W A L C H E M IWAKI America Inc. WDT410 Controllers WDT410 Series Cooling Tower Conductivity plus pH/ORP Controller Instruction Manual Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA TEL: 508-429-1110 FAX: 508-429-7433 WEB: www.walchem.
Notice © 2014 WALCHEM, Iwaki America Inc. (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 permission of WALCHEM, 5 Boynton Road, Holliston, MA 01746.
TABLE OF CONTENTS 1.0 INTRODUCTION ..................................................................................................................... 1 2.0 SPECIFICATIONS .................................................................................................................. 2 2.1 2.2 2.3 2.4 3.0 3.1 3.2 3.3 3.4 3.5 4.0 4.1 4.2 4.3 4.4 4.5 4.6 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18 6.0 6.1 6.2 7.0 7.1 7.2 7.3 7.4 7.5 8.
1.0 INTRODUCTION The Walchem WDT410 Series controllers offer conductivity and watermeter-based control of cooling tower water, control of corrosion/scale inhibitor feed, control of two biocide or dispersant pumps and pH or ORP control for acid feed or chlorination/bromination.
2.0 SPECIFICATIONS 2.1 Measurement Performance Conductivity Range Conductivity Resolution Conductivity Accuracy Temperature Range Temperature Resolution Temperature Accuracy pH Range pH Resolution pH Accuracy (Calibrated) ORP Range ORP Resolution ORP Accuracy(Calibrated) 2.2 0 - 10,000 µS/cm (microSiemens/centimeter) 1 µS/cm 10 - 10,000 µS/cm ± 1% of reading 0 - 10 µS/cm ± 20% of reading 32 – 158°F (0 – 70°C) 0.1°C ± 1% of reading -2 to 16 pH units 0.01 pH units ±0.
2.3 Mechanical Enclosure Material NEMA Rating Dimensions Display Operating Ambient Temp Storage Temperature Graphite electrode pressure rating pH/ORP electrode pressure rating Stainless steel electrode pressure rating High pressure electrode & flow switch manifold pressure rating Flow switch manifold pressure rating Flow switch manifold connections 2.4 Polycarbonate NEMA 4X 8.5" x 6.5" x 5.
WDT Variables and their Limits (continued) Biocide Menus Low Limit Pre-Bleed 1 µS/cm High Limit 9,999 µS/cm (0 disables pre-bleed) Lockout Add Time Daily Adds All other modes 0 minutes 10 hours 0 minutes 0 minutes 144 minutes 1440 minutes 4 & 20 mA Settings 0 µS/cm 10,000 µS/cm 4 & 20 mA Settings 0 pH/-1500 mV 14 pH/1500 mV 0 9999 1% 0 pH/-1500 mV 50 % 14 pH/1500 mV 4-20 mA Menu pH/ORP mA Access Code New Value Alarms* High & Low conductivity (zero disables alarm) High & Low pH/ORP Datal
3.0 UNPACKING & INSTALLATION 3.1 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 WDT410 series controller and an instruction manual. Any options or accessories will be incorporated as ordered. 3.2 Mounting the electronic enclosure The WDT410 series controller is supplied with mounting holes on the enclosure.
3.4 Icon Definitions Symbol 3.5 Publication Description IEC 417, No.5019 Protective Conductor Terminal IEC 417, No. 5007 On (Supply) IEC 417, No. 5008 Off (Supply) ISO 3864, No. B.3.6 Caution, risk of electric shock ISO 3864, No. B.3.1 Caution Electrical installation The various standard wiring options are shown in figure 2, below. Your WDT410 series controller will arrive from the factory prewired or ready for hardwiring.
pH/ORP ELECTRODE SPARE CONDUCTIVITY ELECTRODE FLOW METER 1 (OPTIONAL) FLOW SWITCH (OPTIONAL) SPARE POWER BIO1 BIO2 BLEED 4-20mA #2 (OPTIONAL) ALARM 4-20mA #1 (OPTIONAL) pH/ORP FEED Figure 1 WDT410 Conduit Wiring 7 FLOW METER 2 (OPTIONAL)
COOLING TOWER METERING PUMPS Cooling Tower Controller PREV NE XT ENTER EXIT www.walchem.com HEAT EXCHANGER 22 ½" ¾“ NPTF Cooling Tower Controller FLOW WEL pH/ORP ELECTRODE FLOW SWITCH ¾“ NPTF PREV NEXT ENTER EXIT FLOW 17½" www.walchem.
TYPICAL INSTALLATION INTERMITTENT SAMPLING Cooling Tower Controller TO ELECTRODE PREV NEXT ENTER EXIT TO SOLENOID www.walchem.
