W A L C H E M IWAKI America Inc. WebMaster®ONE Controllers Web Master ONE ® Water Treatment Controller Instruction Manual Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA TEL: 508-429-1110 FAX: 508-429-7433 WEB: www.walchem.
Notice © 2014 WALCHEM, Iwaki America Inc. (hereinafter “Walchem”) 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. 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, Five Boynton Road, Holliston, MA 01746.
TABLE OF CONTENTS 1.0 INTRODUCTION ...........................................................................................................................................1 2.0 SPECIFICATIONS .........................................................................................................................................1 2.1 ..... MEASUREMENT PERFORMANCE .....................................................................................................................1 2.2 .....
6.14 ... FEED VERIFICATION INPUT MENU ................................................................................................................ 81 6.15 ... LEVEL SWITCHES (DIGITAL) INPUT MENU ................................................................................................... 82 6.16 ... GENERIC (DIGITAL) INPUTS MENU............................................................................................................... 83 6.17 ... COUNTER INPUTS MENU ............................
1.0 INTRODUCTION The WebMasterONE series 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. The controller may be configured to control a cooling tower, or a boiler, or both.
2.2 Electrical Inputs Input power 100 – 120/220-240 VAC ±10%, 12A, 50/60 Hz Input signals State-Type Digital Inputs Fuse 1.6A, 5 x 20mm Analog Inputs (1-8) (Optional) Electrical: Non-isolated 5 VDC with 301K ohm pull-up Typical response time: <10 seconds Devices supported: Any isolated dry contact (i.e.
2.3 Mechanical Enclosure Material: NEMA Rating: Dimensions: Display: Operating Ambient Temp: Storage Temp: Weight Polycarbonate 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 32-120°F (0 to 49°C) -20 to 176°F (-29 to 80°C) 11.5lb (5.
Chlorine, Chlorine Dioxide sensors Pressure: Temperature Chlorine Dioxide sensors: Chlorine: Flow Cell Inlet: Flow Cell Outlet: Wetted Materials of Construction: 0 to 1 atm (0 to 14.
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. Sensor Input Menu – if pH Calibration Reminder Alarm Limits Alarm Dead Band Deviation from Primary Sensor Damping Temperature Alarm Limits 0-365 days -2 to 16 -2 to 16 0.
Sensor Input Menu – if Chlorine or Chlorine Dioxide Calibration Reminder Alarm Limits Alarm Dead Band Deviation from Primary Sensor Damping 0-365 days 0 to 10 mg/l 0 to 10 mg/l 0.
Relay Output Menu – Time Proportional Set Point Sample Period Proportional Band Output Time Limit Hand Time Limit Full scale range of the input parameter 1 to 1440 minutes Full scale range of the input parameter 0 = ∞, 1 to 1440 minutes 1 to 1440 minutes Relay Output Menu – Feed with Another Relay Output Time Limit Hand Time Limit 0 = ∞, 1 to 1440 minutes 1 to 1440 minutes Relay Output Menu – Feed after Another Relay (Fixed Time) Fixed Time to Feed Hand Time Limit 0 to 1440 minutes 1 to 1440 minutes R
Relay Output Menu – Spike Set Point Dead Band Relay On-Time Hand Time Limit Full scale range of the parameter Full scale range of the parameter 1 sec to 1440 minutes 1 to 1440 minutes Relay Output Menu – Intermittent, Fixed Blowdown Time Set Point Interval Time Duration of Sample Hold Time Blowdown Time Hand Time Limit Full scale range of the parameter 5 to 1440 minutes 10 seconds to 60 minutes 30 seconds to 10 minutes 1 to 1440 minutes 1 to 1440 minutes Relay Output Menu – Intermittent, Proportional Bl
Relay Output Menu – Target PPM Feed with Feed Verification Makeup Conductivity Unit Volume to Trigger Output Target PPM Set Point Specific Gravity of Chemical Fed Output Time Limit Hand Time Limit Full scale range of the parameter 1 to 999,999,999 (units defined by user) 0 to 100,000 ppm 0 to 10.
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 WebMasterONE and technical support package (contains instruction manual, Quick Start Guide, CD and USB cable). Any options or accessories will be incorporated as ordered. 3.
Boilers: The conductivity probe should be placed as close to the controller as possible, to a maximum distance of 250 ft. The cable MUST be shielded from background electrical noise. Use 24 AWG, 3 twisted pair, shielded, low capacitance (15 pF/ft) cable such as Walchem P/N 102535 (Belden 9680) or equivalent. Important Boiler Installation Notes: (see figure 1b and c) 1. Make sure the minimum water level in the boiler is at least 4-6 inches above the skimmer blowdown line.
3. Determine the Required Blowdown Rate in Pounds Per Hour Blowdown Rate = Steam Production / (Concentration Ratio –1) Example: 3450/(10-1) = 383.33 lbs./hr 4. Determine if Continuous or Intermittent Sampling is Required Use intermittent sampling when the boiler operation or loading is intermittent, or on boilers where the required blowdown rate is less than 25% of the smallest available flow control valve or less than the flow through the smallest orifice. See the graphs on the next page.
Flow Control Valve Maximum Flow Rates in Lbs/hr 25000 20000 1/2" 150 PSI Lbs/hr 15000 1/2" 300 PSI 3/4" 150 PSI 3/4" 300 PSI 10000 5000 0 20 30 40 50 60 70 80 90 100 150 200 300 Pressure PSI Sensor Installation All sensors for the WebMasterONE 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.
3.4 Icon Definitions Symbol Publication Description IEC 417, No.5019 Protective Conductor Terminal IEC 417, No. 5007 On (Supply) IEC 417, No. 5008 Off (Supply) ISO 3864, No. B.3.6 Caution, risk of electric shock Pending Caution, High temperature, risk of burn ISO 3864, No. B.3.
Figure 1a: Typical Installation, Cooling Tower 15
Figure 1b Typical Installation, Boiler Intermittent Sampling 16
Figure 1c: Typical Installation, Boiler Continuous Sampling 17
3.5 Electrical Installation The WebMasterONE 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.
Sensor 4 or 2 (Observe markings on circuit board) Relay outputs Neutral + + + + + + + t+ IN- IN++5V -5V 102839 REV 2 tt+ IN- IN++5V -5V tt+ IN- IN++5V -5V Figure 3 Identification of Parts Fuses RELAY RELAY 8 7 NC COM NC NO RELAY 3 NC NO Relay Outputs Hot RELAY 4 NC NO 102847 REV 3 Power Relay Board RELAY RELAY 2 1 NC NO NC NO 4-20 mA Output Option Cards RELAY 5 NC NO 102815 RV2 RELAY 6 NC NO +24V TB1 + GN +24 - Sensor 2 or 4 (Observe markings on circuit board) Modem Option Card
R1 DRY POWERED POWERED DRY VoltageCode 0 or 4 1 or 6 2 or 5 3 or 7 R2 DRY POWERED POWERED POWERED R3 DRY POWERED POWERED DRY R4 DRY POWERED POWERED POWERED R5 DRY POWERED POWERED DRY R6 DRY POWERED POWERED POWERED R7 DRY POWERED POWERED DRY R8 DRY DRY POWERED POWERED DRY CONTACTS WILL BE LABELED COM INSTEAD OF NC. SEE DETAIL “A” Important: The mains power supply earth ground connection must be retained by separate nut.
