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Walchem WebMaster, Instruction Manual

The Walchem WebMaster offers a comprehensive user manual that can be easily downloaded for free from our website. This detailed manual provides step-by-step instructions for seamless installation and operation of the product. Access the manual at manualshive.com to ensure maximum productivity and efficiency with your Walchem WebMaster.

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TABLE OF CONTENTS 

 

1.0

 

INTRODUCTION ........................................................................................................................................... 1

 

2.0

 

SPECIFICATIONS ......................................................................................................................................... 1

 

2.1

 

 

.....

 

M

EASUREMENT 

P

ERFORMANCE

 ..................................................................................................................... 1

 

2.2

 

.....

 

E

LECTRICAL

 ................................................................................................................................................... 2

 

2.3

 

.....

 

M

ECHANICAL

 ................................................................................................................................................. 3

 

2.4

 

.....

 

V

ARIABLES AND THEIR 

L

IMITS

 ....................................................................................................................... 5

 

3.0

 

UNPACKING & INSTALLATION ............................................................................................................. 10

 

3.1

 

 

.....

 

U

NPACKING THE 

U

NIT

 .................................................................................................................................. 10

 

3.2

 

 

.....

 

M

OUNTING THE 

E

LECTRONIC 

E

NCLOSURE

 ................................................................................................... 10

 

3.3

 

.....

 

I

NSTALLATION

.............................................................................................................................................. 10

 

3.4

 

.....

 

I

CON 

D

EFINITIONS

 ........................................................................................................................................ 14

 

3.5

 

 

.....

 

E

LECTRICAL 

I

NSTALLATION

 ......................................................................................................................... 18

 

4.0 

 

FUNCTION OVERVIEW ............................................................................................................................ 27

 

4.1

 

 

.....

 

F

RONT 

P

ANEL

 ............................................................................................................................................... 27

 

4.2

 

.....

 

D

ISPLAY

 ....................................................................................................................................................... 27

 

4.3

 

.....

 

 

K

EYPAD

 ....................................................................................................................................................... 28

 

4.4

 

 

.....

 

A

CCESS 

C

ODES

 ............................................................................................................................................. 28

 

4.5

 

.....

 

I

NITIAL 

S

TARTUP

 .......................................................................................................................................... 28

 

4.6

 

 

.....

 

C

OMMUNICATING WITH THE 

W

EB

M

ASTER

ONE .......................................................................................... 30

 

4.7

 

.....

 

S

TARTUP

 ...................................................................................................................................................... 36

 

4.8

 

 

.....

 

S

HUT 

D

OWN

 ................................................................................................................................................. 36

 

5.0

 

OPERATION – USING LOCAL DISPLAY AND KEYPAD .................................................................... 36

 

5.1

 

 

.....

 

I

NPUT 

S

UMMARY

 .......................................................................................................................................... 36

 

5.2

 

 

.....

 

I

NDICES

 ........................................................................................................................................................ 37

 

5.3

 

 

.....

 

O

UTPUT 

S

UMMARY

 ...................................................................................................................................... 37

 

5.4

 

.....

 

A

LARMS

 ....................................................................................................................................................... 37

 

5.5

 

 

.....

 

C

ALIBRATION

 ............................................................................................................................................... 37

 

5.7

 

 

.....

 

S

ET 

P

OINTS

 .................................................................................................................................................. 44

 

5.8

 

 

.....

 

C

OMMUNICATION

 ......................................................................................................................................... 48

 

5.9

 

 

.....

 

A

CCESS 

C

ODES

 ............................................................................................................................................. 50

 

5.10

 

...

 

S

OFTWARE 

U

PGRADE

 ................................................................................................................................... 50

 

5.11

 

...

 

C

OPY TO 

USB

 

D

ISK

 ...................................................................................................................................... 50

 

5.12

 

...

 

F

EATURE 

A

CTIVATIONS

 ............................................................................................................................... 51

 

5.13

 

...

 

C

ONTROLLER 

R

ESTART

 ................................................................................................................................ 51

 

6.0 

 

OPERATION – USING PC .......................................................................................................................... 51

 

6.1

 

.....

 

M

ENU 

S

ELECTION 

L

INKS

 .............................................................................................................................. 52

 

6.2

 

.....

 

S

TART UP 

M

ENU

 ........................................................................................................................................... 52

 

6.3

 

 

.....

 

S

YSTEM 

S

UMMARY 

M

ENU

 ........................................................................................................................... 57

 

6.4

 

 

.....

 

S

ENSOR 

M

ENU 

-

 

C

ONDUCTIVITY 

I

NPUT

 ........................................................................................................ 58

 

6.5

 

 

.....

 

S

ENSOR 

M

ENU 

-

 P

H

 

I

NPUT

 ........................................................................................................................... 61

 

6.6

 

.....

 

S

ENSOR 

M

ENU 

-

 

ORP

 

I

NPUT

 ........................................................................................................................ 65

 

6.7

 

.....

 

S

ENSOR 

M

ENU 

–

 

C

HLORINE

,

 

C

HLORINE 

D

IOXIDE 

I

NPUTS

 ............................................................................ 68

 

6.8

 

 

.....

 

L

EVEL 

(4-20

 M

A)

 

I

NPUT 

M

ENU

 .................................................................................................................... 72

 

6.9

 

.....

 

F

LOW 

M

ETER 

(4-20

 M

A)

 

I

NPUT 

M

ENU

 ......................................................................................................... 74

 

6.10

 

...

 

G

ENERIC 

(4-20

 M

A)

 

I

NPUT 

M

ENU

 ................................................................................................................ 75

 

6.11

 

...

 

4-20

 M

A

 

I

NPUT 

M

ENU

 .................................................................................................................................. 77

 

6.12

 

...

 

F

LOW 

M

ETER 

(D

IGITAL

)

 

I

NPUT 

M

ENU

 ......................................................................................................... 79

 

6.13

 

...

 

I

NTERLOCK 

M

ENU

 ........................................................................................................................................ 81

 

Summary of Contents for WebMaster

Page 1: ...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 com WebMaster ONE Controllers W A L C H E M IWAKI America Inc ...

Page 2: ...mechanical parts and electrodes from date of delivery from the factory or authorized distributor under normal use and service and otherwise when such equipment is used in accordance with instructions furnished by WALCHEM and for the purposes disclosed in writing a the time of purchase if any WALCHEM s liability under this warranty shall be limited to replacement or repair F O B Holliston MA U S A ...