TYPICAL INSTALLATION SUBMERSION ELECTRODE Cooling Tower Controller PREV NEXT ENTER EXIT www.walchem.com COOLING TOWER TO 110 VOLT AC OUTLET X Z Y X VALVE CHEMICAL PUMP TO SANITARY SEWER (OPTION "A") CHEMICAL TANK (OPTION "B") PROBE OPEN SUMP CIRCULATION PUMP X Y Z X VALVE TO SANITARY SEWER NOTE: LOCATION OF SOLENOID VALVE USING OPTION "A" OR OPTION "B" DEPENDS ON SYSTEM CONFIGURATION.
R- R+ R- R+ FEED BLEED L2 L2 N.C. N.O. N.C. N.O.
Chart Recorder Chart Recorder L2 L2 L2 L1 L2 L2 L2 BLEED N.C. N.O. BOI 1 FEED N.C. N.O. N.C. BIO 2 N.O. N.C. N.O. ALARM N.C. N.O. N.C. N.O. L2/N GROUND STUD GRN 120V GRN/YEL 240V GRN 120V GRN/YEL 240V BLK 120V BRN 240V GRN 120V GRN/YEL 240V TO GROUND STUD IF MOTORIZED BALL VALVE Bleed Solenoid/ Motorized Ball Valve BIO 1 N.C. N.O. FEED N.C. N.O. BIO 2 N.C. N.O.
4.0 FUNCTION OVERVIEW 4.1 Front Panel Backlit LCD Display Output LEDs Setting Adjustment Keys Menu/Function Keys USB LED On/Off Power Switch USB Connector Figure 5 4.2 Front Panel Display A summary screen is displayed while the WDT410 controller is on. This display shows the conductivity value on the upper left side, the pH/ORP value on the upper right side and current operating conditions.
4.3 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. ENTER is used to enter a submenu and to enter a value. EXIT is used to back up one menu level.
4.6 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. If the shutdown is expected for any longer than a day, and it is possible for the electrode to dry out, remove the electrode from the tee and store it in pH 4 buffer or cooling tower water. Take care to avoid freezing temperatures when storing the pH/ORP electrodes to avoid breakage of the glass. 5.
Figure 7 Main Menu 16 2 1 2000 S pH 4-20mA 2 2000 S pH Ctrl 1 5.05pH 67°F OFF 67°F Legend 2000 S 67°F Access Code DIS 2000 S Bio 1 2000 S Temperature Normal 2000 S Datalog 2000 S Bio 2 2000 S pH Input pH or ORP Adjusting Bleed Feed Pending BIO2 Add* Pre Bleed Feed Timeout BIO1 Add* pH/ORP Hi/Lo Alarm Lockout* 67°F 67°F OFF 67°F 5.05pH 1 NEXT Menu only appears when4-20 mA hardware is installed. 2000 S Config 2000 S Time: Sun PREV.
5.2 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 Self Test Units ppm C.F. Sample Mode C / I To Calibrate the conductivity, use either a hand held meter, or a buffer solution, and adjust the WDT controller to match. Once Calibrate is entered, the unit continuously displays conductivity readings.
Possible status screens Cond Wait 2000 S/cm 68° F Conductivity EXIT Conductivity Menu 23:50 Cond Samp 10:00 Cond Xtend 10:00 ENTER PREV. NEXT 1 Cond 1000µS Calibrate EXIT Cond 1000µS Self Test EXIT ENTER Cond Units ENTER EXIT 1000µS S/cm Cond 1000µS Sample Mode C ENTER EXIT Calibrate Cond 2000 S/cm Cond Self Test 1000 S/cm Units S/cm S/cm Calibrate Cond 1333 ppm Cond Self Test 666 ppm Units ppm ppm 1 Cond 1000µS ppm C.F. 0.
5.3 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" message appears or if the "Man Temp" menu appears after the unit is powered on, it indicates the temp element is not working properly. Refer to the Troubleshooting Section.
5.4 pH/ORP Input Menu Cal'd Displays the date of the last electrode calibration. 2 Pt Calibration for pH electrodes Press the ENTER key to perform a 2 point calibration of the electrode. If using manual temperature compensation, the first display will be: Cal Temp °F/C 68 Use the arrow keys to enter the actual temperature of the buffer solutions. If using automatic temperature compensation, this display will not appear. Press ENTER to continue.
Cal'd Press the ENTER key to perform a 2 point calibration of the electrode. If using manual temperature compensation, the first display will be: 2 Pt Calibration for ORP electrodes Rinse Electrode Remove the electrode from the process and rinse it off. Press ENTER to go to the next step. First Buffer This is a prompt to place the electrode in the first buffer. In a few seconds the controller will automatically go to the next step. Input XX mV The display will show the mV reading from the electrode.