DIGITAL INPUTS SEE DETAIL 'A' t- SENSOR DETAIL "C" Shield (Drain wire) to GND stud on front panel tORN BLU IN+ IN- TT+ ININ+ +5 -5 WHT/BLU WHT/BLU GRN WHT/ORN DIGITAL INPUT A IN+ DIGITAL IN- INPUT B IN+ DIGITAL IN- INPUT C SIGNAL - BLU/WHT * Either an unpowered or a powered device may be connected to each digital input, one device per input.
(See 4-20mA Wiring Guide on the following pages) *Use shielded cable, grounded only at controller end, for ALL connections.
CD WebMaster 4-20 mA Input Wiring Guide GN +24 - INPUT 5 A B + + - INPUT 6 + + - + + - - + + INPUT 7 - KEY: A. (-) minus terminal is the signal input. The 4-20mA signal goes here. B. (+) plus terminal is a +24VDC power supply for the transmitters. C. GND terminal is the return for completing circuits, both signal and power. D. +24 terminal at the top middle of the board is the same supply as the (+) plus terminal.
ADDING AN ISOLATED RECEIVER TO THE LOOP (PLC, CHART RECORDER, ETC) The WebMaster GND must always be at the bottom of the loop. Maximum total loop resistance 1000 ohms. A. Two-Wire Loop-Powered Transmitter Input 1 Input 1 + Input 2 Input 2 + Input 3 Input 3 + Input 4 Input 4 + -SIGNAL +24 - PLC + Notes: The (-) signal is the actual 4-20mA signal and is also the GND return wire to complete the circuit. 'Input -' is internally connected to GND via 25 ohm resistor. B.
Figure 7: Wiring Diagram for Optional Digital Communications 26
4.0 FUNCTION OVERVIEW 4.1 Front Panel Figure 8: Front Panel 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.
4.3 Keypad The keypad consists of 4 directional arrow keys (up, down, left and right), 4 menu/function keys (previous, next, exit and enter), and 4 quick access keys (home, calibrate, relays, and help). The arrow keys are used to change settings (up and down) and move the cursor to a different location within that menu in order to change that setting (left and right). The function keys are used to navigate through the different menu selections. The Next and Prev keys move you from menu to menu.
Currently the WebMasterONE has only limited functionality for the local display and keypad. ALL of the programming must be accomplished using a computer. You will be able to calibrate all sensor inputs, change access codes, and enter the information necessary to communicate with the WebMasterONE via an Ethernet connection or via the modem over the Internet (if a modem card is installed in the controller).
4.6 Communicating with the WebMasterONE 4.6.1 Connection via the USB Port Web Browser (Client) USB Hard coded Fixed IP Address: 199.199.199.2 A USB connection to the WebMasterONE can be made via a temporary cable between a laptop and the front panel of the controller. Equipment Required An USB cable with the appropriate connectors to connect your computer to the WebMasterONE. Features Required in the WebMasterONE Any WebMasterONE controller is capable of an USB connection.
4.6.2 Remote Modem Access: Shoulder Tap Phone line ISP Embedded Web Server Http://w700.walchem.com/ walchem/frontdoor.asp ShoulderTap Connection Utility Equipment Required An Internet-ready computer. An active analog phone line, direct to the controller (without a PBX system in between) must be connected to the modem of the WebMasterONE. A dialup account must be established for the WebMasterONE with an Internet Service Provider (ISP). The connection will only be as reliable as the ISP.
4.6.3 Ethernet Connection to LAN Unsafe Port OR Ethernet LAN Safe Port ROUTER Web Browser Equipment Required An Internet-ready computer. A connection between the PC and the local area network (LAN). An Ethernet connection between the WebMasterONE and the LAN. Utilities you need to set up on your computer There are no special drivers, adapters or other software components required on the PC.
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. An active analog phone line, direct to the controller (without a PBX system in between) must be connected to the modem of the WebMasterONE. Features Required in the WebMasterONE The WebMasterONE must have the modem option installed in order to communicate via Direct Tap.
4.6.5 Direct Ethernet (for a WebMasterONE not connected to a LAN) Web Browser (Client) Fixed IP Address User Assigned User Assigned Fixed IP Address Gateway + Subnet Mask Ethernet Cable Equipment Required An Internet-ready computer. An Ethernet cable connection between the PC and WebMasterONE. Note: Ethernet cross-over cable is required if your PC is using Windows XP. For Vista, Windows 7 or Mac OS, a standard Ethernet cable will work.
4.6.6 Networking WebMasterONE Controllers via Ethernet Slaves Master Web Browser connected using any of the previous methods Hub Equipment Required An Internet-ready computer. An Ethernet cable connection between each WebMasterONE using a hub or connection to LAN. Utilities you need to set up on your computer There are no special drivers, adapters or other software components required on the PC to support networking.
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.
5.2 Indices The Indices menu displays the calculated values of the Ryznar’s Stability Index (RSI), Langliers Saturation Index (LSI), Use the Next key to scroll down the list, or Prev key to scroll up the list. Below the displayed values are menus to change the wet test data used to calculate the various Indices: Calcium Hardness, and Total Alkalinity. Use the Next key to scroll down the list.
Conductivity Calibration – Standard Contacting Electrode “1 pt Process Cal – Calibrate” will be displayed. Press the Enter key to start the calibration. The reading from the system conductivity sensor will be displayed. Measure the conductivity of the system water using a hand held conductivity meter, and use the Arrow keys to enter the actual value. Press the Enter key to highlight ‘CONTINUE’, then press Enter again to put the new value into memory.
Temperature Calibration The current temperature reading will be displayed. Measure the actual temperature of the system water and use the Arrow keys to enter this value. Press the Enter key to highlight ‘CONTINUE’, then press Enter again to put the new value into memory. If the calibration factor is within +/- 15 degrees C (27 degrees F) the display will be “Cal Successful”, otherwise it will be “Cal Fail”. pH Calibration There are three calibration options that will be displayed.
At the end of the calibration, the display will tell you if the calibration was successful or if the calibration failed. If successful, press the Enter key after the electrode has been replaced into the sample stream to resume control. If failed, refer to Section 8 for troubleshooting help. The calculated slope being more than 80% different from theoretical causes a calibration failure, or by the pH 7 mV offset being more than 60 mV.
Step 4 will display the mV output of the electrode in the first buffer. When this reading is stable, press the Enter key to continue. Step 5 will prompt you to rinse the electrode and place it in the second buffer. Press the Enter key to continue. Step 6 will ask you to enter the value of the second buffer. Use the Arrow keys to change the value, then press the Enter key to highlight ‘CONTINUE’, then press Enter again to put the value into memory.
Chlorine or Chlorine Dioxide Calibration 1 pt Process Cal Ensure that the sensor is conditioned and equilibrated to the temperature of the sample. Ensure that the sample flow rate is between 30 and 100 liters/hour. Perform a test on the sample water for the oxidizer concentration. Enter the 1 point process calibration menu. Step 1 will display the current ppm reading of the water.
