EPG LevelMaster CHS Series User manual

CHS Series LevelMaster™ Level Meter

Operations & Configuration Manual

EPG Companies Inc.

19900 County Road 81

Maple Grove, MN 55311

800-443-7426 * www.epgco.com

Tech Support * 800-762-8418

For Models:

CHS1000

CHS1100

CHS1200

INDEX

Introduction 2

Connections 3

Run Mode 4

Configuration Procedure 4

Meter Setup Mode 5

Meter Operations Mode 6

Meter Scaling Setup 7

+AO & +RS232 Options 8/9

Configuration Guide 10

Meter Settings 11

Replacement Guide 13

INTRODUCTION

The feature-rich CHS Series Indicating controller is the heart of the EPG Level Master System.

The level is determined by detecting changes in hydrostatic pressure using a submerged stainless

steel pressure transducer. The EPG Level Indicating Controller ‘reads’ the corresponding analog

current and uses one or two of the three internal relays to turn on and off pumps. Pump control

can be either in pump up or pump down modes with either one or two pumps controlled. The

relays can also be used as alarms outputs and can be fully configured for failsafe operation.

The base Model CHS1000 includes features previously listed. In addition to those features, the

CHS1100 and CHS1200 provide even more output, input, and communication options.

The CHS1100 adds an analog output (a re-transmitted, powered 4-20mA), an internal, 24VDC

transmitter power supply and digital inputs (used for pump disable or monitoring pump on/off status

& run time).

The CHS1200 adds RS-232/485 Communications Ports (Modbus). The supply power for each

model can be 24VDC, 120VAC or 240VAC. The CHS Series standard configuration is in inches,

but can be field configured to any other units required.

1.0 Installation

The power requirements for the meter are listed on the label located on the top of the case. Use

only the power indicated. The label also indicates any optional installed hardware that may be

installed. The pre-set factory configuration of the meter is also listed. The settings of the meter

and the alarms can be changed in the field however prior to unattended operation, it is good

practice to confirm all parameters via the display (see configuration guide at end of this document).

1.1 Mounting

The CHS Series mounts in a standard horizontal 1/8 DIN panel opening. The case mounted “ears”

attach to the side of the meter case after it is inserted in the panel. The installation screws supplied

with the meter can then be tightened to secure the meter.

DIMENSIONS: Face: 3.75” (95mm) X 1-7/8” (46mm)

Depth (back of Panel): 4.5” (114mm)

Panel Cutout: 3.5” (90mm) X 1- 11/16” (43 mm).

CHSXXXX -

1.2 Connections

The rear of the meter may have up to three terminal strips. The main 14 terminal strip (J1) is the

standard. If options are present then two shorter terminal strips (J2 & J3) will be present and

physically located above J1.

J1 (CHS1000, CHS1100, and CHS1200)

1 - VAC Hot / DC+ 6 - Pump Relay # 1 11 - +24VDC @ 100mA

2 - VAC Neutral / DC- 7 – Alarm Relay #1 12 – SIGNAL I/P sinking(+)

3 – Ground 8 – Alarm Relay #1 13 - SIGNAL I/P sinking (-)

4 – Common 9 – Alarm Relay #2 14 – Common

5 – Pump Relay #1 10 – Alarm Relay #2 SEE NOTES BELOW RE: Inputs

J2 (CHS1100 and CHS1200 only)

1 - Common (Pulse return) 5 – Float/HOA switch I/P Disable #2

2 – RUN / Pulse I/P# 2 (5-50VDC) 6 – Float/HOA switch I/P Disable #1

3 – RUN / Pulse I/P#1 (5-50VDC) 7 – Re-transmitted level 4-20mA (-)

4 – Common (HOA return) 8 – Re-transmitted level 4-20mA (+)

J3 (CHS1200 only)

1 – RS-485 (-) 5 – RS-232 RTS (see Note 2)

2 – RS-485 (+) 6 – RS-232 TX data

3 – SIG common 7 – RS-232 RX data

4 – RS-232 RTS (see Note 2)

NOTES:

All relays Form A rated 5A @ 120 VAC

Use Terminals 12 (+) and 13 (-) for sinking inputs (i.e. 2 wire transmitters)

Use terminals 13(+) and 14(-) for sourcing inputs (i.e. 4 wire transmitters)

For RS-485 or for quick turn-around RS-232, jumper RTS and CTS.