Page 3: ...N USING LOCAL DISPLAY AND KEYPAD 36 5 1 INPUT SUMMARY 36 5 2 INDICES 37 5 3 OUTPUT SUMMARY 37 5 4 ALARMS 37 5 5 CALIBRATION 37 5 7 SET POINTS 44 5 8 COMMUNICATION 48 5 9 ACCESS CODES 50 5 10 SOFTWARE UPGRADE 50 5 11 COPY TO USB DISK 50 5 12 FEATURE ACTIVATIONS 51 5 13 CONTROLLER RESTART 51 6 0 OPERATION USING PC 51 6 1 MENU SELECTION LINKS 52 6 2 START UP MENU 52 6 3 SYSTEM SUMMARY MENU 57 6 4 SEN...

Page 4: ...ASED ON MAKEUP VOLUME 115 6 33 RELAY 1 8 OUTPUT MENU ALARM TYPE 117 6 34 RELAY 1 8 OUTPUT MENUS ACTIVATE ON A DI 119 6 35 RELAY 1 8 OUTPUT MENUS TARGET PPM FEED TYPE 121 6 36 RELAY 1 8 OUTPUT MENUS TARGET PPM FEED WITH FEED VERIFICATION TYPE 124 6 37 ANALOG OUTPUT 1 4 MENU RETRANSMIT MODE 127 6 38 ANALOG OUTPUT MENUS 1 4 PROPORTIONAL FEED MODE 128 6 39 REMOTE ALARMING 131 6 40 LSI RSI 132 6 41 VTO...

Page 5: ... periodic basis at a programmable frequency and if equipped with a modem card dial out in the event of an alarm condition The alarm notification may be via phone to a pager or email Our revolutionary digital communications package allows you to change set points manually activate or deactivate pumps and valves upgrade software receive reports and alarms from any PC that has Internet access No prop...

Page 6: ...ance 1000 ohm maximum load Typical response time 10 seconds Sensor STANDARD 1 Sensor OPTIONAL 3 Signal isolated 1 5V Signal isolated 1 5V Temp isolated 1K or 10K or 100K ohm Temp isolated 1K or 10K or 100K ohm Outputs STANDARD Mechanical relays At 115 VAC 10 amp resistive 1 8 HP At 230 VAC 6 amp resistive 1 8 HP R1 R2 R3 and R4 relays are fused together as one group total current for this group mu...

Page 7: ... Glass Filled Polypropylene CPVC HDPE FKM Glass ORP electrode Pressure 0 to100 psi Temperature 32 to 158 F 0 to 70 C Process connections NPTF Wetted Materials of Construction Glass Filled Polypropylene CPVC HDPE FKM Platinum Glass Contacting conductivity electrode Pressure 0 to150 psi Temperature 32 to158 F 0 to 70 C Process connections NPTF Wetted Materials of Construction Glass Filled Polypropyl...

Page 8: ...re boiler contacting conductivity electrode Pressure 0 250 psi Temperature 32 401 F 0 to 205 C Process connections NPTM Wetted Materials of Construction 316 SS PEEK High pressure pH electrode Pressure 0 300 psi Temperature 32 275 F 0 to 135 C Process connections NPTM Wetted Materials of Construction Glass Polymer PTFE 316 SS FKM High Pressure ORP electrode Pressure 0 300 psi Temperature 32 275 F 0...

Page 9: ...ion Factor 0 5 1 0 Alarm Limits 0 to 10 000 units defined by user Alarm Dead Band 0 to 30 000 units defined by user Deviation from Primary Sensor 0 01 to 30 000 units defined by user Damping 0 to 60 seconds Temperature Alarm Limits 23 to 190 F 5 to 88 C Sensor Input Menu if High Temp Contacting Conductivity Calibration Reminder 0 365 days ppm Conversion Factor 0 5 1 0 Alarm Limits 0 to 10 000 unit...

Page 10: ...0 mA 10 000 to 10 000 units defined by user Low Alarm Limit 100 000 000 to 100 000 000 units defined by user High Alarm Limit 100 000 000 to 100 000 000 units defined by user Flowmeter Input Menu Digital Input Type Volume per Contact 0 to 1000 units of measure defined by user K Factor 0 001 to 20 000 Pulses per Gallon or Liter Total Alarm Limit 0 no limit otherwise 0 Rate High Alarm 0 Rate Low Ala...

Page 11: ...ed by user Feed Time per unit Volume 1 second to 1440 minutes Output Time Limit 0 1 to 1440 minutes Hand Time Limit 1 to 1440 minutes Relay Output Menu Biocide Timer Based Output On Time 0 1 to 1440 min Hand Time Limit 1 to 1440 minutes Relay Output Menu Feed After Another Relay of Relay to Feed 0 to 100 Output Time Limit 0 1 to 1440 minutes Hand Time Limit 1 to 1440 minutes Relay Output Menu Feed...

Page 12: ...nutes Hold Time 30 seconds to 10 minutes Blowdown Time 1 to 1440 minutes Hand Time Limit 1 to 1440 minutes Relay Output Menu Alarm On Delay Time 0 to 1440 minutes Power Up On Delay Time 0 to 1440 minutes Output Time Limit 0 1 to 1440 minutes Hand Time Limit 1 to 1440 minutes Relay Output Menu Activate on a DI On Delay Time 10 seconds to 1440 minutes Off Delay Time 10 seconds to 1440 minutes Output...

Page 13: ...S cm to 1000 mS cm Temperature 32 to 392 F 18 to 200 C pH 2 to 16 standard units ORP 1400 to 1400 mV Chlorine Chlorine Dioxide 0 to 10 mg l 4 20 mA Output Menu Proportional Feed Set Point Full scale range of the parameter Minimum Output Allowed 0 100 Input Value when Output is Max Full scale range of the parameter Damping 0 60 seconds Interlock Value 0 100 Input Fault Value 0 100 Input Cal Set Val...

Page 14: ...ns that are in close proximity to sources of electrical noise motor starters power transformers variable speed motor drives radio transmitters etc corrosive fumes or excessive moisture The enclosure requires the following clearances Top 2 Left 10 Right 4 Bottom 8 3 3 Installation Plumbing The WebMasterONE series controllers are supplied with a flow switch manifold designed to provide a continuousl...

Page 15: ...ine to the electrode as short as possible to a maximum of 10 feet 4 Mount the electrode in the side branch of a tee in a horizontal run of pipe This will minimize entrapment of steam around the electrode and will allow any solids to pass through 5 There MUST be a flow restriction after the electrode and or control valve in order to provide back pressure This flow restriction will be either a flow ...

Page 16: ... the valve also gives you a visual indication if the flow rate has been changed If the valve clogs it can be opened to clear the obstruction and closed to the previous position If an orifice plate is used you must install a valve downstream from the orifice in order to fine tune the flow rate and provide additional back pressure in many applications Example An 80 psi boiler has a Required Blowdown...

Page 17: ...ed then 24 AWG shielded low capacitance 15 pF ft twisted pair cable such as Walchem P N 102535 Belden 9680 or equivalent should be used Pay attention to the integrity of the cable shield Always route sensor cables or any other low voltage wiring in conduit that is separated from any AC voltage wiring by at least 6 inches pH and ORP electrodes must be installed such that the measuring surfaces will...

