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MultiSmart
Operation Manual
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MultiTrode MultiSmart Operation Manual

MultiSmart
Pump Station Manager & RTU
MultiSmart Installation & Operation Manual
Page 2 of 260 MultiSmart_IO_Manual_R20
NOTICE
This Manual is the support documentation for the
installation, commissioning and opera tio n of the
MultiTrode MultiSmart Pump Station Manager/RTU
and Reservoir Monitor.
Revision 20
15 May 2013
This manual is used for v3.1.0 of the MultiSmart Pump Station Manager
This document is proprietary to MultiTrode Pty Ltd (the company) and for sole use within the company notwithstanding that this doc ument may from time to tim e be made available to the company’s subcontractors, suppliers, customers and others for purposes associated with manufacturing and other processes as aut horised on an individual basis by Multi Trode Pty Ltd or their representative. In such cases where the document has been issued to external parties, its contents shall not be transcri bed, copied, relayed, or divulged to any other party whatsoever and after satisfying the requirements f or which the document was originally iss ued to any external party shall be either returned to the company, or destroyed as required by the company’s document control procedure and as attested to by the recipient at the time of taking possession of the document. MultiTrode Pty Ltd shall not be held l i able in any way whats oever for any act or omission, either direct or consequential, arising from the use of t he information contained herein.
MULTITRODE is a registered trade mark of MultiTrode Pty Ltd in Australia and many countries worldwide. PUMPVIEW and MULTISMART are trademarks of MultiTrode Pty Ltd and pending A ustralian trade mark registration. Australian Design Registration is pending for the MultiSmart Pump Station Manager and RTU Remote and Base Modules. Patent Pending in Australia. © 2012 MultiTrode Pty Ltd. This publication is protected by copyright. No part of this publication may be reproduced by any process, electronic or otherwise, without the express written permission of MultiTrode Pty Limited.
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1
Warnings & Cautions ...................................................................................................................... 9
1.1 Information to User ................................................................................................................ 9
1.2 Documentation Standards ...................................................................................................... 9
1.3 Installation Notes ................................................................................................................... 9
2 Glossary & Symbols ..................................................................................................................... 10
3 Major New Features & Enhancements in Recent Firmware Releases ...................................... 11
3.1 Version 3.1.0 ........................................................................................................................ 11
Part 1 – Operations ................................................................................................................................... 12
4 Introduction ................................................................................................................................... 12
4.1 Range of Options ................................................................................................................. 12
4.2 Intuitive Operator Interface ................................................................................................... 13
4.3 Intuitive Engineering Interface .............................................................................................. 13
4.4 "Out of the Box" Control of a Pump Station .......................................................................... 14
5 Operator Interface ......................................................................................................................... 15
5.1 LCD Panel ............................................................................................................................ 15
5.2 LED Indicators ..................................................................................................................... 16
5.3 Buttons ................................................................................................................................. 16
5.4 Using the Interface ............................................................................................................... 16
Part 2 – Installation & Commissioning ................................................................................................... 33
6 Mounting Instructions ................................................................................................................... 33
6.1 Mounting the Operator Interface Display .............................................................................. 33
6.2 Mounting the Pump Station Manager ................................................................................... 35
6.3 Connecting the Operator Interface to the Pump Station Manager ....................................... 35
7 MultiSmart Boards ........................................................................................................................ 36
7.1 Power Supply ....................................................................................................................... 38
7.2 Default Wiring Setup for Pump Control Board ...................................................................... 39
7.3 Pump Control Board ............................................................................................................ 44
7.4 CPU Board ........................................................................................................................... 48
7.5 DSP Board ........................................................................................................................... 49
7.6 Energy Monitoring & Motor Protection Board ....................................................................... 56
8 PumpView Hardware Setup .......................................................................................................... 58
8.1 Fault Finding ........................................................................................................................ 58
8.2 Configuring PumpView for a Serial Cellular Modem ............................................................ 59
8.3 Configuring PumpView for an Ethernet Cellular Router ....................................................... 60
9 Quick Commissioning Guide ....................................................................................................... 63
9.1 Setup Wizard Flow Diagrams ............................................................................................... 64
9.2 Setup Wizard Notes ............................................................................................................. 68
9.3 Unassign Any Faults Not Used ............................................................................................ 70
9.4 Level Simulation Mode ......................................................................................................... 72
9.5 Maintenance Mode .............................................................................................................. 72
Part 3 – Advanced Settings ..................................................................................................................... 74
10 High Level Overview ..................................................................................................................... 74
10.1 MultiSmart Pump Station Manager Overview ...................................................................... 74
10.2 Pump Station Manager ........................................................................................................ 75
10.3 Reservoir Monitor ................................................................................................................. 76
10.4 Pump Control Module .......................................................................................................... 77
10.5 Energy Monitoring and Motor Protection .............................................................................. 78
10.6 Supply Protection ................................................................................................................. 79
10.7 Data Logger ......................................................................................................................... 79
10.8 Flow ..................................................................................................................................... 79
10.9 Fault Module ........................................................................................................................ 79
10.10 Security ................................................................................................................................ 79
10.11 PLC Extension (IEC 61131-3) .............................................................................................. 79
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10.12 Logic Engine ........................................................................................................................ 79
10.13 RTU...................................................................................................................................... 80
11 Security .......................................................................................................................................... 82
11.1 Selecting any Digital Input Tag ............................................................................................ 85
11.2 Security Key Setup .............................................................................................................. 86
11.3 Accessing MultiSmart Without a Security Key ..................................................................... 87
12 Fill / Empty & Pump Setpoints, Alarm Setpoints, Delays .......................................................... 88
12.1 Fill / Empty (Charge / Discharge) ......................................................................................... 88
12.2 Default Pump and Alarm Setpoints ...................................................................................... 88
12.3 Changing Pump and Alarm Levels Setpoints ....................................................................... 89
12.4 Setting Pump & Alarm Delays .............................................................................................. 91
13 Pumps and Groups ....................................................................................................................... 93
13.1 Change Alternation & Fixed Duty ......................................................................................... 94
13.2 Moving Pumps Between Groups, or Changing the Order of Pumps .................................... 96
13.3 Adding or Deleting Groups & Changing Group Alternation .................................................. 96
13.4 Decommissioning Pumps ..................................................................................................... 97
14 Configuring I/O, Fault & Level Devices ....................................................................................... 98
14.1 Digital Inputs ........................................................................................................................ 98
14.2 Assigning Faults to Digital Inputs ......................................................................................... 98
14.3 Unassigning Fault Inputs.................................................................................................... 100
14.4 Configuring Digital Inputs ................................................................................................... 100
14.5 Configuring Analog Inputs .................................................................................................. 103
14.6 Advanced Analog Input Options ......................................................................................... 104
14.7 External Digital & Analog Modules ..................................................................................... 104
14.8 Configuring Level Devices ................................................................................................. 109
14.9 Configuring Faults .............................................................................................................. 122
