Digital Constant Speed Controller · G Controls Digi-Gage Plus ser Manual - ersion 012720-DGM-1...

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Digi-Gage Plus™

Digital Constant Speed Controller SCADA-Ready | Remote Access | Backwards Compatible

User Manual

Digi-Gage Plus™

2

EG Controls Digi-Gage Plus User Manual - Version 012720-DG+UM-TJ

D I G I - G A G E P L U S U S E R M A N U A LF O R W A R D

The information in this document reflects product features and functions at the date of printing. EG Controls Inc. reserves the right, subject to all applicable laws, at any time, at its sole discretion, and without notice, to discontinue, change the features, designs, materials and other specifications of its products, and to either permanently or temporarily withdraw any of the forgoing from the market.

All information in this document is provided “as is” without warranty of any kind, either expressed or implied, including but not limited to any implied warranties of merchantability, fitness for a particular purpose, or non-infringement. EG Controls Inc. assumes no responsibility for errors or omissions in the information presented in this document. In no event shall EG Controls Inc. be liable for any special, incidental, indirect or consequential damages of any kind, or any damages whatsoever arising out of or in connection with the use or performance of this infor-mation.

The trade-names, trademarks, logos and service marks presented in this document, including their design, are the property of EG Controls Inc. or other third parties and you are not permitted to use them without the prior written consent of EG Controls Inc. or such third party as may own them.

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D I G I - G A G E P L U S U S E R M A N U A LT A B L E O F C O N T E N T S

1 Introduction

2 Features2.1 Hardware Ratings SystemConfiguration SystemProcessor BaseFeatures Communications

2.2 Process Features

2.3 Features Details Six-PumpSystem Five-PumpSystem Four-PumpSystem Three-PumpSystem 2.4 Controller Functionality

2.5 Typical Wiring Diagrams

3 Modes of Operation 3.1 Clean-Out (Flush) Mode Description (For Lift Stations) TheoryofOperation

3.2 Anti-F.O.G. Mode Description (For Lift Stations) TheoryofOperation

3.3 Clog Prevention Mode (Key Shaft Pumps Only) TheoryofOperation

4 Digi-Gage Plus™ Front Bezel 4.1 System Status / Home 4.2.1 SystemStatus(Detailed)with1or2Transducers 4.2.2 SystemStatus(Detailed)withFloatsOnly 4.2.3 RetroConfiguration

4.3 System Menu

4.4 Pump Details

4.5 Process Trend 4.5.1 AutomaticTrendScaling 4.5.2 ManualTrendScaling

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D I G I - G A G E P L U S U S E R M A N U A LT A B L E O F C O N T E N T S

4.6 System Flow with Attached Flow Meter 4.6.1 FlowBasedonCalculations

4.7 Control Setup 4.7.1 Login 4.7.2 SystemConfiguration 4.7.3 Networksetup 4.7.4 GroupNaming 4.7.5 MotorNaming 4.7.6 MixerSetup 4.7.7 ProcessSensorsetup 4.7.8 GroupSetPoints 4.7.9 FlushControl 4.7.10F.O.G.Reduction 4.7.11PurgeSetup

4.8 Pump Alternation Mode

4.9 Simulation 4.9.1 Simulationcontinued

4.10 System Diag: Digital Inputs 4.10.1SystemDiag:DigitalOutputs

4.11 Alarm Setup: Level by Set Point 4.11.1StartsperHour 4.11.2AlarmBypass 4.12 Active Alarms: Groups with Pending Alarms 4.12.1AlarmsinGroups 4.12.2AlarmDetails

4.13 Alarm History

5 Screen Navigation Map

6 TypicalWiringbyConfiguration

Appendix Glossary/Index ModbusRegisters Alarms

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26 27 28 29 30 31 32 33 34 35 36 37

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1Section

D I G I - G A G E P L U S U S E R M A N U A LI N T R O D U C T I O N

IntroductionThankyouforpurchasingtheDigi-GagePlus™digitalconstantspeedcontrollerbyEGControls.TheDigi-GagePlus™isanaffordable,flexible,compact,SCADA-readysystemcontroller.Itisdesignedtoautomaticallycontrolamaximumofsixpumpsinuptothreeprocessgroupswithindependentstart/stopandalternationineachgroup.

The Digi-Gage Plus™ has features including:

•Remoteaccessfromsmartphones,tabletsandcomputers •Remoteviewingofthebuilt-inscreens •WellClean-Out(Flush)mode •WellF.O.G.mode •Clogpreventionmode(3pumpsorless) •Advancedgrouping •Operationofupto6pumps

TheDigi-GagePlus™isdesignedtobebackwardcompatiblewithEGControl’sclassicDigi-Gage2300,2400,and2600products.ItcanintegrateintovirtuallyanySCADAsystem.PreviousmodelsoftheDigi-Gageproductsnolongerachievetoday’ssystemrequirements,theDigi-GagePlus™can!TheDigi-GagePlus™hasbeendesignedtofitinthesamepanelcutoutofthepreviousmodel.IfapreviousDi-gi-Gagedidn’tcomeinstalledwithSCADAcompatibility,theDigi-GagePlus™can!

TheDigi-GagePlus™canbepartneredwithpopularflowmetersorcanmakebasicflowcalculationsbasedonwet-welldimensions.TheDigi-GagePlus™featuresalternationthatcanalternatetheleadandlagpumps.Itusesinformationthesystemcollectsfrompumpstartandruntimes.TheDigi-GagePluscanoperateasafloatcontrollerandalternatethepumpsunderfloatcontrolifsetupintriplexorduplexoperationsonly.TheDigi-GagePluscanalsoactasafloatmonitortoensurefloatsareoperatingcorrectlywhilethesystemisrunningwithtransducerlevelinput.

