WebMaster Series Cooling Tower Controller Instruction Manual
Notice © 2003 WALCHEM Corporation Five Boynton Road, Holliston, MA 01746 USA (508) 429-1110 All Rights Reserved Printed in USA Proprietary Material The information and descriptions contained herein are the property of WALCHEM Corporation. Such information and descriptions may not be copied or reproduced by any means, or disseminated or distributed without the express prior written permission of WALCHEM Corporation, Five Boynton Road, Holliston, MA 01746.
TABLE OF CONTENTS 1.0 INTRODUCTION .......................................................................................................................................... 1 2.0 SPECIFICATIONS ........................................................................................................................................ 1 2.1 2.2 2.3 2.4 3.0 3.1 3.2 3.3 3.4 3.5 4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 6.0 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.
6.16 INTERLOCK MENU ....................................................................................................................................... 65 6.17 4-20 MA INPUT MENU (ONLY APPEARS IF THE ANALOG INPUT OPTION CARD IS INSTALLED) ....................... 65 6.18 DIGITAL INPUTS MENU (ONLY APPEARS IF THE DIGITAL INPUT OPTION CARD IS INSTALLED)..................... 66 6.19 BLEED OUTPUT MENU .............................................................................................................
1.0 INTRODUCTION The Webmaster series cooling tower controller is multi-functional, but not all of the features mentioned are necessarily present in the controller you have received. All features can be added in the field.
2.2 Electrical Inputs Input power 100 – 120/220-240 VAC ±10%, 12A, 50/60 Hz Fuse 1.6A, 5 x 20mm Input signals STANDARD Water meter Contactor: Isolated dry contact (relay, reed switch or Hall Effect) 0-10 Hz ,50 msec minimum width Paddlewheel Water Meter: Flow switch: Isolated dry contact (relay, reed switch or Hall Effect) 0-300 Hz ,1.
2.3 Mechanical Enclosure Material: NEMA Rating: Dimensions: Display: Operating Ambient Temp: Storage Temp: Weight Molded Fiberglass NEMA 4X 10” x 12” x 5-5/8” (25.4cm x 30.5cm x 14.5cm) 64 x 128 Pixel Backlit LCD Graphics Module 0 to 49° C (32-120°F) -29 to 80°C 11.5lb (5.
High pressure contacting conductivity electrode Pressure: Temperature: Process connections: Wetted Materials of Construction: 0-300 psi 32-158F ¾” NPTM 316 SS, PEEK High pressure pH electrode Pressure: Temperature: Process connections: Wetted Materials of Construction: 0-300 psi 32-275F ½” NPTM Glass, Polymer, PTFE, 316 SS, FKM High Pressure ORP electrode Pressure: Temperature: Process connections: Wetted Materials of Construction: 0-300 psi 32-275F 1/2” NPTM Platinum, Polymer, PTFE, 316 SS, FKM High
2.4 Variables and their Limits All menus shown may not be available. The menus that appear on your controller will vary with options installed and programmed. Conductivity Input Menu Calibration Reminder ppm Conversion Factor Interval between Samples Duration of Sample First Sampling Stage Damping Low Alarm Limit High Alarm Limit 0 – 365 days 0.5 – 1.
Other 4-20 mA Input Menu Parameter = 4 mA Parameter = 20 mA Low Alarm Limit High Alarm Limit -10,000 to 10,000 (units defined by user) -10,000 to 10,000 (units defined by user) -100,000,000 to 100,000,000 (units defined by user) -100,000,000 to 100,000,000 (units defined by user) PosiFlow Input Menu Alarm Time Pump Volume per Stroke 0.1 to 10 minutes 0.
Biocide 1 & 2 Output Menus Program Biocide Additions Bleed Lockout Time Prebleed Conductivity Prebleed Time Hand Time Limit Volume of Makeup to Trigger Add Pump On Time Select day/time in cycle, specify pump on time (1 to 1440 min) 0 to 1440 minutes 1 to 25,000 (units defined by user) 1 to 1440 minutes 0 = ∞, 1 to 1440 minutes 1 to 1,000,000 (units defined by user) (future feature) 1 to 1440 minutes Dispersant Output Menu Pump On Time Hand Time Limit 1-1440 minutes 0 = ∞, 1 to 1440 minutes pH Output Men
3.0 UNPACKING & INSTALLATION 3.1 Unpacking the Unit Inspect the contents of the carton. Please notify the carrier immediately if there are any signs of damage to the controller or its parts. Contact your distributor if any of the parts are missing. The carton should contain a WebMaster series controller and instruction manual. Any options or accessories will be incorporated as ordered. 3.
Electrode Installation All electrodes for the Webmaster series are provided with signal conditioning electronics, and conductivity sensors may be located up to 250 feet (75 meters) from the controller, and pH/ORP sensors may be located up to 1000 feet (303 meters) from the controller . It is highly recommended that the electrodes be installed within 10 feet of the controller in order to make periodic electrode calibration more convenient.
Figure 1: Typical Installation Drawing, Continuous In-line Sampling 10 Bleed Valve Bleed Flowmeter HEAT EXCHANGER Y-strainer EH Metering Pump (up to 6) Foot valve Posiflow Makeup water Flowmeter Y-strainer COOLING TOWER Inhibitor, Bio1, Bio2, pH Adjust, ORP Adjust, or Dispersant Level switch pH Electrode Injection Valve Makeup cond ORP Electrode Flow switch Conductivity electrode
TYPICAL INSTALLATION INTERMITTENT SAMPLING TO ELECTRODE TO SOLENOID A C AC Power Supply SHUTOFF VALVE E A D B F CITY WATER MAKEUP POSIFLOW PE DISCHARGE TUBING SPRAY PUMP SPRAY TOWER EH METERING PUMP INJECTION VALVE TO SANITARY SEWER LEVEL SWITCH A MAKEUP WATER FLOWMETER Unions; installed for replacement of solenoid, strainer or probe B ½" solenoid FOOT VALVE C ½" Y-strainer CHEMICAL TANK D ¾" polypro threaded tee probe (P/N 102884 supplied with controller) E ½" PVC bulkhead fitting F
Figure 3: Typical Installation Drawing, Submersion Sensors 12 102884 TEE 102594 O-RING 102586 NUT 1" PVC PIPE 1" NPTF COUPLING 190986 CONDUCTIVITY ELECTRODE Bleed Valve HEAT EXCHANGER DETAIL OF SUMP Bleed Flowmeter Y-strainer WEL pH or ORP CARTRIDGE WEL pH or ORP HOUSING 1" NPTF COUPLING 1" PVC PIPE SEE DETAIL Foot valve EH Metering Pump (up to 6) Posiflow Injection Valve COOLING TOWER Makeup cond Inhibitor, Bio1, Bio2, pH Adjust, ORP Adjust, or Dispersant Level switch Makeup water F
3.5 Electrical Installation The Webmaster series controllers require the following voltages: 100 –120/200-240 VAC± 10%, 50/60 Hz, 12 amperes maximum The controller must be connected to its own 15 ampere breaker, close by, to act as an alternate power shutdown. Your controller is supplied either factory prewired or ready to be hardwired. Depending upon your choice of options, you may be required to hardwire some or all of the input/output devices. Please refer to Figures 4 through 8 for wiring diagrams.