14.10 Configuring Analog Outputs ............................................................................................... 130
14.11 Configuring Digital Outputs ................................................................................................ 131
15 Profiles ......................................................................................................................................... 135
15.1 Profile Selection Methods .................................................................................................. 136
15.2 Configuring the Setpoints of Profiles .................................................................................. 138
15.3 Configuring Other Profile Properties .................................................................................. 138
16 Station Optimization ................................................................................................................... 140
16.1 Station Optimization Menu ................................................................................................. 141
16.2 Additional Parameters ........................................................................................................ 148
17 Energy Monitoring and Motor Protection .................................................................................. 150
17.1 Setting Motor Protection Values ......................................................................................... 151
17.2 Insulation Resistance Tester .............................................................................................. 154
17.3 Reassigning (Motor) Current Inputs used in Motor Protection ........................................... 158
17.4 Calculating Efficiency ......................................................................................................... 159
18 Supply Protection ........................................................................................................................ 160
18.1 Battery Test ........................................................................................................................ 162
19 Datalogger ................................................................................................................................... 163
19.1 Configuring the Event Logger ............................................................................................ 164
19.2 Crisis Logger ...................................................................................................................... 166
19.3 Interval Logger ................................................................................................................... 168
19.4 Filtering the Data Viewed in the History Page .................................................................... 168
19.5 Storing the Datalogger on the SD Card ............................................................................. 170
19.6 Configuring the datalogger to write directly to an SD Card ................................................ 173
19.7 Adding Comments and Deleting Logs ................................................................................ 173
20 Flow .............................................................................................................................................. 174
20.1 Configure General Flow Setting ......................................................................................... 174
20.2 Configuring Analog Inputs for Flow Measurement ............................................................. 175
20.3 Configuring Analog Inputs for Inflow Measurement ........................................................... 176
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20.4 Configuring Digital Inputs for Flow Measurement .............................................................. 176
20.5 Configuring Calculated Flow Settings ................................................................................ 177
20.6 Flow Alarms ....................................................................................................................... 178
20.7 Smart Outflow .................................................................................................................... 179
20.8 Estimating Duration to Overflow ......................................................................................... 180
21 Reservoir Monitor ........................................................................................................................ 181
21.1 Communications Configuration .......................................................................................... 181
21.2 User Interface .................................................................................................................... 183
21.3 Connection Manager .......................................................................................................... 183
22 RTU Module ................................................................................................................................. 185
22.1 Communications Screen .................................................................................................... 185
22.2 Communication Protocols .................................................................................................. 185
22.3 Enabling and Viewing of DNP and MODBUS Logs ............................................................ 199
22.4 IP Address & Routing Settings ........................................................................................... 200
23 Variable Frequency Drive (VFD) ................................................................................................. 201
23.1 Enabling VFD ..................................................................................................................... 201
23.2 Individual Pump Parameters .............................................................................................. 202
23.3 Setup an Analog Output for use with a VFD Drive ............................................................. 203
23.4 Controlling a VFD Drive Using MODBUS ........................................................................... 203
23.5 Displaying VFD speed on Main Screen.............................................................................. 203
23.6 Calculating Efficiency using VFD ....................................................................................... 203
24 PLC Extension IEC 61131-3 (ISaGRAF) ..................................................................................... 204
24.1 Setting up the Workbench .................................................................................................. 205
24.2 Setting up I/O ..................................................................................................................... 206
24.3 MultiSmart Functions & I/O Blocks ..................................................................................... 206
24.4 Downloading ISaGRAF Resources to MultiS mar t .............................................................. 212
24.5 Compiling and Downloading Multiple Resources ............................................................... 212
24.6 Viewing the Status of ISaGRAF Variables ......................................................................... 212
24.7 The Tags Button ................................................................................................................ 213
24.8 The Params Button ............................................................................................................ 213
24.9 Disabling ISaGRAF Resources .......................................................................................... 213
24.10 Backing Up ISaGRAF Resources ...................................................................................... 213
24.11 ISaGRAF Application Examples ........................................................................................ 214
25 Logic Engine ................................................................................................................................ 215
25.1 MultiSmart Tags ................................................................................................................. 215
25.2 Logic Engine Tags ............................................................................................................. 216
25.3 Mathematical Operators ..................................................................................................... 217
25.4 MultiSmart Logic Functions ................................................................................................ 217
25.5 Advanced Functions .......................................................................................................... 218
25.6 Logic Examples .................................................................................................................. 219
25.7 Uploading Logic Files Using FTP ....................................................................................... 220
25.8 Enabling Logic Files ........................................................................................................... 221
26 SMS Server .................................................................................................................................. 222
27 Customizing the Display ............................................................................................................. 225
27.1 Naming Pumps .................................................................................................................. 225
27.2 Pump Data Display ............................................................................................................ 225
27.3 Bottom Section ................................................................................................................... 226
28 Restarting the MultiSmart ........................................................................................................... 227
29 Site Keys and Enabling New Modules ....................................................................................... 227
29.1 Software Modules Available ............................................................................................... 227
29.2 Enabling Software Modules with a New Site Key ............................................................... 228
30 Upgrading MultiSmart Firmware ................................................................................................ 228
30.1 Upgrading via PC Configuration Utility ............................................................................... 228
31 Backing Up & Restoring Configuration Settings ...................................................................... 229
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31.1 Resetting Defaults .............................................................................................................. 229
31.2 Restore a Backup .............................................................................................................. 230
31.3 Back Up Current Configuration .......................................................................................... 231
32 More Advanced Configuration ................................................................................................... 232
32.1 Default Mode vs. Showing Less Options............................................................................ 232
33 Web Server .................................................................................................................................. 233
33.1 Web Page Security ............................................................................................................ 233
33.2 Security Key Setup ............................................................................................................ 234
34 Troubleshooting .......................................................................................................................... 235
34.1 There is no level displayed on my unit ............................................................................... 235
34.2 Every time the pump starts I see a Contactor Auxiliary fault .............................................. 235
34.3 My unit is showing a “Current Config Fail” fault .................................................................. 236
34.4 My unit has started with the message “Fail Safe Mode”..................................................... 236
34.5 PPP2 Manager Connection Error ....................................................................................... 236
34.6 My unit keeps restarting ..................................................................................................... 236
