EverPump™ Wireless Pump control system - … User Guide V1.4.pdf · Wireless Pump control system ... the Tank Unit will monitor the water level and remotely ... and ^GND _ terminal

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Orbit Communications Pty Ltd

Wireless Pump control system

EverPump™

User Guide

Revision 1.4




Unit 1, 16 Donaldson Street

Wyong, NSW 2259

Australia

Phone +61 (2) 43 554 554

Fax +62 (2) 43 554 994

Email [email protected]

Web www.orbitcoms.com

All right reserved

Copyright Orbit Communications Pty Ltd, 2012



Table of Contents

Introduction 4

How it works 5

Tank LED Status Panel 7

Pump LED Status Panel 8

Optional Monitor 9

Tank Wiring 11

Pump Wiring 12

Digital Inputs 13

Digital Outputs 13

Solar Panel mounting 14

Optional Relay 16

Optional GSM Dialler 17

GSM Dialler commands 18

Programming Dialler 19

Dialler Command List 20

Safety Precautions 21

Warranty 22



Introduction

EverPump is a wireless tank monitoring and pump control solution. EverPump is designed to maintain the tank level between an Upper (HIGH) and Lower (LOW) level limit. The HIGH and LOW levels of the tank are determined by float-switches installed at the desired levels in the tank. The float switches should be configured to CLOSE when they are active (i.e. The LOW float switch should be normally-open and close when tank level falls below the float switch po-sition, the HIGH float switch should also be normally-open and close when the level in the tank exceeds the HIGH level).

During normal operation the Tank Unit will monitor the water level and remotely operate a pump relay at the Pump Unit to maintain the correct Tank level. In the event of an error (such as invalid float switch state or loss of radio communications), the Pump Unit will indicate an alarm condition and switch the pump relay OFF. Additional float switches can be added for Overflow detection (if placed physically above the HIGH float) or Tank Empty detection (if placed below the LOW float level). System can be supplied with optional 230VAC power sup-ply. An optional SMS modem enables the system to send alert messages to mobile phones and allows the system status to be obtained at any time from a mobile phone.

Figure 1. System Overview Diagram

Tank Unit

D1

D2

D3

D4

Empty (optional)

Low

High

Over (Optional)

Pump Unit

R1

Optional Solar

Power Supply

Pump

Optional Monitor Unit

Control Pump

Monitor State

Use Contactor for

load > 7 Amps or

3 Phase motors

Several km

Float Switches

Tank/Dam



How it Works

The Tank Unit continuously monitors the level of the tank and sends tank level information to the Pump Unit.

The Tank unit will send a signal immediately when any float switch changes state.

During times when no changes occur in float switch states, the Tank unit and Pump unit will communicate at regular intervals (15 minutes) to ensure the radio link is working correctly.

If the Tank Unit does not receive a valid response from the Pump unit within any 45-minute pe-riod then an Error condition will be indicated at both ends of the link and a SMS text alarm message will be sent to your mobile phone (if GSM option is fitted). During Error condition, the Pump control relay will be switched OFF until the Error has been rectified.

Typical Normal Control Cycle

For the sake of this explanation we assume the existing tank level is somewhere between the HIGH and LOW levels and the pump is currently OFF. (Tank is DRAINING)

The tank will drain as water is being used. Once the tank level falls below the LOW level, the LOW float switch will be activated (contacts CLOSE). The Tank Unit informs the Pump Unit to switch the pump control relay ON.

The Pump switches ON.

Once the pump is running the tank level will begin to rise. Eventually rising to the level where it activates the HIGH level float switch (contacts CLOSE). The Tank Unit informs the Pump Unit to switch the Pump control relay OFF.

After the pump is switched OFF the tank level again begins to fall and the cycle is repeated.

This control cycle will continue indefinitely unless…

The pump does not switch OFF (water level continues to rise) and a OVERFLOW float is fitted above the High Float level. In this case both the Tank and Pump Units will indicate a Level Error condition and the pump control relay will switch off. If the optional GSM dialler is fitted, an SMS text alarm message will be sent to your mobile phone.

A break in the water feed line or pump runs dry (water level continues to fall) and an EMP-TY float is fitted below the Low Float level. In this case both the Tank and Pump Units will indicate a Level Error condition and the Pump control relay will switch OFF. If the optional GSM dialler is fitted then an SMS alarm message will be sent directly to your mobile phone.

Note: The “PUMP ON” LED at the Tank Unit only be ON when a signal is received from the Pump unit confirming that the Pump control is switched to ON state.



