MultiTrode MultiSmart User manual

MultiSmart
Pump Station Manager & RTU

MultiSmart Installation & Operation Manual
Page 2 of 260 MultiSmart_IO_Manual_R20

MultiSmart Installation & Operation Manual
This Manual is the support documentation for the
installation, commissioning and operation of the
MultiTrode MultiSmart Pump Station Manager/RTU
and Reservoir Monitor.
Revision 20
15 May 2013
This manual is used for v3.1.0 of the MultiSmart Pump Station Manager
NOTICE
This document is proprietary to MultiTrode Pty Ltd (the company) and for sole use within the
company notwithstanding that this document may from time to time be made available to the
company’s subcontractors, suppliers, customers and others for purposes associated with
manufacturing and other processes as authorised on an individual basis by MultiTrode Pty Ltd
or their representative. In such cases where the document has been issued to external
parties, its contents shall not be transcribed, copied, relayed, or divulged to any other party
whatsoever and after satisfying the requirements for which the document was originally issued
to any external party shall be either returned to the company, or destroyed as required by the
company’s document control procedure and as attested to by the recipient at the time of taking
possession of the document. MultiTrode Pty Ltd shall not be held liable in any way whatsoever
for any act or omission, either direct or consequential, arising from the use of the information
contained herein.
MULTITRODE is a registered trade mark of MultiTrode Pty Ltd in Australia and many countries worldwide. PUMPVIEW and MULTISMART
are trademarks of MultiTrode Pty Ltd and pending Australian trade mark registration. Australian Design Registration is pending for the
MultiSmart Pump Station Manager and RTU Remote and Base Modules. Patent Pending in Australia. © 2012 MultiTrode Pty Ltd. This
publication is protected by copyright. No part of this publication may be reproduced by any process, electronic or otherwise, without the
express written permission of MultiTrode Pty Limited.
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MultiSmart Installation & Operation Manual
1Warnings & Cautions...................................................................................................................... 9
1.1 Information to User ................................................................................................................ 9
1.2 Documentation Standards...................................................................................................... 9
1.3 Installation Notes ................................................................................................................... 9
2Glossary & Symbols ..................................................................................................................... 10
3Major New Features & Enhancements in Recent Firmware Releases...................................... 11
3.1 Version 3.1.0........................................................................................................................ 11
Part 1 – Operations................................................................................................................................... 12
4Introduction ................................................................................................................................... 12
4.1 Range of Options................................................................................................................. 12
4.2 Intuitive Operator Interface................................................................................................... 13
4.3 Intuitive Engineering Interface.............................................................................................. 13
4.4 "Out of the Box" Control of a Pump Station.......................................................................... 14
5Operator Interface......................................................................................................................... 15
5.1 LCD Panel............................................................................................................................ 15
5.2 LED Indicators ..................................................................................................................... 16
5.3 Buttons................................................................................................................................. 16
5.4 Using the Interface............................................................................................................... 16
Part 2 – Installation & Commissioning................................................................................................... 33
6Mounting Instructions................................................................................................................... 33
6.1 Mounting the Operator Interface Display.............................................................................. 33
6.2 Mounting the Pump Station Manager................................................................................... 35
6.3 Connecting the Operator Interface to the Pump Station Manager ....................................... 35
7MultiSmart Boards ........................................................................................................................ 36
7.1 Power Supply....................................................................................................................... 38
7.2 Default Wiring Setup for Pump Control Board...................................................................... 39
7.3 Pump Control Board ............................................................................................................ 44
7.4 CPU Board........................................................................................................................... 48
7.5 DSP Board........................................................................................................................... 49
7.6 Energy Monitoring & Motor Protection Board....................................................................... 56
8PumpView Hardware Setup.......................................................................................................... 58
8.1 Fault Finding........................................................................................................................ 58
8.2 Configuring PumpView for a Serial Cellular Modem............................................................ 59
8.3 Configuring PumpView for an Ethernet Cellular Router....................................................... 60
9Quick Commissioning Guide ....................................................................................................... 63
9.1 Setup Wizard Flow Diagrams............................................................................................... 64
9.2 Setup Wizard Notes............................................................................................................. 68
9.3 Unassign Any Faults Not Used............................................................................................ 70
9.4 Level Simulation Mode......................................................................................................... 72
9.5 Maintenance Mode .............................................................................................................. 72
Part 3 – Advanced Settings ..................................................................................................................... 74
10 High Level Overview ..................................................................................................................... 74
10.1 MultiSmart Pump Station Manager Overview ...................................................................... 74
10.2 Pump Station Manager........................................................................................................ 75
10.3 Reservoir Monitor................................................................................................................. 76
10.4 Pump Control Module .......................................................................................................... 77
