Environment One E/One PLC Manuale utente

E/ONE PLC

QUADPLEX PANEL

Installation and

Operation Manual

For Hardwired Pumps

Environment One Corporation

2 NA0702P01 REV A

12/03/2019

Contents

1 Overview ............................................................................................................................................................................................................................................3

2 E/One PLC Quadplex Menu Flowchart (Refer to section 5 for more info on these menus)................................................................................................................4

3 Wiring Instructions.............................................................................................................................................................................................................................5

4 Startup ...............................................................................................................................................................................................................................................5

5 User Menus and Touch Screen Interface ...........................................................................................................................................................................................6

5.1 Main Menu..............................................................................................................................................................................................................................6

5.2 Pump Data Menu ....................................................................................................................................................................................................................6

5.3 Active Alarm / Trouble Log ......................................................................................................................................................................................................7

5.4 Alarm History ..........................................................................................................................................................................................................................7

5.5 Set Points Menus.....................................................................................................................................................................................................................8

5.6 Options Menu .........................................................................................................................................................................................................................8

5.6.1 Voltage Data Menu.......................................................................................................................................................................................................8

6 System Parameters ............................................................................................................................................................................................................................9

6.1 Software Revision....................................................................................................................................................................................................................9

6.2 User Programmable Functions ................................................................................................................................................................................................9

6.2.1 Run Levels.....................................................................................................................................................................................................................9

6.2.2 Overpressure Current (High Amps) Setting ..................................................................................................................................................................9

6.2.3 Run Limit Setting ..........................................................................................................................................................................................................9

6.2.4 Cold Start......................................................................................................................................................................................................................9

6.2.5 Clear Trouble ................................................................................................................................................................................................................9

6.2.6 Restore Factory Defaults ..............................................................................................................................................................................................9

7 Normal Operation ............................................................................................................................................................................................................................10

7.1 Manual Run Operation ..........................................................................................................................................................................................................10

7.2 High Level Alarm Operation ..................................................................................................................................................................................................10

7.3 Audible Alarm Manual Silence...............................................................................................................................................................................................10

7.4 Pump Performance ...............................................................................................................................................................................................................10

7.4.1 Hour Meter (RUNTIME) ..............................................................................................................................................................................................10

7.4.2 Cycle Counter (CYCLES)...............................................................................................................................................................................................10

7.4.3 Last Cycle Runtime (LAST (s))......................................................................................................................................................................................11

7.4.4 Minimum Runtime (MIN RUN (s))...............................................................................................................................................................................11

7.4.5 Maximum Runtime (MAX RUN (s)) .............................................................................................................................................................................11

7.4.6 Average Runtime (AVG RUN (s)) .................................................................................................................................................................................11

7.4.7 Minimum Amps (MIN AMPS (A)) ................................................................................................................................................................................11

7.4.8 Maximum Amps (MAX AMPS (A))...............................................................................................................................................................................11

7.4.9 Average Amps (AVG AMPS (A))...................................................................................................................................................................................11

7.4.10 Minimum Volts (MIN VOLTS (VAC))............................................................................................................................................................................11

7.4.11 Maximum Volts (MAX VOLTS (VAC))...........................................................................................................................................................................11

7.4.12 Average Volts (AVG VOLTS (VAC)) ..............................................................................................................................................................................11

8 Trouble Operation............................................................................................................................................................................................................................11

8.1 Excessive Runtime Operation ................................................................................................................................................................................................11

8.2 Brownout Operation .............................................................................................................................................................................................................12

8.3 Overvoltage Operation..........................................................................................................................................................................................................12

8.4 Overpressure Operation........................................................................................................................................................................................................12

8.5 Comm Lost Indication............................................................................................................................................................................................................12

9 Diagnostics .......................................................................................................................................................................................................................................12

9.1 Alarm Test .............................................................................................................................................................................................................................12

10 Communication................................................................................................................................................................................................................................13

10.1 USB Interface.........................................................................................................................................................................................................................13

11 Trouble Shooting ..............................................................................................................................................................................................................................13

11.1 Troubleshooting Chart...........................................................................................................................................................................................................13

12 Appendix ..........................................................................................................................................................................................................................................15

12.1 Typical Field Wiring Diagram .................................................................................................................................................................................................15

12.2 Alarm Messages ....................................................................................................................................................................................................................16

12.3 Normal and Full Operational Ranges .....................................................................................................................................................................................16

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1Overview

This manual provides information on the operation and use of Environment One PLC Quadplex Panels.If unsure of the

configuration of your panel, contact E/One factory for assistance.

