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IWAKI Walchem W900 Series Instruction Manual

Water treatment controller
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W900 Series
Water Treatment Controller
Instruction Manual
Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA
TEL: 508-429-1110
WEB: www.walchem.com

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Summary of Contents for IWAKI Walchem W900 Series

  • Page 1 W900 Series Water Treatment Controller Instruction Manual Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA TEL: 508-429-1110 WEB: www.walchem.com...

  • Page 2: Proprietary Material

    Notice © 2017 WALCHEM, Iwaki America Incorporated (hereinafter “Walchem”) 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. Such information and descriptions may not be copied or reproduced by any means, or disseminated or distributed without the express prior written per- mission of WALCHEM, 5 Boynton Road, Holliston, MA 01746.

  • Page 3: Table Of Contents

    Contents INTRODUCTION ............................1 SPECIFICATIONS ............................2 2.1 Measurement Performance ......................... 2 2.2 Electrical: Input/Output ..........................3 2.3 Mechanical ..............................5 2.4 Variables and their Limits ..........................6 3.0 UNPACKING & INSTALLATION ....................9 3.1 Unpacking the unit ............................9 3.2 Mounting the electronic enclosure .......................
  • Page 4 5.3.12 Relay, Pulse Proportional Control Mode ................... 57 5.3.13 Relay, PID Control Mode ......................58 5.3.14 Relay, Dual Set Point Mode ...................... 60 5.3.15 Relay, Timer Control Mode ......................61 5.3.16 Relay, Probe Wash Control Mode ..................... 62 5.3.17 Relay, Spike Control Mode ......................63 5.3.18 Relay, Lag Output Control Mode ....................

  • Page 5: Introduction

    1.0 INTRODUCTION The Walchem W900 Series controllers offer a high level of flexibility in controlling water treatment applications. • There are four slots that accept a variety of Input/Output Modules, which provides unparalleled versatility. Dual sensor input modules are available that are compatible with a variety of sensors (two sensors per module): »...

  • Page 6: Specifications

    Our USB features provide the ability to upgrade the software in the controller to the latest version. The Config file feature allows you to save all the set points from a controller onto a USB flash disk, and then import them into another controller, making the programming of multiple controllers fast and easy.

  • Page 7: Electrical: Input/Output

    Electrodeless Conductivity Range Resolution Accuracy 500-12,000 µS/cm 1 µS/cm, 0.01 mS/cm, 0.1 mS/m, 0.001 S/m, 1 ppm 1% of reading 3,000-40,000 µS/cm 1 µS/cm, 0.01 mS/cm, 0.1 mS/m, 0.001 S/m, 1 ppm 1% of reading 10,000-150,000 µS/cm 10 µS/cm, 0.1 mS/cm, 1 mS/m, 0.01 S/m, 10 ppm 1% of reading 50,000-500,000 µS/cm 10 µS/cm, 0.1 mS/cm, 1 mS/m, 0.01 S/m, 10 ppm...
  • Page 8 Digital Input Signals (12 standard): State-Type Digital Inputs Electrical: Optically isolated and providing an electrically isolated 12VDC power with a nominal 2.3mA current when the digital input switch is closed Typical response time: < 2 seconds Devices supported: Any isolated dry contact (i.e. relay, reed switch) Types: DI State Low Speed Counter-Type Digital Electrical: Optically isolated and providing an electrically isolated 12VDC...

  • Page 9: Mechanical

    Mechanical Enclosure Material Polycarbonate Enclosure Rating NEMA 4X (IP65) Dimensions 12.2” W x 13.8” H x 5.4” D (310 mm x 351 mm x 137 mm) Display 320 x 240 pixel monochrome backlit display with touchscreen Operating Ambient Temp -4 to 122 °F (-20 to 50 °C) Storage Temperature -4 –...