10.5 Energy Monitoring and Motor Protection.............................................................................. 78
10.6 Supply Protection................................................................................................................. 79
10.7 Data Logger......................................................................................................................... 79
10.8 Flow..................................................................................................................................... 79
10.9 Fault Module........................................................................................................................ 79
10.10 Security................................................................................................................................ 79
10.11 PLC Extension (IEC 61131-3).............................................................................................. 79
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10.12 Logic Engine........................................................................................................................ 79
10.13 RTU...................................................................................................................................... 80
11 Security.......................................................................................................................................... 82
11.1 Selecting any Digital Input Tag ............................................................................................ 85
11.2 Security Key Setup .............................................................................................................. 86
11.3 Accessing MultiSmart Without a Security Key..................................................................... 87
12 Fill / Empty & Pump Setpoints, Alarm Setpoints, Delays .......................................................... 88
12.1 Fill / Empty (Charge / Discharge)......................................................................................... 88
12.2 Default Pump and Alarm Setpoints...................................................................................... 88
12.3 Changing Pump and Alarm Levels Setpoints....................................................................... 89
12.4 Setting Pump & Alarm Delays.............................................................................................. 91
13 Pumps and Groups....................................................................................................................... 93
13.1 Change Alternation & Fixed Duty......................................................................................... 94
13.2 Moving Pumps Between Groups, or Changing the Order of Pumps.................................... 96
13.3 Adding or Deleting Groups & Changing Group Alternation.................................................. 96
13.4 Decommissioning Pumps..................................................................................................... 97
14 Configuring I/O, Fault & Level Devices ....................................................................................... 98
14.1 Digital Inputs........................................................................................................................ 98
14.2 Assigning Faults to Digital Inputs......................................................................................... 98
14.3 Unassigning Fault Inputs.................................................................................................... 100
14.4 Configuring Digital Inputs................................................................................................... 100
14.5 Configuring Analog Inputs.................................................................................................. 103
14.6 Advanced Analog Input Options......................................................................................... 104
14.7 External Digital & Analog Modules..................................................................................... 104
14.8 Configuring Level Devices ................................................................................................. 109
14.9 Configuring Faults.............................................................................................................. 122
14.10 Configuring Analog Outputs............................................................................................... 130
14.11 Configuring Digital Outputs................................................................................................ 131
15 Profiles......................................................................................................................................... 135
15.1 Profile Selection Methods .................................................................................................. 136
15.2 Configuring the Setpoints of Profiles.................................................................................. 138
15.3 Configuring Other Profile Properties.................................................................................. 138
16 Station Optimization ................................................................................................................... 140
16.1 Station Optimization Menu................................................................................................. 141
16.2 Additional Parameters........................................................................................................ 148
17 Energy Monitoring and Motor Protection.................................................................................. 150
17.1 Setting Motor Protection Values......................................................................................... 151
17.2 Insulation Resistance Tester.............................................................................................. 154
17.3 Reassigning (Motor) Current Inputs used in Motor Protection ........................................... 158
17.4 Calculating Efficiency......................................................................................................... 159
18 Supply Protection........................................................................................................................ 160
18.1 Battery Test........................................................................................................................ 162
19 Datalogger ................................................................................................................................... 163
19.1 Configuring the Event Logger ............................................................................................ 164
19.2 Crisis Logger...................................................................................................................... 166
19.3 Interval Logger................................................................................................................... 168
19.4 Filtering the Data Viewed in the History Page.................................................................... 168
19.5 Storing the Datalogger on the SD Card ............................................................................. 170
19.6 Configuring the datalogger to write directly to an SD Card................................................ 173
19.7 Adding Comments and Deleting Logs................................................................................ 173
20 Flow.............................................................................................................................................. 174
20.1 Configure General Flow Setting......................................................................................... 174
20.2 Configuring Analog Inputs for Flow Measurement............................................................. 175
20.3 Configuring Analog Inputs for Inflow Measurement ........................................................... 176
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MultiSmart Installation & Operation Manual
