

    8.1.2 Electrodeless Conductivity Sensors The calibration will fail if the adjustment to the gain is outside of 0.2 to 10, or the offset is outside of -10,000 to 10,000. Possible Cause Corrective Action Dirty sensor Clean sensor Improper wiring of sensor to controller Correct wiring Sensor placed too close to container walls Relocate sensor...

  • Page 67: Disinfection Sensors

    8.1.5 Disinfection Sensors The calibration will fail if the adjustment to the gain is outside of 0.2 to 10.0, or if the calculated offset is outside of -40 to 40. Possible Cause Corrective Action Insufficient conditioning Wait for the appropriate amount of time before attempting a calibration.

  • Page 68: Alarm Messages

    Alarm Messages HIGH or HIGH-HIGH ALARM Occurs if the sensor reading rises above the high alarm set points. If your unit is programmed for an alarm relay output, the alarm relay will activate. The controller will continue to check the sensor reading, and any outputs using the sensor will remain active.
  • Page 69 DI STATE CUSTOM MESSAGE A digital input that is a DI State type can be set such that either the open or closed state generates an alarm. The alarm message may be customized. The most common use for this will be a Flow Switch. Possible Cause Corrective Action Check piping for closed valves, blockage, etc.
  • Page 70 EVENT SKIPPED ALARM An event skipped alarm is set when a second biocide or timer event occurs while one event is still running (either in prebleed, biocide-add or post-biocide add lockout in the case of the biocide timer mode). An event skipped alarm is also set when the timer relay never turns on during an event because of an interlock condition.

  • Page 71: Procedure For Evaluation Of Conductivity Electrode

    Possible Cause Correction Action Ethernet card locked up Try a power cycle to reset it Ethernet card not seated correctly Unplug the network card and plug it back in Faulty Ethernet card Replace Ethernet card WEB SERVER FAILURE This alarm occurs if the web server on the Ethernet circuit board fails Possible Cause Correction Action Web server locked up...

  • Page 72: Diagnostic Lights

    The last possibility is to try replacing the preamplifier. Diagnostic Lights Some of the circuit boards inside the controller have diagnostic lights. POWER/RELAY BOARD AMBER NEON (ONLY FOR MODELS WITH POWERED RELAYS) Indicates status of the fuse protecting the relays. Normal operation is ON. If not on: Possible Cause Correction Action Fuse has blown or is missing...

  • Page 73: Spare Parts Identification

    Spare Parts Identification 191733 Ethernet board 191732 Analog output board 191730 Sensor board or 191731 Analog input board 191739 Ribbon cable 191729 191738 Safety cover Front panel assembly 191578 Power switch cable 102834 Fuse (W600 & 610 only) 103864 (6x) 191734 W600 Power relay board or 191735 W610 Power relay board or 191736 W620 Power relay board...
  • Page 74 WCT600 Sensor option BD and FD...
  • Page 75 WCT600 Sensor option BN or FN...
  • Page 76 WCT600 Sensor option BA, BB, BC, FA, FB, FC...
  • Page 77 WCT600 Sensor option DE, DF...
  • Page 78 WCT600 Sensor option DN...
  • Page 79 WCT600 Sensor option HA, HB and HC...
  • Page 80 WCT600 Sensor option HD...
  • Page 81 WCT600 Sensor option HN...
  • Page 82 WDS600 Sensor option FF or FN...
  • Page 83 WDS600 Sensor option PN...
  • Page 84 WDS600 Sensor option PX...
  • Page 85 WPH600 Sensor option PN...
  • Page 86 WPH600 Sensor option PX...

  • Page 87: Service Policy

    10.0 SERVICE POLICY The W600 series controller has a 2-year warranty on electronic components and a 1-year warranty on mechanical parts (terminal strip and relays). We stock circuit boards for immediate exchange after we have isolated the cause of the problem.
  • Page 88 Cannon Water Technology Inc. 233 Technology Way Suite 9, Rocklin, CA 95765 Voice: 1 916-315-2691, FAX: 1 916-304-0210 csd@cannonwater.com, https://cannonwater.com/ 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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