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.
Notice © 2014 WALCHEM, Iwaki America Inc. (hereinafter “Walchem”) 5 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, 5 Boynton Road, Holliston, MA 01746.
TABLE OF CONTENTS 1.0 INTRODUCTION ................................................................................................................................ 1 2.0 SPECIFICATIONS ............................................................................................................................. 2 2.1 2.2 2.3 2.4 3.0 3.1 3.2 3.3 3.4 3.5 4.0 4.1 4.2 4.3 4.4 4.5 5.0 MEASUREMENT PERFORMANCE ......................................................................................................
1.0 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. With proprietary on-demand connectivity, the WebAlert is only online when you need it, making it the world’s first practical and secure industrial monitoring Internet solution.
2.0 SPECIFICATIONS 2.1 Measurement Performance 4-20 mA Inputs Range 3.75-20.25 mA Resolution 0.03 mA Calibration ± 1 mA 2.2 Electrical Inputs Input power 100 – 120/220-240 VAC ±10%, 1A, 50/60 Hz Input signals State-Type Digital Inputs Low Speed Counter-Type Digital Inputs High Speed Counter-Type Digital Inputs Analog Inputs (1-6) Fuse 1.0A, 5 x 20mm Electrical: Non-Isolated 5 VDC with 301 K ohm pull-up Typical response time: < 10 seconds Devices supported: Any isolated dry contact (i.e.
2.3 Mechanical Enclosure Material: NEMA Rating: Dimensions: Operating Ambient Temp: Storage Temp: Weight 2.4 Polycarbonate NEMA 4X (IP 66) 32.4 cm x 24.4 cm x 8.3 cm (12.75” x 9.60” x 3.25”) 0 to 60° C (32 to140°F) -29 to 80°C (-20 to 176 °F) 2.0 kg. (4.5 lbs) Variables and their Limits All menus shown may not be available. The menus that appear on your process monitor will vary with options installed and programmed.
Contact Flowmeter Input Menu Volume per Contact (contact style) Total Alarm Limit 0 to 1000 (units of measure defined by user) 0 = no limit, otherwise >0 Counter Input Menu One Count = Total Alarm Limit Rate High Alarm Rate Low Alarm Rate High-High Alarm Rate Low-Low Alarm >0 0 =no limit, otherwise >0 >0 >0 >0 >0 Alarm Output Menu Remote Alarm Delay Time Output Time Limit Alarm Hand Time Limit 1 to 1440 minutes 0 to 1440 minutes (0 = no limit) 1 to 1440 minutes Auto Reporting Menu Logging Frequency 1
The enclosure requires the following clearances: Top: 5 cm (2”) Left: 10 cm (4”) Right: 10 cm (4”) Bottom: 10 cm (4”) 3.3 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.
Figure 1 Identification of Parts 6
Figure 2 – Wiring Diagram for AC Power Input 7
Figure 3 - Wiring Diagram for Digital Inputs and Outputs 8
DEVICES POWERED BY THE WEBALERT Figure 4 - Wiring Diagram for Analog Inputs 9
Figure 5 – Wiring Diagram for USB Devices and Communications 10
4.0 FUNCTION OVERVIEW 4.
4.2 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.
4.3 Communicating with the WebAlert 4.3.1 Direct Connection to the USB Port Web Browser (Client) USB 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). Equipment Required An A to B USB cable.
4.3.2 Remote Modem Access: Shoulder Tap ISP Phone line Embedded Web Server Http://w700.walchem.com/walchem ShoulderTap Connection Utility 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.
4.3.3 Ethernet Connection to LAN Unsafe Port OR Ethernet Safe Port LAN ROUTER Web Browser Web 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. A connection between the PC and the local area network (LAN). An Ethernet connection between the WebAlert and the LAN.
4.3.4 Direct Modem Access: Direct Tap Embedded Web Server Web Browser (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.
4.3.5 Direct Ethernet (for a WebAlert not connected to a LAN) Web Browser (Client) Fixed IP Address User Assigned Ethernet Cross-Over Cable User Assigned Fixed IP Address 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. A null Ethernet cable connection between the PC and WebAlert.