20.4 Configuring Digital Inputs for Flow Measurement .............................................................. 176
20.5 Configuring Calculated Flow Settings................................................................................ 177
20.6 Flow Alarms....................................................................................................................... 178
20.7 Smart Outflow.................................................................................................................... 179
20.8 Estimating Duration to Overflow......................................................................................... 180
21 Reservoir Monitor........................................................................................................................ 181
21.1 Communications Configuration.......................................................................................... 181
21.2 User Interface .................................................................................................................... 183
21.3 Connection Manager.......................................................................................................... 183
22 RTU Module ................................................................................................................................. 185
22.1 Communications Screen.................................................................................................... 185
22.2 Communication Protocols.................................................................................................. 185
22.3 Enabling and Viewing of DNP and MODBUS Logs............................................................ 199
22.4 IP Address & Routing Settings........................................................................................... 200
23 Variable Frequency Drive (VFD)................................................................................................. 201
23.1 Enabling VFD..................................................................................................................... 201
23.2 Individual Pump Parameters.............................................................................................. 202
23.3 Setup an Analog Output for use with a VFD Drive............................................................. 203
23.4 Controlling a VFD Drive Using MODBUS........................................................................... 203
23.5 Displaying VFD speed on Main Screen.............................................................................. 203
23.6 Calculating Efficiency using VFD....................................................................................... 203
24 PLC Extension IEC 61131-3 (ISaGRAF)..................................................................................... 204
24.1 Setting up the Workbench.................................................................................................. 205
24.2 Setting up I/O..................................................................................................................... 206
24.3 MultiSmart Functions & I/O Blocks..................................................................................... 206
24.4 Downloading ISaGRAF Resources to MultiSmart.............................................................. 212
24.5 Compiling and Downloading Multiple Resources............................................................... 212
24.6 Viewing the Status of ISaGRAF Variables......................................................................... 212
24.7 The Tags Button ................................................................................................................ 213
24.8 The Params Button............................................................................................................ 213
24.9 Disabling ISaGRAF Resources.......................................................................................... 213
24.10 Backing Up ISaGRAF Resources...................................................................................... 213
24.11 ISaGRAF Application Examples ........................................................................................ 214
25 Logic Engine................................................................................................................................ 215
25.1 MultiSmart Tags................................................................................................................. 215
25.2 Logic Engine Tags ............................................................................................................. 216
25.3 Mathematical Operators..................................................................................................... 217
25.4 MultiSmart Logic Functions................................................................................................ 217
25.5 Advanced Functions .......................................................................................................... 218
25.6 Logic Examples.................................................................................................................. 219
25.7 Uploading Logic Files Using FTP....................................................................................... 220
25.8 Enabling Logic Files........................................................................................................... 221
26 SMS Server .................................................................................................................................. 222
27 Customizing the Display............................................................................................................. 225
27.1 Naming Pumps .................................................................................................................. 225
27.2 Pump Data Display............................................................................................................ 225
27.3 Bottom Section................................................................................................................... 226
28 Restarting the MultiSmart........................................................................................................... 227
29 Site Keys and Enabling New Modules....................................................................................... 227
29.1 Software Modules Available............................................................................................... 227
29.2 Enabling Software Modules with a New Site Key............................................................... 228
30 Upgrading MultiSmart Firmware................................................................................................ 228
30.1 Upgrading via PC Configuration Utility............................................................................... 228
31 Backing Up & Restoring Configuration Settings...................................................................... 229
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MultiSmart Installation & Operation Manual
31.1 Resetting Defaults.............................................................................................................. 229
31.2 Restore a Backup .............................................................................................................. 230
31.3 Back Up Current Configuration.......................................................................................... 231
32 More Advanced Configuration................................................................................................... 232
32.1 Default Mode vs. Showing Less Options............................................................................ 232
33 Web Server .................................................................................................................................. 233
33.1 Web Page Security ............................................................................................................ 233
33.2 Security Key Setup ............................................................................................................ 234
