Walchem WebMaster ONE Instruction Manual

W
W A L C H E M
IWAKI America Inc.
ebMaster®ONE Controllers
Web
Master®ONE
Water Treatment Controller
Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA
TEL: 508-429-1110 FAX: 508-429-7433 WEB: www.walchem.com
Notice
© 2014 WALCHEM, Iwaki America Inc. (hereinafter “Walchem”) Five Boynton Road, Holliston, MA 01746 USA (508) 429-1110 All Rights Reserved Printed in USA
Proprietary Material
The information and descriptions contained herein are the property of WALCHEM. Such information and descriptions may not be copied or reproduced by any means, or disseminated or distributed without the express prior written permission of WALCHEM, Five Boynton Road, Holliston, MA 01746.
Statement of Limited Warranty
WALCHEM warrants equipment of its manufacture, and bearing its identification to be free from defects in workmanship and material for a period of 24 months for electronics and 12 months for 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. of any defective equipment or part which, having been returned to WALCHEM, transportation charges prepaid, has been inspected and determined by WALCHEM to be defective. Replacement elastomeric parts and glass components are expendable and are not covered by any warranty.
THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY, EITHER EXPRESS OR IMPLIED, AS TO DESCRIPTION, QUALITY, MERCHANTABILITY, and FITNESS FOR ANY PARTICULAR PURPOSE OR USE, OR ANY OTHER MATTER.
180272 Rev AC Jan 2014
TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................................... 1
1.0
2.0 SPECIFICATIONS ......................................................................................................................................... 1
2.1 .....MEASUREMENT PERFORMANCE ..................................................................................................................... 1
2.2.....ELECTRICAL ................................................................................................................................................... 2
2.3.....MECHANICAL ................................................................................................................................................. 3
2.4.....VARIABLES AND THEIR LIMITS ....................................................................................................................... 5
3.0 UNPACKING & INSTALLATION ............................................................................................................. 10
3.1 .....UNPACKING THE UNIT .................................................................................................................................. 10
3.2 .....MOUNTING THE ELECTRONIC ENCLOSURE ................................................................................................... 10
3.3.....INSTALLATION.............................................................................................................................................. 10
3.4.....ICON DEFINITIONS ........................................................................................................................................ 14
3.5 .....ELECTRICAL INSTALLATION ......................................................................................................................... 18
4.0 FUNCTION OVERVIEW ............................................................................................................................ 27
4.1 .....FRONT PANEL ............................................................................................................................................... 27
4.2.....DISPLAY ....................................................................................................................................................... 27
4.3..... KEYPAD ....................................................................................................................................................... 28
4.4 .....ACCESS CODES ............................................................................................................................................. 28
4.5.....INITIAL STARTUP .......................................................................................................................................... 28
4.6 .....COMMUNICATING WITH THE WEBMASTERONE .......................................................................................... 30
4.7.....STARTUP ...................................................................................................................................................... 36
4.8 .....SHUT DOWN ................................................................................................................................................. 36
5.0 OPERATION – 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 .....SENSOR MENU - CONDUCTIVITY INPUT ........................................................................................................ 58
6.5 .....SENSOR MENU - PH INPUT ........................................................................................................................... 61
6.6.....SENSOR MENU - ORP INPUT ........................................................................................................................ 65
6.7.....SENSOR MENU CHLORINE, CHLORINE DIOXIDE INPUTS ............................................................................ 68
6.8 .....LEVEL (4-20 MA) INPUT MENU .................................................................................................................... 72
6.9.....FLOW METER (4-20 MA) INPUT MENU ......................................................................................................... 74
6.10...GENERIC (4-20 MA) INPUT MENU ................................................................................................................ 75
6.11...4-20 MA INPUT MENU .................................................................................................................................. 77
6.12...FLOW METER (DIGITAL) INPUT MENU ......................................................................................................... 79
6.13...INTERLOCK MENU ........................................................................................................................................ 81
6.14...FEED VERIFICATION INPUT MENU ................................................................................................................ 81
6.15...LEVEL SWITCHES (DIGITAL) INPUT MENU ................................................................................................... 82
6.16...GENERIC (DIGITAL) INPUTS MENU ............................................................................................................... 82
6.17...COUNTER INPUTS MENU .............................................................................................................................. 83
6.18... DIGITAL INPUTS MENU ................................................................................................................................ 84
6.19... RELAY (1 8) OUTPUT MENUS ON/OFF SET POINT TYPES ....................................................................... 84
6.20...RELAY (1-8) OUTPUT MENUS TIME PROPORTIONAL TYPES ...................................................................... 87
6.21...RELAY (1 8) OUTPUT MENUS CYCLES OF CONCENTRATION TYPES ........................................................ 89
6.22...RELAY (1 8) OUTPUT MENUS INTERMITTENT (FIXED BLOWDOWN TIME) TYPES ................................... 92
6.23...RELAY (1 8) OUTPUT MENUS INTERMITTENT (PROPORTIONAL BLOWDOWN TIME) TYPES ..................... 94
6.24...RELAY (1 - 8) OUTPUT MENUS FLOW BASED FEED TYPE .......................................................................... 96
6.25...RELAY (1-8) OUTPUT MENUS FEED WITH ANOTHER RELAY TYPES ......................................................... 99
