W-130/230 Series

pH & ORP Transmitter/Monitor

Instruction Manual
Notice
© 2000 WALCHEM Corporation
5 Boynton Road, Hopping Brook Park
Holliston, MA 01746-1446 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
reproduced by any means, or disseminated or distributed without the express
prior written permission of WALCHEM Corporation, 5 Boynton Road, Hopping
Brook Park, Holliston, MA 01746-1446.

This document is for information purposes only and is subject to change without
notice.

Statement of Limited Warranty

WALCHEM Corporation warrants equipment of its manufacture, and bearing its
identification to be free from defects in workmanship and material for a period of
24 months for electronics and 12 months for mechanical parts and electrodes
from date of delivery from the factory or authorized distributor under normal use
and service and otherwise when such equipment is used in accordance with
instructions furnished by WALCHEM Corporation and for the purposes disclosed
in writing at the time of purchase, if any. WALCHEM Corporation's liability under
this warranty shall be limited to replacement or repair, F.O.B. Holliston, MA
U.S.A. of any defective equipment or part which, having been returned to
WALCHEM Corporation, transportation charges prepaid, has been inspected and
determined by WALCHEM Corporation to be defective. Replaceable elastomeric
parts and glass components are expendable and are not covered by any
warranty.

THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EITHER

EXPRESSED OR IMPLIED, AS TO DESCRIPTION, QUALITY,
MERCHANTABILITY, FITNESS FOR ANY PARTICULAR PURPOSE OR USE,
OR ANY OTHER MATTER.

Part Number 180089 (E)

December 2000
Table of Contents

1.0 INTRODUCTION.................................................................................................... 1
2.0 PACKING LIST....................................................................................................... 1
3.0 INSTALLATION...................................................................................................... 1
3.1 Wall Mount ........................................................................................................... 1
3.2 Panel Mount......................................................................................................... 2
3.3 Initial Startup ........................................................................................................ 5
4.0 SPECIFICATIONS ................................................................................................. 5
5.0 PROGRAMMING & KEYPAD .............................................................................. 6
5.1 Overview............................................................................................................... 6
5.2 Programming for pH ........................................................................................... 7
5.2.1 Calibration.............................................................................................. 7
5.2.2 Run Temperature Adjustment ............................................................ 8
5.2.3 Alarm Limit Adjustment........................................................................ 8
5.2.4 4-20 mA Set Points .............................................................................. 9
5.2.5 4-20 Output Adjustment ...................................................................... 9
5.3 Programming for ORP........................................................................................ 9
5.3.1 Calibration............................................................................................10
5.3.2 Alarm Limit Adjustment......................................................................10
5.3.3 4-20 mA Set Points ............................................................................10
5.3.4 4-20 mA Output Adjustment .............................................................10
6.0 OPERATION .........................................................................................................11
7.0 TROUBLESHOOTING ........................................................................................12
8.0 SERVICE POLICY...............................................................................................13
1.0 INTRODUCTION

The W-130/230 series microprocessor based transmitters are used to monitor and
transmit data in pH/ORP applications such as effluent monitoring, signal
conditioning for PC's or PLC's and simple on/off control in water treatment, waste
water treatment and other industrial uses. They are available in wall mount
(W-130 series) and panel mount (W-230 series) enclosures.

Depending on the model ordered, the unit is powered by 24 VDC or AC line

voltage and contains two relays for alarm purposes or for on/off control functions.

Check the model number/serial number label on the unit for the proper voltage
before connecting power to the unit!!

The unit is compatible with any electrode that generates a millivolt signal, and may
be used with Pt 1000 automatic temperature compensation (ATC) elements. If no
ATC probe is detected at power-up, the controller will automatically go into
manual compensation mode.

An isolated 4-20 milliampere output is optional; it is powered internally. The

pH/ORP span between 4-20 mA may be any value, and the mA signal may be
adjusted from the front panel.