34 Troubleshooting.......................................................................................................................... 235
34.1 There is no level displayed on my unit............................................................................... 235
34.2 Every time the pump starts I see a Contactor Auxiliary fault.............................................. 235
34.3 My unit is showing a “Current Config Fail” fault.................................................................. 236
34.4 My unit has started with the message “Fail Safe Mode”..................................................... 236
34.5 PPP2 Manager Connection Error....................................................................................... 236
34.6 My unit keeps restarting..................................................................................................... 236
35 Appendix A – Fault Message Glossary ..................................................................................... 237
36 Appendix B – Display Mounting Template – Metric Units ....................................................... 241
37 Appendix C – Display Mounting Template – US / Imperial Units ............................................ 242
38 Appendix D – MultiSmart Security Explained........................................................................... 243
39 Appendix D – MultiSmart Web Security Explained .................................................................. 245
40 Appendix E – Setting Up WITS-DNP Communications............................................................ 247
40.1 Basic Configuration............................................................................................................ 247
40.2 Connection Details............................................................................................................. 248
40.3 Handling of Redundant Channels with Connection Details................................................ 249
40.4 Device On/Off Scan........................................................................................................... 249
40.5 Scheduled Connection....................................................................................................... 249
40.6 Point On/Off Scan.............................................................................................................. 250
40.7 Analogue Range/Scaling.................................................................................................... 250
40.8 Analogue Limits ................................................................................................................. 250
40.9 Counter Limits.................................................................................................................... 251
40.10 Point Archives.................................................................................................................... 251
40.11 Binary States...................................................................................................................... 251
40.12 Profiles............................................................................................................................... 251
40.13 Rate of Change.................................................................................................................. 251
40.14 Object Flag Actions............................................................................................................ 252
40.15 Minimum, Maximum, and Mean......................................................................................... 252
40.16 Integral Values................................................................................................................... 252
40.17 State Counter..................................................................................................................... 253
40.18 State Runtime.................................................................................................................... 253
40.19 Profile Control Value.......................................................................................................... 253
40.20 Bulk Configurations and Versions...................................................................................... 254
40.21 Event Logs......................................................................................................................... 255
41 Technical Specifications ............................................................................................................ 256
41.1 Processor Unit ................................................................................................................... 256
41.2 RTU/Communications........................................................................................................ 256
41.3 Firmware/Application Upgrade Capability.......................................................................... 256
41.4 I/O Standard Modules........................................................................................................ 256
41.5 I/O-3MP: Motor Protection I/O Board................................................................................. 256
41.6 Power (per unit) ................................................................................................................. 256
41.7 Power Supply & Environmental.......................................................................................... 256
41.8 Product Dimensions........................................................................................................... 256
42 MultiTrode Terms & Conditions of Sale .................................................................................... 257
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MultiSmart Installation & Operation Manual
Summary of Tables
Table 1 – Power Supply Specifications.........................................................................................................................................38
Table 2 – Serial Port Pin Outs ......................................................................................................................................................49
Table 3 – Max. Cable Length at Specific Baud Rates...................................................................................................................52
Table 4 – Can BUS and Can ID Settings......................................................................................................................................53
Table 5 – Key Setup Parameters (can only be modified through the Setup Wizard)....................................................................68
Table 6 – Alternation Schemes.....................................................................................................................................................93
Table 7 – Digital Input Fault Sources............................................................................................................................................98
Table 8 – Advanced Digital Input Options...................................................................................................................................101
Table 9 – Digital Input Mode Examples......................................................................................................................................102
Table 10 – Digital Input Capabilities ...........................................................................................................................................102
Table 11 – Advanced Analog Input Options................................................................................................................................104
Table 12 – Advanced Probe Settings .........................................................................................................................................112
Table 13 – Probe Length in Inches.............................................................................................................................................115
Table 14 – DuoProbe Calibration Parameters............................................................................................................................116
