Techsys SWORDFISH+, Operation Manual

Page 1: ...C o r p o r at io n MULTIPLE PUMP FIXED SPEED PUMP LEVEL CONTROL SYSTEM Version 1 3 L LE EV VE EL L O OP PE ER RA AT TI IO ON N M MA AN NU UA AL L...

Page 2: ...s for simple integration into central control applications Swordfish Level control is suitable for both Tank Fill Tank Empty applications therefore some logic will reverse in this manual pending upon...

Page 3: ...ITING MENU ITEMS 9 MENUS 10 SYSTEM STATUS 17 FAULT HISTORY 17 PUMP DATA LOG 19 ACCESS CODE 21 SETTINGS 21 TIMING 26 CONFIGURE 29 JOCKEY PUMP 34 OUTPUTS 35 INPUTS 39 PUMP PROTECTION 45 CALIBRATION OF A...

Page 4: ...power to Sowrdfish controller 3 Make sure all Pump Mode indicators are OFF If not press the P key to turn pump off All pumps should be off 4 Adjust Overloads to to suit motor ratings Switch ON all cir...

Page 5: ...Cut Out Level screen is reached 8 Adjust the Cut Out Level by pressing the Enter Key once the display should then start to flash now press the UP or DOWN Key to alter the Cut Out Level The same seque...

Page 6: ...idually and check the rotation If the rotation is not correct swap two of the phases coming into the main isolation switch to reverse the rotation Note any wiring changes done within the switchboard s...

Page 7: ...le or the system level drops below the Cut Out Level If at any time the level drops below the Cut Out Level then the OUT delay timer Single Level Mode is started and when it times out a pump will be t...

Page 8: ...indicator will be on To turn a manual pump off press and release the switch when the RUN led turns off The pump is now disabled and to return it to Automatic press the Mode switch again and the Mode...

Page 9: ...table section of the menus If the Access Code is not inserted correctly the system will disable entry into the Submenus and the use of any pump select or enable keys To scroll through the menus select...

Page 10: ...Time Transducer Value Restart Delay Timer Cut Out Level 5 Pump Starts 1 Program Input 2 Digital Output 3 JP In Delay Time Adjust Level No Flow Timer Cut Out Level 6 Pump Starts 2 Program Input 3 Digi...

Page 11: ...s Program Input 1 Digital Output 2 JP Run On Time Transducer Value Restart Delay Timer Alt Cut In 2 Pump Starts 1 Program Input 2 Digital Output 3 JP In Delay Adjust Level No Flow Timer Alt Cut Out 3...

Page 12: ...lt 5 selection None Auto Reboot Logged Pump 2 6 Shutdown are only displayed if Number of pumps is set accordingly Pump 2 6 No Flow are only displayed if Number of pumps is set accordingly Main Menu Su...

Page 13: ...Level is start level for all pumps when Operation Mode set to Single Level Cut Out Level is stop level for all pumps when Operating Mode set to Single Level Cut Out Level 1 2 3 etc is individual pump...

Page 14: ...ion Analogue Analogue Switched Cycle Protection selection Minimum Run Time Minimum Run Time Max Starts PerHr Low Limit Action selection OFF OFF Alarm Shutdown HighLimit Action selection OFF OFF Alarm...

Page 15: ...Alarm Any Alarm Digital Output 3 selection Any Alarm Any Pump Shutdwn Any Pump Running Trip Point Alternate Trip Digital Output 4 selection Any Pump Running Aux Output 1 Aux Output 2 Aux Output 3 Shut...

Page 16: ...x Input 1 Cycle Pumps Reset No Flow Aux 1 Aux 2 Aux 3 Pump 1 6 No Flow Prot Level Cut In 1 Level Cut In 2 Level Cut In 3 Level Cut In 4 Level Cut In 5 Level Cut In 6 Level Cut Out 1 Level Cut Out 2 Le...

Page 17: ...w rate uses information that is input into the Pump Flow rate screen to provide an estimation of the flow rate at any time This calculation automatically compensates for the number of pumps operating...

Page 18: ...corresponding Pump protect 1 6 input has been activated for the period of the input delay time Auto Reboot denotes that the SWORDFISH has automatically restarted due to an internal reset whereas Power...

Page 19: ...run meter attached to record the actual run time for each pump The hour log will accumulate all of the operation time for each pump in both AUTOMATIC and MANUAL modes To reset the time press ENTER th...