Calibrate 1 Pt (if not in Fluorometer Mode) The 1-Point Calibration allows you to adjust the current reading of the process value to match what the actual value is as measured by some independent method (such as a laboratory measurement or handheld instrument). The software will maintain the “4 mA =” setting used to scale the input, and adjust the “20 mA =” setting to make the reading accurate at the value entered in the 1-Point Calibration.
Reset Cal Reset Cal is used to reset the 4 mA and 20 mA calibration coefficients to the factory defaults. Press the Enter key and the factory calibration will be restored. 5.6 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).
Relay 1- 8 Set Points The set points available for each relay will vary depending upon the control mode selected. A computer connection is required to change the control mode. The units of measure of some of the set points will vary depending upon sensor input that may be assigned to the relay. Set Point xxxxx (if control mode is any on/off set point, time proportional, target PPM) Use the arrow keys to change the process value at which you want the relay to activate.
Prop Band (if control mode is intermittent sampling, proportional blowdown) Use the arrow keys to adjust the distance from the set point where the maximum output activation time will occur. This parameter will be in the units of measure of the sensor input used to control the relay. The acceptable range for this set point varies with the input. Press Enter to accept the new value.
Output On Time Setup (if control mode is biocide timer or spike set point based feed) This menu is used to change the amount of time that the output will activate for each programmed event. Again, it is not possible to reschedule events using the keypad. Press Enter with Output On Time highlighted to access the screens that show each event: RLY1-8 TIMER ADDS Event A ... T Time Of Day xx:xx Output On Time (min)xxxx (sec)xx NEXT for next event PREV f.
5.8 Communication This menu is used to enter the information required to communicate with the WebMasterONE using the modem option via the Internet, or using the Ethernet option. Once this information is entered, a remote PC may be used to configuring all or the set points that are unavailable with the keypad. For Internet communications, it is also possible to do a manual test of the WebMasterONE’s ability to use its modem to dial a local Internet Service Provider (ISP) and connect to the Internet.
Dial ISP (only if modem is installed) This menu is used to manually dial the WebMasterONE’s ISP. Press the Enter key when the cursor is on this to start the process. A new screen will appear. The first line will show the Dial up Status. This menu is informational only, and tells you what is happening with the dialup connection. Possible status messages include: Message Explanation Off Line The controller is not connected. Dialing xxx-xxxx The controller is dialing out to the ISP.
5.9 Access Codes There are three levels of access code protection. If the Master password is used in the WebMasterONE, 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.
5.12 Feature Activations This menu is used to activate all of the various communications software features in the field. If you have purchased the controller with the communication feature, it will already be activated and no further action will be necessary. Press Enter to view a list of any activated features. To activate a software feature in the field, purchase the activation key file from your distributor and save it on the root drive of a USB flash drive.
6.1 Menu Selection Links Along the left side of your PC monitor will be links to the various menu pages. The exact configuration of your WebMasterONE Series controller will determine which menus are available to you. Some menus only appear if an optional circuit board is installed. Others only appear if a certain option is selected in the Start Up menu. Below is a list of all possible Menu selections, and when they will appear.
Controller Date Format Click on the radio button that corresponds to the desired date format. The choices are Month/Day/Year, Day/Month/Year or Year/Month/Day. Sensors 1-4 Use the pull-downs to select which type of sensor is connected to that input. If the input option cards are not installed for Sensors 2-4, then the pull-down will not be available. The sensor options are Not Used, Contacting Conductivity, Electrodeless Conductivity, pH, ORP, Chlorine, Chlorine Dioxide and High Temp Conductivity.
4-20 mA Inputs 1 - 8 This section will only appear if there is an analog input card installed in the controller. Use the pull-downs to select the function of the analog input channel. The functions available are described below. Make sure that you correctly match the programmed sensor type with the actual sensor type connected to that input! Not Used should be selected if nothing will be connected to the input channel.
Flow based Feed should be selected if the relay will be triggered to activate for a programmable amount of time after a given volume of water has passed by the flow meter. In the relay menu, the volume to trigger feed, and the amount of time of the feed will be specified. Feed With Another Relay should be selected if you want to activate this relay at the same time as another relay (for example, inhibitor feed and bleed).
Alarm should be selected if the relay is to be activated based on an alarm condition. Activate on a DI should be selected if the relay is to be activated whenever a digital input is in either an open or a closed state. Target PPM Feed should be selected if the relay is to be activated to feed a chemical to achieve a PPM set point. This algorithm triggers the relay activation when a user-defined volume of makeup water (measured by up to 3 water meters) is added to the system.
The relay input assignment choices will be any digital or optional analog inputs that are defined as a flow meter input. If the relay control mode is any of the Biocide Timer Based Feed options: The relay input assignment is Not Applicable. If the relay control mode is Feed with Another Relay, Feed After Another Relay (%) or Feed After Another Relay (Fixed Time): The relay input assignment choices will be all the other relays.
6.4 Sensor Menu - Conductivity Input Select the option or type in the values that you want for each of the sections on the page. When you click on the “Submit” button at the bottom of the page, your changes will take effect. If you move to another page without clicking “Submit” first, your changes will be lost! Certain menu sections will only be visible if you have selected certain options in the start up menu. Type of Sensor Click the pull-down to select the type of sensor that you have installed.
Deviation from Primary Sensor This menu only appears if the Redundant Sensor Setting is Backup. Type the maximum allowable difference between the two sensor readings. If this deviation is exceeded, then control of any outputs using the sensor will stop and an alarm activated. Current Reading/Perform Calibration The current reading is a live reading of the calibrated conductivity of the sample.
Uncalibrated Conductivity This section is for information only, and shows the conductivity reading without any calibration. This is helpful in troubleshooting the conductivity sensor. During a one-point calibration, the new value must be within ± 50% of this reading or else the calibration will be rejected. High-High Alarm Limit Type in the text box the sensor process value above which you a want a high-high alarm to occur.
Temperature Units Click on the radio button to select units of measure of either Fahrenheit or Celsius. Uncalibrated Temperature Displays the temperature reading before correcting with calibration constants. This is helpful for troubleshooting. This menu will not appear if no temperature sensor is detected at power-up. High Alarm In the text box, type the maximum temperature that you would reasonably expect to see for the sample. This is helpful to detect a faulty or poorly calibrated temperature sensor.
Primary Sensor Assignment This menu only appears if the Redundant Sensor Setting is Backup. Use the pulldown arrow to select the sensor to use as the primary control sensor. All sensors of the same type as the backup sensor will appear in the pulldown list. Deviation from Primary Sensor This menu only appears if the Redundant Sensor Setting is Backup. Type the maximum allowable difference between the two sensor readings.
You then be prompted to “Please Rinse the Electrode”. Do so, and then click “Continue”. You will now be prompted to type in the value of the buffer being used. Do so, and then click “Continue”. You will now see the mV output from the electrode. When this value is stable, click “Continue”. The WebMasterONE 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.
Calculated Offset This displays the mV output of the pH electrode in pH 7 as of the last calibration. A perfect electrode will generate 0 mV at pH 7. The offset information is also helpful for troubleshooting. % 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%.
