digital constant speed controller · g controls digi-gage plus ser manual - ersion 012720-dgm-1...
TRANSCRIPT
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ESCSIMPROGAUTOHOME
Digi-Gage Plus™
Digital Constant Speed Controller SCADA-Ready | Remote Access | Backwards Compatible
User Manual
Digi-Gage Plus™
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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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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 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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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 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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EG Controls Digi-Gage Plus User Manual - Version 012720-DG+UM-TJ
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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EG Controls Digi-Gage Plus User Manual - Version 012720-DG+UM-TJ
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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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 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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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 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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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 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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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 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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EG Controls Digi-Gage Plus User Manual - Version 012720-DG+UM-TJ
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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EG Controls Digi-Gage Plus User Manual - Version 012720-DG+UM-TJ
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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EG Controls Digi-Gage Plus User Manual - Version 012720-DG+UM-TJ
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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EG Controls Digi-Gage Plus User Manual - Version 012720-DG+UM-TJ
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:
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
4.2.1 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:
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
4.2.2SystemStatus(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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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:
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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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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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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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4.5.1 Process Trend: Automatic Trend Scaling
1.Closebutton:returnstoTrending(4.5)2.ScaleSPChange:Togglebetweenautomaticandmanual(4.5.2)
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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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4.6SystemFlow:Withattachedflowmeter
1.Displaysthecurrentreadingfromtheflowmeter2.Menu:displaystheSystemMenuscreen(4.3)
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4.6.1 System Flow: Flow based on calculations
1.CalculatedDischargeFlowinGPM:calculatedwhenapumpcomesonlineandpumpsdownthewell2.CalculatedIn-FlowinGPM:calculatedbythetimeittakestofillthewell3.Menu:displaystheSystemMenuscreen(4.3)
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4.7 Control Setup: Login
1.Presstoinputpassword:______contactyourrepforyourpassword2.Ifcorrectpasswordisentered,SystemSetupbuttonappears;presstodisplaythefirstSystemConfigurationscreen3.Menu:displaystheSystemMenuscreen(4.3)
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4.7.1 Control Setup: Login (continued)
1.Passwordwillbedisplayedtoindicateithasbeenaccepted2.PresstoenterSystemSetup(4.7.1)3.Menu:displaystheSystemMenuscreen(4.3)
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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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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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4.7.4 Control Setup: Group Naming
1.Thelabelforeachgrouptobenamed2.Presstosetname;nine-charactermaximumforeachgroup;thenameswilldisplayonnumerousscreens3.Next:displaysthenextconfigurationscreen(4.7.5)
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4.7.5 Control Setup: Motor Naming
1.Thelabelforeachmotortobenamed2.Presstosetname;seven-charactermaximumforeachmotor;thenameswilldisplayonnumerousscreens3.Next:displaysthenextconfigurationscreen(4.7.6)
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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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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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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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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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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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4.7.11ControlSetup:PurgeSetup(iffactoryconfigured)
1.ManualPurgebutton:PresstotriggeraPurgeCycle2.StartHour:Presstoenteravaluefrom0(Midnight)to24(Disable)3.DisplaysthecurrentconfiguredStartHour4.Exitbutton:PresstoclosethePop-upScreen(4.3)
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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)
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4.9 Simulation
1.Selectapumpgroupforsimulation(4.9.1)2.ClosereturnstotheSystemMenu(4.3) blisterbuttonwillalsonavigatedirectlytothisscreen.