More than 1 float is active (Closed) at any time then a Float Error condition will be indi-cated at both Tank and Pump Units. The Pump control relay will be switched OFF and, if the optional GSM dialler is fitted, a SMS alarm message will be sent to your mobile phone.

The Radio link has an error then a Link Error condition will be indicated at both Tank and Pump Units. The Pump control relay will be switched OFF and if the optional GSM dialler is fitted then a SMS alarm message will be sent to your mobile phone.

The Supply voltage at the Tank Falls below 11V DC. For Solar powered systems this could indicate a fault with the solar panel or battery. In event of a Low Battery a fault condition will be indicated at both Tank and Pump unit, the Pump control relay will be switched OFF and if the optional GSM dialler is fitted then a SMS alarm message will be sent to your mobile phone. The Restore level for Battery is 11.6V

GSM Note: Whenever an Error condition is rectified, a SMS RESTORE message is sent to your mobile phone (identifying what condition has been restored) and the normal control cycle will proceed.

Power Up: When power is first applied to the system the default condition for the Pump is OFF and an Error condition will occur. The Pump will switch ON again once the next message from the Tank unit is received (up to 15 minutes) as long as the Tank level is below the LOW float level.

Indicators

Both the Tank Unit and Pump Unit have a LED Status panel that shows the current state of the system. Note: It is recommended for Solar Powered Tank units that the LED display panel be disconnected once the system has been set up to reduce current draw from the battery.



Tank Unit LED Status Panel

The front panel has a number of LEDs that indicate particular conditions for the system.

Figure 2. LED Status Panel

Table 1. Functions of LED Status Panel

Power

LED Description Function

Power Power Indicator ON when unit has power

Link Link Health ON when radio link is healthy

Send Send Status Blinks when sending a radio message

Receive Receive Status Blinks when receiving a radio message

ST1 Floats OK ON Float inputs ok, off when float error

ST2 Pump Status ON Pump at Pump unit is ON

ST3 Battery OK ON power supply > 11V DC

ST4 Tank Level OK ON Tank is Filling or Draining. Off when Hi/Lo

Wireless Input Output Unit

Orbit

Link Send Receive

Radio

ST1 ST2 ST3 ST4

RTU433-4400



Tank Unit LED Status Panel

The front panel has a number of LEDs that indicate particular conditions for the system.

Figure 2. LED Status Panel

Table 1. Functions of LED Status Panel

Power

LED Description Function

Power Power Indicator ON when unit has power

Link Link Health ON when radio link is healthy

Send Send Status Blinks when sending a radio message

Receive Receive Status Blinks when receiving a radio message

ST1 Tank Status ON when Tank level, floats and battery OK

ST2 Pump Status ON Pump relay is ON

ST3 GSM Send ON when optional GSM is sending SMS

ST4 GSM Receive ON when optional GSM is receiving SMS

Wireless Input Output Unit

Orbit

Link Send Receive

Radio

ST1 ST2 ST3 ST4

RTU433-4400



Tank Unit Wiring

The Tank unit must be powered by 12/24V DC (Current requirement < 100mA peak). Typically powered by 10 Watt Solar Power supply kit.

OVERFLOW float switch is connected between “D4” and “GND”

HIGH float switch is connected between input “D3” and “GND”

LOW float switch is connected between input “D2” and “GND”

EMPTY float switch is connected between input “D1” and “GND”

Pump Unit Wiring

The Pump unit must be powered by 12/24V DC (Current requirement < 100mA peak). Note: If GSM option is fitted, the supply must be able to supply up to 2A.

Alarm and Pump control relays are pre-wired. NOTE: If the GSM option is fitted then a Power Up text message will be send each time the unit has power re-moved and re-applied.

Antenna

The Antenna kit is shipped with small metal right angle mounting bracket and 8m cable. The antenna is terminated with TNC plug that screws onto connector on bottom of Tank Unit and Pump Unit.

The antenna should be mounted as high as possible and in good view of the antenna at the other end of the link. Ensure the whip part of the antenna is not located close to metal ob-jects.

Optional Monitor/Over-ride Unit

The Everpump system can be supplied with an optional Monitoring unit. This unit will indicate all transmit and receive activity from Tank Unit and Pump Unit, display Healthy link indication and provide a Manual over-ride facility to switch the Pump ON or OFF as desired.

In order for the Monitoring Unit to operate, all signals from the Tank unit are sent directly to the Monitor Unit instead of the Pump Unit. All control information to the Pump Unit is con-trolled by the Monitor Unit.

Notes:

If the Monitor Unit is switched OFF or removed, the system will no longer operate.

