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Dashboard Configuration Guide

Overview

This guide explains how to configure your Calejo Control Adapter entirely through the web dashboard - no manual configuration required!

🎯 Your Vision Achieved

Before: Manual configuration files, SSH access, complex setup After: One-click setup → Dashboard configuration → Ready to use

🚀 Getting Started

Step 1: Run One-Click Setup

# Local development
./setup-server.sh

# Remote server
./setup-server.sh -h your-server.com -u ubuntu -k ~/.ssh/id_rsa

Step 2: Access Dashboard

Open your browser and navigate to:

http://your-server:8080/dashboard

🔧 Complete Configuration Workflow

1. Configure SCADA Protocols

OPC UA Configuration

Navigate to Protocols → OPC UA
Configure settings:
- Endpoint: opc.tcp://0.0.0.0:4840 (default)
- Security Policy: Basic256Sha256
- Certificate: Auto-generated
Test connection

Example Configuration:

{
  "protocol_type": "opcua",
  "enabled": true,
  "name": "Main OPC UA Server",
  "endpoint": "opc.tcp://192.168.1.100:4840",
  "security_policy": "Basic256Sha256"
}

Modbus TCP Configuration

Navigate to Protocols → Modbus TCP
Configure settings:
- Host: 0.0.0.0 (listen on all interfaces)
- Port: 502 (standard Modbus port)
- Unit ID: 1 (device address)
Test connection

Example Configuration:

{
  "protocol_type": "modbus_tcp",
  "enabled": true,
  "name": "Primary Modbus Network",
  "host": "192.168.1.200",
  "port": 502,
  "unit_id": 1
}

2. Auto-Discover Hardware

Navigate to Hardware → Auto-Discovery
Select protocols to scan
Review discovered equipment
Import discovered stations and pumps

Discovery Results:

{
  "success": true,
  "discovered_stations": [
    {
      "station_id": "station_001",
      "name": "Main Pump Station",
      "location": "Building A",
      "max_pumps": 4
    }
  ],
  "discovered_pumps": [
    {
      "pump_id": "pump_001",
      "station_id": "station_001",
      "name": "Primary Pump",
      "type": "centrifugal",
      "power_rating": 55.0
    }
  ]
}

3. Configure Pump Stations

Navigate to Stations → Add Station
Enter station details:
- Station ID: Unique identifier
- Name: Descriptive name
- Location: Physical location
- Capacity: Maximum pumps and power

Example Station Configuration:

{
  "station_id": "main_station",
  "name": "Main Wastewater Pump Station",
  "location": "123 Industrial Park",
  "max_pumps": 6,
  "power_capacity": 300.0,
  "flow_capacity": 1000.0
}

4. Configure Individual Pumps

Navigate to Pumps → Add Pump
Select station
Enter pump specifications:
- Pump ID: Unique identifier
- Type: Centrifugal, submersible, etc.
- Power Rating: kW
- Speed Range: Min/max Hz

Example Pump Configuration:

{
  "pump_id": "primary_pump",
  "station_id": "main_station",
  "name": "Primary Centrifugal Pump",
  "type": "centrifugal",
  "power_rating": 75.0,
  "max_speed": 60.0,
  "min_speed": 20.0,
  "vfd_model": "ABB ACS880",
  "manufacturer": "Grundfos"
}

5. Set Safety Limits

Navigate to Safety → Limits
Select pump
Configure safety parameters:
- Speed Limits: Min/max Hz
- Power Limits: Maximum kW
- Rate of Change: Hz per minute

Example Safety Configuration:

{
  "station_id": "main_station",
  "pump_id": "primary_pump",
  "hard_min_speed_hz": 20.0,
  "hard_max_speed_hz": 55.0,
  "hard_max_power_kw": 80.0,
  "max_speed_change_hz_per_min": 25.0
}

6. Map Data Points

Navigate to Data Mapping → Add Mapping
Configure protocol-to-internal mappings:
- Protocol: OPC UA, Modbus, etc.
- Data Type: Setpoint, actual speed, status
- Protocol Address: Node ID, register address

Example Data Mapping:

{
  "protocol_type": "opcua",
  "station_id": "main_station",
  "pump_id": "primary_pump",
  "data_type": "setpoint",
  "protocol_address": "ns=2;s=MainStation.PrimaryPump.Setpoint"
}

🎛️ Dashboard Features

Real-time Monitoring

System Status: Application health, protocol status
Performance Metrics: CPU, memory, network usage
Safety Status: Current limits, violations, emergency stop
Protocol Activity: Active connections, data flow

Operations Management

Emergency Stop: Activate/deactivate through dashboard
Setpoint Control: Manual override with safety enforcement
User Management: Add/remove users, set roles
Audit Logs: View security and operational events

Configuration Management

Validation: Check configuration completeness
Export/Import: Backup and restore configurations
Version Control: Track configuration changes
Templates: Save and reuse configuration patterns

🔄 Configuration Workflow Examples

Complete SCADA Integration

# 1. Setup server
./setup-server.sh -h scada-server.company.com -u admin -k ~/.ssh/scada_key

# 2. Access dashboard
http://scada-server.company.com:8080/dashboard

# 3. Configure protocols
- OPC UA: opc.tcp://plc-network:4840
- Modbus TCP: 192.168.1.100:502

# 4. Discover hardware
- Auto-discover connected PLCs and pumps

# 5. Set safety limits
- Min speed: 20 Hz, Max speed: 50 Hz
- Max power: 75 kW

# 6. Map data points
- OPC UA nodes to internal pump controls

# 7. Validate configuration
- Check for completeness and errors

# 8. Start operations!

Quick Configuration Template

{
  "protocols": {
    "opcua": {
      "enabled": true,
      "endpoint": "opc.tcp://plc-network:4840"
    },
    "modbus_tcp": {
      "enabled": true,
      "host": "192.168.1.100",
      "port": 502
    }
  },
  "stations": [
    {
      "station_id": "main_station",
      "name": "Main Pump Station"
    }
  ],
  "pumps": [
    {
      "pump_id": "pump_1",
      "station_id": "main_station",
      "name": "Primary Pump"
    }
  ],
  "safety_limits": [
    {
      "pump_id": "pump_1",
      "hard_min_speed_hz": 20.0,
      "hard_max_speed_hz": 50.0
    }
  ]
}

🛠️ Troubleshooting

Common Issues

Protocol Connection Failed
- Check network connectivity
- Verify protocol settings
- Test with protocol client
Hardware Not Discovered
- Ensure protocols are configured
- Check hardware connectivity
- Verify network permissions
Safety Limits Not Applied
- Validate configuration
- Check pump mappings
- Review audit logs

Validation Checklist

All required protocols configured
Pump stations defined
Individual pumps configured
Safety limits set for each pump
Data mappings established
Configuration validated
Test connections successful

📞 Support

Dashboard Help: Click help icons throughout the interface
Documentation: Full documentation in docs/ directory
Community: Join our user community for support
Issues: Report problems via GitHub issues

Your Calejo Control Adapter is now fully configured and ready for SCADA integration! All configuration is managed through the intuitive web dashboard - no manual file editing required.

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