Page 18: ...cation 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 1 Caution ...

Page 19: ...15 Figure 1a Typical Installation Cooling Tower ...

Page 20: ...16 Figure 1b Typical Installation Boiler Intermittent Sampling ...

Page 21: ...17 Figure 1c Typical Installation Boiler Continuous Sampling ...

Page 22: ...ys are connected in two relay banks each fused at 6 3 amps See figure on the right Assess the steady state amps of all loads before connecting to controller Depending upon your model code some relays may be dry contact and not fused CAUTION There are live circuits inside the controller even when the power switch on the front panel is in the OFF position The front panel must never be opened before ...

Page 23: ... listed are optional and may not be present in your controller Bottom View Digital Inputs Strain relief installed with analog card option Strain relief installed with digital card option Misc Inputs Outputs Analog Inputs Digital Inputs Strain relief installed with analog card option Strain relief installed with digital card option Misc Inputs Outputs Digital Input A Digital Input B Digital Input C...

Page 24: ...rve markings on circuit board 4 20mA Input Option Card Digital Input Option Card 4 20 mA Output Option Cards Relay outputs Neutral Relay Outputs Hot Power Relay Board Fuses t t IN IN 5V 5V 102839 REV 2 t t IN IN 5V 5V 102839 REV 2 t t IN IN 5V 5V 102839 REV 2 INPUT 5 INPUT 5 INPUT 6 INPUT 7 INPUT 4 GN 24 24V TB1 102815 RV2 INPUT 3 INPUT 2 INPUT 1 102847 REV 3 DIG INPUT 6 DIG INPUT 5 DIG INPUT 4 IN...

Page 25: ... GND STUD WHT BLK GRN TO GND STUD BLK GRN WHT HOT GND NEU GROUND STUD SOLENOID OR MOTORIZED BALL VALVE METERING PUMP AC POWER INPUT NEU HOT NC NO NC NO NC NO NC NO NC NO NC NO NC NO NEUTRAL SEE DETAIL A DETAIL A BRACKET PC BOARD SEPARATE NUT PRIMARY EARTH CONNECTION OTHER EARTH CONNECTIONS RELAY8 RELAY7 RELAY6 RELAY5 RELAY4 RELAY3 RELAY2 RELAY1 BLK IF USING A MOTORIZED BALL VALVE Important The mai...

Page 26: ...ce per input DIGITAL INPUTS SEE DETAIL A SENSOR 1 SEE DETAIL C SENSOR 2 or 4 Observe markings on circuit board SEE DETAIL C SENSOR 3 SEE DETAIL C SENSOR 4 or 2 Observe markings on circuit board SEE DETAIL C B1 t t IN IN 5V 5V 102839 REV 2 t t IN IN 5V 5V 102839 REV 2 t t IN IN 5V 5V 102839 REV 2 DIGITAL INPUT D IN IN DIGITAL INPUT E IN IN DIGITAL INPUT F IN IN 12V 12V OR SHIELD TO GROUND STUD GROU...

Page 27: ...See 4 20mA Wiring Guide on the following pages Use shielded cable grounded only at controller end for ALL connections Figure 6 Wiring Diagram for Optional Digital Inputs 4 20 mA Inputs and 4 20 mA Outputs ...

Page 28: ...ers GND terminal is the return for completing circuits both signal and power 24 terminal at the top middle of the board is the same supply as the plus terminal A B C D A B C D Input 1 Input 1 Input 2 Input 2 Input 3 Input 3 Input 4 Input 4 Input 1 Input 1 Input 2 Input 2 Input 3 Input 3 Input 4 Input 4 Input 1 Input 1 Input 2 Input 2 Input 3 Input 3 Input 4 Input 4 E Non Isolated Two Wire External...

Page 29: ...mum total loop resistance 1000 ohms B Two Wire Externally Powered Transmitter POWER POWER SIGNAL SIGNAL GND 24 Notes This transmitter gets its power from its own dedicated power supply Connecting a powered transmitter to the Input terminal of the WebMaster will permanently damage the input Input 1 Input 1 Input 2 Input 2 Input 3 Input 3 Input 4 Input 4 PLC 24V GND C Three Wire Transmitter 24 SIGNA...

Page 30: ...26 Figure 7 Wiring Diagram for Optional Digital Communications ...

Page 31: ...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 In 15 seconds you will hear 3 beeps and the controller is ready to go The Summary Screen will display the sensor inputs analog inputs PPM etc up to 5 parameters selected from the Startup web page an...

Page 32: ...onstruction Refer to Section 5 0 for details on use of the keypad for sensor calibration relay control setting communications parameters etc 4 4 Access Codes The WebMasterONE 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 50 for details There are three ...

Page 33: ...er via the USB port or via the local keypad before attempting a Shoulder Tap connection If you have not yet set up an ISP account and wish to program the WebMasterONE 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 the Ethernet connected then the controller can bec...

Page 34: ...nnect the supplied USB cable between the WebMasterONE and your computer Install the driver on your PC by inserting the disc supplied and following the instructions in the Quick Start Guide This needs to done only once for each PC that will be used to communicate with a WebMasterONE controller Go to Control Panel Network Connections and locate the new Local Area Connection 2 that has been created C...

Page 35: ...ome of this information needs to be provided to you by the Internet Service Provider ISP that the WebMasterONE will use to access the Internet The controller s phone number The local access phone number for the ISP More than one access number may be entered The ISP Username that the controller will use to connect to the ISP The ISP Password that the controller will use to connect to the ISP Steps ...

Page 36: ... the IT Administrator of the LAN The Ethernet IP address of the WebMasterONE If the controller will only be accessed by computers on the LAN then this may be a local IP address If the controller needs to be accessible by computers not on the LAN then this must be an Internet accessible IP address The Subnet Mask The Gateway IP address Steps Required to Establish a Connection Open Internet Explorer...

Page 37: ...he user prior to attempting the communication Steps Required to Establish a Connection Create the dialup networking adapter on your PC This needs to done only once for each PC that will be used to communicate with a WebMasterONE controller Use the dialup networking adapter to connect the PC to the WebMasterONE Open Internet Explorer Type in the address 199 199 199 3 The sign on screen for the WebM...

Page 38: ...l Version 4 TCP IPv4 For Mac OSX Set Configure IPv4 to Manually Select Use the following IP address Change the IP address to 10 0 100 30 Subnet mask should be 255 255 254 0 Parameters that need to be programmed into the WebMasterONE The default settings will work with the LAN settings shown above The default IP address for the controller is 10 0 100 29 The default subnet mask is 255 255 254 0 Step...