6.26...RELAY (1 8) OUTPUT MENUS FEED AFTER ANOTHER RELAY (%) TYPES ............................................. 101
6.27...RELAY (1-8) OUTPUT MENUS FEED AFTER ANOTHER RELAY (FIXED TIME) .......................................... 103
6.28...RELAY (1 8) OUTPUT MENUS FEED AS % OF TIME TYPES ..................................................................... 105
6.29...RELAY (1 8) OUTPUT MENUS BIOCIDE TIMER BASED TYPES ............................................................... 107
6.30...RELAY (1 8) OUTPUT MENUS SPIKE SET POINT TYPES ......................................................................... 110
6.31...RELAY (1 8) OUTPUT MENUS DISPERSANT TYPES ................................................................................ 112
6.32...RELAY (1-8) OUTPUT MENUS - BLEED VOLUME BASED 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...VTOUCH CONFIG ....................................................................................................................................... 133
6.42...SYSTEM STATUS AUTO-REPORTING ........................................................................................................... 134
6.43...DATALOG AUTO REPORT ........................................................................................................................... 135
6.44...MANUAL DATALOG .................................................................................................................................... 137
6.45...GRAPHING/TRENDING ................................................................................................................................ 140
6.46...COMMUNICATIONS MENU .......................................................................................................................... 140
6.47...ADVANCED COMMS ................................................................................................................................... 145
6.48... CONFIGURATION FILE MENU ..................................................................................................................... 146
6.49...NOTEPAD ................................................................................................................................................... 147
6.50...ACCESS CODES ........................................................................................................................................... 147
6.51...SOFTWARE UPGRADES (ONLY APPEARS IF A NEWER REVISION OF SOFTWARE IS AVAILABLE) .................... 147
6.52...SUB-NETWORK .......................................................................................................................................... 148
7.0 MAINTENANCE ........................................................................................................................................ 149
7.1.....FLOW SWITCH CLEANING .......................................................................................................................... 149
7.2.....CONDUCTIVITY SENSOR CLEANING AND CALIBRATION ............................................................................. 151
7.3.....PH ELECTRODE CLEANING AND CALIBRATION .......................................................................................... 152
7.4.....ORP ELECTRODE CLEANING AND CALIBRATION ....................................................................................... 152
7.5.....DISINFECTION SENSOR CLEANING AND CALIBRATION ............................................................................... 153
7.6.....REPLACING THE FUSES ............................................................................................................................... 153
8.0 TROUBLESHOOTING .............................................................................................................................. 154
8.1.....ERROR MESSAGES ................................................................................................................................ 154
8.2.....PROBLEMS THAT DON’T GENERATE AN ERROR MESSAGE ........................................................ 171
8.3 .....CONNECTION PROBLEMS ................................................................................................................... 173
9.0 SERVICE POLICY ..................................................................................................................................... 174
1.0 INTRODUCTION
The WebMasterONE series controller is multi-functional, but not all of the features mentioned are necessarily present in the controller you have received. All features can be added in the field. The controller may be configured to control a cooling tower, or a boiler, or both.
Standard features include a direct sensor measurement of either conductivity, pH, or ORP; six digital inputs (for flow switch, metering pump flow feedback, counter, or other use), eight relay outputs, and both Ethernet and USB connections to a computer.
Optional features include: Up to three additional pH, ORP, chlorine, chlorine dioxide and/or conductivity measurements. Up to six digital inputs (for level switch, metering pump flow feedback, counter, or other use). Up to eight 4-20 mA inputs (for drum level, flow meters, or practically any other parameter). Up to four 4-20 mA outputs (for retransmission of the conductivity, pH, ORP, Cl temperature or any 4-20 mA input signals). A modem card (for remote communications)
The controller can log data and events, automatically generate reports on a 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 proprietary software needs to be installed on the PC, only a web browser.
, ClO2,
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2.0 SPECIFICATIONS
2.1 Measurement Performance
Contacting Conductivity pH
Range 0-10,000 µS/cm Range -2 to 16 pH units Resolution 1 µS/cm Resolution 0.01 pH units Calibration ± 50% of raw reading; Calibration single or dual point scalable to read in ppm
mV Temperature
Range ± 1400 mV Range 32 to 392°F (0 to 200°C) Resolution 1 mV Resolution 1°F (1°C) Calibration single or dual point Calibration single point; degrees C or F
Chlorine Chlorine Dioxide
Range 0 to 8 mg/l Range 0 to 10 mg/l Resolution 0.01 mg/l Resolution 0.01 mg/l Calibration single or dual point Calibration single or dual point
Electrodeless Conductivity Ranges 50 to 1000 µS/cm, 1-10 mS/cm, 10-100 mS/cm, or 100-1000 mS/cm
Resolution 1 µS/cm or 1 mS/cm (range dependent) Calibration single or dual point; scalable to read in ppm or % concentration
1
2.2 Electrical
Inputs
Input power 100 – 120/220-240 VAC ±10%, 12A, 50/60 Hz Fuse 1.6A, 5 x 20mm Input signals
State-Type Digital Inputs Electrical: Non-isolated 5 VDC with 301K ohm pull-up
Low Speed Counter-Type Digial Inputs
High Speed Counter-Type Digial Inputs
Analog Inputs (1-8) (Optional)
Sensor STANDARD (1) 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
Typical response time: <10 seconds Devices supported: Any isolated dry contact (i.e. relay, reed switch) Types: Interlock, Level switch, Generic input Electrical: Non-isolated 5 VDC with 301K ohm pull-up, 0-10 Hz, 50 msec minimum width Devices supported: Any device with isolated open drain, open collector, transistor or reed switch Supported on inputs: Standard inputs A-D, Optional inputs 1-6 Types: Contacting Flowmeter, Feed Verification, Generic Counter Electrical: Non-isolated 5 VDC with 301K ohm pull-up, 0-400 Hz, 1.25 msec minimum width Devices supported: Any device with isolated open drain, open collector, transistor or reed switch Supported on inputs: Standard inputs A-D, Optional inputs 5-6 Types: Paddlewheel Flowmeter, Generic Counter 4-20 mA, 2-wire or 3 -wire, internally powered by 24 VDC, 25 ohm input resistance, 1000 ohm maximum load. Typical response time <10 seconds
Sensor OPTIONAL (3)
STANDARD
Mechanical relays:
R1, R2, R3, and R4 relays are fused together as one group, total current for this group must not exceed 5.5A R5, R6, R7 and R8 relays are fused together as one group, total current for this group must not exceed 5.5A.