Page 20: ...e number under Curr is the current number of times the main processor has not been able to communicate with the analogue system If it is not at Zero it indicates that the analogue system has been subj...

Page 21: ...imit OFF OFF Cut In Level 1 2 3 200 0 9999 Cut Out Level 1 2 3 450 0 9999 HiLevel Shutdown 650 0 9999 HiLevel Alarm 650 0 9999 High Limt OFF OFF Alt Cut In 2 250 0 9999 Alt Cut Out 2 500 0 9999 Alt Cu...

Page 22: ...uration Excess Run Protection Note in Multilevel Mode Cut In Level 1 Cut In Level 2 etc will be displayed pending number of pumps selected Cut Out Level The Cut Out Level is the level at which the sys...

Page 23: ...control signal activating the Alternate 2 settings will force the Swordfish to operate on Alt Cut In 2 Alt Cut Out 2 setting Primary settings Cut In Cut Out 2nd Settings Alt Cut In 2 Alt Cut Out 2 3rd...

Page 24: ...ctivate the relevant input See Inputs for detailed description NOTE These settings will also limit the adjustment of the High level and Low level settings If Alt Cut In Alt Cut Out 2 or 3 are not used...

Page 25: ...elays section for more information on how to set this feature Note The Trip Point Low and Trip Point High screens will only appear if an output is set to Trip Point within the OUTPUTS menu Trip Point...

Page 26: ...gh Level Shutdown Delay Set this time to delay the High Level Shutdown It must time out before the system will shut down in High Level mode The range for this is 0 250 sec If the High level shutdown n...

Page 27: ...losed this timer delays a no flowshutdown by the given amount Input Delay Timer The SWORDFISH has the capacity to accept input signals for various processes This timer sets the delay for reaction to t...

Page 28: ...on system can withstand maximum pump head Maximum Pump Starts This setting is used to prevent switchgear and pumps from failing due to excessive cycling Each pump is prevented from tarting if the Max...

Page 29: ...ro Adjust Pressure Averaging are hidden when in Switched mode Pumps 2 6 are only visible if Number of pumps is set accordingly Pending Tank Fill or Tank Empty selection will reverse some logic i e Cut...

Page 30: ...o confirm Exit out of the menu to store the value Note This screen will not be displayed if the SWORDFISH is running in switched mode Adjust Level The calibration of the analogue sensor is achieved by...

Page 31: ...t be modified to maintain a more accurate figure Auto Rotation This menu allows SWORDFISH to call on one pump to be the lead pump or to allow for a new pump to be the lead pump after each time all of...

Page 32: ...a rise in the output of the transducer o Reverse Analogue This is where a level rise will cause a fall in the output of the transducer These are very rare in level control applications and will depen...

Page 33: ...level condition There are three possible settings OFF This setting completely turns OFF the High level Be aware that if set to OFF there would be no High level protection for the system Alarm This se...

Page 34: ...To enable the jockey pump and allow viewing of the rest of the jockey pumps screens change to Jockey Pump ON JP Cut In Level The JP Cut In Level is the Level at which the pump defined as Jockey pump w...

Page 35: ...Pump is set to ON then Digital Output 4 will not be avaialable for other functions Pump Run 2 6 are only visible if Number of pumps is set accordingly Pump Fault 2 6 are only visible if Number of pump...

Page 36: ...Fault As per delay timer 16 System Paused Instantaneously 17 Low Alarm As per delay timer 18 High Alarm As per delay timer 19 Any Alarm As per delay timer 20 Any Pump Shutdwn As per delay timer 21 Any...

Page 37: ...p in SETTINGS Alternate Trip Each time the system shuts down the energized state of the relay will change E g If the relay on one cycle is closed during operation then the next cycle this relay will b...

Page 38: ...ection Reset Pump 1 6 Manual Run Program Input 11 selection Cycle Pumps Fire Mode Program Input 12 selection Aux Input 1 Cycle Pumps Reset No Flow Aux 1 Aux 2 Aux 3 Pump 1 6 No Flow Prot There are 12...

Page 39: ...ous Continuous 18 Pump 5 Stop Instantaneous Continuous 19 Pump 6 Stop Instantaneous Continuous 20 Pump 1 Manual Run Instantaneous Continuous 21 Pump 2 Manual Run Instantaneous Continuous 22 Pump 3 Man...

Page 40: ...tem Pause An external sensor can be used to PAUSE the system When the system receives a PAUSE command the system will shut down The system turns off all running pumps and a message will be shown on th...