  • Page 10: Variables And Their Limits

    Pressure vs. Temperature 24.1 20.7 17.2 pH/ORP 13.8 10.3 Cond HP Cond/Steel HP pH/ORP/Steel °F °C Variables and their Limits Sensor Input Settings Low Limit High Limit Alarm limits Low end of sensor range High end of sensor range Input alarm dead band Low end of sensor range High end of sensor range Cell constant (conductivity only)

  • Page 11: Low Limit

    K Factor for units of Gallons or Liters 0.01 100,000 K Factor for units of m 1,000,000 Smoothing Factor Set Flow Total 1,000,000,000 Feed Monitor Input Settings Low Limit High Limit Totalizer Alarm 0 vol. units 1,000,000 vol. units Set Flow Total 0 vol.
  • Page 12 Input Minimum (Pulse PID modes) Low end of sensor range High end of sensor range Input Maximum (Pulse PID modes) Low end of sensor range High end of sensor range Wear Cycle Time (Lag mode) 10 seconds 23:59:59 HH:MM:SS Delay Time (Lag mode) 0 seconds 23:59:59 HH:MM:SS Target (Target PPM, PPM Volume modes)

  • Page 13: Unpacking & Installation

    3.0 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 W900 series controller and an instruction manual.
  • Page 14 wiring. These sensors are affected by the geometry and conductivity of their surroundings, so either maintain 6 inches (15 cm) of sample around the sensor or ensure that any nearby conductive or non-conductive items are consistently positioned. Do not install the sensor in the path of any electrical current that may be flowing in the solution, as this will shift the conductivity reading.
  • Page 15 2. Determine the Concentration Ratio (BASED ON FEEDWATER) A water treatment chemical specialist should determine the desired number of cycles of concentration. This is the ratio of TDS in the boiler water to TDS in the feedwater. Note that feedwater means the water that is fed to the boiler from the deaerator and includes makeup water plus condensate return.

  • Page 16: Icon Definitions

    Flow C ontrol Valv e M ax im um Flow Rates in Lbs/hr 25000 20000 15000 1/2 " 150 P S I 1/2 " 300 P S I 3/4 " 150 P S I 3/4 " 300 P S I 10000 5000 Pressure PSI...

