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Wizard Manual

WIZARD MANUAL

SLOAN LUBRICATION SYSTEMS

www.SloanLubrication.com | 1.800.722.0250

ContentsOverview 2

Front Panel 2

Rear Panel 3

Specifications 3

Quick Start 4

Installation 6

Programming 7

Status Displays 8

Main Menu 9

Main Settings 10

Zone Settings 12

Diagnostics 15

Network Settings 17

Modbus Settings 18

Modbus Memory Map 19

Web Based Remote HMI 21

Menu Map 22

Operation 24

TDS (Total Display Switch) 25

Usage Examples 26

Troubleshooting 30

Data Logging 34

Software Updates 36

Contact Information 37

SLOAN LUBRICATION SYSTEMS2

Wizard Manual | Overview

OverviewThe Wizard monitor is designed to provide constant monitoring of your lubrication system, thereby protecting the critical lubricated equipment. It gives operators an easy to see and understand indication of the current system status and flow rate. The Wizard can monitor up to 4 zones of lubrication and provides an independent alarm circuit for each zone.

In each zone, an input from a divider block proximity switch or other

metering device, combined with the known displacement per cycle of

that input, allows for calculation of the flow rate and

ensures that the flow rate stays above a set point. If the flow rate

drops, an alarm relay changes state and, depending on how the zone

is configured, either stays there until it is manually reset or resets

automatically once normal flow resumes.

New features in the Wizard monitor include a 3.5” color LCD

touchscreen, easy setup menus, color status LEDs, and data logging

capabilities. The software in the Wizard is upgradeable in the field

through the USB port. Updates occasionally will be available on

our website.

Front PanelThe Front panel of the Wizard contains the LCD screen, the status LEDs, a USB connection, and 8 buttons.

Each of the 8 buttons corresponds to a button or location on the

screen. If there is an “A” label on the screen, press the A button to

select that option. The operator can also touch the screen itself to

select the same option. This allows an operator to use the basic

functions of the monitor without getting the screen dirty. Some menu

items are only accessible by touching the screen itself; thus they do

not have a corresponding number or letter label. Details for each

menu item and screen are located in the “Programming” section later

in this manual. Examples of common usage scenarios are located in

the “Operation” section.Front Panel

www.SloanLubrication.com | 1.800.722.0250 3

SpecificationsPower supply 90-264 VAC, 47-63 Hz / 12-48VDC 15W Max

Inputs

4 - Zone Proximity switches (low voltage

dry contact)

1 – TDS (low voltage dry contact)

1 – Arm/Disarm Circuit (low voltage dry

contact)

2 - 4-20mA Analog

Outputs

4 - Zone Alarm Relays 250V Max

5A(NO)/3A(NC)

1 - Power Fail Relay 250V Max

5A(NO)/3A(NC)

1 – 4-20mA Analog (future)

Communication

1 - RS485 Modbus Slave

1 – 10/100 Ethernet

Storage

Onboard 256MB – minimum 2 years of

logging @ 1 entry / minute.

External USB – CSV file format

Rear PanelThe rear panel of the Wizard contains all of the electrical connections as shown below. At a minimum, the Wizard needs power and a single zone input to function properly.

Power can be supplied as either AC or DC. See the specifications for

acceptable voltage ranges. The zone inputs are dry contact type

connection either relay contacts or magnetic reed switches to these

inputs will make them function properly. Do not apply external

voltage to the arm/disarm, TDS, or zone input contacts, as this may

damage the Wizard. The TDS input is used temporarily to display

the total flow for each active zone as well as reset any alarms. The

arm/disarm input is used to remotely arm or disarm the alarm

function of the monitor. Each input is explained in more depth in

the “Operation” section

Rear Panel


Wizard Manual | Quick Start

STEP 2. PROGRAM ZONESMinimum settings required for operation

· Divider block displacement

· Low flow setpoint

· Warning to alarm value (0 to disable warning)Zone Inputs

DC Power

AC Power

Alarm Outputs

Quick StartSTEP 1. WIRE POWER, INPUTS, AND OUTPUTSAt minimum:


STEP 3. ENABLE ZONESTouch the square button to enable or disable a zone.

The corresponding LED will light, indicating the zone

is enabled.