35 Appendix A – Fault Message Glossary ..................................................................................... 237
36 Appendix B – Display Mounting Template – Metric Units ....................................................... 241
37 Appendix C – Display Mounting Template – US / Imperial Units ............................................ 242
38 Appendix D – MultiSmart Security Explained ........................................................................... 243
39 Appendix D – MultiSmart Web Security Explained .................................................................. 245
40 Appendix E – Setting Up WITS-DNP Communications ............................................................ 247
40.1 Basic Configuration ............................................................................................................ 247
40.2 Connection Details ............................................................................................................. 248
40.3 Handling of Redundant Channels with Connection Details ................................................ 249
40.4 Device On/Off Scan ........................................................................................................... 249
40.5 Scheduled Connection ....................................................................................................... 249
40.6 Point On/Off Scan .............................................................................................................. 250
40.7 Analogue Range/Scaling.................................................................................................... 250
40.8 Analogue Limits ................................................................................................................. 250
40.9 Counter Limits .................................................................................................................... 251
40.10 Point Archives .................................................................................................................... 251
40.11 Binary States ...................................................................................................................... 251
40.12 Profiles ............................................................................................................................... 251
40.13 Rate of Change .................................................................................................................. 251
40.14 Object Flag Actions ............................................................................................................ 252
40.15 Minimum, Maximum, and Mean ......................................................................................... 252
40.16 Integral Values ................................................................................................................... 252
40.17 State Counter ..................................................................................................................... 253
40.18 State Runtime .................................................................................................................... 253
40.19 Profile Control Value .......................................................................................................... 253
40.20 Bulk Configurations and Versions ...................................................................................... 254
40.21 Event Logs ......................................................................................................................... 255
41 Technical Specifications ............................................................................................................ 256
41.1 Processor Unit ................................................................................................................... 256
41.2 RTU/Communications ........................................................................................................ 256
41.3 Firmware/Application Upgrade Capability .......................................................................... 256
41.4 I/O Standard Modules ........................................................................................................ 256
41.5 I/O-3MP: Motor Protection I/O Board ................................................................................. 256
41.6 Power (per unit) ................................................................................................................. 256
41.7 Power Supply & Environmental .......................................................................................... 256
41.8 Product Dimensions ........................................................................................................... 256
42 MultiTrode Terms & Conditions of Sale .................................................................................... 257
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Summary of Tables
Table 1 – Power Supply Specifications ......................................................................................................................................... 38
Table 2 – Serial Port Pin Outs ...................................................................................................................................................... 49
Table 3 – Max. Cable Length at Specific Baud Rates ................................................................................................................... 52
Table 4 – Can BUS and Can ID Settings ...................................................................................................................................... 53
Table 5 – Key Setup Parameters (can only be modified through the Setup Wizard) .................................................................... 68
Table 6 – Alternation Schemes ..................................................................................................................................................... 93
Table 7 – Digital Input Fault Sources ............................................................................................................................................ 98
Table 8 – Advanced Digital Input Options ................................................................................................................................... 101
Table 9 – Digital Input Mode Examples ...................................................................................................................................... 102
Table 10 – Digital Input Capa b ilities ........................................................................................................................................... 102
Table 11 – Advanced Analog Input Options................................................................................................................................ 104
Table 12 – Advanced Probe Settings ......................................................................................................................................... 112
Table 13 – Probe Length in Inches ............................................................................................................................................. 115
Table 14 – DuoProbe Calibration Parameters ............................................................................................................................ 116
Table 15 – Advanced Fault Parameters ..................................................................................................................................... 123
Table 16 – Fault Actions Parameters .......................................................................................................................................... 125
Table 17 – Digital Output Sources .............................................................................................................................................. 132
Table 18 – Advanced Digital Output Options .............................................................................................................................. 133
Table 19 – Station Optimization Parameters .............................................................................................................................. 140
Table 20 – Pump Reversal Parameters ...................................................................................................................................... 143
Table 21 – Well Washer Parameter s .......................................................................................................................................... 146
Table 22 – CT & FLC Parameters .............................................................................................................................................. 152
Table 23 – Motor Protection Faults ............................................................................................................................................. 152
Table 24 – Basic Fault Options ................................................................................................................................................... 153
Table 25 – IRT Parameters......................................................................................................................................................... 154
Table 24 – Basic IRT Parameters ............................................................................................................................................... 156
Table 26 – Supply Protection Faults ........................................................................................................................................... 161
Table 27 – Supply Protection Fault Parameters ......................................................................................................................... 161
Table 28 – Battery Test Parameters ........................................................................................................................................... 162
Table 29 – Event Datalogger Param eter s ................................................................................................................................... 165
Table 30 – Crisis Logger Configuration for “Trigger” Parameters ............................................................................................... 167
Table 31 – Interval Logger Configuration Parameters ................................................................................................................ 168
Table 32 – Predefined Filters Available in General Filters .......................................................................................................... 169
Table 33 – Filenames for Each Type of Datalog file ................................................................................................................... 171
Table 34 – General Flow Fault Parameters ................................................................................................................................ 174
Table 35 – Smart Outflow Parameters ........................................................................................................................................ 179
Table 36 – Advanced Serial Port Parameters ............................................................................................................................. 195
Table 37 – VFD Parameters ....................................................................................................................................................... 202
Table 38 – ISaGRAF Device Names .......................................................................................................................................... 206
Table 39 – Example of MultiSmart Tags ..................................................................................................................................... 216
Table 40 – Logic Engine Mathematic Operators ......................................................................................................................... 217
Table 41 – Logic Engine Functions ............................................................................................................................................. 217
Table 42 – Logic Engine Advanced Functions ............................................................................................................................ 218
Table 43 - Customize Display - Pump Data ................................................................................................................................ 226
Table 44 - Customize Display - Bottom 3 Lines .......................................................................................................................... 226
Page 8 of 260 MultiSmart_IO_Manual_R20

