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Instruction Manual for Polymaster models including: 1024-4, Multifunctional Controller, Controller
10 oct. 2024 — Installation, Operation &. Maintenance Manual. Underground Rainwater and Septic Tanks. Multifunctional Controller. Instruction Manual. Page 2. polymaster.com.au.
File Info : application/pdf, 16 Pages, 909.07KB
DocumentDocumentInstallation, Operation & Maintenance Manual Multifunctional Controller UInsntrduectrigonroMuannduaRl ainwater and Septic Tanks Contents Controller Front Layout .............................................................................. 3 Controller Internal Layout.......................................................................... 4 Input / Output Wiring .................................................................................. 5 Radar Connection ........................................................................................ 6 Output Test Button ...................................................................................... 6 Display Screens............................................................................................ 7 Truck Fill Home Screen............................................................................ 7 Transfer Station Home Screen ............................................................... 7 Setup Screen.................................................................................................. 8 Alarm Screens ............................................................................................ 10 Tank Low Screen......................................................................................... 10 Tank Full Screen .......................................................................................... 10 Tank Over Full Screen................................................................................. 10 Bund Alarm Screen..................................................................................... 11 Bund & Tank Over Full Alarm Screen ...................................................... 11 External Stop Alarm Screen...................................................................... 11 Run Dry Sensor Alarm Screen.................................................................. 12 Emergency Stop Screen ............................................................................ 12 Alarm Screens order of priority ................................................................ 12 Appendix 1................................................................................................... 13 Tank Working Capacity .............................................................................. 13 Working Area................................................................................................ 13 Working Height ............................................................................................ 13 Tank Working Capacity .............................................................................. 14 Appendix 2................................................................................................... 15 Password ...................................................................................................... 15 2 polymaster.com.au Controller Front Layout 5 12 3 4 2 7 8 9 10 11 12 6 NO DESCRIPTION 1 MAIN ISOLATOR 2 FRONT PANEL LOCKING TAB x2 3 SUNLIGHT SHIELD 4 HMI SCREEN 5 LIGHT BEACON 6 SIREN NO DESCRIPTION 7 ALARM RESET BUTTON 8 THREE PHASE POWER ON/OFF SWITCH 9 THREE PHASE POWER OUTLET 10 EMERGENCY STOP SWITCH 11 SINGLE PHASE POWER ON/OFF SWITCH 12 SINGLE PHASE POWER OUTLET Freecall 1300 062 064 3 Controller Internal Layout 1 23 4 56 7 8 9 10 11 12 13 14 15 16 17 NO DESCRIPTION 1 MAIN ISOLATOR 2 CIRCUIT BREAKER 3-PHASE 3 CIRCUIT BREAKER 1-PHASE 4 CIRCUIT BREAKER POWER SUPPLY 5 20A CONTACTOR 6 16A CONTACTOR 7 CIRCUIT BREAKER PLC & HMI 8 PLC 9 PLC EXPANSION NO DESCRIPTION 10 OUTPUT TESTER BUTTON 11 EARTH TERMINALS 12 NEUTRAL TERMINALS 13 INPUT & OUTPUT NUMBERING LABEL 14 24V TERMINALS 15 0V TERMINALS 16 INPUT / OUTPUT TERMINALS 17 24V 5A POWER SUPPLY NOTE: Polymaster removes the 240V plug that is wired into the box before shipping. It is only to be used for test purposes at Polymaster. 