STEP 4. TEST ALARMS

• Disconnect / disable prox switch

• Observe warning, then alarm

• Check shutdown circuit

-OR-

• While running, set low flow to high value

• Ensure automatic shutdown occurs


Wizard Manual | Installation

InstallationThe Wizard mounts in either a JIC style enclosure or a hazardous

location enclosure with at least a 5-3/8” diameter opening. If

providing your own enclosure, please ensure that the Wizard

monitor will be protected from excessive moisture and dust.

To install, remove all electrical plugs that will be used from the rear

panel. Make sure the power supply is turned off and install each

supplied plug onto the wires.

For the screw connectors, strip the insulation from the end of each

wire, insert the wire into the connector, and tighten the screw. Make

sure there are no stray wire strands that can make an inadvertent

connection to another wire.

After all electrical connections are made, connect the plugs to the

back of the monitor and mount the monitor in the enclosure. The

Wizard is secured by two 10-32 thumb screws. It is not necessary

to make these screws extremely tight, but they should be snug.

Test the power to make sure that the connections were made

properly and, if possible, test each input.

CAUTIONTesting the relay output and shutdown functionality with the control system is imperative before putting a Wizard into service.

If assistance is needed with this procedure, look to our electrical

controls department or contact Sloan.

A Wizard installed in a JIC enclosure is shown above.


ProgrammingSeveral pieces of information are necessary to program the Wizard

monitor. First, know the displacement of the divider block or

metering device. The displacement tells the wizard how much fluid

has been delivered for each cycle of the block.

For a divider block that is measured in cubic inches (in3), the

displacement is calculated by taking the displacement values

of each divider section, adding those numbers together and

doubling the result. Divider block face values are usually written in

thousandths of a cubic inch (in3). For example, a 12T, 6T, 9T block

would have a displacement of (0.012 + 0.006 + 0.009) * 2 = 0.054in3.

The next piece of information needed is the desired flow rate. For

most applications, we recommend using half of that flow rate as

the alarm limit. So, if the desired flow rate is 20 pints / day, the low

flow setpoint should be set to 10 pints / day. When the monitored

flow rate drops below this value, an alarm will be triggered.

To get started, the screen to right is the screen that will be

displayed when the monitor first starts up. The top status bar

indicates that the Wizard is armed and in regular operation, and

the current flow rate for each zone is displayed. If the bar says TDS,

the large number is the accumulated volume since last reset. If the

bar is red and reads “Control Disarmed”, the Wizard is disarmed and

the alarm relays will not trip.

Flow information is displayed in the middle section of the screen.

When only one zone is enabled, the display defaults to the detailed

screen shown to the right. When multiple zones are enabled, only

the flow rate is displayed for each zone. The large number on the

left is the flow rate, the description of the zone is to the right, and

the selected display unit is below that. The flow rate value will

change color corresponding with that zone’s current status.

Pressing either the 1 or 2 button or touching the “Menu”

button on the main status display screen will return the screen

to the main menu.

One cycle is defined by the time it takes for the switch to close, open, and then close again. This is also known as the time between rising edges of the input signal.

An example of the status screen for Zone 1 when it is the only active zone.


Wizard Manual | Programming

Active Zones

Each active zone flow rate is displayed in a color corresponding to its

status. The zone description and selected units are also displayed.

If only one zone is active, only the detail screens shown below will be

visible.

Zone Alarm

When a zone is in alarm, its color flashes to make the alarm

more visible.

Zone Warning

When a zone is in warning, its flow rate display will change color to

yellow.

Reset All

“Reset All” resets all zones and clears any alarms or warnings.

Individual zones can be reset on their breakdown screens.

Zone Detail

Touch a zone flow rate display or press the corresponding button

to the right of the screen to see more detail.

Status Displays


Main MenuMain Settings

Main Settings leads to the settings screen for the entire monitor.

Settings that affect the behavior of the monitor can be changed here.

Zone Settings

Zone Settings are where each zone is set up. This is where the

displacement and alarm data are entered.

Disarm

Disarm manually disarms the monitor. This prevents alarms from

happening while settings are changed.

While disarmed, the flow rate display and LEDs will function as

normal, but the alarm relays will not change state. When the monitor

is re-armed, all Zones reset to normal operation and alarms or

warnings are cleared.

Export Log

Export Log manually writes the internal flash log files to the USB

drive. This button is only active when a drive is inserted and “log files

direct to USB” is not enabled in the main settings.