Note: Many of the inputs and outputs listed are optional and may not be present in your controller. Prewired Option Hardwired Options Misc.
Figure 5: Identification of Parts 15 ORP OPTION CARD MAKEUP CONDUCTIVITY OPTION CARD DISPLAY CORE MODEM OPTION CARD ETHERNET OPTION CARD PH OPTION CARD CORE INTERFACE BOARD SYSTEM CONDUCTIVITY AC POWER IN WATER METERS & FLOW SWITCH RS232 RS-485 RELAY OUTPUT NEUTRAL FUSES RELAY OUTPUT HOT POWER SUPPLY DIGITAL INPUT OPTION CARD 4-20 mA INPUT OPTION CARD RELAY INTERFACE BOARD 4-20 mA OUTPUT OPTION CARDS
Important: The mains power supply earth ground connection must be retained by separate nut.
MAKEUP CONDUCTIVITY OPTION (WIRING THE SAME AS DETAIL "C") pH OPTION (WIRING THE SAME AS DETAIL "C" EXCEPT NO T+ OR T-) SEE DETAIL "A" ORP OPTION (WIRING THE SAME AS DETAIL "C" EXCEPT NO T+ OR T-) SYSTEM COND SEE DETAIL "C" RTS WHT/GRN GRN WHT/ORN ORN WHT/BLU BLU + GR N TXD IN+ +5 GND +V IN+ -5 IN- -S +S -5 +5 BL K R RS-232 N/C +V IN+ IN- ED SHIELD High Pressure Conductivity Electrode MAKEUP WATER METER BLEED WATER METER FLOW SWTICH GND (-) WH T RXD IN- SIGNAL -T -T +T +T - T
CHART RECORDER 4-20mA OUTPUT (POSITION 1) R- R+ OPTIONAL 4-20 mA OUTPUTS (REPEAT FOR 4-20mA OUTPUTS 2 THRU 4) 4-20mA OUTPUT (POSITION 2) 4-20mA OUTPUT (POSITION 3) 4-20mA OUTPUT (POSITION 4) GND -1 + -2 6 3 7 4 8 5 3 6 2 5 1 4 IN- BLK IN+ WHT RE D - + + +24VDC +12VDC GROUND ANALOG INPUT CARD + 420 24 V mA DC OU T + - POWERED DIGITAL INPUT CARD I N- IN+ POLARITY NOT CRITICAL POSIFLOW LEVEL SWITCH 4-20mA SOURCE •SIMULATOR + UNPOWERED •POWERED 4-20mA OUTPUT (i.e.
RJ45 TO ETHERNET HUB, 10BASET CAT 5 CABLE, 100 METERS MAXIMUM RJ45 TO ETHERNET HUB RJ11 TO PHONE LINE SEE DETAIL A&B DETAIL A TB3 TB4 RTS CTS BUNDLE & TAPE ALL UNUSED WIRE TB4 RXD TXD GND N 3 PIN OM M PIN 2 R F FRO M PIN 5 FRO O FR M PI FR OM PI N 8 7 JACKETED CABLE HUB 10BaseT compatible CONNECT & INSULATE DB-9 FEMALE 5 1 STANDARD DB-9 NULL MODEM SERIAL CABLE 9 6 DETAIL B W700 IN NETWORK RTS CTS BUNDLE & TAPE ALL UNUSED WIRE RXD M P IN 3 FR O PIN 7 M O FR F R OM PI N JACKETED CABLE
4.0 FUNCTION OVERVIEW 4.
4.2 Display Turn the power switch on. Be patient, the start up sequence will take about the same time as it takes a computer to boot up, approximately 2 minutes. At first the display backlight will blink and all output LEDS will light. Around 30 seconds later, the display backlight will come on, and the LEDS will shut off. Then the display will come up, and show you the % complete status of the start up process. After around 1 minute, the Summary Screen will appear.
4.4 Access Codes The Webmaster series controller is shipped with the access codes at default values. In order to prevent against unauthorized tampering, you will need to change the access codes to your own values. See section 6.32 for details. There are three levels of protection. If the Master password is used in the Webmaster Authentication page, then any set point can be changed. The default Master password is 2001.
If you have not yet set up an ISP account and wish to program the Webmaster from a remote location, or if you just prefer the “old fashioned method” of direct modem-to-modem communication, go to the section below called “Direct Modem Access: Direct Tap.” If you have an Ethernet card option installed, then the controller becomes another PC on the network.
4.6 Communicating with the WebMaster 4.6.1 Direct Serial Connection to the RS232 Port Web Browser (Client) RS-232(Serial) Hard coded Fixed IP Address: 199.199.199.2 A direct serial connection to the WebMaster can be made in two ways. A temporary connection can be made between a laptop and the front panel of the controller, or a permanent connection can be made between a PC and the RS232 terminal strip connection inside the controller.
4.6.2 Remote Modem Access: Shoulder Tap ISP Phone line Embedded Web Server Http://w700.walchem.com/walchem ShoulderTap Connection Utility Equipment Required § An Internet-ready computer with the following capabilities: 100 MHz minimum processor speed, 40 MB minimum RAM, Windows operating system, and Windows Internet Explorer version 5.0 or higher web browser software.