For external modem use, connect RTS and CTS to the modem. The modem provides the CTS

delays as needed.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

H N G C K1 K1 K2 K2 K3 K3 +24 S+ S- C

1 2 3 4 5 6 7 8

C P2 P1 C HOA2 HOA1 -A/O +A/O

1 2 3 4 5 6 7

-RS485 +RS485 C RS232

CTS

RS232

RTS

RS232 TX RS232

RUN MODE

2.0 Levels and Alarms

During normal operation the meter will display the real time process level in the units (inches,

centimeters etc) in which the level transducer and the CHS1200 were calibrated during setup.

During normal operation the display indicates the process level. If the meter is in alarm or a pump

is on, every 15 seconds the display will toggle to briefly indicate this status (i.e. AlHi, P etc.).

Pressing the UP and DOWN arrows simultaneously will cause the METER TYPE to be displayed.

2.1 Min / Max

During normal operation pressing either the UP or DOWN arrows will cause the most recent

minimum or maximum process level values recorded by the meter since the last active meter reset.

An Active Reset is performed by simultaneously pressing the UP arrow (max reset) or DOWN arrow

(Min reset) and the SETUP/ENTER key together.

2.2 LED Indicators

There are three LED’s located vertically on the left side of the display that indicate the meter’s real

time operating status.

The TOP LED flashes in alarm if the communications option board is present and the

communication has failed. A small LED to the left of this LED flashes if the option is installed and

the meter is communicating.

The MIDDLE LED is non-operational and reserved for future use.

The BOTTOM LED is ON if either a local or remote pump lockout is enabled.

2.3 Real Time Digital Input Status

Press the SETUP/ENTER key momentarily. The display will read ZERO. Enter a Setup Code value

of 2 by pressing the UP arrow twice and press the SETUP/ENTER key. The display will show

‘d????’. Each ‘?’ will be either a 1 (on) or 0 (off) with each digit representing the status of a local

digital inputs. The meter will continue to monitor and control the pumps while this operation is

performed.

CONFIGURATION PROCEDURE

The meter when first plugged in will quickly perform a startup routine confirming the operation of all

the LED segments. It will then display the current input value. If there is no input and the meter

was setup at EPG, (EPG standard configuration is for a 0-5PSIG input with 4-20mA output) the

meter will display –34.6. In order to change any set points or internal values, one must enter the

respective SETUP MODE as defined in the Configuration Guide on page 10 of this manual. To

enter a SETUP MODE (25, 35, 45) simply firmly press the SETUP/ENTER key momentarily. Upon

release the meter’s display will indicate ZERO. Using the UP/DOWN arrow keys, increment this

value to the desired entry code (25, 35, or 45) and press the SETUP/ENTER key. The meter will

automatically step to the next menu item. The meter will display the next menu item briefly and then

either wait for an entry or toggle to show the current value. Use the UP/DOWN keys to set the

required value.

Pressing the SETUP/ENTER key will enter this value into the meter’s internal memory and

increment the display to the next menu item.

* Keyboard inactivity for more than three minutes will cause the meter to exit the setup mode

and return to the run mode.

METER SETUP MODE (CODE 45 – configure first)

3.0 METER TYPE

The meter can be configured for 6 different pump control actions as follows:

NOTES:

1. Control mode types 1, 2, & 3 may also be referred to as emptying or pump out and modes 4, 5

& 6 may be referred to as filling or pump in.

2. The alarm relays are ALL Normally Open (fail safe) and can be field configured as Normally

Open or Normally Closed (see 3.4 & 3.5 below).

3.1 20mA CALIBRATION

The meter is delivered from EPG pre-calibrated. Under normal operation this setting should NEVER

be adjusted. If re-calibration is required consult your EPG representative.