Page 41: ...pumps when above the Cut Out setting The following protection features are disabled High Level Shutdown Low Level Shutdown System Pause No Flow Individual Pump Protection Pump 1 6 Stop Pump 1 6 No Fl...

Page 42: ...xiliary input allows the SWORDFISH to use this input to turn on a Digital Output To do this the output has to be set up to be an Auxiliary output There are three auxiliary functions available Aux Inpu...

Page 43: ...Analogue Input The analogue terminals are located on the left hand side of the PCB near the top The use of 4 20mA and 0 10V transducers require the slide switches to be placed to match the input This...

Page 44: ...au Version 1 3 11 12 11 44 C o r p o r at io n 0 10 V transducers are set up for standard 3 wire operation GND P PRESSURE TRANSDUCER INPUT 24V 24VDC TRANSDUCER SUPPLY INTERNAL TRANSDUCER P VOLTS mA A...

Page 45: ...ISH will shutdown the system until manually reset There is the option to allow a number of automatic restarts after this shutdown There are 0 250 restarts possible and are set in the High level Restar...

Page 46: ...tem or in the tube leading to the transducer On the Transducer Zero screen press ENTER to edit the data and then DOWN to make the reading go to 0 Wait for 5 seconds for the reading to stabilise Take c...

Page 47: ...to suit reservoir pit tank i e 100 100cm of vertical height If it does not press ENTER and then either UP or DOWN to move the displayed level to match the gauge or measured level There is a buffer tha...

Page 48: ...nge Temp max 50 degC 500 psi burst pressure Temperature compensated Time based functions 5 of real time Output Relays 5 amp 250VAC changeover software configurable Switched inputs Voltage free interna...

Page 49: ...3 11 12 11 49 C o r p o r at io n PCB HARDWARE SPECIFICATIONS The figure below shows the terminal configurations for the SWORDFISH Detailed above are the locations for the components for the Swordfis...

Page 50: ...H SIDE O F ENCLOSURE 250 psi MAX MODEL 24PC ON BOARD PRESSURE TRANSDUCER 1 4 BSP M I THREAD 1 2 P 4 20mA GND P PRESSURE TRANSDUCER INPUT 24V 24VDC TRANSDUCER SUPPLY 2 1 P 0 10VDC SERIAL COMMS TERMINA...

Page 51: ...pecific projects Part Code 0 250mV Standard pressure transducer 24P Trans PCB Board 3PC Retrofit panel SW RF Manual SWORDFISH Manual Lexan SWORDFISH Lexan SWORDFISH PCB mounted on retrofit panel SWORD...

Page 52: ...ump won t turn off Manual selected for that pump Running LED flashing Pump Manual Run input active Cut Out level set too high Press pump mode switch once to turn OFF Remove input Adjust Cut Out level...

Page 53: ...sly System needs to be initialised Press the Commissioning Button on the PCB whilst powering up the system to initialise the program System Level not displaying Transducer not connected properly Trans...

Page 54: ...t sunlight Allow the airflow from the fans to be unimpeded The earth needs to be close and not laid parallel with High Voltage cables Inputs Use shielded wire for all inputs Connect the shield to EART...

Page 55: ...rs Run 1 Hours Run 2 Hours Run 3 Hours Run 4 Hours Run 5 Hours Run 6 Pump Starts 1 Pump Starts 2 Pump Starts 3 Pump Starts 4 Pump Starts 5 Pump Starts 6 Pump Starts Last Hr Curr max retry Temperature...

Page 56: ...e Max Pump Start CONFIGURE Operating Mode Control Mode Number of pumps Transducer Zero Adjust Level Averaging Scale An Output Pump Flow Rate Auto Rotation Lo Level Restart Sensing Input Cycle Protecti...

Page 57: ...NPUTS Program Input 1 Program Input 2 Program Input 3 Program Input 4 Program Input 5 Program Input 6 Program Input 7 Program Input 8 Program Input 9 Program Input 10 Program Input 11 Program Input 12...

Page 58: ...www techsys com au Version 1 3 11 12 11 58 C o r p o r at io n NOTES...

Page 59: ...of Menus 10 Loss of prime 41 44 Low Alarm 19 34 Low Limit 19 38 Low Limit Action 29 Low level 19 Main switch 6 Manual 17 Manual mode protection 8 Manual model 8 Max starts per hour 29 Maximum Start pe...

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