Done

Done returns to the main status display

screen.

Next

Next advances the screen to the next page

of menu options.

Diagnostics

The Diagnostics menu is where you can calibrate the screen, erase the

flash memory logs, and see the software version number.

Set Date/Time

Set Date/Time is where the system date and time are set. To make

the log files accurate, ensure this is set correctly. Date and time are

preserved without power to the monitor.

Touch each number to change the system date and time. Time is

entered in a 24 hour format.



Status Interval

Status Interval determines the rate at which the Monitor records

the current status of each zone to memory. 1 log entry per minute

generates ~200kB of data / day.

Disarm Max

Disarm Max indicates how long the disarm button will prevent an

alarm. The monitor starts in disarm mode, therefore this is also the

minimum amount of time an alarm can occur after power-up.

Startup Reset Cyc

Startup Reset Cyc sets how many cycles a warning will auto reset

upon startup or re-arm. This prevents startup glitches such as air in

the system or motors speeding up from displaying persistent

warnings. If the zone goes into alarm during this time, the alarm will

remain. This setting will only clear a zone in warning.

Log Split

Log Split determines the interval at which log new log files

are made.

TDS Also Resets Alarm

TDS Also Resets Alarm allows alarms to be reset with an external

switch. This is useful when the monitor is in a hazardous location and

the front panel cannot be accessed. To reset an alarm with the TDS

switch, hold the switch closed for at least 5 seconds.

Next

See next page.

Log Files Direct To USB

Log Files Direct to USB will write the log files directly to an attached

USB drive continuously as well as writing the logs to internal flash.

This prevents having to use the “export log” option on the main

menu and wait while log files are being written. The USB drive can

be removed at any time, but the log files will be written immediately

after the drive is reinserted.

Allow Remote Disarm

Allow Remote Disarm enables the remote

arm/disarm input on the back of the

monitor. These allow an external control

panel or switch to control the ability for the

Wizard to trip its alarm relays. If the monitor

is watching a system that frequently stops

and starts, this setting can be very useful to

prevent alarms when the equipment stops.

See page 23 for more information.

Main Settings


Unit Number and Unit Description

Unit Number and Unit Description are freeform text entry fields. The

information entered here is included with each log file and can be

useful to help identify where a log file originated.

Displacement Unit

Displacement Unit determines what units the displacement values in

the zone setup screens are in. This setting affects all zones. In most

divider block applications, this setting will be in3, but some

flow meter applications may require cm3.



Check Boxes

Check boxes enable and disable each zone. When a zone is disabled,

all functionality is disabled. No flow rate will be displayed and alarm

relays will not change state.

If any settings are changed, each zone can be turned on or off

independently. Zones do not have to be enabled in any particular

order. For example, zones 2 and 4 may be enabled while 1 and 3

are disabled.

The text color next to each zone also represents that zone’s current

status.

See next page for details.

NOTEWhen setting up a zone, double check the values to make sure they are

correct. If a zone will not activate, the settings are likely in error somewhere.

Zone Configuration

The zone configuration data is entered here. This includes

displacement, alarm set point, description, and warning time.

If any data are changed while the unit is in operation, a reset is

performed on that zone when the settings are saved. This prevents

the monitor from immediately going into alarm if the low flow set

point is adjusted.

Zone Settings


Displacement

Displacement is the corresponding displacement of the divider block

or metering device that is connected to this zone input.

Low Flow Setpoint

Low Flow Setpoint is the flow rate below which warnings and alarms

will occur. This set point is selectable in many different units.

Volume Options

Volume options are pints, cm3, in3, gallons, and liters. Time options

available are seconds, minutes, hours, and days.

Zone Description

The Zone Description is a text label that is displayed on the main

screen. Maximum length is 9 characters.

Cancel

Cancel abandons any changes and returns to the main zone setup

screen.

Save

Save saves any changes and returns to the main zone setup screen.

Next

Push Next to see more options.

NOTEWhen editing values, use the backspace button on the screen

to clear the existing values before entering the new one.



Zone Warning to Alarm

Zone Warning to Alarm is the number of cycles at the low flow

set point between warning and alarm. This is a buffer time in which

the monitor is in warning but has not sounded an alarm yet. The

time to which this setting is equivalent is displayed below the

number of cycles.

