IWAKI WALCHEM Intuition-6 Series User manual

Instruction Manual
Metal Finishing Controller

Notice
© 2022 WALCHEM, Iwaki America Incorporated (hereinafter “Walchem”)
5 Boynton Road, Holliston, MA 01746 USA
[phone]
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 per-
mission of WALCHEM, 5 Boynton Road, Holliston, MA 01746.
This document is for information purposes only and is subject to change without notice.
Statement of Limited Warranty
WALCHEM warrants equipment of its manufacture, and bearing its identication 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 and for the purposes disclosed in writing at the time of
purchase, if any. WALCHEM’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, transportation charges
prepaid, has been inspected and determined by WALCHEM 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 EXPRESS OR IMPLIED, AS TO DESCRIPTION,
QUALITY, MERCHANTABILITY, FITNESS FOR ANY PARTICULAR PURPOSE OR USE, OR ANY OTHER MATTER.
180762 Rev. A April 2022
walchem.com

Contents
1.0 INTRODUCTION ................................................................................... 1
2.0 SPECIFICATIONS................................................................................. 3
2.1 Measurement Performance ..................................................................................... 3
2.2 Electrical: Input/Output ............................................................................................ 5
2.3 Intended Use ........................................................................................................... 6
2.4 Mechanical............................................................................................................... 6
2.5 Variables and their Limits......................................................................................... 7
3.0 UNPACKING & INSTALLATION......................................................... 10
3.1 Unpacking the unit ................................................................................................. 10
3.2 Mounting the electronic enclosure ......................................................................... 10
3.3 Immersible Copper Sensor Installation ................................................................. 10
3.4 Flow Through Copper Sensor/Sample Loop Installation ....................................... 11
3.5 Flow Through Nickel Sensor/Sample Loop Installation ........................................ 11
3.6 Other Sensor Installation ....................................................................................... 13
3.7 IconDenitions ...................................................................................................... 18
3.8 Electrical installation .............................................................................................. 18
4.0 FUNCTION OVERVIEW...................................................................... 34
4.1 Front Panel ............................................................................................................ 34
4.2 Touchscreen .......................................................................................................... 34
4.3 Icons ..................................................................................................................... 34
4.4 Startup ................................................................................................................... 36
4.5 Shut Down ............................................................................................................. 38
5.0 OPERATION using the touchscreen ................................................ 39
5.1 Alarms Menu ........................................................................................................ 47
5.2 Inputs Menu .......................................................................................................... 47
5.2.1 Copper/Nickel ............................................................................................... 50
5.2.2 Contacting Conductivity ................................................................................ 51
5.2.3 Electrodeless Conductivity .................................................................................52
5.2.4 Temperature .......................................................................................................53
5.2.5 pH.......................................................................................................................53
5.2.6 ORP....................................................................................................................54
5.2.7 Disinfection.........................................................................................................54
5.2.8 Generic Sensor ..................................................................................................55
5.2.9 Transmitter Input and AI Monitor Input ...............................................................55
5.2.10 Fluorometer Input ..............................................................................................56
5.2.11 Analog Flowmeter Input ..........................................................................................56

5.2.12 DI State ..................................................................................................................57
5.2.13 Flow Meter, Contactor Type....................................................................................58
5.2.14 Flow Meter, Paddlewheel Type...............................................................................58
5.2.15 Feed Monitor ..........................................................................................................59
5.2.16 DI Counter Input.....................................................................................................61
5.2.17 Virtual Input – Calculation.......................................................................................61
5.2.18 Virtual Input – Redundant.......................................................................................62
5.2.19 Virtual Input – Raw Value .......................................................................................63
5.3 Outputs Menu ................................................................................................................64
5.3.1 Relay, Any Control Mode ........................................................................................64
5.3.2 Relay,On/O󰀨ControlMode ...................................................................................64
5.3.3 Plating Control........................................................................................................65
5.3.4 Plating Follow .........................................................................................................66
5.3.5 Relay, Percent Timer Control Mode........................................................................66
5.3.6 Relay, Alarm Output Mode......................................................................................66
5.3.7 Relay, Time Proportional Control Mode..................................................................67
5.3.8 Relay, Manual Mode...............................................................................................67
5.3.9 Relay, Pulse Proportional Control Mode.................................................................67
5.3.10 Relay, PID Control Mode ........................................................................................68
5.3.11 Relay, Dual Set Point Mode....................................................................................70
5.3.12 Relay, Timer Control Mode .....................................................................................71
5.3.13 Relay, Probe Wash Control Mode ..........................................................................73
5.3.14 Relay, Spike Control Mode .....................................................................................73
5.3.15 Relay Output, Flow Meter Ratio Control Mode .................................................75
5.3.16 Relay Output, Flow Proportional Mode .............................................................75
5.3.17 Relay, Counter Timer Control Mode .......................................................................76
5.3.18 Relay, Dual Switch Control Mode......................................................................76
5.3.19 Relay or Analog Output, Lag Control Mode ......................................................77
5.3.20 Analog Output, Retransmit Mode ...........................................................................83
5.3.21 Analog Output, Proportional Control Mode.............................................................83
5.3.22 Analog or Relay Output, PID Control Mode............................................................83
5.3.23 Analog Output, Manual Mode.................................................................................86
5.4 CongurationMenu ......................................................................................................87
5.4.1 Global Settings .......................................................................................................87
5.4.2 Security Settings.....................................................................................................87
5.4.3 Ethernet Settings....................................................................................................88
5.4.4 Ethernet Details......................................................................................................89
5.4.5 Remote Communications (Modbus and BACnet)...................................................89
5.4.6 Email Report Settings.............................................................................................90
5.4.7 Display Settings......................................................................................................91
5.4.9 Controller Details....................................................................................................92