4 polymaster.com.au Input / Output Wiring 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 TERMINAL LABEL 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 DESCRIPTION BUND LEVEL SWITCH LOW LOW LEVEL SWITCH HIGH HIGH LEVEL SWITCH INPUT EXTERNAL STOP RUN DRY SENSOR EXTERNAL STOP CUSTOMER CONTACT RUN DRY CUSTOMER CONTACT EMERGENCY STOP PRESSED CUSTOMER CONTACT GPO POWER ENABLED CUSTOMER CONTACT BUND ALARM CUSTOMERS CONTACT LOW LEVEL ALARM CUSTOMERS CONTACT HIGH LEVEL ALARM CUSTOMERS CONTACT HIGH HIGH LEVEL ALARM CUSTOMER CONTACT 4-20mA INPUT LEVEL SENSOR SPARE 4-20mA LEVEL OUT CUSTOMER CONTACT EARTH SHIELDING I/O Type INPUT INPUT INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT OUTPUT INPUT OUTPUT Contact Type NC NC NC NC NC NO NO NO NO NO NO NO NO ANALOGUE ANALOGUE Freecall 1300 062 064 5 Radar Connection This connection is located at the bottom right of the controller. It is located in the "INPUT/OUTPUT TERMINALS" and is Terminal:14 Connect the wires of the Radar Sensor into the terminals shown below: - Sensor Brand / Model Terminal Siemens LR100 Vega C11 + Black Brown + - White Blue Output Test Button Inside the controller you can use the OUPUT CHECK button to turn on all outputs. This can be useful to test the customer contacts to ensure they give the results expected at the customers end. 6 polymaster.com.au Display Screens TRUCK FILL HOME SCREEN TRANSFER STATION HOME SCREEN The green box indicates that power is enabled to the GPOs. This will turn red when power is disabled. Freecall 1300 062 064 7 Display Screens SETUP SCREEN To get to the setup screen press SETUP from either of the home screens. The SETUP screen is password protected so only authorised users can edit the controller's functionality. See the password section in Appendix 2 for these details. Click in the white box to enter the password. Type in the password using the keypad and then press ENTER. 8 polymaster.com.au Display Screens From the SETUP screen you are able to: · Set the TANK WORKING CAPACITY. · Select between TRUCK FILL MODE and TRANSFER STATION MODE. · Set the REFILL LEVEL PERCENTAGE (for Transfer Station mode) To change between TRUCK FILL MODE & TRANSFER STATION MODE select the check box. ENTER TANK WORKING CAPACITY To enter the TANK WORKING CAPACITY, click the box that the value is displayed on, and the following keypad will appear. Type in the value and press ENTER to go back to the SETUP screen. It is important to enter the correct value. See Appendix 1 for working capacity calculation. SET REFILL LEVEL In TRANSFER STATION MODE there is a REFILL LEVEL which is set. Once the tank is filled the power to the GPOs is disabled and will not be enabled until the level has dropped below the REFILL LEVEL. This feature stops the pump from short cycling. To change the TRANSFER STATION MODE REFILL LEVEL PERCENTAGE click the box that the default value of 40% is displayed in. The following keypad will appear. Enter a value between 20% 70% and then press ENTER to go back to the SETUP screen. To go back to the HOME SCREEN press OK. Freecall 1300 062 064 9 Alarm Screens TANK LOW SCREEN If the liquid level goes below 20% full on the Radar Sensor or the Tank Low Level Sensor goes low then the TANK LOW warning will be displayed. Low Level Alarm Customer Contact will also be turned on. TANK FULL SCREEN If the liquid level goes between 85% -95% full on the Radar Sensor then the TANK FULL warning will be displayed. High Level Alarm Customer Contact will also be turned on. Power to the GPOs will be disabled. An audible buzzer will sound. Press Alarm Reset to silence the alarm. Press and hold the Alarm Reset Button for 5 seconds to reenable power to the GPOs. TANK OVER FULL SCREEN If the liquid level goes above 95% full on the Radar Sensor or the Tank High High Sensor goes Low then the TANK OVER FULL warning will be displayed. High High Level Alarm Customer Contact will also be turned on. Power to the GPOs will be disabled. An audible buzzer will sound. Press Alarm Reset to silence the alarm. 