WATERGUARD WG-602

FREE CHLORINE ANALYZER

User Manual

V5.15US January 2018

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 Table of Contents
1 General Safety Precautions ............................................................................... 4
2 Preface .............................................................................................................. 5
2.1 Intended Use............................................................................................... 5
2.2 Safety Precautions ...................................................................................... 5
3 Overview ........................................................................................................... 6
3.1 Features...................................................................................................... 6
3.2 System Components ................................................................................... 6
4 Installation ....................................................................................................... 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
5 First 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
6 Routine 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
7 Technical 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………………………………………………….8
Figure 2a: Acrylic Flow cell Overview…………………………………………………8
Figure 3: Controller Overview………………………………………………………….9
Figure 4: Electrodes Card………………………………………………………………10
Figure 5: I/O Card……………………………………………………………………….11
Figure 6: Control Panel Card…………………………………………………………..12
Figure 7: Mounting Panel holes and mechanical installation………………………14
Figure 8: Water connections, Pressure regulating and flow regulating………….. 15
Figure 9: Free Chlorine electrode……………………………………………………. 18
Figure 10: WG602 FCL Control panel and Display………………………………….20

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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 when installing, 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

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

Figure 2a: Acrylic flow cell overview

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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

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Figure 5: I/O card

1. Power supply 100-230 VAC

2. Control output Cl1

3. Control output Cl2

4. Control output pH

5. Control output NTU

6. Control output Alarm

7. Control output Temp

8. Internal flow switch

9. External flow switch

10. Flow meter

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Figure 6: Control panel card

1. Flat cable (from I/O card)

2. 4/20 mA output built-in channel 1

3. 4/20 mA output built-in channel 2

4. 12 VDC

5. 24 VDC

6. RS 485 output (Blue I protocol / MODBUS protocol)

7. Key pad connection cable

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4 Installation
4.1 Location Considerations
Take extra time in selecting a location since the installation location will determine
the ease of the installation and future operation and maintenance. The location
where the WG-602 FCL is installed is dependent on various considerations:

Convenient access – The WG-602 FCL should be installed where it can easily be
viewed and operated.

Dry area – The WG-602 FCL requires a clean, dry area for safe operation and
electrical connections.

Minimum distance from supply pipe - The water sampling line that is connected to
the main pipe should be as short as possible. A long sample line creates as
unnecessary delay between supply and measurement.

Drainage – The installation location requires the sample water outlet of the acrylic
flow cell to be disposed at gravity drain.

Freezing Temperatures – The WG-602 FCL should be installed in a location that is

not susceptible to freezing temperatures. The sample water may freeze, and
components may be damaged due to expansion when ice forms.

4.2 Site Requirements and Installation

The WG-602 FCL assembly is wall mounted. The complete unit with all the
connections weighs 9 kg (about 20 lbs.), so it must be mounted securely onto a
stable wall. The mounting board measures is 800 X 550 mm (31.5'' X 21.7''). The
base of the complete unit assembly should be mounted at least 60 cm (24'') above
the floor (preferably at eye level), to allow ease of operation and maintenance.

The WG-602 FCL unit and its mounting panel are not shipped with mounting screws
or anchors. The installer must provide screws and anchors that can hold the weight
of the complete unit. The screws and anchors must be compatible with the wall
where it will be installed.

4.2.1 Mechanical Installation

The WG-602 FCL is shipped pre-mounted on a mounting panel, along with pre-filter
and pressure regulator. The mounting panel includes four screw holes, compatible
with 5/16'' (8 mm) screws, one in each corner.

1. Determine the location of one hole on the mounting panel.

2. Secure one corner of the mounting panel to the wall.
3. Level the mounting panel and mark the remaining three (3) screw holes.
4. Secure the remaining corners to the wall using 5/16'' (8mm) screws.

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Figure 7: Mounting panel holes and mechanical installation

4.3 Plumbing Requirements and Installation

4.3.1 Water supply and drain

The WG-602 FCL requires a pressurized water supply to the flow cell. An isolating
valve must be installed between the main line and the pipe (tube) to the analyzer.
The water supply need to be connected to the pre-filter with a 6 mm (1/4'') feed tube.
The minimum pressure to the analyzer should be 0.5 bar (7 psi) and should not
exceed 1 bar (14.5 psi). Set the right pressure using the pressure regulator that
attached to the outlet of the pre-filter. Pull up the pressure regulating adjusting valve
and set the right pressure by turning the valve. Push down and lock it when finished.
Adjust the flow rate through the acrylic flow cell so the metal float will be in front of
the proximity flow switch. Use the flow regulating valve (on the bottom left of the
acrylic flow cell) to regulate the flow properly. A gravity drain is recommended for the
water outlet from the acrylic flow cell.

