WebMaster Series Cooling Tower Controller Instruction Manual Notice © 2003 WALCHEM Corporation Five Boynton Road, Holliston, MA 01746 USA (508) 429-1110 All Rights Reserved Printed in USA Proprietary Material The information and descriptions contained herein are the property of WALCHEM Corporation. Such information and descriptions may not be copied or reproduced by any means, or disseminated or distributed without the express prior written permission of WALCHEM Corporation, Five Boynton Road, Holliston, MA 01746. Statement of Limited Warranty WALCHEM Corporation 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 Corporation and for the purposes disclosed in writing a the time of purchase, if any. WALCHEM Corporation’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 Corporation, transportation charges prepaid, has been inspected and determined by WALCHEM Corporation 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. 180135 Rev H2 (applies to software revisions s050v001,002,003,004,005,006,007,008,009.010,11,12,13,14,15,16) January 2004 TABLE OF CONTENTS 1.0 INTRODUCTION .......................................................................................................................................... 1 2.0 SPECIFICATIONS ........................................................................................................................................ 1 2.1 MEASUREMENT PERFORMANCE..................................................................................................................... 1 2.2 ELECTRICAL .................................................................................................................................................. 2 2.3 MECHANICAL ................................................................................................................................................ 2 2.4 VARIABLES AND THEIR LIMITS ...................................................................................................................... 5 3.0 UNPACKING & INSTALLATION .............................................................................................................. 8 3.1 UNPACKING THE UNIT ................................................................................................................................... 8 3.2 MOUNTING THE ELECTRONIC ENCLOSURE .................................................................................................... 8 3.3 INSTALLATION............................................................................................................................................... 8 3.4 ICON DEFINITIONS ......................................................................................................................................... 9 3.5 ELECTRICAL INSTALLATION ........................................................................................................................ 13 4.0 FUNCTION OVERVIEW............................................................................................................................ 20 4.1 FRONT PANEL.............................................................................................................................................. 20 4.2 DISPLAY ...................................................................................................................................................... 21 4.3 KEYPAD ...................................................................................................................................................... 21 4.4 ACCESS CODES ............................................................................................................................................ 22 4.5 INITIAL STARTUP ......................................................................................................................................... 22 4.6 COMMUNICATING WITH THE WEBMASTER.................................................................................................. 24 4.7 STARTUP...................................................................................................................................................... 30 4.8 SHUT DOWN ................................................................................................................................................ 30 5.0 OPERATION – USING LOCAL DISPLAY AND KEYPAD................................................................... 30 5.1 INPUT SUMMARY ......................................................................................................................................... 30 5.2 OUTPUT SUMMARY ..................................................................................................................................... 30 5.3 ALARMS ...................................................................................................................................................... 31 5.4 CALIBRATION .............................................................................................................................................. 31 5.5 RELAY CONTROL (HOA)............................................................................................................................. 36 5.6 SET POINTS.................................................................................................................................................. 36 5.7 COMMUNICATION ........................................................................................................................................ 44 5.8 ACCESS CODES ............................................................................................................................................ 46 6.0 OPERATION – USING PC ......................................................................................................................... 46 6.1 MENU SELECTION LINKS ............................................................................................................................. 46 6.2 START UP MENU ......................................................................................................................................... 47 6.3 SYSTEM SUMMARY MENU........................................................................................................................... 52 6.4 SYSTEM VISUAL SUMMARY MENU (FUTURE FEATURE)............................................................................... 52 6.5 SENSOR GRAPHS (FUTURE FEATURE)........................................................................................................... 52 6.6 CONDUCTIVITY INPUT MENU ...................................................................................................................... 52 6.7 TEMPERATURE INPUT MENU ....................................................................................................................... 54 6.8 PH INPUT MENU (ONLY APPEARS IF PH OPTION CARD IS INSTALLED) .......................................................... 55 6.9 ORP INPUT MENU (ONLY APPEARS IF ORP OPTION CARD IS INSTALLED).................................................... 57 6.10 WATER METER INPUT MENU....................................................................................................................... 59 6.11 FLOW SWITCH INPUT MENU ....................................................................................................................... 60 6.12 LEVEL INPUT MENU .................................................................................................................................... 61 6.13 CORROSION INPUT MENU ............................................................................................................................ 62 6.14 OTHER INPUTS ............................................................................................................................................. 63 6.15 POSIFLOW INPUT MENU............................................................................................................................... 64 6.16 INTERLOCK MENU ....................................................................................................................................... 65 6.17 4-20 MA INPUT MENU (ONLY APPEARS IF THE ANALOG INPUT OPTION CARD IS INSTALLED) ....................... 65 6.18 DIGITAL INPUTS MENU (ONLY APPEARS IF THE DIGITAL INPUT OPTION CARD IS INSTALLED)..................... 66 6.19 BLEED OUTPUT MENU ................................................................................................................................ 66 6.20 FEED OUTPUT MENU .................................................................................................................................. 71 6.21 ... BIOCIDE 1 & 2 OUTPUT MENUS .................................................................................................................