e
5.5 HOA Menu ................................................................................................................ 93
5.6 Graph Menu .............................................................................................................. 93
6.0 OPERATION using Ethernet ..................................................................94
6.1 Connecting to a LAN................................................................................................... 94
6.1.1 Using DHCP ............................................................................................................95
6.1.2 UsingaxedIPAddress .........................................................................................95
6.2 Connecting Directly to a Computer............................................................................. 95
6.3 Navigating the web pages .......................................................................................... 95
6.4 Graphs Webpage........................................................................................................ 96
6.5 Software Upgrade....................................................................................................... 96
7.0 MAINTENANCE .......................................................................................97
7.1 Copper or Nickel Sensor Cleaning ............................................................................. 97
7.2 pH Electrode Maintenance ......................................................................................... 98
8.0 TROUBLESHOOTING .............................................................................98
8.1 Calibration Failure ............................................................................................................99
8.1.1 Copper or Nickel Sensors .......................................................................................99
8.1.2 pH Sensors..............................................................................................................99
8.1.3 Contacting Conductivity Sensors ............................................................................99
8.1.4 Electrodeless Conductivity Sensors........................................................................99
8.1.5 ORP Sensors ........................................................................................................100
8.1.6 Disinfection Sensors..............................................................................................100
8.1.7 Analog Inputs ........................................................................................................100
8.1.8 Temperature Sensors ............................................................................................101
8.2 Alarm Messages ....................................................................................................... 101
8.3 Procedure for Evaluation of Conductivity Electrode ................................................. 105
8.4 Procedure for evaluation of the pH/ORP electrode ................................................. 106
8.5 Diagnostic Lights .................................................................................................... 106
9.0 SparePartsIdentication ....................................................................107
10.0 Service Policy ......................................................................................108

1
1.0 INTRODUCTION
The Walchem Intuition-6™ Series controllers oer a high level of exibility in controlling metal nishing
applications.
One or two sensor inputs are available that are compatible with a variety of sensors:
Single Copper or Nickel plus Single pH
Dual Analog (4-20 mA) Input
Single Analog Input + Single Sensor (Contacting Conductivity, pH, ORP, Disinfection or Generic linear voltage
between -2 and 2 VDC)
Sensor Input (Electrodeless Conductivity, Contacting Conductivity, pH, ORP, Disinfection or Generic linear
voltage between -2 and 2 VDC)
An analog (4-20 mA) sensor input card with two input circuits is also available for use with 2,3 or 4-wire transmitters.
Or a sensor card that combines one sensor (contacting conductivity, pH, ORP, disinfection or generic) plus one analog
(4-20 mA) input is available.
Six Virtual Inputs are congurable in the software, to either allow for calculations based on two real inputs, or to
allow to compare values from two sensors to provide redundancy.
Six relay outputs may be set to a variety of control modes:
Plating Control
Plating Follow
Flow Timer
On/O set point control
Time Proportional control
Pulse Proportional control (when purchased with Pulse solid state opto outputs)
PID control (when purchased with Pulse solid state opto outputs)
Lead/Lag control of up to 6 relays
Dual set point
Timer
Feed as a percent of elapsed time
Always on unless interlocked
Probe Wash timer
Spike to alternate set point on timed basis
Flow Meter Ratio
Counter Timer
Dual Switch
Diagnostic Alarm triggered by:
High or Low sensor reading
No Flow
Relay output timeout
Sensor error
Relays are available in several combinations of powered relays, dry contact relays, and pulse solid state opto relays.
Six virtual Control Outputs are congurable in the software, using most of the possible relay or analog output control
algorithms, that may be used to interlock or activate actual control outputs.
An option card with two isolated analog outputs may be installed to retransmit sensor input signals to a chart recorder,
datalogger, PLC or another device. They may also be connected to valves, actuators or metering pumps for linear propor-
tional control, ow proportional or PID control.

2
An Ethernet option provides remote access to the controller’s programming via a PC connected directly, via a local
area network, or via the Walchem Fluent account management server. It also allows emailing of datalog les (in CSV
format, compatible with spreadsheets like Excel) and alarms, to up to eight email addresses. The Modbus TCP and
BACnet remote communications options allow communication with PC-based applications, HMI/SCADA programs,
Building Energy Management systems, Distributed Control Systems (DCS), as well as stand-alone HMI devices.
Our USB features provide the ability to upgrade the software in the controller to the latest version. The Cong le feature
allows you to save all the set points from a controller onto a USB ash disk, and then import them into another controller,
making the programming of multiple controllers fast and easy. The data logging feature allows you to save the sensor
readings and relay activation events to a USB ash disk.