4.6.3 Ethernet Connection to LAN Unsafe Port OR Ethernet Safe Port LAN ROUTER Web Browser Web Browser Equipment Required § An Internet-ready computer with the following capabilities: 100 MHz minimum processor speed, 40 MB minimum RAM, Windows operating system, and Windows Internet Explorer version 5.0 or higher web browser software. § A connection between the PC and the local area network (LAN). § An Ethernet connection between the WebMaster and the LAN.
4.6.4 Direct Modem Access: Direct Tap Web Browser (Client) Embedded Web Server modem TELCO modem Hard coded Fixed IP Address: 199.199.199.3 Equipment Required § An Internet-ready computer with the following capabilities: 100 MHz minimum processor speed, 40 MB minimum RAM, Windows operating system, modem and Windows Internet Explorer version 5.0 or higher web browser software.
4.6.5 Direct Ethernet (for a WebMaster not connected to a LAN) Web Browser (Client) Fixed IP Address User Assigned Ethernet Cross-Over Cable User Assigned Fixed IP Address Gateway + Equipment Required § An Internet-ready computer with the following capabilities: 100 MHz minimum processor speed, 40 MB minimum RAM, Ethernet card, Windows operating system, and Windows Internet Explorer version 5.0 or higher web browser software. § A null Ethernet cable connection between the PC and WebMaster.
4.6.6 Networking WebMaster Controllers via Ethernet Web Browser connected using any of the previous methods Master Slaves Hub Equipment Required § An Internet-ready computer with the following capabilities: 100 MHz minimum processor speed, 40 MB minimum RAM, Ethernet card, Windows operating system, and Windows Internet Explorer version 5.0 or higher web browser software. § An Ethernet cable connection between each WebMaster using a hub or connection to LAN.
4.7 Startup Once the controller has been set up for your application, start up is a simple process. Check your supply of chemicals, turn on the controller power, calibrate all sensors as necessary, supply the sensors with a flow of sample water, and it will start controlling. 4.8 Shut Down To shut down the controller, simply turn off the power. All set points will be retained in memory. It is important that the optional pH and ORP electrodes remain wet.
5.3 Alarms The Alarms menu displays all alarm messages. Use the Next key to scroll down the list, or the Prev key to scroll up the list. There are no programmable parameters in this menu. No access code is required to enter this menu. Press the Exit key to return to the Main Menu. 5.4 Calibration The Calibration menu is used to calibrate the sensor inputs, as well as any optional 4-20 mA inputs. The list of options displayed will depend upon what options are installed in your WebMaster.
System/Makeup Conductivity Calibration – Electrodeless Sensor “1 pt Process Cal” and “Air Cal (Zero) will be displayed. Use the Next key to move the cursor to the word “Calibrate” under the desired calibration routine. Press the Enter key to start the calibration procedure. Air Cal (Zero) The Air Calibration is necessary on initial start up, or when installing a new sensor, in order to set the sensor to read zero conductivity in air. This step must be done prior to the process calibration.
The “1pt Buffer Cal” is not as accurate, since it assumes that the slope of the electrode is 59 mV/pH unit, which will only be true with a new electrode. This can be OK if the pH never varies far from the value of the standard solution used in the calibration. This method uses manual temperature compensation, since the temperature sensor is contained in the system conductivity sensor, which is not placed in the buffer solution.
Step 3 will prompt you to rinse the electrode, and place it into the buffer solution. Press the Enter key to continue. Step 4 will ask you to enter the value of the buffer solution. Use the Arrow keys to change the value, then press the Enter key to continue. Step 5 will display the mV output of the electrode in the buffer. When this reading is stable, press the Enter key to continue. At the end of the calibration, the display will tell you if the calibration was successful or if the calibration failed.
sample stream to resume control. If failed, refer to Section 7 for troubleshooting help. A calibration will fail if the offset calculated is more than 200 mV, or if the slope calculated is outside of 0.5-1.5. 1 pt Buffer Cal Step 1 will explain that control is suspended during the calibration procedure. Press the Enter key when the cursor is on “Continue” to start the calibration. To cancel the calibration, press the Next key to move the cursor to “Cancel”, then press the Enter key.
5.5 Relay Control (HOA) This menu will present you with a list of each relay. To the right of the name of the relay will be an indication of the current state of the relay (OFF, or ON).
Cycles Set Pt xx.xx (if Bleed based on cycles, 1 source) Use the arrow keys to change the desired set point cycles of concentration.. Any value between 1 and 50 is acceptable. Press Enter to accept the new value. Dead Band xxxxx (if Bleed based on system conductivity or 4-20 mA input) Use the arrow keys to change the conductivity (or ppm) value away from the set point at which the bleed valve will close.
S1 Cycle L Alm xx.xx (if Bleed based on cycles, 2 or 3 sources) Use the arrow keys to change the cycles of concentration for each Source below which you want to activate a low alarm. Press Enter to accept the new value. S2 Cycle L Alm xx.xx (if Bleed based on cycles, 2 or 3 sources) Same as above, for the Source 2 makeup water. S3 Cycle L Alm xx.xx (if Bleed based on cycles, 3 sources) Same as above, for the Source 3 makeup water. S1 Cycle H Alm xx.
Bleed Time Lim xxxx Use the arrow keys to change the maximum amount of time that the bleed valve can be continuously open before the controller shuts the valve and activates a Bleed Time Limit alarm. Press the Enter key to accept the new value. The Time Limit is intended to prevent the bleed valve from turning over the whole system if the conductivity input fails in such a way that it will never close the valve.
Makeup Volume xxxxx (if Feed on makeup volume) Use the arrow keys to change the volume of makeup water that needs to enter the system in order to trigger the inhibitor feed. Any value between 1 and 10,000 is acceptable. Press Enter to accept the new value. Time on / Vol xxxx:xx (if Feed on makeup volume) Use the arrow keys to change the amount of time for the inhibitor feed pump to run, once the previously specified volume of makeup water has entered the system.
