Greyline Instruments PSL 5.0 User manual

www.greyline.com
USER'S GUIDE
Installation & Operation
Instructions
Pump Station Level Controller
Model PSL 5.0
Manual Series A.1.4

Note: This page has been left blank intentionally.

Page 3
PSL 5.0 Pump Station Level Controller
INDEX
CONNECTIONS:..............................................................................................4
KEYPAD SYSTEM...........................................................................................6
CALIBRATION MENU....................................................................................7
ICONS................................................................................................................8
MAIN DISPLAY...............................................................................................9
MESSAGE ICON..............................................................................................9
STATUS ............................................................................................................9
PASSWORD....................................................................................................10
UNITS/MODE.................................................................................................11
CALIBRATION ..............................................................................................12
RELAY PARAMETERS.................................................................................14
DATA LOGGING...........................................................................................16
SPECIAL FUNCTIONS..................................................................................18
SENSOR MOUNTING/LOCATION..............................................................19
SENSOR MOUNTING METHODS...............................................................20
ERROR/WARNING MESSAGES..................................................................22
FIELD TROUBLESHOOTING ......................................................................23
APPLICATIONS HOTLINE...........................................................................27
PRODUCT RETURN PROCEDURE.............................................................28
APPENDIX A - OPTIONS..............................................................................30
CONVERSION GUIDE ..................................................................................38
SPECIFICATIONS..........................................................................................39
PSL 5.0 RELAY CALIBRATION RECORD.................................................44
IMPORTANT NOTE: This instrument is manufactured and calibrated to meet product specifications.
Please read this manual carefully before installation and operation. Any unauthorized repairs or
modifications may result in a suspension of the warranty.
Available in Adobe Acrobat pdf format

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PSL 5.0 Pump Station Level Controller
!
CONNECTIONS:
POWER INPUT: The standard model requires AC power input between 100 to 240 VAC 50/60Hz . No
adjustments are necessary for voltages within this range.
Optional DC input model requires 9-32 VDC/9 Watts. Connect to + and - terminals.
Optional Thermostat and Heater modules are available rated for 115 VAC or 230 VAC.
IMPORTANT NOTE: To comply with CSA/UL electrical safety standards, AC power input and relay
connection wires must have conduit entry to the instrument enclosure. Installation requires a switch,
overcurrent fuse or circuit breaker in the building (in close proximity to the equipment) that is marked
as the disconnect switch.
Risk of electric shock. Loosen cover screw to access connections. Only qualified personnel should
access connections.
Note: Use of instrumentation over 40°C ambient requires special field wiring.
Note: User replaceable fuse is 2 Amp 250V (T2AL250V).

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PSL 5.0 Pump Station Level Controller
CONNECTIONS
HEATER OPTION
AC
LN
NO
C
NC
NO
C
NC
–
+
4-20mA
RLY2
RLY1
AC
GND
NC
C
NO
NC
C
NO
NC
C
NO
NC
C
NO
RLY3 RLY4 RLY5 RLY6
RELAYS
POWER
INPUT
GND
USB HARNESS
CONNECTOR
DATA LOGGER OPTION
PRESSURE
SENSOR
+–+–
CORE
WHT
SHLD
GRN
PZ
SENSOR
SRC SNK

Page 6
PSL 5.0 Pump Station Level Controller
KEYPAD SYSTEM
The following diagram shows the PSL 5.0 menu system. Arrows show the four directions to leave a
menu box. Pressing a corresponding keypad arrow will move to the next item in the direction shown.
Move the cursor (underline) under numerals and increase or decrease numerals with the and keys.
To store calibration values permanently (even through power interruptions), press the .

