Walchem WebMaster Instruction Manual

WebMaster Series Cooling Tower Controller Instruction Manual

6 Other 4-20 mA Input Menu Parameter = 4 mA -10,000 to 10,000 (units defined by user) Parameter = 20 mA -10,000 to 10,000 (units defined by user)

96 6.38 Sub-Network Once you have created a network of two or more WebMaster controllers using Ethernet cards (see Figure 9 B for wiring), purchase

977.0 MAINTENANCE The WebMaster controller requires very little routine maintenance. The electronic enclosure only needs to be wiped down with a d

98 Figure 12 Flow Switch Assembly CAP(P/N 102586)SWITCH HOUSING ASSEMBLY(P/N 190998)RETAINING O-RING(ASSEMBLED ONTO SWITCHHOUSING AFTER FL

997.2 Conductivity Sensor Cleaning and Calibration Contacting Conductivity The frequency of cleaning for the contacting conductivity electrode varie

100 7.3 pH Electrode Cleaning and Calibration The frequency of cleaning for the pH electrode varies with each installation. The best way to determin

101 7.5 Replacing the Fuses CAUTION: Disconnect power to the controller before opening the front panel! Locate the fuses on the relay interface bo

102 8.0 TROUBLESHOOTING 8.1 ERROR MESSAGES No Flow This error message occurs when the input signal to the flow switch terminals is open (disconn

103 pH Calibration Failure This error message occurs after attempting an electrode calibration. The normal slope of a pH electrode is 59 mV/pH unit.

104Bleed Time Out This error message indicates that the bleed relay output has been activated for an amount of time that exceeds the user-programmed

105Feed Time Out This error message indicates that the feed relay output has been activated for an amount of time that exceeds the user-programmed ma

7 Biocide 1 & 2 Output Menus Program Biocide Additions Select day/time in cycle, specify pump on time (1 to 1440 min) Bleed Lockout Time

106Faulty metering pump wiring. Correct wiring. Faulty pH output relay. Replace the relay interface board. ORP Time Out This error message indi

107 Insufficient pressure differential. Ensure that the sample piping is tapped into the discharge side of the circulation pump, and flows to

108You are bleeding based on makeup If you are not bleeding based on conductivity, volume, and have set it for too much but on makeup water volum

109Control direction is set incorrectly. The normal control direction for an open recirculation loop cooling tower is “Force Lower”. Go to the

110pH High Alarm This error message indicates the pH reading exceeds the user-programmed maximum allowable value. Possible Causes Correcti

111The pH dead band is set too high. Go to the pH Output Page and change the dead band to be as low as possible to prevent the pH relay from ch

112ORP Low Alarm This error message indicates the ORP reading is below the user-programmed maximum allowable value. Possible Causes Correc

113Faulty level switch or transmitter wiring. Correct wiring. Make sure that the level sensor is attached to the same input as the one which is

114 Corrosion Monitor High Alarm This error message is caused by the 4-20 mA signal from the corrosion monitor exceeding the user-programmed value fo

115 “Other 4-20 mA Input” High Alarm (one for each, use name defined) This error message is caused by the 4-20 mA signal from a device other than a l

8 3.0 UNPACKING & INSTALLATION 3.1 Unpacking the Unit Inspect the contents of the carton. Please notify the carrier immediately if there are

116 Faulty conductivity sensor wiring. Make sure that the sensor cable is connected (if system conductivity) properly, and there are no s

117 Faulty sensor option circuit board. Go to the ORP Input Menu and perform a self test. If it fails, remove the electrode wires from the ORP

118 Other 4-20 mA Input Sensor Error This error message is caused by a 4-20 mA input signal that is less than 3.9 mA or greater than 21 mA. Possible

119 ORP Board Failure This error message is caused by a failure of the controller to recognize that the option circuit board is connected. The ORP o

120 Ethernet Card Failure This error message is caused by a failure of the controller to recognize that the option circuit board is connected. Possi

121 Faulty circuit board. Go to the Temperature Input Page and perform a self test. If the self test fails, then the sensor input board (if ma

122 Faulty sensor input board. This should cause an “ORP Board Failure. error message, but this can be cleared once the power is cycled. R

