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Walchem WebAlert WA500 Instruction Manual

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W A L C H E M
IWAKI America Inc.
®
WebAlert
WA500 Process Monitor
WebAlert
WA500 Series
®
Process Monitor
Instruction Manual
Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA
TEL: 508-429-1110 FAX: 508-429-7433 WEB: www.walchem.com

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  • Page 1 W A L C H E M IWAKI America Inc. ® WebAlert WA500 Process Monitor WebAlert WA500 Series ® Process Monitor Instruction Manual Five Boynton Road Hopping Brook Park Holliston, MA 01746 USA TEL: 508-429-1110 FAX: 508-429-7433 WEB: www.walchem.com...
  • Page 2 WALCHEM and for the purposes disclosed in writing at 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: Table Of Contents

    TABLE OF CONTENTS INTRODUCTION ..........................1 SPECIFICATIONS ..........................2 ......................2 EASUREMENT ERFORMANCE ............................2 LECTRICAL ............................ 3 ECHANICAL ......................3 ARIABLES AND THEIR IMITS UNPACKING & INSTALLATION ...................... 4 ........................4 NPACKING THE ..................4 OUNTING THE LECTRONIC NCLOSURE ...........................

  • Page 4: Introduction

    INTRODUCTION WebAlert is the first stand- alone remote monitoring device that can web enable your installed equipment without having to replace or upgrade it. Your key system parameters (analog and digital input signals) can now be monitored from any computer – anywhere in the world - with a standard web browser.

  • Page 5: Specifications

    SPECIFICATIONS Measurement Performance 4-20 mA Inputs Range 3.75-20.25 mA Resolution 0.03 mA Calibration ± 1 mA Electrical Inputs Input power 100 – 120/220-240 VAC ±10%, 1A, 50/60 Hz Fuse 1.0A, 5 x 20mm Input signals State-Type Digital Inputs Electrical: Non-Isolated 5 VDC with 301 K ohm pull-up Typical response time: <...

  • Page 6: Mechanical

    Mechanical Enclosure Material: Polycarbonate NEMA Rating: NEMA 4X (IP 66) Dimensions: 32.4 cm x 24.4 cm x 8.3 cm (12.75” x 9.60” x 3.25”) Operating Ambient Temp: 0 to 60° C (32 to140°F) Storage Temp: -29 to 80°C (-20 to 176 °F) Weight 2.0 kg.

  • Page 7: Unpacking & Installation

    Contact Flowmeter Input Menu Volume per Contact (contact style) 0 to 1000 (units of measure defined by user) Total Alarm Limit 0 = no limit, otherwise >0 Counter Input Menu One Count = >0 Total Alarm Limit 0 =no limit, otherwise >0 Rate High Alarm >0 Rate Low Alarm...

  • Page 8: Installation

    The enclosure requires the following clearances: Top: 5 cm (2”) Left: 10 cm (4”) Right: 10 cm (4”) Bottom: 10 cm (4”) Installation The WebAlert receives digital and analog input signals, and sends a digital output signal. The maximum distances for these cables, using 24 AWG shielded twisted pair cable, is 1200 meters (4000 feet) for the 4-20 mA input signals and 300 meters (1000 feet) for the digital input and output signals.
  • Page 9 Figure 1 Identification of Parts...
  • Page 10 Figure 2 – Wiring Diagram for AC Power Input...
  • Page 11 Figure 3 - Wiring Diagram for Digital Inputs and Outputs...
  • Page 12 DEVICES POWERED BY THE WEBALERT Figure 4 - Wiring Diagram for Analog Inputs...
  • Page 13 Figure 5 – Wiring Diagram for USB Devices and Communications...

  • Page 14: Function Overview

    FUNCTION OVERVIEW Front Panel Status LED Alarm LED...

  • Page 15: Initial Startup

    Initial Startup Turn the power on. Be patient, the start up sequence will take about the same time as it takes a computer to boot up, approximately 2 minutes. The Status LED will flash, and when boot up is complete the WebAlert will beep 3 times. Under normal conditions, the Status LED will flash on and off every second.

