Table of Contents
Related Manuals for Walchem WCT400 Series
Summary of Contents for Walchem WCT400 Series
- Page 1 W A L C H E M IWAKI America Inc. WCT400/410 Controllers WCT400/410 Series Cooling Tower Conductivity 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS INTRODUCTION ........................1 SPECIFICATIONS ........................2 Measurement Performance ....................2 Electrical: Input/Output ......................2 Mechanical ..........................2 WCT Variables and their Limits ....................3 UNPACKING & INSTALLATION ....................4 Unpacking the unit ......................... 4 Mounting the electronic enclosure ..................4 Installation .......................... -
Page 4: Introduction
INTRODUCTION The Walchem WCT400 Series controllers offer conductivity and watermeter-based control of cooling tower water, control of corrosion/scale inhibitor feed, and with the WCT410 models, control of two biocide pumps. The inhibitor pump may be selected to operate in one of the following modes:... -
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 - 158°F (0 - 70°C) Temperature Resolution 0.1°C Temperature Accuracy ±... -
Page 6: Wct Variables And Their Limits
WCT 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 Bleed Menu Set Point 0 µS/cm... -
Page 7: 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 WCT400 series controller and instruction manual. Any options or accessories will be incorporated as ordered. - Page 8 COOLING TOWER SOLENOID VALVE WATER METER Cooling Tower Controller METERING PUMPS PREV NEXT ENTER EXIT HEAT www.walchem.com EXCHANGER CIRCULATING PUMP 10.0" (254 mm) FLOW SWITCH Cooling Tower Controller FLOW PREV NEXT ENTER EXIT www.walchem.com ELECTRODE FLOW SAMPLE VALVE 1/4” POLYPRO PANEL...
- Page 9 TYPICAL INSTALLATION INTERMITTENT SAMPLING Cooling Tower Controller TO ELECTRODE PREV NEXT TO SOLENOID ENTER EXIT www.walchem.com SHUTOFF VALVE CONSTANT 110 VOLTS PE DISCHARGE CITY WATER TUBING MAKEUP SPRAY PUMP SPRAY TOWER CHEMICAL PUMP SANITARY (A) Unions; installed for replacement of...
- Page 10 TYPICAL INSTALLATION SUBMERSION ELECTRODE Cooling Tower Controller PREV NEXT ENTER EXIT COOLING www.walchem.com TOWER 110 VOLT AC OUTLET (OPTION "B") PROBE VALVE CHEMICAL OPEN X Y Z X PUMP SUMP SANITARY CIRCULATION SERVER VALVE PUMP (OPTION "A") SANITARY SERVER CHEMICAL TANK (X) Unions;...
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Page 11: 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. CONDUCTIVITY... - Page 12 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 Reed Switch Flow Meter Polarity not Critical Conductivity Electrode...
- Page 13 N.O. to open the valve and one to N.C. to close the valve. BLK 120V BRN 240V Bleed Solenoid/ Motorized Ball Valve PUMP Figure 4a WCT400 Outputs...
- Page 14 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 BLEED FEED BIO 1 BIO 2 ALARM L2/N L2/N L2/N L2/N...
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Page 15: Function Overview
FUNCTION OVERVIEW Front Panel Cooling Tower Controller Backlit LCD Display Output LEDs (WCT400 only has Bleed and Feed 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 WCT 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 16: 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 ENTER, EXIT, NEXT, and PREV (previous). NEXT and PREV scroll through the various menu choices. -
Page 17: 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 18 Figure 7 Main Menu...
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Page 19: 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 Chart. Calibrate To Calibrate the conductivity, use either a hand held meter, or a buffer solution, and adjust the WCT controller to match. - Page 20 Possible status screens Conductivity Menu Cond Wait 23:50 2000 S 68° F Cond Samp 10:00 Conductivity Cond Xtnd 10:00 EXIT ENTER PREV. NEXT Cond 1000µS Cond 1000µS Cond 1000µS Cond 1000µS Cond 1000µS Calibrate Self Test ppm C.F. 0.666 Sample Mode Units...
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Page 21: Temperature Menu
Temperature Menu The Temperature menu contains the following settings: Calibration and Units (if the Temp element is detected when the unit is powered on) or Manual Temp and Units (if no Temp sensor is detected at power up). Refer to the Temperature Menu chart, figure 9. If a "Temp Error"... -
Page 22: Bleed Menu
Bleed Menu The Bleed Menu provides the following settings: Set Point, Dead Band, Bleed Mode, Bleed Vol, Makeup Vol, HOA. The Bleed menu will be indicated on the display by one of the following: (The 'A' indicates that the output is being controlled automatically.) Hint: For easiest programming, program Bleed Mode first, then step through the rest of the bleed parameters. - Page 23 Figure 10 Bleed Menu...