123Link 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 prob

124 8.3 CONNECTION PROBLEMS “The page cannot be displayed message” on your browser This is a standard Microsoft Internet Explorer message when a w

125 9.0 SERVICE POLICY The WebMaster Series Controllers have a 2-year warranty on electronic components and a 1-year warranty on mechanical parts

9 Electrode Installation All electrodes for the Webmaster series are provided with signal conditioning electronics, and conductivity sensors may be

10Figure 1: Typical Installation Drawing, Continuous In-line Sampling HEATEXCHANGERCOOLING TOWEREHMeteringPump(up to 6)PosiflowLevel switchMake

11 Figure 2: Typical Installation Drawing, Intermittent In-line Sampling TO ELECTRODETO SOLENOIDAC PowerSupplyPE DISCHARGETUBINGEHMETERINGPUMPT

12 Figure 3: Typical Installation Drawing, Submersion Sensors COOLING TOWEREHMeteringPump(up to 6)PosiflowLevel switchMakeup condMakeupwaterFlowmete

133.5 Electrical Installation The Webmaster series controllers require the following voltages: 100 –120/200-240 VAC± 10%, 50/60 Hz, 12 amperes maxi

14 Figure 4: Conduit/Wiring Configuration Bottom ViewHardwired Options Prewired OptionBio 2AC PowerDispersant(Recommen

15 Figure 5: Identification of PartsDISPLAYCOREMODEMOPTION CARDETHERNETOPTION CARDMAKEUPCONDU

Notice © 2003 WALCHEM Corporation Five Boynton Road, Holliston, MA 01746 USA (508) 429-1110 All Rights Reserved Printed in USA Proprietary Material

16 Important: The mains power supply earth ground connection must be retained by separate nut. Figure 6: Wiring Diagram for AC Power Input and Re

17 Figure 7: Wiring Diagram for Flow Switches, Water Meter Contactors and Sensors RS-232RXD

18 Figure 8: Wiring Diagram for Optional Digital Inputs, 4-20 mA Inputs and 4-20 mA Outputs

19W700 INNETWORKW700 INNETWORKTB4TB3RJ45 TOETHERNETHUB, 10BASETCAT 5 CABLE,100 METERSMAXIMUMRJ11 TOPHONELINESEE DETAILA & BJACKETED CABLERTSCTSRX

20 4.0 FUNCTION OVERVIEW 4.1 Front Panel Figure 10: Front Panel Setting adjustment keys Backlit

21 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, approxi

224.4 Access Codes The Webmaster series controller is shipped with the access codes at default values. In order to prevent against unauthorized tam

23If you have not yet set up an ISP account and wish to program the Webmaster from a remote location, or if you just prefer the “old fashioned method

244.6 Communicating with the WebMaster 4.6.1 Direct Serial Connection to the RS232 Port A direct serial connection to the WebMaster can be

254.6.2 Remote Modem Access: Shoulder Tap Equipment Required § An Internet-ready computer with the following capabilities: 100 MHz minimum pr

TABLE OF CONTENTS 1.0 INTRODUCTION ...

26 4.6.3 Ethernet Connection to LAN Equipment Required § An Internet-ready computer with the following capabilities: 100 MHz minimum p

27 4.6.4 Direct Modem Access: Direct Tap Equipment Required § An Internet-ready computer with the following capabilities: 100 MHz minimum

284.6.5 Direct Ethernet (for a WebMaster not connected to a LAN) Equipment Required § An Internet-ready computer with the following capab

294.6.6 Networking WebMaster Controllers via Ethernet Equipment Required § An Internet-ready computer with the following capabilities: 10

304.7 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 co

315.3 Alarms The Alarms menu displays all alarm messages. Use the Next key to scroll down the list, or the Prev key to scroll up the list. There ar

32System/Makeup Conductivity Calibration – Electrodeless Sensor “1 pt Process Cal” and “Air Cal (Zero) will be displayed. Use the Next key to move

33 The “1pt Buffer Cal” is not as accurate, since it assumes that the slope of the electrode is 59 mV/pH unit, which will only be true with a new ele

34 Step 3 will prompt you to rinse the electrode, and place it into the buffer solution. Press the Enter key to continue. Step 4 will ask you to ent