The E/One PLC Quadplex panel is an Environment One full-featured Alarm/Monitor panel. The E/One PLC Quadplex

panel monitors for the following operating conditions:

•Pump Overpressure Condition – Pump operating at abnormally high current level

•Brownout Condition – Mains voltage 12% below nameplate rating

•Overvoltage Condition – Mains voltage 12% above nameplate rating

•High Liquid Level

•Low Liquid Level

•Real-time, High, and Low Voltage on the input

•Real-time and High current drawn by the Pump

•Pump failed to start

•Contactor fault

•Extended Pump Runtime

The E/One PLC Quadplex Panel displays pump status, operating parameters, and user options by means of the following

indicators:

•Touch Screen Interface to show Pump & Panel operating conditions & provide for interaction

In addition, the following pump operating parameters can be viewed from the E/One PLC Quadplex Panel:

•Real-time fluid level in tank

•Real-time pump Voltage and Amperage

•Cycles & Hours

•Latched fault conditions

The following features are field programmable:

•Run levels one through four

•Alarm Level

•Overpressure Current

•Extended Pump Runtime Limit

The following are the hardware features:

•IP65 / NEMA 4X Rated Enclosure

•Enclosure made from fiberglass

•Separate pump , control, and input Circuit Breakers

•Audible & Visual Alarm indicators (Silence for Audible Alarm)

•HAND / OFF / AUTO (HOA) switch for each pump (HAND = MANUAL RUN, OFF = PUMP WILL NOT RUN, AUTO =

PLC + PRESSURE TRANSDUCER CONTROL PUMP

•Touch screen interface

•Hinged aluminum deadfront

•Programmable Logic Controller (PLC)

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Options Menu

Voltage Data Menu

Set Points Menu

Run Levels

Trouble Set Points

Active Alarm Log

Alarm History

Trouble Reset Menu

Main Menu

Pump 1 Data 1

Pump 2 Data 1

Pump 3 Data 1

Pump 4 Data 1

Pump 1 Data 2

Pump 2 Data 2

Pump 3 Data 2

Pump 4 Data 2

2E/One PLC Quadplex Menu Flowchart (Refer to section 5 for more info on these menus)

NOTE: VALUES SHOWN DO NOT REPRESENT ACTUAL

VALUES – REFER TO APPENDIX FOR EXPECTED VALUES.

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3Wiring Instructions

WARNING – the E/One Alarm and Control panel is a high voltage system that controls power to an electric

motor(s). Care should be taken whenever performing service on the panel to avoid the risk of electrical shock

and/or damage to property. Because power may be supplied by multiple sources, circuit breakers alone may

not be sufficient to provide adequate protection.

The E/One PLC Quadplex panel wiring can change from model to model. All wiring shall be done in accordance with the

wiring decal on the inside cover of the panel enclosure. Typical wiring can be found in the Appendix of this manual.

4Startup

The E/One PLC Quadplex Panel should arrive from the factory ready to operate. The panel is properly installed and

started by following the steps below.

1. Mount and wire the panel per the instructions on the enclosure door.

2. Ensure that Pressure transducer in the station is set at the appropriate height (10” from the bottom of the tank).

If it is not, the off level will not be at the correct height, and the system may not function properly.

WARNING – Pressure transducer must have a range of 0-2.5m to ensure proper operation. If a different range is

used run levels will be improperly scaled.

3. ‘Cold Start’ the panel – refer to Cold Start section of this manual for more information.

4. Clear the Alarm History – Refer to the Alarm History Log section of this manual for more information.

5. If other than factory default settings are required, set all limits and levels. Factory defaults settings can also be

restored via the user menu. (Refer to the User Programmable Options section of this manual for more on this

feature).

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5User Menus and Touch Screen Interface

The E/One Quadplex PLC panel includes a panel mounted touch screen interface to navigate the various menus and

select the user options (see Figures 2-8). The values displayed in the following figures are not realistic and are intended

to show only the number of digits that each field can contain. See appendix for the expected ranges of various values.

Refer to “System Parameters” section for definition of each field within the menus.

5.1 Main Menu

Real time panel voltage, Next to run (NTR) and real time fluid level in the tank are displayed on the main menu. Five

buttons on the main menu allow the user to access all of the functionality of the touch screen interface.

5.2 Pump Data Menu

The Pump Data menu allows the user to view pages of data for each pump. Each pump menu has two screens to display

amperage, total runtime, fluid level (inches), total cycles, min/max/average current, min/max/average runtime and last

runtime for that pump. Pump operational data may be reset on a screen by screen basis by holding the “RESET” button

for three seconds (Note that resetting the 1st screen of data will reset avg. cycle time (on screen 2), as it resets total

runtime and total cycles). Pump operational status will be indicated in the upper right, next to the arrow button

(Possibilities include “HAND”, “OFF”, “AUTO”, and “TRBL”). Data on additional pumps can be accessed via the left and

right arrow buttons.

