ilevel Installation Manual

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Cleaning Systems Inc. 2 P59000011 Rev:00 Table of Contents Overview... 3 Specifications ... 3 Models ... 3 Required Components ... 3 Dimensions ... 3 Weight ... 3 Electrical Rating ... 3

Locating the iLevel®_{Panel ... 4}

Mounting the iLevel®_{Panel ... 5}

Electrical ... 6 Requirements ... 6 Controller Layout ... 6 Controller Status ... 6 Power Supply ... 7 Ethernet Connection... 7

Control Wiring Connections ... 8

Touchscreen Connections ... 11

Installing Ultrasonic Sensors ... 13

Connecting to the iLevel®_{... 14}

Method 1 – Local network connection ... 14

Method 2 – Wi-Fi Hotspot ... 15

Touchscreen / Interface Screens ... 17

Status Screen... 17

Inputs Screen ... 18

Containers Screen ... 19

Network Screen ... 21

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Cleaning Systems Inc. 3 P59000011 Rev:00

Overview

The iLevel system is a system used to measure and monitor container levels. The iLevel system uses ultrasonic sensors to measure variations in container levels. The iLevel control box can operate up to sixteen ultrasonic sensors sequencing from one sensor to the next measuring container levels. Each sensor can be adjusted to work with different container sizes and shapes.

The iLevel system has 15 inputs that can monitor counts of wash packages to provide information for cost per car calculations, or can be connected to contacts to provide alarm triggers that can be counted and monitored via email.

The iLevel system connects to the local network and can interface with any device with a Web browser on the same network, or wirelessly from a smart device via the built-in Wi-Fi hotspot. The iLevel system has an internal Web server to allow direct connection to view container levels and counts. The same network connection can be used if connected to the internet to send emails when alarms or error states arise. The WEB Server connection also provides diagnostics and a means to configure the unit.

If the iLevel is connected to a network that has an internet connection available, the iLevel can send data to a remote WEB server to provide remote access with advanced features like: multi-site monitoring, advanced email features, cost reporting, historical data collection, and more.

Specifications

Models

P92040004 — iLevel2 Control Box

P92040005 — iLevel2 Control Box with Touchscreen

Required Components

P92060003 — iLevel2 Ultrasonic Sensor P49020005 — iLevel2 Sensor Cable 15’

Dimensions

P92040004/5 — iLevel2 Control Box: 8 ½ x 12 x 3 ¾”

P92060003 — iLevel2 Ultrasonic Sensor: 3” Diameter x 1½”

Weight

P92040004/5 — iLevel2 Control Box– 4.5 lbs.

P92060003 — iLevel2 Ultrasonic Sensor – 0.5 lbs. P49020005 — iLevel2 Sensor Cable – 0.5 lbs.

Electrical Rating

Power Supply: < 3A @ 5VDC Line Supply: < 0.5A @ 115VAC

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Locating the iLevel

®

_Panel

The iLevel control box is to be mounted to a vertical wall. The location of the iLevel control box needs to be within a 15-foot cable reach to the farthest container to be monitored. The iLevel control box also needs an Ethernet connection and a convenience outlet for power. The system is supplied with a 100-240VAC to 5VDC power supply that will plug directly into the convenience outlet and has a 6-foot cord to reach and plug into the control box circuit board. The system also comes with a 10-foot RJ-45 Ethernet cord to plug into the site network. Model P92040005 should be mounted near eye level for accessibility to the touchscreen.

10’ Ethernet Cable

15’ Sensor Cables

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Mounting the iLevel

®

_Panel

• Once the location of the iLevel control box is chosen (See: Locating the iLevel Panel Section) providing: o All containers to be monitored are within 15’ cable run between sensor and plug on control box

circuit board.

▪ If the containers are to be moved after the sensor is installed extra slack in the cable run may be required.

▪ Plan that approximately 6-7” of sensor cable will be consumed within the control box to make the internal connection.

o Convenience outlet is within a 5’ power cord distance to the far-right strain relief on the control box.

▪ The power cord is 6’ long; approximately 12” of cable will be consumed within the control box to make the internal connection, so plan for an outlet within 5’.

o Ethernet connection to the local network is available within 10-feet of the control box circuit board connection.

▪ Plan that approximately 8” of ethernet cable will be consumed making the internal connection.

