WIND Series
WebMaster Multi I/O Industrial Water Treatment Controllers
Part 1.
General
1.1
Scope
A. This section describes the requirements for a multiple input/output industrial water
treatment controller.
B. Under this item, the contractor shall furnish and install the Multi I/O industrial water
treatment control equipment and accessories as indicated on the plans and as herein
specified.
1.2
Submittals
A. The following information shall be included in the submittal for this section:
1. Data sheets and catalog literature for the WebMaster multi I/O industrial water
treatment controller and sensors.
2. Interconnection and dimensional drawings.
3. List of spare parts
Part 2.
Products
2.1
Multi I/O industrial water treatment controller
A. The multi I/O industrial water treatment control system shall be a capable of measuring
system conductivity, makeup conductivity, pH, ORP, chlorine/bromine, chlorine dioxide,
ozone, Peracetic acid, hydrogen peroxide and temperature. The conductivity sensors shall be
either a contacting style or an electrodeless style. All sensors shall have integral signal
conditioning. Additional inputs shall include six standard digital inputs, eight optional 4-20
mA inputs and six optional digital inputs. Outputs shall include eight mechanical relays, and
four optional 4-20 mA outputs. Digital communications shall be via USB, Ethernet, and/or
optional modem. Up to 16 controllers may be networked together over Ethernet. Integration
with DCS, SCADA system or building energy management systems shall be possible using
the optional Modbus TCP/IP feature. The controller shall be accessible via the Internet for
configuring, data logging, and control of relay outputs. The controller shall provide
notification of alarm conditions via relay, pager, and/or email.
B. Control Module:
1. Enclosure: Polycarbonate Resin, NEMA 4X.
2. Power: 100-240 VAC  10%, 50/60 Hz
3. Inputs:
State-Type Digital Inputs
Low Speed Counter-Type Digital Inputs
High Speed Counter-Type Digital Inputs
Sensor
Sensor
STANDARD (1)
OPTIONAL (3)
Electrical: Non-Isolated 5 VDC with 301 K ohm pull-up
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 301 K ohm pull-up, 0-10 Hz, 50 msec minimum width
Devices supported: Any device with isolated open drain, open collector, transistor or reed switch
Support on inputs: Standard inputs A-D, Optional inputs 1-6
Types: Contacting flowmeter, Feed verification, Generic counter
Electrical: Non-Isolated 5 VDC with 301 K 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
Support 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
Signal (isolated)
±1.5V
±1.5V
Temp (isolated)
1K or 10K or 100K ohm
1K or 10K or 100K ohm
4. Outputs:
STANDARD
Mechanical relays
Digital
At 115 VAC, 10 amp (resistive), 1/8 HP
At 230 VAC, 6 amp (resistive), 1/8 HP
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 instruction manual Figure 4. Powered relays have both NO and NC terminals available. Only
powered relays are fused.
USB, Ethernet, 10 Base T
OPTIONAL
4-20 mA( 1-4)
Isolated, 500 ohm max. resistive load, internally powered
5. Software features:
Any relay may be reconfigured to any one of a number of control algorithms,
responding to the signal from any applicable input. Control algorithms available
include On/Off Set Point, Time Proportional, Flow based Control, Activate With
Another, Activate After Another Relay (%), Activate After Another Relay (Fixed
Time), Activate as % Time, Timer, Activate on a DI, Flow Volume based on 2nd
Flow Volume, Pulse Proportional Control, PID, Probe Wash, Counter Based
Control, In/Out of Range, and Alarm.
A self test shall be available to verify the integrity of the control module’s sensor
input circuitry.
A reminder for sensor calibration shall be available.
The controller shall display an evaluation of the pH sensor’s slope versus
theoretical after each two point calibration.
Manual activation of the relays shall be easily accomplished via the keypad, or a
PC.
A maximum output on-time shall be available on the control relays to prevent
runaway control.
The optional analog inputs shall be configurable for level sensors, corrosion
monitors, or any other type of transmitter, providing appropriate units of measure
and scaling.
The digital inputs shall be configurable for contacting watermeter, paddlewheel
flowmeter, level switch, chemical feed verification switch, interlock, counter, or
generic switch operation.