NOTE:
The distance from the main pipe to the analyzer should be as short as possible, in
order to minimize the delay time between the water being sampled and the analyzer
measurement.

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Figure 8: water connections, pressure regulating and flow regulating

1. Water inlet – 6mm (1/4'') quick connection

2. Water inlet ball valve

3. Pressure regulator

4. Pressure regulator adjusting valve

5. Flow regulating valve

6. Metal float

7. Proximity flow switch

8. Water outlet (drain)

4.4 Electrical Requirements and Installation

The WG-602 FCL analyzer requires 100-115 0r 200-230 VAC, 50/60 Hz electrical
power source on a separate 16A circuit in the plant room's electrical board. The main
WG-602 FCL power supply should be connected to a non-dependent power supply,
so that the analyzer remains powered constantly. The active relays should be
connected to a dependent power supply (interlocked power supply).

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4.4.1 Connecting the Main Electrical Power

CAUTION:
Verify that the power switch or circuit breaker to the non-dependent power source is
OFF.

NOTE:
The main power supply may be connected to either 100-115 or 200-230 VAC 50/60
Hz.

1. Connect the line (live) wire to the I/O board connector marked line.
2. Connect the neutral wire to the I/O board connector marked Neutral.
3. Connect the earth wire to the I/O board connector marked Ground.
4. Continue with the other electrical connections.
5. Turn on electrical power only after all electrical connections have been
completed.

4.4.2 Input Switches

Flow input switch terminal blocks on the I/O card allow for three input switched to be
connected to the system as additional layers of security against accidental chemical
additions when there is no flow. If a connection is expected but not detected at each
input, the analyzer/controller will indicate an alarm and will close all relays (and open
the alarm relay). Therefore, if a safety switch (flow, level, etc.) will not be installed, a
fixed connection (jumper wire) is required to allow the controller to operate.

Two flow switches and one flow meter may be connected:

1. Proximity flow switch (internal): Flow switch connected to the flow cell of the
analyzer. Connect the Black wire to "IN", Blue wire to "GND", and Brown wire
to "VCC".
2. External flow switch: Connection for an external 2-wire flow switch. If an
external switch is not connected, a jumper must be installed for the analyzer
to operate properly.
3. Flow meter: Connection of 2 or 3 wire flow meter. The analyzer will not look
for the flow meter connection unless the option is turned ON in the technician
menu; therefore, no jumper is required if a meter in not installed.

CAUTION:
Electrical connections depicted in this section are ONLY recommendations. All
electrical connections should comply with National Electrical Code (NEC) and all
local regulations.

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4.5 Installing electrodes

4.5.1 Free Chlorine electrode OCS140

General Information

Free chlorine is defined as the sum of Hypochlorous acid (HOCL), hypochlorite ions
(OCl ̄ ) and Cl2, and the proportion of the different free chlorine species is pH and
temperature dependent.
The hypochlorous acid (HOCl) contained in the medium diffuses through the sensor
membrane and is reduced to chloride ions (Cl-) on the gold cathode. On the silver
anode, silver is oxidised to silver chloride. The electron release of the gold cathode
and electron acceptance on the silver anode result in a current flow which is
proportional to the HOCL concentration in the medium under constant conditions.
Since the concentration of hypochlorous acid in the medium depends on the pH
value, pH has to be measured in order to perform an accurate compensation and
present a free chlorine value.

Preparation of the free chlorine sensor for start up

NOTE:
The free chlorine sensor is shipped wet, filled with electrolyte from the factory and
does not requires electrolyte refilling before using.

NOTE:
The free chlorine cable will arrive connected to the electrodes card. For more
information about wiring the free chlorine cable look at figure 4.

1. Verify that the chlorine sensor is full with electrolyte and the membrane is not
damaged. Additional information about membrane replacement or electrolyte
refilling exist in chapter 6.4 (Chlorine electrode maintenance).
2. Install the sensor into it's position in the acrylic flow cell and HAND-tighten.
3. Route the wires (if not wired) through an open hole in the gasket and connect
to the electrodes card (figure 3). Connect wire K to CL-K terminal, wire A to
CL-A terminal and the unmarked wire (ground) to the ground terminal.

Safety hint:
Some electrolyte contains diluted acids. Please read the warnings on the electrolyte
bottle.

Safety hint:
Do not Swallow the electrolyte. Avoid contact of the electrolyte with skin and eyes.
Otherwise, wash with a lot of water. in case of eye inflammation, contact a doctor.

NOTE:
It is recommended to read the complete instruction manual provided with the sensor.

