Automated Logic's WebCTRL represents a mature, web-based SCADA platform widely deployed in large commercial and institutional buildings. The system integrates distributed controllers (ZN series, ME series) with a central server running WebCTRL workstation software. This reference covers WebCTRL server error messages, controller LED diagnostics, BACnet communication faults, trend database errors, network supervisor (LGR) communication, and controller firmware upload issues. Understanding the relationship between field controllers, the WebCTRL server, and the web client interface is essential for systematic troubleshooting.
WebCTRL server errors are logged to the central server's error log, accessible via Administration Console or the WebCTRL web interface (Administrator login required). Server errors affect all connected clients and may prevent data collection and control operations.
| Error Message | Severity | Root Cause | Field Solution |
|---|---|---|---|
| "Failed to load device driver: ZN-series driver not found" | Critical | WebCTRL installation incomplete or driver package corrupted | Reinstall WebCTRL server software. Verify installation directory contains /drivers folder with ZN driver JAR files. If corrupted, restore from backup or redownload from Automated Logic portal. |
| "Database initialization failed: Cannot connect to PostgreSQL" | Critical | PostgreSQL service not running or corrupted | Check if PostgreSQL service is running (Windows Services). If not running, start service manually. If startup fails, check /logs/postgresql.log for corruption. May require database restore from backup. |
| "Cannot acquire license: License server unreachable" | Critical | Network unreachable to Automated Logic license server (cloud-based for newer versions) | Check internet connectivity from WebCTRL server. If behind proxy, add license server URL to whitelist. Older perpetual licenses may use local key; verify license file present in WebCTRL directory. |
| "Security certificate expired: HTTPS will be disabled" | Warning | SSL certificate for WebCTRL HTTPS past expiration date | Generate new certificate in WebCTRL Administrator Console > Security > Certificate Management. Browsers will show security warning until new cert installed. |
| "Memory heap size insufficient: Increase -Xmx setting" | Warning | Java heap memory too small for database and user load | Shut down WebCTRL. Edit webctrl.conf or JVM startup script, increase -Xmx parameter (e.g., from 2048m to 4096m). Restart WebCTRL. Monitor memory usage for 24 hours. |
| Error | Impact | Cause | Resolution |
|---|---|---|---|
| "Database transaction timeout after 30 seconds" | Read/write operations fail intermittently | Database under heavy load or locked by long-running query | Check number of connected clients in Administrator Console. Consider off-peak maintenance window to rebuild indexes or analyze query performance. May require database tuning or hardware upgrade. |
| "Attempted to write NULL value to non-nullable column" | Data corruption risk; alarm/trend writes fail | Logic error in controller application or driver | Review recent controller configuration changes. Identify which point is causing NULL write. Correct application and reload to controller. May require manual database cleanup. |
| "Database backup failed: Insufficient disk space (2MB remaining)" | Backup incomplete; recovery capability reduced | /backup or /logs partition nearly full | Delete old backup files or archived logs. Allocate more disk space to partition if possible. Establish regular cleanup schedule (e.g., delete backups >30 days old). |
| "Connection pool exhausted: All 50 database connections in use" | New client connections refused; users cannot log in | Too many simultaneous WebCTRL clients or long-running operations | Increase connection pool size in WebCTRL configuration. Ask idle users to log out. Identify any stuck processes in database admin panel. May indicate need for additional server hardware. |
| Error | Symptom | Root Cause | Fix |
|---|---|---|---|
| "Controller [name] offline for 5 minutes" | All points on controller show stale data in WebCTRL client | BACnet/IP communication lost between server and controller | Check controller Ethernet connectivity (ping from server). Verify controller's BACnet/IP port is enabled. Check firewall rules; port 47808 (BACnet) must be allowed. Restart controller if needed. |
| "Authentication failed: Controller [IP] rejected our BACnet Device ID" | Controller appears in discovery but cannot connect | Device ID conflict or controller security settings restrict server | Use Automated Logic tools to change controller Device ID if duplicate exists. Check controller's BACnet security settings (some devices require ID whitelisting). Restart controller. |
| "Network Supervisor (LGR) no longer responding" | All controllers on that segment unreachable; entire building may be offline | Network Supervisor (LGR-based gateway) has lost power or Ethernet | Check LGR power supply and indicator lights. Verify LGR Ethernet connection to network. May need to restart LGR or power-cycle entire segment. |
| "Excessive packet loss: 25% of BACnet frames dropped" | Intermittent point updates; sluggish control response | Network congestion or poor cable quality between server and controllers | Check network switch for errors (use switch port statistics). Test cable with network tester. Consider separating BAS traffic to dedicated VLAN. Reduce polling rate if possible. |
The WebCTRL Network Supervisor (LGR-based device) serves as a BACnet router between the server and field controllers. LGR failures are critical because they can isolate an entire building segment.