The Monitor option must be supplied at time of purchase of the Everpump system. It cannot be fitted at a later date.



How it works

To use the standard Everpump system with a Monitor unit it is necessary to add a wire link be-tween the “D4” terminal and “GND” terminal on the Pump Unit controller board.

The Monitor Unit is typically located in a house or some central location between the Tank Unit and Pump Unit. The Monitor Unit has 2 operating modes that are set by the Auto/Man switch on the front panel of the Monitor Unit.

AUTO: In Automatic mode, all signals from the Tank Unit are diverted immediately to the Pump Unit and the front panel ON/OFF switch has no effect.

MAN: Manual mode enables the pump to be switched ON or OFF as desired. When in Manu-al mode the Monitor unit ignores pump switching information from the Tank Unit and in-stead sets the state of the Pump based on the state of the ON/OFF switch. If the switch is ON, the pump will be on and visa-versa.

Whenever the float switches at the tank unit change state (or a 15 minute period exists with no change of state) then the Tank Unit will send a signal to the Monitor Unit. The Monitor unit will display the fact that the Radio link to the Tank Unit is OK and send an acknowledgment signal back to the Tank Unit. The Monitor Unit will also display the “transmit” (TXD) and “receive” (RXD) activity from and to the Tank Unit as messages are being received and sent re-spectively.

If the Mode switch of the Monitor Unit is set to manual mode (“MAN”) then no more action will follow with regard to the Tank Unit message.

If the Mode switch is set to automatic mode (“AUTO”) then the Monitor unit will send the mes-sage from the Tank Unit on to the Pump Unit. The Pump Unit will then set the pump ON or OFF and send an acknowledge message back to the Monitor Unit. The Monitor Unit will display the TXD and RXD activity to and from the Pump Unit and display the Radio Link OK for Pump Unit.

In this manner, the Monitor Unit indicates all activity between the Tank Unit and the Pump Unit displays the Healthy radio link status (or fault) and allows manual control of the pump.



Digital Inputs for Float Switches

The Digital Inputs are pulled up to +5V DC via an internal pull-up resistor. The in-puts can tolerate over voltage and reverse polarity voltage to +/- 30V DC. Voltages applied outside of this range may cause damage.

The Digital inputs can be operated using any voltage free contact (such as a Relay contact, open drain or open collector output from another device or a switch), the input can also be connected to a voltage source (recommend 0V to 10V maxi-mum). Note: The Common side of the input devices must connect to the “GND” terminal of the RTU device.

Digital Outputs for Relays

The RTU Digital outputs are Open Collector type and can tolerate a maximum ap-plied voltage of 50VDC and a sink maximum current of 500mA.

Typical applications use the Digital outputs to control relay coils. The outputs are also suitable to connect directly to inputs of other devices (such as a PLC) that re-quire Voltage-Free inputs or for driving indicators such as LEDs.

Each Digital Output has a protection Diode that is internally connected to Supply (+) terminal of the RTU device.



Bottom row of Terminals

+Ve

GN

D

GN

D

GN

D

GN

D

GN

D

GN

D

GN

D

GN

D

+Ve

+Ve

D1

D2

D3

D4

D1 to D4 = Digital input

GND = Power supply negative, ground

+Ve = Power supply positive 12 or 24V DC

D1

GND

Switch, Relay or PLC output

Co

mm

on

(-)

+12

V D

C

LOW Float (Closed when Vertical)

Set so Level hangs vertical at

desired low level

HIGH (Closed when Horizontal)

Set so float rises to horizontal at

desired position

Note: Optional “EMPTY” Alarm float can be connected to “D1” and “GND” using same orientation and wiring as Low

Float.

Optional “OVERFLOW” Alarm float can be connected between “D4” and “GND” using same orientation and wiring as

High Float”

Details of Tank Unit Float inputs



Maximum Voltage = 230 VAC

Maximum Current = 2A

Top row of Terminals

CM

4

A

OP

1

CM

1

CL2

CM

2

CL4

CM

3

OP

3

OP

4

CL3

B

GN

D

CL1

OP

2

“CL” = Normally Closed

“CM” = Common

“OP” = Normally Open

Relay 1 Relay 2 Relay 3 Relay 4 RS485

Details of built-in Relay contacts

Relay 1 contacts can be used to control the Pump. Optional 10A rated external relay is also available.

Details of Pump Unit Relay outputs



50mm Pipe (not supplied)

U-Bolt

V-

Washer

Nut

10W Solar Panel

Solar Kit Mounting Bracket

Attach unit to Pole using U-Bolt as shown



Run cable from rear of solar panel to Tank unit. The cable can be secured to the pole using insulating tape or plastic cable ties. It is recommended that a small loop of cable be left at the bottom of the Tank enclosure where the Solar panel cable enters the cable gland to cause any water to drip off the cable.

