Superior WATERGUARD WG-702 Bedienungsanleitung

WATERGUARD® WG-702

Water Quality Analyzer &

Controller

User Manual

Disclaimer

Chemical Injection Technologies does not accept any

responsibilityfor any damage caused to its products by

unauthorized personnel. Use of non-Chemical Injection

Technologies reagents and/or replacement parts will void all

warranties.

No part of this publication may be reproduced, transmitted,

transcribed, stored in a retrieval system, or translated into any

language or any computer language, in any form or by any third

party, without the prior written permission of Chemical

Technologies.

Table of

Contents

1 General Safety Precautions

............................................................................................... 8

Preface............................................................................................................................. 10

2.1 Intended Use

........................................................................................................... 10

2.2 Overview of

Chapters .............................................................................................. 10

Overview........................................................................................................................... 12

3.1 The WATERGUARD Solution

................................................................................. 12

3.2 Measurements and

Features................................................................................... 12

3.2.1 Wireless Management Package*

........................................................................

3.3 System Components

............................................................................................... 13

4 Installation

........................................................................................................................ 15

4.1 Selecting a Location

................................................................................................ 16

4.2 Site Requirements and

Installation

.......................................................................... 16

4.2.1 Mechanical Installation

Requirements

.................................................................

4.2.2 Mechanical Installation

........................................................................................

4.3 Plumbing Requirements and

Installation

................................................................. 18

4.3.1 Water Supply

.......................................................................................................

4.3.2 Colorimeter

Drainage...........................................................................................

4.4 Electrical Requirements and Installation

................................................................. 19

4.4.1 Connecting the Main Electrical

Power

.................................................................

4.4.2 Input Switches

.....................................................................................................

5 First Time Operation and Calibration

............................................................................... 21

5.1 Installing Additional Sensors

................................................................................... 21

5.1.1 pH, ORP (Redox) and Temperature

Measurements

...........................................

5.2 Installing

Reagents.................................................................................................. 22

5.3 First Time Menu Setup

............................................................................................ 25

5.3.1 WATERGUARD Control

Panel

............................................................................

5.3.2

Menus ..................................................................................................................

5.3.3 Operator

Menu.....................................................................................................

5.3.4 Configuring Settings in the Operator

Menu.........................................................

5.3.5 Technician Menu

.................................................................................................

5.3.6 Configuring Settings in the Technician

......................................................

5.4

Calibration................................................................................................................ 31

5.4.1 Chlorine

Calibration.............................................................................................

5.4.2 pH

Calibration

......................................................................................................

5.4.3 ORP (Redox)

Calibration

.....................................................................................

5.4.4 Temperature

Calibration

......................................................................................

5.4.5 Turbidity

Calibration

.............................................................................................

5.5 Calibration and Initial Operation Checklist

.............................................................. 35

6 Routine Operation and Maintenance

............................................................................... 37

6.1 MonitoringWATERGUARD

Alarms......................................................................... 38

6.2 Replacing Reagents

................................................................................................ 39

6.3 Cleaning the

Filter.................................................................................................... 41

6.4 Shut-Down and

Winterizing..................................................................................... 41

6.5 Start-up and Preventive

Maintenance..................................................................... 42

6.5.1 Replacing Pump Head and

Tubes.......................................................................

6.6

Troubleshooting

....................................................................................................... 43

6.7 Replacing Components

........................................................................................... 47

6.7.1 Replacing

Sensors...............................................................................................

6.7.2 Replacing the Temperature Probe

......................................................................

6.7.3 Replacing Reagent

Siphons

................................................................................

6.7.4 Replacing the Reagent Level

Switch

...................................................................

6.7.5 Replacing Reagent

Pumps

..................................................................................

6.7.6 Replacing the Colorimeter Assembly

..................................................................

6.7.7 Replacing the Solenoid

Valve..............................................................................

6.7.8 Replacing the Control Panel Module (Electronics

Card).....................................

6.7.9 Replacing the I/O

Module ....................................................................................

6.7.10 Replacing the pH, Redox, and Temperature

Card..............................................