Zone Warning Reset

Zone Warning Reset is the number of cycles that must be seen ABOVE

the low flow set point while in alarm before automatically returning to

normal status. When a warning has happened, the status LED for that

zone stays lit yellow to notify an operator that a warning has occurred.

This does not apply on startup or after being armed for the number of

cycles defined by Startup Reset Cyc in the main settings.

Auto Zone Alarm Reset

Auto Zone Alarm Reset lets a zone return to normal operation after

the number of cycles specified by the Zone Warning Reset at a

measured rate higher than the Low Flow Setpoint.

Display Last 10 Avg

Display Last 10 Avg changes the zone display to show the moving

average flow rate of the last 10 cycles. This can be useful on systems

where the flow rate fluctuates.


Calibrate Screens

Calibrate Screen runs through a calibration routine for the touch

screen. This can be useful if the on-screen buttons are not working as

expected.

Update Software

Update Software is used to update the firmware of Wizard. See the

software update section of this document for more information.

Restart Unit

Restart Unit reboots the Wizard.

Clear Flash Logs

This function clears the on-board log file memory. It does not erase

the USB drive, so any logs already transferred to USB are saved.

CAUTION Rebooting the Wizard during operation may shut down equipment.

Diagnostics



Load/Export

Load USB Settings loads a settings file from the USB drive. The file

must be renamed to sbcoSet.dat before the Wizard will load settings

from a file. Export settings saves the current Wizard settings to the

attached USB drive. This may be useful for copying settings from one

Wizard to other units. Contact Sloan for further information about

the settings file structure.

USB Status

This button indicates the status of the USB flash drive.

Current Software

The current software versions are useful when diagnosing a

problem. Have these numbers on-hand when contacting Sloan for

troubleshooting or techanical support.

Final Diagnostics Page

The final diagnostics page displays current network information.

Resetting the network connection will reconnect and re-obtain

DHCP information if enabled.


DHCP

When DHCP is enabled, the Wizard will attempt to automatically

obtain an IP address from a DHCP server on the network.

Manual Settings

Manual settings can be changed if DHCP is disabled.

When enabled, the current DHCP values (along with the units MAC

address) can be seen in the Diagnostics menu.

Remote Access

Pointing a web browser to the Wizard’s IP address will bring up a

remote interface for the unit. These are the username and password

to access the Web UI. It is recommended to change these to a site-

specific and secure value.

Disable the Web HMI to prevent remote access via web

browser entirely.

See page 21 for

more information.

Network Settings


Wizard Monitor

The Wizard monitor supports Modbus communication via Modbus

RTU (RS485) or TCP/IP. Select the appropriate option.

RTU

When using RTU, select the proper settings for RS485 here. Slave ID is

the slave address at which the Wizard will respond to requests.

See the following page for Modbus Memory mapping information.

Modbus TCP

When using Modbus TCP, the port is changed here. Default port for

Modbus TCP is 502.

Troubleshooting

If having trouble interfacing with the Wizard where numbers are

not translating properly, the Byte order can be changed. This is also

known as endianness. Modbus Byte order is Big Endian by default,

but this may assist in interfacing with nonstandard equipment

or software.


Modbus Settings


Modbus Memory Map

MSW Most Significant Word

LSW Least Significant Word

RO Read Only

WO Write Only

RW Read/Write

Street Address 1000

Number of Coils 10Address 1000

Number of Coils 4

Address Description

1000 Zone 1 Input State




Address Description Access Rights1000 Zone 1 Relay State RO

1001 Zone 2 Relay State RO



1004 Power Relay State RO

1005 Armed RW

1006 Zone 1 Reset WO




Coils (Modbus Function 1) Discrete Inputs (Modbus Function 2)

Definitions


Modbus Memory Map


ValueFractionExponentValue Value

See this page for a more thorough description and explanation of special values (0, NaN, etc.):http://steve.hollasch.net/cgindex/coding/ieeefloat.html

Bit 31 Bit 30-23 Bits 22-00 10000010 10001011000011100000000

Sign Exponent Fraction

EEE 754 32-bit Floating Point Example:MSWLSWValueBias

= 0x4145= 0x8794= 0x41458794= 127

= 2Exponent * (1+Fraction)= [(Bit22 * 2-1) + (Bit21 * 2-2) + (Bit20 * 2-3) +…..+ (Bit0 * 2-23)]= Exponent - Bias = 130 - 127 = 3= 23 * (1.543200016021728515625)= 12.34560013