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SectionD I G I - G A G E P L U S U S E R M A N U A L

C O N T R O L L E R D A T A

Digi-Gage Plus™ Controller Data

22.1 Hardware Ratings:

Thehardwareratingsareasfollows:

Display 3.5″graphicaltouchscreendisplay Operating temperature 0to+60°C(32to140°F) Storage temperature -20to+60°C(-4to140°F) Relative humidity (RH) 10to95%(non-condensing) NEMA/IP rating NEMA4X/IP65/66 Voltage range 10.2to28.8VDC<10%ripple Power consumption npninputs280mA@24VDC pnpinputs190mA@24VDC Backlight20mA@24VDC Ethernetcard35mA@24VDC RelayOutputs(ea.)8mA@24VDC

SystemConfiguration:

Thecontrollerincludesanintegratedprocessor,embeddedI/O,colortouchscreenpanel,andfivesealedmembranefunctionkeys.SystemRatingsareasfollows:

•15µsscanrate •AdjustablewhiteLEDbacklightTFTLCDdisplay •Colors65,536(16-bit) •320x240pixelresolution •3.5″viewingarea;resistive,analogtouchscreen •Fivefunctionkeys,sealedmembraneswitch

Controllersupportsthefollowingfeatures:

•Remoteaccess •MicroSDcardbackup/upload/logging •Datalogging •OPCservercompliant •DDEformatread/write

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D I G I - G A G E P L U S U S E R M A N U A LC O N T R O L L E R D A T A

System Processor:

•Removablememory:standardSDorSDHC(32GBmaximum) •Real-timeclock •Batterybackup(sevenyearstypicalat25°C) •Replaceable,coin-typelithiumbattery(CR2450)

Base Features:

•Inputvoltage24VDC •(22)digitalinputsrated24VDC(twoconfigurableasanalogcurrent/voltage) •12relayoutputsrated5Aat250VAC/30VDC •COM1port:RS232/RS485(upto32nodes) •COM2port:Ethernet

Communication Interfaces (optional):

COM1port:

•RS232/485baudratesbetween300and115,200bit/s •RS485upto32nodes/1200m(4000ft.)maximum •USB2.0compliant;fullspeed

COM2port:

•Ethernet

2.2 Process Features:

•Clean-out(flushmode)—simpletime-orcycle-basedconditions

•Fats,OilsandGrease(F.O.G.)builduppreventionmode

•Clogpreventionmode—simpletime-orcycle-basedconditionsupto3pumps.(Optionrequirestheadditionofreversingcontractors,pressurefeedback,andexpandedinputmodule;check with pump manufacturer to ensure reversing pump is allowed)

•Floats

•Pressure

•Level

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D I G I - G A G E P L U S U S E R M A N U A LC O N T R O L L E R P R O C E S S F E A T U R E S

Process Features Continued:

•Flow

•Multi-functionalcontrol

•Pumpup

•Pumpdown

•Functioncombinations

•Advancedgroupingfeaturesupto3groups

2.3 Feature Details:

Six-PumpSystem:

•NouserselectableI/O—usestandardfixedI/Oassignments •Pump/blowergroupingfeature •Clogpreventionfeature •Greasebuildupfeature •Clean-outfeature

Five-PumpSystem:

•Allowsforthreeuser-selectableinputs •Allowsforoneuser-selectableoutput •Pump/blowergroupingfeature •Clogpreventionfeature •Greasebuildupfeature •Clean-outfeature

Four-PumpSystem:

•Allowsforsixuser-selectableinputs •Allowsfortwouser-selectableoutputs •Pump/blowergroupingfeature •Clogpreventionfeature •Greasebuildupfeature •Clean-outfeature

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D I G I - G A G E P L U S U S E R M A N U A LC O N T R O L L E R F U N C T I O N A L I T Y

Three-PumpSystem:

•Allowsfornineuser-selectableinputs •Allowsforthreeuser-selectableoutputs •Pump/blowergroupingfeature(maximumofthreegroups) •Clogpreventionfeature(liftstationfeature) •Greasebuildupfeature(liftstationfeature) •Clean-outfeature(liftstationfeature) •Floatmonitoringfeature(liftstationfeature) •Ifenabled,fiveoftheuser-selectableinputswillbepredefinedasfloatfeedbackinputs

2.4 Controller Functionality:

•Supportsuptosixconstantspeedmotors(pumps,blowers,etc.)

•Alternation: •Alternateonmotorstop •Alternatetoequalizeruntime(indevelopment) •Fixanymotoraslead(noalternation) •Alternatemotorsindependentlywithineachgroup

•Levelsimulationtotestsetupfunctionandalarmsetpoints

•SCADAintegration

•Advancedgrouping: •Groupanynumberofthesixpumpsinuptothreegroups

•Controllercanberemotelyviewableandoperated

•Controllerstoresdatalocallythatcanbeviewedlocallyorremotely

•Controllerhaswebserverfeatures

•Controllercanbeconfiguredfordifferentmodesofoperation: •Pumpdown •Pumpup •Retro

•Controllerisconfigurableforselectablemonitoringmodes: •Floatsystemmonitoring •Backuptransducer •Sealwatersystemmonitoring

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D I G I - G A G E P L U S U S E R M A N U A LC O N T R O L L E R F U N C T I O N A L I T Y

Controller Functionality Continued:

•Pumpmonitoring •Suctionpressure •Dischargepressure

•Calculatesinflowandoutflowdynamicallyingallonsperminuteorcubicfeetperminute(withcompatibleflowmeterinstalled)

•Controllerdisplaysthetotalpumporblowerrun-timehours,totalstarts,andstartsperhour

•Controllerallowsentryofwet-wellgeometryforflowcalculationswhennoflowmeterispresent.

•Relayoutputsforsystemfaults,pumpstart/stops,commonalarmsforhighandlowlevelsavailable

2.5 Typical Wiring Diagrams:

Digitalinputwiring

•TheDigi-GagePlus™controllerisbackwardcompatiblewiththeDigi-Gage2300,2400,and2600asmanufacturedbyEGControlsofJacksonville,Florida.