Figure 3 – Pump Data Menu

Figure 2 – Main Menu

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5.3 Active Alarm / Trouble Log

The Active Alarm Log shows any alarms / trouble conditions that are active in the station. This includes overpressure

(during the lockout period), overpressure final lockout, high level, low level, pump failed to start, contactor fault,

overvoltage, and brownout. It includes a time stamp and a description for each alarm / trouble condition. The log begins

with the most recent alarm / trouble condition, and lists them in reverse chronological order. Once a condition is

cleared, either manually (via pump trouble reset buttons) or automatically an entry will be added (highlighted in green)

showing the alarm was cleared with a timestamp. It will still exist in the alarm history (see section 5.4). The second

button from the right (ACK) will acknowledge an alarm, changing its status for awareness purposes. The arrow in the top

left will return the user to the Main Menu. The “Clear Trouble?” Button will open a menu where you can clear any

trouble conditions preventing a pump from running. This is especially useful for troubleshooting purposes.

5.4 Alarm History

The alarm history shows the last 100 alarms / trouble conditions detected by the panel, regardless of whether they have

been cleared manually or automatically. This includes overpressure (during the lockout period), overpressure final

lockout, high level, low level, pump failed to start, overvoltage, brownout, blocked line, contactor fault, and extended

pump runtime. It includes a time stamp and a description for each alarm / trouble condition. The log begins with the

most recent alarm / trouble condition, and lists them in reverse chronological order. Unlike the Active Alarm Log, events

will remain until the event limit is exceeded after which the oldest event will drop off when a new event is recorded. The

arrow button from the will return the user to the Main Menu.

Figure 4 – Active Alarm Log and Clear Trouble Menu

Figure 5 – Alarm History

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5.5 Set Points Menus

Trouble Set Points and Run levels are accessed via the “Set Points” button in the Main Menu. Overpressure Amperage

and Run Limit may be edited via the trouble parameters panel. See sections 6.2.2 and 6.2.3 for more information

regarding these set points. Run levels 1-4 and the high level set point may be edited through the Run Levels menu. See

section 6.2.1 for more information regarding these set points. The arrows in the upper left will return the user to the

previous menu.

5.6 Options Menu

The options menu contains various options. The software version is displayed on this screen, and the user can access the

cold start and factory default options from this menu. In order to use these functions the buttons must be held for at

least 3 seconds (this is to prevent accidental deletion of operational data). See sections 6.2.4 and 6.2.6 for more

information regarding these options. The alarm light and buzzer can also be tested via this menu by simply holding the

respective button.

5.6.1 Voltage Data Menu

The Voltage Data Menu shows min/max/average voltages and overvoltage and brownout set points. These set points

are not editable. The min/max/average values may be reset by holding the “reset” button on the left for at least 3

seconds. The Voltage Data Menu is accessed via the options menu.

Figure 6 – Run Levels and Trouble Set Point Menus

Figure 7 – Options menu

Figure 7 – Options Menu

Figure 8 – Voltage Data Menu

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6System Parameters

A number of system settings, some of which will be unique to the installation, can be set on-site. All of these settings

can be found within sub-menus in the Touch Screen Interface.

6.1 Software Revision

This read only field displays the revision of the software currently loaded into the panel. This information may be

required when speaking with E/One service personnel. This information can be found in the options menu.

6.2 User Programmable Functions

The following items can be used for system setup. In a Quadplex system all of these parameters are shared between the

4 pumps and cannot be set independently for each pump. Clearing of these values is also universal and affects all

pumps simultaneously.

6.2.1 Run Levels

Run levels 1-4 and the high level set point may be edited through the Run Levels Menu under the Set Points menu.

Simply press the correct set point value and a keyboard will appear allowing you to enter a new value (Note that off and

low level are not editable as they are based on the E/One pumps’ physical characteristics). For normal operation, the run

levels and alarm level must be set such that Off < Run 1 < Run 2 < Run 3 < Run 4 < High. This ensures that all pumps have

an opportunity to turn on before alarm is reached and that the sequencing works as intended. The Touch screen

interface will prevent the user from entering values which do not satisfy this criteria.

6.2.2 Overpressure Current (High Amps) Setting

This field displays the limit that is currently set for the Overpressure / High current protection feature. Though it is

possible to change this setting, it is not advised unless directed by E/One service personnel, as changing this limit will

affect how the overpressure protection feature performs. Doing so without proper guidance may void the product

warranty and can cause damage to the system.

