Pump Boss - Intelligent Pump Control Manual

PUMP BOSS Intelligent Pump Control

Operation Manual HOW SMART PEOPLE CONTROL CHEMICALS

TABLE OF CONTENTS September2008

PUMP BOSS Introduction / Overview

3

Specifications

5

Inputs /Outputs

6

Installation

7

Connections\ Board layout

8

Compatible Flow Devices

9

Flow Verification Devices

10

Navigation

11

Programming

12

Automatic Pump Switchover

13

Proportional Dosing / PPM

15

Basic Timer Functions

17

Proportional Dosing with Timer & Auto Switchover

19

Menu Flow Charts

20

Wiring Diagram

23

Timer Settings Sheet

24

Default and User Settings Log

25

Warranty

26

Copyright

©2008 Chem Flow, Inc. All rights reserved

No part of this publication may be duplicated and/or published through printing, photo-copying, microfilm, electronically or via audio tapes or be stored in any other manner without prior written consent from Chem Flow, Inc 2

INTRODUCTION The Pump Boss is a dual pump controller capable of complex pump control with a variety of controller algorithms. In its most basic operation the Pump Boss can be used as a single or dual channel timer with up to eight daily events, weekly timer with multiple days and multiple events or a duration timer with a single event that repeats (useable for example as a 14, 28 90 day timer). Each channel is programmable so a dual timer based program can be run from a Pump Boss. When used with a flow verification device Pump Boss can control the pump in gallons per hour and totalize flow. Again the Pump Boss can control two pumps independently or when used together powerful dual pump capabilities are possible such as an automatic switch over feature or the ability to use two pumps in a base and trim combination. If a process flow meter is added the Pump Boss can become a powerful process controller allowing you to proportionally dose two separate process flows at separate dose rates, or a single process flow with two separate dose rates, or when coupled with our auto-switch over a single flow with a single dose rate but with automatic pump redundancy. The proportional flow concentration can be displayed in ppm or as a percentage of the flow. The Pump Boss is also an excellent local control station for pumps in your plant. It allows for remote start stop, 4-20 mA follower, alarm if pump/s fail and indication of pumps running. We have advanced remote trigger capabilities that allow you to use a contact closure to initiate the start up of the pump boss. You can chose for simple remote on off, activation after a number of contact closures, activation after a duration of a contact being closed and then when activated the response being just turning on, dosing a specific volume, or proportional dosing in ppm. Keep in mind that the Pump Boss has the ability to run two pump separately. This means you can use the Pump Boss to run two completely different regimes such as channel one dosing proportionally to a flow and the second channel doing simple on off timer control. Also with the inclusion of 2 powered relays for each channel the relay can be used to power valves or other devices to accomplish things like boiler blow down. The Pump Boss is also designed to provide 4-20 mA control signals as well as pulse control. This allows you to use the Pump Boss with larger capacity pumps that may have speed control via a VFD or DC drive. As you become a more accomplished Pump Boss user, you will see how the programming modes can be mixed and matched for you to accomplish pump control schemes that in the past would require you to program a PLC.

3

Operational Modes

INTRODUCTION

The Pump Boss has three ( 3) operational modes. Manual: The chemical pump/s are set to a fixed pumping rate via front panel push buttons for LOCAL operation or external 4-20mA signals for REMOTE operation. Each pump is independently adjustable and not affected by system water flow. Use the manual mode when no flow meter is required. Auto: The chemical pump/s will “follow” the input flow meter to maintain a selected set-point of ppm or % concentration( depending on controller configuration) Set-point can be adjusted via front panel buttons for LOCAL operation or external 4-20mA signals for REMOTE operation. NOTE;A flow meter input is required for auto mode operation. Trigger: The trigger mode has various configurations to operate the controller. To “activate” the controller , an input trigger must be selected. There are two (2) input types: ♦ ♦