S1 % of Per to Fd xxx (if Feed as % of Time, Multiple makeup sources) As described above in % of Per to feed xxx for Source 1 makeup water. S2 % of Per to Fd xxx (if Feed as % of Time, Multiple makeup sources) As described above in % of Per to feed xxx for Source 2 makeup water. S3 % of Per to Fd xxx (if Feed as % of Time, Multiple makeup sources - 3) As described above in % of Per to feed xxx for Source 3 makeup water.
Biocide 1 or 2 Set Points Pump On Time This menu is used to change the amount of time that the biocide pump will run for each programmed event. Again, it is not possible to reschedule events using the keypad. Press Enter with Pump On Time highlighted to access the screens that show each event: BIO 1/2 ADDS Event A ... J Time Of Day xx:xx Pump On Time (min:sec) xxxx:xx NEXT for next event PREV f. previous evnt Use the arrow keys to change the pump on time in minutes.
pH Set Points Set Point xx.xx Use the arrow keys to change the pH value at which the pump will turn on in order to correct it. Any value between –2 and 16 is acceptable (if based on direct pH sensor). If the control mode is based on a 4-20 mA input, then the set point value is limited to the range of the 4-20 mA input. Press Enter to accept the new value. Dead Band xx.xx Use the arrow keys to change the pH value away from the set point at which the pump will stop running.
Hand Time Limit xxxx Use the arrow keys to change the maximum number of minutes that the ORP output can be activated in the Hand mode. Any value between 0 and 1440 is acceptable. A value of 0 means the output can be left on indefinitely. Press Enter to accept the new value. 5.7 Communication This menu is used to enter the information required to communicate with the WebMaster using the modem option via the Internet, or using the Ethernet option.
Message Off Line Dialing xxx-xxxx No Dial Tone No phone number Connecting to ISP On Line Checking for Upgrade Connection Timeout in xxxxx sec Explanation The controller is not connected. The controller is dialing out to the ISP. The controller can not dial out due to phone line or modem problems. There is nothing entered in the ISP Phone No. field. The controller is successfully negotiating a connection with the ISP. The controller is now on the Internet.
5.8 Access Codes There are three levels of access code protection. If the Master password is used in the Webmaster, then any set point can be changed. If the Calibration Level password is used, then sensor calibrations will be allowed, but other changes will not. If the Read Only password is used the user will be able to look at any menu, but will not be allowed to make any changes.
Menus that appear only if a 4-20mA option board is installed: Corrosion Other Inputs 4-20mA Inputs Level Inputs Menus that appear only if a digital input board is installed: Posiflow Input Interlock Input Digital Inputs Level Inputs Menus that appear only if pH sensor input board is installed: pH Input pH Output Menus that appear only if ORP sensor input board is installed: ORP Input ORP Output Menu that appears only if one or more 4-20mA output boards are installed: 4-20mA Outputs Menu that appears only if
Bleed Volume per Makeup Volume is used to open the bleed valve allowing a programmed volume of water out of the system after a programmed volume of makeup water has been added to the system. This option can only be used if water meters are installed in both the bleed piping and the makeup water piping. Time per Makeup Volume is used to open the bleed valve for a programmed amount of time after a programmed volume of makeup water has been added to the system.
ORP Control Mode Click on the radio button of the option that matches your installation: Direct ORP Sensor should be selected if you will be controlling the ORP relay based on a signal from an ORP electrode. Direct ORP Sensor with Spike should be selected if you want to control the ORP relay to a lower ORP set point for most of the time, and occasionally control to a higher set point for a defined period of time.
Time Based means that the bleed solenoid will open for a programmed amount of time prior to the Biocide 1 addition. The conductivity of the system after the pre-bleed will depend upon the starting conductivity, and the flow rate of the bleed line. Cond Based means that the bleed valve will open until the conductivity of the system drops to the programmed level. This will delay the biocide add for an unknown amount of time, which will vary with the starting conductivity and the bleed flow rate.
Units of Measure Click on the radio button corresponding to your preferred unit of measure. Volume Units. If you select “Gallons”, then every volume-related menu (such as drum levels) will be in US Gallons. Otherwise, they will all be in Liters or in Cubic Meters. Flow Units. Select the units of measure desired for all flow measurements (flow rate if using a 420 mA type water meter or water meter totals). Temperature Units. Select between Fahrenheit and Celsius. Conductivity Units.
Interlock should be selected if any device that is intended to interlock any control outputs is connected to that input. The flow switch should be connected to its own terminal strip on the Core Interface Board, not the optional digital input card. 4-20 mA Outputs (only appears if optional card or cards are installed) Click on the radio button that corresponds to the sensor measurement that you would like to retransmit as a 4-20 mA signal.
Current Reading/Calibrate Sys Cond The current reading is a live reading of the calibrated conductivity of the sample. To Calibrate the system conductivity, click on the “Calibrate Sys Cond” button and a new window will appear in your browser. The live conductivity reading will be displayed in the cell labeled “current value”. Measure the system conductivity with a previously calibrated hand held conductivity meter, and enter that measured value in the text box called “new value”.
Makeup Conductivity Menu (only appears if 2nd conductivity option card is installed) All of the menus described above for the system conductivity also apply to the makeup conductivity. Click on the “Submit” button to save the changes. 6.7 Temperature Input Menu Note: The temperature sensor detection is checked when the WebMaster is powered up. Make sure that the sensor connections are made prior to turning on the power.
Makeup Temperature (only appears if the makeup conductivity sensor option card is installed) All of the menus described above for the system temperature also apply to the makeup temperature. Click on the “Submit” button to save the changes. 6.8 pH Input Menu (only appears if pH option card is installed) Current Reading/Perform Calibration The current reading is a live reading of the calibrated pH of the sample.
You will now be prompted to type in the value of the buffer being used. Do so, then click “Continue”. You will now see the mV output from the electrode. When this value is stable, click “Continue”. The WEBMASTER will either pass or fail the calibration, and prompt you to return the electrode to the process. Click “Continue” when you are ready for pH control to resume. If the calibration fails for any reason, refer to Section 8 for troubleshooting help.
% Difference from theoretical This displays the % difference of the slope from the theoretical value as of the last calibration. The higher this percentage, the weaker the pH electrode. The calibration will fail if this percentage exceeds 80%. This number is the most useful to determine how much life is left in the electrode. Self Test The Self Test is used to check the circuitry of the pH input.