1 Warnings & Cautions

1.1 Information to User

Read through this m anual to obtain a good working kno wledge in order to get max imum perform ance from the MultiSmart for your application. After reading, place the manual in a safe place for future reference.

1.2 Documentation Sta ndards

DANGER:
THIS SYMBOL IS USED WHERE NON-COMPLIANCE COULD RESUL T IN INJURY OR DEATH.
WARNING:
THIS SYMBOL IS USED WHERE NON-COMPLIANCE COULD RESULT IN INCORRECT OPERATION, DAMAGE TO OR FAILURE OF THE EQUIPMENT.
NOTE:
THIS SYMBOL IS USED TO HIGHLIGHT AN ISSUE OR SPECIAL CASE WITHIN THE BODY OF THE MANUAL.

1.3 Installa ti on Note s

WARNING:
THE MULTIS MART INSTALLATION AND WIRING MUST BE PERFORMED BY QUALIFIED PERSONNEL.
DANGER:
THE MULTISMART HAS NO USER SERVICEABLE PARTS. TO REDUCE THE RISK OF ELECTRIC SHOCK, LEAVE ALL SERVICING TO QUALIFIED MULTITRODE TECHNICAL STAFF.
DANGER:
INSTALLATION OR USE OF THIS EQUIPMENT OTHER THAN IN ACCORDANCE WITH THE MANUFACTURERS INSTRUCTIONS MAY RESULT IN EXPOSURE TO HARM, SERIOUS I NJURY OR DEATH.
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Abbreviations, Symbols & Units