6.7.11 Replacing the Colorimeter Card

..........................................................................

7 Optional

Features

............................................................................................................. 53

7.1 Optional Measurements

.......................................................................................... 53

7.2 Free and Total Chlorine

Measurements

.................................................................. 53

7.2.1

Installation............................................................................................................

7.2.2 Additional Menus and

Settings............................................................................

7.2.3 Total Chlorine Monitoring

Setup

..........................................................................

7.3 pH, ORP and Temperature

Measurements

............................................................. 60

7.3.1

Installation............................................................................................................

7.3.2 pH

Calibration

......................................................................................................

7.3.3 ORP

Calibration

...................................................................................................

7.3.4 Temperature

Calibration

......................................................................................

7.4 Conductivity

Measurement

...................................................................................... 60

7.4.1

Installation............................................................................................................

7.4.2 First Time Set-up and General Operation

...........................................................

7.4.3 Routine

Maintenance

...........................................................................................

7.4.4 Shut-down and

Winterizing..................................................................................

7.5 Flow

Meter

............................................................................................................... 62

7.5.1

Installation............................................................................................................

7.5.2 Routine Flow Meter Maintenance and

Troubleshooting

......................................

7.6 Modbus Communication

Protocol............................................................................ 64

7.7 Communication Options

.......................................................................................... 68

7.7.1 Internal 4-20 mA Output

......................................................................................

7.8 Chlorine Shock Mode

.............................................................................................. 70

8 Relays and Closed-Loop Control

..................................................................................... 71

8.1 Connecting external equipment to the

relays.......................................................... 71

8.2 Wiring to Dosing Systems

....................................................................................... 71

8.3 Replacing

Relays

..................................................................................................... 72

9 Setting Proportional

Control............................................................................................. 73

9.1 Proportional Control

Overview................................................................................. 73

9.2 Setting Proportional

Factor

..................................................................................

9.3 Setting Pump

Period

................................................................................................ 74

9.4 Step by Step Proportional

Settings.......................................................................... 75

10 Technical

Specifications.............................................................................................. 76

Table of

Figures

Figure 1: WATERGUARD HG-702

Components ....................................................................

Figure 2: MountingWATERGUARD on the Wall

....................................................................

Figure 3: Pressure Reducing

Valve

.........................................................................................

Figure 4: Sampling Cell and Colorimeter

Components

...........................................................

Figure 5: Reagent Bottle

Labels

..............................................................................................

Figure 6: Mixing Indicator Salt into Indicator Fluid

..................................................................

Figure 7: Reagent Bottles and Siphon

Caps...........................................................................

Figure 8: Reagent Bottles in

Position......................................................................................

Figure 9: WATERGUARD Control Panel

................................................................................

Figure 10: Sensor Reading After

Calibration...........................................................................

Figure 11: Press Tab above Siphon Cover and Pull Bottle

Down...........................................

Figure 12: Colorimeter Assembly

Unit

.....................................................................................

Figure 13: Solenoid Valve with Colorimeter Module and Sampling

Cell

.................................

Figure 14: Replacing All Types of Electronic

Card

..................................................................

Figure 15: Free and Total Chlorine

Controller

.........................................................................

Figure 16: Relay positions on

board

........................................................................................

Figure 17: Proportional Control of Chemical

Dosing

...............................................................

Figure 18: P-factor computation example

...............................................................................

Table of

Tables

Table 1 - Control panel

structure

............................................................................................. 25

Table 2 - Operator Menu Functions and

Descriptions............................................................. 26

Table 3 - Operator Menu Functions - Minimum and Maximum

Values

................................... 27

Table 4 - Technician Menu Functions and Descriptions

......................................................... 29

Table 5 - Technician Menu and Variable Limits

...................................................................... 30

Table 6 - Calibration Table

...................................................................................................... 36

Table 7 - Periodic Maintenance

Schedule............................................................................... 37

Table 8 - Alarm Descriptions and

Results............................................................................... 38

Table 9 - Troubleshooting: Alarm Descriptions and Solutions

................................................ 43

Table 10 - Troubleshooting: Problems and Suggested

Solutions........................................... 46

Table 11 - Additional features in Operator Menu (With Total Chlorine Monitoring)................