  • Page 17: Electrical Installation

    Electrical installation The various standard wiring options are shown in figure 1, below. Your controller will arrive from the factory pre- wired or ready for hardwiring. Depending on your configuration of controller options, you may be required to hard- wire some or all of the input/output devices. Refer to figures 6 through 17 for circuit board layout and wiring. Note: when wiring the optional flow meter contactor input, the 4-20 mA outputs or a remote flow switch, it is advis- able to use stranded, twisted, shielded pair wire between 22-26 AWG.
  • Page 18 COOLING TOWER METERING PUMPS HEAT EX CHANGER Figure 2 Typical Installation – Cooling Tower...
  • Page 19 AC POWER FLOW IN FLOW OUT SUBMERSION ELECTRODE BASE ACID PROBE Figure 3 Typical Installation – Cooling Tower Submersion...
  • Page 20 R E C O M M E N D E D I N S T A L L A T I O N S k im m e r B lo w do w n L ine I N T E R M I T T E N T S A M P L I N G 3/4"...
  • Page 21 SAMPLE RETURN 1 ATMOSPHERE MAX IMUM ROTAMETER 30- 100 LPH SENSOR FLOW CELL ISOLATION FLOW VALVE SWITCH (NORMALLY FLOW OPEN) CONTROL VALVE SAMPLE VALVE RECIRCULATION PUMP PROCESS WATER Figure 5 Typical Installation – Disinfection Sensor...
  • Page 22 Figure 6 Parts Identification...
  • Page 23 I/O Boards 1 through 4 I/O Board P/N Identification Labels I/O Board wiring labels I/O Board Part Number I/O Board 1- 4 Terminal Blocks P/N 191910 SENSOR INPUT(2) TBxA - SENSOR 1 TBxB - SENSOR 2 Channel 1 Contacting Conductivity (CCOND) Contacting Conductivity (CCOND) ECOND CCOND...
  • Page 24 I/O Boards 1 through 4 I/O Board P/N Identification Labels I/O Board wiring labels I/O Board 1- 4 Terminal Blocks I/O Board Part Number P/N 191910 SENSOR INPUT(2) TBxA - SENSOR 1 TBxB - SENSOR 2 ECOND CCOND pH/ORP DIS RCV+ RCV–...
  • Page 25 I/O Boards 1 through 4 I/O Board P/N Identification Labels I/O Board wiring labels I/O Board 1- 4 Terminal Blocks I/O Board Part Number P/N 191910 SENSOR INPUT(2) TBxA - SENSOR 1 TBxB - SENSOR 2 ECOND CCOND pH/ORP DIS RCV+ RCV–...
  • Page 26 I/O Boards 1 through 4 I/O Board P/N Identification Labels I/O Board wiring labels I/O Board Part Number I/O Board 1- 4 P/N 191912 4-20 mA INPUT (2) Terminal Blocks TBxA - INPUTS 1-2 TBxB - NOT USED UNPOWERED 2 Wire 2 Wire 3 Wire 4 Wire...
  • Page 27 I/O Boards 1 through 4 I/O Board P/N Identification Labels I/O Board wiring labels I/O Board 1- 4 Terminal Blocks I/O Board Part Number P/N 191913 4-20 mA INPUT (4) TBxA - INPUTS 1-3 TBxB - INPUT 4 2 Wire 2 Wire U NPO WERED 3 Wire...
  • Page 28 I/O Boards 1 through 4 I/O Board P/N Identification Labels I/O Board wiring labels I/O Board 1- 4 I/O Board Part Number Terminal Blocks P/N 191914 4-20 mA INPUT (6) TBxA - INPUTS 1-3 TBxB - INPUTS 4-6 U NPO WERED 2 Wire 2 Wire 3 Wire...
  • Page 29 I/O Boards 1 through 4 I/O Board P/N Identification Labels I/O Board wiring labels I/O Board 1- 4 Terminal Blocks I/O Board Part Number P/N 191915 4-20 mA OUTPUT (2) TBxA - OUTPUTS 1-2 TBxB - NOT USED 4-20 mA Output –...
  • Page 30 I/O Boards 1 through 4 I/O Board P/N Identification Labels I/O Board wiring labels I/O Board 1- 4 I/O Board Part Number Terminal Blocks P/N 191916 4-20 mA OUTPUT (4) TBxA - OUTPUTS 1-2 TBxB - OUTPUTS 3-4 4-20 mA Output –...
  • Page 31 I/O Boards 1 through 4 I/O Board P/N Identification Labels I/O Board wiring labels I/O Board Part Number I/O Board 1- 4 Terminal Blocks P/N 191918 4-20 mA INPUT (2)/OUTPUT (4) TBxA - INPUT 1, OUTPUTS 1-2 TBxB - INPUT 2, OUTPUTS 3-4 2 Wire 2 Wire 4-20 mA...
  • Page 32 D1– SIGNAL IN – D2– PO WER +12 V D3– FLOW SWITCH Hall Effect Contact Closure: FLOW METER Polarity not critical D4– Reed Switch D5– FLOW METER Polarity not Critical D6– D7– D8– D9– D10+ D10– D11+ D11– D12+ D12– TBDI Figure 16 Digital Input Wiring...
  • Page 33 Relay Model Code Powered Powered Powered Powered Powered Powered Powered Powered Powered Powered Powered Powered Powered Powered Powered Pulse Pulse Powered Powered Powered Powered Pulse Pulse Pulse Pulse Powered Powered Pulse Pulse Powered Powered Pulse Pulse Powered Powered Powered Powered Powered Powered Pulse...

  • Page 34: Function Overview

    4.0 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 or status of outputs. Touching any of the items on the Home Screen will bring up the item’s Details Screen, where you can access calibration and setting menus.
  • Page 35 Outputs Menu Configuration Menu HOA Menu Graph Menu Home Page Other icons may appear in the menu screens. Calibration icon appears in sensor input menus and brings up the calibration menu Cancel icon aborts a calibration or setting change The Page Down icon scrolls down to a new page in a list of options. The Page Up icon scrolls up to a new page in a list of options.

  • Page 36: Changing Numeric Values

    Overview of the use of icons Changing Numeric Values To change a number, use the Character Delete icon to the digit to be changed. If the new number will be neg- ative, start with touching the minus sign, then use the numeric touchpad and decimal point to type the number (some entries must be integers and the decimal will be ignored and the setting rounded to the nearest integer).