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PSL 5.0 Pump Station Level Controller
CALIBRATION MENU
--Password----------
Password 0000 --Data Logging-------
Log Site ID 0}
LevelMode
Jun 26 12Set Date /20
2351Set Time 1: :0
1Interval 0sec
LoggingLog
--Units/Mode--------
Mode}Level
Linear in
Temperature C
--Calibration-------
Min Range}16.00in
144.0inMax Range
Damping 10%
SsLO Time 30
--Relay Parameters--
Relay 1}
LevelFunction
Mode Pump
55.000inOn
40.000inOff
SLO mode Off
YesAlternate
Force Alt 5min
On Delay 5s
in
Relays 1 2 3 4 5 6
29.055
--Message-----------
Data log Stopped
Log Used 0%
Sensor A Good
BSensor Good
Temperature 21C
-- ----Relay Run Times
R1 0.12hr
R2 .05hr0
R3 0.32hr
R4 0.50hr
R5 1.09hr
R6 0.51hr
Sensor B 0.13hr
--Status------------
Range}A 50.98in
Range B 47.83in
EC 100%
Relays 1 2 3 4 5 6
--Special Functions-
Language English}
Analog Out 4-20mA
Backlight High
Relay LogReset NO
Restore Defaults NO
New Password 0000
--Simulation--------
}Test Actual
Level 29.02in
4-20mA Level 10.45
Relays 1 2 3 4 5 6
--Configuration-----
1.}25.00
Utility
Sonar 1.14
24Logger 1. T
6Relays
Analog Out 1
--Menu Selections----
Units / Mode}
Calibration
Relay Parameters
Data Logging
Special Functions
Simulation
Configuration
--24 hr log----------
Date Feb. 12/20}10
29.036inAverage
29.056inMaximum
12:32:00Max Time
29.016inMinimum
12:33:00Min Time

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PSL 5.0 Pump Station Level Controller
ICONS
1. 2.
Message waiting. Press .Ç
Data logging .off
1. 2.
Data logging .on
1. 2. 3. 4.
USB file download.
File download completed.
Download Error.
Echo OK.
Measurement switched to pressure sensor.
3.
3.
2.
2.
1.
1.
No Echo .

Page 9
PSL 5.0 Pump Station Level Controller
MAIN DISPLAY
The main display shows the units selected from the Units/Mode menu, Level or
Range being measured and RELAY states.
MESSAGE ICON
Press from the MAIN display to view status of the data logger and
error/warning messages provided by the instrument. The Message icon will
blink on the MAIN display if error messages are being generated by the
instrument. Refer to the manual section Error/Warning Messages for a
description. Press to return to the main display.
STATUS
Press from the MAIN display to view instrument status. Range will be
displayed in linear units, for both the sonar and pressure sensors.
Range A Range measurement of PZ transducer.
Range B Equivalent range measurement of pressure transducer.
EC Displays echo confidence.
Relays Energized relays will display as a white character on a black
background.
RELAY RUN TIMES
Tracks run times of the six relays. Also indicates total down time of the ultrasonic
transducer.
in
Relays 1 2 3 4 5 6
29.055
--Message-----------
Data log Stopped
Log Used 0%
Sensor A Good
Sensor B Good
Temperature 21C
--Status------------
Range A 50.98in
Range B 47.83in
EC 100%
Relays 1 2 3 4 5 6
}
--Relay Run Times----
R1 0.12hr
R2 0.05hr
R3 0.32hr
R4 0.50hr
R5 1.09hr
R6 0.51hr
Sensor B 0.13hr

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PSL 5.0 Pump Station Level Controller
PASSWORD
The password (a number from 0000 to 9999) prevents unauthorized access to the
Calibration menu.
From the Main display press the key to get to Password. Factory default
password is 0000 and if it has not been changed press the to proceed to the
Menu Selections screen.
If a password is required, press to place the cursor under the first digit and or
to set the number, then to the second digit, etc. Press or to proceed to
the Menu Selections screen.
A new password can be stored by going to Special Functions/New
Password.
--Password----------
Password 0000

