Greyline Instruments Inc.

- Model PSL 5.0 - Hybrid Pump Station Level Controller

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New Pump and Lift Station Level Controller: Ideal for sewage pump stations, lift stations, wet wells and tank level control with a non-contacting ultrasonic sensor mounted above the liquid. The new Greyline PSL 5.0 Level Controller has 6 independently programmable control relays for pump or valve control, level alarms, dialers, temperature alarm and echo-loss alarm.

Mount the non-contacting, ultrasonic sensor in the tank or wet well and install the watertight electronics in the control room or any location within 500 ft / 150 m. Use the simple menu system and built-in keypad to set up measurement range, relay set points and pump alternation sequence. A relay/pump run time report is updated and stored automatically for viewing on the PSL 5.0 backlit LCD display.

For hazardous locations, the ultrasonic sensor is rated Intrinsically Safe with an optional safety barrier. It is rated for measurement ranges up to 32 ft / 10 m, or use the optional PVC Sensor rated for 50 ft / 15.6 m measurement range.

Pump Station Level Control, Monitoring and Reporting.

Ideal for Level Control
Designed for pump stations, wet wells and tank level control the new Greyline PSL 5.0 Pump Station Level Controller has six independently programmable control relays for pump or valve control, level alarms, autodialers, temperature or fault alarms.

No contact, No maintenance
Mount the non-contacting, ultrasonic sensor in the tank or wet well and install the watertight electronics in the control room or any location within 500 ft / 150 m. Use the simple menu system and built-in keypad to set up measurement range, relay set points and pump alternation sequence. A relay/pump run time report is updated and stored automatically for viewing on the instrument’s backlit LCD display.

New Dual-Technology
Sensor Feature

Redundant Level Sensing
Connect a submersible pressure sensor or other 4-20mA level transmitter to the PSL 5.0 for fail-safe hybrid sensing. The PSL 5.0 will auto-calibrate the redundant sensor and if signal is lost to the ultrasonic sensor, the redundant sensor will seamlessly take over monitoring until signal resumes from the ultrasonic. The redundant sensor is continuously monitored to ensure availability during primary sensor failure.

  • Controls, Transmits and Displays
  • Non-Contacting Ultrasonic Sensor
  • New Dual-Technology Feature 
    • Redundant Level Sensor Input
  • 6 Relays for Pump Control, Pump Alternation and Level Alarms
  • Isolated 4-20mA output
  • Built-in 5-Key Calibrator
  • Logs and Displays Relay Run Times

Easy to Install with Non-Contacting Sensor
The PSL 5.0 Pump Station Level Controller is designed for Pump Station and Tank Level Control applications. Mount the non-contacting ultrasonic sensor above the well or at the top of a tank. Use the built-in keypad to calibrate measurement span, relay set-points, pump alternation sequence and level alarms. Assign the six built-in control relays for ON/OFF pump control, Hi or Lo level alarms, autodialer activation, air temperature alarm or sensor echo loss alarm. Connect the isolated 4-20mA output to your SCADA system, PLC's or recorders.

Redundant Sensor Level Control
The PSL 5.0 sets a new level of reliability. It operates with an ultrasonic level transducer as its primary sensor but also accepts connections from 4-20mA level sensors for redundancy. If the ultrasonic transducer loses signal from foam on the water surface for example, the redundant sensor will take over reading instantly. As soon as the ultrasonic sensor receives new echoes, it will resume function as the primary sensor.

An animated icon on the PSL 5.0 digital display indicates that the ultrasonic sensor is active. The icon indicates if the system automatically switches to the redundant sensor.

Calibration of the Redundant Sensor is Totally Automatic
You can use hydrostatic pressure sensors, radar, or any 4-20mA transmitter for redundant level sensing. The PSL 5.0 automatically scales and calibrates the redundant sensor during each pump cycle. Once the PSL has operated through at least one pump cycle, the redundant sensor will be calibrated and ready to function.