35sample stream to resume control. If failed, refer to Section 7 for troubleshooting help. A calibration will fail if the offset calculated is more t

6.16 INTERLOCK MENU ...

36 5.5 Relay Control (HOA) This menu will present you with a list of each relay. To the right of the name of the relay will be an indication of th

37 Cycles Set Pt xx.xx (if Bleed based on cycles, 1 source) Use the arrow keys to change the desired set point cycles of concentration.. Any value be

38S1 Cycle L Alm xx.xx (if Bleed based on cycles, 2 or 3 sources) Use the arrow keys to change the cycles of concentration for each Source below whic

39 Bleed Time Lim xxxx Use the arrow keys to change the maximum amount of time that the bleed valve can be continuously open before the controller sh

40Makeup Volume xxxxx (if Feed on makeup volume) Use the arrow keys to change the volume of makeup water that needs to enter the system in order to t

41 S1 % of Per to Fd xxx (if Feed as % of Time, Multiple makeup sources) As described above in % of Per to feed xxx for Source 1 makeup water. S2 %

42Biocide 1 or 2 Set Points Pump On Time This menu is used to change the amount of time that the biocide pump will run for each programmed event. Aga

43pH Set Points Set Point xx.xx Use the arrow keys to change the pH value at which the pump will turn on in order to correct it. Any value between –2

44Hand Time Limit xxxx Use the arrow keys to change the maximum number of minutes that the ORP output can be activated in the Hand mode. Any value be

45Message Explanation Off Line The controller is not connected. Dialing xxx-xxxx The controller is dialing out to the ISP. No Dial To

11.0 INTRODUCTION The Webmaster series cooling tower controller is multi-functional, but not all of the features mentioned are necessarily present

465.8 Access Codes There are three levels of access code protection. If the Master password is used in the Webmaster, then any set point can be ch

47Menus that appear only if a 4-20mA option board is installed: Corrosion Other Inputs 4-20mA Inputs Level Inputs Menus that appear only if a digita

48Bleed Volume per Makeup Volume is used to open the bleed valve allowing a programmed volume of water out of the system after a programmed volume of

49ORP Control Mode Click on the radio button of the option that matches your installation: Direct ORP Sensor should be selected if you will be contr

50 Time Based means that the bleed solenoid will open for a programmed amount of time prior to the Biocide 1 addition. The conductivity of the system

51Units of Measure Click on the radio button corresponding to your preferred unit of measure. Volume Units. If you select “Gallons”, then every volu

52Interlock should be selected if any device that is intended to interlock any control outputs is connected to that input. The flow switch should be

53Current Reading/Calibrate Sys Cond The current reading is a live reading of the calibrated conductivity of the sample. To Calibrate the system cond

54 Makeup Conductivity Menu (only appears if 2nd conductivity option card is installed) All of the menus described above for the system conductivity

55Makeup Temperature (only appears if the makeup conductivity sensor option card is installed) All of the menus described above for the system tempe

2 2.2 Electrical Inputs Input power 100 – 120/220-240 VAC ±10%, 12A, 50/60 Hz Fuse 1.6A, 5 x 20mm Input signals STANDARD Water meter Contactor

56You will now be prompted to type in the value of the buffer being used. Do so, then click “Continue”. You will now see the mV output from the elec

57% Difference from theoretical This displays the % difference of the slope from the theoretical value as of the last calibration. The higher this pe

58 1 Point Calibration First you will see a warning that ORP control will be suspended during the calibration. Click on “Continue” to start the calib

59Offset This displays the mV output of the ORP electrode at 0 mV as of the last calibration. The offset information is helpful for troubleshooting.

