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Walchem Intuition-6 Controller

Source: Intuition-6 Instruction Manual Rev. H, Pages: 1–6 The Walchem Intuition-6 Series controller is a microprocessor-based measuring and control instrument designed for water treatment applications. It combines flexible sensor inputs with powerful control algorithms to manage chemical dosing, blowdown, and monitoring across cooling towers, boilers, and industrial process systems.
Intuition-6 front panel showing touchscreen home screen with sensor inputs and relay outputs

Intuition-6 controller with 5-inch color touchscreen

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Product Family

The Intuition-6 is available in application-specific configurations, each optimized with pre-configured sensor and control options:
All models share the same controller hardware and firmware. The model designation determines the pre-configured sensor packages and mounting options available when ordering.

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Key Capabilities

Sensor Inputs

One or two sensor inputs supporting conductivity, pH, ORP, disinfection sensors, and 4-20 mA transmitters

Control Outputs

Up to six relay outputs with powered, dry contact, or pulse solid state options

Digital Inputs

Six digital input channels for flow switches, water meters, and feed monitors

Connectivity

Ethernet for web access, email alerts, Modbus TCP, and BACnet integration

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Sensor Compatibility

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Control Output Options

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Control Modes

The Intuition-6 includes over 20 control algorithms covering virtually every water treatment scenario:
Some control modes require specific hardware configurations. Pulse proportional and PID control require opto relay outputs. Analog control modes require the optional 4-20 mA output card.

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Connectivity Options

Use these options to connect the controller to local networks or remote services.

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Ethernet

Remote access via direct connection, LAN, or Walchem Fluent cloud service:
  • Web-based configuration and monitoring
  • Email alerts and datalog reports
  • Modbus TCP and BACnet integration
  • Remote sensor calibration
Walchem Fluent is a cloud-based water treatment management platform that extends controller capabilities:
  • Real-time monitoring — Access controller data from any device
  • Alarm management — Prioritized alarms with escalation and acknowledgment
  • Data visualization — Interactive graphs with historical trending
  • Multi-site management — Organize customers and facilities in a single dashboard
  • Team permissions — Admin, technician, and view-only user roles
Fluent connects to Intuition-6 controllers via the Ethernet option.

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USB

Local utility functions:
  • Firmware upgrades
  • Configuration file backup and transfer
  • Datalog export to spreadsheet format

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Virtual Inputs and Outputs

The controller provides six virtual inputs and six virtual control outputs for advanced applications:
Virtual inputs can calculate values from physical sensors:
  • Difference — Input 1 minus Input 2
  • Ratio — Input 1 divided by Input 2 (cycles of concentration)
  • Total — Input 1 plus Input 2
  • % Difference — Percent rejection calculations
  • Redundant — Primary/Backup or Min/Max sensor selection
Virtual outputs implement control algorithms that can interlock or activate physical outputs, conserving relay resources for complex control schemes.

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Typical Applications

Cooling Tower Control

  • Conductivity-based blowdown with inhibitor feed
  • Biocide timer programs with pre-bleed
  • Flow proportional chemical dosing
  • Cycles of concentration monitoring

Boiler Blowdown

  • Intermittent sampling with trapped sample
  • Continuous or proportional blowdown
  • Surface and bottom blowdown coordination

Disinfection Control

  • Chlorine/bromine residual control
  • ORP-based oxidant control with spike events
  • pH-chlorine combination sensors
  • EPA Method 334.0 compliant chlorine reporting

Process Control

  • pH adjustment with proportional or PID
  • Corrosion inhibitor dosing
  • Tagged tracer (PTSA/polymer) monitoring
Cooling tower system diagram showing controller, metering pumps, sensors, and flow switch manifold

Typical cooling tower installation with Intuition-6 controller

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Physical Characteristics

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What’s Included

Each Intuition-6 controller ships with:
  • Controller with installed option cards per order
  • Instruction manual
  • Power cord (prewired models) or conduit fittings (hardwired models)
The controller contains live circuits even when the front panel power switch is OFF. Always disconnect power at the source before opening the enclosure.

Specifications

Detailed measurement and electrical specifications

Installation

Mounting, sensor installation, and wiring diagrams

Programming Guide

Complete control mode reference for all relay algorithms

Operation

Touchscreen interface and menu navigation

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Sources

Intuition-6 Instruction Manual Rev. H

Pages 1–6 • February 2024