Relays 1-8 may be dry contact or may switch line (mains) voltage, depending upon model code; refer to Figure 4. Powered relays have both NO and NC terminals available. Only powered relays are fused. Digital: USB
Ethernet, 10 Base T
At 115 VAC, 10 amp (resistive), 1/8 HP At 230 VAC, 6 amp (resistive), 1/8 HP
OPTIONAL
4-20 mA (1-4): Isolated, 500 ohm max. resistive load, internally powered
Agency Approvals
Safety ANSI/UL 61010-1:2012 3rd Ed.
C22.2 No. 61010-1:2012 3rd Ed. IEC 61010-1:2010 3rd Ed.
EN 61010-1:2010 3rd Ed. EMC IEC 61326-1:2005 EN 61326-1:2006
Note: For EN61000-4-6, and EN 61000-4-3, the controller meets performance criteria B. *Class A equipment: Equipment suitable for use in establishments other than domestic, and those directly connected to a low voltage (100-240 VAC) power supply network which supplies buildings used for domestic purposes.
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2.3 Mechanical
Enclosure
Material: Polycarbonate NEMA Rating: NEMA 4X Dimensions: 10” x 12” x 5-5/8” (25.4cm x 30.5cm x 14.5cm) Display: 64 x 128 Pixel Backlit LCD Graphics Module Operating Ambient Temp: 32-120°F (0 to 49°C) Storage Temp: -20 to 176°F (-29 to 80°C) Weight 11.5lb (5.2kg)
Flow switch manifold
Pressure: 150 psi up to 100° F, 50 psi @140° F Temperature: 32 to 140°F (0 to 60°C) Process connections: ¾” NPTF Wetted Materials of construction: Glass-Filled Polypropylene, PVC, FKM, Isoplast
pH Electrode
Pressure: 0 to100 psi Temperature: 50 to158°F (10 to 70°C) Process connections: ¾” NPTF Wetted Materials of Construction: Glass-Filled Polypropylene, CPVC, HDPE, FKM, Glass
ORP electrode
Pressure: 0 to100 psi Temperature: 32 to 158°F (0 to 70°C) Process connections: ¾” 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: ¾” NPTF Wetted Materials of Construction: Glass-Filled Polypropylene, Graphite, FKM
Electrodeless conductivity sensor
Pressure: 0 to150 psi Temperature: 32 to158°F (0 to 70°C) Process connections: ¾” NPTF Wetted Materials of Construction: Glass-Filled Polypropylene, CPVC, FKM
Stainless steel contacting conductivity electrode
Pressure: 0-150 psi Temperature: 32-158°F (0 to 70°C) Process connections: ¾” NPTF Wetted Materials of Construction: Glass-Filled Polypropylene, 316 SS, FKM
3
Chlorine, Chlorine Dioxide sensors
Pressure: 0 to 1 atm (0 to 14.7 psi) Temperature
Chlorine Dioxide sensors: 41 to 122°F (5 to 50°C)
Chlorine: 41 to 113°F (5 to 45°C) Flow Cell Inlet: ¼” NPTF Flow Cell Outlet: ¾” NPTF Wetted Materials of Construction: PVC, Silicone or PTFE, Nylon, Isoplast, FKM
High pressure tower contacting conductivity electrode
Pressure: 0-300 psi Temperature: 32-158°F (0 to 70°C) Process connections: ¾” NPTM Wetted Materials of Construction: 316 SS, PEEK
High pressure boiler contacting conductivity electrode
Pressure: 0-250 psi Temperature: 32-401°F (0 to 205°C) Process connections: ¾” 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: ¾” NPTM Wetted Materials of Construction: Glass, Polymer, PTFE, 316 SS, FKM
High Pressure ORP electrode
Pressure: 0-300 psi Temperature: 32-275°F (0 to 135°C) Process connections: ¾” NPTM Wetted Materials of Construction: Platinum, Polymer, PTFE, 316 SS, FKM
High Pressure flow switch
Pressure: 0-300 psi Temperature: 32-158°F (0 to 70°C) Process connections: ¾” NPTF Wetted Materials of Construction: Carbon steel, Brass, 316SS, FKM”
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2.4 Variables and their Limits
All menus shown may not be available. The menus that appear on your controller will vary with options installed and programmed.