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Figure 9: Free chlorine Electrode

1. Electrode cable

2. Large surface silver / silver chloride anode

3. Gold cathode

4. Measuring chamber

5. Membrane cap

6. Screw cap for fixing of the membrane cap

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4.5.2 pH electrode

pH electrode is shipped from the factory in the original package. Open the package
and install the electrode into its position in the acrylic flow cell and HAND-tighten.
Connect the pH cable on the top of the electrode and HAND-tighten.

Connecting the pH electrode cable:

1. Connect the center wire to the pH (+) terminal block
2. Connect the clamp onto the outside of the wire being sure that the wire mesh
is in contact with the metal plate on the electronics card.
3. The pH (-) terminal block will remain empty.

NOTE:
The pH electrode cable will arrive connected to the electrodes card. For more
information about wiring the pH electrode cable look at figure 4.

4.5.3 Temperature sensor

Temperature sensor is shipped from the factory installed within the flow cell, and
wired to the electrodes card.

Connecting the temperature cable to the electrodes card:

1. Connect the Black wire to the connection labeled Black
2. Connect the White or Yellow wire to the connection labeled Yellow
3. Connect the Red wires to the connections labeled Red. Either Red wire may
go to either connection.

NOTE:
The Temperature sensor will arrive connected to the electrodes card. For more
information about wiring the temperature cable look at figure 4.

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5 First Time Operation and Calibration
5.1 Menu Setup

This section describes how to configure the various settings (set points, alarms, and
calibrations) using the WG-602 control panel.

CAUTION:
The WG-602 FCL controller should not be opened except for initial installation and
troubleshooting and should only be opened by a trained and approved technician.

The WG-602 FCL menu is a simple and intuitive interface with a large display. The
control panel includes the following components:

1. LCD display: measurements displayed on the top; alarms displayed on the

bottom.
2. Menu bottom – Enters and scrolls through the menus.
3. Esc bottom – Moves one level back in the menu without making changes.
4. OK – Enters setting change modem and accepts setting change
5. Up/Down arrows – Changes values up or down

Figure 10: WG602 FCL control panel and display

WG-602 FCL includes operator menu and technician menu. Each menu has a
separate password.

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5.2 Operator Menu

Each of the parameters in the operator Menu is configured in the same way. The
following procedure describes how to configure a typical setting:
1. Locate the desired parameter in the menu:
a) Press Menu until the desired parameter name appears in the LCD display.
2. Press OK. “Enter Password 100” appears in the LCD display.
3. Enter the operator password 123 (or technician password 456; both are
accepted).
4. Press the up arrow or down arrow until the password number is reached.
5. Press OK to accept the password. The parameter’s name and current setting
appear in the LCD display.
6. Press OK, again. The LCD display shows the parameter and the current setting.
7. Enter the new parameter setting:
a) Press the up arrow or down arrow until the desired value is reached.
b) The second row of the menu display, below the value that is being changed,
shows the current value.
8. Press Enter to save the new setting or Esc to abort without saving the new setting.
To change the settings of additional parameters, press menu until the desired
parameter appears in the LCD display. Repeat steps 6-8 above to set the new
parameter.

NOTE:
The factory-set operator password is 123. The operator password can be changed
in the technician menu (see technician menu setup).

NOTE:
Holding Menu while pressing up or down will advance the first digit. Holding up or
down for an extended period of time will proceed through the numbers more quickly.

NOTE:
The Menu button displays the next parameter in the list, so that the operator can
check every parameter in the menu. There is no scroll-back option. To view or
change a previous parameter in the menu, you must exit the menu by pressing
Esc, and start the above procedure from the beginning.

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OPERATOR MENU FUNCTIONS AND DESCRIPTIONS
# Function name Description
#1 Shock chlorination Additional Cl dosing mode (On/OFF)
#2 Menu relays Manual activation of relays
#3 Cl set point 1 Control Cl relay 1 – On/OFF or proportional
#4 Cl shock set point Control Cl relay shock mode
#5 Cl set point 2 Control Cl relay 2 – On/OFF only
#6 FCl calibrated to FCl calibration
#7 Cl low alarm Cl low limit / alarm
#8 Cl high alarm Cl High limit / alarm
#9 pH set point Control pH relay 3 – On/Off or proportional
# 10 pH 7 calibrated to pH calibration
# 11 pH 4, 10 calibrated to pH calibration
# 12 pH low alarm pH low limit / alarm
# 13 pH high alarm pH high limit / alarm
# 14 ORP calibrated to ORP calibration
# 15 ORP low alarm ORP low limit / alarm
# 16 ORP high alarm ORP high limit / alarm
# 17 Temp. calibrat. to Temp calibration
# 18 Temp. low alarm Temp low limit / alarm
# 19 Temp. high alarm Temp high limit / alarm
# 20 Turbidity set point Control turbidity relay 4
# 21 NTU1 calibrated to Low Turbidity calibration
# 22 NTUh calibrated to High Turbidity calibration
# 23 Turb. high alarm Turbidity high limit / alarm
# 24 Conduc. set point Control conductivity relay 6
# 25 Conduc. calibrated to Conductivity calibration
# 26 Conduc. low alarm Conductivity Low limit/ alarm
# 27 Conduc. high alarm Conductivity High limit/ alarm
# 28 Conduc. active time Activation time of conductivity relay
# 29 Alarm delay Time delay for relay 5 (alarm)
# 30 Flow low limit Low limit for external flow meter
# 31 Flow K-factor K-factor for external flow meter
# 32 Total alkalinity Manually entered for Langelier Index
# 33 Total hardness Manually entered for Langelier Index
# 34 TDS Manually entered for Langelier Index
# 35 Language Choice of language
# 36 SYSTEM RESET On/Off for controller power