1 Point Calibration First you will see a warning that ORP control will be suspended during the calibration. Click on “Continue” to start the calibration, or “Cancel” to abort the calibration. You then be prompted to “Please Rinse the Electrode”. Do so, then click “Continue”. You will now be prompted to type in the value of the standard solution being used. Do so, then click “Continue”. You will now see the mV output from the electrode. When this value is stable, click “Continue”.
Offset This displays the mV output of the ORP electrode at 0 mV as of the last calibration. The offset information is helpful for troubleshooting. Self Test The Self Test is used to check the circuitry of the ORP input. Click on the “Self Test” button, and the controller will display either Pass or Fail, and also readings of a simulated ORP.
Status Possible status messages are; Normal (everything is OK) If the type of water meter is “4-20 mA”; Sensor Error (the sensor signal is not valid), Over Range (between 20 and 21 mA), Under Range (between 3.9 and 4.0 mA), or Circuit Board Failure. See section 8.1 for a complete description of error messages. Units Click on the radio button to select volume in units of Gallons or Liters. If you change the units in this screen, changes will not occur on the page until the “Submit” button is pressed.
6.12 Level Input Menu (only appears if a 4-20 mA input or digital input option card is installed, and a Level radio button is selected in the Start Up page) Any digital or 4-20 mA input that has been defined as a level input will be set up in this menu. If there are level inputs that don’t appear on this page, return to the Start Up page, and click on the “level” radio button for that input. Click on the “Submit” button to save the changes.
Point Level Input Menu (only appears if a digital input option card is installed, and a level switch radio button is selected in the digital input section of the Start Up page) Input Displays which digital inputs are defined as level inputs. Drum Type in the text box the name of the container the level sensor to the left is measuring. Status Displays whether the drum is currently “Empty” or “Not Empty.” Possible status messages for point level switches are; Normal, Low Alarm or Circuit Board Failure.
High Alarm Limit Type in the text box the corrosion rate at which you want a high alarm to occur. Click on the “Submit” button to save the changes. 6.14 Other Inputs Input Displays which 4-20 mA inputs have been selected as “Other” in the 4-20 mA input section of the Start Up page. Name Type in the text box a name to describe the device connected to that 4-20 mA input (for example “Phosphate”).
High Alarm Limit Type into the text box the value for that input above which you want a high alarm to occur. Any value between –10,000 and 10,000 is acceptable. 6.15 Posiflow Input Menu (only appears if a digital input option card is installed, and a PosiFlow radio button is selected in the digital input section of the Start Up page) Digital Inputs Displays which digital inputs have been defined as PosiFlow inputs in the start up page.
6.16 Interlock Menu (only appears if a digital input option card is installed and an Interlock radio button is selected in the digital input section of the Start Up page) The Interlock feature allows you to use a contact closure (other than the standard flow switch) to shut down certain control outputs. For example, a dry contact from a DCS could be sent when the cooling tower is shutdown for maintenance.
Other should be selected if the 4-20 mA transmitter connected to that input is anything other than the previously mentioned ones. Later when you re-submit the 4-20 mA Input Page, you will be able to name the input (for example, Phosphate or System Pressure) and also define the Units of Measure (like mg/l or psi). 4-20 mA Input Calibration Menu This table is used to calibrate the 4-20 mA inputs.
Cycles of Concentration is used to open the bleed valve when the ratio of the system conductivity to the makeup water conductivity exceeds the programmed value. Choose the option that matches the number of makeup water sources that you will have (up to 3). The option with one makeup source may be selected without a makeup water sensor installed if the conductivity of the makeup water is consistent enough for a manual entry of the value.
Cycles Measured (only appears if a makeup conductivity input card is installed or type of bleed is based on cycles of concentration) This displays the current cycles of concentration of the cooling tower (the ratio of the system conductivity to the makeup conductivity).
Control Direction (only appears if Type of Bleed is Based on System Conductivity or Other 4-20 mA input 4) Click on the radio button to select between the normal “Force Lower” or “Force Higher”. Dead Band (only appears if Type of Bleed is Based on System Conductivity or other 4-20mA input 4) Type in the text box the conductivity (or ppm) value away from the set point at which the bleed valve will close.
then the bleed valve will open at 6.01 cycles and close at 5.90 cycles. The purpose of the dead band is to prevent rapid chattering of the relay open and closed, which can shorten its life. The dead band should be set for the lowest value that still prevents the relay from chattering. Source 1, 2 or 3 Cycles Low Alarm (only appears if Type of Bleed is Based on Cycles of Concentration) Type in the text box the cycles of concentration for each Source below which you want to activate a low alarm.
If you select Off, the valve will not open again until either Hand or Auto is selected! If you select Hand, the valve will open until either Auto or Off is selected, or until the Hand Time Limit (programmed in the next menu) expires. The Off mode is handy to prevent the valve from opening while you are changing set points. The Hand mode is handy to be able to test the valve, wiring, etc without needing to change set points. Event Log Click on the link to view the event log.
Status This displays the current status of the Feed Output, either “Off” or “On”, and if on, the time it has been on and any alarm conditions. Possible status messages are Off, Off/manual, On/Time counting up (for feed and bleed), On/Time counting down (for feed for a known time) and On/Time counting down/Hand (for manual relay activation). Possible error messages are Timeout, No Flow, Interlock, or Pump Failure. See section 8.1 for a complete description of error messages.
Makeup Volume (only appears if Feed Mode is selected as Feed Based On Makeup Volume) Type in the text box the volume of makeup water that needs to enter the system in order to trigger the inhibitor feed. Any value between 1 and 10,000 is acceptable. Time Per Unit Volume (only appears if Feed Mode is selected as Feed Based On Makeup Volume) Type in the text box the amount of time for the inhibitor feed pump to run, once the previously specified volume of makeup water has entered the system.
Source 1, 2 or 3 Conductivity Range (only appears if Feed Mode is one of the Multiple Sources types) Type in the text box the range conductivity (or ppm) values that the controller will use to identify the makeup water source. For example, if the water from this source is typically 275 µS/cm, set the range at 200 to 350 µS/cm. Source 1 must be the lowest conductivity range, Source 2 the next highest, and Source 3 the highest conductivity.