  • Page 37: Calibrate The Sensor

    Set global units of measure Touch the Scroll Up or Down icon until Global Units is displayed and then touch it. Touch the desired units. Touch the Confirm icon to accept the change. Set temperature units of measure Touch the Scroll Up or Down icon until Temp Units is displayed and then touch it. Touch the desired units. Touch the Confirm icon to accept the change.
  • Page 38 MAIN MENU/HOME SCREEN OVERVIEW Inputs Sensor (S11) 3038 µ S/cm Temp (S12) 77.1° F HOME SCREEN (example) Generic AI (S21) 30.5% Generic AI (S22) 37.9% Flowswitch (D1) No Flow Config SENSO R (S1) CCond (S11) 3041 µ S/cm Global Settings List of possible Inputs: Temp (S12) 77.0°...
  • Page 39 Inputs Main Menu 09:19:01 14-Mar-2017 Config Sensor (S11) 3038 µ S/cm Inputs Temp (S12) 77.1° F Outputs Generic AI (S21) 30.5% Alarms Graph Generic AI (S22) 37.9% > Calibration Inputs> Sensor (S11) SENSO R (S1) One Point Process Calibration Details Screen One Point Buffer Calibration Content v aries w ith Two Point Buffer Calibration...
  • Page 40 Outputs RELAY OUTPUTS (R1-R8) Main Menu 09:19:01 14-Mar-2017 (CONTINUED ON NEXT PAGE) Config On/Off (R1) Inputs Inhibitor (R2) Outputs Only if HVAC mode is enabled Additional Settings for Intermittent Sampling Mode: Flow Timer (R3) Int. Sampling (R1-R8) Sample Time Min Relay Cycle Alarms Graph Manual (R4)
  • Page 41 Outputs Main Menu 09:19:01 14-Mar-2017 Config On/Off (R1) Inputs Inhibitor (R2) RELAY OUTPUTS (R1-R8) Continued Outputs Flow Timer (R3) Alarms Graph Manual (R4) Outputs> On/Off (R1) Details Screen Content v aries w ith ou tpu t type Additional Settings for Target PPM Control Mode: Target PPM (R1-R8) Speci c Gravity Hand Time Limit...

  • Page 42: Config Menu

    CONFIG MENU HOME SCREEN (example) Config Flowswitch (D1) No Flow Main Menu 09:19:01 14-Mar-2017 Global Settings CCond (S11) 3041 µ S/cm SENSO R (S1) Inputs Config Security Settings Temp (S12) 77.0° F Network Settings Outputs Network Details Flowswitch (D1) No Flow Alarms Graph Additional Config Settings:...

  • Page 43: Normal Startup

    Outputs (see section 5.3) Program the settings for each output The R1 relay output will be displayed. Touch the relay field to get to the Details screen. Touch the Settings icon. If the name of the relay does not describe the control mode desired, touch the Scroll Down icon until Mode field is displayed.

  • Page 44: Inputs Menu

    Inputs Menu Touch the Inputs icon to view a list of all sensor and digital inputs. The Page Down icon pages down the list of inputs, the Page Up icon pages up the list of inputs, the Main Menu icon brings back the previous screen. Touch the input to access that input’s details, calibration (if applicable) and settings.
  • Page 45 First Buffer Value (does not appear if automatic buffer recognition is used) Enter the value of the buffer being used Rinse Sensor Remove the sensor from the process, rinse it off, and place it in the buffer solution. Touch Confirm when ready. Stabilization When the temperature (if applicable) and signal from the sensor is stable, the controller will automatically move to the next step.
  • Page 46 Third Buffer Temperature (only appears if no temperature sensor is detected) Enter the temperature of the buffer and touch Confirm. Third Buffer Value (does not appear if automatic buffer recognition is used) Enter the value of the buffer being used Rinse Electrode Remove the sensor from the process, rinse it off, and place it in the buffer solution.

  • Page 47: 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 dead- band is 10, the alarm will activate at 3001 and deactivate at 2990.

