Superior WATERGUARD WG-702 User manual

Copyright © Chemical Injection Technologies, Inc.
WATERGUARD® WG-702
Water Quality Analyzer &
Controller
User Manual

Copyright © Chemical Injection Technologies, Inc.
Disclaimer
Chemical Injection Technologies does not accept any
responsibilityfor any damage caused to its products by
unauthorized personnel. Use of non-Chemical Injection
Technologies reagents and/or replacement parts will void all
warranties.
No part of this publication may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into any
language or any computer language, in any form or by any third
party, without the prior written permission of Chemical
Technologies.

Copyright © Chemical Injection Technologies, Inc.
Table of Contents
1 General Safety Precautions
............................................................................................... 8
2
Preface............................................................................................................................. 10
2.1 Intended Use
........................................................................................................... 10
2.2 Overview of Chapters .............................................................................................. 10
3 Overview........................................................................................................................... 12
3.1 The WATERGUARD Solution
................................................................................. 12
3.2 Measurements and Features................................................................................... 12
3.2.1 Wireless Management Package* ........................................................................ 13
3.3 System Components ............................................................................................... 13
4 Installation ........................................................................................................................ 15
4.1 Selecting a Location
................................................................................................ 16
4.2 Site Requirements and Installation .......................................................................... 16
4.2.1 Mechanical Installation Requirements ................................................................. 17
4.2.2 Mechanical Installation ........................................................................................ 17
4.3 Plumbing Requirements and Installation ................................................................. 18
4.3.1 Water Supply ....................................................................................................... 18
4.3.2 Colorimeter Drainage........................................................................................... 18
4.4 Electrical Requirements and Installation ................................................................. 19
4.4.1 Connecting the Main Electrical Power ................................................................. 19
4.4.2 Input Switches ..................................................................................................... 19
5 First Time Operation and Calibration ............................................................................... 21
5.1 Installing Additional Sensors
................................................................................... 21
5.1.1 pH, ORP (Redox) and Temperature Measurements ........................................... 21
5.2 Installing Reagents.................................................................................................. 22
5.3 First Time Menu Setup ............................................................................................ 25
5.3.1 WATERGUARD Control Panel ............................................................................ 25
5.3.2 Menus .................................................................................................................. 25
5.3.3 Operator Menu..................................................................................................... 26
5.3.4 Configuring Settings in the Operator Menu......................................................... 28
5.3.5 Technician Menu ................................................................................................. 29
5.3.6 Configuring Settings in the Technician Menu ...................................................... 31
5.4 Calibration................................................................................................................ 31
5.4.1 Chlorine Calibration............................................................................................. 32
5.4.2 pH Calibration ...................................................................................................... 33
5.4.3 ORP (Redox) Calibration ..................................................................................... 34
5.4.4 Temperature Calibration ...................................................................................... 34
5.4.5 Turbidity Calibration ............................................................................................. 35
5.5 Calibration and Initial Operation Checklist .............................................................. 35
6 Routine Operation and Maintenance ............................................................................... 37
6.1 MonitoringWATERGUARD
Alarms......................................................................... 38
6.2 Replacing Reagents ................................................................................................ 39
6.3 Cleaning the Filter.................................................................................................... 41
6.4 Shut-Down and Winterizing..................................................................................... 41
6.5 Start-up and Preventive Maintenance..................................................................... 42
6.5.1 Replacing Pump Head and Tubes....................................................................... 42