Sensor Input Menu – if pH
Calibration Reminder 0-365 days Alarm Limits -2 to 16 Alarm Dead Band -2 to 16 Deviation from Primary Sensor 0.01 to 18 Damping 0 to 60 seconds Temperature Alarm Limits 23 to 302°F (-5 to 150 °C)
Sensor Input Menu – if ORP
Calibration Reminder 0-365 days Alarm Limits -1400 to 1400 mV Alarm Dead Band -1400 to 1400 mV Deviation from Primary Sensor 0.01 to 2800 mV Damping 0 to 60 seconds Temperature Alarm Limits 23 to 190°F (-5 to 88 °C)
Sensor Input Menu – if Contacting Conductivity
Calibration Reminder 0 – 365 days ppm Conversion 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 (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 32 – 392°F (0 to 200°C)
Sensor Input Menu – if Electrodeless Conductivity
Calibration Reminder 0 – 365 days ppm Conversion Factor 0.5 – 1.0 Alarm Limits 0 to full scale of range Alarm Dead Band 0 to full scale of range Deviation from Primary Sensor 0.01 to full scale of range Temperature Alarm Limits 23 to 190°F (-5 to 88 °C)
5
Sensor Input Menu – if Chlorine or Chlorine Dioxide
Calibration Reminder 0-365 days Alarm Limits 0 to 10 mg/l Alarm Dead Band 0 to 10 mg/l Deviation from Primary Sensor 0.01 to 10 mg/l Damping 0 to 60 seconds
Flowmeter Input Menu – Analog Input Type
Flow Rate at 4 mA 0 to 1000 (units of measure defined by user) Flow Rate at 20 mA 0 to 1000 (units of measure defined by user)
Level Input Menu – Analog Input Type
Empty mA 0 to 20 mA Full mA 0 to 20 mA Full volume 0 to 10,000 (units defined by user) Low Level Alarm Limit 0.001 to 10,000 (units defined by user)
Generic 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) 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 Alarm >0
Feed Verification Input Menu
Alarm Time 0.1 to 10 minutes Pump Volume per Stroke 0.000 to 100 (units of measure defined by user)
Counter Input Menu
One Count = >0 Total Alarm Limit 0 =no limit, otherwise >0 Rate High Alarm >0 Rate Low Alarm >0
Relay Output Menu – On/Off Set Point
Set Point Full scale range of the input parameter Dead Band Full scale range of the input parameter Output Time Limit 0 = , 1 to 1440 minutes Hand Time Limit 1 to 1440 minutes
6
Relay Output Menu – Time Proportional
Set Point Full scale range of the input parameter Sample Period 1 to 1440 minutes Proportional Band Full scale range of the input parameter Output Time Limit 0 = , 1 to 1440 minutes Hand Time Limit 1 to 1440 minutes
Relay Output Menu – Feed with Another Relay
Output Time Limit 0 = , 1 to 1440 minutes Hand Time Limit 1 to 1440 minutes
Relay Output Menu – Feed after Another Relay (Fixed Time)
Fixed Time to Feed 0 to 1440 minutes Hand Time Limit 1 to 1440 minutes
Relay Output Menu – Flow Based Feed
Volume to trigger Feed 1 to 99,999 (units defined 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 as % Time
Time Period 1 – 1440 minutes % of Period to Feed 0.1 to 100% Output Time Limit 0 = , 1 to 1440 minutes Hand Time Limit 1 to 1440 minutes
Relay Output Menu – Cycles of Concentration
Cycles Set Point 1 – 50 cycles Cycles Dead band 0.01 – 20 cycles Cycles Low Alarm 0 – 50 cycles Cycles High Alarm 0 – 50 cycles Output Time Limit 0 = , 1 to 1440 minutes Hand Time Limit 1 to 1440 minutes
7
Relay Output Menu – Spike
Set Point Full scale range of the parameter Dead Band Full scale range of the parameter Relay On-Time 1 sec to 1440 minutes Hand Time Limit 1 to 1440 minutes
Relay Output Menu – Intermittent, Fixed Blowdown Time
Set Point Full scale range of the parameter Interval Time 5 to 1440 minutes Duration of Sample 10 seconds to 60 minutes Hold Time 30 seconds to 10 minutes Blowdown Time 1 to 1440 minutes Hand Time Limit 1 to 1440 minutes
Relay Output Menu – Intermittent, Proportional Blowdown Time
Set Point Full scale range of the parameter Interval Time 5 to 1440 minutes Duration of Sample 10 seconds to 60 minutes 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 Time Limit 0 = , 1 to 1440 minutes Hand Time Limit 1 to 1440 minutes
Relay Output Menu – Target PPM Feed
Makeup Conductivity Full scale range of the parameter Unit Volume to Trigger Output 1 to 999,999,999 (units defined by user) Target PPM Set Point 0 to 100,000 ppm Specific Gravity of Chemical Fed 0 to 10.000 g/ml Pump Flow Rate 0 to 1,000 (units defined by user) Output Time Limit 0 = , 1 to 1440 minutes Hand Time Limit 1 to 1440 minutes
8
Relay Output Menu – Target PPM Feed with Feed Verification
Makeup Conductivity Full scale range of the parameter Unit Volume to Trigger Output 1 to 999,999,999 (units defined by user) Target PPM Set Point 0 to 100,000 ppm Specific Gravity of Chemical Fed 0 to 10.000 g/ml Output Time Limit 0 = , 1 to 1440 minutes Hand Time Limit 1 to 1440 minutes
4-20 mA Output Menu - Retransmit