Address 1000

Number of Registers 36

Value Meaning

0 Zone Off

1 Zone Ok

2 Zone In Warning

3 Zone In Alarm

Input Registers

(Modbus Function 4)

Zone Status Key

Address Description Format Num Registers1000 Zone 1 flowrate FLOAT (IEEE 754 32-bit) 2

1001 (part of above value)

1002 Zone 2 flowrate FLOAT (IEEE 754 32-bit) 2

1003 (.. remainder removed)



1008 Zone 1 Total Flow FLOAT (IEEE 754 32-bit) 2




1016 Zone 1 Low Point FLOAT (IEEE 754 32-bit) 2




1024 Zone 1 Displacement FLOAT (IEEE 754 32-bit) 2




1032 Zone 1 Status Decimal 1




Binary

Function


The Wizard monitor includes a built in web server for remote

access. To access the web HMI, point a web browser to the IP

address of the Wizard. To gain access, a user needs to enter

the username and password specified in the Network Settings

menu on the unit.

In the web HMI, status of various zones can be accessedas

well as some settings. Crucial settings such as zone

displacement and low flow set point can only be entered via

the front panel of the Wizard itself.

The pages are laid out in a similar fashion to the screens on

the unit itself, so refer to the previous sections of this manual

for explanation.

NOTE:

Be certain to set a site-specific password for the web access

functionality. If it will not be used, Sloan recommends that

the feature be disabled via the front panel to limit potential

security risk.

Web Based Remote HMI


Wizard Manual | Menu Map

Menu Map


Wizard Manual | Operation

During normal operation, the primary status display is shown. The

status of each zone is reflected in the color of the flow rate number

as well as the LED color above the display. The LEDs will also flash

blue to indicate that the attached proximity switches are functioning.

If a zone is disabled, the LED for that zone is also disabled.

If the flow rate for a zone falls below the programmed set point, the

zone enters warning. From there, if the flow rate continues to fall

below that set point for the number of cycles in the Zone Warning to

Alarm setting, the zone will go into alarm and the alarm relay will trip.

If the flow rate climbs back above the set point and Auto Zone Alarm

Reset is enabled for that zone, it will go back into warning mode and

then back into normal mode.

When a warning has occurred on a zone, but normal operation

continued, the LED for that zone will remain yellow to notify the

operator that a warning had occurred. The date and time of the last

warning for a zone can be seen on the second Zone Breakdown

screen. The exception to this rule is during start-up when a value

is entered into the Startup Reset Cyc setting. In this case, the LED

will return to green if a warning is encountered during the specified

number of cycles. This can be useful on larger systems or where it

may take some time for the system to stabilize. Alarms will still occur

during this time, so the lubricated equipment is still protected.

The power failure relay also can be used in series with any of the

other relays or separately to indicate a failure of power to the

monitor. The relay energizes when power is applied to the Wizard

and will de-energize when power is removed.

Zone Status LEDs indicating a failure on zone 2. Zones 1 and 3 are normal. Zone 4 is disabled.

Zone Status LEDs indicating a single enabled zone in warning.

Operation


In most installations, the Wizard monitor is mounted in an enclosure with a switch on the side, typically labeled TDS (Total Display Switch).

This switch is wired to the TDS contacts on the back of the wizard and

performs several functions. It allows an operator to see the total flow on a

zone since the last TDS reset was performed as well as reset warnings and

alarms. This functionality is particularly useful in hazardous locations where

the enclosure cannot be opened during normal day-to-day activities. In this

case, the switch is probably an aluminum plug with a magnet hanging nearby.

Touching the plug with the magnet activates the switch.

TDS operations are as follows:

• Touch (<5 seconds) to change between flow rate and total displays.

• Hold (>5 seconds and <10 seconds) to reset alarms on all zones. (This only applies if the TDS Also Resets Alarms check box is checked.)

• Hold (>10 seconds) to reset the total value.