Page 39: ...l keypad The Ethernet IP address of the WebMasterONE The Subnet Mask The Gateway IP address The master must be selected as the master and the slaves selected as slaves Steps Required to Establish a Connection Connect to the master controller using one of the methods described in sections 4 6 1 through 4 6 5 The sign on screen of the WebMasterONE will come up Type the User Name and Password Access ...

Page 40: ...up the WebMasterONE display will show the process values from the sensors and the most important alarm message If there is more than one alarm then pressing the Down Arrow key will display the additional alarm messages Pressing the Enter key will display the Main Menu The menu selections are Input Summary Indices Output Summary Alarms Calibration Relay Control HOA Set Points Communication Access C...

Page 41: ...while the output that is in timeout is highlighted Press the Exit key to return to the Main Menu 5 4 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 5 Calibration The Calibra...

Page 42: ...ecessary 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 Place the Sensor in Air Remove the sensor from the water and make sure that it is dry especially in the holes Wait for several minutes while the conductivity reading stabilizes Press the Enter key to continue If the value i...

Page 43: ...litmus paper It also assumes a perfect slope 2 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 Step 2 will ask you to enter the temperature of the buffer solutions Use the Arrow ke...

Page 44: ... 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 1 pt Process Cal Step 1 will display the current pH reading of the sys...

Page 45: ...ep 2 will prompt you to rinse the electrode and place it into the buffer solution Press the Enter key to continue Step 3 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 highlight CONTINUE then press Enter again to put the value into memory Step 4 will display the mV output of the electrode in the buffer When this reading is ...

Page 46: ...the Zero Cal menu Step 1 will display the current mV reading from the sensor Stir the water with the sensor until the mV reading is stable for at least 5 minutes When the reading is stable press Enter to continue If the value is within the range of calibration it will display Cal Successful Press the Enter key after replacing the sensor in the flow cell If not it will display Calibration Failed Re...

Page 47: ...brate 1 Pt 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 P...

Page 48: ...the controller dictates that the relay should be ON or OFF IF THE POWER TO THE CONTROLLER IS CYCLED OFF AND BACK ON THE RELAY WILL REVERT BACK TO AUTO MODE If the relay is in the HAND mode then the relay will be closed regardless of whether the programming of the controller dictates that the relay should be ON or OFF If a Hand Time Limit has been programmed in the controller the relay will shut of...

Page 49: ... 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 Duration if control mode is intermittent sampling Use the arrow keys to set the minutes and press Enter...

Page 50: ... to accept the changes Any value between 0 and 100 is acceptable Spike Point if control mode is any spike set point Use the arrow keys to change the higher set point then press Enter to accept the changes The set point value is limited to the range of the sensor input Unit Vol to Trigger xxxxx if control mode is flow based feed or target PPM Use the arrow keys to change the volume of solution that...

Page 51: ... in minutes seconds to delay the relay deactivation once the DI changes to the non active state then press Enter to accept the changes Any value between 1 and 1440 is acceptable Specific Gravity if control mode is target PPM Use the arrow keys to change the specific gravity of the chemical product being fed Any value between 0 and 10 g ml is acceptable Pump Rating if control mode is target PPM Use...

Page 52: ...at it has an account Enter the user name here Dial up ISP Password only if modem is installed Similarly the controller needs to identify itself with a password in order to connect with the ISP Enter the password here Dial up ISP Local Phone only if modem is installed Enter the phone number for the controllers Internet Service Provider This will be the phone number that it attempts to dial when get...

Page 53: ...ed to the WebMasterONE by its ISP the last time it connected When the manual ISP Dial up process is successful this number should change The third line is the date and time of the last successful connection with the ISP The bottom line will display Dial ISP Log Off and Cancel Pressing the Enter key while the cursor is on Dial ISP will make another attempt to dial the ISP Pressing the Enter key whi...

Page 54: ...ller is REMOVED The software of the controller may be easily updated in the field adding new features or fixing any bugs This can be accomplished in a few quick steps a Save the new software upgrade to a 32 MB or higher USB flash memory stick These are available from the factory or may be found locally b Plug the memory stick into one of the USB Host connections on the core interface board see Fig...

Page 55: ... process must be repeated for each one 5 13 Controller Restart This menu is used to safely restart the controller This should be used instead of cycling power in order to shut down the program in the proper manner 6 0 OPERATION Using PC These units control continuously as long as power is applied This section describes how to set up the controller utilizing a PC See Section 5 0 for instructions ut...

Page 56: ... Codes Custom Name Relay 7 Digital Inputs Help Custom Name Relay 8 Menu that appears only if one or more sensor input boards are installed Custom Name Sensor 2 Custom Name Sensor 3 Custom Name Sensor 4 Menu that appears only if a software upgrade is available Software upgrade Menu that appears only if one or more 4 20mA output boards are installed Custom Name Analog Output 1 Custom Name Analog Out...

Page 57: ...Flow Meter should be selected if a high frequency 10 300 Hz Hall Effect style flow meter is connected to the input The input is not compatible with flow sensors that generate their own sine wave A sensor of this type must be connected to Digital Input A D or 5 6 Counter should be selected if the contact closure from the sensor will be used to log counts and or to initiate a relay to activate for a...

Page 58: ...ed below Once the control modes have been selected click the Submit Changes button This will change the Relay Input Assignment section that comes next making the possible choices for the input assignment match the control mode Not Used should be selected if the relay is not being used On Off Set Point should be selected if the relay needs to respond to a sensor input or analog input signal The rel...

Page 59: ...me and then spiking the concentration for a programmable amount of time as often as once per day on a bi weekly schedule This is typically an oxidizer addition based on an ORP electrode Spike Set Point 4 Week Cycle should be selected to activate the relay based on one set point for a majority of the time and then spiking the concentration for a programmable amount of time as often as once per day ...

Page 60: ...t section that comes next making the possible choices for the input assignment match the control mode Analog Output Control Mode 1 4 This section will only appear if there are one or more 4 20 mA output cards installed Use the pull downs to select the control mode for each analog output Not Used or Retransmit Relay 1 8 Input Assignment This section is where the input used to control the relay is a...

Page 61: ...gnment is Not Applicable If the relay control mode is Activate on a DI The relay input assignment will be any Interlock or Generic Input digital inputs Analog Output Input Assignment 1 4 This section will only appear if there are one or more 4 20 mA output cards installed Use the pull downs to select the input signal that will be retransmitted as a 4 20 mA output signal The possible choices includ...

Page 62: ...hoices are 0 1000 µS cm 0 10 000 S cm 0 100 mS cm or 0 1 000 mS cm You must have the correct sensor to match the conductivity range Conductivity Units Click on the radio button to select the units of measure that you want to use You will have to click the Submit button at the bottom of the page to see more menus that relate to ppm or concentration if you change units of measure Backup Sensor Mode ...