3.2 MODBUS ADDRESS (Addr = 1- 240)

Use the UP/DOWN arrow keys to enter the desired Modbus address and press the SETUP/ENTER

key. This is only active if this option is installed

3.3 MODBUS Serial Baud Rate

The communication transfer rate can be toggled between 1200 Baud (bd-12) and 9600 Baud (bd-

96) using the UP/DOWN arrows. This is only active if the option is installed.

3.4 2nd Alarm Contact Configuration (terminals 9 & 10)

Use the UP/DOWN arrows to toggle between Normally Open & Normally Closed relay configuration

for relay #2 associated with the second alarm of Single Pump Systems or the Pump 2 function of

dual pump system.

3.5 1st Alarm Contact Configuration (terminals 7 & 8)

Use the UP/DOWN arrows to toggle between Normally Open & Normally Closed relay configuration

for the relay associated with the HI alarm.

# CODE EQUIPMENT ACTION ALARM #1 ALARM #2

1 SdHL Single Pump Pump Down Hi Lo

2 SdHH Single Pump Pump Down Hi Hi Hi

3 ddH Dual Pump Pump Down Hi P2 On/Off

4 SuHL Single Pump Pump Up Hi Lo

5 SuHH Single Pump Pump Up Hi Hi Hi

6 DuH Dual Pump PumpUp Hi P2 On/Off

METER OPERATIONS MODE (CODE 35 – sets alarm & pump control points)

4.0 Menu Items Overview (described below) for METER TYPE

4.1 PrHI (Relay #1 – terminal strip J1 #5 & 6)

This is the upper on or off set point for the main pump control and is adjusted using the UP/DOWN

arrow keys.

4.2 PrLo

This is the lower set point for the main pump control and is adjusted using the UP/DOWN arrow

keys.

4.3a AlHi (Relay#2 – terminal strip J1 #7 & 8)

Use the UP/DOWN arrow keys to adjust the Hi Alarm. OR

4.3b PrHi2

This is the upper on or off set point for the secondary pump in a lead/lag control situation. It is

adjusted using the UP/DOWN arrow keys.

4.4a HyHi

The High alarm hysteresis determines the value by which the process must deviate from the alarm

set point before the relay returns to its normal state. OR

4.4b PrLo2

This is the lower on or off setpoint for the secondary pump control and is adjusted using the UP/

DOWN arrow keys.

4.5a AlLo (Relay#3 – terminal strip J1 #9 & 10)

Use the UP/DOWN arrow keys to set a lower alarm limit for a single pump system.

4.5b AlHi2 / AlHi

Use the UP/DOWN arrow keys to adjust the Hi/Hi or Hi Alarm for single or dual pump systems. 4.6

HyLo or HyHi (Same as 4.4a above)

Step # SdHL SdHH ddH SuHL Suhh duH

1 PrHi PrHi PrHi PrHi PrHi PrHi

2 PrLo PrLo PrLo PrLo PrLo PrLo

3 AlHi AlHi PrHi2 AlHi AlHi PrHi2

4 HyHi HyHi PrLo2 HyHi HyHi PrLo2

5 AlLo AlHi2 AlHi AlLo AlHi2 AlHi

6 HyLo HyHi2 HyHi HyLo HyHi2 HyHi

METER SCALING SETUP (Setup Code 25 - scales display)

5.0 DECIMAL POINT

Using the UP / DOWN arrow keys the decimal point can be moved to the left or the right providing

the resolution required for the application.

NOTE: Moving the decimal point to the far right will cause it to be “hidden”.

5.1 SCALING FACTOR

It is necessary to cause the display counts (0-2000) to read in actual engineering units. . This is

done using a Scaling Factor and a Scaling Offset Factor.

Using the factory standard level transducer as an example (0 – 5 PSI two-wire transducer scaled in

inches with an output of 4 – 20mA’s) these factors are calculated as follows.