  • Page 48: Temperature

    Cable Length The controller automatically compensates for errors in the reading caused by varying the length of the cable. Gauge The cable length compensation depends upon the gauge of wire used to extend the cable Cell Constant Do not change unless instructed by the factory. The Walchem sensor is 6.286. Sensors made by others are not supported.

  • Page 49: Orp

    Buffers Select if calibration buffers will be manually entered, or if they will be automati- cally detected, and if so, which set of buffers will be used. The choices are Manual Entry, JIS/NIST Standard, DIN Technical, or Traceable 4/7/10. Default Temp If the temperature signal is lost at any time, then the controller will use the Default Temp setting for temperature compensation.

  • Page 50: Generic Sensor

    Smoothing Factor Increase the smoothing factor percentage to dampen the response to changes. For example, with a 10% smoothing factor, the next reading shown will consist of an average of 10% of the previous value and 90% of the current value. Cable Length The controller automatically compensates for errors in the reading caused by vary- ing the length of the cable.

  • Page 51: Fluorometer Input

    Transmitter Select the type of transmitter connected (2-wire loop powered, 2-wire self-powered, 3-wire, or 4-wire). Reset Calibration Values Enter this menu to reset the sensor calibration back to factory defaults. Cal Required Alarm To get an alarm message as a reminder to calibrate the sensor on a regular schedule, enter the number of days between calibrations.

  • Page 52: Di State

    5.2.10 Flowmeter Input 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 dead- band is 0.1, the alarm will activate at 7.01 and deactivate at 6.90.

  • Page 53: Flow Meter, Contactor Type

    Feed Monitor The Feed Monitor Digital Input type performs the following functions: • Monitors a pulse signal from a pump (Iwaki PosiFlow, Tacmina Flow Checker, LMI Digital Pulse, etc) • Totalizes the chemical feed and calculates the current flow rate •...
  • Page 54 Each Feed Monitor input can be linked to any type of output channel (powered relay, dry contact relay, solid state relay, or analog 4-20 mA) to validate chemical feed from any type of pump. Total Alarm The W900 monitors the total feed and activates a Total Alarm if the value exceeds the Totalizer Alarm set point. When used in conjunction with Scheduled Reset selections (Daily, Monthly, or Annually), this alarm can be used to alert users to situations where excess chemical product is used and/or to discontinue chemical feed if the amount exceeds the set point during the specified time period.

  • Page 55: Virtual Input

    reset, alarms, the status of the output linked to the input, the date and time of the last total reset, 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 accumulated volume of chemical fed may be set, to trigger a Total Alarm.
  • Page 56 Virtual Input Details The details for any type of virtual input include the current value calculated, alarms, the status, and the input type. Settings Touch the Settings icon to view or change the settings related to the virtual input. Alarms Low-Low, Low, High and High-High Alarms limits may be set.

  • Page 57: 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. Touch an output to access that output’s details and settings.

  • Page 58: Relay, Flow Timer Control Mode

    Duty Cycle Enter the percentage of the cycle period that the relay will be active. Set the percentage to 100 if use of a duty cycle is not required. On Delay Time Enter the delay time for relay activation in hours:minutes:seconds. Set the time to 00:00:00 to immediately activate the relay.

  • Page 59: Relay, Percent Timer Control Mode

    5.3.6 Relay, Percent Timer Control Mode Output Details The details for this type of output include the relay on/off state, HOA mode or Interlock status, cycle time, accumulated on-time, alarms related to this output, current cycle on time, relay type and the current control mode setting. Settings Touch the Settings icon to view or change the settings related to the relay.

  • Page 60: Relay, Alarm Output Mode

    Settings Touch the Settings icon to view or change the settings related to the relay. Event 1 (through 10) Enter these menus to program timer events via the menus below: Repetition Select the time cycle to repeat the event: Daily, 1 Week, 2 Week, 4 Week, or None. An event means that the output is turned on at the same time of day, for the same amount of time, and except for the Daily cycle, on the same day of the week.

  • Page 61: 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, current cycle on time, relay type and the current control mode setting.