(parameter selected) = 4 mA Full scale range of the parameter (parameter selected) = 20 mA Full scale range of the parameter
Full Scale Ranges are:
Contacting Conductivity: 0 to 10,000 μS/cm Electrodeless Conductivity: 50 to 10,000 μS/cm Or 10 mS/cm to 100 mS/cm Or 100 mS/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 Value 0 – 100% Output Time Limit 0 = , 1 to 1440 minutes Hand Time Limit 1 to 1440 minutes Hand Value 0 – 100%
Full Scale Ranges are:
Contacting Conductivity: 0 to 10,000 μS/cm Electrodeless Conductivity: 50 to 10,000 μS/cm Or 10 mS/cm to 100 mS/cm Or 100 mS/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
Data Logging Menu
Logging Interval 10 to 1440 minutes
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3.0 UNPACKING & INSTALLATION
3.1 Unpacking the Unit
Inspect the contents of the carton. Please notify the carrier immediately if there are any signs of damage to the controller or its parts. Contact your distributor if any of the parts are missing. The carton should contain a WebMasterONE and technical support package (contains instruction manual, Quick Start Guide, CD and USB cable). Any options or accessories will be incorporated as ordered.
3.2 Mounting the Electronic Enclosure
The WebMasterONE is supplied with mounting holes on the enclosure. It should be wall mounted with the display at eye level on a vibration-free surface, utilizing all mounting holes for maximum stability.
The enclosure is NEMA 4X rated, suitable for outdoor installation. The maximum ambient operating temperature is 120° F (49° C); this should be considered if installation is in a high temperature location.
The installation site should be in close proximity to grounded AC power, the chemistry to be controlled, and phone line or Ethernet hub (if applicable).
Avoid locations 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 continuously flowing sample of cooling water to the sensors. Please refer to Figures 1 (a-d) below for some typical installation drawings.
Cooling Towers:
Tap off the discharge side of the recirculation pump to provide a minimum flow of 1 gallon per minute through the flow switch manifold. The sample must flow into the bottom of the manifold in order to close the flow switch, and return to a point of lower pressure in order to ensure flow. Install an isolation valve on both sides of the manifold to stop flow for sensor maintenance.
IMPORTANT: To avoid damaging the female pipe threads on the supplied plumbing parts, use no more than 3 wraps of PTFE tape and thread into the pipe FINGER tight only! DO NOT use any pipe dope, plumber’s putty or other sealing products that contain diacetone alcohol, as these attack the flow switch plastic! Use PTFE tape ONLY!
10
Boilers:
The conductivity probe should be placed as close to the controller as possible, to a maximum
distance of 250 ft. The cable MUST be shielded from background electrical noise. Use 24 AWG,
3 twisted pair, shielded, low capacitance (15 pF/ft) cable such as Walchem P/N 102535 (Belden
9680) or equivalent.
Important Boiler Installation Notes: (see figure 1b and c)
1. Make sure the minimum water level in the boiler is at least 4-6 inches above the skimmer
blowdown line. If the skimmer line is closer to the surface, it is likely that steam will be drawn into the line instead of boiler water. The skimmer line must also be installed above the highest tube.
2. Maintain a 3/4 inch minimum pipe ID with no flow restrictions from the tap for the boiler
skimmer blowdown line to the electrode. If the ID is reduced below 3/4 inch, then flashing will occur beyond that point and the conductivity reading will be low and erratic. Minimize the usage of tees, valves, elbows or unions between the boiler and the electrode.
3. A manual shut off valve should be installed so that the electrode can be removed and cleaned.
This valve must be a full port valve in order to avoid a flow restriction. Keep the distance between the tap for the boiler skimmer line 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 control valve or an orifice union. The amount of the flow restriction will affect the blowdown rate as well, and should be sized accordingly.
6. Install the motorized ball valve or solenoid valve per the manufacturer’s instructions.
7. For best results, align the hole in the conductivity electrode such that the direction of water flow
is through the hole.
Guide to Sizing Blowdown Valves and Orifice Plates
1. Determine the Rate of Steam Production in Pounds per Hour:
Either read off the boiler name plate (water-tube boilers) or Calculate from horsepower rating (fire-tube boilers): HP x 34.5 = lbs/hr. Example: 100 HP = 3450 lbs/hr.