PSL 5.0 Pump Station Level Controller

  • Non-Contacting Ultrasonic Sensor
  • Accepts Pressure Sensor Input for Redundant Monitoring
  • 6 Control Relays with Programmable Pump Alternation
  • Automatically Logs and Reports Relay Run Times for Pump Performance Evaluation
  • Plug and Play Optional Data Logger
  • Isolated 4-20mA Output

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Connect a submersible pressure sensor or other 4-20mA level transmitter to the PSL 5.0 for fail-safe hybrid sensing. The PSL 5.0 will auto-calibrate the redundant sensor and if signal is lost to the ultrasonic sensor, the redundant sensor will seamlessly take over monitoring until signal resumes from the ultrasonic. The redundant sensor is continuously monitored to ensure availability during primary sensor failure.

Sewage lift stations at the Town of Eckville Alberta were plagued by callout alarms from ultrasonic level controllers as foam and grease covered the water surface and caused echo loss. Operators installed new Greyline PSL 5.0 Pump Station Level Controllers with redundant sensors to solve the problem.

Greyline ultrasonic sensors are mounted at the top of a tank or in a position above the liquid being measured. The sensor continuously transmits pulses of high frequency sound (typically 42 kHz) which travel away from the sensor, hit the surface of the liquid and return to the sensor.

The instrument electronics measure the time it takes from transmitted sound to return of the echo. With reference to the speed of sound in air, the exact distance of the liquid surface from the sensor can be calculated with high accuracy (±0.25% of maximum range).

Since the speed of sound is affected by air temperature, Greyline ultrasonic level sensors include a built-in temperature sensor. Level/distance measurements are automatically temperature compensated throughout the operating temperature range of the sensor.
   
The sensor should be positioned so that it has a clear 'view' of the liquid surface and away from ladders, pipes or other obstructions. Greyline recommends 1 ft. from the sidewall for every 10 ft. depth (300 mm for every 3 m depth). False echoes from agitators (sweeping under the sensor), turbulence and waves can be filtered and disregarded by the instrument.

Greyline models range from simple 4-20mA level indicating transmitters, to sophisticated monitoring, controlling and data logging models. Return to Greyline Products for Level model details and specifications. For information on a wide range of level instrument technologies including ultrasonics, read Wastewater Level Measurement Techniques.

General Specifications: Greyline Pump Station Level Controller

  • Accuracy: ±0.25% of Range or 2 mm (0.08') whichever is greater
  • Electronics Enclosure: Watertight, dust tight NEMA4X (IP 66) polycarbonate with a clear, shatter-proof face
  • Operating Temperature: Electronics: -5 to 140°F (-20 to 60°C)
  • Power Input: 100-240VAC 50-60Hz (see Options), 3 Watts maximum (with standard features)
  • Surge Protection: AC power, 4-20mAand ultrasonic sensor
  • Outputs: Isolated 4-20mA (1000 ohm)
  • Control Relays: 6 form 'C dry contact Relays rated 5 amp SPDT; programmable level alarm and/or pump control modes, pump alternation/sequencing, failsafe/echo-loss, air temperature alarm
  • Display: White, backlit matrix - displays calibration menu, relay status, runtime reports and sensor status
  • Calibration: Level or Range mode in selectable units
  • Programming: Built-in, 5-button keypad, password-protected

PZ34 Sensor:

  • Maximum Range: 32 ft (10 m) - optional sensors for longer ranges
  • Deadband (blanking): Programmable, minimum 16' (406.4 mm)
  • Beam Angle: 8°, Locate 1 ft (300 mm) from wetwell sidewall for every 10 ft (3 m) depth
  • Operating Frequency: 46 kHz
  • Exposed Materials: PVC
  • Operating Temperature: -40 to 150°F (-40 to 65°C)
  • Operating Pressure: 0-20 psi (0-1.35 bar)
  • Sensor Cable: RG62AU coaxial, 25 ft (7.6 m) standard length - see Options

Options:

  • Sensors: Long and short range models / all Teflon construction / Intrinsically safe / Pressure
  • Sensor Cable: 50 ft (15 m) or 100 ft (30 m) RG62AU coaxial continuous from ultrasonic sensor, or splice up to 500 ft (150 m)
  • Sensor Cable Junction Box: watertight NEMA4 steel with terminal connection strip
  • Power Input: 9-32 VDC
  • Data Logger: 20 million point Data Logger with output to USB flash drive. Windows software.
  • Enclosure Heater: Thermostatically controlled - recommended for temperatures below 32°F (0°C)
  • Enclosure Panel Mount: Flange and bracket assembly mounts enclosure in panel face
  • Hazardous Locations: Intrinsic Safety Barrier for ultrasonic Sensor mounting in hazardous areas. NEMA7 explosion proof enclosure for electronics mounting in hazardous locations.

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  • Sewage Lift Stations
  • Water Storage Tanks
  • Level Process Control

Ideal for Water, Wastewater and Process Automation
Use the PSL 5.0 Pump Station Level Controller for pump or level control and for automatic pump alternation/sequencing. It is designed for the harsh operating conditions in wet well or tank level control applications. The non-contacting ultrasonic Sensor mounts at the top of a wet well or tank, and you can connect a redundant 4-20mA level sensor for added reliability in challenging pump station applications.

Relay Run Time Reporting System
View the PSL 5.0 relay run time report directly on the backlit digital display. You can identify 'lazy' pumps before pump failures occur and plan pump maintenance to reduce call-outs and down-time. If a redundant level sensor is connected its operation time is also indicated.

Reliable, Accurate, Simple Calibration:

  • Built-in, 5-button keypad
  • Easy calibration with 6 control relays for simplex pump stations, duplex, triplex, quadruplex or more...
  • Non-Contacting, no-maintenance ultrasonic sensor
  • Redundant level sensor connection - use any 4-20mA transmitter for fail-safe level sensing
  • Independently programmable Pump Up and Pump Down modes
  • Programmable 'forced alternation' to prevent pump damage
  • Isolated 4-20mA output for connection to Variable Speed Drives, SCADA systems, PLC's or Recorders
  • Plug and Play options including a 20-million point data logger

SCOPE: This specification covers a non-contacting ultrasonic Pump Station Level Controller as manufactured by Greyline Instruments, Massena New York / Long Sault, Ontario. This instrument shall provide for indicating, transmitting of wet well or tank level, and control of up to six pumps or alarms.

General

  1. Pump Station Level Controller to consist of an non-contacting ultrasonic sensor, connecting cable, and a remote enclosure with indicating, transmitting and controlling electronics.
  2. Measurement accuracy shall be ±0.25% of Range or 2 mm (0.08'), whichever is greater, and shall be automatically temperature compensated.
  3. Sensor cable length shall be as required by installation, not to exceed 500' (152 m).
  4. System shall have no moving parts and shall not contact the material being measured.
  5. Shall include a built-in keypad and simple menu system for calibration.
  6. Shall include a non-contacting ultrasonic level sensor plus hybrid sensor function for dual-technology redundant level sensing with input from a 4-20mA level transmitter.

Transducer/Sensor

  1. Non-contacting ultrasonic sensor shall be constructed of PVC.
  2. The sensor shall have a minimum deadband or blanking of 16' (407 mm) and a maximum range of 32 ft. (10 m), and have an operating frequency of 46 kHz with an ultrasonic beam angle of 8 Degrees.
  3. Sensor shall withstand accidental submersion to 20 psi.
  4. Sensor operating temperature shall be from -40°F to 150°F (-40°C to 65°C).
  5. Sensor shall include integral temperature sensor. Temperature sensors requiring separate mounting and wire runs shall not be accepted.
  6. Sensor cable shall be installed in plastic or grounded metal conduit.