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PSL 5.0 Pump Station Level Controller
UNITS/MODE
From Mode press the and then the or to select Level or
Range.
Range mode displays distance from the sensor to the target or liquid surface
like a tape measure. Range mode is useful to measure the exact
distance from the sensor to the zero level during calibration, or to
monitor "outage" or free space in a tank.
Level mode can be used to measure tank level in linear units.
Press the to store your selection then the to the next menu item and to
enter.
Linear press the key and then the or to select your units
of measurement. Press the to store your selection.
Temperature press and then or to select C or F
(Centigrade or Fahrenheit).
Press or to return to the Menu Selections screen.
--Units/Mode--------
Mode Level
Linear in
Temperature C
}
--Units/Mode--------
Temperature C
F
}

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PSL 5.0 Pump Station Level Controller
CALIBRATION
Press the to Calibration and to enter. Use or to position 
before each menu item and to enter. When settings are completed press to
store and return to the Calibration menu.
Min Range Distance from the sensor face to highest expected level.
Max Range Distance from sensor to Zero level.
Damping Minimum damping allows fast response to level changes.
Increasing damping slows the PSL 5.0's response to level changes
and is ideal to smooth the display and outputs in turbulent
conditions. Damping value is shown in percent (0-99%). Some
experimentation may be required to select the optimum damping
value. A value of 1% is recommended for most applications. For
fast level changes (up to ½ inch/sec - 13 mm/sec), a Damping
value of 1% is recommended.
LOS Time Press and or to change the number of seconds without
receiving a level measurement from either the PZ or pressure
sensor before the PSL 5.0 displays ECHO LOSS, and Control
relays change state as calibrated under Relay Parameters.
Factory default is 30 seconds and is recommended for most
applications. Minimum is 1 second and maximum is 99 seconds.
Press from the Units/Mode display to return to Menu Selections.
--Calibration-------
Min Range 8.000in
Max Range 80.000in
Damping 10%
LOS Time 30s
}

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PSL 5.0 Pump Station Level Controller
CALIBRATION
Calibrate the PZ Sensor for Level Measurement
1. Before starting the calibration determine:
a) MAX RANGE = ________________
(Maximum range = distance from Sensor to Zero level)
b) MAX LEVEL = ________________
(Maximum level of product being measured)
c) MIN RANGE = ________________
(Distance from sensor to Max Level)
Minimum range = MAX RANGE - MAX LEVEL
(must be at least 8" / 203 mm depending on sensor model)
2. Check the maximum range with the sensor installed by:
a) When liquid is at zero level press to view the Range reading in the
Status menu. Use this range measured by the PSL 5.0 as the Max Range
setting.
or
b) Carefully measure distance from sensor to zero level with a tape measure,
and use this measurement as the Max Range setting.
Redundant 4-20mA input (pressure) Sensor Installation and Self-
Calibration
1. Install the redundant 4-20mA input sensor near the bottom of the well
according to manufacturer’s instructions and below the zero level.
2. Ensure that the PSL 5.0 with PZ sensor has been properly calibrated to
measure water level and is functioning properly.
3. Connect the 4-20mA redundant sensor to the PSL 5.0 SRC terminals when
the transmitter is loop-powered (24VDC power provided by the PSL 5.0) or
to SNC terminals when the 4-20mA transmitter is powered from another
source.
4. Operate the PSL 5.0 through several pump cycles to allow the 4-20mA input
sensor to self-calibrate.
5. Note: When 4-20mA input sensor has completed self-calibration the Message
window will indicate that Sensor B status is Good.
MAX LEVEL
ZEROLEVEL
MAX RANGE
4-20 mAinput
sensor (pressure)
MINRANGE
INSTALLATION
INWELL
PZ SENSOR