2. Determine the Concentration Ratio (BASED ON FEEDWATER)
A water treatment chemical specialist should determine the desired number of cycles of concentration. This is the ratio of TDS in the boiler water to TDS in the feedwater. Note that feedwater means the water that is fed to the boiler from the deaerator and includes makeup water plus condensate return. Example: 10 cycles of concentration has been recommended
11
3. Determine the Required Blowdown Rate in Pounds Per Hour
Blowdown Rate = Steam Production / (Concentration Ratio –1) Example: 3450/(10-1) = 383.33 lbs./hr
4. Determine if Continuous or Intermittent Sampling is Required
Use intermittent sampling when the boiler operation or loading is intermittent, or on boilers where the required blowdown rate is less than 25% of the smallest available flow control valve or less than the flow through the smallest orifice. See the graphs on the next page.
Use continuous sampling when the boiler is operating 24 hours per day and the required blowdown rate is more than 25% of the smallest applicable flow control valve or orifice. See the graphs on the next page.
Use of a flow control valve will give you the best control of the process, since the flow rate can be easily adjusted. The dial on 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 Rate of 383.33 lbs./hr. The maximum flow rate of the smallest flow control valve is 3250 lbs./hr. 3250 x 0.25= 812.5 which is too high for continuous sampling. Using an orifice, the flow rate through the smallest diameter plate is 1275 lbs./hr. This is too high for continuous sampling.
5. Determine the Orifice or Flow Control Valve Size for this Blowdown Rate
Use the following graphs to select a flow control device:
Flow Rate in Lbs/hr for Various Orifices
18000
16000
14000
12000
10000
Lbs/hr
8000
6000
4000
2000
0
10 20 30 40 50 60 70 80 90 100 200 300
Pressure PSI
1/8 inch dia 3/16 inch dia 1/4 inch dia 5/16 inch dia
12
Flow Control Valve
25000
Maximum Flow Rates in Lbs/hr
20000
15000
Lbs/hr
10000
5000
0
20 30 40 50 60 70 80 90 100 150 200 300
Sensor Installation
All sensors for the WebMasterONE series are provided with signal conditioning electronics, and conductivity sensors may be located up to 250 feet (75 meters) from the controller, and pH/ORP sensors may be located up to 1000 feet (303 meters) from the controller. It is highly recommended that the sensors be installed within 20 feet of the controller in order to make periodic calibration more convenient.
Sensors should be located such that they respond rapidly to a well-mixed sample of the process water and the treatment chemicals. If they are too close to the chemical injection point, they will see spikes in concentration and cycle on and off too frequently. If they are too far away from the chemical injection point, they will respond too slowly to the concentration changes, and you will overshoot the set point.
If the sensor cables need to be extended, 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 always remain wet. A U-trap provided in the manifold design should achieve this, even if the sample flow stops. These electrodes also must be installed with the measuring surfaces pointing down; that is 5 degrees above the horizontal, at a minimum.
If the sensors are to be submersed in the process, mount them firmly to the tank, and protect the cable with plastic pipe, sealed at the top with a cable gland, to prevent premature failure. Place the sensors in an area of good solution movement.
1/2" 150 PSI 1/2" 300 PSI 3/4" 150 PSI 3/4" 300 PSI
Pressure PSI
13
3.4 Icon Definitions
Symbol Publication Description
IEC 417, No.5019 Protective Conductor Terminal
IEC 417, No. 5007 On (Supply)
IEC 417, No. 5008 Off (Supply)
ISO 3864, No. B.3.6 Caution, risk of electric shock
Pending
Caution, High temperature, risk of burn
ISO 3864, No. B.3.1 Caution
14
Figure 1a: Typical Installation, Cooling Tower
15
Figure 1b Typical Installation, Boiler
p
g
Intermittent Sam
16
lin
Figure 1c: Typical Installation, Boiler
p
g
Continuous Sam
lin
17
3.5 Electrical Installation
The WebMasterONE series controllers require the following voltages: 100 –120/200-240 VAC± 10%, 50/60 Hz, 12 amperes maximum The controller must be connected to its own 15 ampere breaker, close by, to act as an alternate power shutdown.
Your controller is supplied either factory prewired or ready to be hardwired. Depending upon your choice of options, you may be required to hardwire some or all of the input/output devices. Please refer to Figures 4 through 8 for wiring diagrams.
The output loads may be connected to pigtail (125V prewired) connections or terminal block (hardwired) connections. The total output current must not exceed 11 amps. The output relays 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 power to the controller is REMOVED!
If your controller is prewired, it is supplied with a 10 foot, 14 AWG power cord with USA style plug and 8 inch, 18 AWG USA style receptacle cords for the powered relay outputs. A tool (#1 Phillips driver) is required to open the front panel.
CAUTION! The electrical installation of the controller must be done by trained personnel only
and conform to all applicable National, State and Local codes!
MAINS VOLTAGE
6.3A F3
R1 R2 R3 R4
6.3A F2
R5 R6 R7 R8
18
A
Sensor Inputs
A
A
A
(up to 4)
(Recommended)
R4
C Power
R7
Note: Many of the inputs and outputs listed are optional and may not be present in your controller.