3
2.0 SPECIFICATIONS
2.1 Measurement Performance
Sensor Specs
Copper
Range 0.10 to 99 g/l (varies with the chemical being measured)
0.10 to 5.50 g/l typical for electroless copper
Resolution 0.01 g/l
Accuracy ± 0.01 g/l
Nickel
Range 0.10 to 25 g/l (varies with the chemical being measured)
Resolution 0.01 g/l
Accuracy ± 0.01 g/l
0.01 Cell Contacting Conductivity
Range 0-300 µS/cm
Resolution 0.01 µS/cm, 0.0001 mS/cm, 0.001 mS/m, 0.0001 S/m, 0.01 ppm
Accuracy ± 1% of reading or 0.01 µS/cm, whichever is greater
0.1 Cell Contacting Conductivity
Range 0-3,000 µS/cm
Resolution 0.1 µS/cm, 0.0001 mS/cm, 0.01 mS/m, 0.0001 S/m, 0.1 ppm
Accuracy ± 1% of Reading or 0.1 µS/cm, whichever is greater
1.0 Cell Contacting Conductivity
Range 0-30,000 µS/cm
Resolution 1 µS/cm, 0.001 mS/cm, 0.1 mS/m, 0.0001 S/m, 1 ppm
Accuracy ± 1% of Reading or 1 µS/cm, whichever is greater
10.0 Cell Contacting Conductivity
Range 0-300,000 µS/cm
Resolution 10 µS/cm, 0.01 mS/cm, 1 mS/m, 0.001 S/m, 10 ppm
Accuracy ± 1% of Reading or 10 µS/cm, whichever is greater
pH ORP/ISE
Range -2 to 16 pH units
Resolution 0.01 pH units
Accuracy ± 0.01% of reading
Range -1500 to 1500 mV
Resolution 0.1 mV
Accuracy ± 1 mV
Disinfection Sensors
Range (mV) -2000 to 1500 mV Range (ppm) 0-2 ppm to 0-20,000 ppm
Resolution (mV) 0.1 mV Resolution (ppm) Varies with range and slope
Accuracy (mV) ± 1 mV Accuracy (ppm) Varies with range and slope

4
100Ω RTD Temperature
Range 23 to 500°F (-5 to 260°C)
Resolution 0.1°F (0.1°C)
Accuracy ± 1% of Reading or ± 1°C, whichever is greater
1000Ω RTD Temperature
Range 23 to 500°F (-5 to 260°C)
Resolution 0.1°F (0.1°C)
Accuracy ± 1% of Reading or ± 0.3°C , whichever is greater
10k or 100k Thermistor Temperature
Range 23 to 194°F (-5 to 90°C)
Resolution 0.1°F (0.1°C)
Accuracy ± 1% of Reading or ± 0.3°C, whichever is greater
Analog (4-20 mA)
Range 0 to 22 mA
Resolution 0.01 mA
Accuracy ± 0.5% of reading
Electrodeless Conductivity
Range Resolution Accuracy
500-12,000 µS/cm 1 µS/cm, 0.01 mS/cm, 0.1 mS/m, 0.001 S/m, 1 ppm 1% of reading
3,000-40,000 µS/cm 1 µS/cm, 0.01 mS/cm, 0.1 mS/m, 0.001 S/m, 1 ppm 1% of reading
10,000-150,000 µS/cm 10 µS/cm, 0.1 mS/cm, 1 mS/m, 0.01 S/m, 10 ppm 1% of reading
50,000-500,000 µS/cm 10 µS/cm, 0.1 mS/cm, 1 mS/m, 0.01 S/m, 10 ppm 1% of reading
200,000-2,000,000 µS/cm 100 µS/cm, 0.1 mS/cm, 1 mS/m, 0.1 S/m, 100 ppm 1% of reading
Temperature °C Range Multiplier Temperature °C Range Multiplier
0 181.3 80 43.5
10 139.9 90 39.2
15 124.2 100 35.7
20 111.1 110 32.8
25 100.0 120 30.4
30 90.6 130 28.5
35 82.5 140 26.9
40 75.5 150 25.5
50 64.3 160 24.4
60 55.6 170 23.6
70 48.9 180 22.9
Note: Conductivity ranges on page 2 apply at 25°C. At higher temperatures, the range is reduced per the range multiplier
chart.

5
2.2 Electrical: Input/Output
Input Power 100 to 240 VAC, 50 or 60 Hz, 7 A maximum
Fuse: 6.3 A
Inputs
Copper/Nickel Sensor Signals (0, 1 or 2 depending on model code):
Copper Walchem 190787 immersible OR 190785, 190893, 191596 ow through
sensors
Nickel Walchem 190784 ow through sensor
Sensor Input Signals (0, 1 or 2 depending on model code):
Contacting Conductivity 0.01, 0.1, 1.0, or 10.0 cell constant OR
Electrodeless Conductivity (not available on the combination sensor/analog input card) OR
Disinfection OR
Amplied pH, ORP or ISE Requires a preamplied signal. Walchem WEL or WDS series recommended.
±5VDC power available for external preamps.
Each sensor input card contains a temperature input
Temperature 100 or 1000 ohm RTD, 10K or 100K Thermistor
Analog (4-20 mA) Sensor Input (0, 1,
2 or 4 depending on model code):
2-wire loop powered or self-powered transmitters supported
3 or 4 –wire transmitters supported
Each dual sensor input board has two channels
Channel 1, 130 ohm input resistance
Channel 2, 280 ohm input resistance
The combination input board has one channel, 280 ohm input resistance
Available Power:
One independent isolated 24 VDC ± 15% supply per channel
1.5 W maximum for each channel
2W (83 mA at 24 VDC) total power consumption for all channels (four
total channels possible if two dual boards are installed; 2W is equivalent to
2 Little Dipper sensors)
Digital Input Signals (6):
State-Type Digital Inputs Electrical: Optically isolated and providing an electrically isolated 9V
power with a nominal 2.3mA current when the digital input switch is
closed
Typical response time: < 2 seconds
Devices supported: Any isolated dry contact (i.e. relay, reed switch)
Types: Interlock
Low Speed Counter-Type Digital
Inputs
Electrical: Optically isolated and providing an electrically isolated 9VDC
power with a nominal 2.3mA current when the digital input switch is
closed 0-20 Hz, 25 msec minimum width
Devices supported: Any device with isolated open drain, open collector,
transistor or reed switch
Types: Contacting Flowmeter, Flow Verify
High Speed Counter-Type Digital
Inputs
Electrical: Optically isolated and providing an electrically isolated 9VDC
power with a nominal 2.3mA current when the digital input switch is
closed, 0-500 Hz, 1.00 msec minimum width, Minimum pulse rate to see
paddlewheel rate = 0.17 Hz
Devices supported: Any device with isolated open drain, open collector,
transistor or reed switch
Types: Paddlewheel Flowmeter, DI Counter
Note: Total available power on the Digital Input 9 VDC is 111 mA