Click the Submit button. The new value will be displayed. Click the Close button to close the calibrate window. This menu will not appear if no temperature sensor is detected at power-up. Temperature Units Click on the radio button to select units of measure of either Fahrenheit or Celsius. Uncalibrated Temperature Displays the temperature reading before correcting with calibration constants. This is helpful for troubleshooting. This menu will not appear if no temperature sensor is detected at power-up.
the sensor error alarm will activate. If both sensors are invalid, control stops and the sensor error alarms activate. To select this sensor as the backup sensor, click the Enable radio button, then click on the Submit button at the bottom of the page. The page will reload showing the status of the sensor as Backup, and offer additional menus: Primary Sensor Assignment This menu only appears if the Redundant Sensor Setting is Backup.
You will now be prompted to type in the value of the standard solution being used. Do so, and then click “Continue”. You will now see the mV output from the electrode. When this value is stable, click “Continue”. The WebMasterONE will either pass or fail the calibration, and prompt you to return the electrode to the process. Click “Continue” when you are ready for ORP control to resume. If the calibration fails for any reason, refer to Section 8 for troubleshooting help.
Calculated 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. High-High Alarm Limit Type in the text box the sensor process value above which you a want a high-high alarm to occur. High Alarm Limit Type in the text box the sensor process value above which you a want a high alarm to occur. Low Alarm Limit Type in the text box the sensor process value below which you want a low alarm to occur.
the sensor error alarm will activate. If both sensors are invalid, control stops and the sensor error alarms activate. To select this sensor as the backup sensor, click the Enable radio button, then click on the Submit button at the bottom of the page. The page will reload showing the status of the sensor as Backup, and offer additional menus: Primary Sensor Assignment This menu only appears if the Redundant Sensor Setting is Backup.
At the end of the calibration, the display will tell you if the calibration was successful or if the calibration failed. If successful, press the Enter key after the sensor has been replaced into the sample stream to resume control. If failed, refer to Section 8 for troubleshooting help. The WebMasterOne will either pass or fail the calibration. Control of the oxidizer will continue throughout this process. If the calibration fails for any reason, refer to Section 8 for troubleshooting help.
Low Alarm Limit Type in the text box the sensor process value below which you want a low alarm to occur. Low-Low Alarm Limit Type in the text box the sensor process value below which you want a low-low alarm to occur. Alarm Dead Band Type in the text box the dead band to be used for each alarm set point. Damping Damping is applied to the sensor input by taking a running average of the readings of the input signal over the time frame specified by the damping setting (0-60 seconds).
Low Alarm In the text box, type the minimum temperature that you would reasonably expect to see for the sample. This is helpful to detect a faulty or poorly calibrated temperature sensor. Click on the “Submit” button to save the changes. 6.8 Level (4-20 mA) Input Menu (Only appears if a 4-20 mA input option card is installed, and a Level pull-down is selected in the 4-20 mA Input section of the Start Up page) Input Displays which 4-20 mA inputs are defined as level inputs.
Low Alarm Limit Type in the text box the process value below which you want a low alarm to occur. Low-Low Alarm Limit Type in the text box the process value below which you want a low-low alarm to occur. Alarm Dead Band Type in the text box the dead band to be used for each alarm set point. Damping Damping is applied to the input by taking a running average of the readings of the input signal over the time frame specified by the damping setting (0-60 seconds).
6.9 Flow Meter (4-20 mA) Input Menu (Only appears if a 4-20 mA input option card is installed, and a Flow Meter pull-down is selected in the 4-20 mA Input section of the Start Up page) Backup Sensor Mode The redundant sensor algorithm will allow the user to define a primary sensor to use for control and a backup sensor. If the primary sensor goes invalid, the backup sensor will automatically take over control, and the sensor error alarm will activate.
Dead Band The dead band prevents the flow total from accumulating when the flowmeter transmitter output is just slightly above 4 mA. For example, entering a dead band of 0.1 mA means that any transmitter signal below 4.1 mA will be recorded as a flow rate of 0. 20 mA = Type the flow rate at which the water meter will send a 20 mA signal into the text box. This will generally be at the maximum rated flow rate of the meter. Units Type the units of measure for the flow rate into the text box.
Present Value This displays the current reading of the device, using the mA signal from the device, the span of the 4-20 mA signal defined in “4 mA =” and “20 mA =” below, and the units of measure defined below. Present mA This displays the present raw mA signal from the device. This is helpful in troubleshooting. Status This displays whether the present value is “Normal”, or in a “Low Alarm” or “High Alarm” condition.
Fluorometer Mode The Fluorometer Mode should be selected if a Turner Fluorometer is being used. This will change the 1-Point Calibration to make it easy to adjust the ppm reading of the chemical product based on measurement of the fluorescent dye. To select this transmitter as fluorometer, click the Enable radio button, then click on the Submit button at the bottom of the page.
Not Used should be selected if nothing is connected to that input. Level should be selected if a continuous level transmitter is attached to that output. For point level devices, which do not use a 4-20 mA signal, wire into and program with the Digital Inputs section. Flow Meter should be selected if an analog flow transmitter is connected to that input. Generic should be selected if the 4-20 mA transmitter connected to that input is anything other than the previously mentioned ones.
Current mA Displays a live reading of the mA output of the transmitter. Product Level Displays the live calculated process value, using the existing 4 mA = , 20 mA = and Dye/Product Ratio settings. New Value Enter the desired new reading for the ppb of fluorescent dye. Dye/Product Ratio The Dye-to-Product ratio is the ratio of the fluorescent dye in ppb to the active ingredient in the chemical product in ppm. Type the ratio (given to you by your chemical supplier). Click Continue.
Status Possible status messages are; Normal (everything is OK) or Circuit Board Failure (Digital Inputs 1-6 only). See section 8.1 for a complete description of error messages. Volume per Contact (appears only if the Contact type is selected) Type the volume of solution that needs to flow through the flow meter before the meter sends a contact into the text box. The controller uses this information to update the totalizer.
To select this sensor as the backup sensor, click the Backup radio button, then click on the Submit button at the bottom of the page. The page will reload showing the status of the sensor as Backup, and offer additional menus: Primary Sensor Assignment (appears only if the Paddlewheel type is selected) This menu only appears if the Redundant Sensor Setting is Backup. Use the pulldown arrow to select the sensor to use as the primary control sensor.
Feed Verification Status This column lets you know if the Feed Verification device is sensing flow from the pump or not. Vol. per Stroke Type in the text box the volume of chemical that the metering pump delivers each time it strokes the diaphragm. This information is used to totalize the volume of chemical delivered, by multiplying the volume per stroke by the number of strokes counted by the Feed Verification device.
6.16 Generic (Digital) Inputs Menu Digital Inputs This column shows all digital inputs that have been defined as generic input types. Custom Name You may give the input a custom name by typing it in the text box. Custom Message for Open Contact You may specify a custom message to be displayed in the System Summary when the digital input contact is open. Type it in the text box.
Rate Units Select the units of measure that you want to use using the pull-down. The choices are pulses per second, minute, hour, day, week, month, or year. One Count = This menu allows you to specify that each count (contact closure) signifies a certain number of the custom units of measure. For example, one count could equal 100 liters of fluid. Total Alarm Limit You may specify a total number of counts accumulated above which an alarm message will occur. Type this in the text box.
Relay Input Assignment Click on the arrow of the pull down menu and select the input that will be used to control the relay. See Section 6.2 for details. Current Reading This field is for information only, and will display the calibrated reading from the sensor that is assigned to control the relay. Status This menu is for information only, and displays whether the output is “Off” or “On” and if on, for how much time, as well as any alarm conditions.