2.0 PACKING LIST

Notify your carrier immediately if there are any signs of damage to the transmitter
or its parts. Contact your distributor if any parts are missing. The W-130/230 series
transmitter shipping carton should contain the following items:

W-130/230 series pH/ORP transmitter/monitor

Instruction Manual
Mounting clips (W-230 panel mount models only)

3.0 INSTALLATION

The W-130/230 series units are designed to be mounted within 20 feet of the
electrode. The W-130 series models are supplied with wall mountable enclosures,
while the W-230 models are in panel mount enclosures.

3.1 Wall Mount

The W-130 series models are ideally mounted with the display at eye level, on a
vibration-free surface, in a location where it will not be splashed while the
enclosure cover is off.

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 Take off the front cover and mount the unit to the wall using #6 screws which are
inserted into the holes at the four corners of the enclosure. See fig 1 for mounting
template. DO NOT use any of the blind holes on the back of the enclosure for
mounting!
(The screws may penetrate the enclosure and damage the internal electronics.)
Route the wires through the provided cable glands. Install the wiring, carefully
observing the polarity of all DC connections (see fig. 2). Replace the front panel
of the unit and tighten the cable glands around the wiring just installed. Connect
the pH or ORP electrode to the BNC connector.

3.2 Panel Mount

Mount the unit in the panel cutout and secure with the provided mounting clips.
Install the wiring, carefully observing the wiring diagram and the polarity of all
DC connections (see fig. 3). Note that the terminal strips on the rear of the panel
mount unit unplugs, to enable wiring of the unit. Connect the pH or ORP electrode
to the BNC connector.

Mounting template for W-130 wall mount

Transmitter/monitor

4.21” x 4.21”

Panel cutout for W-230 panel mount

Transmitter/monitor

1.75” x 3.58”

Figure 1 Mounting Templates

2
 Low High
Alarm Alarm Power Temp
C N.O. C N.O. V+ V- T1 T2

24 VDC TERMINAL STRIP

4-20 mA

115V
230V
R+ R-

Fuse

ORP
Low High

pH
Alarm Alarm Power Temp Terminal Strip
C N.O. C N.O. T1 T2 Low High
Alarm Alarm Power Temp
C N.O. C N.O. T1 T2

115/230 VAC TERMINAL STRIP BNC

Gnd

(CAUTION: CHECK FOR PROPER VOLTAGE For AC Liquid Tight

OF YOUR UNIT BEFORE CONNECTING POWER!) Power Cord Connector
for wiring
optional devices:
ATC probe Pt 1000
or
4-20 mA to recorder
max load 500 Ω
etc.

Figure 2A W-130 Wall Mount Circuit Board and Typical Wiring

Low High
Alarm Alarm Power Temp
Note: Alarms are dry contact relays.
C N.O. C N.O. T1 T2 (Polarity not critical)

Example of wiring when using

relay to switch AC power.

BLK P.L.C.
GRN Using relay as a dry switch closure
WHT
External
Power

Figure 2B Wiring Alarm Relays

(Wall Mount and Panel Mount)

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 TEMP 4-20 mA
T1 T2 R+ R-

A.T.C. probe 4-20 mA to recorder

Pt 1000 max load 500 Ω
LOW ALARM HI ALARM POWER GROUND
C N.O. C N.O.

BNC

LOW ALARM HI ALARM POWER GROUND LOW ALARM HI ALARM POWER GROUND
C N.O. C N.O. +V -V C N.O. C N.O. LINE NEU

24 VDC TERMINAL STRIP 115/230 VAC TERMINAL STRIP

(CAUTION: CHECK FOR PROPER VOLTAGE OF YOUR UNIT BEFORE CONNECTING POWER!)