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OPERATOR MENU AND VARIABLES LIMITS
# Function name Min value Max value Default Units
#1 Shock chlorination Off On Off ---
#2 Menu relays OFF ON OFF ---
#3 Cl set point 1 0 9.99 1.50 ppm
#4 Cl shock set point 0 9.99 3.00 ppm
#5 Cl set point 2 0.1 9.99 0.50 ppm
#6 FCl calibrated 0.1 9.99 1.50 ppm
#7 Cl low alarm 0 9.99 0.50 ppm
#8 Cl high alarm 0 10 2.00 ppm
#9 pH set point 4 14 7.40 ---
# 10 pH 7 calibrated to --- --- 7.40 ---
# 11 pH 4, 10 calibrated to --- --- 7.40 ---
# 12 pH low alarm 4 9.99 7.00 ---
# 13 pH high alarm 7 9.99 7.8 ---
# 14 ORP calibrated to 0 1999 740 mV
# 15 ORP low alarm 0 1999 600 mV
# 16 ORP high alarm 0 1999 850 mV
# 17 Temp. calibrat. to --- --- 22.0/ 71.6 C/F
# 18 Temp. low alarm 1/34 49.9/121.9 0.0/ 32.0 C/F
# 19 Temp. high alarm 1/34 49.9/121.9 100/ 212 C/F
# 20 Turbidity set point 0 200 0.60 NTU
# 21 NTU1 calibrated to --- --- 0.50 NTU
# 22 NTUh calibrated to --- --- 1.01 NTU
# 23 Turb. high alarm 0 99.9 99.99 NTU
# 24 Conduc. set point 1 10000 1000 µS/cm
# 25 Conduc. calibrated to 1 5000 740 µS/cm
# 26 Conduc low alarm 1 5000 0 µS/cm
# 27 Conduc. high alarm 1 5000 4900 µS/cm
# 28 Conduc active time --- --- 0:01 Min
# 29 Alarm delay 0 10 0:30 Min
# 30 Flow low limit 0 200 or 999 0=OFF m³/h / GPM
# 31 Flow K-factor 0.001 655 0.01 ---
# 32 Total alkalinity 0 600 0 ppm
# 33 Total Hardness 0 600 0 ppm
# 34 TDS 0 5000 0 ppm
# 35 Language --- --- English ---
# 36 SYSTEM RESET --- --- --- ---

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5.3 Technician Menu

NOTE:
The technician menu includes advanced parameter settings and accessible
separately from the operational menu. Anyone can view the settings, however,
only someone with the technician password can make changes in the technician
menu.

NOTE:
Entering into the technician menu is simple. Press menu to enter into the operator
menu. When in the operator menu, press the up and down arrows simultaneously.
The first function in the technician menu will be #51.

NOTE:
Changing settings in the technician menu is similar to changing settings in the
operator menu. Only technician password in allowed in order to make changes.

Each of the parameters in the technician Menu is configured in the same way. The
following procedure describes how to configure a typical setting:
1. Press menu to enter into the operator menu. When in the operator menu, press
the up and down arrows simultaneously.
2. Locate the desired parameter in the menu:
a) Press Menu until the desired parameter name appears in the LCD display.
3. Press OK. “Enter Password 100” appears in the LCD display.
4. Enter the technician password 456 (only technician password is accepted).
5. Press the up arrow or down arrow until the password number is reached.
6. Press OK to accept the password. The parameter’s name and current setting
appear in the LCD display.
7. Press OK, again. The LCD display shows the parameter and the current setting.
8. Enter the new parameter setting:
a) Press the up arrow or down arrow until the desired value is reached.
b) The second row of the menu display, below the value that is being changed,
shows the current value.
9. Press Enter to save the new setting or Esc to abort without saving the new setting.
To change the settings of additional parameters, press menu until the desired
parameter appears in the LCD display. Repeat steps 7-9 above to set the new
parameter.