Contact Closure 4-20mA

Contact Closure Trigger : A dry contact connection to pump#2 REMOTE CONTROL (TB207,1 TB207-2) The are three (3) trigger options: On/Off, # Events and Duration. 1. On/Off: Controller operates immediately when the contact closure is made. 2. # Events: Controller operates AFTER the preset number of contact closures are made. While waiting for the trigger, the number of events can be adjusted via front panel push buttons. Once activated, the NEXT contact closure will disable the controller and wait for the next sequence of contact closures. 3. Duration: Controller operates AFTER contact closure has been maintained for a pre-set number of minutes. While waiting for the trigger, the duration delay can be adjusted via front panel push buttons. 4-20 Trigger : A 4-20madc connection to Pump #2 REMOTE CONTROL 4-20 INPUT ( TB209-1, TB209-2) Controller operates immediately when a preset mA is present at the EXTERNAL INPUT. While waiting for the trigger, the level can be adjusted via front panel push buttons. After a trigger function has been defined, the controller ACTION must be configured. There are three(3) types of controller actions for the trigger mode: ♦ Full On ♦ Volume ♦ Proportional. Full On: Controller delivers chemical at 1005 pumping rate for a preset number of minutes. The set point duration can be adjusted via front panel push buttons. Volume: Controller delivers a preset volume of chemical at 100% pumping rate. The set point volume can be adjusted via front panel push buttons. Proportional (PROPRTNL) : Controller maintains a selected set point of ppm or % concentration (depending on controller configuration). The set point can be adjusted via front panel push buttons. Note: A flow meter input is required for proportional mode of operation.

4

SPECIFICATIONS

Inputs//Outputs: (See attached Pump Boss I/O Connection figure)

Display: Eight (8) digit, 0.3 inch high alphanumeric red LED. Resolution +/- one digit. Temporary or long-term power loss does not affect program setups. Four LED indicators for each pump (total eight) monitor pump operation status. Pump Power Output: Relay, contact closure, SPST, 10 ampere N.O. may be connected for controlling AC loads. Pump Status Outputs: Relay, contact closure, SPST, 10 ampere N.O. may be connected for controlling AC loads. Alarm Power Output: Relay, contact closure, SPST, 10 ampere N.O. may be connected to signal for alarm purposes. Operates during pump error.( With Feed Verification device) Note 1 : All relays are non-powered , dry contacts. Note2: Concentration error does not activate alarm. Electronic Pump Control: Two solid state switch contact closure, SPST, 25 mAdc, 15 VDC, isolated Input Operating Voltage: 100 to 240 VAC, 47 to 63 Hertz. Fuse, 3AG, 5 ampere. Programming: Eight (8) panel pushbuttons allow programming and controller operation. Enclosure:

Polycarbonate, Grey NEMA-4X, IP-66 Size: 14.21” L-R 10" T-B 4.37" Depth

Program Memory: All operating software is contained in three microprocessors with flash memory to facilitate easy field changes in the operation or adding features. Software version number is displayed during power-up sequence.

5

Inputs & Outputs POWER - LARGE TERMINALS: TB201-1 - POWER IN (HOT) TB201-2 - POWER IN (COM) TB201-3 - POWER IN (EARTH) TB201-4 - PUMP #1 POWER CONTROL TB201-5 - PUMP #1 POWER COMMON TB201-6 - PUMP #2 POWER CONTROL TB201-7 - PUMP #2 POWER COMMON TB201-8 - PUMP #1 ACTIVE SIGNAL TB201-9 - PUMP #1 ACTIVE COMMON TB201-10 - PUMP #2 ACTIVE SIGNAL TB201-11 - PUMP #2 COMMON TB201-12 - ALARM OUTPUT TB201-13 - ALARM COMMON

SIGNALS - SMALL TERMINALS: TB202-1 - PULSE FLOW METER +12VDC TB202-2 - PULSE FLOW METER +INPUT TB202-3 - PULSE FLOW METER -INPUT TB202-4 - PULSE FLOW METER COMMON TB203-1 - FLOW METER (4-20mADC ) + INPUT TB203-2 - FLOW METER (4-20mADC) COMMON TB204-1 - PUMP #1 POSI-FLOW +12VDC TB204-2 - PUMP #1 STANDARD POSI-FLOW SIGNAL TB204-3 - PUMP #1 TURBINE CHEM FLOW SIGNAL TB204-4 - PUMP #1 POSI-FLOW COMMON TB205-1 TB205-2 TB205-3 TB205-4

