W A L C H E M IWAKI America Inc. WBL400/410 Boiler Controller WBL400/410 Series Boiler 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 Measurement Performance ......................................................................................................2 2.2 Electrical: Input/Output ................................................
1.0 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.
2.0 SPECIFICATIONS 2.1 Measurement Performance 2.2 Conductivity Range Conductivity Resolution Conductivity Accuracy 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 Temperature Range Temperature Resolution Temperature Accuracy 32 - 401°F (0 - 205°C) 0.1°C ± 1% of reading Electrical: Input/Output 100-240 VAC, 50/60 Hz, 8A Fuse: 1.
2.4 WBL Variables and their Limits Low Limit High Limit Conductivity menu 0.200 ppm/µS/cm 1.
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 WBL series controller and instruction manual. Any options or accessories will be incorporated as ordered. 3.2 Mounting the electronic enclosure The WBL series controller is supplied with mounting holes on the enclosure.
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. 7. Install the motorized ball valve or solenoid valve per the manufacturer’s instructions. 8.
5.
Skimmer Blowdown Line 3/4" Min. up to Electrode 10 ft. max. with minimal valves, elbows & unions CONDUCTIVITY ELECTRODE Full Port Block Valve ¾" Cross 2 ft. minimum Motorized Ball or Solenoid Valve Flow Control Valve or Orifice Union 1 to 3 ft. maximum Manual Clean-Out (Normally Closed) Manual Blowdown (Normally Closed) To Drain TO DRAIN RECOMMENDED INSTALLATION INTERMITTENT SAMPLING Install accessories either vertically or horizontally, per manufacturer's instructions.
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. Your WBL series controller will arrive from the factory prewired or ready for hardwiring.
CONDUCTIVITY ELECTRODE FLOW SWITCH (OPTIONAL) POWER FEED SPARES BLOWDOWN 4-20mA (OPTIONAL) FLOW METER (OPTIONAL) PLUG Figure 2a WBL400 Conduit Wiring CONDUCTIVITY ELECTRODE FLOW SWITCH (OPTIONAL) POWER AUX1 AUX2 AUX4/ALARM SPARES BLOWDOWN PLUG 4-20mA (OPTIONAL) AUX3 Figure 2b WBL410 Conduit Wiring 9 FLOW METER (OPTIONAL)
FEED BLEED L2 L2 N.C. N.O. N.C. N.O.
Chart Recorder FEED BLEED L2 L2 N.C. L1 N.O. N.C. N.O. L2/N GR GRN/Y N 120V E L 240 V GROUND STUD GRN 120V GRN/YEL 240V BLOWDOWN N.C. N.O. FEED N.C. N.O. IF MOTORIZED BALL VALVE W BL HT U 12 24 0 0V V WHT 120V BLU 240V BLK 120 BRN 240V NOTE: When connecting a motorized ball valve, the pre-wired pigtail must be removed and the valve requires two wires, one to N.O. to open the valve and one to N.C. to close the valve.
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 L2/N L2/N L2/N BLOWDOWN N.O. N.C. AUX 1 N.C. N.O. WHT 120V BLU 240V L2/N WHT 120V BLU 240V L2/N WHT 120V BLU 240V WHT 120V BLU 240V L2/N AUX 2 N.C. N.O. BLK 120V BRN 240V AUX 3 N.C. N.O. BLK 120V BRN 240V GRN 120V GRN/YEL 240V TO GROUND STUD ALARM N.O. N.C.
4.0 FUNCTION OVERVIEW 4.1 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 4.2 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.
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.
5.0 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. After ten minutes of inactivity in the menu, the display will return to the summary display.
Figure 7 Main Menu 16 77°F OFF 1000 µs 77°F Time : SUN 3:00 77°F OFF 1000 µs WM1 77°F 1000Gal Press Enter key to enter menu. Press Exit key to exit menu. Blinking fields may be edited with the adjust arrows. Operation 1000 µs Aux 4 A 3 1000 µs BloDwn A 1000 µs WM2 1000 µs Feed A NEXT 2 1000 µs 77°F Temperature 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 Chrt. Calibrate To Calibrate the conductivity, use either a hand held meter, or a standard solution, and adjust the controller to match. Once Calibrate is entered, the unit continuously displays conductivity readings.
BlowTime (H) 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.