Hardwired Options
Bottom View
Strain relief
installed with
analog card option
nalog Inputs
Digital Input A Digital Input B Digital Input C
digital card option
Digital Inputs
(Recommended)
Strain relief
installed with
R5 R6 R8
Misc. Inputs/
Outputs
(Recommended)
R1 R2 R3
Sensor Inputs
(up to 4)
R4
C power
R7
analog card option
nalog Inputs Digital Inputs
Digital Input A Digital Input B Digital Input C
Figure 2: Conduit/Wiring Configuration
Prewired Option
Bottom View
Strain relief
installed with
Strain relief
installed with
digital card option
R5 R6 R8
Misc. Inputs/
Outputs
R1 R2 R3
19
D
i
l
Power
use
s
Relay
Digital
Input
Option
Card
Board
DIG INPUT 6 DIG INPUT 5 DIG INPUT 4
IN-
IN+ +v IN- IN+ IN+IN-+v +v
REV 3
-
+-+-+
INPUT 3 INPUT 2 INPUT 1
102847
+-+-+-+
INPUT 4
+v+v +v
IN-IN-IN-
IN+IN+IN+
DIG INPUT 3DIG INPUT 2DIG INPUT 1
4-20 mA Output
Option Cards
INPUT 5
INPUT 5 INPUT 6 I NPUT 7
-
102815 RV2
+24V
TB1
GN+24
-
+
RELAY1NC NO
RELAY2NC NO
3
RELAY
NC NO
RELAY4NC NO
5
RELAY
NC NO
6
RELAY
NC NO
RELAY7NC NO
8
RELAY
NC COM
Hot
Relay Outputs
F
ay sp
Ethernet
USB
RJ45
Power Supply
Modem
Host
Core
Neutral
Relay outputs
Card
4-20mA
Input Option
RJ11
Digital
Inputs
A, B, C, D, E & F
Modem
Option
Card
t- t+ IN- IN+ +5V -5V
Sensor 1
t- t+ IN- IN++5V -5V
Core
Interface
Board
t- t+ IN- IN++5V -5V
B1
REV 2 102839
t- t+ IN- IN++5V -5V
(Observe
markings on
circuit board)
Sensor 4 or 2
Figure 3 Identification of Parts
20
REV 2 102839
REV 2 102839
Sensor 2 or 4
(Observe markings
on circuit board)
Sensor 3
VoltageCode
S
0 or 4 DRY DRY DRY DRY DRY DRY DRY DRY 1 or 6 POWERED POWERED POWERED POWERED POWERED POWERED POWERED DRY 2 or 5 POWERED POWERED POWERED POWERED POWERED POWERED POWERED POWERED 3 or 7 DRY POWERED DRY POWERED DRY POWERED DRY POWERED
R1 R2 R3 R4 R5 R6 R7 R8
DRY CONTACTS WILL BE LABELED COM INSTEAD OF NC.
EE
DETAIL “A”
GROUND
STUD
WHT
GND
GRN
NEU
HOT
BLK
NEU HOT
NEUTRAL
Important: The mains power supply earth ground connection must be retained by separate nut.
RELAY8 RELAY7 RELAY6 RELAY5 RELAY4 RELAY3 RELAY2 RELAY1
IF USING
A MOTORIZED
WHT
BLK
WHT
TO GND
STUD
BALL VALVE
GRN
NC NONC NONC NONC NONC NONC NONC NO
BLK
BLK
AC POWER
INPUT
Figure 4: Wiring Diagram for AC Power Input and Relay Outputs
GRN
METERING
PUMP
SEPARATE
PRIMARY EARTH CONNECTION
21
TO GND
STUD
NUT
BRACKET
SOLENOID OR
MOTORIZED BALL VALVE
OTHER EARTH CONNECTIONS
PC
BOARD
B1
DIGITAL INPUTS SEE DETAIL 'A'
SENSOR 4 or 2
(Observe markings
on circuit board)
SEE DETAIL 'C'
SENSOR 3 SEE DETAIL 'C'
SENSOR DETAIL "C"
Low Pressure
CONDUCTIVITY
102839
REV 2
102839
REV 2
WHT/GRN
GRN
WHT/ORN
ORN
BLU
WHT/BLU
SHIELD
TO GND STUD
pH/ORP OR
SENSOR
T­T+ IN-
IN+ +5
-5
GROUND/SHIELD
t- t+ IN- IN++5V -5V
t- t+ IN- IN++5V -5V
102839
REV 2
SENSOR 2 or 4 (Observe markings on circuit board) SEE DETAIL 'C'
Shield
(Drain wire)
to GND stud on
front
panel
-T -T
+T
W
H
High Pressure
Conductivity
Electrode
WHT/GRN
GRN
WHT/ORN
ORN BLU
WHT/BLU
Sensor 1 Terminal
Block
t- t+ IN- IN++5V -5V
t- t+ IN- IN++5V -5V
SENSOR 1** SEE DETAIL 'C'
* Either an unpowered or a powered device may be connected to each digital input, one device per input.
WHT/GRN
GRN
WHT/ORN
WHT/BLU
-S
+
+S
-
+T
T
-5
G
B
R
L
N
K
RE
ORN
BLU
+5
D
T­T+
IN­IN+
+5
-5
SIGNAL +
SIGNAL -
POWERED
DEVICES
HALL EFFECT WATERMETER
OR
PADDLEWHEEL
t- t+ IN- IN+ +5V -5V
** Please note: Sensor 1 terminal
block is oriented OPPOSITE of
sensors 2-4.