Table 12 - Additional Alarms (With Total Chlorine Monitoring)

............................................... 56

Table 13 - Alarms (With Total Chlorine

Monitoring) ................................................................ 57

Table 14 - Technician Menu (With Total Chlorine

Monitoring)

................................................ 58

Table 15 - Modbus Configuration

Options............................................................................... 65

Table 16 - Modbus CommunicationsOptions

......................................................................... 66

Table 17 - Relays and their controlled dosing

systems........................................................... 72

1 General Safety Precautions

This section presents important information intended to ensure safe and

effective use of this product.

Read the following carefully before handling the product. These warnings and

cautions must be followed carefully to avoid injury to yourself or damage to

equipment.

Warning: Only properly trained and licensed

electricians should attempt to wire or service the

electronic components of the analyzer/controller.

There is an Electrical Shock Hazard when

servicing this system.

Always verify that all electrical power source(s)

are off before opening the analyzer/controller

unit or attempting to service electronic

components or wiring.

Caution: Extreme caution should be used when

installing, operating, and maintaining the

WATERGUARD® Analyzer. Only properly

trained technicians are authorized to install and

maintain the analyzer/controller.

Attention! Seuls des électriciens qualifiés ayant

reçu la formation adéquate peuvent

entreprendre le branchement, l’entretien ou la

réparation des composants électroniques de

l’analyseur/du contrôleur.

Il existe un risque de choc électrique lors de

l’entretien de ce système.

Ayez soin de toujours vérifier que la ou les

source(s) d’alimentation électrique est ou sont

bien déconnectée(s) avant d’ouvrir l’unité ou

d’entreprendre toute opération de service

technique et tout branchement des composants

électroniques.

Attention! Il y a lieu d’agir avec une extrême

prudence lors de l’installation, de la mise en

œuvre et de la maintenance du contrôleur

WATERGUARD®. Seuls des techniciens dûment

formés à cet effet sont autorisés à effectuer

l’installation et la maintenance de l’analyseur/du

contrôleur.

Only properly trained and licensed operators

should attempt to make any changes to

chemical dosing levels.

Seuls des opérateurs qualifiés ayant reçu la

formation adéquate sont habilités à modifier les

dosages des produits chimiques utilisés.

Always follow local health and safety regulations

when performing any service on the

analyzer/controllerunit or when changing

chemical dosing settings.

Conformez-vous sans exception aux consignes

locales de santé et de sécurité lorsque vous

effectueztoute opération technique sur

l’analyseur/le contrôleur, ou lorsque vous

modifiez les paramètres de dosages chimiques.

Each relay connection is limited to 8 amps, to

prevent overheating. The relays mayshow a

higher rating but do not connect equipment

exceeding 8 amps.

Chaque connexion relais est limitée à 8 Amp.

afin d’éviter toute surchauffe. Même si les relais

affichent éventuellement une valeur supérieure,

ils ne se connecteront pas à un élément

dépassant 8 Amp.

All electrical connections should comply with

National Electrical Code (NEC) and all local

regulations.

Tous les branchements électriques doivent être

conformes au Code Electrique National (NEC –

National Electrical Code) ainsi qu’à toutes les

consignes locales.

Mixing reagents:

Caution: Use protective gear as recommended

in MSDS.

Caution: Do not use chemicals that reduce the

surface tension. When using hydrochloric acid,

observe all safetyregulations.

Mélanges réactifs:

Attention! Utilisez l’équipement de protection

préconisé dans la fiche de données de sécurité

(MSDS).

Attention! N’utilisez pas de produits chimiques

susceptibles de réduire la tension superficielle.

Lors de l’utilisation d’acide chlorhydrique,

appliquez scrupuleusement toutes les consignes

pertinentes.

Caution: WATERGUARD's control board unit

should not be opened except for

initial

installation

and troubleshooting, and should only

be opened by a trained and approved

technician.