4.3.6 Networking WebAlert Process monitors via Ethernet Web Browser connected using any of the previous methods Slaves Master Hub 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. An Ethernet cable connection between each WebAlert using a hub or connection to LAN.
4.4 Startup Once the WebAlert has been set up for your application, start up is a simple process. Simply turn on the power, and it will begin monitoring the process. 4.5 Shut Down To shut down the process monitor, simply turn off the power. All set points will be retained in memory. 5.0 OPERATION When you first access the process monitor, the System Summary page will be displayed in the main frame of the browser, and the Name of the unit and Alarm Status will be displayed in the top frame.
5.2 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” first, your changes will be lost! Custom Name Type the name that you want to use to identify the unit, up to 32 characters, in the text box. For example, “XYZ Corp, North Tower”.
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. Level should be selected if a continuous level transmitter is attached to that output.
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. This is helpful for troubleshooting. Status This displays current status of the input.
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” type. Custom Name You may give the input a custom name by typing it into the text box.
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. Rate High-High Alarm Type into the text box the value for that input above which you want a high-high alarm to occur. Any value between –100,000 and 100,000 is acceptable.
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 =” setting to make the reading accurate at the value entered in the 1-Point Calibration. A new window will open when you click the 1 Pt Cal button.
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. K Factor The instructions for the flow meter, or the flow meter itself should have the K Factor (pulses per unit volume) that is necessary to calculate the flow rate. Type this into the text box.
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. Volume per Contact The instructions for the flow meter, or the flow meter itself should have the volume per contact that is necessary to calculate the total flow. Type this into the text box.
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. For example, one count could equal 100 liters of fluid.
5.7 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.
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.
5.8 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). Auto Report Log Click the link to View Log File. The Auto Report Log will tell you the status of any report emails that may have been sent.
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.
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.
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. Click the “Yes” radio buttons of the parameters that you want to log, and the “No” radio buttons of the parameters that you do not want to log. Log Files Links to the last two copies of the log files are saved.
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. When you want to communicate with the controller from your PC on the network, you go to your Browser and type in the controller’s address.
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. Obtain this address from your ISP and type it into the text box.
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. Type in the text box the number of minutes that you want to pass by before disconnecting the Internet connection.
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. You will be prompted to either open the file (.
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. Maximum PPP MTU Size Normally the PPP MTU packet size will be negotiated with the cell service. Some services require a manual setting of a smaller size. Type this in the text box if necessary.
5.14 Software Upgrade Whenever you connect to the WebAlert via an Internet connection, it will check to see if any software upgrades are available. If there are, then the Software Upgrade page link will appear. Note that this can only occur if the WebAlert is connected to the Internet, either through the modem or Ethernet. If there is a newer version of software that you would like to load into your unit, then you can upgrade to the latest revision.
Browse In order to transfer a previously saved UCF from your computer to this WebAlert, first click the Browse button to locate the file on your computer. A “Choose File” dialog box will open. Click on the correct file, then click Open. Import UCF Once the file name is displayed in the Browse text box, click the Import UCF button to transfer the file to the WebAlert. 5.
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.
6.0 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. No user adjustments are inside. This panel should only be opened by trained maintenance personnel. 6.1 Replacing the Battery Using a small flat screwdriver, gently lift the battery up and out of its clip.
7.0 TROUBLESHOOTING 7.1 ERROR MESSAGES “ (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 transmitter is out of specifications condition. .
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. Possible Causes Normal function of the switch Corrective Actions Determine the cause of the process problem. Faulty switch or wiring.
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 Normal operation, total has been reached Corrective Actions None False contacts at a high rate. Separate cable from AC voltage. Use shielded cable.
8.0 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. Out of warranty repairs are done on a flat fee basis.
Model Code WA500 - Wiring Comms Hardware Comms Software 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 48
FIVE BOYNTON ROAD TEL: 508-429-1110 HOPPING BROOK PARK FAX: 508-429-7433 HOLLISTON, MA 01746 USA Web: www.walchem.