Sensor Connecting Cable

  1. Provide RG62AU coaxial cable 25' (7.6m) continuous length, with waterproof, potted bond to the Sensor head.
  2. Extended sensor cable shall be RG62AU coaxial to a maximum of 500' (152m). Cable shall be spliced with screw terminal connections in manufacturer's recommended Junction Box.
  3. Level and temperature signals shall be conducted on one single coaxial cable. Separate or multiple-conductor cables shall not be accepted.
  4. Sensor cable shall be installed in grounded metal conduit.

Transmitter

  1. The Pump Station Level Controller shall accept 4-20mA input from an external level transmitter for redundancy. The redundant sensor shall be continuously auto-calibrated by the Pump Station Level Controller’s ultrasonic sensor.
  2. The transmitter shall provide for password-protected calibration in Range or Level modes and user-selected engineering units. Field calibration shall allow selection and automatic conversion of measurement units, measurement span and control relays. Systems requiring calibration by Parameter codes, BCD switches or external calibrators shall not be accepted.
  3. The transmitter power input shall be 100-240VAC 50/60Hz requiring less than 3 Watts.
  4. Calibration data and instrument settings shall be stored through power interruptions for a minimum of 12 months.
  5. Transmitter shall permit field programmable damping to smooth output in turbulent level conditions, and programmable rejection time to disregard false signals from turbulence, waves and spurious echoes.
  6. Transmitter operating temperature shall be from -5° to 140°F (-20° to 60°C).
  7. Transmitter shall have an isolated 4-20mA output into a 1000 ohm maximum load.
  8. Provide 6 Form 'C' dry contact control relays rated 5 ampere SPDT. Relays shall be individually programmable for High or Low level alarms, dual set point pump control, pump alternation, sensor temperature alarm and echo loss alarm. Relays shall permit user-adjustable On time delay settings to prevent pump or motor power surges. Relays may be individually configured to hold state, energize or de-energize in the event of an echo-loss condition.
  9. Provide a white, backlit LCD display indicating level and relay states in user-selected engineering units.
  10. Transmitter display indicating level, units of calibration and relay states, shall be visible without opening the instrument cover.
  11. The instrument shall include a relay run time reporting system and display hours of pump, alarm and failsafe sensor operation on the backlit LCD display.
  12. Transmitter shall be housed in a wall-mount, watertight NEMA4X (IP 66) polycarbonate enclosure with hinged, clear cover. Mounting hardware shall be included.
  13. Transmitter electronics shall be surge protected on AC power input, sensor and 4-20mA outputs.
  14. The transmitter shall permit plug-in field installation and auto-detection of optional accessories including data logger.

Optional Features For Insertion As Required

  1. Sensor, connecting cable and junction boxes shall be rated intrinsically safe to Class I,II,III, Div. I,II, Groups C,D,E,F,G.
  2. Have a thermostat controlled enclosure heater for Transmitter operation at temperatures below freezing.
  3. Have an all-Teflon sensor Model PZ32TE rated intrinsically safe when connected through an approved safety barrier, and rated for operation from -40°F to 170°F (-40°C to 76°C).
  4. Have a PVC and Teflon sensor Model PZ52T rated for measurement range on liquids up to 50 ft. (15.6 m).
  5. Have a Teflon-faced flange mount sensor model PZ34TxF rated for 32 ft (10 m) measurement range. Specify flange size of 4” or 6”.
  6. Have a redundant submersible pressure transducer with 40 ft (12 m) cable rated for 35 ft (10 m) water depth.
  7. Have manufacturer's recommended enclosure sunscreen to permit Transmitter mounting in direct sunlight.
  8. Have manufacturer's recommended Sensor sunscreen to permit temperature-compensated Sensor mounting in direct sunlight.
  9. Have manufacturer's recommended Panel Mount Flange assembly for enclosure installation.
  10. Have a built-in 2 million point Data Logger with USB output to flash drive or mass storage device. Include Windows software.
  11. Have power input of 9-32VDC and power consumption of less than 3.5 Watts.

Manufacturer
Pump Station Level Controller shall be model PSL 5.0 as manufactured by Greyline Instruments Inc. and shall be warranted against defects in materials and workmanship for one year.

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