WaterLine Controls WLC-9000 User manual

Installation Instructions for Model WLC-9000
IMPORTANT SAFETY INSTRUCTIONS
Page 1
© SDI 2008
is the optimum choice for any situation requiring the
precise control of a water level. It is ideal for automatically maintaining the
correct level in cooling towers, storage tanks, or process water applications.
Model WLC-9000 achievescontrol by the use of a
corrosion resistant probes that sense the water level and then in conjunction with
electronics and a microprocessor, provides signals that can be used to open/close
valves and other control or recording devices thus maintaining correct levels.
Levolor is a registered trademark of Jandy Pool Products, Inc. and used under license only. SDI and Jandy Pool Products, Inc. are not affiliated companies.
Waterline Controls is a registered trademark of SDI.
1. Call the factory with any questions. 1-888-905-1892 or write to:
System Dynamics, P.O. BOX 12544, Scottsdale, AZ 85260
2. Read and follow all instructions.
3. Disconnect all power before opening the internal cover/s or making any connections to the unit.
4. Do not install in locations where sprinklers or other watering devices will allow water to impinge on the unit.
5. Sensor wires must be continuous and not spliced.
6. Make sure the unit is connected properly to earth ground.
7. Only qualified personnel should install this unit or replace the "replaceable" parts.
8. Only factory supplied parts should be used whenever a replaceable part is needed.
9. The manufacture will not be liable for any injury or damage that may arise from the misuse of this
unit or from failure to follow all of these instructions.
10. Save these instructions and provide them to the end user.
11. This unit shall not be used in any "safety critical" application or where the failure of any function or component may cause death or personal injury.
11. Ne pas utilisez cet élément quand les blessures oú la mort peuvent les présenter.
12. Use copper (CU) wire only for all connections.

TM
Page 2
© SDI 2008
T he unit is powered by either 110 VAC or
220 VAC 60 HZ 0.5 Amp. The input voltage is determined by
the option selected. If the 110 VAC option is selected, then the
input power wires are: one black and one white. If the 220 VAC
option is selected, then the two input power wires are both black.
The unit is rated for indoor or outdoor installation.
These power relays may be used to control valves, or
solenoids; but not motors. There are also low power SPST
relays whose contacts are rated at 50 VAC/DC 0.25 Amp.
that can be used as an additional indicator or to provide an
indication to an event recorder, computer or automation system.
The normal indicator on the unit is a green LED that is
a "power ON" indicator and is on whenever power is applied to
the unit. There are also other LED's that turns ON whenever
the relay contacts are closed. These indicate a very high
level condition, or a DRAIN I or DRAIN II condition and will
remain ON until the level changes to some other level.
See Table 1 for the LED functions associated with the
various models. The contact with the water is sensed by
electronics and the microprocessor then provides the
necessary control for the various outputs.
The parts supplied are:
1 - The Waterline Control CONTROLLER.
1 - Stainless steel probe assembly with 50 feet of wire.
2 - U bolts with nuts.
1 - Mounting bracket.
* Power Relays (as required)
Figure 1.
WLC-8000
Sensor Low Voltage Raceway
POWER
ALARM DRAIN IHIGH
ALARM
TESTING
PRESS TO TEST
Green (Ground)
Black
Black
220VAC OR 110VAC
White
Black
LOW ALARM
(LA)
HIGH ALARM
(HA)
FILL
Brown
Pair
Green
Pair
Red
Pair
Quantity of relays
and lights are a
function of
the model.
"Bottom plate removed
in illustration."
DRAIN II
WLC Relay
(N.O.)
LOAD
(Solenoid, Pump,
Contactor)
* All loads combined
cannot exceed
Circuit Breaker Rating
Hot
Neutral
Single Pole Relay
LINE
(110VAC)
The "replaceable" parts are:
Waterline Control CONTROLLER part # WLC-9000 with option110 or
220 vac (specify option: 110 or 220 VAC)
Stainless steel probe assembly See Sensor assembly appendix.
Power relay part # PG8P
Solenoid part # 8221G5 (other options for voltage &
pipe size are available; Contact the factory).
This size is 110VAC 1" pipe. (optional)
U Bolts/nuts U20P5-9
Mounting bracket MB2