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Analoginputwiring

Relayoutputwiring

D I G I - G A G E P L U S U S E R M A N U A LC O N T R O L L E R W I R I N G D I A G R A M S

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SectionD I G I - G A G E P L U S U S E R M A N U A L

M O D E S O F O P E R A T I O N

Modes of Operation

33.1 Clean Out (Flush) Mode Description (For Lift Stations):

Thesystememploysuser-adjustabletime/cyclesetpointstoallowpumpstorunbeyondthenormallevelsetpointstoflushthewetwelltohelppreventabuildupofsolids.

Clean Out Theory of operation:

Astheliftstationoperatesbasedonconfiguredlevelsetpoints,thepumpsgothroughtheautomatedoperationstopumpdowntheliftstationtotheconfiguredlow-levelpumpshutoffsetpoint.Ascreenisprovidedfortheuserconfiguredpumpdowncycles,num-berofdaysofoperation,andaClean-Out(enable/disable)mode.

Oncethismodeisenabledandthenumberofcyclesornumberofdaysisconfigured,thesystemwilloperateasfollows:

Oncetheuser-configuredsetpoint(eitherthenumberofcyclesornumberofdays)isreached,thesystemwillignorethenormalstart/stoppumpsetpointsandallowthestationtofilltotheflushhigh-levelsetpoint.Oncethisflushhighlevelisreached,thesystemwillstarttheuser-selectedavailablepumpstopumpdowntheliftstationandflushthestationwetwell.

3.2 Anti-F.O.G. Mode Description (For Lift Stations):

Thisfeatureprovidesthesystemwithavaryingstartlevel(percentagebased)modetohelppreventF.O.G.(Fats,Oils,Grease)buildupduetothewet-welllevelreachingthesamepoint,causinganaccumulationofF.O.G.onthesidesoftheliftstation.

Ascreenisprovidedfortheusertoenable/disablethisfeatureandtosetthepercentagevariationallowedtothelevel.

ATTENTION:Useofthisfeaturerequiresunderstandingofliftstationandpumpoperations.Thisfeatureshouldbesetupbyqualifiedpersonneltoensureproperfunctionalityandpreventpotentialdamagetopumpsandlift-stationhardware.

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Anti-F.O.G. Theory of operation:

WhentheAnti-F.O.G.modeisenabled,thepercentagevariableisset.Eachtimethepumpdowncycleisinitiated,thesystemwilladjusttheuser-definedlevelsetpointbythepercentageenteredintothevariancefield.Thenextcyclewillwaituntilthis“calculated”levelvalueisreachedandstartthepumpdowncycle.Thesystemwillrunthroughaseriesofthesecalculationstoallowasemi-randomlevelforstartingthepumpdowncycle.

Anti-F.O.G.willnotnecessarilyreducetheamountofmatteronthewellwalls.Anti-F.O.G.willeliminate“shelves”ofmatterbuildingup.

3.3 Clog Prevention Mode (Key Shaft Pumps Only):

Thisfeatureprovidesanautonomousmeansofhelpingtopreventclogsthatbuilduponapump’simpeller.

Clog Prevention Theory of Operation:

Ascreenisprovidedtoenable/disabletheClogPreventionmode.Thede-matteroperationisbasedonaconfigurablenumberofpumpingcy-clesornumberofdays.Oncethismodeisenabledandthenumberofcyclesornumberofdaysisset,thesystemwilloperateasnormaluntilthesetpointisreached.Aclogpreventioncyclewillinitiate,andthepumpwillreversedirectionandthenrunforward(basedonthenumberofcyclessetbytheuser)toattempttocleanthepumpimpeller.Thisisanopen-loopautomaticmodethatdoesnotuseanyfeedbacktodetermineaclogormatterbuildup.

ATTENTION:Useofthisfeaturerequiresunderstandingofliftstationlevels.Thisfeatureshouldbesetupbyqualifiedpersonneltoensureproperfunctionalityandpreventnuisanceactivationoffloatbackupoperations.

ATTENTION:Ensurethatreversefunctionisavailablefromthepumpmanufacturer.Useofthisfeaturewithoutkey-shaftedpumpscandamagepumps!

ATTENTION:Useofthisfeaturerequiresadditionalreversingstartersandhardwareinstalledinthecontrolpanel.

ATTENTION:Thisoptionworksonsystemsof3pumpsorless.

D I G I - G A G E P L U S U S E R M A N U A LM O D E S O F O P E R A T I O N

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Section

4Digi-Gage Plus™ Front Bezel

D I G I - G A G E P L U S U S E R M A N U A LC O N T R O L L E R F R O N T B E Z E L

Buttons:

HOME AUTO PROG SIM ESC

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1

3

4

5

Returnstothetraditionalsystemstatusscreen

Terminatessimulationcontrol

DisplaystheSystemMenuscreen

DisplaystheSimulateLevelscreen

Returnstopreviousscreenor“back”button

Thesefiveblisterbuttonsareavailabletotheoperatoratanytime,fromanyscreen.