pH

ORP

Transformer

BNC
J1

Fuse

UPPER CIRCUIT BOARD LOWER CIRCUIT BOARD

Figure 3 W-230 Panel Mount Wiring and Circuit Boards

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3.3 Initial Startup

The monitor arrives with the alarm limits set to 2 and 12 pH or -1000 and 1000
mV (ORP). The 4-20 mA is also set to represent the entire 0-14 pH span or -2000
to 2000 mV. The unit is calibrated to read a perfect pH electrode at 20°C (68°F) or
0.00 mV. As a minimum you will want to calibrate the monitor to read your
specific pH or mV electrode correctly. Power on the unit, calibrate, and for pH, set
the process temperature. After the initial calibration, very little effort will be
required to keep the transmitter in operation. Calibrations will be required in the
future but the frequency will depend entirely on your process. Walchem
recommends that you perform a calibration at least once every week to start.

4.0 SPECIFICATIONS

pH Input
Range: 0-14
Resolution: 0.01 pH
Stability: 0.01 pH

ORP Input
Range: -2000 -+2000 mV
Resolution: 1 mV
Stability: 1 mV

Temperature Input
Range: 0-100°C, 212°F
Resolution: 1 degree
Accuracy: ± 1 degree
Pt 1000 ohm RTD: Not required and no fixed resistor required to
replace RTD
Power Requirements
115 VAC ± 20%, 1 Amp
230 VAC ± 20%, 1 Amp
Voltage in 24VDC nominal, range 14-36 VDC

Note: 24 VDC power supply must be isolated from earth ground. Only one unit
may be attached to a single power supply, or a ground loop may be created.

4-20mA Output Maximum Load

500 Ohms
Relay Outputs
Unpowered Relays Rated 5 Amps (resistive), @ 115/230VAC, 30VDC (max)
3 Amps (inductive) @ 115/230 VAC, 30 VDC

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5.0 PROGRAMMING & KEYPAD

5.1 Overview
Programming is performed using the three function keys, ö, ÷ and Enter , located
under the LED display panel.

pH mA
mV deg
MENU

HIGH

r
te
p
En
LOW V

m
A m
m

Te
EXIT

Figure 4 Front Panel (W130 shown)

Press the ÷ and Enter keys simultaneously to enter the programming (menu)
mode. Press the ö and ÷ keys simultaneously to exit the programming mode.

Once you are in the programming mode, changing a number is easy. Use the ö or
÷ key to change the value. The effect of the key gets faster the longer you hold
down the key. Once the value displayed is what you desire, press Enter. If you
change your mind press the exit key combination, ö and ÷. The display will
return to the previous setting. (To exit the menu entirely, press ö and ÷ again.)

Each individual key has another function, indicated in the blue area in the right
corner.
View mA
When the unit is operating, pressing the ö/mA key will change the display to read
the current milliamp output, for as long as you depress that key. The corresponding
mA LED on the display panel will light.

View mV
Pressing the ÷/mV key will change the display to read the current millivolt value,
for as long as you depress that key. The corresponding mV LED on the display
panel will light.

View Temperature
If you are using an automatic temperature compensated sensor for pH
measurement, the current temperature will be displayed. Pressing the Enter/Temp
key will change the display to show the current programmed process temperature,
for as long as you depress that key. A corresponding LED on the display panel will
light.

6
 In the paragraphs that follow, the letters shown in bold are what will appear on the
display. The values you enter in the programming mode are stored in non-volatile
EEPROM memory. You may enter the programming mode at any time and view
the set points without disrupting the 4-20 mA output or the alarm condition. If you
modify a set point the new value will take affect as soon as you press Enter .

5.2 Programming for pH

5.2.1 Calibration

Two Point Calibration

Every time you enter the programming mode you will be presented with the
message CAL 2. If you press Enter you will be presented with a series of
instructions prompting you through the calibration process. The steps progress in a
logical manner and even attempt to make it impossible for calibration errors to
cause any problems.

If using manual temperature compensation, first you will be given the opportunity
to set the temperature of the buffers used in the calibration. Press Enter and the
display will change toCAL t. Press Enter and you will see dEg F or dEg C. Use
the arrow keys to scroll between dEg F and dEg C, then select by pressing Enter.
The temperature value will appear and you may change it up or down using the
arrow keys. Press Enter to accept temperature value.