| LGR Indicator | Status | Meaning | Action |
|---|---|---|---|
| Power (Green LED) | Solid ON | 24V supply stable | Normal |
| Power | OFF | No power | Check 24V supply, circuit breaker, and terminal connections |
| Network (Blue LED) | Solid ON | Ethernet link established | Normal |
| Network | Flashing (1/sec) | Ethernet traffic active | Normal |
| Network | OFF | No link or disconnected | Check Ethernet cable and switch port |
| Backup (Yellow LED) | OFF (normal) | No redundancy active | Single LGR operation; consider adding second for redundancy |
| Backup | Flashing | Backup LGR is online and synchronized | Good; you have redundancy |
| Status (Red LED) | OFF (normal) | No faults | Normal operation |
| Status | Solid ON | Fault detected | Review LGR logs via WebCTRL server or local serial connection |
| Error Message (from WebCTRL logs) | Cause | Solution |
|---|---|---|
| "LGR: Unable to synchronize with Master LGR" | Two LGRs configured for redundancy but out of sync | Check Ethernet connection between the two LGRs. Manually restart Backup LGR; it should re-synchronize with Primary. If it does not, replace cable or LGR unit. |
| "LGR: BACnet MS/TP segment failure" | LGR has lost communication with controllers on MS/TP bus | Check MS/TP termination resistors (120Ω at each end of backbone). Verify controller power. May indicate bad cable or controller failure on that segment. |
| "LGR: Memory exhaustion - too many stored alarms" | LGR local buffer is full of unacked alarms | Clear acknowledged alarms from WebCTRL server or via LGR admin interface. Increase alarm buffer size if persistently full. Reduce number of network-wide alarms. |
| "LGR: Configuration mismatch with server" | LGR and WebCTRL server have conflicting device IDs or BACnet object lists | Reload LGR configuration from WebCTRL server (Administration > Network > LGR Setup > Synchronize). Or manually reconfigure LGR via serial terminal. |
Automated Logic ZN and ME series controllers use multi-colored LED indicators to convey operational state. Each controller model may have slightly different LED layouts, but the meaning of colors and patterns is consistent.