2 Glossary & Symbols

Terminology
Activation Level
Alternate Mode
Deactivation Level
Decommissioned Pump
Duty (Lead) Pump
Empty (Discharge) Mode
Fill (Charge) Mode
Fixed Sequence
InterPump Start Delay
InterPump Stop Delay
Probe
Standby (Lag) Pump
The point at which a pump or alarm is switched On.
The Pump Station Manager automatically switches the lead (duty) pump each cycle.
The point at which a pump or alarm is switched Off. A pump that has been removed from duty or an installation, e.g. for maintenance
purposes. The main pump or the first pump to start within a pumping cycle.
When the Pump Station Manager is set to empty a tank or pit.
When the Pump Station Manager is set to fill a tank or pit.
Pump 1 or pump 2 is fixed as the lead (duty) pump.
The delay between any two pumps starting.
The delay between any two pumps stopping. MultiTrode manufactures a range of conductive level sensors. They have many
advantages over traditional devices such as ball floats. Advantages include: resistance to fatty deposit build-up, tangle-free and an adjustable sensitivity to liquid to prevent false readings.
The secondary pump or the next pump to start within a pumping cycle.
ISaGRAF
PSM
Ω
EMC
Hz
LED
MTU
N/C
N/O
RTU
VAC
VDC
ISaGRAF is a control software environment which supports all of the internationally recognised IEC 61131-3 control languages and offers a combination of highly portable and robust control engine.
Pump Station Manager Resistance Value (Ohm) Electromagnetic Compatibility Frequency (Hertz) Light Emitting Diode Master Terminal Unit Normally Closed Normally Open Remote Telemetry Unit Alternating Current Voltage Direct Current Voltage
VFD
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Variable Frequency Drive

3 Major New Features & Enhancements in Recent Firmware Releases

3.1 Version 3.1.0

Version 3.1.0 includes a large number of enhancements and bug fixes. This section lists some of the major highlights of this release.

3.1.1 New Features

• Enhanced security features supporting different levels of security for accessing screens
• SMS Server functionality for sending SMS messages on alarm conditions
• Web-based monitoring services and web security for accessing web pages
• Well cleanout can now be controlled by watching current drawn
• Ability to calculate statistics whenever event triggers occur (e.g. average, minimum, and maximum
current while the pump is running)
• Support for DNP Secure Authentication Version 5
• Support for WITS-DNP V2.0

3.1.2 Screen Changes

• Setup Wizard redesign – once completed, users are prompted to set up additional common features
• Device network information now displayed on a Network page under the Info group of pages
• Deactivating faults now show time until reset
• Faults in the fault screen are now shown in order of most recent fault first
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Part 1 – Operations

4 Introduction

Congratulations on your purchase of the MultiTrode MultiSmart Pump Station Manager. Depending on the options you have purchased, the unit may be configured as either a Pump Station
Manager or a Reservoir Monitor or as a Remote Telemetry Unit. The generic product description of MultiSmart Pump Station Manager is used throu ghout the manual and for conveni ence refers to any of the three configurations.
The pump station manager is an "out of the box" Pump Station Manager for water and sewerage pump stations. The large LCD s creen with sof t-ke ys eliminates the n eed for selec tor switches, p ush buttons , fault lights, meters, accumulators and other additional panel items. This simplifies panel wiring and reduces costs.
The product has a very low “whole of life” cost compared with a PLC due to the pum p control functionality already developed in the product. Users simply configure the parameters, rather than program the unit. This reduces engineering cost and greatly increases reliability.
The MultiSmart pump station manager has t h e op tio n o f an IEC 6 113 1-3 PLC program m ing lan gua ge so that additional functionality can be added by the user if required.
The MultiSm art has fully open communications and c an be supplied with Modbus and DNP3 protocols. A MultiSmart can also be shipped just as an RTU without any pump control functionality or user interface.
The Reservoir Mon itor is a version of the product for monitoring reservoi rs and communic ating with remote pump stations.
MultiSmart is fully config urable f rom the LCD us er inter face. H owever, ther e is al so a PC -based Configurator program with comprehensive functionali t y now availa b le.

4.1 Range of Options

The functionality of the basic product can be enhanced with additional software modules, such as:
• DNP3 RTU with security
• Security key - based on the ‘Dallas Key’
• VFD control - variable frequency/speed drive
• “Energy Monitoring and Motor protection” option which allows power, energy, power factor and
pump efficiency monitoring as well as 3-phase currents, motor protection functions and insulation resistance tests (requires energy monitoring and motor protection I/O module)
• Logic engine (for custom logic additions)
• ISaGRAF (IEC 61131-3) PLC programming
• Well Mixer
• PumpView – a web-based monitoring and control system via the cellular/mobile network
• SMS Server - for sending SMS messages in the event of configured alarm conditions
The product can be shipped with these software modules enabled or they can be enable d in the field with the appropriate enable code. T o the base uni t, an add itio nal I/O boar d can b e instal led in t he fac tory to all ow for either an expansion of I/O or motor protection options.
Page 12 of 260 MultiSmart_IO_Manual_R20

4.2 Intuitive Operator Interface

The MultiSmart has screens which have been designed for operators of pump stations. The operator can see at a glance:
• Level
• Pump mode
• Pump availability
• Detailed fault information
• Date/time of each fault occurring and clearing
• Single or 3-phase supply, DC supply
• Fault and event history (up to 50,000 records, or millions of records with SD card)
• Accumulators (starts, hours, faults, etc)
• Pump efficiency (requires energy monitoring, motor protection and flow enabled)
• Status of all I/O
• Status of a communications link
• Duration to Overflow

4.3 Intuitive Engineering Interface

The product has clear menu screens for altering:
• Pump set points
• Alarm set points
• Delays
• Alternation and grouping
• Level device and backup level device
• Number of pumps
• I/O and fault configuration
• Supply protection
• Energy Monitoring and Motor protection (where installed)
• Station optimization parameters (max run time, max off time, max starts per hour, plus many more)
• Data logging parameters
• Communications
• Profiles
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gases or powders.