If using ATC, place the electrode in the first buffer solution, and let the
temperature display stabilize. Then you will be prompted to specify buFr 1. Press
the Enter key to continue. You may accept the value presented to you (probably
7.00) or change it as described above. Press the Enter key when the first buffer is
correct.

Next the display will change to indicate the mV reading of the pH electrode.
When this reading is stable press any key to accept the value and continue with the
calibration process. If the display is flashing, the mV reading does not correspond
to the pH buffer value you programmed. Double check to make sure that the
electrode is in the correct pH buffer.

The display will next read buFr 2. and the same process is repeated for the second
buffer. When you accept the second mV reading the calibration process is
complete and the unit tests to see if the process was done correctly. If so, the
message CAL d is displayed. Otherwise the message FAiLd is displayed and the
results of the calibration attempt are discarded. Press any key to continue in the
programming mode. The display will return to CAL 2.

7
One Point Calibration
Press the ö key and you will see an alternative to the above calibration procedure,
CAL 1. This procedure is almost identical to the CAL 2 procedure, except only
one buffer is used. This method is faster but is not as accurate.

Press Enter and the display will change to CAL t. Press Enter and you will see dEg
F or dEg C. Use the arrow keys to scroll between dEg F and dEg C, then select by
pressing Enter. The temperature value will appear and you may change it up or
down using the arrow keys. Press Enter to accept temperature value.

If using ATC, place the electrode in the buffer solution, and let the temperature
display stabilize. The display will next read buFr. Use the ö and ÷ keys the scroll
to the pH value of the buffer you will be using. Press Enter. (Place the electrode in
the buffer solution if it isn't already.) The display will change to indicate the mV
reading of the pH electrode. When this reading is stable, press any key to accept
the value. If the display is flashing, the mV reading does not correspond to the pH
buffer value you programmed. Double check to make sure that the electrode is in
the correct pH buffer.

Note that buffer 7 may not be used in the CAL 1 procedure.

When you have accepted the mV reading, the calibration process is completed and
the unit tests to see if the process was done correctly. If so, the message CAL d is
displayed. Otherwise the message FAiLd is displayed and the results of the
calibration attempt are discarded. Press any key to continue in the programming
mode. The display will return to CAL 1.

5.2.2 Run Temperature Adjustment

Press the ö key until the display reads run t. Press Enter to adjust (or view) the
temperature. The display will change to indicate the current unit of measure (deg C
or deg F). Press Enter to accept the units or an arrow key to change the units.
Then change the displayed temperature to match your process temp. If you
installed an ATC sensor, the current temperature will be displayed until you press
a key.

5.2.3 Alarm Limit Adjustment

Press the ö key until the display reads SEtHi pH. Press Enter. This will give you
the opportunity to set the pH value that should correspond to a high alarm output.
Use the ÷ or ö key to change the value and press Enter to store the new value.

Press the ö key until the display reads SEtLo pH. Press Enter. This will give you
the opportunity to set the pH that should correspond to a low alarm output. Use
the ÷ or ö key to change the value and press Enter to store the new value.

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5.2.4 4-20 mA Set Points

Press the ö key until the display reads SEt 4 mA. Press Enter. This will give you
the opportunity to set the pH value that should correspond to a 4 mA output. This
is commonly known as the offset value. Use the ÷ or ö key to change the value
and press Enter to store the new value.

Press the ö key again to display SEt20 mA. Press Enter. This will give you the
opportunity to set the pH value that should correspond to a 20 mA output. In
conjunction with the 4 mA output setting you will determine the span of the 4-20
output. Use the ÷ or ö key to change the value and press Enter to store the new
value.