  • Page 62: Relay, Manual Mode

    Deadband (only shown if trap sample is disabled) Enter the sensor process value away from the set point at which the relay will deactivate. Sample Time Enter the length of time the blowdown valve will be open in order to capture a fresh sample of boiler water.

  • Page 63: Relay, Pid Control Mode

    5.3.13 Relay, PID Control Mode ONLY AVAILABLE IF CONTROLLER INCLUDES PULSE OUTPUT HARDWARE & HVAC MODE IS DISABLED The PID algorithm controls a solid state relay using standard Proportional-Integral-Derivative control logic. The algorithm provides feedback control based on an error value continuously calculated as the difference between a measured process variable and a desired set point.
  • Page 64 Current Integral during each cycle may be positive or negative based on the current Direction setting as well as the relative values of the current process reading and the set point. Override Control The Current Integral accumulates when the output is set to Auto mode. If the controller is switched to Off mode, the value no longer accumulates, but it is not cleared.

  • Page 65: Relay, Dual Set Point Mode

    Derivative Gain When the Gain Form setting is Parallel, this value is multiplied by the change in error between the current reading and the previous reading to determine the derivative com- ponent of the calculated output percent. Reset PID Integral The PID Integral Value is a running total of the accumulated area under the error curve (Current Integral).

  • Page 66: Relay, Timer Control Mode

    5.3.15 Relay, Timer Control Mode ONLY AVAILABLE IF HVAC MODES ARE DISABLED IN CONFIG MENU – GLOBAL SETTINGS Basic Timer Operation When a timer event triggers the algorithm will activate the relay for the programmed time. Special Condition Handling Overlapping timer events If a second timer event occurs while the first one is still active, the second event will be ignored.

  • Page 67: Relay, Probe Wash Control Mode

    5.3.16 Relay, Probe Wash Control Mode Basic Timer Operation When a Probe Wash event triggers, the algorithm will activate the relay for the programmed time. The relay will activate a pump or valve to supply a cleaning solution to the sensor or sensors. The output of the selected sensors will either be held or disabled during the cleaning cycle, and for a programmable hold time after the cleaning cycle.

  • Page 68: Relay, Spike Control Mode

    Sensor Mode Select the effect that the probe wash event will have on any control outputs that use the sensor(s) being washed. The options are to either Disable the sensor readings (turn the control output off) or Hold the sensor reading at the last valid sensor reading prior to the start of the probe wash event.

  • Page 69: Relay, Lag Output Control Mode

    Duty Cycle Period Using a duty cycle helps to prevent overshooting the set point in applications where the response of the sensor to chemical additions is slow. Specify the amount of time for the cycle, and the percentage of that cycle time that the relay will be active.

  • Page 70: Control Operation

    Output Activation Modes Depending on the control mode selected for the Lead output, Lag output(s) can be configured for activation of additional outputs based on one or more of the following criteria: On-time (for example, energize a second relay 10 minutes after the primary relay is turned on) Control set points (for example, energize a second relay if the pH continues to rise) Switch change (for example, energize a second pump to maintain a tank level when the low-low level switch opens Control Operation...
  • Page 71 Time Balanced Time balanced mode alternates outputs in a manner that equalizes the runtime of all connected pumps. This mode takes into account how long each output in the Lead Lag group has been running (since a manual reset) and selects the output that has the lowest on-time during each cycle.
  • Page 72 Example: In a two-output Lead Lag group (R1←R2), the Lead (R1) output, set for Dual Setpoint control, is pro- grammed to energize its output when the D.O. reading is outside the 4.0-4.5 ppb control range with a deadband of 0.1 ppb. Time based output activation is selected with a delay time of 15 minutes. When the D.O. value falls below 4.0 ppb, R1 is activated.

  • Page 73: Advanced Functionality

    Advanced Functionality The examples listed above detail the control behavior if wear leveling or output activation modes are enabled. The features are implemented independently. Wear Leveling modes are used to determine which output(s) are acti- vated. Output Activation modes determine how many output(s) are activated at one time. More advanced output control strategies can be implemented when these features are used in combination.