4.4 "Out of the Box" Control of a Pump Station

When the unit is first power ed up, it starts controlling a pum p station using its def ault parameters. Although it’s shipped with this basic configurat ion, the configur ation can be easily modified to suit a wide range of applications by running through the Setup Wizard.
The Setup W izard takes into ac count the MultiTrode probe or other level devices, fill or em pty applications, number of pumps, num ber of wells, station power supply, type of pum p sensors and DNP comm unication settings.
Even though the basic setup meets most of the normal pump station requirements, with a few button presses the MultiSmart can be setup to perform most of the complex pump station management requirements.
Changing between a reser voir and a pump station, the number of pum ps, the number of wells, or empty (discharge) to fill ( charge) is done through t he Setup W izard an d takes onl y a few m inutes, whi ch is far less time than that required to implement the same functionality using a standard PLC.
Complete station setups can be saved and/or loaded via an SD card or USB. If the extensive rang e of existing features do not cover a part icular requirement, additional functionality can
be added by writing new code using either Logic Engine (a simple Boolean language) or ISaGRAF (a suite of PLC languages).
WARNING:
Do not use this unit in environments that may contain flammable/explosive or chemically aggressive
Page 14 of 260 MultiSmart_IO_Manual_R20

5 Operator Interface

The MultiSmart pum p station m anager has an easy to use in terface f eaturing a large graphica l LCD. A large amount of critical information is displa yed on the main screen, m aking it simple for an operator to determ ine the current status of the pump station at a glance.
The buttons (or soft-keys) aroun d the edge of the screen ar e used t o access f eatures, depending on what is displayed at the time.
Figure 1 – MultiSmart Display
1. Fault Indication LED (Red)
2. Power Status LED (Green)
3. Home Button
4. Help Button
5. Increase Contrast
6. Decrease Contrast

5.1 LCD Panel

The large LCD gives the oper ator a clear view of how the pum p station is opera ting. Water levels are shown graphically. A back light turns on when any of the display butto ns are pushed. The back light turns off again after a set time of inactivity (this time is user configurable).
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5.2 LED Indicators

5.2.1 Power

The Power LED is at the bottom left hand corner of the display and indicates that the DC supply is connected and turned on.

5.2.2 Faults

The fault LED is above the power LED. It flashes on ce a second when a fault is detec ted. This gives the operator a quick indication of whether a fault is present without having to access the LCD screen.

5.3 Buttons

5.3.1 Home/Help Button

The Home/Help button has two positions:
• Press ing the Home icon returns the user to the main status screen.
• Pressing the Help icon displays online help for the currently displayed screen.

5.3.2 Contrast Button

The contrast button is us ed to adjust the LCD scr een’s contr ast. Press “ +” or “–“ as required to optimis e the display for the light conditions.

5.3.3 Display Buttons

Eleven buttons are loc ated ar ound the ed ge of the LC D displa y. These ar e used to ac cess m enu item s and other data on the display. For any screen, the display indicates what each button is used for.

5.3.4 Numerical Keypad

A numerical keypad is locat ed at the right of the interface. This is us ed to enter alpha-numeric character s during configuration.