Mutual Interlocks Click the check boxes to select or de-select the relays and analog output control outputs that you want to be prevented from turning ON if this output relay is already 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 Relay 2 has Relay 4 interlocked, then R2 won’t turn on if R4 is already on, and R4 won’t turn on if R2 is already on.
Type of Event Relay output Interlock DI Level Switch DI Status to generate a ‘1’ in the log Relay activated In the Interlock state as defined in the Interlock page In the Low Alarm state as defined in the Level Switches page In the Alarm state as defined in the Generic Inputs page Switch closed Status to generate a ‘0’ in the log Relay not activated In the non-Interlock state as defined in the Interlock page In the Normal state as defined in the Level Switches page In the Normal state as defined in the Ge
Reset Timeout There is a button called “Reset Timeout” which is used to reset the output if it has been activated for longer than the time limit imposed in the “Output Time Limit” menu described below. Custom Name This menu allows you to rename the output if desired. Type the new name into the text box. Set Point Type in the text box the process value at which you want the relay to activate. The set point value is limited to the range of the assigned input.
Hand Time Limit Type in the text box the maximum number of minutes that the relay can be activated in the Hand Mode. Any value between 1 and 1440 is acceptable. Click on the “Submit” button to save the changes. Output Mode Click on the radio buttons to manually control the relay. The normal selection will be Auto, where the controller uses the various set points to open and close the relay.
Relay Control Mode Click on the arrow of the pull down menu and select the way that you want to control the relay. See Section 6.2 for details on each control mode. Sys. Cond. Input Assignment Click on the arrow of the pull down menu to select the conductivity sensor that is installed in the cooling tower water. Makeup Cond. Input Assignment Click on the arrow of the pull down menu to select the conductivity sensor that is installed in the makeup water.
Mutual Interlocks Click the check boxes to select or de-select the relays and analog output control outputs that you want to be prevented from turning ON if this output relay is already 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 Relay 2 has Relay 4 interlocked, then R2 won’t turn on if R4 is already on, and R4 won’t turn on if R2 is already on.
Type of Event Relay output Interlock DI Level Switch DI Generic DI – Alarm selected Generic DI – No Alarm selected Status to generate a ‘1’ in the log Relay activated In the Interlock state as defined in the Interlock page In the Low Alarm state as defined in the Level Switches page In the Alarm state as defined in the Generic Inputs page Switch closed Status to generate a ‘0’ in the log Relay not activated In the non-Interlock state as defined in the Interlock page In the Normal state as defined in the L
Status This displays the current status of the relay output, either “Off” or “On”, and if on, the amount of time it has been on. Possible status messages are Off, Off/Manual, On/Time counting down/Sampling, Off/Time counting down/Holding, On/Time counting down/Blowdown, Off/Time counting down/Waiting and On/Time counting down/Hand (for manual activation). The only possible error messages are Interlock and Sensor Error. See section 8.1 for a complete description of error messages.
If you select Off, the relay will not activate again until either Hand or Auto is selected (or if power is cycled)! If you select Hand, the relay will activate until either Auto or Off is selected, or until the Hand Time Limit (programmed in the next menu) expires or until the controller power is cycled. The Off mode is handy to prevent the relay from activating while you are changing set points. The Hand mode is handy to be able to test the pump or valve, wiring, etc without needing to change set points.
If the conductivity is still too high, the blowdown time is recalculated and the valve is opened for that time. This continues until the conductivity is below the set point. The valve closes and will not reactivate until the Interval Time has expired. You may also change the Relay Control Mode here. If you do, you will have to reselect the Input Assignment as well. This section assumes that the Relay Control Mode is set to Intermittent (Proportional Blowdown Time).
Blowdown Time Type in the desired maximum time to blowdown if the conductivity is above the set point. Too long a time will waste water and drop the conductivity well below the set point. Too short a time could cause the conductivity to rise too high, potentially resulting in scale or carryover. Proportional Band Type in the conductivity above the set point that will correlate to the maximum blowdown time.
Type of Event Relay output Interlock DI Level Switch DI Generic DI – Alarm selected Generic DI – No Alarm selected Status to generate a ‘1’ in the log Relay activated In the Interlock state as defined in the Interlock page In the Low Alarm state as defined in the Level Switches page In the Alarm state as defined in the Generic Inputs page Switch closed Status to generate a ‘0’ in the log Relay not activated In the non-Interlock state as defined in the Interlock page In the Normal state as defined in the L
Accumulated Volume This displays the volume of flow that has accumulated so far towards triggering the next feed event. This is not the total flow, as seen in the System Summary page. This total will reset itself once the feed has occurred. You can manually reset this total using the “Reset Total” button to the right. Custom Name This menu allows you to call the output another name if desired. Type the new name in the text box.
Output Mode Click on the radio buttons to manually control the relay. The normal selection will be Auto, where the controller uses the various set points to open and close the relay. You can force the relay closed regardless of the set points by selecting Hand, or force the relay open regardless of the set points by selecting Off.
Assign Relay to Feed With Click on the arrow of the pull down menu and select the relay that will be used to control this relay. Status This displays the current status of the relay output, either “Off” or “On”, and if on, the amount of time it has been on. Possible status messages are Off, Off/Manual, On/Time counting down and On/Time counting down/Hand (for manual activation). The only possible error message is Interlock. See section 8.1 for a complete description of error messages.
Hand Time Limit Type in the text box the maximum number of minutes that the relay can be activated in the Hand mode. Any value between 1 and 1440 is acceptable. 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, as well as the state of each Interlock, Level Switch, or Generic digital input.
Status This displays the current status of the relay output, either “Off” or “On”, and if on, the amount of time it has been on. Possible status messages are Off, Off/Manual, On/Time counting down and On/Time counting down/Hand (for manual activation). The only possible error message is Interlock. See section 8.1 for a complete description of error messages. Custom Name This menu allows you to call the output another name if desired. Type the new name in the text box.
Hand Time Limit Type in the text box the maximum number of minutes that the relay can be activated in the Hand mode. Any value between 1 and 1440 is acceptable. 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, as well as the state of each Interlock, Level Switch, or Generic digital input.
Status This displays the current status of the relay output, either “Off” or “On”, and if on, the amount of time it has been on. Possible status messages are Off, Off/Manual, On/Time counting down and On/Time counting down/Hand (for manual activation). The only possible error message is Interlock. See section 8.1 for a complete description of error messages. Custom Name This menu allows you to call the output another name if desired. Type the new name in the text box.
Hand Time Limit Type in the text box the maximum number of minutes that the relay can be activated in the Hand mode. Any value between 1 and 1440 is acceptable. 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, as well as the state of each Interlock, Level Switch, or Generic digital input.
Time Period Type in the desired time period, between 1 and 1440 minutes. The relay will activate at the beginning of the time period, for the percentage of it specified below. % of Period to Feed Use this menu to type in the percentage of the time period that this relay will be active. Mutual Interlocks Click the check boxes to select or de-select the relays and analog output control outputs that you want to be prevented from turning ON if this output relay is already ON.
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, as well as the state of each Interlock, Level Switch, or Generic digital input.