-

PUMP PUMP PUMP PUMP

#2 #2 #2 #2

POSI-FLOW +12VDC STANDARD POSI-FLOW SIGNAL TURBINE CHEM FLOW SIGNAL POSI-FLOW COMMON

TB206-1 - PUMP #1 REMOTE CONTROL + INPUT TB206-2 - COMMON

ANALOG BOARD: TB301-1 - PUMP #1 CONTROL(4-20mADC) + OUTPUT TB301-2 - SPARE TERMINAL FOR LOAD SERIES CONNECTION TB301-3 - PUMP #1 CONTROL(4-20mADC) COMMON TB302-1 - PUMP #1 REMOTE PUMP SPEED(4-20mADC) + OUTPUT TB302-2 - SPARE TERMINAL FOR LOAD SERIES CONNECTION TB302-3 - PUMP #1 REMOTE PUMP SPEED(4-20mADC) COMMON TB303-1 - PUMP #2 CONTROL(4-20mADC) + OUTPUT TB303-2 - SPARE TERMINAL FOR LOAD SERIES CONNECTION TB303-3 - PUMP #2 CONTROL(4-20mADC) COMMON TB304-1 - PUMP #2 REMOTE PUMP SPEED(4-20mADC) + OUTPUT TB304-2 - SPARE TERMINAL FOR LOAD SERIES CONNECTION TB304-3 - PUMP #2 REMOTE PUMP SPEED(4-20mADC) COMMON

TB207-1 - PUMP #2 REMOTE CONTROL + INPUT TB207-2 - COMMON (NOTE: TB207 IS ALSO TRIGGER MODE C.C. INPUT) TB208-1 - PUMP #1 REMOTE CONTROL (4-20mADC) + INPUT TB208-2 - PUMP #1 REMOTE CONTROL (4-20mADC) COMMON TB209-1 - PUMP #2 REMOTE CONTROL (4-20mADC) + INPUT TB209-2 - PUMP #2 REMOTE CONTROL (4-20mADC) COMMON (NOTE: TB209 IS ALSO TRIGGER MODE 4-20mADC INPUT) TB210-1 - PUMP #1 PULSE OUTPUT TB210-2 - PUMP #1 PULSE COMMON TB211-1 - PUMP #2 PULSE OUTPUT TB211-2 - PUMP #2 PULSE COMMON

Note: Input 4-20mAmadc signals are not isolated.

6

INSTALLATION

Select a location for mounting the controller on a vertical wall, pole, or panel with good visual accessibility and away from direct sunlight. Operating power must be supplied together with the input/outputs. A customer supplied external power disconnect switch with ground fault interruption (GFI) protection must be provided as a power switch or GFI protection is not provided within the controller.

7

CONNECTIONS ♦

YELLOW ARE PUMP ONE CONNECTIONS

♦

RED ARE PUMP TWO CONNECTIONS

♦

GREEN ARE COMMON ITEMS (FLOW METERS AND ALARMS)

All of the descriptions and terminal numbers are silk screened onto the PCB

Q

P

F A

B

C

D

G

H

I

R

S

J k L M N O

E F: FLOW METER PULSE G: FLOW METER 4-20 mA

LARGE TERMINAL STRIP A-E Non Powered Relays 90-265 VAC based on incoming voltage. Pump One Power: A Pump One Running Relay: C Pump One Power: B Pump One Running Relay: D 8

COMPATIBLE FLOW DEVICES PROCESS FLOW METERS: The Pump Boss can accept two process flow signals that the pumps can deliver chemical in proportion to the flow. If there is only one pump, you are using auto switch over, or base and trim then the Pump Boss can only control proportionally to one flow signal. This flow signal can either be a pulse type or a 4-20 mA signal. If you run two pumps from the Pump Boss each pump can be proportional to a separate process flow. However you will need to use one flow meter that has a pulse and one that provides a 4-20 mA signal. You can not run a pump boss with two analog or two pulse flow meters.