HOME

AUTO

PROG

SIM

ESC

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Display:

D I G I - G A G E P L U S U S E R M A N U A LC O N T R O L L E R S C R E E N S

4.1 System Status / Home

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1.Alarmstatus2.Sensorinuse3.Level:units(PSI,DO,FT,GPM)fortheprocessvalueassignedtothegroupdisplayed4.ScaledProcessValue:currentmeasurement;presstodisplaytheSystemStatusdetailedscreen.(4.2.1)5.BarGraph:scaledas0%–100%oftheprocessvalue6.LagPump(s)Status:white(Off),blinkingred(Starting),solidred(Running)7.LeadPumpStatus:white(Off),blinkingred(Starting),solidred(Running)8.MixerStatus:white(Off),solidred(Running)9.Low-LevelIndicator:solidred(Low-LevelAlarm)10.High-LevelIndicator:solidred(High-LevelAlarm)11.GroupStatus:displayscurrentgroupSystemStatus;presstotogglebetweentheconfiguredgroups(typicalofeachgroup;maximumofthreegroups)

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Display:


4.2.1 System Status (detailed) with 1 or 2 transducers

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1.Measuredoutputoftransducer1ifpresent2.Pumpidentifier3.Startingidentifier4.Motorstatus5.Hourmeter6.Mixerstatusifpresent7.Alarmstatus8.Measuredoutputoftransducer2ifpresent blisterbuttonsnavigateoffthisdisplayHOME PROG ESC

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Display:


4.2.2SystemStatus(detailed)withfloatsonly

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1.Statusofeachofthe6Floatsneededforpropercontrolofthepumps:•HighFloat:HighWetWellLevelAlarmFloat•LAG2Float:2ndLagPumpcalltoRunFloat•LAG1Float:LagPumpcalltoRunFloat•LeadFloat:LeadPumpcalltoRunFloat•StopFloat:PumpStopFloat•LowFloat:LowWetWellLevelAlarmFloat2.FloatStatusKey:REDFloatnotTipped;GREENFloatisTipped3.PumpNameasdefinedintheControlSetupscreensdisplayshere4.StatusofthePump;RUNNINGorSTOPPED5.PumpH-O-ASwitchstatus:AUTO,NOTAUTO blisterbuttonsnavigateoffthisdisplayHOME PROG ESC

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Display:


4.2.3RetroConfiguration1

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1.Units(PSI,DO,FT,GPM)fortheProcessValueassignedtotheGroupsetintheengineeringscreens2.ScaledProcessValuecurrentmeasurement3.Abargraph,scaledas0-100%oftheProcessValue-4.PurgeCycleStatus:whiteoff,solidredPurgeinProgress(AvailableonTriplexandQuadplex)5.IsolationValveStatus:whiteValveOpen,solidredValveClosed(AvailableonTriplexandQuadplex)6.LagPump(s)Status:whiteoff,blinkingredStarting,solidredRunning7.LeadPumpStatus:whiteoff,blinkingredStarting,solidredRunning8.lowlevelindicator:solidredLow-LevelAlarm9.Highlevelindicator:solidredHigh-LevelAlarm10.DisplaysthePurgesetupscreen(AvailableonTriplexandQuadplex)(4.7.10)

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Display:


4.3 System Menu

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1.SystemStatus:displaystheSystemStatushomescreen(4.1)2.PumpDetails:displaysPumpDetailsscreen(4.4)3.ProcessTrend:displaystheProcessTrendscreen(4.5)4.SystemFlow:displaystheSystemFlowscreen(4.6)5.ControlSetup:displaystheControlSetupscreen(4.7)6.PumpAltMode:displaystheAlternationSetupscreensforeachconfiguredgroup(4.8)7.SimulateLevel:displaystheSimulationLevelscreenforgroupprocessvariable(4.9)8.SystemDiag:Displaysinputandoutputstatus(4.10)9.HornSilence:silencesthehorninanalarmcondition10.AlarmSetup:displaystheAlarmSetupscreenforeachoftheconfiguredgroups(4.11)11.ActiveAlarms:displaystheActiveAlarmspop-upscreen(4.12)12.AlarmHistory:displaystheAlarmHistoryscreen(4.13)13.AlarmReset:resetsthealarmlogiciftheconditionhasbeencleared

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Display:


4.4 Pump Details

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1.PumpName:displayspumpname,asdefinedintheControlSetupscreen2.PumpH-O-ASwitchStatus:displaysAutowhencontrolpanelisinAuto.DisplaysNotAutowhencontrolpanelisinOfforHand.3.GroupandPosition:thegroupthepumpbelongstoandthepump’spositioninthealternationsequenceofthatgroup4.StatusofthePump:RunningorStopped5.PresstotoggleEnabledorDisabled6.Displaysthenumberoftotalstarts7.Displaysthenumberofstartsperhour8.Elapsedtimemeter9.Next:displaysthenextPumpDetailsscreen(typicalforeachPumpDetailscreen;maximumoffivepumps)10.Menu:displaystheSystemMenuscreen(4.3)

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Display:


4.5 Process Trend

1.TrendName:groupprocessvalueandflowmeter,ifconfigured2.Trendoftheprocessvalue3.TapScreen:togglesbetweengroupsandflowmeter(maximumthreegroups)4.TogglestheScrollbuttonsOnandOff5.TogglesthegridOnandOff6.Trendaperture.Thisissetupin4.7.6ifthefluidlevelisoutsideofthisrange,nothingwillbedisplayed7.Menu:displaystheSystemMenuscreen(4.3)8.Scalebutton:SetupTrendScaling(4.5.1)9.Selectedengineeringunit(PSI,DO,FT,GPM)

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Display:


4.5.1 Process Trend: Automatic Trend Scaling

1.Closebutton:returnstoTrending(4.5)2.ScaleSPChange:Togglebetweenautomaticandmanual(4.5.2)

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Display:


4.5.2 Process Trend: Manual Trend Scaling

1.Closebutton:returnstoTrending(4.5)2.ScaleSPChange:Togglebetweenautomaticandmanual(4.5.1)3.SetmanualsetpointsMinandMax

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Display:


4.6SystemFlow:Withattachedflowmeter

1.Displaysthecurrentreadingfromtheflowmeter2.Menu:displaystheSystemMenuscreen(4.3)

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Display:


4.6.1 System Flow: Flow based on calculations

1.CalculatedDischargeFlowinGPM:calculatedwhenapumpcomesonlineandpumpsdownthewell2.CalculatedIn-FlowinGPM:calculatedbythetimeittakestofillthewell3.Menu:displaystheSystemMenuscreen(4.3)

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Display:


4.7 Control Setup: Login

1.Presstoinputpassword:______contactyourrepforyourpassword2.Ifcorrectpasswordisentered,SystemSetupbuttonappears;presstodisplaythefirstSystemConfigurationscreen3.Menu:displaystheSystemMenuscreen(4.3)

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Display:


4.7.1 Control Setup: Login (continued)

1.Passwordwillbedisplayedtoindicateithasbeenaccepted2.PresstoenterSystemSetup(4.7.1)3.Menu:displaystheSystemMenuscreen(4.3)

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Display:


4.7.2ControlSetup:SystemConfiguration

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1.SystemClock:displaysthecurrenttimeinthecontroller;presstochangethetime2.SystemClock:displaysthecurrentdateinthecontroller;presstochangethedate3.StartDelayAfterPowerUp:thedelay,inseconds,beforestartingpumpsafterpoweruporresetfromfloatcontrol;presstoenteranewvalue4.StopTrendtoSDCard:presstostoreprocessdatatoanSDcard(anSDcardmustbeinstalled)5.ThecontrollerdetectstheexistenceofanSDcardanddisplaystheresults6.DelayBetweenPumpStarts:thedelay,inseconds,betweenpumpstarts(preventssimultaneousstartsifmorethanonepumpiscalledatthesametime);presstoenteranewvalue7.Next:displaysthenextconfigurationscreen(4.7.3)

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Display:


4.7.3 Control Setup: Network Setup

1.CurrentEthernetaddress;presstoenteranewEthernetaddress2.Currentsubnetmask;presstoenteranewsubnetmask3.Currentgatewayaddress;presstoenteranewgatewayaddress4.TheControllerwilldetecttheEthernetcardanddisplaytheresults5.CurrentModbusaddress;presstoenteranewModbusad-dress6.Next:displaysthenextconfigurationscreen(4.7.4)7.ResetPLC:Foranymodificationsonthisscreentocomplete,thepowermustbecycled.PressingResetPLCwillfinalizethisprocess.

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ATTENTION:CyclepowertothecontrollertosavetheEthernetaddress.

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Display:


4.7.4 Control Setup: Group Naming

1.Thelabelforeachgrouptobenamed2.Presstosetname;nine-charactermaximumforeachgroup;thenameswilldisplayonnumerousscreens3.Next:displaysthenextconfigurationscreen(4.7.5)

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Display:


4.7.5 Control Setup: Motor Naming

1.Thelabelforeachmotortobenamed2.Presstosetname;seven-charactermaximumforeachmotor;thenameswilldisplayonnumerousscreens3.Next:displaysthenextconfigurationscreen(4.7.6)

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Display:


4.7.6ControlSetup:MixerSetup(iffactoryconfigured)

1.Selectwhenthemixercanrun:•Pumpsarestopped•Pumpsarerunning•Anytime2.TimeControl:controlsthemixerbasedontime3.Thenumberofminutesthemixerruns4.Thenumberofminutesthemixerisoff5.LevelControl:selecttocontrolthemixerbaseonlevelsetpoints6.Thestartlevelforthemixer7.Thestoplevelforthemixer8.Next:displaystheSystemMenuscreen(4.7.7)

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Display:


4.7.7 Control Setup: Process Sensor Setup

1.Presstosetlevelvaluefor4mAsignal;thisdeterminestheminimumvaluefortheprocessvaluethecontroller’smeasure-ments2.Presstosetlevelvaluefor20mA;thisdeterminesthemaxi-mumvaluefortheprocessvaluethecontroller’smeasurements3.ResponseTrigger:avaluebetween0and5thatcorrespondstosamplingdelayof0–250mS;presstosetvalueforthesamplerateforthecontrollertoreadtheprocessvalue4.AnalogInput:scaledvalueofthesensorinmA5.ScaledValue:engineeringunitsbasedontheinputsabove6.Selectedengineeringunit(PSI,DO,FT,GPM)7.Thegrouporflowmeterassignedtotheprocessvalve8.Next:displaysthenextconfigurationscreen(4.7.8)

Note:ThisscreenistypicaltotheProcessSensorNo.2Scalingscreen.

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Display:


4.7.8 Control Setup: Group Set Points

1.Presstoentertheleadpumpstartlevelsetpoint(typical)2.Presstoentertheleadpumpstoplevelsetpoint(typical)3.Displaystheconfiguredengineeringunits4.Next:displaysthenextconfigurationscreen(4.7.9)

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Display:


4.7.9ControlSetup:FlushControl(iffactoryconfigured)

1.Displaysthecurrenttime2.Statusoftheflushprotocol:Stopped,WaitingonLevel,orRunning3.Startsetpointforleveloftheflush;presstochangethevalue4.Hourtostarttheflush;presstochangethevalue5.Dayoftheweektoruntheflush:Monday,Tuesday,Wednes-day,Thursday,Friday,orDisable6.PresstheUporDownarrowstochangethedayofweek7.Stopsetpointforleveloftheflush;presstochangethevalue8.Start:startstheflush,overridingtheautomaticconfiguration9.Stop:stopstheflush,overridingtheautomaticconfiguration10.BarGraph:displaystheactualwelllevel11.Next:displaysthenextconfigurationscreen(4.7.10)12.Menu:displaystheSystemMenuscreen(4.3)13.Numberofflushcyclesperformed14.Numberofpumpsselected-thisislimitedtothenumberofpumpsinthegroup

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Display:


4.7.10ControlSetup:F.O.G.Reduction(iffactoryconfigured)

1.LeadStartLevelRangebutton:Presstoenteravalue.IfthevalueexceedstheLag1StartLevelset-pointtheenteredvaluewillbeautomaticallyadjustedbelowtheLag1set-point.2.DescriptionandinstructionontheF.O.G.Reductionfeature3.NEXTbuttondisplaysGroup2LevelSetPointscreen.IfonlyoneGroupisconfiguredtheMainMenuisdisplayed(4.3)