Scaling Factor = Desired Reading Range / Max. Display Count

Therefore: The URL (5 PSIG) converted to inches is 138.55” (5 X 27.71” H2O per 1 PSI)

Because the transducer is “zero based” (0-138.55”) and the current output is “live” (4-20), 25% or

(1/4) of the URL value must be added: 138.55 / 4 = 34.64 + 138.55 = 173.19 or ~173.2

Remove the decimal point for calculation: 1732 / 2000 = .866 >> The scaling factor is: .866

5.2 SCALING OFFSET

It is now necessary to perform an offset or to suppress the above range to Zero. The factory default

for the 0-5 PSIG transducer with a 4-20mA Output is –34.6

The standard equation for doing this is: The negative value of (Suppressed Range (4mA) / Active

Range (16mA)) * Desired Units Full Scale

- (4 / 16) * 138.55 = -34.6 >> The offset factor is: -34.6

TROUBLESHOOTING TIPS

1. Pressing the UP/ DOWN arrows simultaneously will cause the meter to display its current

configuration and alarm type.

2. Confirm power to all devices and equipment

3. Check configuration of meter (including decimal point location)

OPTIONS

DIGITAL INPUTS & ANALOG OUTPUT (+AO option / CHS1100 & CHS1200 only)

6.0 Pump Run Status (terminal strip J2 #1,2 & 3)

There are two local digital inputs that can be used to monitor pump operation or other conditions.

Internally generated ‘bits’ in the Digital Input Register reflect the inputs’ current state. These inputs

also have associated internal registers that:

a) count the number of pump starts &

b) accumulate a “runtime” in tenths of hours

These two inputs (terminals 2 & 3) also share a common return (term.#1) and are polarity

insensitive. In addition there are internal registers that accumulate the number of starts and the

runtime based on the meter’s own pump relay outputs. All this information can only be accessed by

using the RS-232/485 communications port.

6.1 Lockout Inputs (terminal strip J2 #4, 5 & 6)

There are two local digital inputs that can be used to disable the pump control operation. They may

be used with floats or other “backup” limit / lockout conditions. They may also be used to sense the

run / off / auto conditions from an HOA switch.

The connections are not polarity sensitive and share a common return (term#4).

NOTE: These disable terminals DO NOT replace standard lock out procedures used when

performing maintenance on equipment. Proper safety procedures should always be

observed when working on or around all electrical equipment.

6.2 Analog Output (terminal strip J2 #7 & 8)

An analog output (4-20mA) proportional to the level input is re-transmitted from terminals 7 & 8 of

the J2 option board. If the input loop is open (0 mA) then the re-transmitted output will read Zero

and not 4mA.

6.3 Remote Lockout (communications option required)

reset. This bit is similar to local Lockout inputs in preventing the pump output from activating. Any

Lockout condition is indicated by the Lower Status LED at the left side of the display.

NOTE: The periodic status message showing “P” indicating the level is such that the pump would

normally be required to run will continue to flash despite an active Lockout that prevents the pump

relay from actually energizing.

COMMUNICATIONS OPTION (+RS232 option / CHS1200 only)

7.0 MODBUS ADDRESS

The Modbus address can be set to any address between 1 and 240

7.1 REGISTER DATA (mapping)

7.2 DETAILS

The AIH (40003) register contains the scaled analog level as displayed on the meter. Note that the

decimal point is implied as this is an integer register.

The DIREGo (40001) contains:

Modbus Address Modbus Reg Description Offset

40001 DIREG0 DIGITALINS 0

40002 RAIL RAWS AI 1

40003 AIH ANALOG IN 2

40004 CYC0H STARTS EXT1 3

40005 CYC1H STARTS EXT2 4

40006 CYC2H STRTS INTNL PMP CALL 5

40007 CYC3H STRTS INTNL PMP CALL 6

40008 RUNT0H DURATION EXT 1 7

40009 RUNT1H DURATION EXT 2 8

40010 RUNT2H DUR INTNL PMP CALL 9

40011 RUNT3H DUR INTNL PMP2 CALL 10

40012 MAXH MAXIMUM 11

40013 MINH MINIMUM 12

40014 DOREG0 Internal Digital Outputs 13

40015 DOREG1 Remote Lockout (s) 14

CHS Series Configuration Guide

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