Copyright © Chemical Injection Technologies, Inc.
6.6 Troubleshooting ....................................................................................................... 43
6.7 Replacing Components ........................................................................................... 47
6.7.1 Replacing Sensors............................................................................................... 47
6.7.2 Replacing the Temperature Probe ...................................................................... 48
6.7.3 Replacing Reagent Siphons ................................................................................ 48
6.7.4 Replacing the Reagent Level Switch ................................................................... 48
6.7.5 Replacing Reagent Pumps .................................................................................. 48
6.7.6 Replacing the Colorimeter Assembly .................................................................. 49
6.7.7 Replacing the Solenoid Valve.............................................................................. 50
6.7.8 Replacing the Control Panel Module (Electronics Card)..................................... 51
6.7.9 Replacing the I/O Module .................................................................................... 51
6.7.10 Replacing the pH, Redox, and Temperature Card.............................................. 51
6.7.11 Replacing the Colorimeter Card .......................................................................... 52
7 Optional Features ............................................................................................................. 53
7.1 Optional Measurements
.......................................................................................... 53
7.2 Free and Total Chlorine Measurements .................................................................. 53
7.2.1 Installation............................................................................................................ 53
7.2.2 Additional Menus and Settings............................................................................ 55
7.2.3 Total Chlorine Monitoring Setup .......................................................................... 59
7.3 pH, ORP and Temperature Measurements ............................................................. 60
7.3.1 Installation............................................................................................................ 60
7.3.2 pH Calibration ...................................................................................................... 60
7.3.3 ORP Calibration ................................................................................................... 60
7.3.4 Temperature Calibration ...................................................................................... 60
7.4 Conductivity Measurement ...................................................................................... 60
7.4.1 Installation............................................................................................................ 60
7.4.2 First Time Set-up and General Operation ........................................................... 61
7.4.3 Routine Maintenance ........................................................................................... 61
7.4.4 Shut-down and Winterizing.................................................................................. 62
7.5 Flow Meter ............................................................................................................... 62
7.5.1 Installation............................................................................................................ 62
7.5.2 Routine Flow Meter Maintenance and Troubleshooting ...................................... 63
7.6 Modbus Communication Protocol............................................................................ 64
7.7 Communication Options .......................................................................................... 68
7.7.1 Internal 4-20 mA Output ...................................................................................... 68
7.8 Chlorine Shock Mode .............................................................................................. 70
8 Relays and Closed-Loop Control ..................................................................................... 71
8.1 Connecting external equipment to the
relays.......................................................... 71
8.2 Wiring to Dosing Systems ....................................................................................... 71
8.3 Replacing Relays ..................................................................................................... 72
9 Setting Proportional Control............................................................................................. 73
9.1 Proportional Control
Overview................................................................................. 73
9.2 Setting Proportional Factor ..................................................................................
9.3 Setting Pump Period ................................................................................................ 74
9.4 Step by Step Proportional Settings.......................................................................... 75
10 Technical Specifications.............................................................................................. 76

Copyright © Chemical Injection Technologies, Inc.
Table of
Figures
Figure 1: WATERGUARD HG-702
Components .................................................................... 15
Figure 2: MountingWATERGUARD on the Wall
.................................................................... 17
Figure 3: Pressure Reducing
Valve ......................................................................................... 18
Figure 4: Sampling Cell and Colorimeter
Components ........................................................... 19
Figure 5: Reagent Bottle
Labels .............................................................................................. 22
Figure 6: Mixing Indicator Salt into Indicator Fluid
.................................................................. 23
Figure 7: Reagent Bottles and Siphon
Caps........................................................................... 23
Figure 8: Reagent Bottles in
Position...................................................................................... 24
Figure 9: WATERGUARD Control Panel
................................................................................ 25
Figure 10: Sensor Reading After
Calibration........................................................................... 32
Figure 11: Press Tab above Siphon Cover and Pull Bottle
Down........................................... 40
Figure 12: Colorimeter Assembly
Unit ..................................................................................... 49
Figure 13: Solenoid Valve with Colorimeter Module and Sampling
Cell ................................. 51
Figure 14: Replacing All Types of Electronic
Card .................................................................. 51
Figure 15: Free and Total Chlorine
Controller ......................................................................... 54
Figure 16: Relay positions on
board ........................................................................................ 71
Figure 17: Proportional Control of Chemical
Dosing ............................................................... 73
Figure 18: P-factor computation example
............................................................................... 74