Status reports and data files shall be sent automatically via email on an
adjustable schedule.
The controller set points may be entered by downloading them from one
controller, and uploading them into another controller.
Access to the controller shall be possible using an USB connection, Ethernet,
direct modem-to-modem, via the Internet, or via the local display and keypad,
simultaneously if desired.
No proprietary software shall be required on the user’s computer to communicate
with the controller, or to view or change set points.
The controller software shall be able to be upgraded remotely via the Internet.
C. Sensors:
Contacting Conductivity
1. Operating principle: The conductivity sensor shall be driven with a low voltage AC
signal, and the return signal voltage will vary with the conductivity of the
intervening solution. The temperature sensor within this sensor compensates for the
effect of temperature on the conductivity signal.
2. Materials of construction: Glass-Filled Polypropylene, Graphite, FKM
3. Process connections: ¾” NPTF
4. Temperature range: 32-158 F, 0-70 C
5. Pressure range: 0-150 psi
6. Other materials and higher pressure sensors shall be made available.
Electrodeless Conductivity
1. Operating principle: The conductivity sensor shall be driven with a low voltage AC
signal, which induces a current in the surrounding liquid which varies in intensity
with the conductivity of the liquid, which is picked up by the sensor and transmitted
to the controller. The temperature sensor within this sensor compensates for the
effect of temperature on the conductivity signal.
2. Materials of construction: CPVC, FKM
3. Process connections: ¾” NPTF
4. Temperature range: 32-158 F, 0-70 C
5. Pressure range: 0-150 psi
pH
1. Operating principle: The pH sensor shall consist of a replaceable cartridge
containing a pH sensitive glass and silver/silver chloride reference. Voltage signals
from these shall be measured against the solution ground, and the differential voltage
measurement sent to the control module. The temperature signal from the
conductivity sensor shall be used to compensate the pH reading as well.
2. Materials of construction: Glass-Filled Polypropylene, CPVC, HDPE, FKM, Glass
3. Process connections: ¾” NPTF
4. Temperature range: 50-158 F, 10-70 C
5. Pressure range: 0-100 psi
6. Other materials and higher pressure sensors shall be made available.
ORP
1. Operating principle: The ORP sensor shall consist of a replaceable cartridge
containing a platinum electrode and silver/silver chloride reference. Voltage signals
from these shall be measured against the solution ground, and the differential voltage
measurement sent to the control module.
2. Materials of construction: Glass-Filled Polypropylene, CPVC, HDPE, FKM, Glass,
and Platinum.
3. Process connections: ¾” NPTF
4. Temperature range: 32-158 F, 0-70 C
5. Pressure range: 0-100 psi
6. Other materials and higher pressure sensors shall be made available.
DISINFECTION
1. Operating principle:
The oxidizer molecules diffuse through the membrane and in the acidic
environment of the electrolyte fill solution, a redox reaction occurs at the
electrodes in the sensor. The current generated by this reaction is converted to a
robust voltage signal that is linear with the concentration of the oxidizer.
2. Materials of construction: PVC, Polycarbonate, Silicone rubber, Stainless Steel
3. Process connections: ¼” NPTF inlet, ¾” NPTF outlet
4. Temperature range:
Chlorine Dioxide, Peracetic Acid, and Ozone: 0 - 50°C (32 - 122°F)
Chlorine/Bromine, Hydrogen Peroxide: 0 - 45°C (32 - 113°F)
5. Pressure range: 0 - 14.7 psi (0 - 1 atm)
D.
Controller and Sensor Performance
1. Range: 0 to 10,000 S/cm conductivity, -2 to 16 pH, -1000 to 1000 mV ORP
2. Accuracy:  1 S/cm conductivity,  0.01 pH,  1 mV ORP
3. Resolution: 1 S/cm conductivity, 0.01 pH, 1 mV ORP
4. Maximum separation between controller and sensor shall be 1000 feet for
Disinfection, pH and ORP, 250 feet for conductivity.
E. Indication
1. Graphic User Interface
A 64 x 128 Pixel Backlit LCD Graphics Module display shall indicate the
process values, and the status of outputs and alarms.