  • Page 16: Communicating With The Webalert

    Communicating with the WebAlert 4.3.1 Direct Connection to the USB Port Web Browser (Client) Hard coded Fixed IP Address: 199.199.199.2 A direct USB connection to the WebAlert can be made in two ways. A temporary connection or a permanent connection can be made between a PC and the USB connector inside the unit. The cable length is limited to 5 meters (15 feet).
  • Page 17 A dialup account must be established for the WebAlert with an Internet Service Provider (ISP). The connection will only be as reliable as the ISP. You should avoid small mom-and-pop ISPs unless you know that they can provide reliable connection to the Internet. Contact Walchem for recommendations.
  • Page 18 4.3.3 Ethernet Connection to LAN Unsafe Port Safe ROUTER Ethernet Port Web Browser Browser Equipment Required  An Internet-ready computer with the following capabilities: 100 MHz minimum processor speed, 40 MB minimum RAM, Windows operating system, and Windows Internet Explorer version 5.0 or higher web browser software.
  • Page 19 4.3.4 Direct Modem Access: Direct Tap Embedded Web Browser Web Server (Client) modem TELCO modem Hard coded Fixed IP Address: 199.199.199.3 Equipment Required  An Internet-ready computer with the following capabilities: 100 MHz minimum processor speed, 40 MB minimum RAM, Windows operating system, modem and Windows Internet Explorer version 5.0 or higher web browser software.
  • Page 20 4.3.5 Direct Ethernet (for a WebAlert not connected to a LAN) Web Browser (Client) Fixed User Assigned Ethernet Cross-Over Cable IP Address Fixed IP Address User Assigned Gateway + Subnet Mask Equipment Required  An Internet-ready computer with the following capabilities: 100 MHz minimum processor speed, 40 MB minimum RAM, Ethernet card, Windows operating system, and Windows Internet Explorer version 5.0 or higher web browser software.
  • Page 21 4.3.6 Networking WebAlert Process monitors via Ethernet Web Browser Master Slaves connected using any of the previous methods Equipment Required  An Internet-ready computer with the following capabilities: 100 MHz minimum processor speed, 40 MB minimum RAM, Ethernet card, Windows operating system, and Windows Internet Explorer version 5.0 or higher web browser software.

  • Page 22: Startup

    4-20 mA Inputs 4-20 mA Calibration Digital Inputs Flowmeter Generic Inputs Generic Counters Digital Inputs Outputs Alarm Utilities System Auto Report Datalog Auto Report Manual Datalog Graphing/Trending Communications Software Upgrade Configuration File Notepad Access Codes WebAlert Help Walchem Home Page...

  • Page 23: Startup

    Startup Select the option 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”...

  • Page 24: System Summary Menu

    4-20 mA Input Assignment Click on the radio button which best describes the devices you have attached to the 4-20 mA inputs, for each input labeled 1 through 6. Make sure that you select the type of device that is actually wired to that terminal of the card! Not Used should be selected if nothing is connected to that input.
  • Page 25 Custom Name You may give the level input a custom name by typing it in the text box. Present Value This displays the current level in that container. Present mA This displays the mA output of the level transmitter, before it is converted into a volume, distance or other engineering units.
  • Page 26 Generic 4-20 mA Input This type of analog input is programmed exactly like the Level type. The only difference is that the Level type will calculate the Usage, while the Generic type will not. Flow meter 4-20 mA Input Input Displays which 4-20 mA inputs have been selected as “Flow meter”...

  • Page 27: Ma Calibration

    Rate Low-Low Alarm Type into the text box the value for that input below which you want a low-low alarm to occur. Any value between –100,000 and 100,000 is acceptable. You must go to the Alarm page to specify that this alarm condition is a critical alarm in order to close the alarm relay or send an email.

  • Page 28: Digital Inputs

    1 Pt Cal 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 =”...
  • Page 29 Status This menu reports the status of the input. Possible messages are Normal, High Alarm, Low Alarm, or Total Limit. Units Select the units of flow that you want to use. The choices are Gallons, Liters or Cubic Meters per minute.
  • Page 30 Last Total Reset The date and time of the last time the total was reset will be displayed here. Status This menu reports the status of the input. Possible messages are Normal or Total Limit. Units Select the units of flow that you want to use. The choices are Gallons, Liters or Cubic Meters per minute.
  • Page 31 Status This menu reports the status of the input. Possible messages are Normal, High Alarm, Low Alarm, or Total Limit. Custom Units Select the units of measure that you want to use. Type the name in the text box. One Count = This menu allows you to specify that each count (contact closure) signifies a certain number of the custom units of measure.

  • Page 32: Alarm

    Alarm This page is used to configure the Alarm Output. Select the options 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! Relay Control Mode Use the pulldown arrow to select if the relay will be Not Used or will be set to Alarm.
  • Page 33 Output Mode Click on the radio buttons to manually control the alarm relay. The normal selection will be Auto, where the WebAlert uses the various set points to open and close the relay. You can force the relay open regardless of the presence of an alarm condition by selecting Off, or force the relay closed regardless of the presence of an alarm condition by selecting Hand.

  • Page 34: System Status Auto-Reporting

    System Status Auto-Reporting The system status auto report is an email in html format that is a snapshot of current conditions, identical to what is displayed on the System Summary web page. System Status Reporting Click the appropriate radio button to select whether the report should be sent by email (Enable) or not (Disable).
  • Page 35 Data Log Reporting Click the appropriate radio button to enable or disable 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.