Page 63: ...or will reject it if the conductivity entered is too far from the factory calibration reading The limit is 50 of the uncalibrated reading Click the Close button to return to the Conductivity Input page Status This section is for information only and lets you know if any alarm conditions exist Possible status messages are Normal everything is OK Sensor Error the sensor signal is not valid High Alar...

Page 64: ...the damping setting 0 60 seconds The averaged reading is displayed and used for control Type in the text box the desired time frame Temperature Note The temperature sensor detection is checked when the WebMasterONE is powered up Make sure that the sensor connections are made prior to turning on the power Current Temperature Displays a live reading of the temperature of the system water If no tempe...

Page 65: ...ur 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 The rest of this section assumes that you have selected pH Custom Name You can rename the input by typing a custom name in the text box provided This name will appear as the link to the i...

Page 66: ...the controller will allow you to enter the buffer temperature manually Otherwise it will display the electrode temperature 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 first 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 Continu...

Page 67: ...Board Failure for Sensors 2 3 or 4 or Calibration Time See section 8 1 for a complete description of error messages Date of Last Calibration This section is for information only and lets you know when the last calibration occurred Calibration Reminder If you want to be reminded when the sensor needs calibration for example every 30 days then type the desired number of days between calibration in t...

Page 68: ... 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 The averaged reading is displayed and used for control Type in the text box the desired time frame Temperature Note The temperature sensor detection is checked whe...

Page 69: ...or Menu ORP 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...

Page 70: ...int process calibration by clicking the appropriate button 2 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 and then click Continue You will now be prompted to type in the value of the first standard solutio...

Page 71: ...n Time See section 8 1 for a complete description of error messages Date of Last Calibration This section is for information only and lets you know when the last calibration occurred Calibration Reminder If you want to be reminded when the electrode needs calibration for example every 30 days then type the desired number of days between calibration in the text box A value of zero means you will ne...

Page 72: ...es 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 ...

Page 73: ...iate button Zero Calibration A zero calibration must be performed on initial installation or after cleaning or replacing the membrane or electrolyte This step must be done prior to the process calibration Remove the sensor from the flow cell and place it in a beaker of clean oxidizer free water Allow the sensor 15 minutes to equilibrate to the water temperature Click on the Zero Calibration button...

Page 74: ...nded The highest value allowed is 365 days Self Test The Self Test is used to check the circuitry of the sensor input Click on the Self Test button and the controller will display either Pass or Fail and also readings of a simulated oxidizer sensor If the controller passes self test and you are having problems reading the correct value or calibrating then the problem must be with the sensor wiring...

Page 75: ...er sensor types the temperature signal may be logged of used to control an output but it is not used to correct the sensor reading Current Temperature Displays a live reading of the temperature of the system water Status Possible status messages are Normal everything is OK Sensor Error the signal is not valid High Alarm or Low Alarm See section 8 1 for a complete description of error messages Cali...

Page 76: ...mitter before it is converted into a volume This is helpful for troubleshooting Status This displays whether the current drum level is Normal or in Low Alarm Possible status messages for level transmitters are Normal everything is OK Sensor Error the sensor signal is not valid Over Range between 20 and 21 mA Under Range between 3 9 and 4 0 mA Low Alarm or Circuit Board Failure Full Volume Type int...

Page 77: ...within user defined limits but both are valid readings control will stop and a Sensor Deviated alarm will activate If the backup sensor goes invalid while the primary sensor is OK control continues but 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 Backup radio button then clic...

Page 78: ...t 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 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...

Page 79: ...e 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 Rate 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 s...

Page 80: ...ext box the value that corresponds to a 20 mA output signal from the device For example if the pressure transmitter sends out 20 mA at 100 psi type in 100 Any value between 10 000 and 10 000 is acceptable Units Type into the text box the units of measure that you want to use for the device connected to that input For example you could use psi Bars etc High High Alarm Limit Type in the text box the...

Page 81: ...s Backup and offer additional menus 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 maxim...

Page 82: ...alibrate the controller 1 Pt Cal 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...

Page 83: ...alibration was successful 6 12 Flow Meter Digital Input Menu All flow meters connected to digital inputs will be configured in this menu Each meter will have a separate section The sections available for a contact meter will differ than those for a paddlewheel meter Volume Units Click on the radio button to select volume in units of Gallons Liters or Cubic Meters If you change the units in this sc...

Page 84: ...ant a low alarm to occur Rate Low Low Alarm Limit appears only if the Paddlewheel type is selected Type in the text box the process value below which you want a low low alarm to occur Alarm Dead Band appears only if the Paddlewheel type is selected Type in the text box the dead band to be used for each alarm set point Damping appears only if the Paddlewheel type is selected Damping is applied to t...

Page 85: ...an Interlock input in the digital input section of the Start Up page Outputs Interlocked Click on the check box to the left of the relays that you want to be deactivated when the dry contact signal is received by the controller Clicking once places a check in the box clicking again removes the check from the box Interlock when contact is Click on the radio button that describes how your Interlock ...

Page 86: ... column gives you the date and time that the total was last reset Reset Total Click on the Reset Total button to reset the value in the Total column back to 0 0 Click on the Submit button to save the changes 6 15 Level Switches Digital Input Menu Digital Inputs 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...

Page 87: ...en neither contact state will initiate the critical alarm action 6 17 Counter Inputs Menu Custom Name You may give the input a custom name by typing it in the text box Total The total number of counts since the last time the total was reset will be displayed here The Reset Total button allows you to set the total back to 0 Last Total Reset The date and time of the last time the total was reset wil...

Page 88: ...fine each input as Not Used Contacting Flow Meter Paddlewheel Flow Meter Counter Interlock Level Switch Feed Verification or Generic Input Click on the Submit button to save the changes 6 19 Relay 1 8 Output Menus On Off Set Point types This page is used to select the set point dead band etc Which units of measure appear depends upon how the input assigned to the relay is configured If you make ch...

Page 89: ...te at 2001 S cm and deactivate at 1900 S cm The purpose of the dead band is to prevent rapid cycling 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 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 turni...

Page 90: ...nts The Hand mode is handy to be able to test the pump or valve wiring etc without needing to change set points 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 Type of Event Status to generate a 1 in the log Status to generate a 0 in the ...

Page 91: ...elect the way that you want to control the relay See Section 6 2 for details on each control mode 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 Statu...

Page 92: ... with caution since it can potentially delay a chemical addition for a long time 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 deac...

Page 93: ...eric DI No Alarm selected Switch closed Switch open A window will open to ask if you would like to open the file or save it to disk Select the method you would like to use The file is csv comma separated variable file that will open in a spreadsheet such as Excel 6 21 Relay 1 8 Output Menus Cycles of Concentration Types This page is used to activate the relay based on a set point that is the ratio...