OR
SHIELD
(TO GROUND
STUD)
UNPOWERED
OR*
WATERMETER-CONTACTOR
DEVICES
RELAY, REED SWITCH
DIGITAL
IN+
INPUT A
IN­IN+
DIGITAL
INPUT B
IN­IN+
DIGITAL
INPUT C
IN­IN+
DIGITAL INPUT D
IN­IN+
DIGITAL INPUT E
IN­IN+
DIGITAL INPUT F
IN-
12V 12V
DETAIL "A"
GND
-5V
+5V
TC+ TC- GND
VpH
COM
TC
GROUND
OPTIONAL TEMPERATURE COMPENSATION (pH ONLY)
TC+ TC- TC
Figure 5: Wiring Diagram for Sensor Inputs and Digital Inputs A-F
TO GROUND STUD INSIDE ENCLOSURE
PREAMPLIFIER
High Pressure pH/ORP Sensor
22
T-
T+ IN-
WHT
IN+
+5
-5
RED
GRN
BLACK
TO GND STUD
SHIELD
DISINFECTION
SENSOR
SENSOR
DETAIL "C"
(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
23
+24V
C
y
D
TB1
WebMaster 4-20 mA Input Wiring Guide
KEY:
(-) minus terminal is the signal input. The 4-20mA signal goes here.
A.
(+) plus terminal is a +24VDC power supply for the transmitters.
B.
GND terminal is the return for completing circuits, both signal and power.
C.
+24 terminal at the top middle of the board is the same supply as the (+) plus terminal.
D.
-
A
+
B
-
+
-
+
-
+
GN +24
Use shielded cable, grounded only at the controller end, for all connections.
INPUT 5
INPUT 5 INPUT 6 INPUT 7
-
+
-
+
-
+
-
+
A. Two-Wire Loop-Powered Transmitter
Input 1 ­Input 1 +
- SIGNAL + 24
Input 2 ­Input 2 + Input 3 ­Input 3 + Input 4 ­Input 4 +
C. Three-Wire Transmitter
Notes: The (-) signal wire is the actual 4-20mA signal and is also the GND return wire to complete the circuit. 'Input -' is internally connected to GND via 25 ohm resistor.
GND +24
Input 1 ­Input 1 + Input 2 ­Input 2 + Input 3 ­Input 3 + Input 4 ­Input 4 +
+24
-SIGNAL +SIGNAL
B. Two-Wire Externally-Powered Transmitter
Input 1 -
GND +24
Input 1 + Input 2 ­Input 2 + Input 3 ­Input 3 + Input 4 ­Input 4 +
D. Four-WireTransmitter
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!
GND +24
Input 1 ­Input 1 + Input 2 ­Input 2 + Input 3 ­Input 3 + Input 4 ­Input 4 +
POWER+ POWER-
-SIGNAL +SIGNAL
+24 GND
-SIGNAL +SIGNAL
+24V
GND
E. Non-Isolated Two-Wire Externally-Powered Transmitter
GND +24
Input 1 ­Input 1 + Input 2 ­Input 2 + Input 3 ­Input 3 + Input 4 -
Isolator OUT- IN­OUT+ IN+
Input 4 +
Notes: The analog inputs share their negative terminals. They are all isolated from earth ground but not isolated from each other. One non-isolated device may be connected without pr ob le ms. If more than one non-isolated transmit ter is connected, the
F. Non-Isolated Four-Wire Externally-Powered Transmitter
GND +24
Input 1 ­Input 1 + Input 2 -
POWER+ POWER-
-SIGNAL +SIGNAL
must be installed with an isolator.
Input 2 + Input 3 ­Input 3 + Input 4 ­Input 4 +
+24 GND
-SIGNAL +SIGNAL
24
ADDING AN ISOLATED RECEIVER TO THE LOOP (PLC, CHART RECORDER, ETC) The WebMaster GND must always be at the bottom of the loop. Maximum total loop resistance 1000 ohms.
A. Two-Wire Loop-Powered Transmitter
Input 1 -
- PLC +
Input 1 + Input 2 ­Input 2 + Input 3 ­Input 3 + Input 4 ­Input 4 +
B. Two-Wire Externally-Powered Transmitter
Input 1 ­Input 1 + Input 2 ­Input 2 + Input 3 ­Input 3 + Input 4 ­Input 4 +
GND +24
- PLC +
C. Three-Wire Transmitter
Input 1 ­Input 1 + Input 2 ­Input 2 + Input 3 ­Input 3 + Input 4 ­Input 4 +
GND +24
- PLC +
-SIGNAL +24
POWER+ POWER-
-SIGNAL +SIGNAL
+24
-SIGNAL +SIGNAL
Notes: The (-) signal is the actual 4-20mA signal and is also the GND return wire to complete the circuit.
'Input -' is internally connected to GND via 25 ohm resistor.
Notes: This transmitter gets its power from its own dedicated power supply.
+24V
* Connecting a powered transmitter to the
GND
'Input +' terminal of the WebMaster will permanently damage the input!
D. Four-Wire T ran smitter
Input 1 ­Input 1 + Input 2 ­Input 2 + Input 3 ­Input 3 + Input 4 ­Input 4 +
GND +24
- PLC +
+24 GND
-SIGNAL +SIGNAL
25
Figure 7: Wiring Diagram for Optional Digital Communications
26
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