1 Pt Calibration for ORP electrodes Rinse Electrode Remove the electrode from the process and rinse it off. Press ENTER to go to the next step. First Buffer This is a prompt to place the electrode in the first buffer. In a few seconds the controller will automatically go to the next step. Input 96 mV The display will show the mV reading from the electrode.
Figure 10 pH/ORP Input Menu 23
5.5 Bleed Menu The Bleed Menu provides the following settings: Set Point, Dead Band, Control Direction, 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 feed parameters.
Figure 11 Bleed Menu 25 ENTER PREV. Appears only in Continuous Sample Mode. Appears only if Limit Timer has expired. Appears only in Bleed Volume or Makeup Volume Mode. 2 3 NEXT ENTER L H Bleed Mode B BD Vol on MU Vol Bleed Mode Low Set Point Bleed Mode High Set Point EXIT Bleed A 1:01:15 Bleed A 1:01:15 Bleed Mode H Bleed A 1:01:15 Time Limit 1:15 Press Enter key to enter menu. Press Exit key to exit menu. Blinking fields may be edited with the adjust arrows.
5.6 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 Mode turns the Feed output On and Off at the same time as the Bleed output. The lockout setting determines the maximum allowable time for the Feed output. If this time is exceeded the Feed output is turned off and Locked out until the Bleed output turns off.
Feed Based on Water Contactor Mode Time/Cont. (Time per contact.) This determines the length of time that the feed pump should be on for each contact that is received. ÷ 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.
Possible status screens Feed A 2000 S/cm 68° F Feed A 21:05 EXIT Feed Menu Off Feed A 21:05 Feed A Lockout Feed A No Flow Feed A Timeout ENTER PREV. NEXT (Hint: program Mode first) Menu choices depend on feed mode Feed A TIMEOUT Chem Feed Mode Feed A TIMEOUT Lockout 99:00 Feed A HAND OFF TIMEOUT >AUTO 1 1 Feed A TIMEOUT Max Time 99:00 Feed A TIMEOUT % of Bleed 10 2 EXIT ENTER 2 Feed A TIMEOUT % of Time 10 Feed A TIMEOUT Cycle Time 10:00 Feed A TIMEOUT Time/cont.
5.7 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 Totalizer N This allows you to restart the totalizer display. Press the Up or Down arrow key to change the N to Y and press ENTER to reset the totalizer to 0 gal. The totalizer will count up to a maximum of 99,999,999. After that it will reset itself to zero.
5.8 pH/ORP Control Menu The pH/ORP Control Menu provides the following independent settings: Set Point, Dead Band, Time Limit, Control Direction, and HOA. The top level menu status line may display the following messages: Off, Intrlck, Timeout, or a time. "Off" indicates that the output is off. "Intrlck" indicates that a signal from a flow switch or level switch is stopping control and has disabled the control outputs.
Figure 14 pH/ORP Control Menu 31
5.9 Bio1 and Bio2 Menus 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 OFF Bio 1 A PENDING Bio 1 A PRE BLD Bio 1 A 4:50 Bio 1 A NO FLOW Indicates that the Bio 1 output is off.
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. Use the arrow keys to edit the starting time or length of the add.
Figure 15 Biocide 1 Menu 34
Figure 16 Biocide 2 Menu 35
5.10 Time Menu This menu has only one choice, to set the Time used for Biocide adds 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. If either biocide is set for a 2 or 4 week cycle, you can change the current week in the cycle by changing the week number. If the longest biocide cycle is 2 weeks, the 3Sun through 4Sat choices are not shown.
5.11 Cond Alarm Menu The Cond Alarm menu screen will appear as follows: Cond Alrm OFF Cond Alrm LOW ALRM Cond Alrm HI ALRM Set % Low This is the % below the bleed set point that the LOW ALARM will activate. If the conductivity set point is 1000 and the % Low setting is 20 then the Low alarm will activate at 800. The alarm can be disabled by setting it to zero. Set % High This is the % above the bleed set point that the HIGH ALARM will activate.
5.12 pH/ORP Alarm Menu The pH Alarm menu screen will appear as follows: pH Alrm OFF pH Alrm LOW ALRM pH Alrm HI ALRM Low Alarm This is the pH/ORP setting below which will produce a pH/ORP Lo Alarm indication on the main status screen. The alarm can be disabled by setting it to zero. Hi Alarm This is the pH/ORP setting above which will produce a pH/ORP Hi Alarm indication on the main status screen. The alarm can be disabled by setting it to zero.
5.13 4-20mA Menu (Optional) This menu is only available if the optional 4-20mA output board(s) is (are) 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. Set 20mA Pt This conductivity setting will correspond to a 20mA output from the controller.