5.2.5 4-20 Output Adjustment

This function is to allow you to adjust accuracy of the 4-20 mA output. Attach an
ammeter to the controller as shown in the figure below. Press the ö key until the
display reads ADJSt. Press Enter. The display will change to ADJ 4. If the
ammeter does not read exactly 4.00, use the ö and ÷ keys to adjust the output
until the meter reads 4.00 Press Enter.

The display will now read ADJ20. If the ammeter does not read exactly 20.00,
use the ö or ÷ keys to adjust the output until the ammeter reads 20.00. Press
Enter.

4-20 mA output
from unit

R+ R-

Recorder

Ammeter

5.3 Programming for ORP

If you have ordered a W-130-MVxx or W-230-MVxx, the unit is preset as an ORP

version, and no further action is required. If not, simply disconnect power and set
the pH/ORP switch to the ORP position. The switch is red and is located on the
main board inside the unit. See figures 2 and 3 for location. Put the unit back
together and power on. The display will now indicate the input as a mV value.

9
 The 4-20mA settings and Alarm settings are similar to the pH mode. However, the
complex pH calibration procedures are no longer needed. See programming
instructions below.

5.3.1 Calibration

The CaL menu is used to adjust the mV reading to match the expected value of a
standard solution, or the reading of a previously calibrated meter.

When you enter the programming mode, the first display will be CaL. Place the
ORP electrode into a solution of known mV value. This may be a standard
solution such as a saturated solution of Quinhydrone in pH 4 or pH 7 buffer, or the
process solution that has been measured by a previously calibrated meter. Press
Enter to perform the calibration.

The display will now show the mV output of the electrode. If this is different from
the known value, use the ö and ÷ keys to make the reading match the known
value. Press Enter when the reading is correct.

5.3.2 Alarm Limit Adjustment

Press the ö key until the display reads SEtHi mV. Press Enter. This will give you
the opportunity to set the mV value that should correspond to a high alarm output.
Use the ÷ or ö key to change the value and press Enter to store the new value.

Press the ö key until the display reads SEtLo mV. Press Enter. This will give you
the opportunity to set the mV value that should correspond to a low alarm output.
Use the ÷ or ö key to change the value and press Enter to store the new value.

5.3.3 4-20 mA Set Points

Press the ö key until the display reads SEt 4 mA. Press Enter. This will give you
the opportunity to set the mV value that should correspond to a 4 mA output. This
is commonly known as the offset value. Use the ÷ or ö key to change the value
and press Enter to store the new value.

Press the ö key again to display SEt20 mA. Press Enter. This will give you the
opportunity to set the mV value that should correspond to a 20 mA output. In
conjunction with the 4 mA output setting you will determine the span of the 4-20
output. Use the ÷ or ö key to change the value and press Enter to store the new
value.

5.3.4 4-20 mA Output Adjustment

See section 5.2.5 on previous page.

10
6.0 OPERATION

Once all of the values have been programmed to the desired settings, the 4-20 mA
output is continuously updated and the alarm points are monitored.

The 4-20 mA output is capable of driving a maximum load of 500 Ω, which should
be suitable for most applications.

The alarm outputs are electro-mechanical relays rated for 5 Amps at 115/230 VAC
or 30 VDC.

The alarm relays are activated for high or low alarm conditions and the
corresponding indicators on the front panel are lit.

During a given alarm condition, the alarm relay may be de-energized by pressing
the ö and Enter keys simultaneously. The alarm output will not be re-energized
until the current alarm condition is cleared. The front panel LED’s are not affected
by the alarm acknowledge feature.

The alarm limits have a built in dead band of 0.05 pH (5 mV). This means that
once the high alarm is tripped the alarm light will not turn off until the pH is 0.05
less than the high alarm set point (or 5 mV, for ORP).

Press and hold the ÷ key to display the current mA output value. Releasing this
key will restore the display to the current pH value. Similarly, press and hold the
ö key to display the input mV reading. Use the Enter key to display the current
temperature reading. None of these view keys affect the operation of the monitor.