Week 1-4 Schedule (only appears if the Relay Control Mode is selected as Weekly, Bi-Weekly, or Monthly) Day of Week: Click on the check box next to the days of the week during which you want a relay activation to occur. If a box is checked and you don’t want an addition that day, click it to uncheck the box. 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.
Assign Prebleed Conductivity Input (only appears if Prebleed is Conductivity Based) Click on the arrow of the pull down menu to select the sensor input which is used for system conductivity (normally S1). Prebleed Conductivity (only appears if Prebleed is Conductivity Based) Type the conductivity set point for the prebleed into the text box. This should be less than the normal bleed set point.
The Off mode is handy to prevent the relay from activating while you are changing set points. The Hand mode is handy to be able to test the pump or valve, wiring, etc without needing to change set points. Hand Time Limit Type in the text box the maximum number of minutes that the relay can be activated in the Hand mode. Any value between 1 and 1440 is acceptable Click on the “Submit” button to save the changes. Event Log Click on the link to view the event log.
Status This displays the current status of the relay output, either “Off” or “On”, and if on, the amount of time it has been on. Possible status messages are Off, Off/Manual, On/Time counting down and On/Time counting down/Hand (for manual activation). The only possible error messages are Interlock, Timeout and Sensor Error. See section 8.1 for a complete description of error messages. Custom Name This menu allows you to call the output another name if desired. Type the new name in the text box.
Output Time Limit Type in the text box the maximum amount of time that the relay can be continuously activated before the controller deactivates the relay and activates an Output Time Limit alarm. This is intended to prevent the output from running out of control if the input fails in such a way that it will never deactivate the relay. Note that the relay will not activate again until someone resets the timer! It will take some experience to find out what the normal output on-time will be.
6.31 Relay (1 – 8) Output Menus – Dispersant Types This page is used to activate the relay either before or after a Biocide Timer relay activates. This is normally used to feed a Dispersant, Penetrant or Surfactant to a cooling tower. You may also change the Relay Control Mode here. If you do, you will have to reselect the Input Assignment as well. This section assumes that the Relay Control Mode is set to Dispersant. Other control mode types are described in other sections of the manual.
It will take some experience to find out what the normal output on-time will be. If the relay cycles open and closed under worst case conditions in 30 minutes, you may want to set the Output Time Limit at 60 minutes. Output Mode Click on the radio buttons to manually control the relay. The normal selection will be Auto, where the controller uses the various set points to open and close the relay.
6.32 Relay (1 - 8) Output Menus - Bleed Volume based on Makeup Volume This page is used to activate the relay until a programmed volume of water flows through the bleed water meter(s). The relay activation is triggered by a programmed volume of makeup water flowing through the makeup water meter(s) You may also change the Relay Control Mode here. If you do, you will have to reselect the Input Assignment as well. This section assumes that the Relay Control Mode is set to Bleed Volume based on Makeup Volume.
Mutual Interlocks Click the check boxes to select or de-select the relays and analog output control outputs that you want to be prevented from turning ON if this output relay is already 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 Relay 2 has Relay 4 interlocked, then R2 won’t turn on if R4 is already on, and R4 won’t turn on if R2 is already on.
Type of Event Relay output Interlock DI Level Switch DI Generic DI – Alarm selected Generic DI – No Alarm selected Status to generate a ‘1’ in the log Relay activated In the Interlock state as defined in the Interlock page In the Low Alarm state as defined in the Level Switches page In the Alarm state as defined in the Generic Inputs page Switch closed Status to generate a ‘0’ in the log Relay not activated In the non-Interlock state as defined in the Interlock page In the Normal state as defined in the L
Power-up Alarm Delay Time In order to avoid being notified of an alarm condition that is only present because the system is just powering up, you set a delay time for the alarm action. If the alarm condition still exists at the end of the delay time, then the alarm relay will activate. If the alarm condition no longer exists at the end of the delay time, no notification will occur. Any value between 0 and 1440 minutes is acceptable.
If you select Off, the alarm relay will not be triggered again until either Hand or Auto is selected! If you select Hand, the relay will be closed 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 use as an alarm silence. The Hand mode is handy to be able to test the relay, wiring, etc without needing to force an alarm condition.
Status This displays the current status of the relay output, either “Off” or “On”, and if on, the amount of time it has been on. Possible status messages are Off, Off/Manual, On/Time counting down and On/Time counting down/Hand (for manual activation). The only possible error messages are Relay or Analog Output Lockout and Timeout. See section 8.1 for a complete description of error messages. Custom Name This menu allows you to call the output another name if desired. Type the new name in the text box.
It will take some experience to find out what the normal output on-time will be. If the relay cycles open and closed under worst case conditions in 30 minutes, you may want to set the Output Time Limit at 60 minutes. Output Mode Click on the radio buttons to manually control the relay. The normal selection will be Auto, where the controller uses the various set points to open and close the relay.
6.35 Relay (1 - 8) Output Menus – Target PPM Feed Type This page is used to set the flow volume to trigger feed, PPM set point, etc. Which units of measure appear depends upon how the flow meter input assigned to the relay is configured. If you make changes to the Input Assignment, you will need to click on the “Submit” button in order to see all the correct units. You may also change the Relay Control Mode here. If you do, you will have to reselect the Input Assignment as well.
Status This displays the current status of the Relay 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 down, Off/Time counting down or On/Time counting down/Hand (for manual relay activation). Possible error messages are Timeout, Interlock, or Pump Failure. See section 8.1 for a complete description of error messages. Custom Name This menu allows you to call the output another name if desired.
It will take some experience to find out what the normal output on-time will be. If the relay cycles open and closed under worst case conditions in 30 minutes, you may want to set the Output Time Limit at 60 minutes. Hand Time Limit Type in the text box the maximum number of minutes that the relay can be activated in the Hand mode. Any value between 1 and 1440 is acceptable. Click on the “Submit” button to save the changes. Output Mode Click on the radio buttons to manually control the relay.
6.36 Relay (1 - 8) Output Menus – Target PPM Feed with Feed Verification Type This page is used to set the flow volume to trigger feed, PPM set point, etc. Which units of measure appear depends upon how the flow meter input assigned to the relay is configured. If you make changes to the Input Assignment, you will need to click on the “Submit” button in order to see all the correct units. You may also change the Relay Control Mode here. If you do, you will have to reselect the Input Assignment as well.
Status This displays the current status of the Relay 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 down, Off/Time counting down or On/Time counting down/Hand (for manual relay activation). Possible error messages are Timeout, Interlock, or Pump Failure. See section 8.1 for a complete description of error messages. Custom Name This menu allows you to call the output another name if desired.
Output Mode Click on the radio buttons to manually control the relay. The normal selection will be Auto, where the controller uses the various set points to open and close the relay. You can force the relay closed regardless of the set points by selecting Hand, or force the relay open regardless of the set points by selecting Off.
Input Status This column shows the status of the sensor that has been mapped to the 4-20 mA output. Possible messages include Normal, Unmapped, and Sensor Error. Input Reading 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 mA Value This column shows the status of the 4-20 mA output in mA.
Input Assignment Click on the arrow of the pull down menu and select the analog or sensor input that will be used to modulate the analog output. Custom Name This menu allows you to call the output another name if desired. Type the new name in the text box. Live Readings These are for information only and display the sensor input reading, the sensor input status, the analog output mA value, and the analog output status.