Table 15 – Advanced Fault Parameters .....................................................................................................................................123
Table 16 – Fault Actions Parameters..........................................................................................................................................125
Table 17 – Digital Output Sources..............................................................................................................................................132
Table 18 – Advanced Digital Output Options..............................................................................................................................133
Table 19 – Station Optimization Parameters ..............................................................................................................................140
Table 20 – Pump Reversal Parameters......................................................................................................................................143
Table 21 – Well Washer Parameters..........................................................................................................................................146
Table 22 – CT & FLC Parameters ..............................................................................................................................................152
Table 23 – Motor Protection Faults.............................................................................................................................................152
Table 24 – Basic Fault Options...................................................................................................................................................153
Table 25 – IRT Parameters.........................................................................................................................................................154
Table 24 – Basic IRT Parameters...............................................................................................................................................156
Table 26 – Supply Protection Faults...........................................................................................................................................161
Table 27 – Supply Protection Fault Parameters .........................................................................................................................161
Table 28 – Battery Test Parameters...........................................................................................................................................162
Table 29 – Event Datalogger Parameters...................................................................................................................................165
Table 30 – Crisis Logger Configuration for “Trigger” Parameters...............................................................................................167
Table 31 – Interval Logger Configuration Parameters................................................................................................................168
Table 32 – Predefined Filters Available in General Filters..........................................................................................................169
Table 33 – Filenames for Each Type of Datalog file...................................................................................................................171
Table 34 – General Flow Fault Parameters................................................................................................................................174
Table 35 – Smart Outflow Parameters........................................................................................................................................179
Table 36 – Advanced Serial Port Parameters.............................................................................................................................195
Table 37 – VFD Parameters.......................................................................................................................................................202
Table 38 – ISaGRAF Device Names..........................................................................................................................................206
Table 39 – Example of MultiSmart Tags.....................................................................................................................................216
Table 40 – Logic Engine Mathematic Operators.........................................................................................................................217
Table 41 – Logic Engine Functions.............................................................................................................................................217
Table 42 – Logic Engine Advanced Functions............................................................................................................................218
Table 43 - Customize Display - Pump Data................................................................................................................................226
Table 44 - Customize Display - Bottom 3 Lines..........................................................................................................................226
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MultiSmart Installation & Operation Manual
1 Warnings & Cautions
1.1 Information to User
Read through this manual to obtain a good working knowledge in order to get maximum performance from
the MultiSmart for your application. After reading, place the manual in a safe place for future reference.
1.2 Documentation Standards
DANGER:
THIS SYMBOL IS USED WHERE NON-COMPLIANCE COULD RESULT IN INJURY OR DEATH.
WARNING:
THIS SYMBOL IS USED WHERE NON-COMPLIANCE COULD RESULT IN INCORRECT
OPERATION, DAMAGE TO OR FAILURE OF THE EQUIPMENT.
NOTE:
THIS SYMBOL IS USED TO HIGHLIGHT AN ISSUE OR SPECIAL CASE WITHIN THE BODY OF
THE MANUAL.
1.3 Installation Notes
WARNING:
THE MULTISMART INSTALLATION AND WIRING MUST BE PERFORMED BY QUALIFIED
PERSONNEL.
DANGER:
THE MULTISMART HAS NO USER SERVICEABLE PARTS. TO REDUCE THE RISK OF
ELECTRIC SHOCK, LEAVE ALL SERVICING TO QUALIFIED MULTITRODE TECHNICAL STAFF.
DANGER:
INSTALLATION OR USE OF THIS EQUIPMENT OTHER THAN IN ACCORDANCE WITH THE
MANUFACTURERS INSTRUCTIONS MAY RESULT IN EXPOSURE TO HARM, SERIOUS INJURY
OR DEATH.
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2 Glossary & Symbols
Terminology
Activation Level The point at which a pump or alarm is switched On.
Alternate Mode The Pump Station Manager automatically switches the lead (duty) pump each cycle.
Deactivation Level The point at which a pump or alarm is switched Off.
Decommissioned Pump A pump that has been removed from duty or an installation, e.g. for maintenance
purposes.
Duty (Lead) Pump The main pump or the first pump to start within a pumping cycle.
Empty (Discharge) Mode When the Pump Station Manager is set to empty a tank or pit.
Fill (Charge) Mode When the Pump Station Manager is set to fill a tank or pit.
Fixed Sequence Pump 1 or pump 2 is fixed as the lead (duty) pump.
InterPump Start Delay The delay between any two pumps starting.
InterPump Stop Delay The delay between any two pumps stopping.
Probe
MultiTrode manufactures a range of conductive level sensors. They have many
advantages over traditional devices such as ball floats. Advantages include:
resistance to fatty deposit build-up, tangle-free and an adjustable sensitivity to liquid
to prevent false readings.
Standby (Lag) Pump The secondary pump or the next pump to start within a pumping cycle.
ISaGRAF ISaGRAF is a control software environment which supports all of the internationally
recognised IEC 61131-3 control languages and offers a combination of highly
portable and robust control engine.
Abbreviations, Symbols & Units
PSM Pump Station Manager
ΩResistance Value (Ohm)
EMC Electromagnetic Compatibility
Hz Frequency (Hertz)
LED Light Emitting Diode
MTU Master Terminal Unit
N/C Normally Closed
N/O Normally Open
RTU Remote Telemetry Unit
VAC Alternating Current Voltage
VDC Direct Current Voltage
VFD Variable Frequency Drive
Page 10 of 260 MultiSmart_IO_Manual_R20