6
Outputs
Powered mechanical relays (0 or 6
depending on model code):
Pre-powered on circuit board switching line voltage
6 A (resistive), 1/8 HP (93 W)
All six relays are fused together as one group, total current for this group
must not exceed 6A
Dry contact mechanical relays (0, 2
or4 depending on model code):
6 A (resistive), 1/8 HP (93 W)
Dry contact relays are not fuse protected
Pulse Outputs (0, 2 or4 depending on
model code):
Opto-isolated, Solid State Relay
200mA, 40 VDC Max.
VLOWMAX = 0.05V @ 18 mA
Accuracy (0-10 Hz): ± 0.5% of Pulse Rate, (10-20 Hz): ± 1.0%, (20-40
Hz): ± 2.0%
4 - 20 mA (0 or 2) Internally powered
Fully isolated
600 Ohm max resistive load
Resolution 0.0015% of span
Ethernet 10/100 802.3-2005
Auto MDIX support
Auto Negotiation
USB Connector: Type A receptacle
Speed: High speed (480 Mbit)
Power: 0.5 A maximum
Battery (Real-Time Clock) Model BR2032, 3-volt Lithium Coin Cell 20 mm diameter
Agency Approvals:
EMC UL 61010-1:2012 3rd Ed + Rev:2019
CSA C22.2 No. 61010-1:2012 3rd Ed. + U1; U2
IEC 61010-1:2010 3rd Ed. + A1:2016
EN 61010-1:2010 3rd Ed. + A1:2019
BS EN 61010-1:2010 + A1:2019
EMC IEC 61326-1:2020
EN 61326-1:2013
BS EN 61326-1:2013
For EN 61000-4-3 Radiated RF Immunity, the controller meets Performance Criteria B. In environments where severe radio-frequency
interference (RFI) is present, the controller may reboot/restart. If this occurs, the controller should be relocated away from the electromagnetic
interference (EMI) source.
*Class A equipment: Equipment suitable for use in establishments other than domestic, and those directly connected to a low voltage
(100-240 VAC) power supply network which supplies buildings used for domestic purposes.
2.3 Intended Use
The Walchem Intuition-6 is a microprocessor-based measuring and control instrument used to measure water quality param-
eters and other process variables in a wide range of water and wastewater treatment applications. Operating the instrument
in any way other than as described in these instructions may compromise the safety and function of the measuring system
and is therefore impermissible. Electrical connection work and maintenance work may only be carried out by qualied per-
sonnel. The manufacturer is not liable for damage caused by improper or non-designated use.
2.4 Mechanical
Enclosure Material Polycarbonate
Enclosure Rating NEMA 4X (IEC 60529 to IP66)
Dimensions 11.1” x 8.3” x 5.5” (282 mm x 211 mm x 140 mm)

7
Display 5" TFT color display, 800 x 480 pixels with capacitive touchscreen
Operating Ambient Temp -4 to 131 °F (-20 to 55 °C)
Storage Temperature -4 – 176°F (-20 – 80°C)
Humidity 10 to 90% non-condensing
pH/ORP
LD2
Cond
HP Cond/Steel
0
50
100
150
200
250
300
350
30 40 50 60 70 80 90
100 110 120 130 140 150 160 170 180
°F
Pressure vs. Temperature
PSI
-1.1 4.4 10.0 15.5 21.1 26.6 32.2 37.7 43.3 48.8 54.4 60.0 65.5 71.1 76.6 82.2
°C
Bar
HP pH/ORP/Steel
24.1
20.7
17.2
13.8
10.3
6.9
3.4
2.5 Variables and their Limits
Sensor Input Settings Low Limit High Limit
Calibration Oset (Copper or Nickel only) -10 g/l or oz/gal 10 g/l or oz/gal
Stabilization Time (Copper or Nickel only) 0:00 minutes 59:59 minutes
Alarm limits Low end of sensor range High end of sensor range
Input alarm dead band Low end of sensor range High end of sensor range
Cell constant (conductivity only) 0.01 10
Smoothing Factor 0% 90%
Temp Comp Factor (conductivity linear ATC only) 0% 20.000%
Installation Factor (Electrodeless conductivity only) 0.5 1.5
Cable length 0.1 3,000
PPM conversion factor (only if units = PPM) 0.001 10.000
Default temperature -20 500
Deadband Low end of sensor range High end of sensor range
Calibration Required Alarm 0 days 365 days
Sensor Slope (Generic sensor only) -1,000,000 1,000,000
Sensor Oset (Generic sensor only) -1,000,000 1,000,000
Low Range (Generic sensor only) -1,000,000 1,000,000
High Range (Generic sensor only) -1,000,000 1,000,000
4 mA value (Transmitter, AI Monitor analog input only) 0 100
20 mA value (Transmitter, AI Monitor analog input only) 0 100
Flow meter input settings Low Limit High Limit
Totalizer alarm 0 100,000,000
Volume/contact for units of Gallons or Liters 1 100,000