• Place the control box in the location desired and mark the mounting hole locations (4) using a felt marker or pencil.

• For concrete or block walls drill the four marked locations with a ¼” drill bit. For surfaces that a sheet metal screw can go in directly drill a 1/8” pilot hole in the four locations.

• Insert ¼” wall anchors if applicable.

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Electrical

Requirements

• The iLevel panel requires a convenience outlet to plug in the 5VDC power supply. o No ground connection is used.

• An Ethernet connection to the network the iLevel will be controlled and monitored from is to have an RJ-45 female plug.

• All iLevel control board inputs are contact closure only, NO power is to be supplied to the inputs.

Controller Layout

Controller Status

The Status LED is used to indicate system status as follows:

Status LED

State

Description

No Light/Power Controller is not plugged in, receiving power, or there is a hardware issue.

No Connection Controller is not connected to the internet or the connection is blocked.

FLASHING Maintenance Mode Controller is in maintenance mode. Sensor readings cease.

iLevel Comm. Controller is powered up and connected to the internet.

FLASHING Email Comm. (Not used at this time)

Sensors #1-12 Inputs #1-5 Inputs #6-10 Inputs #11-15 Input LED’s Board to board connector Touchscreen connector MicroSD Card

(Program) 5V power connector

I2C Port -Temperature Sensor 5V Power connector Maintenance mode input Output connector Sensors #13-16 Status LED 5V Power LED

Maintenance Input LED

Output LED

USB 2.0 (x4)

RJ45 Ethernet port

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Power Supply

The iLevel control box is supplied with a 100-240VAC to 5VDC power supply that plugs directly into a convenience outlet. This outlet should be on a power source that will be able to supply power 24-7 to allow 24-7 connection to the iLevel unit.

Locate the convenience outlet and route the 6-foot outlet plug to the iLevel control box, through the far-right cord strain relief located on the bottom of the control box, and plug the power supply 5VDC barrel plug into the iLevel control board. Do not plug in the wall supply

to the convenience outlet until installation is complete and/or the unit is ready to be powered up for setup. Sensor cables with sensors attached should not be plugged in or unplugged from the control board while the unit is powered up to avoid damaging the sensor.

Ethernet Connection

Route the supplied Ethernet patch cord from the RJ-45 connection of the local site network to the iLevel control box, through the cord strain relief on the far-right bottom side of the control box. Plug the Ethernet cable into the control board Ethernet port located near the middle center of the control board. If installation requires a longer run than the supplied 10-foot patch cord a longer network Ethernet cable can be made to run directly from the site router to the iLevel control box and plugged directly into the control board.

*NOTE*

Due to the diameter of the Ethernet cable, the power supply MUST be routed through the strain relief first, before the Ethernet cable.

Power supply connection

Ethernet connection

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Control Wiring Connections

The iLevel control box can have up to sixteen (16) ultrasonic sensors, fifteen (15) dry digital inputs, and one (1) output (contact closure).

Ultrasonic Sensors:

An ultrasonic sensor cable (P49020005) is required for each individual sensor (P92060003) to connect the sensor to the control board. The sensor cable plugs into the control board connecting the four wires from the sensor to the controller.

Route each cable through the sensor strain relief(s) and connect to the corresponding sensor input on the control board. Up to eight sensor cables may be run through a single strain relief. After all connections are complete, attach the silicone bushing to the cables and push the cable bundle up and into the strain relief. Tighten the cap to secure the cables.

Document and plug the sensor into the proper sensor number location so the container information can be entered into the setup information at start up.

Sensors #1-8

strain relief strain relief location Sensors #9-16 (Strain relief shipped loose)

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Cleaning Systems Inc. 9 P59000011 Rev:00 Digital Inputs

Digital inputs can be used to count wash packages or any item that you wish to count when it turns on or off. Digital inputs can also be used to count and send an alarm warning via email (if email is configured and available) when the input turns on or off.

WARNING: It is important to verify when connecting the digital inputs that NO external power is connected to control board input terminals. The digital inputs require a dry contact closure

between the control board control common and the desired input to send a signal.

It is also important that the wires running from the iLevel control box terminal blocks do not exceed a wire length of 50 feet and are routed in a fashion that they are not in close proximity to devices and wiring emitting electrical noise (Ex: light ballasts, variable frequency drives, or wiring to or from variable frequency drives).