  • Page 36: Manual Datalog

    5.10 Manual Datalog You may either download data files automatically, or manually. To have the data automatically sent to you via email, set up the data log in the Auto Reporting page (See Section 5.9). The Manual and Auto Reporting data logs are dynamically connected to each other. For each data log, select the parameters to log, and the maximum time frame of the data log and submit the changes.

  • Page 37: Graphing/Trending

    Select items to log You will be presented with a list of all of the parameters that can be logged, including analog input readings, totalizers, flow rates, and 4-20 mA input raw mA. The contents of the list will vary depending on what options you have installed or programmed.
  • Page 38 Ethernet (LAN) Enable DHCP Click on the radio button to enable DHCP if you want the controller to obtain its IP address from the local area network. This option only works if the controller is connected to a LAN. Ethernet IP Address When a controller is attached to a network, your IT Administrator needs to assign it an Ethernet IP address.
  • Page 39 Send Email Via If you have both a modem card and an Ethernet card 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.
  • Page 40 Last Connection Date and Time This menu is informational only, and tells you when the controller was contacted last. Click on the “Submit” button to save the changes. Connection 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.

  • Page 41: Advanced Communications Settings

    Upload Key File Rather than type the key, a key file may be imported in order to activate a special software feature. Browse for the file, and once it is selected, click the Import Key File button. Activation Status For information, this field shows if any special software features have been activated. Activation Log Click on the Activations Log link to view the log file.
  • Page 42 Modem Baud Rate Click on the arrow of the pull-down to select different modem baud rates. The baud rate will be negotiated at power-up. Normally there will be no reason to change the baud rate. The baud rate may be reduced if there are problems at the higher speed due to poor signal conditions.

  • Page 43: Software Upgrade

    If the WebAlert is not connected to the Internet, an upgrade may be accomplished using an upgrade file and USB flash drive: Download the upgrade file from the Walchem web site. Certain upgrade files will only work to go from a few specific versions to another. Make sure that the upgrade file matches the software version you have now.

  • Page 44: Notepad

    (Word, Notepad, etc.).” 5.18 Walchem Web Page Click on this link to go directly to the Walchem web site, where you can find the latest instruction manuals, technical data sheets, email help, or to surf to another WebAlert.

  • Page 45: Sub-Network

    5.19 Sub-Network Once you have created a network of two or more WebAlert process monitors, purchased the Master Capability software for the master process monitor, defined the master unit as the master and slave units as slaves (see section 5.11) in the Communications page, and given each process monitor unique Ethernet IP addresses in the Communications page, the links under Sub-Network will be active.

  • Page 46: Maintenance

    MAINTENANCE The WebAlert process monitor requires very little routine maintenance. The electronic enclosure only needs to be wiped down with a damp cloth to keep it clean. CAUTION! The WebAlert power supply cover is secured with Phillips (#1) screws, which require a tool to open.

  • Page 47: Troubleshooting

    TROUBLESHOOTING ERROR MESSAGES “<Input Name> (AI_#) Input” High or High-High Alarm (one for each, use name defined) This error message is caused by the 4-20 mA signal from a transmitter exceeding the user-programmed value for the high alarm limit. Possible Causes Corrective Actions The process value being measured by the Determine the reason for the out of spec transmitter...
  • Page 48 Generic Input Open/Closed Alarm (one for each used) This error message appears if a switch connected to a digital input is putting out a signal that indicates an alarm condition. This could mean that the switch is either open or closed. The custom name of the input and the custom message will appear in the alarm message.
  • Page 49 Digital Input Total Limit This error message appears if a Flow meter or Generic Counter digital input type receives a total number of contact closures higher than the limit programmed in the Total Alarm Limit field. Possible Causes Corrective Actions Normal operation, total has been reached None False contacts at a high rate.

  • Page 50: Service Policy

    SERVICE POLICY The WebAlert Series process monitors have a 2-year warranty on electronic components and a 1-year warranty on mechanical parts. We stock replacement parts for immediate exchange after we have isolated the cause of a problem. Factory authorized repairs that are received via next-day-air will be returned within 24 hours. Normal turnaround time for returns is two weeks.
  • Page 51 Model Code Wiring Comms Hardware Comms Software WA500 WIRING H = Hardwired, cable glands P = USA power cord w/cable glands COMMUNICATIONS (USB & ETHERNET STANDARD) N = No additional communications M = Modem card G = Cellular modem card (GPRS) COMMUNICATIONS SOFTWARE N = None 1 = Ethernet Networking Master Capability...
  • Page 52 FIVE BOYNTON ROAD HOPPING BROOK PARK HOLLISTON, MA 01746 USA TEL: 508-429-1110 FAX: 508-429-7433 Web: www.walchem.com...

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