W A L C H E M IWAKI America Inc. WDB400 Dual Boiler Controller WDB400 Series Dual 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 WDB400 Series controllers offer conductivity control of boiler water and control of chemical feed of two separate boilers.
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 Input Power 100-240 VAC, 50/60 Hz, 8A Fuse: 1.
2.4 WDB Variables and their Limits Low Limit High Limit 0.200 ppm/µS/cm 5 minutes 1 minute 1 second 1 minute 1 minute 0 -50% 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 WDB series controller and instruction manual. Any options or accessories will be incorporated as ordered. 3.2 Mounting the electronic enclosure The WDB 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.
Flow Rate in Lbs/hr for Various Orifices 18000 16000 14000 12000 Lbs/hr 1/8 inch dia 10000 3/16 inch dia 1/4 inch dia 8000 5/16 inch dia 6000 4000 2000 0 10 20 30 40 50 60 70 80 90 100 200 300 Pressure PSI Flow Control Valve Maximum Flow Rates in Lbs/hr 25000 20000 1/2" 150 PSI Lbs/hr 15000 1/2" 300 PSI 3/4" 150 PSI 10000 3/4" 300 PSI 5000 0 20 30 40 50 60 70 80 90 Pressure PSI 6 100 150 200 300
FIGURE 1 RECOMMENDED INSTALLATION INTERMITTENT SAMPLING Skimmer Blowdown Line 3/4" Min. up to Electrode 10 ft. max. with minimal valves, elbows & unions CONDUCTIVITY ELECTRODE Full Port Block Valve ¾" TEE 2 ft. minimum Motorized Ball or Solenoid Valve Flow Control Valve or Orifice Union 1 to 3 ft. maximum Manual Blowdown (Normally Closed) To Drain TO DRAIN Boiler Controller PREV NEXT ENTER EXIT Install accessories either vertically or horizontally, per manufacturer's instructions. www.
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 3, below. Your WDB series controller will arrive from the factory prewired or ready for hardwiring.
AUX B BLOWDOWN A CONDUCTIVITY ELECTRODE A WATER METER B (OPTIONAL) SPARES CONDUCTIVITY ELECTRODE B 4-20mA 1 (OPTIONAL) 4-20mA 2 (OPTIONAL) SPARE POWER BLOWDOWN B WATER METER A (OPTIONAL) FLOW SWITCH B (OPTIONAL) AUX A ALARM Figure 3 Conduit/Wiring Configuration 9 FLOW SWITCH A (OPTIONAL)
R- R+ R- R+ FEED BLEED L2 L2 N.C. N.O. N.C. N.O.
SYSTEM B SYSTEM A Chart Recorder Chart Recorder L2 L2 L2 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. IN- FLOW SW 1 IN+ IN+ IN- FLOW MTR 1 IN- IN+ COND T+ T- RED +5V BLK IN+ FLOW SW 2 FLOW MTR 2 COND T+ T- RED +5V BLK L1 L2/N GROUND STUD GRN 120V GRN/YEL 240V GRN 120V GRN/YEL 240V TO GROUND STUD IF MOTORIZED BALL VALVE Blowdown Solenoid/ Motorized Ball Valve BLOWDN B N.O. N.C.
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 6 Front Panel 4.2 Display A summary screen is displayed while the WDB controller is on.
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 8 Main Menu 15 ENTER ENTER PREV. A: 1000 µs 77°F Temperature Same as A A 100 B 100 µs Boiler B A: 1000 µs Blowdown 77°F A 100 B 100 µs Time:Sun 3:00 NEXT A: 1000 µs Aux 1 77°F A 100 B 100 µs Access Code B 100 µs A: 1000 µs 77°F 4-20 mA 9.32 mA A 100 Config If using Intermittent Sampling, this menu will display “Cond” then the stage of the Sampling currently active.
5.2 Conductivity (A or B) 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 9, Conductivity Menu Chart. 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.
