Superior WATERGUARD WG-602 User manual

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WATERGUARD WG-602
FREE CHLORINE ANALYZER
User Manual
V5.15US January 2018

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Table of Contents
1General Safety Precautions............................................................................... 4
2Preface.............................................................................................................. 5
2.1 Intended Use............................................................................................... 5
2.2 Safety Precautions...................................................................................... 5
3Overview ........................................................................................................... 6
3.1 Features...................................................................................................... 6
3.2 System Components................................................................................... 6
4Installation....................................................................................................... 13
4.1 Location Considerations............................................................................ 13
4.2 Site Requirements and Installation............................................................ 13
4.2.1 Mechanical Installation....................................................................... 13
4.3 Plumbing Requirements and Installation................................................... 14
4.3.1 Water supply and drain ...................................................................... 14
4.4 Electrical Requirements and Installation.................................................... 15
4.4.1 Connecting the Main Electrical Power................................................ 16
4.4.2 Input Switches.................................................................................... 16
4.5 Installing electrodes .................................................................................. 17
4.5.1 Free Chlorine electrode OCS140....................................................... 17
4.5.2 pH electrode....................................................................................... 19
4.5.3 Temperature sensor........................................................................... 19
5First Time Operation and Calibration............................................................... 20
5.1 Menu Setup............................................................................................... 20
5.2 Operator Menu.......................................................................................... 21
5.3 Technician Menu....................................................................................... 24
5.4 Calibration.................................................... Error! Bookmark not defined.
5.4.1 Temperature Calibration..................................................................... 27
5.4.2 pH Calibration.................................................................................... 28
5.4.3 Chlorine Electrode Calibration............................................................ 29
5.5 4 to 20 mA Output configuration................................................................ 30
6Routine Operation and Maintenance ............................................................... 31
6.1 Filter Cleaning........................................................................................... 31
6.2 Shut-down and Winterizing ....................................................................... 31
6.3 Start-up and Preventive Maintenance ....................................................... 31
6.4 Chlorine Electrode Maintenance ............................................................... 31
6.4.1 Cleaning the electrode....................................................................... 31
6.4.2 Electrolyte Change............................................................................. 32
6.4.3 Membrane Cap Change..................................................................... 32
6.4.4 Storage.............................................................................................. 33
7Technical Specification.................................................................................... 33

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Table of figures
Figure 1: WG602 FCL Analyzer –General overview……………………………………
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Figure 2: Acrylic Flow cell Overview………………………………………………….
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Figure 2a: Acrylic Flow cell Overview…………………………………………………
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Figure 3: Controller Overview………………………………………………………….
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Figure 4: Electrodes Card………………………………………………………………
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Figure 5: I/O Card……………………………………………………………………….
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Figure 6: Control Panel Card…………………………………………………………..
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Figure 7: Mounting Panel holes and mechanical installation………………………
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Figure 8: Water connections, Pressure regulating and flow regulating…………..
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Figure 9: Free Chlorine electrode…………………………………………………….
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Figure 10: WG602 FCL Control panel and Display………………………………….
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1 General Safety Precautions
This section presents important information intended to ensure safe
and effective use of this product.
Read the following carefully before handling the product. These
warnings and cautions must be followed carefully to avoid injury to
yourself or damage to equipment.
Warning: Only properly trained and licensed electricians should attempt to wire or service
the electronic components of the analyzer/controller.
There is an Electrical Shock Hazard when servicing this system.
Always verify that all electrical power source(s) are off before opening the
analyzer/controller unit or attempting to service electronic components or wiring.
Caution: Extreme caution should be used when installing, operating, and maintaining the
WATERGUARD®Analyzer. Only properly trained technicians are authorized to install and
maintain the analyzer/controller.
Always follow local health and safety regulations when performing any service on the
analyzer/controller unit or when changing chemical dosing settings.
Each relay connection is limited to 8 amps, to prevent overheating. The relays may show a
higher rating but do not connect equipment exceeding 8 amps.
All electrical connections should comply with National Electrical Code (NEC) and all local
regulations.
Caution: Do not use chemicals that reduce the surface tension. When using hydrochloric
acid, observe all safety regulations.
Electrodes:
Warning: Do not swallow the electrolyte. Avoid electrolyte contact with skin or eyes. In
case of accidental contact, wash with cold water! In case of eye inflammation, contact a
doctor immediately. Wear safety glasses and gloves when working with the electrolyte
solution.
Caution: Do not touch or damage the electrodes. The electrolyte is sensitive to oxidation:
Always keep the electrolyte bottle closed after use. Do not transfer the electrolyte to other
containers. The electrolyte should not be stored for more than one year and should be
clear (not yellow) in appearance (for use by date, see label). Avoid forming air bubbles
when pouring the electrolyte into the measuring chamber.
Caution: WATERGUARD's controller unit should not be opened except for initial
installation and troubleshooting, and should only be opened by a trained and approved
technician.