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PSL 5.0 Pump Station Level Controller
RELAY PARAMETERS
Relay Press and or to select a corresponding relay number (6
relays are standard).
Function Press or to select Off, Range, or Level.
Level Press to Mode and to select
Pump, Low Alarm or Hi Alarm.
Note: Function setting Level will change according to selections made
under Units/Mode eg Level or Range,
Press to return to Menu Selections.
LOS mode Set the desired relay condition in the case that PSL cannot
obtain a level measurement or set relay to provide a LOS
alarm:
Off Sets Relay state to Off if PSL cannot obtain
level reading.
On Sets Relay state to On if PSL cannot obtain
level reading.
Hold Holds relay state if PSL cannot obtain level
reading.
Sensor B Acts as PZ sensor signal loss alarm when
Pump On and Off set to the same level.
Alarm will indicate whenever PSL is
operating off of the redundant 4-20mA
input (pressure) sensor.
Sen B Fault Acts as 4-20mA input sensor fault alarm
when Pump On and Off set to the same
level. Alarm will indicate fault of the 4-
20mA input sensor.
--Relay Parameters--
Relay 1
Function Level
Mode Pump
On 55.000in
Off 40.000in
LOS mode Off
Alternate Yes
Force Alt 5min
On Delay 5s
}

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PSL 5.0 Pump Station Level Controller
Alternate Up to six pumps/relays can be set to alternate when in pump
mode. Following the end of a pump cycle pumps will swap
ON and OFF relay settings.
Note: Alternating pumps must have different On setpoints to
alternate correctly, otherwise alternating pumps will turn On at
the same time.
Force Alt Set time for forced alternation. PSL will automatically trigger
pump alternation if time expires over a longer pump cycle.
On Delay Set On Delay to invoke a delay between simultaneous changes
to pump states.
SENSOR
LAG
PUMP 1
LAG
PUMP 2
LEAD
PUMP
ON
ON
OFF
OFF
ON
OFF
PUMP ALTERNATION (R1, R2, R3)
LEAD
PUMP
LAG
PUMP 1
LAG
PUMP 2
1st CYCLE
2nd CYCLE
3rd CYCLE
...ETC
12
23
31
3
1
2

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PSL 5.0 Pump Station Level Controller
DATA LOGGING
Setup
Select Data Logging from Menu Selections.
Log Site ID Enter a number from 00 to 99. The site ID will
become part of the downloaded file name to help
distinguish downloads from different instruments. Press 
to store the setting.
Mode Select Level or Range. Press to store the
setting.
Set Date Press or to scroll and select Month, Day and Year.
Press to store the setting.
Set Time Press or to select the current time in Hours, Minutes
and Seconds. Press to store the setting.
Interval Press or to select the logging interval.
Press to store the setting.
Log Stop, Start or Delete the log file.
Press or to Delete and to delete the log file.
Press or to Start and to restart the logger.
Note: You MUST delete old file and start a new log to apply any changes
that have been made to the Log Site ID, Mode or
Interval.
RETRIEVE LOG FILE
Plug a USB Flash Memory Drive (not supplied by Greyline) into the USB output
cable from the instrument. The instrument display will show the USB file
download icon until the log file is transferred to the memory card and then display
file download completed icon. The USB flash drive may be removed.
Download file names will appear in this format:
Tag is set according to the Log Site ID entered in the instrument Data Logging
menu.
--Data Logging-------
Log Site ID 00
99
Mode Level
Range
Set Date Feb 18/2008
Mar 19/2009
Set Time 11:27:40
12:28:41
Interval 10sec
60min
30min
15min
10min
5min
2min
1min
30sec
Log Start
Stop
Delete
}
PSL_ _00A.LOG
MODELTAG DOWNLOAD

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PSL 5.0 Pump Station Level Controller
Download letter will be A for the first download from an instrument. B for the
second, then C etc. At the letter Z a - character will appear indicating that the
maximum number of downloads for that instrument are on the USB flash drive.
Older files can be erased or moved from the flash memory drive or a new memory
drive can be used.
OPENING LOG FILES
Install Greyline Logger on your PC or laptop. Refer to the Help menu in the
program for detailed instructions.
Select File/Open/Instrument Log (.log) to open the log file from your USB flash
drive.