Copyright © Chemical Injection Technologies, Inc.
Table of Tables
Table 1 - Control panel
structure ............................................................................................. 25
Table 2 - Operator Menu Functions and
Descriptions............................................................. 26
Table 3 - Operator Menu Functions - Minimum and Maximum
Values ................................... 27
Table 4 - Technician Menu Functions and Descriptions
......................................................... 29
Table 5 - Technician Menu and Variable Limits
...................................................................... 30
Table 6 - Calibration Table
...................................................................................................... 36
Table 7 - Periodic Maintenance
Schedule............................................................................... 37
Table 8 - Alarm Descriptions and
Results............................................................................... 38
Table 9 - Troubleshooting: Alarm Descriptions and Solutions
................................................ 43
Table 10 - Troubleshooting: Problems and Suggested
Solutions........................................... 46
Table 11 - Additional features in Operator Menu (With Total Chlorine Monitoring)................
56
Table 12 - Additional Alarms (With Total Chlorine Monitoring)
............................................... 56
Table 13 - Alarms (With Total Chlorine
Monitoring) ................................................................ 57
Table 14 - Technician Menu (With Total Chlorine
Monitoring) ................................................ 58
Table 15 - Modbus Configuration
Options............................................................................... 65
Table 16 - Modbus CommunicationsOptions
......................................................................... 66
Table 17 - Relays and their controlled dosing
systems........................................................... 72

Copyright © Chemical Injection Technologies, Inc.
1 General Safety Precautions
This section presents important information intended to ensure safe and
effective use of this product.
Read the following carefully before handling the product. These warnings and
cautions must be followed carefully to avoid injury to yourself or damage to
equipment.
Warning: Only properly trained and licensed
electricians should attempt to wire or service the
electronic components of the analyzer/controller.
There is an Electrical Shock Hazard when
servicing this system.
Always verify that all electrical power source(s)
are off before opening the analyzer/controller
unit or attempting to service electronic
components or wiring.
Caution: Extreme caution should be used when
installing, operating, and maintaining the
WATERGUARD® Analyzer. Only properly
trained technicians are authorized to install and
maintain the analyzer/controller.
Attention! Seuls des électriciens qualifiés ayant
reçu la formation adéquate peuvent
entreprendre le branchement, l’entretien ou la
réparation des composants électroniques de
l’analyseur/du contrôleur.
Il existe un risque de choc électrique lors de
l’entretien de ce système.
Ayez soin de toujours vérifier que la ou les
source(s) d’alimentation électrique est ou sont
bien déconnectée(s) avant d’ouvrir l’unité ou
d’entreprendre toute opération de service
technique et tout branchement des composants
électroniques.
Attention! Il y a lieu d’agir avec une extrême
prudence lors de l’installation, de la mise en
œuvre et de la maintenance du contrôleur
WATERGUARD®. Seuls des techniciens dûment
formés à cet effet sont autorisés à effectuer
l’installation et la maintenance de l’analyseur/du
contrôleur.
Only properly trained and licensed operators
should attempt to make any changes to
chemical dosing levels.
Seuls des opérateurs qualifiés ayant reçu la
formation adéquate sont habilités à modifier les
dosages des produits chimiques utilisés.
Always follow local health and safety regulations
when performing any service on the
analyzer/controllerunit or when changing
chemical dosing settings.
Conformez-vous sans exception aux consignes
locales de santé et de sécurité lorsque vous
effectueztoute opération technique sur
l’analyseur/le contrôleur, ou lorsque vous
modifiez les paramètres de dosages chimiques.

Copyright © Chemical Injection Technologies, Inc.
Each relay connection is limited to 8 amps, to
prevent overheating. The relays mayshow a
higher rating but do not connect equipment
exceeding 8 amps.
Chaque connexion relais est limitée à 8 Amp.
afin d’éviter toute surchauffe. Même si les relais
affichent éventuellement une valeur supérieure,
ils ne se connecteront pas à un élément
dépassant 8 Amp.
All electrical connections should comply with
National Electrical Code (NEC) and all local
regulations.
Tous les branchements électriques doivent être
conformes au Code Electrique National (NEC –
National Electrical Code) ainsi qu’à toutes les
consignes locales.
Mixing reagents:
Caution: Use protective gear as recommended
in MSDS.
Caution: Do not use chemicals that reduce the
surface tension. When using hydrochloric acid,
observe all safetyregulations.
Mélanges réactifs:
Attention! Utilisez l’équipement de protection
préconisé dans la fiche de données de sécurité
(MSDS).
Attention! N’utilisez pas de produits chimiques
susceptibles de réduire la tension superficielle.
Lors de l’utilisation d’acide chlorhydrique,
appliquez scrupuleusement toutes les consignes
pertinentes.
Caution: WATERGUARD's control board unit
should not be opened except for initial
installation and troubleshooting, and should only
be opened by a trained and approved
technician.
Attention! Le tableau de commandes de
l’WATERGUARD ne doit en aucun cas être
ouvert si ce n’est lors de l’installation initiale et
en cas de dépannage –auquel cas son
ouverture ne doit être effectuée que par un
technicien ayant reçu la formation adéquate et
dûment habilité.