8
Volume/contact for units of m30.001 1,000
K Factor for units of Gallons or Liters 0.01 100,000
K Factor for units of m31 1,000,000
Paddlewheel rate alarm limits 0 High end of sensor range
Paddlewheel rate alarm deadband 0 High end of sensor range
Smoothing Factor 0% 90%
Set Flow Total 0 1,000,000,000
Feed Monitor Input Settings Low Limit High Limit
Totalizer Alarm 0 vol. units 1,000,000 vol. units
Set Flow Total 0 vol. units 1,000,000,000 vol. units
Flow Alarm Delay 00:10 Minutes 59:59 Minutes
Flow Alarm Clear 1 Contact 100,000 Contacts
Dead Band 0% 90%
Reprime Time 00:00 Minutes 59:59 Minutes
Volume/Contact 0.001 ml 1,000.000 ml
Smoothing Factor 0% 90%
Counter Input Settings Low Limit High Limit
DI Counter Rate Alarms 0 30,000
DI Counter Rate Deadband 0 30,000
Totalizer Alarm 0 2,000,000,000
Set Total 0 2,000,000,000
Units per Pulse 0.001 1,000
Smoothing Factor 0% 90%
Relay output settings Low Limit High Limit
Output Limit Time 1 second 86,400 seconds (0 = unlimited)
Hand Time Limit 1 second 86,400 seconds (0 = unlimited)
Min Relay Cycle 0 seconds 300 seconds
Set Point Low end of sensor range High end of sensor range
Spike Set Point (Spike mode) Low end of sensor range High end of sensor range
Onset Time (Spike Mode) 0 seconds 23:59:59 HH:MM:SS
On Delay Time (Manual, On/O, Dual Setpoint modes, Dual
Switch, Alarm modes)
0 seconds 23:59:59 HH:MM:SS
O Delay Time (Manual, On/O, Dual Setpoint modes, Dual
Switch, Alarm modes)
0 seconds 23:59:59 HH:MM:SS
Dead Band Low end of sensor range High end of sensor range
Turnover Volume (Plating Control, Plating Follow modes) 0 10,000
Turnover Limit (Plating Control, Plating Follow modes) 0 100
Set Turnover Value (Plating Control mode) 0 100
Pump Capacity (Plating Control, Plating Follow modes) 0 1,000
Pump Setting (Plating Control, Plating Follow modes) 0% 100%
Feed duration (Flow Timer, Counter Timer mode) 0 seconds 86,400 seconds
Accumulator Setpoint (Counter Timer mode) 1 1,000,000
Accumulator Volume (Flow Timer, Target PPM, PPM
Volume, Volumetric Blend, Flow Meter Ratio modes)
1 1,000,000
Event duration (Timer modes) 0 30,000
Proportional band (Time/Pulse Proportional mode) Low end of sensor range High end of sensor range
Sample period (Time Proportional mode) 0 seconds 3600 seconds

9
Hold Time (Probe Wash modes) 0 seconds 3600 seconds
Max Rate (Pulse Proportional, Pulse PID modes) 10 pulses/minute 2400 pulses/minute
Minimum Output (Pulse Proportional, Pulse PID modes) 0% 100%
Maximum Output (Pulse Proportional, Pulse PID modes) 0% 100%
Gain (Pulse PID Standard mode) 0.001 1000.000
Integral Time (Pulse PID Standard mode) 0.001 seconds 1000.000 seconds
Derivative Time (Pulse PID Standard mode)us 0 seconds 1000.000 seconds
Proportional Gain (Pulse PID Parallel mode) 0.001 1000.000
Integral Gain (Pulse PID Parallel mode) 0.001 /second 1000.000 /second
Derivative Gain (Pulse PID Parallel mode) 0 seconds 1000.000 seconds
Input Minimum (Pulse PID modes) Low end of sensor range High end of sensor range
Input Maximum (Pulse PID modes) Low end of sensor range High end of sensor range
Wear Cycle Time (Lag mode) 10 seconds 23:59:59 HH:MM:SS
Delay Time (Lag mode) 0 seconds 23:59:59 HH:MM:SS
Analog (4-20 mA) Output Settings Low Limit High Limit
4 mA Value (Retransmit mode) Low end of sensor range High end of sensor range
20 mA Value (Retransmit mode) Low end of sensor range High end of sensor range
Hand Output 0% 100%
Set Point (Proportional, PID modes) Low end of sensor range High end of sensor range
Delay Time (Lag mode) 0 seconds 23:59:59 HH:MM:SS
Bleed Volume (Flow Meter Ratio mode) 1 1,000,000
Pump Capacity (Flow Prop mode) 0 gal/hour or l/hour 10,000 gal/hour or l/hour
Pump Setting (Flow Prop mode) 0% 100%
Specic Gravity (Flow Prop mode) 0 g/ml 9.999 g/ml
Target (Flow Prop mode) 0 ppm 1,000,000 ppm
Analog (4-20 mA) Output Settings Low Limit High Limit
4 mA Value (Retransmit mode) Low end of sensor range High end of sensor range
20 mA Value (Retransmit mode) Low end of sensor range High end of sensor range
Hand Output 0% 100%
Set Point (Proportional, PID modes) Low end of sensor range High end of sensor range
Proportional Band (Proportional mode) Low end of sensor range High end of sensor range
Minimum Output (Proportional, PID modes) 0% 100%
Maximum Output (Proportional, PID modes) 0% 100%
O Mode Output (Proportional, PID modes, Flow Prop modes) 0 mA 21 mA
Error Output (not in Manual mode) 0 mA 21 mA
Hand Time Limit (not in Retransmit mode) 1 second 86,400 seconds (0 = unlimited)
Output Time Limit (Proportional, PID modes) 1 second 86,400 seconds (0 = unlimited)
Gain (PID, Standard mode) 0.001 1000.000
Integral Time (PID Standard mode) 0.001 seconds 1000.000 seconds
Derivative Time (PID Standard mode) 0 seconds 1000.000 seconds
Proportional Gain (PID Parallel mode) 0.001 1000.000
Integral Gain (PID Parallel mode) 0.001 /second 1000.000 /second
Derivative Gain (PID Parallel mode) 0 seconds 1000.000 seconds
Input Maximum (PID modes) Low end of sensor range High end of sensor range
Pump Capacity (Flow Prop mode) 0 gal/hour or l/hour 10,000 gal/hour or l/hour
Pump Setting (Flow Prop mode) 0% 100%
Specic Gravity (Flow Prop mode) 0 g/ml 9.999 g/ml