NOTE:
The factory-set technician password is 456. Restoration of the technician password
is not possible. If lost, replacing the control panel card is required.

NOTE:
Holding Menu while pressing up or down will advance the first digit. Holding up or
down for an extended period of time will proceed through the numbers more quickly.

NOTE:
The Menu button displays the next parameter in the list, so that the operator can
check every parameter in the menu. There is no scroll-back option. To view or
change a previous parameter in the menu, you must exit the menu by pressing
Esc, and start the above procedure from the beginning.

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TECHNICIAN MENU FUNCTIONS AND DESCRIPTIONS
# Function name Description
# 51 Cl P factor Proportional Factor for Cl Relay 1
# 52 Cl pump period 1 Pump cycle (on+off time) for Cl relay
# 53 Cl pump freq. Cl pump max pulses/min, 0 for on/off pump
# 54 Cl averaging Displays an average of the last 4 Cl readings
# 55 Cl sensor type Not relevant for Free Cl.
# 56 pH P factor Proportional Factor for pH Relay 3
# 57 pH pump period 1 pump cycle (on + off time) for pH relay 3
# 58 pH pump freq. pH pump max pulses/min, 0 for on/off pump
# 59 pH balance type Selection of Acid or Base to adjust pH
# 60 Flow sensor Turns Flow sensor on/off (optional module)
# 61 Flow rate Choose between metric and US units
# 62 Celsius / Fahrenheit Choose between metric and US units
# 63 pH P factor Proportional Factor for pH Relay 3
# 64 Turbidity Turbidity module on/off (optional module)
# 65 NTU wiper interval Cleaning interval for turbidity sensor
# 66 Turbidity range Selection of turbidity measurement range
# 67 Conductivity range Selection of conductivity measurement range
# 68 Minutes Current time for Data Logger
# 69 Hour Current time for Data Logger
# 70 Day Current time for Data Logger
# 71 Month Current time for Data Logger
# 72 Year Current time for Data Logger
# 73 Recording interval Time interval for Data Logger
# 74 View Free Chlor Displays measurement value on LCD
# 75 View pH Displays measurement value on LCD
# 76 View Conductivity Displays measurement value on LCD
# 77 View ORP Displays measurement value on LCD
# 78 Address Controller ID – used with remote comm.
# 79 Software ver. Current SW version
# 80 Max Flow Range Maximum Flow Rate of 4-20mA module
# 81 4-20 mA Output Settings Configures 4/20 mA outputs
# 82 On Alarm go to Configures 4/20 mA outputs
# 83 Blue I /Modbus. Format Communication protocol
# 84 Operator password Change operator’s password

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# 85 Technical password Change technician’s password

TECHNICIAN MENU AND VARIABLES LIMITS

# Function name Min value Max value Default Units
# 51 Cl P factor 0.1 50 1 ---
# 52 Cl pump period 0.5 4 0:30 min
# 53 Cl pump freq. 0=on/off 120 0 Pulse/min
# 54 Cl averaging OFF ON ON ---
# 55 Cl sensor type 1 2 1 ---
# 56 pH P factor 0.1 100 1.0 ---
# 57 pH pump period 0.5 4 0:30 min
# 58 pH pump freq. 0=on/off 120 0 Pulse/min
# 59 pH balance type Acid Base Acid ---
# 60 Flow sensor OFF ON OFF ---
# 61 Flow rate m³/h gpm m³/h ---
# 62 Celcius / Fahrenheit C° F° C° ---
# 63 Temperature sensor --- --- Pt 100 ---
# 64 Turbidity OFF ON OFF ---
# 65 NTU wiper interval 1 60 2:00 min
# 66 Turbidity range 0 20 20 NTU
# 67 Conductivity range 0 5000 5000 µS/cm
# 68 Minutes 1 59 20 min
# 69 Hour 0 23 19 hour
# 70 Day 1 31 2 day
# 71 Month 1 12 8 month
# 72 Year 1 99 17 year
# 73 Recording interval 1 240 0:03 min
# 74 View Free Chlor OFF ON ON ---
# 75 View pH OFF ON ON ---
# 76 View ORP OFF ON ON ---
# 77 View Conductivity OFF ON OFF ---
# 78 Address 1 32 1 ---
# 79 Software ver. N/A N/A N/A ---
# 80 Max Flow Range 9 200/999 100 m³/h / gpm
4-20 mA Output
# 81 See menu See menu See menu See menu
Settings
# 82 On Alarm go to 2 or hold 20 or hold 2 mA
# 83 Modbus. Format 0 31 0 ---
# 84 Operator password 1 999 123 ---

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 # 85 Technical password 1 999 456 ---

5.4 Calibration

Parameters must be calibrated with measurements taken with external testing

devices. Always use digital calibration devices, not the less accurate visual test kits.
Alternatively, standard solutions may be used. Make sure the standard solution is not
expired or contaminated prior to using. Follow the procedures below as instructed.