5.4 Using the Interfa ce

5.4.1 Main Status Screen

Pressing the Home butt on turns on the LCD backlight and als o returns the MultiSmart displa y to the main status screen. The following screen displays the current status of all pumps connected to the MultiSmart:
Figure 2 – Main Status Screen
Page 16 of 260 MultiSmart_IO_Manual_R20
5.4.1.1 Pump Mode The buttons located next to each pump are used to switch the pump into Manual (Hand), Off, or Auto modes.
• Auto – I n this mode a pum p starts when the activation s etpoint is reache d. The pum p automaticall y stops when the deactivation setpoint is reached.
• Off – This turns a pump off, so pump run commands are ignored b y the of f pump regardless of leve l. In order to meet secur ity requirements, the Of f mode can be disabled from the advanced menu. (If changed while the pump is already in the Off mode, it stays off until the mode changes).
• Manual (Hand) – is semi-automatic manual, as the mode returns automatically to Auto when the deactivation setpoint of the pump is reached. (This prevents pumps from being left on unintentionally).
A pump is placed into Full Manual m ode as follows: when the pump is in Off mode, instead of just briefly pressing the Auto/Off/Manual button, press and hold it on. This puts the pump into Full Manual mode for as long as the button is pressed.
5.4.1.2 Running Status The Running Status of each pump appears to the right of the Pump Name. The various states are:
• Stopped – Pump is stopped
• Starting in x seconds – Pump is about to start and a delay is counting down
• Running – Pump is running
• Stopping in x seconds – Pump is about to stop and a delay is counting down
• Next to Run – Indicates the next pump to run. (Not applicable in multiple well configurations).
• Request to Run – The controller is waiting for the feedback from the contactor. (A contactor
auxiliary is wired in and the command to run a pump has been sent).
• External Run - If the pump is started by an external control method (for example, via a manual override switch), the contactor will be closed but no run command would have been sent by the controller, hence External Run is displa yed. The Mu ltiSmart c ontinues to up date the pum p run time statistics and other relevant historical data. As well, the relevant faults and warnings are generated.
• Reversing in x seconds – The pump is about to reverse
• Reversing for x seconds – The pump is currently being reversed
• Decommissioned – The pump has been taken out of service
5.4.1.3 Availability Status The Availability of each pump is displayed below the Running Status. The states are:
• Available – There are no curr ent faults for this pump. The pum p is available to run ( this condition does not consider the mode of the pump, so if the pump is OFF, the pump will not run).
• Unavailable – A fault is present or a fault requires manual acknowledgment.
• Hold Out – The text,” Hold Out” flashes indicating a fault is present and the pump is unavailable.
• Inhibit – Station or individual pump inhibited from SCADA
5.4.1.4 Fault Status The Fault Status of each pump is displayed below the Availability Status. The states are:
• Fault Present
• Ack Required – A fault condition has cleared and is not holding out the pump, but requires
acknowledgement.
• Reset Required – A fault condition has cl eared and is holding out the pum p, so requires reset (see Section 5.4.2).
• Reset in x sec – A f ault condition has clear ed and the pum p will auto-reset when the count down is complete.
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A bar graph is displayed next to the pumps and shows:
55.0%
Lag (Standby) Pump
activation and deactivation levels
Lead (Duty) Pump
activation and deactivation levels
Level Alarms
Figure 3 – Level Indication
than 1 well.
5.4.1.5 Level Indication and Setpoints Display
• Current liquid level
• Each pump’s activation and deactivation levels
• Level alarms that have been enabled
5.4.1.6 Soft-keys The buttons at the bottom of the screen are used to access the following areas:
• Settings - used to configure the MultiSmart pump station manager
• Info: displays full station and pump information
• History: shows alarms and event history
• Faults: shows details of current fault conditions
NOTE:
When the unit is controlling 5 or more pumps, a Next Pumps button also appears on the bottom line allowing access to pumps 5 and 6, etc. This button is also present when the unit is configured for more

5.4.2 Faults / History

When a fault occurs, a large FAULT box is displayed at the bottom of the screen. At the s ame time, the fault status changes to Fault Present.
Figure 4 – Fault Indication
The left Fault soft-key butt on flashes when a fault is p res ent. Pus hing t his button (or the rig ht Faul ts bu tton) displays a screen which det ails the fault. (Appendix A contains a description of all faults displayed).
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Figure 5 – Fault Reset Screen
Use the selector buttons to select each fault in turn. From this screen the opera tor can reset the fault if the f ault condition is no long er present. If the fault is still
present, the Reset Fault button does not appear. A Mute Fault button appears for faults that can be muted. It is used to s top sirens or flashing li ghts t hat may
have been activated by the fault. A Reboot Unit button app ears for a Config Changed - Reboot Required fault. Pres sing this butt on will save
current values and then reboot the unit. Press the Yes button to confirm a restart of the controller. This process takes one to two minutes to complete.
By default, digital out put 4 (DO4) is linked to th e high-le vel alarm and can be m uted. The digital out put can be configured for Pulsed or Steady operation and is typically connected to an external warning light or alarm.
• The Mute button is only available for other faults if the user has configured them to be mutable.
• Press ing the History button displays the entire fault & event history log.
• Press ing the Main button returns the operator to the main status screen.
Figure 6 – Fault History S creen
Section 19.4 explains more about Filters and section 19.7 explains the Add/Delete button.
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5.4.3 Information Screen