Possible status screens Cond Wait 23:50 Cond Samp 10:00 Cond Xtend 10:00 Cond BlwDn 10:00 2000 S/cm 68° F Conductivity Cond Hold EXIT 10:00 ENTER PREV. NEXT 1.2.3. 4 Cond Calibrate EXIT 1000S Cond Self Test EXIT ENTER Calibrate Cond 1333 ppm Cond Units ENTER EXIT Cond Self Test 666 ppm 4 4 1000S S/cm Cond ppm C.F. 1000S 0.666 Cond 1000S Sample Mode C ENTER EXIT Units S/cm S/cm Units ppm ppm Cond Self Test 1000 S/cm Calibrate Cond 2000 S/cm 4 1000S . . . .
5.3 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. Man Temp This menu appears only if no temperature element is connected at power-up.
5.4 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 OFF Indicates that the blowdown output is currently OFF. Blowdn A 10:00 Blowdn A TIMEOUT Indicates that the output has been on longer than the programming time limit.
BloDwn Menu Possible status screens BloDwn BloDwn BloDwn BloDwn 2000 S/cm 68° F BloDwn 1:01:15 EXIT OFF Sample Timeout No Flow ENTER PREV. NEXT 1 2 BloDwn Set Point 1:01:15 2000 BloDwn 1:01 Dead Band 200 BloDwn Time Limit BloDwn Reset Timer 1:01 1:15 1:01 N 2 BloDwn Control Dir EXIT Legend 1 Appears only if limit timer has expired. 2 Appears only if continuous sampling has been selected in Conductivity Menu..
5.5 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: A Blowdown and Feed with Optional Lockout Blowdown and Feed Mode turns the Feed output On and Off at the same time as the Blowdown output.
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 2000 S/cm 68° F Feed 21:05 EXIT ENTER Feed Off Feed Feed 21:05 Lockout Feed No Flow Feed Timeout Feed Menu ONLY FOR WBL400 MODELS PREV.
Figure 12 Auxiliary (1-4) Menu 26 ENTER Menu choices that appear when Feed based on Water Contactor input is selected. 4 Menu choices that appear when Feed based on Paddlewheel Input is selected. 3 1 Menu choices that appear when Feed as % of BloDwn mode is selected. 2 Menu choices that appear when Feed as % of Time mode is selected. Legend Output Mode ALARM Output Mode FEED EXIT FEED ENTER Output Mode Aux EXIT A:2000 S 68° F Aux A HI ALRM A LO ALRM A HI ALRM NEXT Aux Aux PREV.
5.6 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. 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.
5.7 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.
5.8 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. If the set point is 1000 and the % Low setting is 20 then the Low alarm will activate at 800. Alarm % High This is the % above the blowdown set point that the HIGH ALARM will activate.
5.9 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. Set 20mA Pt This conductivity setting will correspond to a 20mA output from the controller.
5.10 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.
5.11 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 Datalog Current Datalog Next 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 Prev ENTER EXIT Datalog Transfer Success Figure 18 Datalog Menu 33 Datalog Copy Reset Log ENTER EXIT Datalog Transfer Success
5.12 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.
5.13 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. Press the Enter key to import the software upgrade file from the stick to the controller. The controller will display the progress of the file import process.
6.0 MAINTENANCE The WBL 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.
7.0 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 caution to ensure safety and limit unnecessary further damage. Contact the factory. 7.1 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.
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. Blowdown flow rate too low. Check for clogged strainer. Check for insufficient pressure differential. Blowdown valve not opening. Check for faulty blowdown valve. Check blowdown valve wiring. Check controller relay.
7.3 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. The display should read 1000 ± 100µS/cm.
Model Code WBL4 Control 0 - Voltage Output Sensor U (USB) CONTROL 0 = Two (2) powered relays 1 = Six (6) powered relays VOLTAGE 1 = 120 VAC, prewired 5 = 100-240 VAC, conduit OUTPUT N = No data output 4 = Isolated 4-20 mA output 2 = Two isolated 4-20 mA outputs SENSOR N = No electrode 5 = Standard electrode (up to 250 psi) USB FEATURES U = Integrated datalogging, event/reset logging, and configuration file import/export FIVE BOYNTON ROAD TEL: 508-429-1110 HOPPING BROOK PARK FAX: 508-429-7433 H