5.14 pH/ORP 4-20mA Menu (Optional) This menu will only appear if the optional 4-20mA output board is installed on the pH input board. It is used to set the scale of the 4-20 mA output. It contains the following menu selections: 4 mA Point, 20 mA Point and Calibrate. 4mA Pt Use the arrow keys to enter the process value (in either pH units or mV if ORP) that you want to correspond to a 4 mA output from the controller.
5.15 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. With the access code enabled, any user can view any parameter, but cannot change them.
5.16 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. The controller has four logs, the Current Datalog, the Backup Datalog, the Event Log, and the Reset Log. All files are in a CSV format that may be opened in a spreadsheet such as Microsoft Excel.
2000 µS Datalog Menu 67° F Datalog ENTER EXIT Next Datalog Current Datalog Datalog Backup DataLog Prev Possible Status Screens Transfer Success Transfer Fail 1 ENTER EXIT Datalog Transfer Success Next Next Datalog Copy Event Log Prev ENTER EXIT Datalog Transfer Success Figure 23 Datalog Menu 43 Datalog Copy Reset Log Prev ENTER EXIT Datalog Transfer Success ENTER EXIT Datalog Transfer Success
5.17 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. Press the Enter key to export the configuration file from the controller to the stick. The file name will be UCF.ini.
5.18 Upgrade Menu This menu is used to upgrade the software to a newer version. 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. 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. Press the Enter key to import the software upgrade file from the stick to the controller.
6.0 MAINTENANCE The WDT 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. 6.1 Electrode Cleaning NOTE: The controller must be recalibrated after cleaning the electrode. Frequency The electrode should be cleaned periodically. The frequency required will vary by installation. In a new installation, it is recommended that the electrode be cleaned after two weeks of service.
6.2 Replacing the Fuses CAUTION: Disconnect power to the controller before opening front panel! Locate the fuses on the circuit board at the back of the controller enclosure. (See figure 3.) Gently remove the old fuse from its retaining clip and discard. Press the new fuse into the clip, secure the front panel of the controller and return power to the unit. Warning: Use of non-approved fuses can affect product safety approvals. Specifications are shown below.
LOW ALARM The summary screen will display an L at the left end of the bar graph and the alarm relay will trip. The controller will continue to check the conductivity and feed inhibitor as programmed. Possible Cause Corrective Action Sensor disconnected Reconnect. Check cable for continuity. Sensor dry Check tee for obstruction. Verify flow. Change location of electrode. Pre-bleed set too low Check pre-bleed setting compared to % low. Solenoid valve stuck open Repair or replace solenoid valve.
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. Bleed flow rate too low Check for clogged strainer. Check for insufficient pressure differential. Bleed valve not opening Check for faulty bleed valve. Check bleed valve wiring. Check controller relay.
pH HIGH ALARM This error message indicates that the pH is above the programmed pH High Alarm value. The pH will continue to be monitored, and the control output will be allowed to be activated. This troubleshooting assumes acid feed. Possible Cause Corrective Action Pumping problem Check chemical supply. Check pump for prime. Check tubing for blockage or leaks. ORP HIGH ALARM This error message indicates that the ORP is above the programmed ORP High Alarm mV value.
7.2 Conductivity Readout Does Not Change If the readout is stuck at or near zero: Possible Causes Corrective Action Dry electrode Electrode is disconnected Check for flow through system. Check wiring to electrode. Go to self-test menu as described in section 5.2. If readout changes to 900-1100, the problem is with electrode or connections. See section 7.3 If still at zero, problem is with controller. Consult the factory.
7.5 Procedure for checking relay outputs If any prewired output is not activating the device (pump, valve, etc.) attached to it: If the relay is internally powered, verify that the F2 fuse is OK by measuring the AC voltage between Neutral and both ends of the fuse. Verify that the pump or valve is not faulty by plugging it directly into a wall socket. In some controllers, certain relays are NOT internally powered. Check the instruction manual to determine if the relay is a dry contact type.
8.0 SERVICE POLICY The WDT410 series Cooling Tower Controller has a 2-year warranty on electronic components and a 1-year warranty on mechanical parts (keypad, terminal strip and relays). We stock circuit boards for immediate exchange after we have isolated the cause of the problem. Factory authorized repairs that are received by next-day-air will be returned within 24 hours. Normal priority for returns is two weeks.
Model Code WDT410 - Voltage Output Sensor U (USB) 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 N = No electrode WDT410 1 = SS + pH electrodes & tees, (inline or submersion), 20ft. (6.1m) cable 2 = SS + ORP electrodes & tees (inline or submersion), 20 ft. (6.1m) cable 3 = SS + pH electrodes & flow switch manifold on PP panel, 5ft. (1.
FIVE BOYNTON ROAD TEL: 508-429-1110 HOPPING BROOK PARK FAX: 508-429-7433 HOLLISTON, MA 01746 USA Web: www.walchem.