A relay can be added to provide a dry (un-powered) contact if it is not available. The relay can be located at the point the input signal is provided or if the point the signal is connected to is greater than 50 feet or there are items generating electrical noise in-between the signal location and the iLevel control box the relay

could be mounted near the iLevel control box. The coil of the relay is controlled by the signal source and the dry contact of the relay is connected to the iLevel digital input.

The digital inputs are divided into three terminal blocks containing one common connection and five inputs. The common terminal on each terminal block is the same reference point, so one of the three common

connection points may be used for all 15 inputs if desired. The digital input terminals are caged

spring clamp connections and can be used with 16 – 20 AWG wire. To open the

terminal, press down on the green release tab of the appropriate terminal position with a small screwdriver. Release the tab to lock the wire in place.

The Input LED’s on the control board will light green to indicate when an input is in the ON state (contact closed).

Inputs strain relief (Shipped loose – remove

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Cleaning Systems Inc. 10 P59000011 Rev:00 Output

The controller output is a feature that can turn on an indicator light or alarm at the location the iLevel is installed when any alarm mode including: Container Low Alarm, Container High Level Alarm, or Bad Sensor Alarm are sensed by the iLevel.

The output is a 2 Amp dry contact relay contact that will close when any of the alarm modes listed are active. A plug in terminal block is provided to connect the power supply and alarm device to the iLevel control box. The terminal block plugs into the control board connecting the two pins of the output location of the control board to the corresponding holes of the terminal block located just above the screw securing the wires.

Since the contact closure of the output on the iLevel board is dry (no power), a power supply to operate the alarm needs to be provided. Connect one of the connections from the power source supplying the alarm device to one of the connections points of the alarm output terminal block. Connect one of the connections of the alarm device to the other open connection point of the alarm terminal block. Connect the other open connection of the alarm device to the open connection of the power supply.

The output cable may be routed through a strain relief with excess space, or one of the hole plugs removed and a strain relief installed to accommodate the output cable.

The output LED on the control board will light green to indicate when the output is in the ON state (contact closed).

Output LED

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Touchscreen Connections

A ribbon cable and two power wires (+5V and GND) are required between the touchscreen board and iLevel board (factory installed). If the cover is removed for installation or maintenance, these connections must be disconnected from the iLevel board for the cover to separate, and reconnected when the cover is placed back on the enclosure for the touchscreen to function. A quick disconnect terminal is provided for the two power wires (+5V and GND) on the iLevel board. The 15-pin white ribbon cable should also be removed from the controller on the iLevel side. Leave the two power wires and ribbon cable attached to the touchscreen unit (only disconnect from the iLevel controller) to separate the cover from the enclosure.

In the event the power wires come loose or need to be replaced, the termination points on both the iLevel board and touchscreen board are labelled as 5V or GND. Pay attention to the polarity; if the wires are reversed the touchscreen will not function.

*Only applies to model P92040005*

iLevel board +5VDC and GND Connections iLevel board +5VDC and GND Terminal Plug

+5V and GND Connection for Touchscreen

Touchscreen +5V and GND Connections +5V and GND

Connection on Touchscreen

+5V

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Cleaning Systems Inc. 12 P59000011 Rev:00 The white 15-pin ribbon cable must be installed with the silver contacts face-up (towards you) looking at the touchscreen board, and facing right looking at the iLevel board. To remove or install, gently loosen the retaining clip on the ribbon cable connector and pull the cable out, or set the cable in and tighten the retaining clip. The retaining clip should push in easily if the cable is positioned correctly. Do not force the retaining clip shut if it does not want to go (reposition cable and try again), also do not force the ribbon cable into or out of the connector with the retaining clip tightened, it could scratch the contacts and damage the ribbon cable.

Ribbon cable connection on touchscreen board Ribbon cable connection on iLevel board Retaining Clip

Retaining Clip

To remove ribbon cable, gently pull up on the retaining clip

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Installing Ultrasonic Sensors

The two part numbers below are the required components necessary for the iLevel control board to monitor the chemical level in a container.