Antenna

Drip Loop

Cable Connectors

Solar Panel

Cable Ties along pole

RTU Device

Drip Loops

V-

V+

Bat-

Bat+

PV-

PV+ To Solar Panel

Internal connection of Solar Panel to Regulator

To Battery

To Control PCB



Optional External Relay

The optional relay provides higher switching capacity than the built-in relay contacts. The

recommended method is to connect the Pump or contactor between Normally OPEN (N/O)

and Common contacts (either A or B as shown below). The relay contacts are rated up to

240VAC and current handling capacity to 7 Amps for an inductive load (such as a motor) and

10 Amps for resistive loads.

Figure 4. Relay Contact Details

Coil(-) Coil(+)

Common (B)

N/O (B)

N/C (A) N/C (B)

N/O (A)

Common (A)

Fitting PCB to DIN Rail

Tilt rear of unit down to enable base to clip onto back of DIN rail

Lower front and press onto DIN rail until locking mechanism clicks into place

Removing PCB from DIN Rail

Use small screwdriver for pull locking TAB (at front of unit) toward you.

Lift Unit up at front and then and away from DIN Rail

Figure 5. PCB attachment to DIN rail

LED ON when relay

Activated



GSM Dialler

The optional GSM/Next-G dialler unit that will operate on worldwide GSM and Next-G/3G mobile phone net-

works. All that is needed to use the GenTemp™ unit is an active SIM card. These cards are normally provided

through mobile phone vendors.

Note: It is recommended NOT to use a pre-paid SIM card as the system has know means to identify when the

card requires topping up.

To install the SIM card into the GSM Dialler

1. Switch off the power and remove battery connection (if battery used)

2. Slide SIM card into SIM socket as shown below.

3. Switch on the power and reconnect battery connector.

Once power is re-applied, the system will switch the dialler off for a short period. After a period of time, the

Green POWER LED will switch on and the Green STATUS LED will come on.

The initialisation period of the GSM dialler is around 35 seconds.

Dialler PCB

SIM Card SIM Socket

Gold contacts face down

GSM

Status



GSM Dialler Commands (if Option Fitted)

The GSM Dialler option provides a SMS alarm indication up to maximum of 5 mobile phones in event of error.

The option also enables the user to request status of the system and place the system in Manual ON, Manual

OFF and AUTO mode from any mobile phone.

Before the GSM dialler can be used.

1. A valid SIM card must be installed (refer to GSM Dialler page for details)

2. The phone numbers to send text message in case of alarm need to be programmed.

Programming the system:

Install EzGSM software. Navigate to www.orbitcoms.com/updates/ezgsm/setupEZGSM.htm

Click the “Install” button on screen to start the installation process. Follow on screen prompts.

Once EzGSM software has been installed plug supplied USB to RS232 adaptor cable into computer. The com-

puter should automatically detect and install the USB adaptor.

Ensure Pump unit has 12/24V DC power and is switched ON.

Plug supplied RS232 cable into 9-way computer connector (attached to inside of enclosure) and plug into USB

to RS232 adaptor.

Run EzGSM software:



Select “Serial Port” from top menu. Select the appropriate port by double clicking on the name of the serial port that is assigned to the

USB to serial adaptor. Note: If this is unknown then proceed to Windows “Start” menu. Right click on “Computer” and select

“Properties”. Select “Device Manager and open the item “Ports (COM & LPT)”. In example shown below, the port is assigned to “COM

6).

The Selected serial port will then be shown on the bottom status line.

Click “Read” to read the current settings from the Unit. The default settings are shown below (including Orbit test mobile number).

At very least, change the phone number to number required. The password and site title can also be changed as desired. Click “Save

Settings” to save new values into unit.

To TEST the GSM dialler, click “Test Dialler” on top menu. A Status message should be sent to all phone numbers that are set (Phone 1

to Phone 5). The site will be identified by the text in “Site Text”.



To test the dialler response to SMS requests.

Send a reply to the receive text message on the mobile.

“Gsm status”

The system should respond by sending back a status text message.