| LED | Color | State | Meaning | Action |
|---|---|---|---|---|
| Power | Green | Solid | 24V supply present and stable | Normal |
| Power | Green | Flashing (1/sec) | Low battery (uninterruptible power backup, if installed) | Backup battery depleting; will run out in hours. Restore main power immediately. |
| Power | Red/Off | OFF | No 24V power | Check transformer, breaker, and terminal connections. Measure 24V with multimeter. |
| LAN (Network) | Green | Solid | Ethernet connected | Normal |
| LAN | Green | Flashing | Active BACnet/IP traffic | Normal; especially during polling cycles |
| LAN | Red/Off | OFF | No Ethernet link | Check cable and switch port. Test with known-good cable. |
| BMS (WAN link to server) | Green | Solid | Connected to WebCTRL server | Normal |
| BMS | Green | Flashing | Syncing data with server (trend upload, config download) | Normal; may take 1-10 minutes |
| BMS | Red | Solid | Cannot reach WebCTRL server | Check network routing to server IP. Verify server is reachable (ping from another client). Check firewall rules. |
| BMS | Off | Dark | BMS communication disabled or not configured | Expected if controller is standalone. If should be connected, configure in controller app or WebCTRL server. |
| Status (System) | Green | Solid | All systems operational | Normal |
| Status | Amber | Flashing (1/sec) | Warning condition (non-critical) | Controller is functional but has minor issue. Review WebCTRL server logs for details. Usually resolves automatically. |
| Status | Red | Solid | Fault condition detected | Critical. Immediately review controller's local event log (if accessible via button) or check WebCTRL server logs. See "Controller Fault Codes" section. |
| Status | Red | Flashing (fast, >2/sec) | Catastrophic fault or watchdog reset occurring | Controller may reboot momentarily. Wait 30-60 seconds. If persists, power-cycle controller. If fault recurs, likely firmware corruption; escalate. |
ME series (Equipment controllers for chillers, boilers, RTUs) have simpler LED schemes:
| LED | Color | State | Meaning |
|---|---|---|---|
| Power | Green | On | 24V present; controller running |
| Power | Off | Off | No power |
| Link (Comms) | Green | Solid/Flashing | Communication active with parent controller or WebCTRL server |
| Link | Red | Off or Red | Communication lost |
| Fault | Red | Off | Normal operation |
| Fault | Red | On | Fault detected in equipment (e.g., pressure sensor failure, loss of flame, etc.) |
When a ZN or ME controller's Status LED turns red, fault code information is stored in the controller's non-volatile memory. Access this data via WebCTRL server or (for older controllers) via local serial connection.
Via WebCTRL Server (Recommended):
Via Local Serial Connection (if LAN unavailable):
logs or faults command (varies by controller model).| Fault Code | Fault Type | Description | Root Cause | Field Fix |
|---|---|---|---|---|
| F001 | Watchdog Timeout | CPU did not complete a scan cycle within timeout period | Logic program too slow or firmware hang | Power-cycle controller (on/off). If fault recurs, simplify logic program or reload firmware. |
| F002 | Stack Overflow | Function block stack exceeded maximum depth | Logic program creating excessive nesting or recursion | Review program for recursive blocks. Remove unnecessary nesting. Simplify logic. |
| F003 | Heap Memory Exhaustion | Dynamic memory allocation failed (too many alarms, trends, or points) | System overloaded with data | Clear old alarm and trend data from controller. Reduce number of stored trends. Simplify application. |
| F004 | EEPROM Write Error | Attempted to write to non-volatile memory and failed | Hardware fault or power supply instability | Check power supply stability (should be 24V ±2V). If fault persists, EEPROM may be worn; controller may need replacement. |
| F005 | I/O Module Offline | An I/O module is not responding to the controller | Module powered down or communication bus offline | Check module power and Ethernet/serial connection. Verify module is on same network. Restart module. |
| F006 | Temperature Out of Range | Processor temperature exceeded safe operating limit | Controller in hot environment without proper ventilation | Ensure controller has 2+ inches clearance on all sides. Install external cooling fan if needed. Relocate if in direct sunlight. |
| F010 | BACnet Device ID Conflict | Another device on the network has same BACnet Device ID as this controller | Duplicate device ID assigned | Use WebCTRL server to reconfigure one device with new Device ID. Or use local serial tool to change Device ID. Restart controller. |
| F015 | Network Supervisor Offline | LGR or Network Supervisor no longer responding | LGR power lost, Ethernet disconnected, or device failed | Check LGR power and Ethernet connection. Restart LGR. If it does not come back online, may need replacement. |
| F020 | Authentication Failure | WebCTRL server rejected connection from controller | Device ID or security credentials mismatched | Verify Device ID matches WebCTRL configuration. Check BACnet security settings (if any). Restart controller to retry connection. |
| F025 | Backup Battery Low | Uninterruptible power backup battery voltage below threshold | Battery aging and losing capacity | Replace backup battery (if removable). If non-removable, plan controller replacement within 1-2 years. |