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Display:


4.7.11ControlSetup:PurgeSetup(iffactoryconfigured)

1.ManualPurgebutton:PresstotriggeraPurgeCycle2.StartHour:Presstoenteravaluefrom0(Midnight)to24(Disable)3.DisplaysthecurrentconfiguredStartHour4.Exitbutton:PresstoclosethePop-upScreen(4.3)

1

2

3

4

38


Display:


4.8 Control Setup: Pump Alternation Mode (in development)

1.LabelsasdefinedinProcessMotorNames(see4.7.5)andtheirpositionsinthealternationschema2.PresstoChangeAlternationMode:togglesbetweenanumberofmodes,dependingonthenumberofpumpsconfiguredforthegroup.Possiblemodes:•AlternateonPumpStop•AlternatetoEqualizePumpRuntime•Motor1LeadNoAlternation•Motor2LeadNoAlternation•Motor3LeadNoAlternation•Motor4LeadNoAlternation•Motor5LeadNoAlternation•Motor6LeadNoAlternation3.DisplayscurrentAlternationmode4.EnterOffsetSP:displaystheAlternatetoEqualizePumpRun-Timemode;presstoentervalue5.Menu:displaystheSystemMenuscreen(4.3)

1

2

4

3 5

39


Display:


4.9 Simulation

1.Selectapumpgroupforsimulation(4.9.1)2.ClosereturnstotheSystemMenu(4.3) blisterbuttonwillalsonavigatedirectlytothisscreen.

1

2

SIM

40


Display:


4.9.1 Simulation

1.BarGraph:displaystheactuallevel2.BarGraph:displaysthesimulatedlevel3.PumpConfigurations:•DisplayspumpnameasdefinedintheControlSetupscreens•Thegroupnumberthepumpbelongstoandthepump’spositioninthealternationsequence•Statusofthepump:RunningorStopped•PumpH-O-Aswitchstatus:AutoorNotAuto4.LevelUp:increasestheSimulationLevelbyone-tenthofaunit5.LevelDown:decreasestheSimulationLevelbyone-tenthofaunit6.ExitSimulation:exitsSimulationLevelscreenandreturnstheprocessvalueinputasthecontrollingsignal7.Menu:displaystheSystemMenuscreen(4.3)

675

1

2

4

3

41


Display:


4.10 System Diag: Digital Inputs

1.Nextbutton:todisplayDigitalOutputs(4.10.1)

1

42


Display:


4.10.1 System Diag: Digital Outputs

1.Menubutton:ReturnstoSystemMenu(4.3)

1

43


Display:


4.11 Alarm Setup: Level Set Point by Group

1.Presstosetgroup1high-levelalarmsetpoint2.Presstosetgroup1low-levelalarmsetpoint3.Presstosetgroup2high-levelalarmsetpoint4.Presstosetgroup2low-levelalarmsetpoint5.Presstosetgroup3high-levelalarmsetpoint6.Presstosetgroup3low-levelalarmsetpoint7.Next:displaysthesecondAlarmSetupscreen(4.11.1)8.Menu:displaystheSystemMenuscreen(4.3)

Thenumberofgroupssetupwillbedisplayed

8

6

7

5

1

2

4

3

44


Display:


4.11.1 Alarm Setup: Starts Per Hour

1.Presstosetpump1startsperhoursetpoint2.Presstosetpump2startsperhoursetpoint3.Presstosetpump3startsperhoursetpoint4.Presstosetpump4startsperhoursetpoint5.Presstoreturnthemainmenu(4.3)6.Presstosetpumps5and6thennextAlarmSetupscreen(4.11.2)

6

5

1

2

4

3

45


Display:


4.11.2 Alarm Setup: Alarm Bypass

1.PresstosetDisable/EnableGroup1Highlevel2.PresstosetDisable/EnableGroup1Lowlevel3.PresstosetDisable/EnableGroup2Highlevel4.PresstosetDisable/EnableGroup2Lowlevel5.PresstosetDisable/EnableGroup3Highlevel6.PresstosetDisable/EnableGroup3Lowlevel7.Presstoreturntothemainmenu(4.3)

7

6

5

1

2

4

3

46


Display:


4.12 Active Alarms: Groups with Pending Alarms

1.Displaysalarmgroupdetails(4.12.1)2.AlarmRefresh:presstoreset;thealarmwilltriggeragainiftheconditionthatcausedthealarmstillexists3.Esc:returnstothepreviousscreen(4.3)

1

2

3

47


Display:


4.12.1 Active Alarms: Alarms in Group

1.Displaysalarmdetails(4.12.2)2.AlarmRefresh:presstoreset;thealarmwilltriggeragainiftheconditionthatcausedthealarmstillexists3.Esc:returnstothepreviousscreen(4.12)

1

2

3

48


Display:


4.12.2 Active Alarms: Alarm Details

1.Priority:displaysprioritylevelofthealarm2.Group:displaysalarm’sgroupIDnumber3.Alarmgroupname4.Alarm’sID5.Alarm’sname6.Dateandtimestampwhenthealarmbecameactive7.Dateandtimestampwhenthealarmbecameinactive8.Dateandtimestampwhenthealarmwasacknowledged9.Dateandtimestampwhenthealarmwasreset10.Timestampofthedurationofalarmevents(active,inactive,acknowledged,andreset)11.Navigation:scrollsbetweenalarms12.Esc:closestheAlarmHistoryscreen(4.12.1)

10

1

2

4

6

8

9

7

3

5

12

11

Alarm Details

49


Display:


4.13 Alarm History

1.Priority:displaysprioritylevelofthealarm2.Group:displaysalarm’sgroupIDnumber3.Alarmgroupname4.Alarm’sID5.Alarm’sname6.Dateandtimestampwhenthealarmbecameactive7.Dateandtimestampwhenthealarmbecameinactive8.Dateandtimestampwhenthealarmwasacknowledged9.Dateandtimestampwhenthealarmwasreset10.Timestampofthedurationofalarmevents(active,inactive,acknowledged,andreset)11.Navigation:scrollsbetweenalarms12.Esc:closestheAlarmHistoryscreen(4.3)