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2 Preface
The WaterGuard WG-602 Free chlorine (FCL) is an amperometric chlorine analyzer
that measures free chlorine in water applications.
2.1 Intended Use
This manual is for qualified and trained service technicians who will install and
service the WaterGuard WG-602 Chlorine Analyzer. It provides instructions on how
to install the WaterGuard system, as well as how to calibrate, operate, and maintain
the system.
2.2 Safety Precautions
WARNING
Only properly trained and licensed electricians should attempt to wire or service
the electronic components of the analyzer. There is an Electrical Shock Hazard
when servicing this system. Always verify that all electrical power source(s) are
off before opening the analyzer unit or attempting to service electronic
components or wiring.
CAUTION
Extreme caution should be used wheninstalling, operating, and maintaining the
WaterGuard WG-602 Water Quality Analyzer and Controller. Only properly
trained technicians are authorized to install and maintain the analyzer. Only
properly trained and licensed electricians should attempt any change to the
system’s electrical components. Only properly trained and licensed operators
should attempt to make any changes to chemical dosing levels.
NOTE
Always follow local health and safety regulations when performing any service
on the WaterGuard unit or changing chemical dosing settings.

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3 Overview
3.1 Features
The WaterGuard WG602 Free chlorine (FCL) is an amperometric chlorine analyzer
that measures free chlorine in water applications. The analyzer includes a free
chlorine electrode, pH and temperature sensors.
The WG602 FCL analyzer includes 2 built-in 4/20 mA analog outputs, and can
support additional 4 analog outputs (total of 6 analog outputs) when required.
The WG602 FCL analyzer includes RS485 digital output that support MODBUS
communication protocol OR BLUE I communication protocol for remote
communication options. For more information about remote communication and
WATERGUARD ON-LINE remote management tools please contact your local
distributor or representative.
The WG602 FCL analyzer supports connection of external conductivity and turbidity
sensors, fully displayed. For more information about conductivity and turbidity
measurements options please contact your local distributor or representative.
3.2 System Components
The WG602 FCL analyzer is a board mounted analyzer and includes all required
components for installation.
The system includes the following components:
1. Controller –includes the display and keyboard panel. Includes 3 electronic
cards: Control panel card, I/O card and electrodes card.
2. Acrylic flow cell –includes free chlorine electrode, pH electrode, Temperature
sensor, flow switch (proximity flow switch), water inlet and outlet ports, and
sampling port.
3. Pre-filter (washable disc filter) –the filter is a 120 micron disc filter and it's
goal is to remove large particles from getting in to the acrylic flow cell.
4. Pressure regulator –the pressure regulator maintains a constant pressure
and flow in the acrylic flow cell, to allow stable readings of the chlorine
electrode.

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Figure 1: WG602 FCL Analyzer - General overview
1. Controller
2. Free chlorine electrode
3. pH electrode
4. Acrylic flow cell
5. Water inlet (on/off ball valve)
6. Pre-filter (washable disc filter)
7. Pressure regulator
8. Water drain
9. Power connection

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Figure 2: Acrylic flow cell overview
Figure 2a: Acrylic flow cell overview
1. Free chlorine electrode
2. pH electrode
3. Float (proximity flow switch)
4. Proximity flow switch
5. Flow regulator
6. Temperature sensor
7. Flow cell water inlet
8. Sampling valve
9. Sampling connection
10. Flow cell water drain

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Figure 3: Controller overview
1. Electrodes card
2. I/O card
3. Control panel card

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Figure 4: Electrodes card
1. pH electrode [+]
2. pH electrode [-] sheath
3. ORP jumper
4. ORP jumper
5. FCL electrode wire A
6. FCL electrode wire K
7. FCL electrode wire GROUND
8. Temp sensor (color coded)
9. Temp sensor (color coded)
10. Temp sensor (color coded)
11. Temp sensor (color coded)
12. Flat cable from I/O card