Attention! Le tableau de commandes de

l’WATERGUARD ne doit en aucun cas être

ouvert si ce n’est lors de l’installation initiale et

en cas de dépannage –auquel cas son

ouverture ne doit être effectuée que par un

technicien ayant reçu la formation adéquate et

dûment habilité.

2. Preface

2.1 Intended Use

This manual is for qualified and trained service technicians who will install and service the

WATERGUARD HG-702Water Quality Analyzer. It provides instructions on how to install the

WATERGUARD system, how to integrate it with external chemical dosing systems and how to calibrate,

operate and maintain the system.

2.2 Overview of Chapters

This document is functionally divided into chapters according to the various steps involved in

installing and operating the WATERGUARD system.

Chapter 1: General Safety Precautions

This section presents important information intended to ensure safe and effective use of this

product.

Chapter 2: Preface

Intended use of the manual and safety issues

Chapter 3: Controller Overview

General description of how water quality is maintained and how WATERGUARD

automaticallymonitors and controls

Chapter 4: Installation

Instructs how to install WATERGUARD and how to integrate it with water quality systems

Chapter 5: First Time Set-up

Instructs how to configure, calibrate, and operate the WATERGUARDsystem immediately

after it is installed

Chapter 6: Routine Operation and Maintenance

Instructs

how to

respond

to alarmsand

troubleshooting

issues

Chapter 7: Optional features

Describes some optional components that may be installed on the controller or added later

Chapter 8: Relays & Closed-Loop Control

Lists and describes WATERGUARD's operational components

Chapter 9: Setting Proportional Control

Describes how WATERGUARD implements proportional monitoring and control and instructs

how to configure it in various environments.

Chapter 10: Technical Specifications

Includes information about dimensions, electrical systems, relays, measurement of chlorine,

turbidity and pH, etc.

3. Overview

The WATERGUARD HG-702 Water Quality Analyzer & Controller continuouslymonitors and

automaticallycontrols chemical levels in process water and potable water applications.

WATERGUARD performs automated analysis of free and/or total chlorine, turbidity, pH, ORP (redox),

temperature, conductivity and flow rate, administering chemicals as required, according to the results

of these tests.

3.1 The WATERGUARD Solution

Various methods have been developed over the years to monitor the concentration and balance of

chemicals used in water treatment. WATERGUARD measures free and/or total chlorine levels with a

digital photometer, which has many advantages over other types of sensors. Digital photometer

testing is completely objective. It is not dependent on lighting conditions or the operator’s eyesight,

and is far more accurate. It does not require frequent calibration and is compatible with all types of

disinfectant systems. WATERGUARD performs colorimetric testing in a closed reading cell. It is the

only system that automaticallyand accuratelymeasures free chlorine using small amounts of reagent.

WATERGUARD provides a turbidity measurement in NTU (Nephelometric Turbidity Units). This

provides a consistently objective evaluation of the overall water quality. High

turbidity may

be a result

of poor filtration or unbalanced water chemistry. The turbidity value

will provide

an indication that one

of these conditions exists and that action is required to improve the water quality. In many cases the

turbidity can be reduced by adding a flocculent to

the filter

which will improve filtration. A turbidityrelay

is included in the controller and will operate when turbidity is above the set point. This may be

connected to a flocculent dosing pump or other equipment used to reduce turbidity, providing an

automatic response and maintaining clear water without manual intervention. Likewise, if the turbidity

ever exceeds a pre-set limit, the controller will set off an alarm indicating that attention is required.

Once installed and calibrated, WATERGUARD is fully automatic. It will monitor and can control dosing

systems directly, releasing the proper quantity of chemicals based on frequent automatic

measurements.WATERGUARD is simple to use. Its straight-forward control panel and parameters

menu make chemical balance control an easy task. All basic information can be viewed at a glance,

and changing settings is as simple as scrolling through the menu and adjusting the current settings.

3.2 Measurements and Features

The WATERGUARDHG-702 can be configured to measure any combination of the following water

qualityparameters:

•Free chlorine

•Total chlorine

•Both free chlorine and total chlorine

•Turbidity

•Temperature

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