P92060003 SENSOR ULTRASONIC iLEVEL2 P49020005 HARNESS ILEVEL2 SENSOR 15'

The gray polypropylene sensor housing is chemical resistant and was designed to fit in the bung of a 5-gallon pail, 30 and 55-gallon drum, as well as a custom machined hole on the top of the Ultraflex reservoir. For 5-gallon pail, or 30 and 55-gallon drum installation, remove the cap or bung and set the sensor into the hole.

If the sensor is installed in a non-CSI container, a 50mm hole saw should be used to cut a hole in the container and create a snug press-fit mounting hole for the sensor to push into.

For Ultraflex®_{reservoir installation:}

Remove the factory installed 2” hole plug located in the top center hole. A screwdriver may be needed to gently pry the plug out. Slowly press the iLevel ultrasonic sensor into the center hole until it stops. For best sensor performance, the sensor should be positioned so the cable pigtail points left looking down on the reservoir.

Remove factory installed 2” hole plug

Optimal sensor orientation

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Connecting to the iLevel

®

You can connect directly to the iLevel at a wash site to quickly view container status, input counts, and device settings by means of three different methods. Through any of the methods the interface screens are identical and match what is displayed on the touchscreen model. The screens are explained in detail in the next section “Touchscreen / Interface Screens”.

Method 1 - With any device that is connected to the same network as the iLevel and has a WEB browser application, i.e.: Desktop PC, Laptop, iPhone, Android, or tablet as examples. This method requires the iLevel be connected and communicating with the local site network, but it does not require internet access.

Method 2 - With a smart device connected directly to the Wi-Fi hotspot on the iLevel. No network or internet connection required.

Method 3 - With the touchscreen (only applies to model P92040005). No network or internet connection required. Skip to section “Touchscreen / Interface Screens” for operation.

Method 1 – Local network connection

Any device connected (via Ethernet or Wi-Fi) to the same local network as the iLevel can access the interface through a web browser.

Step 1) Locate the serial number label on the outside of the iLevel enclosure and keep track of the 3-digit serial number (i.e. “018”).

Step 2) On the device connected to the same network, open a web browser and type “ilevelxxx” into the URL, where “xxx” is the serial number of the iLevel. For example, “ilevel018”. Hit Enter or Go, and the interface status screen will appear. If it does not appear, verify the iLevel is connected to the local network.

Type “ilevel” followed by serial number into URL

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Method 2 – Wi-Fi Hotspot

The iLevel control board has a built-in Wi-Fi hotspot that is always enabled by default. A smart device (iPhone, Android, tablet, laptop, etc…) or a desktop computer with Fi may be used to connect directly to the iLevel Wi-Fi hotspot. No local network or internet access is required.

Step 1) Locate the serial number label on the outside of the iLevel enclosure and keep track of the 3-digit serial number (i.e. “018”).

Step 2) Turn on Wi-Fi on the smart or Wi-Fi enabled device that is to connect to the iLevel and find the hotspot. The network name will appear as “iLevelxxx”, where “xxx” is the serial number of the device. If more than one iLevel is installed at the site, more than one iLevel network may appear depending on device locations.

Step 3) Click on the iLevel hotspot network to connect. When prompted to enter a password, enter “ilevelcsi” (all lowercase). Click “Connect”. You will see the device is connected if successful. If not successful, try connecting again. The hotspot password may be changed by the user through the interface settings.

Turn on Wi-Fi and find the hotspot network

Connect to network with password “ilevelcsi”

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Cleaning Systems Inc. 16 P59000011 Rev:00 Step 4) Open a WEB browser application and type “10.1.1.1” into the URL and press Enter or Go. The interface status screen will appear if successful. If not successful, verify you are still connected to the iLevel Wi-Fi hotspot, or go back to the previous step to try connecting again.

Navigate to “10.1.1.1”

Interface status screen will appear when connected

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Touchscreen / Interface Screens

Status Screen

The left-hand tab menu is always present and will navigate you to various screens that are used to perform different tasks. The status screen shows both a graph and table representation of the current container levels. If the container is disabled (see “Containers Screen” for details), it will not appear on the status screen, and if a container is enabled but not connected, it will show a value of 0. The container levels are updated on the status screen every 5 minutes.

