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Walchem WDB400 Series Instruction Manual

Summary of WDB400 Series

  • Page 1

    Wdb400 series dual 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 w a l c h e m wdb400 controllers.

  • Page 2

    Notice © 2008 walchem corporation 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 corporation. Such information and descriptions may not be copied or reproduce...

  • Page 3

    Table of contents 1.0 introduction....................................................................................................................1 2.0 specifications .................................................................................................................2 2.1 measuremen...

  • Page 4

    1 1.0 introduction the walchem wdb400 series controllers offer conductivity control of boiler water and control of chemical feed of two separate boilers. The chemical feed pump may be selected to operate in one of the following modes: feed and blowdown feed and blowdown with lockout feed as a percen...

  • Page 5

    2 2.0 specifications 2.1 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 tem...

  • Page 6

    3 2.4 wdb 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 hold time 1 second 499 min: 59 sec blowdown time 1 minute 8 hrs: 20 min ma...

  • Page 7

    4 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 controlle...

  • Page 8

    5 5. Mount the electrode in the side branch of a cross in a horizontal run of pipe. This will minimize entrapment of steam around the electrode and will allow any solids to pass through. 6. There must be a flow restriction after the electrode and/or control valve in order to provide back pressure. T...

  • Page 9

    6 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 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 10 20 30 40 50 60 70 80 90 100 200 300 pressure psi lbs/hr 1/8 inch dia ...

  • Page 10

    7 figure 1 recommended installation intermittent sampling install accessories either vertically or horizontally, per manufacturer's instructions. To drain skimmer blowdown line 3/4" min. Up to electrode full port block valve manual blowdown (normally closed) motorized ball or solenoid valve flow con...

  • Page 11: Caution

    8 3.4 icon definitions symbol 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 3.5 electrical installation the various standard wiring op...

  • Page 12

    9 power aux a blowdown a conductivity electrode a flow switch a (optional) water meter a (optional) water meter b (optional) blowdown b alarm spares spare aux b 4-20ma 1 (optional) 4-20ma 2 (optional) conductivity electrode b flow switch b (optional) figure 3 conduit/wiring configuration.

  • Page 13

    10 power supply (115 vac or 230 vac) contact closure: polarity not critical reed switch flow meter polarity not critical in- flow mtr 1 flow mtr 2 in+ flow sw 1 in+ in- in+ +5v blk red cond t- t+ bleed n.C. Feed n.O. N.C. N.O. L2 l2 l1 l2/n hall effect flow meter g r e e n w h it e ground stud shiel...

  • Page 14

    11 pump alarm blowdown solenoid/ motorized ball valve l1 l2/n l2 l2 l2 l2 l2 l2 bleed n.C. N.O. N.C. Boi 1 n.O. N.C. Feed n.C. Bio 2 n.O. N.C. N.O. N.O. Alarm n.C. N.O. L2/n l2/n l2/n l2/n l2/n l2/n blowdn a n.C. N.O. Blowdn b n.O. N.C. Aux a n.C. Aux b n.O. N.C. N.O. Alarm n.C. N.O. Ground stud w h...

  • Page 15

    12 4.0 function overview 4.1 front panel figure 6 front panel 4.2 display a summary screen is displayed while the wdb controller is on. The operating conditions that are displayed on the bottom line of this display are hi alarm a, hi alarm b, low alarm a, low alarm b, temp err a, temp err b, cond er...

  • Page 16

    13 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 (previ...

  • Page 17

    14 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 ne...

  • Page 18

    15 a 100 b 10 0 µs boiler a a 1 00 b 100 µs n o rmal main men u press enter key to enter menu. Pres s ex it key t o e x it me nu. Blinking fie ld s may be e d ited w ith the a d just a rro ws. Ne xt pr ev . En te r ex it en te r ex it operation a 10 0 b 1 0 0 µs bo ile r b a 100 b 10 0 µs ac ces s c...

  • Page 19

    16 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 ha...

  • Page 20

    17 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 on...

  • Page 21

    18 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 wit...

  • Page 22

    19 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 i...

  • Page 23

    20 figure 11 blowdown (a or b) menu.

  • Page 24

    21 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...

  • Page 25

    22 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 co...

  • Page 26

    23 chem feed mo de a ble e d & feed ch e m fee d mode c fee d % of t ime chem feed mo de b fe e d % of bl e e d ch em fee d mode d w a ter co ntactor a u x c h em f eed mode ti m e ou t aux time ou t h and o f f > a u t o aux o f f feed s e tup a au x of f a aux 21:0 5 a aux l o ckou t a aux no flow...

  • Page 27

    24 5.6 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. 2000 s 68° f time sat 12:15 μ tim...

  • Page 28

    25 5.7 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 on the lower power supply board in the controller will assign it to boiler a. Installing a 4-20ma option board on the top front panel assembly assigns the o...

  • Page 29

    26 5.8 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 cod...

  • Page 30

    27 5.9 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 ...

  • Page 31

    28 datalog current datalog datalog copy event log datalog menu enter exit 67° f datalog 2000 µs datalog transfer success next prev datalog copy reset log next prev enter exit enter exit enter exit datalog transfer success datalog transfer success possible status screens transfer success transfer fai...

  • Page 32

    29 5.10 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. Place a usb flash drive with at least 10 mb capacity into the usb port on the front panel of the co...

  • Page 33

    30 5.11 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...

  • Page 34

    31 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 elect...

  • Page 35

    32 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 erro...

  • Page 36

    33 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...

  • Page 37

    34 7.2 conductivity readout does not change if the readout is stuck at or near zero: possible cause corrective action 1. Dry electrode check for flow through system. 2. Electrode is disconnected. Check wiring to electrode. Go to self-test menu, as described in section 5.2 if readout changes to 900- ...

  • Page 38

    35 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 tim...

  • Page 39

    36 tel: 508-429-1110 fax: 508-429-7433 www.Walchem.Com.