TDS (Total Display Switch)



Example #1 – Simple Or Legacy Style Connections

In this example, the Wizard is monitoring the flow rates on a GMVA-8-3 integral engine/

compressr with 8 power cylinders and 4 compressor cylinders. There are 2 lubrication zones,

1 to the compressor cylinders at 4.5 pints / day and 1 to the power cylinders at 24.0 pints / day.

System layout is as shown.

8 RPM Input

Lubricator Box

Supply Shutoff & C/V

CrankcaseSupply

Inlet Filter Assembly

CompressorGauge

PowerGauge

CompressorPrimary

PowerPrimary

CompressorSecondary x3

PowerSecondary x2

Compressor Secondary

Details

0.3 PPD, Cyl.0.3 PPD, Cyl. 6T

6S

3S

0.6 PPD, Pkg.0.3 PPD, Cyl.

Divider Assembly Details:16 feeds to power for 24.0 pints/dayPower primary cycle time is 18.0 seconds.144 cubic inches delivered to secondaries per cycle

12 feeds to compressor for 4.5 pints/dayCompressor primary cycle time is 24.0 seconds.030 cubic inches delivered to secondaries per cycle

8 RPM Input

Lubricator Box


CrankcaseSupply


CompressorGauge

PowerGauge

CompressorPrimary

PowerPrimary


PowerSecondary x2


Details


6S

3S




8 RPM Input

Lubricator Box


CrankcaseSupply


CompressorGauge

PowerGauge

CompressorPrimary

PowerPrimary


PowerSecondary x2


Details


6S

3S




Usage Examples


For this application, the Wizard would be set as follows:

Main settings: Status interval is 5 (for 5 minute log intervals), disarm max is

60, and startup reset cycles is 10 (this unit is air started and takes a while to

get up to speed). The unit number is 2, and “station 21 gmva-8-3” will go in the

description so that the log files can be identified easily.

Zone 1 displacement is 0.030 in^3 and the alarm is set to 2.3 pints/day.

This zone is labeled “comp.”

Zone 2 displacement is 0.072 in^3 and the alarm is set to 12 pints / day.

This zone is labeled “pwr”.

Zones 3 and 4 are disabled.

Wire the Wizard according to the diagram below.

The wizard will have power applied when the compressor starts.

The legacy alarm circuit (normally closed) is wired into the Z1, Z2,

and Power fail relays.



Example #2 – PLC Integrated Installation

In this example, the Wizard is monitoring the flow rates on an Ariel JGC/4 operating

in a refinery gas recycle process. It has two stages with 9.626” and 6.75” cylinders

and 6.5” stoke. It is electrically driven, running @ 1000 RPM. There are two

lubrication zones, one to each stage. Zone 1 is the 1st (LP) stage and requires 3.9

pints/day. Zone 2 is the 2nd (HP) stage and requires 3.0 pints/day. The pumps are

electrically driven and the oil is supplied from a daytank. The Wizard will be integrated

into the skid PLC control system using Modbus TCP/IP.

System layout is as shown.


For this application, the Wizard would be set as follows:

Main settings: Status interval is 1 (for 1 minute log

intervals), disarm max is 60, and startup reset cycles is 5.

The unit number is 1 and “C-301 recycle a” will go in the

description so that the log files can be identified easily.

Zone 1 displacement is 0.036 in^3 and the alarm is set

to 2.5 pints/day. This zone will be labeled “hp cyl”. Zone

warning to alarm is set at 4 cycles, and warning reset

is 2 cycles.

Zone 2 displacement is 0.036 in^3 and the alarm is set

to 2.0 pints / day. We will label this zone “lp cyl”. Zone

warning to alarm is set at 4 cycles, and warning reset

is 2 cycles.

Zones 3 and 4 are disabled.

In Network Settings, the network is set to DHCP as the

plant DHCP server will be assigning IP addresses. The web

HMI is enabled. Modbus is set to TCP with the default port

of 502. Bit format is the default ABCD.

The Wizard is wired according to the diagram to the right.

The Wizard will always have power applied when the

control panel is powered.

The PLC is polling the Wizard at 250ms intervals. If

the wizard does not respond for 5000ms, an operator

notification is sent. If no response after 2 minutes, the

compressor is shut down for communication error. If

a Zone status remains 3 (decimal) for 30 seconds, the

compressor is shut down on “no flow.”