Copyright © Chemical Injection Technologies, Inc.
2. Preface
2.1 Intended Use
This manual is for qualified and trained service technicians who will install and service the
WATERGUARD HG-702Water Quality Analyzer. It provides instructions on how to install the
WATERGUARD system, how to integrate it with external chemical dosing systems and how to calibrate,
operate and maintain the system.
2.2 Overview of Chapters
This document is functionally divided into chapters according to the various steps involved in
installing and operating the WATERGUARD system.
Chapter 1: General Safety Precautions
This section presents important information intended to ensure safe and effective use of this
product.
Chapter 2: Preface
Intended use of the manual and safety issues
Chapter 3: Controller Overview
General description of how water quality is maintained and how WATERGUARD
automaticallymonitors and controls
Chapter 4: Installation
Instructs how to install WATERGUARD and how to integrate it with water quality systems
Chapter 5: First Time Set-up
Instructs how to configure, calibrate, and operate the WATERGUARDsystem immediately
after it is installed
Chapter 6: Routine Operation and Maintenance
Instructs how to respond to alarmsand troubleshooting issues
Chapter 7: Optional features
Describes some optional components that may be installed on the controller or added later
Chapter 8: Relays & Closed-Loop Control
Lists and describes WATERGUARD's operational components
Chapter 9: Setting Proportional Control
Describes how WATERGUARD implements proportional monitoring and control and instructs
how to configure it in various environments.
Chapter 10: Technical Specifications
Includes information about dimensions, electrical systems, relays, measurement of chlorine,
turbidity and pH, etc.

Copyright © Chemical Injection Technologies, Inc.
3. Overview
The WATERGUARD HG-702 Water Quality Analyzer & Controller continuouslymonitors and
automaticallycontrols chemical levels in process water and potable water applications.
WATERGUARD performs automated analysis of free and/or total chlorine, turbidity, pH, ORP (redox),
temperature, conductivity and flow rate, administering chemicals as required, according to the results
of these tests.
3.1 The WATERGUARD Solution
Various methods have been developed over the years to monitor the concentration and balance of
chemicals used in water treatment. WATERGUARD measures free and/or total chlorine levels with a
digital photometer, which has many advantages over other types of sensors. Digital photometer
testing is completely objective. It is not dependent on lighting conditions or the operator’s eyesight,
and is far more accurate. It does not require frequent calibration and is compatible with all types of
disinfectant systems. WATERGUARD performs colorimetric testing in a closed reading cell. It is the
only system that automaticallyand accuratelymeasures free chlorine using small amounts of reagent.
WATERGUARD provides a turbidity measurement in NTU (Nephelometric Turbidity Units). This
provides a consistently objective evaluation of the overall water quality. High turbidity may be a result
of poor filtration or unbalanced water chemistry. The turbidity value will provide an indication that one
of these conditions exists and that action is required to improve the water quality. In many cases the
turbidity can be reduced by adding a flocculent to the filter which will improve filtration. A turbidityrelay
is included in the controller and will operate when turbidity is above the set point. This may be
connected to a flocculent dosing pump or other equipment used to reduce turbidity, providing an
automatic response and maintaining clear water without manual intervention. Likewise, if the turbidity
ever exceeds a pre-set limit, the controller will set off an alarm indicating that attention is required.
Once installed and calibrated, WATERGUARD is fully automatic. It will monitor and can control dosing
systems directly, releasing the proper quantity of chemicals based on frequent automatic
measurements.WATERGUARD is simple to use. Its straight-forward control panel and parameters
menu make chemical balance control an easy task. All basic information can be viewed at a glance,
and changing settings is as simple as scrolling through the menu and adjusting the current settings.
3.2 Measurements and Features
The WATERGUARDHG-702 can be configured to measure any combination of the following water
qualityparameters:
•Free chlorine
•Total chlorine
•Both free chlorine and total chlorine
•Turbidity
•Temperature