10
Target (Flow Prop mode) 0 ppm 1,000,000 ppm
Congurationsettings Low Limit High Limit
Local Password 0000 9999
Fluent update period 1 minute 1440 minutes
Fluent reply timeout 10 seconds 60 seconds
Alarm Delay 0:00 minutes 59:59 minutes
SMTP Port 0 65535
TCP Timeout 1 second 240 seconds
Auto Dim Time 0 seconds 23:59:59 HH:MM:SS
Graph settings Low Limit High Limit
Low axis limit Low end of sensor range High end of sensor range
High axis limit Low end of sensor range High end of sensor range
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 an Intuition-6™ Series controller and
an instruction manual. Any options or accessories will be incorporated as ordered.
3.2 Mounting the electronic enclosure
The 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. Do not install the enclosure in a lo-
cation where it will be exposed to direct sunlight. Use M6 (1/4” diameter) fasteners that are appropriate for the substrate
material of the wall. The enclosure is NEMA 4X (IP66) rated. The maximum operating ambient temperature is 131°F
(55°C); this should be considered if installation is in a high temperature location. The enclosure requires the follow-
ing clearances:
Top: 2” (50 mm)
Left: 8” (203 mm) (not applicable for prewired models)
Right: 4” (102 mm)
Bottom: 7” (178 mm)
3.3 Immersible Copper Sensor Installation
The immersible copper sensor is designed for direct in-tank monitoring of electroless copper and microetch solutions.
By monitoring the copper content directly in the solution, control lag and hydraulic problems are eliminated.
The sensor is constructed such that a constant path length exists between the ber optic light guides. The solution
between the light guides absorbs light at specic wavelengths in proportion to the copper concentration. The lamp and
4.8 in
122 mm
9.6 in 244 mm
5.5 in
140 mm
8.3 in
211 mm
11.1 in 282 mm
8.9 in 226 mm
6.7 in
170 mm
9.0 in 229 mm
6.8 in
173 mm
4.4 in
112 mm