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PSL 5.0 Pump Station Level Controller
SPECIAL FUNCTIONS
Language Select English, French or Spanish
and press .
Analog Out Select 4-20mA or 0-5V mode for the analog output.
Backlight Select High, Medium or Low for continuous
backlight.
Select Key Hi/Lo for high backlight for 1 minute
after a keypress and then Lo backlight until a key
is pressed again.
Select Key High, Med or Low for backlight
for 1 minute after a keypress and then backlight off
until a key is pressed again.
Reset Relay Log Select Yes and press to erase Relay Runtime log.
Restore Defaults Select Yes and press to erase all user settings
and return the instrument to factory default settings
New Password Select any number from 0000 to 9999 and press .
Default setting of 0000 will allow direct access to the
calibration menus. Setting of any password greater
than 0000 will require the password to be entered to
access the calibration menus.
Press to return to Menu Selections.
SIMULATION
Exercises the 4-20mA (0-5V) output, digital display and control relays.
Test Select Maximum and press to simulate maximum Range or Level
and to output 20mA (5V) to the analog channel.
Select Minimum and press to simulate minimum Range or Level
and to output 4mA (0V) to the analog channel.
To simulate an intermediate Range or Level set Test to Actual
and then enter a value for the Range or Level. The analog output
and control relays will respond to the simulated value.
--Special Functions-
Language English
Analog Out 4-20mA
Backlight High
Reset Relay Log NO
Restore Defaults NO
New Password 0000
}
--Special Functions-
Language English
Backlight Hig
Medium
Low
Key Hi/Lo
Key High
Key Med
Key Low
Off
}h
--Simulation--------
Test Actual
Range 8.00in
4-20mARange 4.00
Relays 1 2 3 4 5 6
}

Page 19
PSL 5.0 Pump Station Level Controller
SENSOR MOUNTING/LOCATION
- Tank Level/Inventory Applications
Each PSL 5.0 Level Transmitter includes a non-
contacting ultrasonic sensor. The sensor must be
installed in a position to obtain unobstructed echoes
from the liquid or material being measured.
Mount the sensor away from pipes, ladders, or
structural members which might cause continuous false
echoes.
BAD GOOD
90°

Page 20
PSL 5.0 Pump Station Level Controller
SENSOR MOUNTING METHODS
4" OR 6" BLIND FLANGE
TAPPED ¾" NPT
FLEXIBLE
CONDUIT
JUNCTION
BOX
(OPTION JB)
ISOLATION
COUPLING
(SUPPLIED)
MUST BE
USED
DO NOT
CLAMP IN
THIS AREA
¾" NPT
NIPPLE
FLANGE MOUNT
ISOLATION
COUPLING
(SUPPLIED)
MUST BE
USED
DO NOT
CLAMP IN
THIS AREA
CLAMP
3/4"
CONDUIT
CROSS BAR MOUNT
ISOLATION
COUPLING
(SUPPLIED)
MUST BE
USED
DO NOT
CLAMP IN
THIS AREA
3/4" NPT
NIPPLE
ANGLE MOUNT
ISOLATION
COUPLING
(SUPPLIED)
MUST BE
USED
DO NOT
CLAMP IN
THIS AREA
3/4"
CONDUIT
CONDUITMOUNT
Notes:
1.Use the ¾" NPT "Isolation
Coupling"supplied and
only. Do not clamp sensor
bodyor stem.
2.Locate the sensor 1 ft (30 cm) from
the sidewall or obstruction for every
10 ft (3 m) depth.
3.mount in direct sunlight.
4. Extend sensor cableupto500 ft
(150 m) with RG62AU coaxialonly.
hand
tighten
Do not
GRIND OR FILE
PIPE EDGE
SMOOTH
STAND PIPE MOUNT
STANDPIPE LENGTH
AS SHORT AS POSSIBLE
STANDPIPE DIAMETER
AS LARGE AS POSSIBLE
TYPICAL STANDPIPE:
4” / 100 mm DIAMETER
12”/300 mm LENGTH
NARROW DIAMETER
STANDPIPES (<4” / 100 mm)
MAY AFFECT ACCURACY
OF READING