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Page 24: Feed Menu
Feed Menu The Feed Menu adapts to the selected Feed output mode. Hint: For easiest programming, program Feed Mode first, then step through the rest of the feed parameters. The modes are defined as follows: Bleed and Feed with Optional Bleed and Feed Mode turns the Feed output On and Off at the same time as the Bleed output. - Page 25 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 26 Possible status screens Feed Menu Feed 2000 S/cm 68° F Feed 21:05 Feed 21:05 Feed Lockout Feed No Flow Feed Timeout EXIT ENTER PREV. NEXT (Hint: program Mode first) Menu choices depend on feed mode Feed Feed TIMEOUT TIMEOUT Chem Feed Mode HAND OFF >AUTO...
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Page 27: Wm1 And Wm2 Menus
WM1 and WM2 Menus The Water Meter 1 and 2 menus are used to set up the type of meter and how to convert the water meter signal into volume. The Water Meter menus will be indicated on the display as follows: WM1 100 Gal or Liters Reset Total This allows you to restart the totalizer display. -
Page 28: Bio1 And Bio2 Menus
Bio1 and Bio2 Menus These menus are only available on the WCT410 controller. The Bio 1 and Bio 2 menus are separate from each other but operate in exactly the same way. Each menu provides the following independent settings: Prog Bio Adds, Bio Pre-Bleed, Bio Lockout Time, Set Bio Mode, HOA. Bio menus may display the following screens: Bio 1 A Indicates that the Bio 1 output is off. - Page 29 Prog Bio 1 Add Press ENTER here to see a list of all of the biocide adds presently scheduled. The first screen displayed is for Today's Biocide add. Use the NEXT key to see Tomorrow's add or the PREV key to see Yesterday's add.
- Page 30 Possible status screens Bio 1 10:00 Biocide 1 Menu Bio 1 2:00 2000 S 68° F Bio 1 Bio 1 PRE BLD Bio 1 NO FLOW Bio 1 PENDING EXIT ENTER PREV. NEXT (Hint: program Mode first) Bio 1 Bio 1 PRE BLD Bio 1...
- Page 31 Possible status screens Bio 2 10:00 Biocide 2 Menu Bio 2 2:00 2000 S 68° F Bio 2 Bio 2 PRE BLD Bio 2 NO FLOW Bio 2 PENDING EXIT ENTER PREV. NEXT (Hint: program Mode first) Bio 2 Bio 2 Bio 2 PRE BLD...
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Page 32: Time Menu
Time Menu This menu has only one choice, to set the Time used for Biocide adds (WCT410) or Datalogs. This menu will appear as follows: Time: 2Mon 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 33: Conductivity Alarm Menu
Conductivity Alarm Menu This menu is available for both WCT400 and WCT410 series controllers, however, only the WCT410 has a relay output for the alarm. On both units the settings here determine when the (L) and (H) indicators appear on the summary screen. The Alarm menu screen will appear as follows:... -
Page 34: 4-20Ma Menu
This menu is only available if the 4-20mA output is installed in the controller. The 4-20mA output is available for either the WCT400 or WCT410 series controllers. This menu provides for scaling and calibrating the output. The 4-20mA menu screen appears as follows: 4-20mA 9.20mA... -
Page 35: Access Code Menu
5.11 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 36: Datalog Menu
Datalog Menu This menu is available on both the WCT400 and WCT410, 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 37: Config Menu
Config Menu This menu is available on both the WCT400 and WCT410 models. It 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. -
Page 38: Upgrade Menu
Upgrade Menu This menu is available in both WCT400 and WCT410 models. It 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. -
Page 39: Maintenance
MAINTENANCE The WCT 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 40: 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... -
Page 41: Conductivity Readout Does Not Change
BLEED TIMEOUT This error condition will stop conductivity control. It is caused by the bleed output being activated for longer than the programmed Bleed Time Limit. Possible Cause Corrective Action Programmed value too low for normal conditions. Increase Bleed Time Limit. Check for clogged strainer. -
Page 42: Procedure For Evaluation Of Conductivity Electrode
Procedure for Evaluation of Conductivity Electrode Can be used for troubleshooting low conductivity, high conductivity, conductivity stuck at 0, and/or conductivity stuck at a number other than 0. Try cleaning the electrode first (refer to Sect. 6.1). To find out if the electrode or the controller is faulty, step through the Self-Test menu, as described in section 5.2. - Page 43 Model Code WCT400 Voltage Output Sensor U (USB) WCT410 VOLTAGE 1 = 120 VAC, prewired 5 = 100-240 VAC, conduit OUTPUT N = No data output 4 = Single 4-20 mA output 2 = Dual 4-20 mA output (WDT) SENSOR...