11
electronics are located under the cover of the sensor. In order to avoid a shift in calibration due to condensation, the
sensor’s cover should NEVER be opened.
The immersible sensor is provided with a mounting plate and 20 feet of cable. Extension cable is available if the sen-
sor cannot be mounted within 20 feet of the controller. The maximum cable length is 80 feet.
While the positioning of the sensor is not particularly sensitive to the tank layout, the following suggestions are given
to aid installation:
• Do not place the sensor beside heaters; if solution ow stops, the polypropylene guard may melt.
• Do not immerse the entire sensor, or the cable.
• Place the sensor where the loads of parts will not strike it.
• Place the sensor in an area of good solution movement, but not directly in the path of any air agitation.
• Mount the sensor securely to the rim of the tank using the holes provided. If the tank is rimless, use a block to
provide the support for the mounting plate.
• Attach the cable’s connector to the WCU controller. The connector is keyed, do not force! The sensor you
receive with the controller has already been calibrated.
3.4 Flow Through Copper Sensor/Sample Loop Installation
The copper ow through sensor is designed for out-of-tank monitoring of electroless copper and microetch solutions.
The sensor is designed with a glass tube that contains the copper solution that forms a xed path length between the
lamp and receptor module. The solution absorbs light at specic wavelengths in proportion to the copper concentra-
tion. In order to avoid a shift in calibration caused by condensation, the sensor cover should NEVER be removed!
The ow through sensor is provided with a mounting plate and 20 feet of cable. Extension cable is available if the
sensor cannot be placed within 20 feet of the controller. The maximum cable length is 80 feet.
The sample loop consists of a shut o valve, a cooling coil or plate, a sensor and a pump or any combination thereof.
The shut o valve is to quickly isolate the system if necessary. A cooling coil or plate is necessary to cool the cop-
per solution down to a temperature acceptable to a sample pump. Cooling the solution is also recommended to help
reduce the amount of plate out which may form in the sample loop. The pump may be either a stand alone sample
pump (which typically have temperature restriction) or a high temperature pump (which is usually just a branch o
the recirculation pump).
3.5 Flow Through Nickel Sensor/Sample Loop Installation
The nickel ow through sensor is designed for out-of-tank monitoring of electroless nickel solutions.
The sensor is designed with a glass tube that contains the nickel solution that forms a xed path length between the
lamp and receptor module. The solution absorbs light at specic wavelengths in proportion to the nickel concentra-
tion. In order to avoid a shift in calibration caused by condensation, the sensor cover should NEVER be removed!
The ow through sensor is provided with a mounting plate and 20 feet of cable. Extension cable is available if the
sensor cannot be placed within 20 feet of the controller. The maximum cable length is 80 feet. Always route AC volt-
age wiring in conduit that is separated a minimum of 6 inches from low voltage DC signal lines (such as the sensor
signal).The sample loop consists of a shut o valve, a cooling coil or plate, a sensor, an optional pH adapter assembly,
a pump, or any combination thereof. The shut o valve is to quickly isolate the system if necessary. A cooling coil or
plate is necessary to cool the nickel solution down to a temperature acceptable to a sample pump and/or pH electrode
(if applicable). Cooling the solution is also recommended to help reduce the amount of plate-out that may form in the
sample loop. The pH adapter assembly is used to mount an in-line pH electrode. It should be mounted such that the
electrode is always immersed in the ‘U’ trap. The pump may be either a stand-alone sample pump (which will typical-
ly have high temperature restrictions), or a high temperature pump (which is usually a branch o of the recirculation
pump).

12
The ow through sensor/sample loop must be installed according to the following guidelines:
• Mount the sensor on a vibration-free, vertical surface so that the sensor tubing inlet connection is at the bottom and
the outlet is at the top. The vertical orientation will prevent air bubbles from being trapped in the sensor.
• Install a shut-o valve at the beginning of the sample loop so that the system may be shut o quickly if necessary.
• If a sample pump is to be used, it must be installed last, after the cooling coil or cooling plate, the ow through
sensor, and the pH adapter assembly, if applicable.
• If a high temperature recirculation pump is to supply ow, adjust ow rate through the sample loop between 400
- 500 mL/min (approx. 0.11 - 0.13 gal/min). This ow rate will help ensure adequate cooling of the solution while
maintaining a reasonable lagtime in longer runs of tubing. If this is not possible or is undesirable, see Application
Notes below.
Other installation guidelines that may be helpful in the overall system:
• Mount the sensor as close to solution as possible. Keep tubing distances to the sensor inlet as short as possible to
avoid hydraulic lag time. Maximum recommended length of tubing from solution to sensor is 25 feet. If this is not
possible, see Application Notes below.
• The solution inlet should draw sample from an area of good solution movement in order to respond quickly to
chemical additions. However, the solution inlet should not draw too near to where the chemistry is added to avoid
articial ‘spikes’ in concentration.
• The solution discharge should be open to atmospheric pressure in order to ensure proper ow.
• The cable connector to the controller is keyed, do not force!
Application Notes
If the distance from the solution to the sensor is further than the recommended length of 25 feet, the maximum lagtime
must be calculated from the desired control band to determine a pump ow rate based on a given distance of standard,
uniform tubing. The maximum lagtime is the maximum allowable time for the solution to continuously get to the
sensor in order to achieve the desired control band.
To calculate maximum lagtime:
Max. Lagtime = Desired Control Band*
4 x Depletion Rate
where Control band = Maximum deviation of concentration
Depletion rate = Rate at which the bath will deplete per unit of time
The deadband should be adjusted so that it is 1/4 the desired control band.
For Example: The set point is 4.00 g/L.
If the desired control band is 0.20 g/L (± 0.10 g/L or 2.5%) and the bath is depleting at a rate of 1.25 g/L every
15 minutes (0.08333 g/L every minute),
then Max. Lagtime = 0.20 g/L = 0.60 minutes
4 x (0.08333 g/L /min)
So, 0.60 minutes is the maximum time it should take for the solution to reach the sensor.