  • Page 74: Activation Mode

    Wear Cycle Time* This setting only appears if Time Balanced or Time Unbalanced Wear Leveling has been selected above. Enter the amount of elapsed time before time on totals for each output are reevaluated for wear leveling. Activation Mode* This entry is only appears if the control mode of the Lead output is On/Off, Dual Setpoint, Spike or Manual.

  • Page 75: Error Output

    Hand Output This menu only appears for pulse relay or analog output Lead outputs. Enter the output % desired for each output in the group when the output is in Hand mode. Off Mode Output This menu only appears for analog output Lead outputs.Enter the output mA value de- sired for each output in the group when the output is in Off mode, or being Interlocked, or during a calibration of the sensor being used as an input.

  • Page 76: Relay, Ppm By Volume Control Mode

    If the trigger volume is achieved again before the activation time has expired, the newly calculated on-time per unit volume is added to the remaining on-time. If the relay state is continuously on for longer than the Output Time Limit, then relay will deactivate. Output Details The details for this type of output include the relay on/off state, HOA mode or Interlock status, total accumulated on-time, alarms related to this output, current cycle on time, remaining on-time, accumulator total, cycles of con-...

  • Page 77: Relay, Flow Proportional Mode

    Settings Touch the Settings icon to view or change the settings related to the relay Target Enter the desired PPM set point for the product. Specific Gravity Enter the specific gravity of the product to be added. Accumulator Volume Enter the volume of water passing through the water meter to trigger the chemical feed. Flow Input Select the flow meter to be used as an input for this control relay.

  • Page 78: Analog Output, Retransmit Mode

    Low Cycles Limit Enter the lower limit for cycles of concentration, if used. The calculated on-time is limited to a maximum value if the cycles of concentration gets too low. 5.3.22 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, current cycle on time, relay type and the current control mode setting.

  • Page 79: Analog Output, Pid Control Mode

    % output = Target PPM x Water Flow Rate (liter or gal) Cycles x Pump Capacity (liter or gal/hr) x Pump Setting (%) x Speci c Gravity x 166.67 % output = Target PPM x Water Flow Rate (m ) Cycles x Pump Capacity (liter/hr) x Pump Setting (%) x Speci c Gravity x 0.16667 Control Operation If the output is continuously on for longer than the Output Time Limit, then output will deactivate.
  • Page 80 PID Equation Formats The controller supports two different forms of the PID equation as specified by the Gain Form setting. The two forms require different units for entry of the PID tuning parameters. Standard The standard form is more commonly used in industry because its time-based settings for the integral and deriva- tive coefficients are more meaningful.
  • Page 81 Wind-up Suppression The Current Integral value that is accumulating while the output is set to Auto can become very large or very small if the process value remains on the same side of the set point for a prolonged period of time. However, the control- ler may not be able to continue to respond if its output is already set to the minimum or maximum limits (0-100% by default).

  • Page 82: Analog Output, Manual Mode

    Error Output Enter the output mA desired when the sensor is not giving the controller a valid signal. The acceptable range is 0 to 21 mA. Input Select the sensor to be used by this output. Direction Set the control direction. This setting is used to determine the sign of the calculated error (current process value versus set point) and allows flexible control with only posi- tive values for all PID tuning parameters.

  • Page 83: Network Settings

    Local Password Used to change the touchscreen password needed for full configuration capability if security has been enabled. The default local password is 5555. This can and should be changed using this menu if Security is enabled. 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.

  • Page 84: Email Report Settings

    Verbose Logging If logging is Enabled, all Modbus requests will be logged in the Event Log (any errors, the function called, starting register, number of registers, value of the first register). This is useful when first setting up the HMI, but it will quickly fill the Event Log if it is not Disabled during normal operation.

  • Page 85: Display Settings

    ASMTP Password Enter the password required for authentication. Only appears if the email server type is ASMTP. 5.4.7 Display Settings Home 1 Select the input or output to display on the 1 line of the display Home screen. Home 2 Select the input or output to display on the 2 line of the display Home screen.