10

1

2

4

6

8

9

7

3

5

12

11

D I G I - G A G E P L U S U S E R M A N U A LS C R E E N N A V I G A T I O N M A P

50


5Section

System Menu Screen Navigation

5

PUMP DETAILS

PROCESS MOTOR NAMES

SYSTEM STATUS /

HOME

GROUP 2 MAIN

SYSTEM STATUS / DETAILED

GROUP 3 MAIN

PUMP 2 DETAILS

PUMP 3 DETAILS

PUMP 4 DETAILS

PUMP 5 DETAILS

PUMP 6 DETAILS

PROCESS TREND

GROUP 2 TREND

GROUP 3 TREND

FLOW- METER TREND

SYSTEM FLOW

GROUP 2 TREND

GROUP 3 TREND

CONTROL SETUP

LOGIN

SYSTEM CONFIG

ETHERNET IP

GROUP NAMING

MIXER SETUP

PROC SENSOR 1 SCALING

PROC SENSOR 2 SCALING

GROUP 1 LEVEL

SETPOINTS

GROUP 1 FLUSH

CONTROLS

GROUP 1 F.O.G.

CONTROLS

GROUP 2 LEVEL

SETPOINTS

GROUP 2 FLUSH

CONTROLS

GROUP 2 F.O.G.

CONTROLS

GROUP 3 LEVEL

SETPOINTS

GROUP 3 FLUSH

CONTROLS

GROUP 3 F.O.G.

CONTROLS

Navigation of Displays

ButtonwilldisplaythesystemmenuscreenPROG

D I G I - G A G E P L U S U S E R M A N U A LS C R E E N N A V I G A T I O N M A P

51


PUMP ALT MODE

GROUP 2 CONFIG

GROUP 3 CONFIG

ALARM RESET

HORN SILENCE

ALARM HISTORY

ACTIVE ALARMS

ALARM SETUP

ALARM SETUP

GROUP 2

SYS DIAG DIGITAL INPUTS

ALARM SETUP

GROUP 3

MOTOR STARTS

PER HOUR

MOTOR STARTS

PER HOUR

SYS DIAG DIGITAL

OUTPUTS

SIMULATE LEVEL

GROUP 1 SIMULATION

SIMULATION FOR GROUP SELECTED

GROUP 2 SIMULATION

GROUP 3 SIMULATION

Navigation of Displays

Buttonwilldisplaythesystemmenuscreen

ButtonwilldirectlyenterthesimulationareaSIM

PROG

52


Section

Typical Wiring by Configuration

6D I G I - G A G E P L U S U S E R M A N U A L

W I R I N G C O N F I G U R A T I O N S

Wiringconfigurations:

ThefollowingpagesshowfullpageterminationsforSimplex,Duplex,Triplex,Quadplex,Fiveplex,Sixplex,FloatOnlyandRetroconfigura-tions.

53


SimplexConfiguration:

D I G I - G A G E P L U S U S E R M A N U A LW I R I N G C O N F I G U R A T I O N S

Please note:

NotUsedalsomeansNotAvailabletothefactorysetconfiguration.

54



DuplexConfiguration:

Please note:


55


TriplexConfiguration:


Please note:


56



QuadplexConfiguration:

Please note:


57


FiveplexConfiguration:


Please note:


58



SixplexConfiguration:

Please note:


59


FloatsOnlyConfiguration:


Please note:


60



RetroConfiguration:

Please note:


61


Appendix

Glossary / Index

GD I G I - G A G E P L U S U S E R M A N U A LG L O S S A R Y

% DO EngineeringUnit:Percentagedissolved oxygen

20mA Value Maximumscaledvaluewhentheprocess valueisat20mA

4mA Value Minimumscaledvaluewhentheprocessvalueis at4mA

Ack. Time Timetakentoacknowledgethealarm

Alarm Asystemorequipmentfault

Alarm ID Identificationnumberassociatedwithanalarm

Alarm Name Thenameofanalarm

Alternate Sequencemotoroperationtoshareleadposition

Analog Input ProcessvalueinmA

Auto Thesetconditionforthecontrollerto automaticallystart/stopmotor(s)

Duration Howlonganeventtookplace

Equalize Alternationsettingtobalancetheruntimehours betweenmotors

Ethernet (IPAddress)Auniquenumberassignedtoa Address devicetocommunicateonanetwork

Ethernet Card Hardwaremodulefornetworkcommunications

Pages 15,18,21,33

Page 33

Page 33

Pages 48, 49

Pages 9, 10, 15, 16, 19, 43-49, 68,69

Pages 46-49

Pages 46-49

Pages 5, 9, 38

Pages 7, 11, 33

Pages 17, 20, 22, 23, 40

Pages 48, 49

Pages 9, 38

Page 29

Pages 6, 29

62


External Float Floatcontrolsystemtorunpumpswithout Control thecontrollerinput

Flow meter Adevicethatcalculatesflowofmaterial

Flush Aprotocolmeanttopumpalargevolumeoffluid atonetimetoclearanyrestrictionsinthepipes

Flush Start Theflushprotocolstartsetpoint

Flush Stop Theflushprotocolstopsetpoint

F.O.G. Fats,OilsandGrease

Ft EngineeringUnits:LevelmeasuredinFeet

Gateway ArouterinterfaceconnectedtothelocalnetworkAddress thatsendsdatapacketsoutofthelocalnetwork

GPM EngineeringUnits:GallonsPerMinute

Group 1 Thefirstgroupingofmotors(1-6)

Group 2 Thesecondgroupingofmotors(1-5)

Group 3 Thethirdgroupingofmotors(1-4)