24V DCPower

LP Divider HP Divider Tank Low Level Switch

The PLC is interfacing with the following registers via Modbus TCP/IP:

Function 1 (read coil) Address 1005 (Arm/disarm status)

Function 5 (Write single coil) Addresses 1005 (arm/

disarm set), 1006 (Reset Zone 1), 1007 (Reset Zone 2)

Function 2 (Read inputs) Addresses 1000 (Zone 1 switch),

1001 (Zone 2 switch), 1003 (Zone 4 switch, tank Low level)

Function 4 (Read input registers) Addresses 1000&1001

(Zone 1 flow rate), 1002&1003 (Zone 2 flow rate), 1032

(Zone 1 status), 1033 (Zone 2 status)



Wizard will not power on

Ensure that the power source is connected to the proper input. The Wizard

has connections for both AC and DC power supplies.

If connected, make sure the input voltage and current at the Wizard plug are

within the proper operating range.

Zone input does not appear to be working

Check prox switch wiring. Ensure that external voltage is not applied

to the input.

Double check that the input is functioning by watching a small green LED

on the I/O circuit board directly next to the input plug. This can be useful

for troubleshooting purposes as a lit LED indicates a closed circuit.

Make sure the corresponding zone is enabled (zone status LED on the front

panel will be lit) and has valid settings. Required settings are Displacement

and Low Flow Setpoint.

When a zone registers a cycle from the input, the zone status LED

will flash blue.

Wizard will not display a flow rate

Verify that Wizard is properly registering input cycles (zone status LED is

flashing blue once every cycle).

Manually run pump or cycle prox switch by hand to simulate flow.

Check zone settings to make sure they have correct values. The block

displacement and low flow setpoint must have values.

*

Troubleshooting


Displayed flow rate does not match what I expected

Double check block displacement. Ensure that the displacement units

are correct (either In^3 or Cm^3) for the monitored block in the main

settings screen.

Verify that wiring connections between the prox switch and Wizard are good

and there are no loose wires.

Alarms do not appear to be working as expected

Verify zone settings.

Make sure warning to alarm values are set.

Ensure that unit is not disarmed and that “remote arm/disarm” functionality is

properly selected in the main settings screen.

Double check that the output is functioning by watching a small green LED on

the I/O circuit board directly next to the output relay plug. This can be useful

for troubleshooting purposes as a lit LED indicates an energized relay.

Wizard indicates that it is “disarmed” and will not arm

Verify proper selection of the “remote arm/disarm” functionality in the main

settings sreeen.

Make sure the remote arm/disarm wires are properly connected. Like the

zone inputs, this is a dry contact circuit and should not have external

voltage applied.



Modbus (RS485) is not working

Make sure wiring is correct.

Double check that RTU is selected in the Modbus settings screen.

Double check slave unit number and serial port settings. Port settings must

match all other devices on the network and unit number must be unique.

Start with a single register (like zone 1 input) and verify that it is fully functional

before adding the rest.

Some systems may offset their registers by 1; therefore the PLC register “1000”

may actually be 999, or 1001. Some trial and error may be required to figure

out the offset.

Modbus TCP/IP is not working

Make sure wiring is properly connected. Double check proper termination of

any plugs on the network cable.

Check switch and Wizard plug for link lights. If there are no link lights, there is

a wiring issue.

Double check network settings. If DHCP is being used, double check that

Wizard is receiving a valid IP address.

Make sure TCP is selected on the Modbus settings page and that the proper

port number is entered.

If network settings are correct, try loading the remote HMI site by pointing a

web browser at the Wizards IP address. If that is working, networking is OK

and the issue is specific to Modbus.

Try steps in the next troubleshooting section.


Modbus is working, but the values do not match what is expected

Some systems may offset their registers by 1. So the PLC register “1000” may

actually be 999, or 1001. Some trial and error may be required to figure out

the offset is.

Start with a single register (like zone 1 input) and verify that it is fully functional

before adding the rest.

Remote HMI web server is not working

Try the first 5 steps under “Modbus TCP/IP is not working” first.

Double check that the Remote HMI is enabled in the 3rd page ofNetwork

Settings.

Double check the username and password are correct and match those

entered in the Network Settings screen.

For any other issues, contact Sloan at any time! See contact information on page 37.