NOTE:
Always take water for calibration from the sampling valve, NOT from the process
line directly. The analyzer should always be calibrated with water from the same
source.

5.4.1 Temperature Calibration

Calibration o temperature requires an accurate external thermometer.

1. Place the external thermometer in the flow cell or place both the PT-100 and
thermometer in the same sample.
2. Wait for temperature readings to stabilize.
3. Press menu (Operator menu) until "Temp Calibrated to" (#17) appears in the
LCD display.
4. Press OK.
5. Enter the password (operator or technician password). Press the up arrow or
down arrow until the password is reached.
6. Press OK.
7. The value that appears is the last calibrated value.
8. Press OK again.
9. Press the up arrow or down arrow until the value is the same as the
independent digital thermometer.
10. Press OK to save the new calibration or Esc to abort without saving.
11. Press Esc to return to the main display.

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5.4.2 pH Calibration

pH is calibrated using an external testing device or Buffer solutions.

1. Shut off the water inlet and outlet from the flow cell.
2. Remove the pH sensor and temperature probe from the flow cell.
3. Wipe the sensor probe with a dry cloth and submerge it and the (PT-100)
temperature sensor into a cup with a buffer 7 solution. Wait for the reading to
stabilize.
4. Press menu until “pH 7 Calibrated to” (#10) appears in the LCD display.
5. Press OK.
6. Enter the password. Press the up arrow or down arrow until the password is
reached.
7. Press OK.
8. Press OK again.
9. Press the up arrow or down arrow until the value is the same as the value
printed on the buffer 7 solution.
10. Press OK to save the new calibration or Esc to abort without saving.
11. Press menu until “pH 4,10 Calibrated to” (#11) appears in the LCD display.
12. Press OK.
13. Enter the password. Press the up arrow or down arrow until the password is
reached.
14. Press OK.
15. Press OK again.
16. Press the up arrow or down arrow until the value is the same as the value
printed on the buffer 4 or 10 solution.
17. Press OK to save the new calibration or Esc to abort without saving.
18. Press Esc to return to the main display.

NOTE:
When calibrating pH using buffer solutions, the reading of the pH electrode will not
stabilize if the temperature probe is not also in the buffer solution.

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5.4.3 Chlorine Electrode Calibration

NOTE:
Calibrate the free chlorine sensor after operating at least 1 hour. Check for
calibration after 24 hours of operation. If required, perform another calibration.

NOTE:
Reliable chlorine testing device is required for proper calibration of chlorine
electrode.

1. Open the water sampling valve.

2. Test the water sample for chlorine using a digital photometer or other reliable
external device.
3. Press menu until “Cl Calibrated to” (#6) appears in the LCD display.

The top line will display “Cl Calibrated to” and a number. The number displayed
is the last value entered for the calibration.
The bottom line will display “Cl Sensor was” and a number. This number is the
sensor reading without any calibration at the time of the last calibration.
If there is a large discrepancy between the above two numbers - the sensor
was calibrated improperly or there is a problem with the analyzer.
The analyzer uses the calibrated value, as shown on the main screen, to
determine dosing rates.

4. Press OK.
5. Enter the password. Press the up arrow or down arrow until the password is
reached.
6. Press OK.
7. Press OK again.

The display will now show “Calibrate Cl to” on the top line and “Sensor
Reading” on the bottom line.
The “Sensor Reading” is the current reading of the sensor with no calibration.
The “Calibrate Cl to” value is the new value which you want to set.

8. Press the up arrow or down arrow until the value is the same as the value given
by the digital photometer.
9. Press OK to save the new calibration or Esc to abort without saving.
10. Press Esc to return to the main display.

NOTE:
Chlorine calibration should always be performed within 25% of the set point. If
current chlorine level is 25% above or below the set point, do not perform
calibration until the chlorine level is closer to the set point.

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5.5 4 to 20 mA Output configuration

The WG-602 TCL analyzer includes 2 built-in 4/20 mA analog outputs that can be
used for any of the measured parameters. If required, there is an option to add
additional 4 outputs on the "Conductivity / NTU card". For additional information
about the "Conductivity / NTU card" contact your local representative.

Set the 4-20 mA outputs

The menu for "4-20 mA output settings" is found in the technician menu (#81).