Eight LED lamps shall indicate the on/off status of the control outputs.
F.
Part 3.
Equipment
The multi I/O industrial water treatment controller shall be a Walchem WebMaster
WIND8 series.
Operator Functions
3.1
Calibration
A. The contacting conductivity electrode calibration shall be a one point process
calibration.
B. The electrodeless conductivity sensor calibration shall be a two point calibration (in
air and at the process value), or a one point process calibration.
C. The disinfection sensor calibration shall be a two point calibration (in air and at the
process value), or a one point process calibration.
D. The pH electrode calibration shall be either a one or two point calibration utilizing
standard pH buffer solutions or a single point process calibration.
E. The ORP electrode calibration shall be either a one or two point calibration utilizing
standard solutions or a single point process calibration.
F.
All set points shall be set through the 12 button keypad, or via a PC connected
either locally via USB or Ethernet, or remotely via modem or Ethernet.
G. Three levels of access codes shall be available to protect all set points and
calibrations, while allowing the user to view any set point.
Part 4.
Execution
4.1
Installation
A. The sensors shall be installed in a location where they will always remain immersed
in the sample.
B. The sensors shall be installed in a location where there is good solution movement
and where they will respond rapidly to changes
C. The sensor cables shall be routed such that they are separated from any AC voltage
by at least 6 inches.
D. If the sensor cable needs to be extended beyond the standard length, then 24 AWG,
3 twisted pair, shielded cable shall be utilized.
E. If the optional 4 – 20 mA outputs, inputs, or digital inputs are installed, then 22-26
AWG, twisted pair, shielded cable shall be utilized.
Part 5.
Warranty
5.1
Terms
A. The manufacturer of the above specified equipment shall guarantee 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
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 the manufacturer and for the purposes disclosed in writing at the time of
purchase, if any.
B.
Part 6.
In the event a component fails to perform as specified and having been returned to the
manufacturer transportation charges prepaid, and is proven defective in service during the
warranty period, the manufacturer shall repair or replace the defective part. Replaceable
elastomeric parts and glass components are expendable and are not covered by any
warranty.
Options
6.1
Part 7.
Related Equipment
A.
Level switch for chemical level monitoring
B.
Metering pumps for chemical control
Spare Parts
7.1
Recommended Spare Parts
A.
102833 Fuse, F1, 1.6 amp
B.
102834 Fuse, F2 and F3, 6.3 amp
C.
WEL-PHF-NN Electrode, pH
D.
WEL-MVR-NN Electrode, ORP, rod style
Dimensions
10.54
A
3.79
3.20
2x 2.40
ø .50 thru
C
L
2x
.80
12.54
10x ø1.63
10x ø1.05
4x 1.11
4.10
6x 1.60
4x 10-32
threaded insert
marked A
8.00
A
A
Note: Many of the inputs and outputs listed are optional
and may not be present in your controller.
Prewired Option
Hardwired Options
Bottom View
Strain relief