Conductivity (A or B) Menu Possible status screens A: 2000 S 68° F Conductivity EXIT Cnd Wait 23:50 Cnd Cnd Cnd Cnd 10:00 10:00 10:00 10:00 Samp Xtnd BlwDn Hold ENTER PREV. NEXT 4 Cond 1000 S Self Test Cond 1000 S Calibrate EXIT EXIT ENTER Calibrate Cond 1333 ppm ENTER EXIT Cond Self Test 1000 S/cm Calibrate Cond 2000 S/cm 4 Cond Units 4 Cond Self Test 666 ppm 4 1000 S S Cond 1000 S ppm C.F. 0.
5.3 Temperature (A or B) 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 270°F Normal operation Temp Error Indicates that there is a problem with the temperature input. See figure 10. Calibrate This menu only appears if a temperature element is connected at power-up.
5.4 Blowdown (A or B) 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 TIMEOUT Indicates length of time that the blowdown output has been ON.
Figure 11 Blowdown (A or B) Menu 21 ENTER 68° F 1:01 PREV. Press Enter key to enter menu. Press Exit key to exit menu. Blinking fields may be edited with the adjust arrows. Press Enter when modification is complete to return to BloDwn Menu Level.
5.5 Auxiliary Menu The Auxiliary output may be used either to control a chemical feed pump or as an alarm. When setting up the controller for the first time, the Output Mode should be selected first. Press ENTER at the Aux menu, scroll to the Output Mode menu and press ENTER again . To change the output mode, press ENTER again and use the UP or DOWN arrow keys to toggle between "Feed" and "Alarm." Press ENTER when the correct choice is displayed. 5.5.
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.
Figure 12 Auxiliary Menu 24 ENTER Output Mode ALARM Output Mode FEED EXIT FEED ENTER Aux Output Mode EXIT A:2000 S 68° F Aux A HI ALRM A NO FLOW A TIMEOUT A LO ALRM A HI ALRM NEXT Aux Aux PREV. Aux A TIMEOUT % of Time 10 Aux A TIMEOUT % of BoDwn 10 4 Aux A TIMEOUT Contacts by 1 A TIMEOUT Aux Cycle Time 10:00 Aux A TIMEOUT Max Time 99:00 Aux A TIMEOUT Vol to Init 5:00 3 2 1 Menu choices that appear when Feed as % of Time mode is selected.
5.6 WM1 and WM2 Menu 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 4-20mA (A or B) Menu This menu is only available if the 4-20mA output board is installed in the controller. Installing this option board in the left hand position in the controller will assign it to Boiler A. Installing a 4-20mA option board in the right hand position assigns the output to Boiler B. See Figure 4. 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.
5.9 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.
5.10 Datalog Menu 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 17 Datalog Menu 30 Datalog Copy Reset Log ENTER EXIT Datalog Transfer Success
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. Press the Enter key to export the configuration file from the controller to the stick. The file name will be UCF.ini.
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. 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 WDB 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 electrodes. Frequency The electrodes should be cleaned periodically. The frequency required will vary by installation. In a new installation, it is recommended that the electrodes 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.
BLODOWN TIMEOUT This error condition will stop conductivity control. It is caused by the blowdown 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 blowdown valve wiring. Check controller relay.
7.2 Conductivity Readout Does Not Change If the readout is stuck at or near zero: Possible Cause 1. Dry electrode 2. Electrode is disconnected. Corrective Action Check for flow through system. Check wiring to electrode. Go to self-test menu, as described in section 5.2 If readout changes to 9001100, the problem is with electrode or connections. (see section 7.3) If still at zero, problem is with controller. Consult the factory. If the readout is stuck at another number: Possible Causes 1.
With power removed, remove the terminal block that has the black (hot) wires from all of the pigtails (TB2). This simply pulls up off some metal pins. Check these pins for corrosion. If they seem coated with anything, scrape off the coating by replacing and removing the terminal block several times. Restore power and manually activate the relay.
Model Code - WDB400 Voltage Output Sensor U (USB) 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 de archivos FIVE BOYNTON ROAD HOPPING BROOK PARK HOLLISTON, MA 01746 USA TEL: 508-429-1110 FAX: 508-429-7433 Web: www.walchem.