During Input Calibration Click on the radio button to select how you want the analog output to react during calibration of the input: Remain Active: The Output % continues to respond to changes as normal. Set Value: When the calibration begins the Output % is forced to the Input Cal Set Value (see below). Normal response resumes once the calibration is complete. Last Value: When the calibration begins the Output % is frozen at the last value calculated before the calibration.
The Off mode is handy to prevent the output from responding while you are changing set points. The Hand mode is handy to be able to test the pump,, wiring, etc without needing to change set points. Hand Value Type in the text box the output % that the output will use when activated in the Hand mode. 4-20 mA Loop Cal This menu is used to calibrate the device connected to the analog output. Click on Set 4 mA and the output will drive the loop with a fixed 4 mA of current.
Alarm Delay Time In order to avoid being notified of an alarm condition that quickly corrects itself, you set a delay time for the alarm action. If the alarm condition still exists at the end of the delay time, then the alarm action will occur. If the alarm condition no longer exists at the end of the delay time, no notification will occur. Any value between 0 and 1440 minutes is acceptable.
System Conductivity The system conductivity reading from the selected conductivity sensor is displayed here. Makeup Conductivity The conductivity reading from the selected makeup water conductivity sensor is displayed here. If the sensor is Not Used, a text box will allow manual entry of the makeup conductivity. System Temperature The system temperature reading from the selected conductivity sensor is displayed here. If the sensor is Not Used, a text box will allow manual entry of the temperature.
Last Config Date & Time This line displays the last time that a Configuration Packet was attempted to be sent. It will show “OK” if it was successful. Last Data Date & Time This line displays the last time that a Data Packet was attempted to be sent. It will show “OK” if it was successful. Log Click the Download Log link to download a CSV file that may be opened in Excel, that details the date and time of each packet sent and if it was successful or not. 6.
6.43 Datalog Auto Report The other type of automatic report is a data log report. This report will email a data log file of any parameters selected. This file may be opened in a spreadsheet for graphing or other data manipulation. This report is sent on a cyclical schedule. The Manual (see next section) and Auto Reporting data logs are dynamically connected to each other. For each data log, select the parameters to log, and the maximum time frame of the data log and submit the changes.
Logging Interval Type in the text box the time required between data points. If this is set to a particular value, and changes to the logging parameters results in a larger minimum interval, the time previously set will be replaced by the new minimum interval. Datalogging Mode If data needs to be logged at all times, select Normal.
6.44 Manual Datalog You may either download data files automatically, or manually. To have the data automatically sent to you via email, set up the data log in the Auto Reporting page (See Section 6.43). The Manual and Auto Reporting data logs are dynamically connected to each other. For each data log, select the parameters to log, and the maximum time frame of the data log and submit the changes.
If datalogging of some parameters needs to be suspended during an Interlock condition, or when a generic digital input is in a certain state, or when a relay is on or off (as in during a Probe Wash cycle, for example) or during an alarm condition, select Suppressed by Events. The data will be suppressed for as long as the trigger is active.
Scenario 1: Maximum Log Duration Datalog 1 Maximum Log Datalog 2 DataLog 1 downloaded by user If downloaded successfully by Flashstick or Web Page, DataLog 1 is deleted from the controller. DataLog 2 starts Maximum Log Duration RESETs Scenario 2: Maximum Log Duration Maximum Log Duration Datalog 1 Maximum Log Duration Datalog 2 Datalog 3 Datalog 1 full & saved.
Log files that are actively filling will be erased (after a warning pop-up) if the user changes critical parameters such as: • The parameter being logged • The alarm used to trigger the log • The logging duration • The logging interval Or for the related inputs used for alarm triggered logging • The type of sensor or analog input • The units of measure of the sensor or analog input • The type of digital input of the trigger DI The Logging Interval may increase automatically if the memory required for the Au
Primary ISP Phone No. Type in the text box the access phone number for the controller’s Internet Service Provider. APN (only appears with GPRS activations) Type in the text box the APN (Access Point Name) provided by the cell service provider. Controller Phone No When you need to communicate with the controller, you go to the web site, link to the WebMasterOne access page, and a call is made from our server to the controller to wake it up.
Cell Phone Text Message Addresses The email message above is in html format and will not be displayed correctly on a cell phone. The cell phone text message email will be truncated. Data log and summary reports are not sent to these addresses, only alarm emails. 1st Address – 4th Address Type in the text box the addresses for a text message to be sent. Up to four addresses are available.
Connection Status This menu is informational only, and tells you what is happening with the Internet connection. Possible status messages vary with the type of connection and include: Message Explanation Off Line The controller is not connected. Dialing xxx-xxxx The controller is dialing out to the ISP. No Dial Tone The controller can not dial out due to phone line or modem problems. No phone number There is nothing entered in the ISP Phone No. field.
Last Known Signal Strength This field will display the actual modem response string from the wireless modem. An rssi signal of 12-36 is good, the higher the number the better. If it’s 12 then the signal is very marginal and you should attempt to improve it. A signal of 99 is very poor. Internet Connection Log (PSTN or cell modem only) Click on the link to view the Internet Connection log file. You will be prompted to either open the file (.
6.47 Advanced Comms Internet Dialup (only appears if PSTN modem is installed) Wait for dial tone before dialing Click to place a check in the box if you want the modem to wait for a dial tone before calling out. In some countries the dial tone may not be recognized. If the modem will not recognize the dial tone, uncheck the box. Modem Baud Rate Click on the arrow of the pull-down to select different modem baud rates. The WebMaster modem is 38400. Normally there will be no reason to change the baud rate.
Gateway Port (only for VNet Activations) Type the desired VNet port in the text box. This will normally not change from the default port of 1194. Sub-Network Settings (only appears if the controller has master networking activated) Mapped Internet IP Address If you are accessing the master process monitor 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 process monitor.
Import UCF Once the file name is displayed in the Browse text box, click the Import UCF button to transfer the file to the WebMasterONE. 6.49 Notepad The configuration Notepad gives you a place to make notes regarding any changes that you have made to the set points, to document calibrations, system upsets or anything else that you want to note. Simply type your message into the text box. 6.50 Access Codes There are three levels of access code protection.
Note: Control is suspended during a software upgrade. If the controller being updated is a slave on a network of WebMasterONEs, both the master controller and the slave being updated will have control suspended during the upgrade process. Depending upon the extent of the changes and Internet traffic, the upgrade can take anywhere from 15 minutes to 2 hours to complete. 6.
7.0 MAINTENANCE The WebMasterONE 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. CAUTION! The WebMasterONE inner hinged face panel is secured with Phillips (#1) screws, which require a tool to open. No user adjustments are inside. This panel should only be opened by trained maintenance personnel. 7.
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 10 Flow Switch Assembly 150
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.
For loose coatings, wipe with a cloth. Use a bottle brush to clean out the internal channels. For removal of scale, dip in a dilute hydrochloric or gallic acid solution, and rinse. The electrodeless sensor is immune to oily coatings. Reassemble all parts. Make sure that the sample valve is closed, open the isolation valves, and inspect for leaks. After cleaning, it is necessary to recalibrate the electrode. This is only accurate when the electrode is installed in the piping. 7.
