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
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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