Group ID Identificationnumberagroupassociatedwithan alarm

Group Name Thenameofthegroup

Hand Thesetconditionmanuallystart/stopmotor(s)

High-Level Levelsetpointtotriggerahighlevelalarm

Horn Theaudiblenoiseassoicatedwiththealarm

D I G I - G A G E P L U S U S E R M A N U A LG L O S S A R Y

Pages 19, 21, 24, 52, 33

Pages 7, 12, 35

Page 35

Page 35

Pages 7, 12, 13, 36

Pages 15, 18, 21, 33

Page 29

Pages 15, 18, 21, 25, 33

Groups are covered on pages 8, 9, 15, 18, 19, 20, 21, 30, 33-36, 38-40, 43, 45-49

Page 20

Pages 12, 18, 45

Page 19

63


Internal Float Floatcontrolsystemtorunthepumpswith Control controllerinput

Lag 1 Secondmotortostartinthequeue

Lag 2 Thirdmotortostartinthequeue

Lag 3 Forthmotortostartinthequeue

Lag 4 Fifthmotortostartinthequeue

Lag 5 Sixthmotortostartinthequeue

Lead Firstmotortostartinthequeue

Level Theheightmeasurementoftheprocessliquid

Low-Level Measurementdeemedtoolowforappropriate function

Mixer Asingleoutputtocontrolablowerormixer basedontimeorlevel

Modbus Atypeofindustrialcommunicationprotocol overseriallinesbetweenelectronicdevices

Off Thesetconditionmanuallykeepingmotor(s) fromrunning

Priority Theseverityofatriggeredalarm

Process Sensor Adevicethattakesthemeasurementsandgives ananalogvaluetothecontroller

PSI EngineeringUnit:PressureperSquareInch

Pump Delay Theamountoftimethedevicewillwaitbefore turningonapumpormotor

Pump Down ReadslevelandpumpswateroutofthewellControl whenwaterlevelsaretoohigh


Page 28

Lead / Lag is covered on pages 9, 15, 17, 18, 34, 36, 38

Pages 7, 9, 10, 12-15, 17-19, 21, 32-36, 40, 43, 45

Pages 12, 15, 18, 43

Pages 15, 16, 32

Pages 29, 65-67

Pages 48, 49

Page 33

Pages 15, 18, 21, 33

64


Pump Up UsespressuretodetectwhenwaterlevelsareControl lowandpumpswaterbackintothewell

Queue Asequenceofmotors

Reset Time Timetakentoresetafteranalarm

Response Adelayintheprocessvaluesampling(0-250)inTrigger Value miliseconds

Running Feedbacktothecontrollerthemotorisin operation

Scaled Value ProcessvaluedisplayedinEngineeringUnits

Start Delay Theminimumtimebetweenpumpstarts

Start Set Point Theprocessvaluehasreachedacondition wherethemotoriscalledtostart

Stop Set Point Theprocessvaluehasreachedacondition wherethemotoriscalledtostop

Stopped Feedbacktothecontrollerthemotorisnotin operation

Subnet Mask AnumberthatdefinesarangeofIPaddresses availablewithinanetwork

Trigger Rise Dateandtimestampwhenthealarmbecame Time active

Trigger Fall Dateandtimestampwhenthealarmbecame Time inactive


Pages 48, 49

Pages 33, 37

Pages 15, 17, 18, 20, 32, 35, 40

Page 33

Page 28

Page 35

Page 35

Pages 17, 20, 32, 35, 40

Page 29

Pages 17, 33

Pages 17, 33

65


Appendix

MModbus Registers

D I G I - G A G E P L U S U S E R M A N U A LM O D B U S R E G I S T E R S

Register Definition

MB 300 PhaseLoss

MB 301 FloatBackupActive

MB 302 Pump1Running

MB 303 Pump1Auto

MB 304 Pump1FaultorOver-tempAlarm

MB 305 Pump2Running

MB 306 Pump2Auto


MB 308 Pump3Running

MB 309 Pump3Auto


MB 311 Pump4Running

MB 312 Pump4Auto

MB 313 Pump4FaultAlarm

MB 316 Pump5Running

MB 317 Pump5Auto


MB 319 Pump6Running

MB 320 Pump6Auto


66


MB 322 Pump1SealFail



MB 680 LeadFloatInput

MB 681 StopFloatInput

MB 682 LowLevelFloatInput

MB 683 Lag1FloatInput

MB 684 Lag2FloatInput

MB 685 3orLessPumps

MB 686 HighFloatInput

MB 330 Pump1Start/Stop






MB 336 HighLevelAlarmTriggerbyXdcr

MB 337 LowLevelalarmbyXdcr

MB 338 CommonAlarmLight

MB 340 PLCFaultedorPurgeCycle

MB 341 MixerControlorRetroIsolationSolenoid

MI 304 Pump1RunHrstoHMI




67





MI 43 Group1LevelSignal




68


D I G I - G A G E P L U S U S E R M A N U A LA L A R M S

Alarms

AAppendix

Alarm Definition

000 AlarmG1HighLevel

001 AlarmG1LowLevel

002 Pump1FailtoStart

003 Pump2FailtoStart

004 P1CommonAlarmorOver-temp

005 P2CommonAlarmorOver-temp

006 HighFloat

007 Phase

008 FloatsEnabled

009 AnalogSignaloutofRangeorHighFloatInput

010 Pump1Starts/HrExceeded


012 AnalogSignal1outofRange

013 G2HighLevelAnalog

014 AlarmG2LowLevelAnalog

015 LowFloat

016 Pump1SealFailure



019 Pump3FailedtoStart

69


D I G I - G A G E P L U S U S E R M A N U A LA L A R M S

020 P3CommonalarmorOver-temp


022 G3HighLevel

023 G3LowLevel




027 Pump4CommonAlarmorSealFail



030 AlarmP6Starts/HrExceeded

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