Page 94: ...lways a High set point so if the measured cycles exceeds the set point the relay will activate until the measured cycles is less than the set point minus dead band Cycles Low High Alarm Type in the desired alarm points 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 alr...

Page 95: ...e 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 The event log contains the date and time of each relay activation and deactivation as well as the state of each Interlock Level Swi...

Page 96: ... 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 Fixed Blowdown Time Other control mode types are described in other sections of the manual 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 mod...

Page 97: ...on and R4 won t turn on if R2 is already on This feature should be used with caution since it can potentially delay a chemical addition for a long time 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 selec...

Page 98: ...ontrol valve allowing a sample of the boiler water to flow past the electrode The valve remains open for the time programmed in Duration of Sample The relay deactivates and closes the control valve The sample is held in the pipe for the time programmed in Hold Time At the end of the hold time the controller reads the conductivity and compares it to the set point value If it is above the set point ...

Page 99: ...as short as possible while still guarantying a fresh sample of boiler water at the electrode Hold Time Type in the desired time to hold the water sample while it returns to boiler pressure 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 ca...

Page 100: ... 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 Type of Event Status to generate a 1 in the log Status to generate a 0 in the log Relay output Relay activated Relay not activat...

Page 101: ...ff 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 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 ...

Page 102: ...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 You can force the relay closed regardless of the set points by selecting Hand or force the relay...

Page 103: ...ay 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 Interlo...

Page 104: ...nts by selecting Off 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 ...

Page 105: ...s relay is activated for the correct percentage of that time 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 This section assumes that the Relay Control Mode is set to Feed After Another Relay Other control mo...

Page 106: ...s 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 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 ...

Page 107: ...rammable amount of time 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 This section assumes that the Relay Control Mode is set to Feed After Another Relay Fixed Time Other control mode types are described in ...

Page 108: ...s 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 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 ...

Page 109: ... 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 Feed as of Time Other control mode types are described in other sections of the manual 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 detail...

Page 110: ...s 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 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 ...

Page 111: ...ode is set to Daily Biocide Timer 1 Week Biocide Timer 2 Week Biocide Timer or 4 Week Biocide Timer Other control mode types are described in other sections of the manual 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 Relay Input Assignment Click on the arrow of the pull down menu an...

Page 112: ...in the text box the amount of time that you want the relay output to be active when it makes its addition Any value between 1 and 1440 is acceptable Assign Bleed Lockout Relay If you want to lockout bleed after the biocide addition click on the arrow for the pull down menu and select the relay you have configured as the bleed relay normally R1 Bleed Lockout Time If you want to lockout bleed after ...

Page 113: ...spersant 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...

Page 114: ...hod you would like to use The file is csv comma separated variable file that will open in a spreadsheet such as Excel 6 30 Relay 1 8 Output Menus Spike Set Point Types This page is used to activate the relay based on one set point for a majority of the time and then spiking the concentration for a programmable amount of time as often as once per day on a one week 2 week or 4 week schedule This is ...

Page 115: ... acceptable For Bi Weekly or Monthly Modes repeat this process for each week in the cycle Control Direction Click on the appropriate radio button If the sensor reading naturally drops and you want to bring it back up select Force Higher 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 o...

Page 116: ...le 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 Type of Event Status to generate a 1 in the log Status to generate a 0 in the log Relay output Relay activated Relay not activated Interlock...

Page 117: ...lect 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 o...

Page 118: ...hanges 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 Type of Event Status to generate a 1 in the log Status to generate a 0 in the log Relay output Relay activated Relay not activated Interlock DI In the Interlock state as defined in th...

Page 119: ...signed Assign Bleed Meter 1 or 2 Click on the arrow of the pull down menu to select the flow meter input to be used to activate this relay Up to 3 flow meters may be assigned 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 man...

Page 120: ...s 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 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 ...

Page 121: ...given how your controller is configured will appear To the right of each type of alarm condition there will be a column labeled Critical Alarm with a choice of Yes or No Click on the No radio button if you do not want that type of alarm to activate this relay Status This menu is for information only and tells you if the alarm relay is currently on or off and if it is on for how much time Possible ...

Page 122: ...if R4 is already on and R4 won t turn on if R2 is already on This feature should be used with caution since it can potentially delay a chemical addition for a long time 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 out...

Page 123: ... comma separated variable file that will open in a spreadsheet such as Excel 6 34 Relay 1 8 Output Menus Activate on a DI In Activate on a DI mode the relay will activate in response to a selected Generic digital input switch changing state The triggering state may be either switch open or switch closed You may also change the Relay Control Mode here If you do you will have to reselect the Input A...

Page 124: ...ny 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 This feature should be used with caution since it can potentially delay a chemical addition for a long time Output Time Limit Type in the text box the maximum amo...

Page 125: ... defined in the Interlock page In the non Interlock state as defined in the Interlock page Level Switch DI In the Low Alarm state as defined in the Level Switches page In the Normal state as defined in the Level Switches page Generic DI Alarm selected In the Alarm state as defined in the Generic Inputs page In the Normal state as defined in the Generic Inputs page Generic DI No Alarm selected Swit...

Page 126: ...at 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 System Conductivity This field displays the current system conductivity reading Makeup Conductivity This field displays the current makeup co...

Page 127: ...ready on and R4 won t turn on if R2 is already on This feature should be used with caution since it can potentially delay a chemical addition for a long time 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 ru...

Page 128: ...larm selected In the Alarm state as defined in the Generic Inputs page In the Normal state as defined in the Generic Inputs page Generic DI No Alarm selected Switch closed Switch open A window will open to ask if you would like to open the file or save it to disk Select the method you would like to use The file is csv comma separated variable file that will open in a spreadsheet such as Excel 6 36...

Page 129: ...This field displays the current system conductivity reading Makeup Conductivity This field displays the current makeup conductivity reading Cycles This field displays the current calculated cycles of concentration 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 Tim...

Page 130: ... 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 Clic...

Page 131: ...trol mode This section assumes that the control mode is set to retransmit Input Assignment Click on the arrow to pull down the choices of which sensor measurement will be retransmitted as a 4 20 mA signal The choices are any of the sensor inputs any of the sensor s temperature compensation inputs LSI RSI any paddlewheel flow meter or any 4 20 mA input signal only if the 4 20 mA input option is ins...

Page 132: ...splayed in percent 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 4 20 mA Output Control Mode here If you do you will have to reselect the Input Assignment as well This section assumes that the 4 20 mA Output Control Mode is set to Proportional Feed Other control mode types are described in other...

Page 133: ... input or a relay output or by another analog output the Analog Output will default to this set value Type the desired output in in the text box If you want the pump to shut off enter 0 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...