Notes:

Do NOT add the quotation marks

Only use a single space between password (gsm) and status

If you have changed the Password then replace “gsm” with the password you programmed into the unit

The text is NOT case sensitive

GSM Commands

The following commands can be sent to the system at any time from any mobile phone. The format is always

PASSWORD single space COMMAND

Command Description

STATUS Obtain current Status of system. Includes Pump state and battery voltage

INFO Obtain system model and serial number details

ON Switch Pump in Manual ON mode. Pump will stay on until switched OFF or AUTO

OFF Switch Pump in Manual OFF mode. Pump will stay on until switched ON or AUTO

AUTO Switch Pump to Auto mode. Pump is controlled by Tank level

Supported GSM text commands



Safety Precautions The following safety precautions must be observed whenever the Orbit wireless device system is in operation or in service. Failure to comply with these precautions violates the safety standards of the design, manufacture and intended use of the product

- The system is not to be used:

In hospitals or places where medical equipment may be in use.

In an aircraft (whether on the ground or in the air)

Refuelling points

Explosive areas

- Restricted use of the Orbit wireless device

Near any chemical plant

Near any Fuel depot

The Orbit wireless device system receives and transmits radio frequency energy while switched on, therefore interference can occur if the Orbit wireless device is located near TVs, radios, PCs or any inadequately shielded equipment.

WEEE directive 2002/96/EC, disposal of old electronic equipment

This product shall not be treated as household waste. It must be placed at an appropriate collection point for the recycling of electrical and electronic equipment. By ensuring the correct disposal of this equipment, it will help the environment and human’s health. The recycling will help to conserve the natural resources.

Important

Due to the nature of wireless systems, transmission and reception of data can never be guaranteed. Data may be corrupted (i.e. Have errors) or be totally lost at certain times due to the environment, other machinery or malfunction of electronic components. Although significant loss of data are rare when wireless devices such as the Orbit wireless device system are used in a normal manner, Orbit’s wireless device system should not be used in situations where failure to transmit or receive data could result in damage of any kind to the user or any other party, including but not limited to personal injury, death or loss of property. Orbit Communications Pty Ltd accepts no responsibility for damages of any kind resulting from errors in data transmitted or received using Orbit’s Orbit wireless device systems, or for the failure of the Orbit wireless device system to transmit or receive such data.

Do not operate the Orbit wireless device system in areas where blasting is in progress, where explosive at-mospheres may be present, near medical equipment, near life support equipment, or any equipment which may be susceptible to any form of radio interference, in such areas, Orbit’s wireless device system must be powered OFF.



Do not operate Orbit wireless device system in any aircraft, whether the aircraft is on the ground or in flight. In an aircraft the Orbit wireless device system must be powered OFF.

The information in Orbit Communications Pty Ltd documents are subject to change without notice and do not represent a commitment on the part of Orbit Communications Pty Ltd. Orbit Communications Pty Ltd and its affiliates specifically disclaim liability for any and all direct, indirect, special, general, incidental, conse-quential, punitive or exemplary damages including, but not limited to, loss of profits or revenue or anticipat-ed profits or revenue arising out of the use or inability to use any Orbit Communications Pty Ltd product, even if Orbit Communications Pty Ltd and/or its affiliates have been advised of the possibility of such damag-es or they are foreseeable or for claims by any third party.

Notwithstanding the foregoing, in no event shall Orbit Communications Pty Ltd and/or its affiliates aggregate liability arising under or in connection with the Orbit Communications Pt Ltd product, regardless of the num-ber of events, occurrences or claims giving rise to liability, be in excess of the price paid by the purchaser for the Orbit Communications Pty Ltd product.

Warranty All products manufactured by Orbit Communications Pty Ltd are warranted to be free from defects in materi-als and workmanship under normal use and service for 12 months from the date of shipment unless other-wise specified. Orbit Communications’ obligation under this warranty is limited to repairing or replacing (at Orbit’s discretion) defective products. The customer shall assume all costs of removing, reinstalling and ship-ping defective products to Orbit Communications. Orbit Communications will return such products by surface carrier prepaid. This warranty shall not apply to any Orbit product that has been subject to modification, mis-use, neglect, accidents of nature or shipping damage. This warranty is in lieu of all other warranties, ex-pressed or implied, including warranties of merchantability or fitness for a particular purpose. Orbit Commu-nications is not liable for special, indirect, accidental, or consequential damages. Products may not be returned to Orbit Communications without prior authorization. To obtain a Returned Product Authorization (RPA), contact Orbit Communications by phone, fax or email. An RPA number will be issued after our staff determines the nature of the problem. Please write the RPA number on the outside of the shipping container. Any non-warranty products returned for repair should be accompanied by a purchase order to cover the cost of the repairs.

Documents

EverPump™ Wireless Pump control system - … User Guide V1.4.pdf · Wireless Pump control system ... the Tank Unit will monitor the water level and remotely ... and ^GND _ terminal