6.21 Biocide 1 & 2 Output Menus (will not appear if the Biocide Feed Mode section of the Start Up page is selected as “Not Used”) There are separate pages for Biocide 1 and Biocide 2, but they are programmed exactly the same way. The two biocide outputs are completely independent, so Biocide 1 can be set up on a 4 week schedule, while Biocide 2 can be on a daily schedule.
Time: Type in the text boxes the hour and minute for the addition to occur. Use the arrow for the pull down menu to select between AM and PM. On Time: Type in the text box the amount of time that you want the biocide pump to run when it makes its addition. Any value between 1 and 1440 is acceptable. For 2 Week or 4 Week Modes, repeat this process for each week in the cycle.
Cond Based means that the bleed valve will open until the conductivity of the system drops to the programmed level. This will delay the biocide add for an unknown amount of time, which will vary with the starting conductivity and the bleed flow rate. If you change the Prebleed mode while on this page, you must click on the Submit button in order to see the correct set of menus. Prebleed Time (only appears if Time Based Prebleed is selected) Type in the text box the amount of time desired for the prebleed.
Hand Time Limit Type in the text box the maximum number of minutes that the Biocide 1 or 2 output can be activated in the Hand mode. Any value between 0 and 1440 is acceptable. A value of 0 means the output can be left on indefinitely. Click on the “Submit” button to save the changes. Event Log Click on the link to view the event log. The event log contains the date and time of each relay activation and deactivation. The data will be a 1 if the relay is closed and a 0 if the relay is open.
Interlock Outputs Click the check boxes to select or de-select the relays that you want to be forced OFF if this output relay is turned ON. If you do not need any other output to shut off when this relay turns on, UNCHECK all boxes. The selection is mutually exclusive, meaning that if the Feed output has the pH output interlocked, the feed won’t turn on if the pH output is on, and the pH output won’t turn on if the Feed output is already on.
Current pH (only appears if pH Control Mode is selected as Direct pH Sensor) Displays the current pH reading from the electrode. Status This menu is for information only, and displays whether the pH output is “Off” or “On” and if on, for how much time, or if any alarm conditions exist. Possible status messages are Off, Off/Manual, On/Time counting up (for adds based on pH input signal) and On/Time counting down/Hand (for manual activation).
Output Time Limit Type in the text box the maximum amount of time that the pH pump can be continuously running before the controller shuts off the pump and activates an Output Time Limit alarm. This is intended to prevent the pump from emptying an entire drum of chemical because of a problem somewhere in the system. Note that the pump will not run again until someone resets the timer! The time limit should be set at approximately twice the normal worst case on time.
Other (4-20 mA input 7) should be selected if you will control the ORP relay based on a signal from a transmitter that is connected to 4-20 mA input 7. This option is only possible if your controller is equipped with the analog input option card. Current ORP (only appears if ORP Control Mode is selected as Direct ORP Sensor) Displays the current ORP reading from the electrode.
Output Time Limit Type in the text box the maximum amount of time that the ORP pump can be continuously running before the controller shuts off the pump and activates an Output Time Limit alarm. This is intended to prevent the pump from emptying an entire drum of chemical because of a problem somewhere in the system. Note that the pump will not run again until someone resets the timer! The time limit should be set at approximately twice the normal worst case on time.
Sensor Status This column shows the status of the sensor that ha been mapped to the 4-20 mA output. Possible messages include Normal, Unmapped, and Sensor Error. Input Value This column shows the process value of the input that is mapped to the 4-20 mA output. This will be in units of conductivity, pH, ORP, temperature or whatever the 4-20 mA input is using for units of measure. Output Status This column shows the status of the 4-20 mA output.
Remote Alarm Action Status This menu is for information only, and displays the status of the remote alarm notification. The possible messages to display are: Alarm Action Completed: Found New Alarm: Alarm Due in HH:MM:SS Taking action Sending Email Sending Page The last alarm notification has already occurred and no further action is pending. A new alarm has occurred and no notification has yet occurred. The alarm delay time will be displayed with time counting down. The alarm notification about to occur.
A window will open to ask if you would like to open the file or save it to disc. Select the method you would like to use. The file is a basic text file with a .log extension that may be opened in any word processing program (Word, Notepad, etc.). Event Log Click on the link to view the event log. The event log contains the date and time of each relay activation and deactivation. The data will be a 1 if the relay is closed and a 0 if the relay is open.
6.28 Auto Reporting There are two types of reports that may be sent to you automatically. One is a system summary report, which will contain all of the information that is found on the System Summary page. This includes sensor readings and 4-20 mA inputs with a 24 hour minimum, maximum and average calculated, relay status, point level status, flow switch status, water meter totals, and alarms. This report may be sent by email. The other type of automatic report is a data log report.
Data Log Auto Reporting, Reporting Mode Click the appropriate radio button to select either a Cyclical report schedule or a Calendar report schedule. Data Log Auto Reporting, Logging Frequency Type the frequency of the data points into the text box. Data Log Auto Reporting, Log Duration If you have selected a cyclical schedule, select a Daily, Weekly, Biweekly, or Monthly report frequency.
6.30 Communications Menu (only appears if either an Ethernet or a modem option card is installed) Internet Dial Up Account Controller ISP User Name When the controller needs to dial out and connect to the Internet Service Provider, it needs to identify itself with a user name, so that the ISP knows that it has an account. Type in the text box the user name that the controller will use.
SMTP IP Address In order for the controller to send an email, the email must first be routed to the SMTP IP address that the Internet Service Provider specifies. Obtain this address from your ISP and type it into the text box. Controller email Address The controller needs to be given an email address, which your ISP uses to identify the controller as having an account, so that the ISP will accept the email that the controller is sending, and route it to the intended recipient.
Network Detection Click on the Detect Network button of the Master Controller and it will look at all of the devices that are connected to it, determine which devices are its slaves, and refresh the Sub-Network frame in the lower left corner of your browser with all of the slaves detected. Ethernet IP Address When a controller is attached to a network, your IT Administrator needs to assign it an Ethernet IP address.
Dialup Dynamic IP Address This menu is informational only, and tells you the IP address of the last person to contact the controller. Last Dialup Date and Time This menu is informational only, and tells you when the controller was contacted last. Click on the “Submit” button to save the changes. Dialup Connection Lifetime This menu allows you to set a time limit on the Internet connection if no changes have been made. This will help control the cost of operating the controller if you forget to log off.