Misc. Inputs/
Outputs
Strain relief
installed with
digital card option
Sensor Inputs installed with
(up to 4) analog card option
Analog Inputs
Sensor Inputs
(up to 4)
Digital Inputs
Digital Input A
Digital Input B
R4
Didgital Input C
AC Power
R7
(Recommended)
R5
R6
R8
(Recommended)
Bottom View
R1
R2
R3
(Recommended)
R4
AC power
R7
Strain relief
installed with
analog card option
Strain relief
installed with
digital card option
Analog Inputs
Digital Inputs
R1
R2
R3
Digital Input A
Digital Input B
Digital Input C
Conduit/Wiring Configuration
Misc. Inputs/
Outputs
R5
R6
R8
Voltage
Code
0 or 4
1 or 6
2 or 5
3 or 7
E or G
F or H
R1
R2
R3
R4
R5
R6
R7
R8
DRY
POWERED
POWERED
DRY
POWERED
DRY
DRY
POWERED
POWERED
POWERED
POWERED
DRY
DRY
POWERED
POWERED
DRY
PULSE
PULSE
DRY
POWERED
POWERED
POWERED
PULSE
PULSE
DRY
POWERED
POWERED
DRY
POWERED
DRY
DRY
POWERED
POWERED
POWERED
POWERED
DRY
DRY
POWERED
POWERED
DRY
PULSE
PULSE
DRY
DRY
POWERED
POWERED
PULSE
PULSE
SEE
DETAIL “A”
GROUND
STUD
NEU HOT
NEUTRAL
RELAY8 RELAY7 RELAY6 RELAY5 RELAY4 RELAY3 RELAY2 RELAY1
NC NO NC NO NC NO NC NO NC NO NC NO NC NO
BLK
IF USING
A MOTORIZED
BALL VALVE
WHT
NEU
BLK
BLK
WHT
HOT
GND
GRN
WHT
TO GND
STUD
BLK
GRN
SOLENOID OR
MOTORIZED
BALL VALVE
TO GND
STUD
GRN
METERING
PUMP
SEPARATE
NUT
AC POWER
INPUT
OTHER EARTH
CONNECTIONS
PC
BOARD
PRIMARY EARTH
CONNECTION
BRACKET
DETAIL “A”
Wiring Diagram for AC Power Input and Relay Outputs
DIGITAL INPUTS
SEE DETAIL 'A'
t-
SENSOR DETAIL "C"
BLU
WHT/BLU
t-
WHT/GRN
T-
GRN
WHT/ORN
T+
ORN
BLU
IN+
IN-
IN+
+5
DIGITAL
INPUT A
IN+
DIGITAL
IN- INPUT B
IN+ DIGITAL
IN- INPUT C
IN-
-5
WHT/BLU
ORN
Shield
(Drain wire)
to GND
stud on
front
panel
* Either an unpowered or a powered device may be
connected to each digital input, one device per input.
SIGNAL -
GRN
WHT/ORN
SENSOR 1**
SEE DETAIL 'C'
SIGNAL +
T- T+ IN- IN+ +5 -5
WHT/GRN
t+ IN- IN++5V -5V
t+ IN- IN++5V -5V
SENSOR 2 or 4
(Observe markings
on circuit board)
SEE DETAIL 'C'
SENSOR 3
SEE DETAIL 'C'
Sensor 1
Terminal
Block
** Please note: Sensor 1 terminal
block is oriented OPPOSITE of
sensors 2-4.
t-
t-
t+ IN- IN++5V -5V
102839
REV 2
t-
102839
REV 2
102839
REV 2
t+ IN- IN++5V -5V
SENSOR 4 or 2
(Observe markings
on circuit board)
SEE DETAIL 'C'
t+ IN- IN+ +5V -5V
B1
IN+ DIGITAL
IN- INPUT D
-T -T +T +T -
SHIELD
WH
GR
N
-S +S -5 +5
BL
K
IN+ DIGITAL
IN- INPUT F
ED
R
TO GND STUD
T
+
IN+ DIGITAL
IN- INPUT E
High Pressure
Conductivity
Electrode
Low Pressure
pH/ORP OR
CONDUCTIVITY
SENSOR
12V
OR
12V
WHT/GRN
SHIELD
(TO GROUND
STUD)
GRN
WHT/ORN
POWERED
DEVICES
ORN
BLU
WHT/BLU
OR*
HALL EFFECT
WATERMETER
OR
PADDLEWHEEL
GROUND/SHIELD
UNPOWERED
DEVICES
RELAY, REED SWITCH
WATERMETER-CONTACTOR
DETAIL "A"
T- T+ IN- IN+ +5 -5
TC+ TC- TC +5V -5V COM VpH
GND
RED
BLACK
WHT
TO GROUND STUD
INSIDE ENCLOSURE
GRN
TO GND STUD
TC
TC+ TC- GND
GROUND
PREAMPLIFIER
High Pressure
pH/ORP Sensor
OPTIONAL TEMPERATURE
COMPENSATION (pH ONLY)
SENSOR
DETAIL "C"
Wiring Diagram for Sensor Inputs and Digital Inputs A-F
SHIELD
DISINFECTION
SENSOR
Wiring Diagram for Optional Digital Inputs, 4-20 mA Inputs and 4-20 mA Outputs
WebMaster Controllers
in Network
Wiring Diagram for Optional Digital Communications