The Information screens show:
• Hours run, starts and faults for each pump and the station
• The status of all I/O
• Flow data (when the optional flow module is installed)
• System log (identifies any application problems)
• Version and modules installed in the unit
• Power and Efficiency – kW, kVA, power factor, pump efficiency, energy accumulators (kWh and
kVAh) for various periods: toda y/ yesterd a y; this week /las t week
• Communications statistics for DNP3/ Modbus slave and the current DNP3 Modbus tag values
• Option to browse MultiSmart internal tag database
• Option to view ISaGRAF 5 tags and values useful for PLC programming
To navigate to the Information screen, press the Info button on the main operator screen.
Figure 7 – Information Screen 1 of 2
Pressing More displays the second scr een, which includes the Version button which gives details on the firmware version installed on the unit. (Free firmware upgrades are available from the MultiTrode website).
Figure 8 – Information Screen 2 of 2
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5.4.3.1 Power & Efficiency This screen shows the power fac tor and ef ficienc y of the pumps . Efficienc y, energ y and appare nt ener gy of
the present day, yesterday, this week, last week, this month, last month and totals are displayed on this screen. There is also a Benchmark Efficiency (further down the screen) which can be entered as a comparison value (see section 17.1).
Navigate to:
Figure 9 – Power Efficiency Screen
5.4.3.2 I/O Information Information about the S ystem, DC Voltage, Top Board, Bott om Boar d and Probe c an be seen in this s creen.
The I/O information sc reens are especiall y useful in troubles hooting input/output related issues. Insulation Resistance test (IRT) can be accessed from within the I/O information sc reen, (the test is only performed when the pumps are not running).
Navigate to:
Figure 10 – I/O Information Screen
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in the digital inputs advanced options.
To determine the configuration and current state of the digital inputs, navigate to the I/O Information: Digital Inputs screen.
The current state of a digital input is displayed on the top line: Value. Press the Advanced button to displa y configuration inform ation on the digita l inputs, f or example Mo de and
Sensitivity. The resistance as measured by the input is also displayed in Advanced mode. When the measured
resistance is below the Sensitivity, then the inp ut turns on (unless it is in verted, in which cas e the reverse i s true).
NOTE:
The Sensitivity used by the probe (default of 22k ohms, Section 14.8.3
) is not the same Sensitivity found
Figure 11 – Digital Inputs Information Screen
High Density IO info page screens display the state of all digital inputs/outputs on one page for one unit/board at a time. T he unit name and board name are displa yed at the top. By pressing the N ext/Prev button, the I/O for the next/previous unit/board can be viewed.
To determine the current state of all digital input s/outputs, navigate to the I/O Information: High Density IO
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5.4.3.3 Flow The station inflow rate, pum p outflow rat e, volum e pumped dur ing a range of inter vals, number of overflows ,
last overflow tim e, last overf low duration, duratio n to overf low, and total o verflow volume can be se en in th is screen.
Navigate to:
Figure 12 – Flow Screen – Part 1
Navigate to: and scroll down.
Figure 13 – Flow Screen - Part 2
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Figure 14 – Flow Screen - Part 3
MultiSmart Installation & Operation Manual
Page 24 of 260 MultiSmart_IO_Manual_R20
5.4.3.4 Pump Information Under this screen, the Runtime, Start, Reverse and Fault statistics as well as IRT information can be
accessed. These options are illustrated in this section.
(a) Runtime Statistics
Navigate to:
Figure 15 – Pump Run Time Statistics
Runtime is calculated base d on when the pum p is considered run ning via the con tactor auxil iary status. T his includes when the pump is externally run (determined via the contactor auxiliary status). If no contactor auxiliary is wire d in, the runtime is c alculated from when t he pump is called for by MultiSmart, and ext ernal pump runs (e.g. via external switch) will not be included. This is also the case for Starts (below).
In the case of the runtime statistic s, t he station runtime may not equal th e sum of the pum p runtimes. For example, if Pum p 1 is running for 1 hour by itself, followed b y Pum p 2 running for 1 hour by itself, then both pumps run for 1 hour together . The Pump 1 an d Pump 2 runtim es will be 2 hour s each whereas the Station runtime will be 3 hours since both the pumps were running together for an hour.
For the Generator Run Time s tatistics to be calculate d, a digital input m ust be wired into the MultiSm art and configured as the Generator Running fault.
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(b) Start Statistics
MultiSmart Installation & Operation Manual
Navigate to:
Figure 16 – Pump Start Statistics
(c) Fault Statistics
Navigate to:
Figure 17 – Fault Statistics
This screen disp lays the total fau lts that occurred, tod ay, yesterda y, this week an d last week for each pum p and the station.
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(d) Insulation Resistance
Navigate to:
Figure 18 – Insulation Resistance
The insulation resistanc e t e s t c an be acti va ted f r om this screen. The result of the test and re lat ed values are displayed in this screen. This test can on ly be performed when the pump is not running. (IR T can also be accessed from the I/O information screen).
(e) Reverse Statistics
Navigate to: Pump reverse information can be viewed here. Three different Reverse Statistic s can be viewed. (i) Total Reversals
Figure 19 – Pump Total Reversal Statistics
This gives the total reversal statistics for the pumps as well as the station.
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(ii) Preventative Reversals
MultiSmart Installation & Operation Manual
Figure 20 – Pump Preventative Reversal Statistics
This gives the preventative reversals statistics, which is reversals on start/stop. (iii) Fault Reversals
Figure 21 – Pump Fault Reversal Statistics
This gives the blockage removal reversal statistics (reversals triggered by faults).
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5.4.3.5 Communications The DNP and Modbus master and s lave status and values can be seen from this menu. Vie wing the tag
values in real-time helps with trouble shooting communication errors. If logging is enabled (via the Advanced menu) and the View Log button is pressed, then the related communications messages are displayed. (If both DNP and Modbus m asters and slaves are present, a sec ond screen is created to cover al l stats and values).
Navigate to:
Figure 22 – Communications
5.4.3.6 Browse Database The Browse Database menu option lists all nodes within the r eal-tim e database in the MultiSmart. The t ags
are categorized and group ed into nodes as illustrated below. Each node can co ntain a list of tags as well as a number of child nodes. This screen allows for the selection and display of the real-time value of a tag.
Navigate to:
Figure 23 – Browse Database
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5.4.3.7 Version Information The hardware and soft ware versions and the MultiSm art serial number are displayed in this screen. This
information ma y be requir e d if MultiSmart technical s upport is reques t ed. (The MultiSmar t f irm ware vers ion i s listed beside the Build Version).
Navigate to:
Figure 24 – Version Information
5.4.3.8 ISaGRAF 5 This screen displays ISaGRAF resource information including compile date, download rate, mode, cycle
time, cycle overf low, cycle count, and tags. Parameters and v ariables can be viewed through th is screen. Also the value of parameters can be changed from this menu.
Navigate to:
Figure 25 – ISaGRAF Resource Summary Screen
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