1. Manuals
  2. Brands
  3. Walchem Manuals
  4. Controller
  5. WBL400 Series
  6. Instruction manual

Walchem WBL400 Series Instruction Manual

Boiler controller
Hide thumbs
Table of Contents

Advertisement

Quick Links

W A L C H E M
WBL400/410 Controllers
WBL400/410 Series Boiler 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

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the WBL400 Series and is the answer not in the manual?

Questions and answers

Related Manuals for Walchem WBL400 Series

Summary of Contents for Walchem WBL400 Series

  • Page 1 W A L C H E M WBL400/410 Controllers WBL400/410 Series Boiler 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...
  • 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 ..........................2 WBL Variables and their Limits ....................3 UNPACKING & INSTALLATION ....................4 Unpacking the unit........................4 Mounting the electronic enclosure....................4 Installation ..........................4 Icon Definitions.........................8 Electrical Installation ........................8 FUNCTION OVERVIEW ......................13 Front Panel..........................13 Display ...........................13 Keypad ...........................14...

  • Page 4: Introduction

    INTRODUCTION The Walchem WBL Series controllers offer conductivity control of boiler water and control of chemical feed. The WBL400 series controller has one feed/auxiliary relay available. The WBL410 series controller has four feed/auxiliary relays. The chemical feed pump may be selected to operate in one of...

  • Page 5: Specifications

    SPECIFICATIONS Measurement Performance Conductivity Range 0 - 10,000 µS/cm (microSiemens/centimeter) Conductivity Resolution 1 µS/cm Conductivity Accuracy 10 - 10,000 µS/cm ±1% of reading 0 - 10 µS/cm ±20% of reading Temperature Range 32 - 392°F (0 - 200°C) Temperature Resolution 0.1°C Temperature Accuracy ±...

  • Page 6: Wbl Variables And Their Limits

    WBL Variables and their Limits Low Limit High Limit Conductivity menu PPM Conversion Factor 0.200 ppm/µS/cm 1.000 ppm/µS/cm Interval Time (sampling) 5 minutes 24:00 hours Duration Time (sampling) 1 minute 59 min: 59 sec % Calibration Range No variables Temperature Menu BlowdownMenu Set Point 0 µS/cm...

  • 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 WBL series controller and instruction manual.
  • Page 8 6. There MUST be a flow restriction after the electrode and/or control valve in order to provide back pressure. This flow restriction will be either a flow control valve or an orifice union. The amount of the flow restriction will affect the blowdown rate as well, and should be sized accordingly.
  • Page 9 5. Determine the Orifice or Flow Control Valve Size for this Blowdown Rate Use the following graphs to select a flow control device: Flow Rate in Lbs/hr for Various Orifices 18000 16000 14000 12000 1/8 inch dia 10000 3/16 inch dia 1/4 inch dia 8000 5/16 inch dia...
  • Page 10 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" Orifice Union Valve Cross 2 ft. 1 to 3 ft. minimum maximum Manual Clean-Out...

  • Page 11: 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 12 CONDUCTIVITY ELECTRODE FLOW SWITCH (OPTIONAL) FLOW METER POWER FEED (OPTIONAL) SPARES BLOWDOWN 4-20mA (OPTIONAL) PLUG Figure 2a WBL400 Conduit Wiring CONDUCTIVITY ELECTRODE FLOW SWITCH (OPTIONAL) FLOW METER POWER AUX1 AUX2 AUX4/ALARM (OPTIONAL) BLOWDOWN SPARES 4-20mA (OPTIONAL) PLUG AUX3 Figure 2b WBL410 Conduit Wiring...
  • Page 13 BLEED FEED N.C. N.O. N.C. N.O. L1 L2/N GROUND STUD L1 L2/N FLOW SW 1 FLOW MTR 1 FLOW MTR 2 WHT 120V BLU 240V COND Contact Closure: SHIELD Polarity not critical Hall Effect Flow Meter Do not connect shield drain wire Reed Switch at this end! Flow Meter...
  • Page 14 Chart Recorder BLEED FEED N.C. N.O. N.C. N.O. L2/N GROUND STUD GRN 120V GRN/YEL 240V BLOWDOWN FEED N.C. N.O. N.C. N.O. IF MOTORIZED BALL VALVE WHT 120V BLU 240V BLK 120 BRN 240V BLK 120V BRN 240V Bleed Solenoid/ Motorized Ball Valve PUMP Figure 4a WBL400 Outputs...
  • Page 15 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 GROUND STUD GRN 120V GRN 120V GRN/YEL 240V GRN/YEL 240V BLOWDOWN AUX 1 AUX 2 AUX 3 AUX 4 ALARM L2/N L2/N...

  • Page 16: Function Overview

    FUNCTION OVERVIEW Front Panel Backlit LCD Display Output LEDs (WBL400 only has Blowdown and Feed LEDs) Setting Adjustment Keys Menu/Function Keys USB LED On/Off Power Switch USB Connector Figure 5 WBL410 Front Panel Display A summary screen is displayed while the WBL controller is on. This display shows a bar graph of the conductivity relative to the set point, the actual conductivity value, and current operating conditions.

  • Page 17: Keypad

    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. The function keys are , and (previous).