Page 134: ...tion will be Auto where the controller uses the various set points to modulate the output You can force the output to a specific regardless of the set points by selecting Hand or force the output off 0 or 4 mA regardless of the set points by selecting Off If you select Off the output will not respond again until either Hand or Auto is selected or if power is cycled If you select Hand the output wi...

Page 135: ...on has already occurred and no further action is pending Found new alarm A new alarm has occurred and no notification has yet occurred Alarm due in HH MM SS The alarm delay time will be displayed with time counting down Taking action The alarm notification is about to occur Sending email If notification is via email this will be displayed Sending page If notification is via pager this will be disp...

Page 136: ...s used for the Makeup water Conductivity If there is no makeup conductivity sensor installed and it is necessary to manually enter the makeup conductivity select Not Used Assign Temperature Input Click on the arrow of the pull down menu to select the sensor input that is used for the temperature input If there is no temperature sensor installed and it is necessary to manually enter the temperature...

Page 137: ...en the Submit button is clicked your changes will be saved and a new VTouch Configuration packet will be sent to VTouch containing the names units of measure and the latest data for each parameter VTouch Communications Settings This section is used to adjust the VTouch data update settings Enable Service Use the pulldown to enable or disable the data updates Data Refresh Rate Enter the number of m...

Page 138: ...ould 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 Status This menu is informational only telling you when the next report is due to be sent Reporting Mode Click the appropriate radio button to select an Hourly 12 Hours Daily Weekly Biweekly or Monthly report frequency Type the time of day for receiving the report ...

Page 139: ...the data log report feature Auto Report Log File Click on the link called Log to download the Auto Report log This log details the date and time of the report which type of report was sent how the report was sent email via modem or email via Ethernet if the report was sent successfully or not and if not what the problem was You will be presented with the standard Windows dialog box asking if you w...

Page 140: ...th a list of all of the parameters that can be logged including sensor readings totalizers drum levels and 4 20 mA inputs The contents of the list will vary depending on what options you have installed or programmed Click the Yes radio buttons of the parameters that you want to log and the No radio buttons of the parameters that you do not want to log Suppresses Datalogging This only appears if th...

Page 141: ...r downloads the file whichever comes first Once the log file is downloaded it is erased and a new log file is started If the file is not downloaded by the end of the maximum duration the log file is saved and a new file is started No more than two files may be stored at any time so if the file is not downloaded by the time the second file is full the first file is erased Refer to the chart below M...

Page 142: ...epending on what options you have installed or programmed Click the Yes radio buttons of the parameters that you want to log and the No radio buttons of the parameters that you do not want to log Suppresses Datalogging This only appears if the Datalogging Mode is set to Suppressed by Events Columns to the right of each parameter will show a link to a page listing each event capable of suppressing ...

Page 143: ...og 1 full saved DataLog 2 started Maximum Log Duration RESETs Maximum Log Duration Maximum Log Duration Datalog 1 Datalog 2 Datalog 3 Datalog 1 full saved DataLog 2 started Maximum Log Duration RESETs Maximum Log Duration Datalog 2 full saved DataLog 1 deleted Datalog 3 started Maximum Log Duration RESETs Maximum Log DataLog 1 downloaded by user If downloaded successfully by Flashstick or Web Page...

Page 144: ...d 12 hour views every 3 minutes in the Last Day and every 20 minutes in the other views Click the Submit button for the changes to take effect The graphs selected will be presented below the check boxes on the web page You may view details by moving your mouse over the portion of the graph that is of interest The date time and data of that coordinate will be displayed in the upper right hand corne...

Page 145: ... address Type that address into the text box Ethernet IP Netmask When a controller is attached to a network your IT Administrator must also assign the IP Netmask Type the number assigned in the text box Ethernet Gateway When a controller is attached to a network your IT Administrator must also assign the Gateway Type the number assigned in the text box Network Mode If you have purchased the softwa...

Page 146: ...installed click on the radio button of which you need to use to send an email notification of an alarm condition or an automatic report Email and Text Message Server Settings 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 S...

Page 147: ...ection Lifetime PSTN or cell modem only 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 Type in the text box the number of minutes that you want to pass by before disconnecting the Internet connection Entering a connection lifetime of 0 means the connection will nev...

Page 148: ...dsheet from its current location or to save the file to disk Make your selection The file will display the date and time of the VNet connections if the attempt was a success or a failure and if it failed what the failure mode was Activations Upload Key File Activation key files must be imported in order to activate a special software feature Browse for the file and once it is selected click the Im...

Page 149: ...is the Access Point Name provided by the cell service provider SIM Card Number For information only The number is read from the SIM card Modem Type Select between North America and Outside North America to specify the band of the cell modem Modem Band Display the band of the modem Modem Baud Rate Click on the arrow of the pull down to select different modem baud rates The baud rate will be negotia...

Page 150: ... 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 NOTE If the software version of the controller that the configuration file was exported from is not the same as the controller it is imported to the import will either fail or not all settings will be modified Use the so...

Page 151: ... can and should be changed to assure security Change User Log in Name You may also change the user name for logging into the WebMasterONE Type the new user name into the text box 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 o...

Page 152: ...ach controller unique Ethernet IP addresses in the Communications page then the links under Sub Network will be active To navigate between controllers on the sub network start by logging onto the master controller This may be via USB Ethernet or modem Once connected to the master click on a link to the slave The link will be given the custom name of the controller from the Startup page The first t...

Page 153: ...essive and there are on site personnel available installation of a Y strainer will reduce the time required for maintenance Refer to the exploded view drawing of the assembly on the following page To clean the flow switch close the isolation valves to stop sample flow Open the sample valve to relieve the pressure in the manifold Remove the nut that holds the flow switch assembly in place Pull the ...

Page 154: ...low Switch Assembly CAP P N 102586 SWITCH HOUSING ASSEMBLY P N 190998 RETAINING O RING ASSEMBLED ONTO SWITCH HOUSING AFTER FLOAT ASSY P N 102919 FLOAT ASSEMBLY P N 190996 O RING P N 102594 FLOW SWITCH BODY P N 102881 ...

Page 155: ...ay 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 To clean the high temperature contacting conductivity electrode close the isolation valve s t...

Page 156: ...r gallic acid solution and rinse For oils including fingerprints wash with a detergent or isopropyl alcohol 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 Refer to Section 6 5 for detailed calibration instructions 7 4 ORP Electrode Cleaning and Calibration The frequency of cl...

Page 157: ... inspect for leaks After cleaning it is necessary to recalibrate the electrode Refer to Section 6 7 for detailed calibration instructions If this membrane cleaning does not correct the accuracy replace the membrane cap as described in the sensor manual 7 6 Replacing the Fuses CAUTION Disconnect power to the controller before opening the front panel Locate the fuses on the relay interface board on ...