60Status Possible status messages are; Normal (everything is OK) If the type of water meter is “4-20 mA”; Sensor Error (the sensor signal is not vali

61 6.12 Level Input Menu (only appears if a 4-20 mA input or digital input option card is installed, and a Level radio button is selected in the St

62 Point Level Input Menu (only appears if a digital input option card is installed, and a level switch radio button is selected in the digital inpu

63 High Alarm Limit Type in the text box the corrosion rate at which you want a high alarm to occur. Click on the “Submit” button to save the changes

64High Alarm Limit Type into the text box the value for that input above which you want a high alarm to occur. Any value between –10,000 and 10,000 i

65 6.16 Interlock Menu (only appears if a digital input option card is installed and an Interlock radio button is selected in the digital input se

32.3 Mechanical Enclosure Material: Molded Fiberglass NEMA Rating: NEMA 4X Dimensions: 10” x 12” x 5-5/8” (25.4cm x 30.5cm x

66Other should be selected if the 4-20 mA transmitter connected to that input is anything other than the previously mentioned ones. Later when you re

67Cycles of Concentration is used to open the bleed valve when the ratio of the system conductivity to the makeup water conductivity exceeds the prog

68Cycles Measured (only appears if a makeup conductivity input card is installed or type of bleed is based on cycles of concentration) This display

69Control Direction (only appears if Type of Bleed is Based on System Conductivity or Other 4-20 mA input 4) Click on the radio button to select bet

70then the bleed valve will open at 6.01 cycles and close at 5.90 cycles. The purpose of the dead band is to prevent rapid chattering of the relay op

71If you select Off, the valve will not open again until either Hand or Auto is selected! If you select Hand, the valve will open until either Auto o

72Status This displays the current status of the Feed Output, either “Off” or “On”, and if on, the time it has been on and any alarm conditions. Pos

73Makeup Volume (only appears if Feed Mode is selected as Feed Based On Makeup Volume) Type in the text box the volume of makeup water that needs to

74Source 1, 2 or 3 Conductivity Range (only appears if Feed Mode is one of the Multiple Sources types) Type in the text box the range conductivity (o

75 6.21 Biocide 1 & 2 Output Menus (will not appear if the Biocide Feed Mode section of the Start Up page is selected as “Not Used”) There ar

4 High pressure contacting conductivity electrode Pressure: 0-300 psi Temperature: 32-158F Process connections: ¾” NPTM Wetted Mat

76 Time: Type in the text boxes the hour and minute for the addition to occur. Use the arrow for the pull down menu to select between AM and PM. On

77Cond Based means that the bleed valve will open until the conductivity of the system drops to the programmed level. This will delay the biocide add

78Hand Time Limit Type in the text box the maximum number of minutes that the Biocide 1 or 2 output can be activated in the Hand mode. Any value betw

79Interlock Outputs Click the check boxes to select or de-select the relays that you want to be forced OFF if this output relay is turned ON. If you

80 Current pH (only appears if pH Control Mode is selected as Direct pH Sensor) Displays the current pH reading from the electrode. Status This menu

81Output Time Limit Type in the text box the maximum amount of time that the pH pump can be continuously running before the controller shuts off the

82Other (4-20 mA input 7) should be selected if you will control the ORP relay based on a signal from a transmitter that is connected to 4-20 mA inpu

83Output Time Limit Type in the text box the maximum amount of time that the ORP pump can be continuously running before the controller shuts off the

84Sensor Status This column shows the status of the sensor that ha been mapped to the 4-20 mA output. Possible messages include Normal, Unmapped, and

85Remote Alarm Action Status This menu is for information only, and displays the status of the remote alarm notification. The possible messages to di

52.4 Variables and their Limits All menus shown may not be available. The menus that appear on your controller will vary with options installed and

86A window will open to ask if you would like to open the file or save it to disc. Select the method you would like to use. The file is a basic text

87 6.28 Auto Reporting There are two types of reports that may be sent to you automatically. One is a system summary report, which will contain all

88Data Log Auto Reporting, Reporting Mode Click the appropriate radio button to select either a Cyclical report schedule or a Calendar report schedul

896.30 Communications Menu (only appears if either an Ethernet or a modem option card is installed) Internet Dial Up Account Controller ISP User N

90 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 Prov

91Network Detection Click on the Detect Network button of the Master Controller and it will look at all of the devices that are connected to it, dete

92 Dialup Dynamic IP Address This menu is informational only, and tells you the IP address of the last person to contact the controller. Last Dialup

93Sub-Network Settings Mapped Internet IP Address If you are accessing the master controller by using NAT to translate a real IP address to a fake IP

946.32 Configuration File Menu If many of your cooling tower applications are nearly identical, you can save a lot of time in the set up by downloa

95 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 dat