Press all three of the front panel keys simultaneously to perform a display test. All
of the display characters and indicators should light up. Release the keys to return
to normal operation.

11
7.0 TROUBLESHOOTING

“FAiLd” message
Cause: The calibration process yielded a “slope” less than 35 mV/pH or greater
than 80 mV/pH, or an offset from the expected mV reading that is greater than ±35
mV. This may be caused by an incorrect calibration attempt or defective electrode,
cable, buffer solution or wiring.

Correction: Use this table as a guide when calibrating your pH/ORP electrode. It
lists the most common buffers and their corresponding mV readings when used at
different temperatures.

Temp = 20°C Temp = 25°C Temp= 30°C

pH mV mV mV
4.00 174 177 180
7.00 0 0 0
10.00 -174 -177 -180

If your readings do not match these guidelines, try to determine if the monitor or
the pH electrode is at fault. To do this, disconnect the pH/ORP electrode from the
BNC connector. Use a pH simulator to give the unit a known mV input. If the unit
reads correctly, then the electrode or its cable is at fault. If a simulator is not
available, use a bent paper clip to short the outside shell of the BNC to the inside
contact of the BNC. This should simulate pH 7 or mV 0.00. Use the ÷ key to view
the mV reading. If the reading is between +10mV and -10mV then the electrode is
probably at fault. If the reading does not improve with a new electrode, contact
Walchem customer service.

pH doesn’t match the pH reading of another meter

Causes: Incorrect calibration of either or both meters.

Inconsistency between electrodes.
Lab meter’s electrode is not at the same temperature as the process.
Analysis sample taken from different location than the process sample.

Correction: This is a complex problem that can best be corrected with some
simple guidelines. Make sure all process related variables are taken into
consideration. Calibrate both meters with the same buffer solutions, carefully
following the manufacturers guidelines. If the process measurement is being done
at an elevated temperature, make certain that the lab meter’s sample has been
heated to the same temperature as the process. If all of these suggestions are
followed and the pH still does not match, recalibrate the unit using the process
value (as read by the lab meter) as the buffer in the CAL 1 procedure.

12
pH recorder works backwards

Cause: The 4 mA set point is higher than the 20 mA set point.

Correction: Move either or both set points so that the 20 mA setting is greater
than the 4 mA setting. The inverse action you were witnessing is provided for use
with a proportional valve or pump and not a recorder.

Wild swings in 4-20 mA output

Cause: The 4 mA setting is too close to the 20 mA setting.

Correction: There should be at least a 1 pH unit span between the two set point
values. If you have set the 4 mA set point = the 20 mA set point the transmitter
will produce 4 mA when the pH is below the set point and 20 mA when the pH is
above the set point. This is probably not the action you desired.

“rECAL” message or
Set points changed back to default

Cause: The internal memory has been corrupted.

Correction: The unit was designed to be installed and run without human
intervention. However, if the EEPROM memory has been corrupted the best the
unit can do is reset all of the values you have programmed to the factory defaults.
(4-20 mA = 0-14 pH, or -2000 to +2000 mV.) The machine will also recalibrate to
the “perfect electrode”. This is not likely to match your electrode even right out of
the box from the manufacturer. Still this action is usually better than no action at
all in the absence of an operator. If no operator is present and the rECAL message
has been on the display for about a minute, the unit will begin to run. Turn off the
power to the unit, wait a few moments and then turn the power back on. If the
rECAL message appears contact Walchem customer service.

8.0 SERVICE POLICY

The W-130/230 series pH & ORP transmitters/monitors have a 2-year warranty on

electronic components and a 1-year warranty on mechanical parts (keypad,
terminal strip, relays).

We stock circuit boards for immediate exchange after we have isolated the cause
of the problem. Factory authorized repairs that are received by "next day air" will
be returned within 24 hours. Normal priority for returns is two weeks. Out of
warranty repairs or circuit board exchanges are done on a flat fee basis after the
warranty is expired.

13