  • Page 86: Hoa Menu

    Software Version Displays the software version on the controller board Power Board Displays the part number and revision of the power/relay board Sensor Board #1 - #4 Displays the part number and revision of the I/O boards (One entry for each board installed, up to 4) Software Version Displays the software version on each I/O board (One entry for each board installed,...
  • Page 87 Touching any point on either line on the graphs displays a vertical line plus the details for that data point: date and time, value of the sensor, and an arrow showing if the state or the digital input/relay was high or low at that time. Touching the or the icons will redraw the graph forward or backwards in time, in increments of one...

  • Page 88: Operation Using Ethernet

    6.0 OPERATION using Ethernet All of the same settings that are available using the touchscreen are also available using a browser that is connected to the controller’s Ethernet IP address. The controller may be connected to a Local Area Network (LAN), directly to the Ethernet port of a computer, or to the VTouch account management system server.

  • Page 89: Maintenance

    7.0 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 90: Troubleshooting

    8.0 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 cau- tion to ensure safety and limit unnecessary further damage. Contact the factory. Calibration Failure Calibrations will fail if the adjustments to the reading are outside of the normal range for a properly functioning system.

  • Page 91: Orp Sensors

    8.1.4 ORP Sensors The calibration will fail if the adjustment to the gain is outside of 0.5 to 1.5, or if the calculated offset is outside of -300 to 300. Possible Cause Corrective Action Dirty electrode Clean electrode Improper wiring of sensor to controller Correct wiring Faulty electrode Replace electrode...

  • Page 92: 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. Possible Cause Corrective Action The process went further out of control than normal.
  • Page 93 Incorrect feed monitoring device wiring Correct wiring. Make sure that digital input that the feed monitoring device is connected to has been assigned to the correct relay Faulty feed monitoring sensor Replace feed monitoring sensor Blown fuse Verify the pump is getting power. Replace fuse Faulty output relay Replace relay board Faulty digital input...
  • Page 94 SYSTEM TEMP LOW This alarm indicates that the temperature inside the controller is below -10 °C. Possible Cause Correction Action Low ambient temperatures Provide heat for the controller SYSTEM TEMP HIGH This alarm indicates that the temperature of the controller or sensor processor IC is above 75 °C, or that the temperature of the Eth- ernet card processor IC is above 85 °C.
  • Page 95 Wrong digital input assigned to the output Correct programming error Faulty verification device Repair or replace device Faulty wiring of output to pump Correct wiring Faulty output board Repair or replace board Faulty digital input Replace board CONTROLLER, POWER, DISPLAY, OR SENSOR BOARD ERROR This alarm occurs if the board listed is not recognized Possible Cause Correction Action...

  • Page 96: Procedure For Evaluation Of Conductivity Electrode

    FRAM FILE SYSTEM ERROR This alarm occurs if the FRAM is not detected at power up Possible Cause Correction Action The FRAM was or is not functioning If the error message clears on its own, no action is required. If the error message persists, cycle power. If the error message still persists, replace the controller board.
  • Page 97 CONTROLLER BOARD D11 LED Indicates the status of the 5VDC power supply. Normal operation is ON. If not on: Possible Cause Correction Action Faulty ribbon cable Replace ribbon cable Faulty power supply Replace power supply CONTROLLER BOARD D10 LED Indicates the status of the 3.3VDC power supply. Normal operation is ON. If not on: Possible Cause Correction Action Faulty ribbon cable...

  • Page 98: Spare Parts Identification

    9.0 Spare Parts Identification 191931 Safety Cover 191931 I/O Board Holder 192612 WiFi Board 191921 191762 Controller Board + Ribbon Cable Display 191932 Power Supply 191902 Cable, Power Switch 190630 Connector 103281 Power Switch 103282 Switch Boot I/O Boards: 103832 103911 191910 Dual Sensor Input USB Cap Gasket 191912 Dual Analog Input...

  • Page 100: Service Policy

    10.0 Service Policy Walchem controllers have a 2-year warranty on electronic components and a 1-year warranty on mechanical parts and electrodes. See Statement of Limited Warranty in front of manual for details. Walchem controllers are supported by a worldwide network of authorized master distributors. Contact your autho- rized Walchem distributor for troubleshooting support, replacement parts, and service.

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