6.2.3 Run Limit Setting

The Run Limit option is a user editable feature that can be set from the Trouble set points Menu. The factory default

setting for this feature is 10 minutes. This feature will cause a trouble alarm to be activated if an individual pump run

cycle exceeds the set value.

6.2.4 Cold Start

The Cold Start option is found within the Options menu. In order to cold start the panel the button must be held for a

minimum of 3 seconds. Cold Starting the panel erases all stored operating parameters listed within the Pump

Performance section (Section 7.4), and should be done when the panel is first installed. All previously stored operating

parameters will be cleared.

6.2.5 Clear Trouble

The Reset menu accessed from the active alarm log allows the user to manually clear trouble conditions for one or all

pumps. This is intended to be used for troubleshooting purposes after a pump has been locked out. If the trouble

condition persists, the pump will be locked out again on the next run. A successful, trouble free 5-second manual or

automatic run will also clear certain trouble conditions.

6.2.6 Restore Factory Defaults

The Restore Factory Defaults function will restore all set points and limits to factory original. This functionality is

accessed through the Options Menu. In order to restore factory defaults the button must be held for a minimum of 3

seconds. Restoring the factory default values returns the following fields to their factory preset conditions as follows:

Overpressure Limit [12.5 A], Run Limit [10 MINUTES], Run Levels 1,2,3,4,High [16, 18, 20, 22, 26].

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7Normal Operation

Under normal operating conditions, the E/One PLC Quadplex panel will perform as follows when power is applied:

1. During the boot-up period, all panel indications and outputs will be OFF.

During this boot up sequence, all operating parameters are recovered from non-volatile memory. If this is the

first time the panel has been started, these will be the factory defaults and all operating parameters will be 0.

Otherwise, these values will be what they were the last time the panel operated. If the panel requires a reset to

restore factory defaults, refer to the Restore Factory Defaults feature in the User Programmable Functions

section (Section 6.2) of this manual.In addition, a Cold Start may be needed to clear out the Pump Performance

operating parameters; refer to the Cold Start feature within the user programmable functions section of this

manual.

2. Under normal conditions, the Touch Screen Interface will display the real-time Panel Voltage, Station Fluid level,

and NTR at all times.

3. After each completed pump run cycle, the Pump data screens are updated to reflect the most current data.

Refer to the Pump Performance section of this manual for more on this feature.

7.1 Manual Run Operation

The lead pump can be operated manually by pressing and holding the HOA switch on the dead-front in the Manual Run

position (Labelled on deadfront). The pump will run and all the operational data associated with it will be available on

its data screen. The Manual Run feature is capable of bypassing trouble conditions – it should be used with caution in

cases where overpressure or overvoltage / brownout are a factor. Releasing the switch will stop the pump. Each pump

can be operated individually by using its own HOA switch.

7.2 High Level Alarm Operation

A High Level Alarm is initiated if the liquid level in the tank reaches the high level as determined by the Pressure

Transducer or backup high level float. If a High Level is detected, the panel will energize the contactors for all 4 pumps

(if they are not already energized), and turn on the alarm light and buzzer. This condition will remain until the 4 pumps

have pumped the station below 2 inches below the alarm level. This is the most critical alarm condition as it indicates

that the pumps cannot keep up with inflow or the pressure transducer is malfunctioning.

7.3 Audible Alarm Manual Silence

Any time the audible alarm / buzzer is activated by the system, and the PLC is functioning, it can be silenced by pressing

the ‘SILENCE’ button located on the exterior underside of the enclosure. If the buzzer has been activated due to a PLC

failure then the Alarm Breaker must be switched off to silence the buzzer.

7.4 Pump Performance

Pressing the Pump Data button on the main menu will display data for each pump e.g. runtime / total cycles. All

parameters are non-volatile (retained through a power loss), unless otherwise stated. Pressing the Voltage Data button

on the Options Menu will display mains voltage data e.g min/max/average voltage. The following values are displayed

on the Pump Data and Voltage Data menus.

7.4.1 Hour Meter (RUNTIME)

Accumulated runtime - The time is displayed as Runtime: HH:MM:SS, where HH are the total hours, MM minutes, and

SS seconds since the last reset. The maximum runtime value that can be stored is 99999:59:59 (> 11 years). Beyond this

limit the value displays as 99999:MM:SS (minutes and seconds will continue to cycle but hours will display as 99999).

7.4.2 Cycle Counter (CYCLES)

Accumulated cycles - The value is displayed as Cycles: XX, where XX are the total accumulated pump cycles since the last

reset. The maximum cycle value that can be displayed is 9999999.Beyond this limit the value displays as 9999999 until

reset to 0 by the user.

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