© SDI 2008 Page 3
The sensor assembly (see Figure 2) must be mounted so that the end of
the PVC pipe is below the minimum water level that is to be maintained.
Secure the probe assembly to a suitable mounting surface with the correct size
"U" (U2OP5-9) bolts and the mounting bracket (M2OP5-9). Be careful to insure
that the top portion of the assembly is not in contact with the water and that the
"U" (U2OP5-9) bolts are above the high water level. Note: There are two small
1/8 inch vent holes near the top of the housing in the
PVC pipe. Make certain this vent holes are not obstructed in any way.
They must be clear in order for the sensor assembly to function properly.
The probe assembly is supplied such that it has the sensor
cable pre-installed. Route the cable along an appropriate location and
determine if the length needs to be shortened. The wire may be cut to a
shorter length if required.
NOTE: THE SENSOR WIRES MUST NOT BE SPLICED IN ORDER TO
INCREASE THE LENGTH.
Fasten the wire to a water tight PVC compression connector and then install
into the bottom of the Waterline WLC7000 housing. The output control wires
are connected to the relays output terminals
(¼ inch spade) connector supplied by the user.
NOTE: the rating on the relay should not be exceeded.
Use water tight PVC conduit for all connections and route the location
desired by the end user.
If the depth of the probes need to be seen while the sensor assembly is
installed mark the sensor probe levels on the outside of the pipe with
a "Sharpie". The center of the nominal set point is marked with
a black button in the outer pipe.
SENSOR ASSEMBLY INSTALLATION
The Waterline WLC7000 through WLC-9100 should be mounted in a covenant location where water spray will not impinge upon the
unit and at a height consistant with figure 2. The unit and the input/output cabling must be securely attached to the mounting surface.
Sensor Assembly
Structural Wall
Sensor Wire
(no splicing)
"U" Bolts
4 inches
Mounting
Bracket
Probe Illustration for WLC-9000
Figure 2.
MB2
420P5-9
Min.

© SDI 2008
Page 4
The following test procedure will test the electronics and output relay functions. The test verifies all of the electronics from the location of the
sensor wire connection to the PCB through the output relays. It verifies the functions of the Waterline WLC-9000.
THIS TEST IS VALID FOR THE WLC-9000. To initiate the test,
perform the following:
1. Press the "PRESS TO TEST" push button momentarily. The yelllow LED will light and remain on until the "test function" is completed.
2. The controller automatically sequences through the functions.
Note: once the "PRESS TO TEST" button is depressed the test sequence cannot be interrupted. This test will take approximately 2 minutes.
The functions of the LED's, the power relays and the indicator relays are shown in the following truth tables.
TEST INSTRUCTIONS
TESTING TRUTH TABLE
DEFINITIONS
DRAIN I: The water level is approaching the unsafe level.
DRAIN II: The water level is approaching the unsafe level.
HIGH ALARM: The water level is approaching the maximum allowed level.
FUNCTION TRUTH TABLE
TEST SEQUENCE DRAIN IDRAIN II HIGH ALARM
1
2
3
4
5
6
7
8
9
10
11
OFF
OFF
OFF
ACTIVATED
ACTIVATED
ACTIVATED
ACTIVATED
ACTIVATED
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ACTIVATED
ACTIVATED
ACTIVATED
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ACTIVATED
OFF
OFF
OFF
OFF
OFF
*For the WLC9100, the test sequence repeats and the DRAIN Ialternates with DRAIN II
MODEL HIGH ALARM DRAIN IDRAIN II TEST FUNCTION
WLC-9000 YES YES
YES YES