1. Enter the technician menu and scroll until “4-20mA output settings” appears in
the LCD display (#81).
2. Press OK.
3. Enter the technician password and press OK.
4. Select "Built-in ch. # (1 or 2)" and press OK.
5. Select parameter (Cl for free chlorine reading, pH, etc.) and press OK.
6. Select "Set value for 4mA" and press OK.
7. Select "Set value for 20mA" and press OK.
8. Select "set test channel" (to be used for troubleshooting purposes or initial
tests): 2mA, 4mA, 12mA, 20mA, and press OK.
9. Press Esc to return to the set-up menu and repeat the above steps for all active
4/20 mA outputs.

Set the 4/20 mA alarm

The menu for "On alarm go to" is found in the technician menu (#82).
This is the 4-20mA output value that will indicate whenever an alarm condition exists
or communication between the analyzer and 4-20 module is interrupted.

1. Enter the technician menu and scroll until “On alarm go to” appears in the LCD
display (#82).
2. Press OK.
3. Enter the technician password and press OK.
4. Press OK again.
5. Select the desired output 2mA, 4mA, 20mA, or hold and press OK.
6. Press Esc to return to the main display.

NOTE:
The alarm will not activate at low or high chlorine levels. It will only go on in case of
low or no flow and /or when there is a communication failure between the analyzer
and the mA output i.e. power failure.

Confirming operation and communication

Prior to connecting to the external monitoring or control system, it is best to confirm
that all desired outputs are working properly using a digital multimeter. This must be
done without output wires connected to an external system. Set the multimeter to
measure current and connect the multimeter to an active output (an output is inactive
if it does not have a chipset installed next to the terminal block). Record the output in
mA and confirm that the value is accurate using the following equation:

mA=[16 X (Measured Value - Min Value)] / [Max value-Min Value] + 4

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6 Routine Operation and Maintenance
6.1 Filter Cleaning
The WG-602 FCL analyzer has a pre-filter installed in its water supply pipe, which
collects particles and impurities. It should be cleaned or replaced periodically,
depending on water quality. The filter is a washable disc filter. Open the filter cap and
remove the discs. Separate the discs and wash them under flowing water. Place the
disc back in the filter and close the filter cap.

6.2 Shut-down and Winterizing

If the analyzer will not be operating for an extended period of time or in areas where
temperatures drop below freezing, all water must be removed from the analyzer to
prevent components from breaking. The probes must be removed and stored in a
warm area and kept wet at all times. Drain the flow cell completely and leave the
valve in open position to allow complete drying. Check the controller doors to ensure
maximal weather-proof and seal.

6.3 Start-up and Preventive Maintenance

A preventative inspection and cleaning of components should be completed
whenever the analyzer is restarted after a long (> 2 weeks) downtime or at least
annually if the analyzer is operating constantly. Likewise, the analyzer has several
mechanical components that will wear out over time. To prevent future
problems, these components should be checked and/or replaced periodically.

6.4 Chlorine Electrode Maintenance

6.4.1 Cleaning the electrode
Check the sensor regularly for dirt, algae and bubbles. If the membrane is visibly
soiled, remove the electrode from the flow cell. Clean the membrane mechanically

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with a gentle water jet or swirl solution of 2% hydrochloric acid (no other additives). If
the membrane cannot be cleaned properly, replace the membrane.

6.4.2 Electrolyte Change

1. Unscrew the measuring chamber from the shaft.
2. Hold the measuring chamber at an angle and fill approximately 7 to 8 ml
electrolyte, up to approximately 1 cm under the top edge.
3. Tap the filled chamber several times on a flat surface, so that adherent air bubbles
can detach and rinse.
4. Screw the electrode shaft into the measuring chamber vertically from above,
ensuring that all inside air is displaced.
5. As soon as the inserted O-ring begins to seal, tighten slowly to the stop.

NOTE:
Refill the electrode with every 6-12 months, or when unstable values displayed.
Depending on the chlorine content on site, this period can be reduced or
expended.

NOTE:
If the chlorine electrode continues to display unstable values, a new membrane
cap must be used.

WARNING:
Do not swallow the electrolyte. Avoid contact of the electrolyte with skin or eyes. In
case of accidental contact, wash with a lot of 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 electrolyte. The electrolyte is sensitive to oxidation:
Always keep the electrolyte bottle closed after use. Do not transfer the electrolyte
into other containers. The electrolyte should not be stored for more than one year
and should be clear (not yellow) in appearance (use by date, see label). Avoid
forming air bubbles when pouring the electrolyte into the measuring chamber.

6.4.3 Membrane Cap Change

1. Unscrew the measuring chamber from the shaft.
2. Unscrew the front screw cap holding the membrane.
3. Remove the old membrane and replace with a new membrane.
4. Refill the measuring chamber with electrolyte.

NOTE:
Change the membrane cap once a year, or when unstable values displayed.

NOTE:
If the chlorine electrode continues to display unstable values, a check /
reconditioning by the manufacturer has to be done.