Page 158: ...ct sensor cable used Refer to Installation Guidelines in Section 3 3 Sensor cable disconnected Reconnect cable Sensor cable connected incorrectly Check connections of all 6 wires against Fig 5 Problem with hand held instrument Refer to the troubleshooting guide for the hand held instrument used to determine the system conductivity Faulty sensor Replace sensor Faulty core interface circuit board Re...

Page 159: ...ctrode housing Faulty core interface circuit board Replace the core interface board if Sensor 1 Faulty sensor option circuit board Replace the sensor option board if Sensors 2 4 ORP Calibration Failure This error message occurs after calibrating the ORP electrode If the difference between the raw mV reading and the calibrated value exceeds 50 then the calibration will fail Possible Causes Correcti...

Page 160: ...odge bubbles Adjust flow rate higher if necessary Faulty membrane Replace membrane High Pressure Reduce pressure to below 1 atmosphere and refill cap with electrolyte No electrolyte fill solution in membrane cap Fill membrane cap with electrolyte Replace membrane cap if it will not hold solution Faulty analysis equipment or reagents Consult test equipment instructions Sensor cable disconnected Rec...

Page 161: ...d check the setting for the control direction Faulty control device attached to relay Repair or replace control device Relay is interlocked when it should not Evaluate switch for Interlock Fuse blown Replace fuse F2 or F3 Faulty wiring of control device Correct wiring Faulty relay Replace the relay interface board You are feeding based on flow meter volume Go to the Flow Meter Input Page and verif...

Page 162: ...Conductivity Low Alarm This error message indicates the conductivity reading is below the user programmed minimum allowable value Possible Causes Corrective Actions Dirty conductivity electrode Clean and calibrate the conductivity sensor as described in Section 7 2 above If calibration fails see troubleshooting for Conductivity Calibration Failure above Faulty conductivity electrode wiring Correct...

Page 163: ...orrectly For acid feed the control direction should be force lower for caustic feed force higher Go to the Relay Output Page and verify the correct setting Control device set at too high a flow rate Reduce the flow rate of the control device Metering pump is siphoning Install or repair the anti siphon valve Faulty control device Repair or replace the control device Blown fuse Replace the fuse F2 o...

Page 164: ...ion set incorrectly For acid feed the control direction should be force lower for caustic feed force higher Go to the Relay Output Page and verify the correct setting Control device set at too high a flow rate Reduce the flow rate of the control device Metering pump is siphoning Install or repair the anti siphon valve Faulty control device Repair or replace the control device Blown fuse Replace th...

Page 165: ...ol direction should be force higher for reducer force lower Go to the ORP Output Page and make sure that the correct control direction is selected Control device set at too high a flow rate Reduce the flow rate of the control device Chemical supply empty Replenish chemical supply Metering pump is siphoning Repair or install an anti siphon valve If a brominator solenoid valve is stuck open Repair o...

Page 166: ...de as described in Section 7 4 above If the calibration fails refer to ORP Calibration Failure troubleshooting above Control direction set incorrectly For oxidizer feed the control direction should be force higher for reducer force lower Go to the ORP Output Page and make sure that the correct control direction is selected Faulty metering pump brominator solenoid Repair or replace the metering pum...

Page 167: ...ake 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 low when Go to the Level Input Page and verify that the switch is open closed menu Drum low 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 If there ...

Page 168: ...on sensor Replace Feed Verification sensor Blown fuse Replace fuse F2 or F3 Faulty output relay Replace relay board Faulty digital input circuit board Verify that Feed Verification device is making contact closures using an ohmmeter If OK and connected properly replace digital input board 4 20 mA Input High Alarm This error message is caused by the 4 20 mA signal exceeding the user programmed valu...

Page 169: ... above the full scale maximum Any relay controlled by the sensor will be forced off Possible Causes Corrective Actions The conductivity is extremely high Go to the Conductivity Input Page and check over full scale the uncalibrated conductivity reading Compare this to a calibrated hand held instrument Faulty core interface or sensor option Go to the Conductivity Input Page and circuit board perform...

Page 170: ...the self test again If it passes the problem is in the electrode housing or its wiring If it still fails replace the pH input board ORP Sensor Error This error message is caused by the signal from the ORP electrode being outside of the normal range 1450 to 1450 mV Any relay being controlled by the sensor will be forced off Possible Causes Corrective Actions Faulty ORP cartridge Replace cartridge F...

Page 171: ...ircuit board If OK make sure that the wires are connected firmly to the correct terminals Faulty conductivity sensor If you measure resistance outside the acceptable range directly from the sensor replace the sensor Faulty sensor input board Go to the Conductivity Input Page and perform a self test If this passes then the problem is with the sensor or its wiring If it fails then disconnect the sen...

Page 172: ...ut is no longer connected Check the wiring Short the cable at the device end to verify that it is OK Faulty device Repair or replace the device Faulty digital input If shorting the input does not yield a count replace the input circuit board Sensor calibration time Normal condition programmed calibration reminder time has elapsed 4 20 mA Input Sensor Error This error message is caused by a 4 20 mA...

Page 173: ...d mating connectors for corrosion or damage Reinstall the option board Faulty 4 20 mA input board Replace the board Digital Input Board Failure This error message is caused by a failure of the controller to recognize that the option circuit board is connected If utilizing the Interlock feature then any outputs that are set to deactivate in case of an Interlock condition will be forced off Possible...

Page 174: ...ed value for the high alarm limit Possible Causes Corrective Actions The actual temperature is too high Correct problem with process The programmed value is set too close to Go to the sensor input page and increase the the normal operating temperature high alarm limit The temperature sensor has lost calibration Go to the Temperature Input Page and calibrate the temperature Faulty circuit board Go ...

Page 175: ...he 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 Clean tighten all connections to the temperature sensor 8 2 PROBLEMS THAT DON T GENERATE AN ERROR MESSAGE Submit buttons do not appear on any page You have logged in using a Calibration level...

Page 176: ...r more 4 20 mA output boards and turn power on Poor connection of the 4 20 mA output Remove the option board and inspect both board mating connectors for corrosion or damage Reinstall the option board on turn power on 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 Corrective Actio...

Page 177: ...n a new version of software becomes available the link will appear you will be able to see a description of the changes and will have the option to download it if you want 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 Corrective Actions Connection has timed out Re...

Page 178: ...put Start Up Datalog Comms Ethernet 7 25 seconds Other pages Ethernet 3 10 seconds First page loading after log in USB 30 90 seconds System Summary 4 20 Input Start Up Datalog Comms USB 22 35 seconds Other pages USB 7 14 seconds First page loading after log in Internet 30 90 seconds System Summary 4 20 Input Start Up Datalog Comms Internet 13 20 seconds Other pages Internet 4 8 seconds 9 0 SERVICE...

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