  • Page 18: Operation

    OPERATION These units control continuously while power is applied. Programming is accomplished via the local keypad and display. To view the top level menu, press any key. The menu structure is grouped by inputs and outputs. Each input has its own menu for calibration and unit selection as needed. Each output has its own setup menu including set points, timer values and operating modes as needed.
  • Page 19 Figure 7 Main Menu...

  • Page 20: Conductivity Menu

    Conductivity Menu The conductivity menu provides the following settings: Calibration, Self Test, Unit selection, and sampling mode setup. Additional settings are also discussed below. Refer to figure 8, Conductivity Menu Chrt. Calibrate To Calibrate the conductivity, use either a hand held meter, or a standard solution, and adjust the controller to match.
  • Page 21 BlowTime This is the length of time of the blowdown used in Intermittent Sampling with Timed Blowdown sampling mode. This is set in Hours:Minutes and can be set from 1 minute to 8 hours 20 minutes. At the end of the blowdown time, the controller will check the conductivity of a held sample once again. If the conductivity is still above the set point, another blowdown cycle will occur.

  • Page 22: Temperature Menu

    Temperature Menu The Temperature menu provides the following settings: Calibration, Unit selection. The Temperature menu will be indicated on the display by one of the following: Temperature Normal operation Temp 70°F Normal operation Temp Error Indicates that there is a problem with the temperature input. See figure 9. Calibrate This menu only appears if a temperature element is connected at power-up.

  • Page 23: Blowdown Menu

    Blowdown Menu The Blowdown Menu provides the following settings: Set Point, Dead Band, Time Limit, Control Direction, HOA. The Blowdown menu will be indicated on the display by one of the following: (The 'A' indicates that the output is being controlled automatically.) Blowdn A Indicates that the blowdown output is currently OFF.
  • Page 24 BloDwn Menu Possible status screens BloDwn μ 2000 S/cm 68° F BloDwn Sample BloDwn 1:01:15 BloDwn Timeout BloDwn No Flow EXIT ENTER PREV. NEXT BloDwn 1:01 BloDwn 1:01 BloDwn 1:01:15 BloDwn 1:01:15 BloDwn 1:01 BloDwn 1:01 Reset Timer Control Dir HAND OFF >...

  • Page 25: Feed Menu

    Feed Menu The Chemical Feed Menu adapts to the selected Feed output mode. Note: When programming the unit for the first time, it is recommended that the Chemical Feed Mode Menu be chosen first, then step through the rest of the Feed Menu indicated in Figure 11. The modes are defined as follows: Blowdown and Feed Mode turns the Feed output On and Off at the same time as the Blowdown and Feed with...
  • Page 26 Feed Based on Time/Cont. (Time per contact.) This determines the length of time that the feed pump should be on for each contact Water Contactor that is received. Mode ÷ Contacts By This setting allows a divider to be entered. The divider will count actual contacts from the meter until the setting is reached before a contact is considered to be received.
  • Page 27 Figure 11 Feed Menu...
  • Page 28 Figure 12 Auxiliary (1-4) Menu...

  • Page 29: Time Menu

    Time Menu This menu has only one choice, to set the Time used for Datalogs. This menu will appear as follows: Time: Mon 10:20 Set Time Press ENTER to set the Time. Use the arrow keys to adjust the day and time and then press ENTER to store or EXIT to discard.

  • Page 30: Alarm Menu (Only For Wbl400 Models)

    Alarm Menu (Only for WBL400 models) The possible status screen for this menu are shown below. Note: Alarms produce a top level status message only. There is no alarm relay available. Alarm OFF Alarm LOW ALRM Alarm HI ALRM Alarm % Low This is the % below the blowdown set point that the LOW ALARM will activate.

  • Page 31: 4-20Ma Menu

    4-20mA Menu This menu is only available if the 4-20mA output is installed in the controller. This menu provides for scaling and calibrating the output. The 4-20mA menu screen appears as follows: 4-20mA 9.20mA This indicates that the current output of the 4-20mA card is 9.20 mA. Set 4mA Pt This conductivity setting will correspond to a 4 mA output from the controller.

  • Page 32: 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 33: 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 34 Datalog Menu 2000 µS 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 35: 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 36: 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 executable (.exe file extension) file stored on the root directory of the stick.

  • Page 37: Maintenance

    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...

  • Page 38: Troubleshooting

    TROUBLESHOOTING CAUTION: Disconnect power to the controller before opening front panel! Troubleshooting and repair of a malfunctioning controller should only be attempted by qualified personnel using caution to ensure safety and limit unnecessary further damage. Contact the factory. Error Messages HIGH ALARM - (main summary screen only) The summary screen will display an H at the right end of the bar graph if the conductivity rises above the high conductivity alarm set point.

  • Page 39: Conductivity Readout Does Not Change

    BLOWDOWN TIMEOUT This error condition will stop conductivity control. It is caused by the bleed output being activated for longer than the programmed Blowdown Time Limit. Possible Cause Corrective Action Programmed value too low for normal conditions. Increase Blowdown Time Limit. Check for clogged strainer.

  • Page 40: Procedure For Evaluation Of Conductivity Electrode

    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 10746 USA TEL: 508-429-1110 FAX: 508-429-7433 WEBSITE: www.walchem.com...

This manual is also suitable for:

Wbl410 series

Table of Contents