10 polymaster.com.au Alarm Screens BUND ALARM SCREEN If the Bund Sensor goes Low then the BUND SENSOR warning will be displayed. Bund Alarm Customer Contact will also be turned on. Power to the GPOs will be disabled. An audible buzzer will sound. Press Alarm Reset to silence the alarm. BUND & TANK OVER FULL ALARM SCREEN If the Bund Sensor goes Low and the RADAR is measuring above 95% then the BUND SENSOR & TANK OVER FULL warning will be displayed. Bund Alarm & High High Level Alarm Customer Contacts will also be turned on. Power to the GPOs will be disabled. An audible buzzer will sound. Press Alarm Reset to silence the alarm. EXTERNAL STOP ALARM SCREEN If External Stop input goes low show the EXTERNAL STOP ALARM warning. External Stop Customer Contacts will be turned on. Power to the GPOs will be disabled. An audible buzzer will sound. Press Alarm Reset to silence the alarm. Freecall 1300 062 064 11 Alarm Screens RUN DRY SENSOR ALARM SCREEN If Run Dry Sensor input goes low and the controller is in TRANSFER STATION MODE show the RUN DRY SENSOR warning. Input Run Dry Customer Contact will also be turned on. Power to the GPOs will be disabled. An audible buzzer will sound. Press Alarm Reset to silence the alarm. Press and hold Alarm Reset for 5 seconds to run the pump. (Note you must keep holding the Alarm Reset Button to run the pump) If TRANSFER STATION MODE is not selected, then none of the above happens in TRUCK FILL MODE. EMERGENCY STOP SCREEN If Emergency Stop is pressed the EMERGENCY STOP SCREEN will be shown. Emergency Stop Pressed Customer Contact will also be turned on. Power to the GPOs will be disabled. ALARM SCREENS ORDER OF PRIORITY If multiple alarms are active at once the most important alarm will take priority and be displayed. 12 polymaster.com.au Priority Alarm Screen 1 Emergency Stop 2 Bund Sensor & Tank Over Full 3 Bund Sensor 4 Tank Over Full Priority Alarm Screen 5 External Stop 6 Pump Run Dry 7 Tank Full 8 Tank Low Appendix 1 TANK WORKING CAPACITY A 10,000 Litre tank can not hold a working capacity of 10,000 Litres due to the overflow point. Therefore, the value entered into the SETUP SCREEN is important to be correct and needs to be calculated for each individual tank. The following section shows how to calculate the Tank Working Capacity and gives examples of values for our standard tanks. However, each tank should be checked as manufacturing tolerances may affect this. WORKING AREA The working area is the area inside the internal wall diameter. Examples of our tank range sizes are shown to the right. Tank Capacity (Litres) Internal Diameter of Tank (m) 1500 2300 3300 5000 7000 10000 13000 21000 30000 0.986 1.280 1.508 1.932 2.190 2.380 2.802 3.044 3.550 Working Area of Tank (m2) 0.76 1.29 1.79 2.93 3.77 4.45 6.17 7.28 9.9 Working Area of Tank * 1000 760 1290 1790 2930 3770 4450 6170 7280 9900 WORKING HEIGHT Working Height of Tank = Height from ground to bottom of overflow pipe Tank Base Thickness. = (Measured Value) 0.01m = m To be exact you need to measure the realworld value. However, for our standard tanks that have not been customised the following table shows the working heights: (Note: This is for a Standard 90 PE fitting position) Tank Capacity (Litres) Height to bottom of Overflow (m) Tank Base Thickness (m) Tank Working Height (m) 1500 2300 3300 5000 7000 10000 13000 21000 30000 1.826 1.660 1.715 1.635 1.722 2.080 2.060 2.822 2.926 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 1.825 1.650 1.705 1.625 1.712 2.070 2.050 2.812 2.916 Freecall 1300 062 064 13 Appendix 1 TANK WORKING CAPACITY Tank Working Capacity = Working Area (m2 *1000) x Working Height (m) = Use the following table and multiply by working height to find the Tank Working Capacity. ` Tank Capacity (Litres) 1500 2300 3300 5000 7000 10000 13000 21000 30000 Working Area (m2*1000) 760 1290 1790 2930 3770 4450 6170 7280 9900 Standard Tanks with 90 PE Overflow For our standard tanks with 90 PE Overflow in the standard fitting position the following table applies. Tank Capacity (Litres) Working Area (m2*1000) Working Height (m) Working Capacity (Litres) 1500 2300 3300 5000 7000 10000 13000 21000 30000 760 1290 1790 2930 3770 4450 6170 7280 9900 1.825 1.650 1.705 1.625 1.712 2.070 2.050 2.812 2.916 1393 2123 3045 4764 6449 9209 12641 20464 28863 14 polymaster.com.au Appendix 2 PASSWORD The password is a conversion of the last 4 digits of the MAC address of the HMI screen from hexadecimal to decimal. For example the HMI MAC ADDRESS can be found here: The last 4 digits are E9F1 Use the following link to use a Hexidecimal to Decimal converter: https://www.rapidtables.com/convert/number/hex-to-decimal.html The password is therefore: 59889 Freecall 1300 062 064 15 1800 062 064 polymaster.com.au Follow us: Polymaster Group PUB-2024-10