7.5 Disinfection Sensor Cleaning and Calibration The frequency of cleaning for the disinfection sensors varies with each installation. The best way to determine the frequency is to verify that the desired oxidizer concentration closely matches an offline analysis (such as a DPD test). When the two readings differ by an amount that you deem to be excessive then it time to clean and recalibrate the sensor. This should be every 2-3 months. To clean the sensor, close the isolation valves to stop sample flow.
8.0 TROUBLESHOOTING 8.1 ERROR MESSAGES Conductivity Calibration Failure This error message occurs after calibration of the conductivity sensor. A clean sensor should give a predictable signal in a solution of known conductivity. If the calibration adjusts the signal more than 50% away from the predicted value, the calibration will fail. A signal this far off indicates a problem with the reading, and is not normal. Possible Causes Corrective Actions Dirty sensor. Clean sensor as described in Section 7.
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 WebMasterONE 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.
Disinfection Sensor Calibration Failure This error message occurs after calibrating the chlorine or chlorine dioxide electrode. The controller will display a calibration failure if the offset calculated in the Zero Calibration is outside of the range –20 to 40 mV or the slope calculated in the One Point Process Calibration is outside of the range -10 to -100 mV per ppm. Possible Causes Corrective Actions Insufficient conditioning Wait for the appropriate amount of time before attempting a calibration.
Output Time Out This error message indicates that the relay output has been activated for an amount of time that exceeds the user-programmed maximum allowable time. The output relay will be forced off until the “Reset Timeout” button found in that Relay Output Page is clicked. Possible Causes Corrective Actions Maximum time is set too low for normal circumstances . Process value was higher/lower than normal. Go to the Relay Output Page and increase the programmed value for the maximum time.
Conductivity High Alarm This error message indicates the conductivity reading exceeds the user-programmed maximum allowable value. Possible Causes Corrective Actions Programmed value is too close to conductivity set point. Go to the Conductivity Input Page and make sure that the high alarm limit is set at least 5% above the set point. Control direction is set incorrectly. Go to the Relay Output Page and check the setting for the control direction. Faulty control device.
pH High Alarm This error message indicates the pH reading exceeds the user-programmed maximum allowable value. Possible Causes Corrective Actions 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. Chemical supply empty. Replenish chemical supply. Faulty pH electrode. Clean and calibrate the electrode as described in Section 7.3 above.
pH Low Alarm This error message indicates the pH reading is below the user-programmed minimum allowable value. Possible Causes Corrective Actions The programmed value is too close to pH set point. Go to the pH input page and make sure that the the Low Alarm Limit is set for at least 0.5 pH units below the set point minus the dead band. Chemical supply empty. Replenish chemical supply. Faulty pH electrode. Clean and calibrate the electrode as described in Section 7.3 above.
ORP High Alarm This error message indicates the ORP reading exceeds the user-programmed maximum allowable value. Possible Causes Corrective Actions The programmed value is too close to the ORP set point. Go to the ORP Input Page and make sure that the High Alarm Limit is more than 50 mV above the set point plus the dead band. Slow ORP electrode response, dirty electrode. Clean and calibrate the ORP electrode as described in Section 7.4 above.
ORP Low Alarm This error message indicates the ORP reading is below the user-programmed maximum allowable value. Possible Causes Corrective Actions The programmed value is too close to the ORP set point. Go to the ORP Input Page and make sure 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.
Drum Level Low Alarm (one for each used) This error message appears if either a level switch or level transmitter is putting out a signal that indicates a low level of solution. This could mean that the level switch is either open or closed, or that the level transmitter is indicating a volume below the user-programmed low alarm limit. Possible Causes Corrective Actions Low chemical level. Replenish chemical supply. Level switch float is stuck. Clean level switch. Faulty level switch.
Pump Failure (one for each monitored) This error message appears if contact closures from the Feed Verification flow monitor are expected but are not detected by the digital input option circuit board. Possible Causes Corrective Actions Metering pump has lost prime. Re-prime metering pump. Faulty metering pump. Repair or replace metering pump. Faulty metering pump wiring. Correct wiring. Faulty Feed Verification device wiring. Correct wiring.
4-20 mA Input Low Alarm This error message is caused by the 4-20 mA signal being lower than the user-programmed value for the low 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 low alarm limit for the process being measured is set too high. Decrease the low limit in the 4-20 mA Input Page.
pH Sensor Error This error message is caused by the signal from the pH electrode being outside of the normal range (pH less than –2 or greater than 16, or input voltage outside –1.45 VDC to +1.45 VDC). Any relay being controlled by the sensor will be forced off. Possible Causes Corrective Actions Faulty pH cartridge. Replace cartridge. Faulty pH electrode wiring. Make sure that the electrode cartridge is firmly screwed into the housing. Make sure that there is no water inside the housing.
Temperature Sensor Error This error message is caused by the temperature signal being outside the normal range (around 1500-33,000 ohms for contacting conductivity sensors, 15,000 to 330,000 for electrodeless conductivity sensors, 1000 to 1400 ohms for pH sensors and high temperature conductivity sensors). Any relay controlled by the faulty sensor will be forced off.
Rate High Alarm The rate for a flow meter input or counter input has exceeded its programmed maximum limit. Possible Causes Corrective Actions The system has experienced too high a rate Evaluate system The rate high alarm point is too low Go to the input page and reset the limit You are getting false contacts. Go to the appropriate Input Page and verify that the total is increasing even when the solution is not flowing.
Sensor 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. Possible Causes Corrective Actions 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. Possible Causes Corrective Actions 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.
Temperature Low Alarm This error message is caused by the temperature signal from a sensor being below the userprogrammed value for the low alarm limit. Possible Causes 8.2 Corrective Actions The actual temperature is too low. Correct problem with process. The programmed value is set too close to the normal operating temperature. Go to the sensor input page and. decrease the low alarm limit. The temperature sensor has lost calibration. Go to the sensor input page and calibrate the temperature.
Temperature calibration, high/low alarm menus missing from Sensor Input page The controller not detecting the temperature sensor at power up causes this problem. Possible Causes The temperature sensor is not connected. Corrective Actions Connect the temperature sensor and turn power on. Faulty temperature sensor. Measure the temperature signal using an ohmmeter between the green wire and the WHT/GRN wire as close to the sensor as possible with the wires disconnected from the terminal strip.
Link to Analog Inputs page does not appear The controller not detecting an analog input board at power up causes this problem. Possible Causes No analog input board is installed Corrective Actions Install the analog input 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.
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Model Code 1 WMT8 SINGLE COOLING TOWER A System Cond 0 = No sensor 1 = Graphite electrode, 150 psi 2 = Electrodeless, 150 psi 3 = SS electrode, 150 psi 4 = High pressure, 300 psi B pH/ORP 0 = None 1 = pH, flat, 100 psi 2 = ORP, rod, 100 psi 3 = Both, 100 psi 4 = pH, bulb, high pressure, 300 psi 5 = ORP, high pressure, 300 psi 6 = Both, 300 psi C Makeup Cond 0 = None 1 = Graphite electrode 2 = Electrodeless 3 = SS electrode 4 = High pressure, 300 psi 2 WMB8 BOILER Sensors 1 WMT8 A B C SINGLE Cooling Tow
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