Sub-Network Settings Mapped Internet IP Address If you are accessing the master controller by using NAT to translate a real IP address to a fake IP address, then type the real IP address into this field of the master controller.. Direct Modem Connection (Point to Point) Minimum Required Direct Modem Rings Set the number of rings before the unit will answer the call as a modem to modem connection. If the controller receives less rings before the call is disconnected, it will interpret it as a ShoulderTap.
6.32 Configuration File Menu If many of your cooling tower applications are nearly identical, you can save a lot of time in the set up by downloading a typical configuration file to your hard drive, and later uploading the configuration file to another controller. Export UCF In order to transfer the User Configuration File (UCF) from the WebMaster to your computer, click the Export UCF link. You will be presented with the standard Windows dialog box to download a file.
Download Access Log Click the link to View Log File. The Modem Access Log will tell you when the controller was accessed. It will show you the date and time of access, the method of access, the user name used, the IP address of the computer used for access, and the level of access code used (or that the attempt failed). A window will open to ask if you would like to open the file or save it to disc. Select the method you would like to use. The file is a basic text file with a .
6.38 Sub-Network Once you have created a network of two or more WebMaster controllers using Ethernet cards (see Figure 9 B for wiring), purchased the Master Capability software for the master controller, defined the master unit as the master and slave units as slaves (see section 6.29) in the Communications page, and given each controller unique Ethernet IP addresses in the Communications page, then the links under Sub-Network will be active.
7.0 MAINTENANCE The WebMaster controller requires very little routine maintenance. The electronic enclosure only needs to be wiped down with a damp cloth to keep it clean. All other maintenance involves cleaning and calibrating sensors, described in detail below.
CAP (P/N 102586) SWITCH HOUSING ASSEMBLY (P/N 190998) FLOAT ASSEMBLY (P/N 190996) RETAINING O-RING (ASSEMBLED ONTO SWITCH HOUSING AFTER FLOAT ASSY) (P/N 102919) O-RING (P/N 102594) FLOW SWITCH BODY (P/N 102881) Figure 12 Flow Switch Assembly 98
7.2 Conductivity Sensor Cleaning and Calibration Contacting Conductivity The frequency of cleaning for the contacting conductivity electrode varies with each installation. The best way to determine the frequency is to compare the reading of the controller to the reading of a calibrated hand held instrument. When the two readings differ by an amount that you deem to be excessive (perhaps 5%), then it time to clean and recalibrate the electrode. The frequency should be every 2-3 months or so.
7.3 pH Electrode Cleaning and Calibration The frequency of cleaning for the pH electrode varies with each installation. The best way to determine the frequency is to compare the reading of the controller to the reading of a calibrated hand held instrument. When the two readings differ by an amount that you deem to be excessive (perhaps 0.5 pH units), then it time to clean and recalibrate the electrode. This should be every 2-3 months.
7.5 Replacing the Fuses CAUTION: Disconnect power to the controller before opening the front panel! Locate the fuses on the relay interface board on the lower left side of the back of the controller enclosure. See figure 5, Identification of Parts. Gently remove the old fuse from its retaining clip. You can verify that the fuse has been blown by measuring continuity between the ends of the fuse using an ohmmeter. If it is blown, discard.
8.0 TROUBLESHOOTING 8.1 ERROR MESSAGES No Flow This error message occurs when the input signal to the flow switch terminals is open (disconnected). When sample flow past the flow switch is sufficient, the switch should be closed. All control outputs will be forced off until the flow signal returns. Corrective Actions Possible Causes Valve is closed. Y Strainer is plugged. Open valve to restore sample flow. Clean Y strainer. Circulation pump has stopped. If this is not normal, repair circulation pump.
pH Calibration Failure This error message occurs after attempting an electrode calibration. The normal slope of a pH electrode is 59 mV/pH unit. As the electrode ages, this slope will decrease. The WEBMASTER reports the % difference from the theoretical slope after each calibration. When the slope reaches 12 mV/pH unit (80% difference), the calibration fails. Possible Causes Corrective Actions Dirty electrode. Clean electrode and recalibrate as described in Section 7.3 above.
Bleed Time Out This error message indicates that the bleed relay output has been activated for an amount of time that exceeds the user-programmed maximum allowable time. The bleed output relay will be forced off until the “Reset Time out” button found in the Bleed Output Page is clicked. Possible Causes Corrective Actions Maximum bleed time is set too low for normal circumstances Go to the Bleed Output Page and increase the programmed value for the maximum bleed time. .
Feed Time Out This error message indicates that the feed relay output has been activated for an amount of time that exceeds the user-programmed maximum allowable time. The feed output relay will be forced off until the “Reset Time out” button found in the Feed Output Page is clicked. Corrective Actions Possible Causes Maximum feed time is set too low for normal circumstances. Go to the Feed Output Page and increase the programmed value for the maximum feed time to reflect normal circumstances.
Faulty metering pump wiring. Correct wiring. Faulty pH output relay. Replace the relay interface board. ORP Time Out This error message indicates that the ORP relay output has been activated for an amount of time that exceeds the user-programmed maximum allowable time. The ORP output relay will be forced off until the “Reset Time Out” button found in the ORP Output Page is clicked. Possible Causes Corrective Actions Maximum on-time is set too low for normal circumstances.
Insufficient pressure differential. Ensure that the sample piping is tapped into the discharge side of the circulation pump, and flows to either atmospheric pressure (the cooling tower sump) or the suction side of the circulation pump. Insufficient prebleed prior to biocide addition and bleed lockout.
You are bleeding based on makeup volume, and have set it for too much time or volume. If you are not bleeding based on conductivity, but on makeup water volume, recheck your calculations on how much time, or how much bleed volume needs to be done per makeup water volume. Go to the Bleed Output Page to make sure the correct values are entered. Also go to the Water Meter Input Page to make sure that the correct volume per contact, K factor, or flow rate at 4 and 20 mA menus are entered.