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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)
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4.10 System Diag: Digital Inputs
1.Nextbutton:todisplayDigitalOutputs(4.10.1)
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4.10.1 System Diag: Digital Outputs
1.Menubutton:ReturnstoSystemMenu(4.3)
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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
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4.11.1 Alarm Setup: Starts Per Hour
1.Presstosetpump1startsperhoursetpoint2.Presstosetpump2startsperhoursetpoint3.Presstosetpump3startsperhoursetpoint4.Presstosetpump4startsperhoursetpoint5.Presstoreturnthemainmenu(4.3)6.Presstosetpumps5and6thennextAlarmSetupscreen(4.11.2)
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4.11.2 Alarm Setup: Alarm Bypass
1.PresstosetDisable/EnableGroup1Highlevel2.PresstosetDisable/EnableGroup1Lowlevel3.PresstosetDisable/EnableGroup2Highlevel4.PresstosetDisable/EnableGroup2Lowlevel5.PresstosetDisable/EnableGroup3Highlevel6.PresstosetDisable/EnableGroup3Lowlevel7.Presstoreturntothemainmenu(4.3)
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Display:
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4.12 Active Alarms: Groups with Pending Alarms
1.Displaysalarmgroupdetails(4.12.1)2.AlarmRefresh:presstoreset;thealarmwilltriggeragainiftheconditionthatcausedthealarmstillexists3.Esc:returnstothepreviousscreen(4.3)
1
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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
4.12.1 Active Alarms: Alarms in Group
1.Displaysalarmdetails(4.12.2)2.AlarmRefresh:presstoreset;thealarmwilltriggeragainiftheconditionthatcausedthealarmstillexists3.Esc:returnstothepreviousscreen(4.12)
1
2
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Display:
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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)
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3
5
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11
Alarm Details
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Display:
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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)
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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
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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 LS C R E E N N A V I G A T I O N M A P
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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
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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.
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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.
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DuplexConfiguration:
Please note:
NotUsedalsomeansNotAvailabletothefactorysetconfiguration.
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TriplexConfiguration:
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.
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QuadplexConfiguration:
Please note:
NotUsedalsomeansNotAvailabletothefactorysetconfiguration.
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FiveplexConfiguration:
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.
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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 LW I R I N G C O N F I G U R A T I O N S
SixplexConfiguration:
Please note:
NotUsedalsomeansNotAvailabletothefactorysetconfiguration.
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FloatsOnlyConfiguration:
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.
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RetroConfiguration:
Please note:
NotUsedalsomeansNotAvailabletothefactorysetconfiguration.
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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
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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
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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
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
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
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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
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 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
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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 307 Pump2FaultorOver-tempAlarm
MB 308 Pump3Running
MB 309 Pump3Auto
MB 310 Pump3FaultorOver-tempAlarm
MB 311 Pump4Running
MB 312 Pump4Auto
MB 313 Pump4FaultAlarm
MB 316 Pump5Running
MB 317 Pump5Auto
MB 318 Pump5FaultAlarm
MB 319 Pump6Running
MB 320 Pump6Auto
MB 321 Pump6FaultAlarm
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MB 322 Pump1SealFail
MB 323 Pump2SealFail
MB 324 Pump3SealFail
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 331 Pump2Start/Stop
MB 332 Pump3Start/Stop
MB 333 Pump4Start/Stop
MB 334 Pump5Start/Stop
MB 335 Pump6Start/Stop
MB 336 HighLevelAlarmTriggerbyXdcr
MB 337 LowLevelalarmbyXdcr
MB 338 CommonAlarmLight
MB 340 PLCFaultedorPurgeCycle
MB 341 MixerControlorRetroIsolationSolenoid
MI 304 Pump1RunHrstoHMI
MI 305 Pump2RunHrstoHMI
MI 306 Pump3RunHrstoHMI
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
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MI 307 Pump4RunHrstoHMI
MI 308 Pump5RunHrstoHMI
MI 309 Pump6RunHrstoHMI
MI 43 Group1LevelSignal
MI 75 Group2LevelSignal
MI 176 Group3LevelSignal
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
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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 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
011 Pump2Starts/HrExceeded
012 AnalogSignal1outofRange
013 G2HighLevelAnalog
014 AlarmG2LowLevelAnalog
015 LowFloat
016 Pump1SealFailure
017 Pump2SealFailure
018 Pump3SealFailure
019 Pump3FailedtoStart
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020 P3CommonalarmorOver-temp
021 Pump3Starts/HrExceeded
022 G3HighLevel
023 G3LowLevel
024 Pump4FailedtoStart
025 Pump5FailedtoStart
026 Pump6FailedtoStart
027 Pump4CommonAlarmorSealFail
028 Pump4Starts/HrExceeded
029 Pump5Starts/HrExceeded
030 AlarmP6Starts/HrExceeded
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Serving Your Fluid Management Needs Since 1969
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