13
To calculate pump ow rate:
Minimum Pump Flow Rate = Volume of System*
Maximum Lagtime
where Volume of system = π ( Tubing I.D.) 2 x Length of tubing
2
Maximum lagtime = Previously calculated time to get solution to sensor.
* Volume is based on length from solution to sensor, not the return.
For Example: If the system parameters are: Tubing is 3/8” O.D. ‘ 1/4” I.D.
Length is 30 feet (360 inches)
then the volume of the system = π ( 0.25 in )2 x (360 in)
2
= 17.7 in3
Note: 1 U.S. Gallon = 231 U.S cubic inches 1 Liter = 61.03 U.S. cubic inches
Note: Volume of Cooling Coil: 0.018 Gallons
0.068 Liters
Volume of Cooling Plate: 0.023 Gallons
0.088 Liters
Volume of 3/8” O.D. x 1/4” I.D. (0.59 in3/ft): 0.00255 Gallons/linear ft
0.00965 Liters/linear ft
Volume of the system = 17.7 in3 = 0.0765 gallons
231 in3 / gallon
Maximum lagtime = 0.60 minutes (previously calculated)
So, the minimum pump ow rate = 0.0765 gallons = 0.127gal/min (483 mL/min)
0.60 minutes
Caution: The calculated pump ow rate is the minimum required to obtain the desired control band, however, if the
ow rate increases over the recommended rate of 500 mL/min (approx. 0.13 gal/min) the rate of cooling will de-
crease. This may be compensated for by re-evaluating the system criteria: length / desired control band or to double
up on the cooling plate/coil.
Consult factory with any further installation questions.
3.6 Other Sensor Installation
Refer to the specic instructions supplied with the sensor being used, for detailed installation instructions.
General Guidelines
Locate the sensors where an active sample of water is available and where the sensors can easily be removed
for cleaning. Position the sensor such that air bubbles will not be trapped within the sensing area. Position the
sensor where sediment or oil will not accumulate within the sensing area.
In-Line Sensor Mounting
In-line mounted sensors must be situated so that the tee is always full and the sensors are never subjected to a
drop in water level resulting in dryness. Refer to Figure 3 for typical installation.
Tap o the discharge side of the recirculation pump to provide a minimum ow of 1 gallon per minute through

14
the ow switch manifold. The sample must ow into the bottom of the manifold in order to close the ow switch,
and return to a point of lower pressure in order to ensure ow. Install an isolation valve on both sides of the man-
ifold to stop ow for sensor maintenance.
IMPORTANT: To avoid cracking the female pipe threads on the supplied plumbing parts, use no more than 3
wraps of Teon tape and thread in the pipe FINGER tight plus 1/2 turn! Do not use pipe dope to seal the threads
of the ow switch because the clear plastic will crack!
Submersion Sensor Mounting
If the sensors are to be submersed in the process, mount them rmly to the tank, and protect the cable with
plastic pipe, sealed at the top with a cable gland, to prevent premature failure. Place the sensors in an area of good
solution movement.
Sensors should be located such that they respond rapidly to a well-mixed sample of the process water and the
treatment chemicals. If they are too close to the chemical injection point, they will see spikes in concentration
and cycle on and o too frequently. If they are too far away from the chemical injection point, they will respond
too slowly to the concentration changes, and you will overshoot the set point.
The contacting conductivity sensor should be placed as close to the controller as possible, to a maximum
distance of 250 ft. (76 m). Less than 25 ft. (8 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.
The electrodeless conductivity sensor should be placed as close to the controller as possible, to a maximum
distance of 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 sensors are aected by the geometry and conductivity of their surroundings, so either maintain 6
inches (15 cm) of sample around the sensor or ensure that any nearby conductive or non-conductive items are
consistently positioned. Do not install the sensor in the path of any electrical current that may be owing in the
solution, as this will shift the conductivity reading.
The pH/ORP/ISE electrode should be placed as close to the controller as possible, to a maximum distance of 1000
feet (305 m) from the controller. A junction box and shielded cable are available to extend the standard 20 foot (6
m) length. pH and ORP electrodes must be installed such that the measuring surfaces will always remain wet. A
U-trap provided in the manifold design should achieve this, even if the sample ow stops. These electrodes also
must be installed with the measuring surfaces pointing down; that is 5 degrees above the horizontal, at a minimum.
The ow velocity past the sensor must be less than 10 ft./sec. (3 m/sec.)
The disinfection sensor should be placed as close to the controller as possible, to a maximum distance of 100
feet (30 m) from the controller. A junction box and shielded cable are available to extend the standard 20 foot (6
m) length. The sensor should be mounted such that the measuring surfaces will always stay wet. If the membrane
dries out, it will respond slowly to changing disinfectant values for 24 hours, and if dried out repeatedly, will fail
prematurely. The ow cell should be placed on the discharge side of a circulation pump or downhill from a grav-
ity feed. Flow into the cell must come from the bottom side that has the ¾” x ¼” NPT reducing bushing installed.
The reducing bushing provides the ow velocity required for accurate readings and must not be removed! A “U”
trap should be installed so that if the ow stops, the sensor is still immersed in the water. The outlet of the ow
cell must be plumbed to open atmosphere unless the system pressure is at or below 1 atmosphere. If the ow
through the line cannot be stopped to allow for cleaning and calibration of the sensor, then it should be placed in
a by-pass line with isolation valves to allow for sensor removal. Install the sensor vertically, with the measuring
surface pointing down, at least 5 degrees above horizontal. Flow rate regulation must be done upstream from the
sensor, because any ow restriction downstream can increase the pressure above atmospheric and damage the
membrane cap!

15
Figure 1
CONVEYORIZED SPRAY EQUIPMENT
W A L C H E M
COPPER CAUSTIC
FORMAL-
DEHYDE
STABILIZER
POWER
POWER
20 FT
IMMERSIBLE
SENSOR
PLATING BATH
SODIUM
PERSULFATE
CIRCULATING
PUMPS
MANUAL
VALVE FLOW
THROUGH
SENSOR
METERING PUMPS
TO
WASTE
TREATMENT
"BLEED"
3/8" TUBING
(< 20' PERFERRABLE)
WCU WITH FLOW-THROUGH SENSOR
(TYPICAL MICROETCH APPLICATION)
WCU WITH IMMERSIBLE SENSOR
(TYPICAL ELECTROLESS COPPER APPLICATION)
(80 FT MAX.)
80 FT. MAX.