Current screen name

Container # Container level bar Minimum setpoint

Container level in gallons or liters

Percent (%) capacity scale Navigation tabs

Container #

Current container level in gallons or liters, and

percent (%) full

Container level color indication: Level > “Maximum Level” setpoint

(Min. level / Max. level) + 15% < Level <= “Maximum Level” setpoint

“Minimum Level” setpoint < Level <= (Min. level / Max. level) + 15%

Level <= “Minimum Level” setpoint

7.5 Gallon Container Example: (Min. setpoint = 1 gal, Max. setpoint = 7.5 gal)

100% Full, 7.5 Gal

28.3% Full, 2.1 Gal 13.3% Full, 1 Gal

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Inputs Screen

The inputs screen displays the daily count and historical averages for inputs connected to the iLevel. Input numbers are color coded and shown in a legend across the top of the screen.

• There is a separate input counter for each digital input.

• Input counts are the number of times the digital input receives a rising edge. • Inputs have a 100ms on and off delay before state changes.

Input numbers color coded.

#1-5 Active

On April 17th_{, 3 counts} for Input #1 and 2 counts for Input #2 occurred for a total of 5

input counts

Weekly Total/Average:

Total input counts for the week listed. Weeks start on Monday and end on Sunday. Daily average for the week is the total count divided by the number of days so far in the week. For example if 100 inputs occurred by Tuesday, the average for the week is (100 counts)/(2 days) = 50 input counts per day.

Monthly Total/Average:

Total input counts for the month listed. Months start on the 1st and end on the last day of the month listed. Daily average for the month is the total count divided by the number of days so far in the month. For example if 300 inputs occurred by the 17th, the average for the month is (300 counts)/(17 days) = 17.6 input counts per day (rounded down from 17.647).

Yearly Total/Average:

Total input counts for the year listed. Years start on day 1 and end on day 365. Daily average for the year is the total count divided by the number of days so far in the year. For example if 3000 inputs occurred by April 17th, the average for the year is (3000 counts)/(106 days) = 28.3 input counts per day.

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Containers Screen

The containers screen allows the user to enable/disable containers being monitored as well as select a predefined container size or enter custom container settings. The container settings are required for all enabled containers and used to convert the raw ultrasonic sensor readings into a fluid level representation in the container.

Container navigation Enable/disable container button Save changes Help icon Current container settings profile Current container Settings profile Available default Container settings profiles Enter custom container settings (non-CSI containers)

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Cleaning Systems Inc. 20 P59000011 Rev:00 Custom container settings may beentered if

using a non-CSI container, or the container settings profile does not exist. All four settings must be entered to monitor the container, and the default values of the last saved container profile will appear when selecting “Custom”. Hit “Save” after entering the settings to save the profile and activate the changes.

• Milliliters Per Millimeter (or Gallons per inch):

o Container size is used to calculate the volume of liquid per millimeter or inch of height in the container. For example, if the container is square with an internal length and width of 300mm, the number of milliliters per 1 millimeter of height is:

▪ Area = (Length)x(Width) = (300mm)x(300mm) = 90,000mm2

▪ Conversion factor of 0.001mL = 1mm3

▪ (90,000mm2_{)x(0.001mL/1mm}3_{) =}_{90 mL/mm} • Container Empty Distance (Millimeters or Inches):

o The amount of distance from the sensor face to the bottom of the container. • Maximum Level (Milliliters or Gallons):

o The maximum level is the capacity the container will read 100% full. The maximum capacity needs to be a capacity that provides a distance no less than 127mm (5in.) from the sensor face to the liquid. • Minimum Level (Milliliters or Gallons):

o The minimum level is the level at which the system will send a notification that the container level is low (internet access required).

Help icons Custom container settings screen

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Network Screen

The network screen is used to either enable DHCP network configuration (default) or manually enter static network settings to connect the iLevel to the site network and internet. The help icons can be used for a description of each network setting. You must hit “Save” after any changes are made including enabling/disabling DHCP, in order for the changes to take effect.

Enable/disable DHCP button

Help icons

DHCP Enabled

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Cleaning Systems Inc. 22 P59000011 Rev:00 • Enable DHCP: Check this box to enable the Dynamic Host Configuration Protocol (DHCP) for the

iLevel board

o Enabled by default

o If DHCP is enabled an IP Address, Gateway, and Subnet Mask will be assigned to the iLevel board from your network router’s DHCP server when enabled on the router.