Control direction is set incorrectly. The normal control direction for an open recirculation loop cooling tower is “Force Lower”. Go to the Bleed Output Page and check the setting for the control direction. Faulty bleed solenoid. Repair or replace the bleed solenoid. Fuse blown. Replace fuse (F3). Faulty bleed solenoid wiring. Correct wiring. Faulty bleed relay. Replace the relay interface board.
pH High Alarm This error message indicates the pH reading exceeds the user-programmed maximum allowable value. Corrective Actions Possible Causes The programmed value is too close to pH set point. Go to the pH Input Page and make sure that the the High Alarm Limit is set at least 0.5 pH units above the set point. Assuming you are feeding acid: Chemical supply empty. Replenish chemical supply. Faulty pH electrode. Clean and calibrate the electrode as described in Section 7.3 above.
The pH dead band is set too high. Go to the pH Output Page and change the dead band to be as low as possible to prevent the pH relay from chattering. If the pH reading fluctuates by +/- 0.02 pH units, then a dead band of 0.05 is sufficient. Faulty metering pump wiring. Correct metering pump wiring. pH output relay is stuck closed. Replace the relay interface board. ORP High Alarm This error message indicates the ORP reading exceeds the user-programmed maximum allowable value.
ORP Low Alarm This error message indicates the ORP reading is below the user-programmed maximum allowable value. Corrective Actions Possible Causes Assuming you are feeding an oxidizer: The programmed value is too close to the set point. Go to the ORP Input Page and make sure ORP that the Low Alarm Limit is at least 50 mV below the set point. Chemical supply empty. Replenish chemical supply. Faulty ORP electrode. Clean and calibrate the ORP electrode as described in Section 7.4 above.
Faulty level switch or transmitter wiring. Correct wiring. Make sure that the level sensor is attached to the same input as the one which is defined for that drum in the Level Input Page. Incorrect setting of “Drum empty when switch is open/closed” menu. Go to the “Level Input Page and verify that the “Drum empty when switch is” menu is set for the proper selection. You can check the operation of the switch by measuring between the two wires with an ohmmeter.
Corrosion Monitor High Alarm This error message is caused by the 4-20 mA signal from the corrosion monitor exceeding the user-programmed value for the high alarm limit. Possible Causes Corrective Actions The corrosion rate is too high. Determine the cause for the high corrosion rate and correct it. The high alarm limit is set too low. Go to the Corrosion Page and increase the high alarm limit. The corrosion monitor is not calibrated correctly.
“Other 4-20 mA Input” High Alarm (one for each, use name defined) This error message is caused by the 4-20 mA signal from a device other than a level transmitter, water meter, or corrosion monitor exceeding the user-programmed value for the high alarm limit. Possible Causes Corrective Actions The process value being measured by the transmitter is out of specifications . Determine the reason for the out of spec condition. The high alarm limit for the process being measured is set too low.
Faulty conductivity sensor wiring. Make sure that the sensor cable is connected (if system conductivity) properly, and there are no shorts in any extension cables. Also make sure that the sensor cable is not routed near any AC voltage wiring. Make sure that the cable is properly shielded. Faulty conductivity sensor. Replace sensor.
Faulty sensor option circuit board. Go to the ORP Input Menu and perform a self test. If it fails, remove the electrode wires from the ORP input option board and try the self test again. If it passes, the problem is in t he electrode, housing or its wiring. If it still fails, replace the ORP input option board.
Other 4-20 mA Input Sensor Error This error message is caused by a 4-20 mA input signal that is less than 3.9 mA or greater than 21 mA. Corrective Actions Possible Causes Faulty transmitter. Make sure that the transmitter is functioning by measuring the output using an ammeter. If the output directly from the transmitter is less than 4 mA, the transmitter is the problem. Faulty wiring between transmitter and analog input option circuit board.
ORP Board Failure This error message is caused by a failure of the controller to recognize that the option circuit board is connected. The ORP output relay will be forced off. Corrective Actions Possible Causes Poor connection of the option board to the sensor interface board. Remove the option board and inspect both mating connectors for corrosion or damage. Reinstall the option board. Faulty sensor input board. Replace the sensor input board.
Ethernet Card Failure This error message is caused by a failure of the controller to recognize that the option circuit board is connected. Corrective Actions Possible Causes Poor connection of the option board to the core board. Remove the option board and inspect both mating connectors for corrosion or damage. Reinstall the option board. Faulty Ethernet board. Replace the board.
8.2 Faulty circuit board. Go to the Temperature Input Page and perform a self test. If the self test fails, then the sensor input board (if makeup) or the core interface board (if system) should be replaced. Faulty temperature sensor. If a successful calibration is not possible, the temperature sensor is probably faulty, and the sensor should be replaced. Poor connection of temperature wires. Excessive resistance from extension cables or poor connections can lower the temperature reading.
Faulty sensor input board. This should cause an “ORP Board Failure. error message, but this can be cleared once the power is cycled. Replace the sensor input board. Makeup Conductivity menus missing from Conductivity Input page The controller not detecting the makeup conductivity input option board at power up causes this problem. Possible Causes No sensor input board is installed in the makeup conductivity position. Corrective Actions Install a sensor input board in the makeup conductivity position.
Link to Level page does not appear The controller not detecting either a digital input board or an analog input board at power up causes this problem. Possible Causes No digital or analog input board is installed. Corrective Actions Install the desired option board and turn power on. Poor connection of the option board. Remove the option board and inspect both mating connectors for corrosion or damage Reinstall the option board on turn power on.
8.3 CONNECTION PROBLEMS “The page cannot be displayed message” on your browser This is a standard Microsoft Internet Explorer message when a web page cannot be located. Possible Causes Connection has timed out. Corrective Actions Return to web site and reconnect to the WebMaster. Go to the Communications page and make the Dialup Connection Lifetime longer, if desired. Connection to your ISP has been lost. Reconnect to your ISP and then reconnect to the WebMaster.
9.0 SERVICE POLICY The WebMaster Series Controllers have a 2-year warranty on electronic components and a 1-year warranty on mechanical parts (keypad, terminal strip and relays). Conductivity sensors and pH/ORP electrodes have a 1-year warranty against manufacturing defects only. We stock replacement parts for immediate exchange after we have isolated the cause of a problem. Factory authorized repairs that are received via next-day-air will be returned within 24 hours.