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6.4.4 Storage
The chlorine electrode can remain in the flow cell for short term, as long as the flow
cell is not drained. If this is not ensured, remove the electrode from the flow cell and
place the yellow protection cap on top of the electrode to keep it wet. Make sure that
the inner sponge inside the yellow protection cap is wet.

NOTE:
When maintaining chlorine electrodes, follow guidelines and information in user
manuals and operating instructions that supplied together with the total chlorine
electrode.

7 Technical Specification

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MEASUREDPARAMETERS
Chlorine electrodes Free Chlorine standard range 0.05-10 ppm or
Free Chlorine low range 0.03-5* ppm
Flow Cell Chlorine, pH, Temp, ORP
External connection Turbidity or Conductivity
FREECHLORINE(FC) MEASUREMENT
Passive-operated Chlorine sensor with gold
Free Chlorine Electrode
cathode & silver/silver chloride anode
Measuring Range 0.05-10 ppm (standard)
Accuracy ± 2 %or ± 0.01 ppm whichever is greater
Minimum Detection Limit 0.05 ppm
Resolution 0.01 ppm
Repeatability 1%span
Response time Approx. 2 min
pHoperation range 4 to 8
Body material PVC
Membrane material PTFE
pHMEASUREMENT
Electrode Ceramic diaphragm and gel filling
Measurement Range 0 to 12
Input impedance 0.5 x 1.12k Ω
ORP (REDOX) MEASUREMENT
Sensor Ceramic diaphragm and gel filling
Measurement range 0 to 2000 mV
TEMPERATUREMEASUREMENT
Sensor PT-100
Measurement range 0°Cto 100°C(32°F to 212°F)
ANLYZERFLOWMONITORING
Flow sensor Inductive proximity switch
FLOWMEASUREMENT (Main line)
Measurement range 0-1000 Cu.m/h (0-11 Mgpd)
Frequency input Via I/Ocard
Or 4-20 mA input Via NTUcard

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ELECTRICAL CONNECTION
Power supply 100-115 VAC, 50/60 Hz, 1.0 Amp
200-230 VAC, 50/60 Hz, 0.5 Amp
Power consumption Approx. 60 VA
Power supply for RTC 3.6V Lithium Battery memory (CR2032)
MECHANICAL DATA & DIMENSIONS
Dimensions (controller) 340 x 220 x 120 mm
(L x W x D) (14.0" x 7.0" x 5.0")
Dimensions (Mounting board) 800 x 550 x 5 mm
(L x W x D) (31.5" x 21.7" x 0.2")
Weight (approx.) 9 kg (22 lbs.)
Display 5.5'' graphic monochromatic display
Cable entries PG9 cable Glands
Enclosure rating IP 65 (NEMA 4 equivalent)
OPERATIONAL REQUIREMENTS
Sample and drain connection Pressurized sample inlet and gravity drain
Inlet Pressure 0.35-1 bar (5-14.5 psi)
Outlet pressure (Closed cell) up to 0.9 bar (13 psi)
Measuring cell flow rate 35-60 l/h (9-16 gph)
Ambient temperature 2°Cto 50°C(35.6°F to 122°F)
Sample temperature 1°Cto 45°C(33.8°F to 113°F)
DATAOUTPUT
Digital communication RS485 Modbus ORBLUEI protocol
Local I/O 2 Standard 4-20 mA outputs
4 or 6 Optional 4-20 mA outputs
SECURITY
Operation password Yes
Technician password Yes

35
RELAYS
Cl (Chlorine) set point 1 250 VAC/DC8 Amp max**
Cl (Chlorine) set point 2 250 VAC/DC8 Amp max**
pH1 250 VAC/DC8 Amp max**
Turbidity control*1 250 VAC/DC8 Amp max**
Temperature control 250 VAC/DC8 Amp max**
General Alarm 250 VAC/DC8 Amp max**
CHLORINECONTROL #1
Control function PI or On/Off or frequency
Proportional band Yes
Relay function Pulse length proportional controller
Pulse frequency proportional controller
CHLORINECONTROL #2
Control function On/Off
Proportional band No
Relay function Pulse length proportional controller
Pulse frequency proportional controller
pHVALUECONTROL
Control function P or PI or On/Off or frequency
Characteristics Normal / Inverted
Relay function Pulse length proportional controller
Pulse frequency proportional controller
ORP CONTROL
Control function High alarm as chlorine override

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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 Injection Technologies Inc. Disclaimer
Chemical Injection Technologies, Inc. does not accept any responsibility
for any damage caused to its products by unauthorized personnel. Use of
non-SUPERIOR reagents and/or replacement parts will void all
warranties.

Chemical Injection Technologies

835 Edwards Rd. Fort Pierce, FL 34982
www.chlorinators.com

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