• IP Address: A unique string of numbers separated by periods that identifies each device using the Internet Protocol to communicate over a network

o If the "Enable DHCP" is "Checked" this field is read only identifying the assigned IP address for the iLevel Board by the router.

o If the "Enable DHCP" is "Not Checked" type the unique IP address desired for the iLevel board in the setup screen IP address box provided.

o Format: x##.x##.x##.x## (Example:192.168.1.100)

• Gateway: Gateway address is the IP address of the router interface connected to the local network that sends out information packets on the local network.

o If the "Enable DHCP" is "Checked" this field is read only identifying the assigned Gateway IP address for the local network assigned by the router.

o If the "Enable DHCP" is "Not Checked" type the Gateway IP address of the router attached to the local network manually.

• Subnet Mask: A mask used to determine what subnet an IP address belongs to.

o If the "Enable DHCP" is "Checked" this field is read only identifying the Subnet Mask of the local network assigned by the router.

o If the "Enable DHCP" is "Not Checked" Type the Gateway Subnet Mask of the attached network to the iLevel board manually.

• Primary DNS Server: DNS Server is the Internet's system for converting alphabetic names into numeric IP addresses, Primary server is the first server asked to identify a name.

o If the "Enable DHCP" is "Checked" this field is not displayed

o If the "Enable DHCP" is "Not Checked" type in the Primary DNS Server IP address of the internet service provider (ISP) or local DNS Server if applicable

o Format: x##.x##.x##.x## (Example:10.147.150.1) o Free Public Server is : 8.8.8.8

• Secondary DNS Server: DNS Server is the Internet's system for converting alphabetic names into numeric IP addresses, Secondary server is the second server asked to identify a name if the primary fails.

o If the "Enable DHCP" is "Checked" this field is not displayed

o If the "Enable DHCP" is "Not Checked" Type in the Secondary DNS Server IP address of the internet service provider (ISP) or local DNS Server if applicable

o Format: x##.x##.x##.x## (Example:10.147.150.2) o Free Public Server is: 8.8.4.4

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Settings Screen

There are navigation tabs along the top of the Settings Screen that allow the user to: • View device serial number/SSID of hotspot and update hotspot password • Enable/disable password protection on device and set/recover device password • Change the unit of measure (English or Metric)

• Set the time zone of the device • Reset to factory defaults

Hotspot

The hotspot settings tab allows the user to view the SSID (network name) of the hotspot and change the hotspot password from the factory default. The factory default password is “ilevelcsi” (all lowercase). The password must be at least 8 characters and less than 64 characters. To change the password, enter a new password in the “Hotspot Password:” and “Confirm Password:” fields and hit “Save”.

Settings navigation

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Cleaning Systems Inc. 24 P59000011 Rev:00 Passcode

The passcode settings tab allows the user to enable/disable passcode protection on the device (separate from the hotspot password to connect to the interface). This passcode will prevent users from viewing and changing any settings on the Containers, Network, and Settings screens until the passcode is entered, but will still permit any user to view the contents of the Status and Inputs screens. The Status and Inputs screens are unsecured. The passcode is a 4-digit numeric code.

After a reboot or 10 minutes of inactivity on the touchscreen or interface screens, the passcode must be re-entered to access the secured screens.

Enable/disable passcode protection

Enter 4-digit numeric code (i.e. 1234) and

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Cleaning Systems Inc. 25 P59000011 Rev:00 A Login screen will appear anytime the device protection passcode is required. Enter the 4-digit code to gain access, or use the “Lost Passcode?” button to recover a forgotten passcode.

To recover a forgotten passcode, enter the Module ID (SSID) viewable on the hotspot settings screen and hit “Submit”. The passcode will generate underneath the “Submit” box.

Login screen will appear when passcode is enabled

Enter 4-digit numeric passcode

Recover forgotten passcode

Enter Module ID (SSID) and hit “Submit”

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Cleaning Systems Inc. 26 P59000011 Rev:00 Measure

The measure settings tab changes between English or Metric units. The units change immediately without the option of hitting “Save”. The unit of measure is set to Metric by default, and will reset back to Metric if the device is rebooted.

Timezone

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Cleaning Systems Inc. 27 P59000011 Rev:00 Reset

The reset settings tab allows a user to reset the device to factory default settings. All containers will be disabled by default and input counts on the device will be deleted.