Wizard Manual | Data Logging

Data logging on the Wizard is continuous and cannot be disabled. The USB

drive can be removed or inserted at any time except when the screen displays

“Writing files to USB…”

When Log Files Direct to USB is enabled in the main settings menu, the log files

are continuously written and are always up-to-date. A second copy of the logs

is also held in main memory and is updated even while the USB drive is not

attached. Re-inserting the drive or inserting a new blank drive will immediately

re-write all the logs in internal memory. This is the recommended setting as

the USB drive always has the most current copy of the log files. The log files are

also accessible when the monitor does not have power or has been disabled in

some way.

If Log Files Direct to USB is not enabled, logs must be manually written to

the USB drive using the Export Log button in the main menu. Note that if the

Wizard has been in operation for some time with the Status Interval (min) value

set to a low number, the log files may be substantial in size and take a long time

to generate and write to USB. During this time, the lubricated equipment is still

protected, but the Wizard cannot be used for anything else and will not display

current flow data. For this reason alone, we recommend that the log files are

always logged directly to USB as well as stored in main memory.

There are two types of log files written by the Wizard. One begins with an S and

other begins with an E. Both log files are split up by day, with the date of the log

(YYMMDD) as the file name.

The “E” logs record any changes made to the Wizard along with any alarms or

other zone status changes. Each entry has a date and time stamp along with

information as to why the entry was recorded.

Data Logging


The “S” logs are a record of the status of the Wizard Monitor at regular intervals.

This interval is determined by the Status Interval (min) setting. Setting this value

to 1 records a new status entry once a minute and generates approximately

200kB of data per day. Each log entry is a snapshot of the Wizard at that time

and includes the current flow rate, status, and alarm condition of each zone as

well as the status of the alarm relays and temperature of the monitor.

The Wizard Monitor can store at least 2 years of log data internally with the

log interval set to 1 minute. Once the internal memory is full, the monitor will

start to overwrite the oldest data first. This also applies to the USB drive. The

included USB drive should be sufficient to contain 5 years of log data.

In order to keep the time required to write the log files to USB to a

minimum, we recommend that users back up the files from and clear the USB

drive once a year. Also delete the internal flash logs on the Wizard itself at this

time. This function can be found in the Diagnostic menu.


Wizard Manual | Software Updates

Occasionally, Sloan will post software updates to the Wizard Monitor on our

website – www.sbco.com. Each update will include the required files as well as

a list of changes or fixes made by the update. In most cases, the update will

not affect the underlying functionality of the monitor, but will fix minor bugs or

visual glitches.

CAUTIONPrior to performing a software update, ensure that the monitor is not currently protecting any piece of equipment! During the process, the alarm relays will change state.

The following procedure applies to Wizard monitors shipped before 05/01/2015 and with serial numbers below 15-D00001.

NOTE: This update procedure will delete existing data logs from the Wizard.

Back up your current logs if you wish to retain this data.

• Put all update files onto a USB Stick and insert the USB stick into the port

on the Wizard.

• Hold the buttons 1 & 3 & A & C down together until the top row of LEDs

turns green and the screen goes blank. This takes 5 seconds. Release the

buttons and the first update procedure will run. This takes between 30

and 60 seconds.

• Once the monitor has rebooted, go into Menu->Diagnostics->Page 2 and

select “Update Software”

• The complete software update procedure will now run. This

process takes between 90 seconds and 2 minutes.

• Your Monitor is now all up-to-date! From this point forward, the software

on this monitor can be updated using the “Update Software” menu item on

the second diagnostics screen.

Software Updates


Thank you for using the Wizard Monitor! If you have any additional questions, call us at any time at 1-800-722-0250.

After hours, leave a message and someone will be in touch shortly.

We are also available via email at [email protected] or you can contact any

of us personally on our cell phones or via email:

C.J. Sloan

Matt McCarthy

Brian Sloan

Eric Sloan

For Wizard Monitors shipped after 05/01/2015 and with Serial numbers above 15-D00001 OR units that have had a software version starting with 4 Installed, follow the following procedure.

• Put all update files onto a USB stick and insert the USB stick into

the port on the Wizard.

• Navigate to the diagnostics menu and select item b. “Update

Software”.

• Select Yes to perform the update.

412-491-2308 [email protected]




Contact Information

168 Armstrong Drive, Freeport, PA 16229 | 1.800.722.0250 | www.SloanLubrication.com

Wizard Manual

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