Walchem WTCW100 Series Instruction Manual

Contents

Walchem WTCW100 Series Instruction Manual Manual pdf 6 page image

6 7Always route low voltage (sensor) signals with at least a 6” (15 cm) separation from AC voltage wiring.The electrodeless conductivity sensor should be placed as close to the controller as possible, to a maximum distanceof 120 ft. (37 m). Less than 20 ft. (6 m) is recommended.. The cable must be shielded from background electrical noise.Always route low voltage (sensor) signals with at least a 6” (15 cm) separation from AC voltage wiring. These sensorsare affected by the geometry and conductivity of their surroundings, so either maintain 6 inches (15 cm) of samplearound the sensor or ensure that any nearby conductive or nonconductive items are consistently positioned. Do not installthe sensor in the path of any electrical current that may be flowing in the solution, as this will shift the conductivity reading.IMPORTANT: To avoid damaging the female pipe threads on the supplied plumbing parts, use no more than 3 wrapsof PTFE tape and thread into the pipe FINGER tight only! DO NOT use any pipe dope, plumber’s putty or othersealing products that containdiacetone alcohol, as these attack the flow switch plastic! Use PTFE tape ONLY!Boilers:The conductivity sensor should be placed as close to the controller as possible, to a maximum distance of 250 ft.(76m). The cable MUST be shielded from background electrical noise. Use 24 AWG cable.Important Boiler Installation Notes: (see figures 3 and 4)1. Make sure the minimum water level in the boiler is at least 4-6 inches (10-15 cm) above the skimmer blowdownline. If the skimmer line is closer to the surface, it is likely that steam will be drawn into the line instead of boilerwater. The skimmer line must also be installed above the highest tube.2. Maintain a 3/4 inch minimum pipe ID with no flow restrictions from the tap for the boiler skimmer blowdownline to the electrode. If the ID is reduced below 3/4 inch, then flashing will occur beyond that point and the con-ductivity reading will be low and erratic. Minimize the usage of tees, valves, elbows or unions between the boilerand the electrode.3. A manual shut off valve should be installed so that the electrode can be removed and cleaned. This valve must bea full port valve in order to avoid a flow restriction.4. Keep the distance between the tap for the boiler skimmer line to the electrode as short as possible, to a maximumof 10 feet (3m).5. Mount the electrode in the side branch of a tee in a horizontal run of pipe. This will minimize entrapment ofsteam 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. Thisflow restriction will be either a flow control valve or an orifice union. The amount of the flow restriction willaffect the blowdown rate as well, and should be sized accordingly.7. Install the motorized ball valve or solenoid valve per the manufacturer’s instructions.For best results, align the hole in the conductivity electrode such that the direction of water flow is through the hole.Guide to Sizing Blowdown Valves and Orifice Plates1. Determine the Rate of Steam Production in Pounds per Hour:Either read off the boiler name plate (water-tube boilers) or Calculate from horsepower rating (fire-tube boilers):HP x 34.5 = lbs./hr. Example: 100 HP = 3450 lbs./hr2. Determine the Concentration Ratio (BASED ON FEEDWATER)A water treatment chemical specialist should determine the desired number of cycles of concentration. This is theratio of TDS in the boiler water to TDS in the feedwater. Note that feedwater means the water that is fed to theboiler from the deaerator and includes makeup water plus condensate return.Example: 10 cycles of concentration has been recommended3. Determine the Required Blowdown Rate in Pounds Per HourBlowdown Rate = Steam Production / (Concentration Ratio –1)4 mA Value 0 30,00020 mA Value 0 30,000Hand Output 0% 100%Set Point 0 30,000Proportional Band 0 30,000Minimum Output 0% 100%Maximum Output 0% 100%Off Mode Output (Proportional, PID, Flow Prop modes) 0 mA 21 mAPump Capacity (Flow Prop mode) 0 gal/hour or l/hour 10,000 gal/hour or l/hourPump Setting (Flow Prop mode) 0% 100%Specific Gravity (Flow Prop mode) 0 g/ml 9.999 g/mlTarget (Flow Prop mode) 0 ppm 1,000,000 pmError Output 0 mA 21 mAConfiguration settings Low Limit High LimitLocal Password 0000 9999Alarm Delay 0:00 minutes 59:59 minutes3.0 UNPACKING & INSTALLATION3.1 Unpacking the unitInspect the contents of the carton. Please notify the carrier immediately if there are any signs of damage to thecontroller or its parts. Contact your distributor if any of the parts are missing. The carton should contain a W100series controller and an instruction manual. Any options or accessories will be incorporated as ordered.3.2 Mounting the electronic enclosureThe controller is supplied with mounting holes on the enclosure. It should be wall mounted with the display at eye level,on a vibration-free surface, utilizing all four mounting holes for maximum stability. Use M6 (1/4” diameter) fastenersthat are appropriate for the substrate material of the wall. The enclosure is NEMA 4X (IP65) rated. The maximumoperating ambient temperature is 131°F (55°C); this should be considered if installation is in a high temperaturelocation. The enclosure requires the following clearances:Top: 2” (50 mm)Left: 8” (203 mm) (not applicable for prewired models)Right: 4” (102 mm)Bottom: 7” (178 mm)3.3 InstallationOnce the controller is mounted, the metering pumps may be located at any distance from the controller.PlumbingThe W100 series controllers can be supplied with a flow switch manifold designed to provide a continuously flowingsample of cooling water to the sensors. Please refer to Figures 2 through 6 below for some typical installation drawings.Cooling Towers:Tap off the discharge side of the recirculation pump to provide a minimum flow of 1 gallon per minute past the sensor.The sample must flow into the bottom of the manifold in order to close the flow switch, and return to a point oflower pressure in order to ensure flow. Install an isolation valve on both sides of the manifold to stop flow forsensor maintenance.The contacting conductivity sensor should be placed as close to the controller as possible, to a maximum distance of250 ft. (76 m). Less than 25 ft. (8 m) is recommended. The cable must be shielded from background electrical noise.