Pulse The maximum flow for dilution water input is selected based upon the size of flow meter selected. The Menu allows inputting the “K” value for the particular flow meter. “K” value refers to the number of pulses per gallon of water for the specific flow meter utilized. When the ON/OFF Key is pressed, a default number will be displayed. To change, press an arrow key to increase or decrease, then press ON/OFF. Press ON/OFF to return to the Menu after the number is complete. Press the arrow key for the next selection. Depending upon the type of pulse flow meter selected, jumper JB201/JB202 located on the main power supply must be correctly positioned. For “sinking” output (Seametrics) connect as follows: 1. 2. 3. 4. 5. 6.

Flow meter power to TB202A No connection to TB202B Signal to TB202C Common to TB202D Shunt jumper on JP201 Open connection on JP202

For “source” output connect as follows: Flow meter power to TB202A Signal to TB202B No connection to TB202C Common to TB202D Open connection on JP201 Shunt connection on JP202

4-20mA Set Up Procedure Allows calibrating both the 4-20 mAdc input and output. Use arrow keys to select Input or Output. Refer to Setup Menu #2. Use must supply known, stable 4-20mA signal for Calibration.

9

FLOW VERIFICATION DEVICES The pump boss works with a wide variety of flow verification devices that are either three or four wire devices. Please see wiring diagram to wire up the device of your choice. Approved devices are : Iwaki Posiflow flow verification device ( Primary Preferred Device) Kobold Oval Gear Meter ( Secondary Preferred Device) Blue White Micro flow verification device Select the device based on the fluid and volume you are pumping. Connect as determined by the flow signal developed. Flow verification devices must be installed, enabled and pump calibration must be performed for chemical pump totalizer operation and accuracy.

Slo-Blo Fuse

10

NAVIGATION The Pump Boss interface has a single line scrolling LED interface providing data and messages. The system also includes a LED to denote when a particular pump is in remote control, in an alarm state or under timer control. The Pump On light blinks with each pulse the Pump Boss sends to the associated pump.

UP ARROW FOR CYCLING THROUGH MENUS AND INCREASING SPEED

DOWN ARROW FOR CYCLING MENUS AND ADJUSTING SPEED DOWN TURNS PUMP ON AND OFF. PRESS FOR 5 SECONDS TO GET INTO PROGRAMMING.

SWITCHES FROM LOCAL CONTROL TO REMOTE CONTROL

Navigating controls is done through the keypad on the front of the controller. All programming is done with the use of the on/off button and the up and down arrows. To enter the programming menus, press and hold the on/off button for five seconds when the pump is not operating. (Pumps will turn off automatically) Panel Control Description Eight Digit Alpha-numeric Display a. When operating, the display provides real- time parameters as values and/or unit status. b. During programming mode, the display shows the programmed information for each input and preset value.

11

PROGRAMMING YOUR PUMP BOSS The Programming Menu has two levels. The first is the user level and the second is the set up level. Both are password protected and can have separate passwords. No passwords are needed to adjust flow rate, to stop and start the pumps, or to switch between remote and local operation. The default password is 0000 If you chose to run each channel separately then you have the ability to run two entirely different control strategies. If however you wish to use the auto switchover feature or the base and trim feature then only one strategy can be programmed.

In either case, modes of control are designed to be used together, so you can use the real time clock (2400 hr format) to start the pump AND dose in ppm or percentage concentration to a process stream. You can use trigger modes and also dose in ppm. This allows for complex addition strategies that also accommodate process fluctuations, and in the case of auto switch over increase reliability with automated redundancy.

Control Options

1. Auto-Switchover with remote control 2. Auto-switchover with proportional dosing and remote control 3. Basic Timer control 4. Timer Control with Auto-Switchover

12

1

AUTO SWITCH OVER

When To Use This Configuration: When you want to dose a chemical in proportion to a process flow in either ppm or percentage and make sure that if your main pump fails to meter chemical that a second pump will recover metering without user intervention. This is ideal for applications where chemical needs to fluctuate with increases and decrease of flow and equipment is remote or has limited supervision.

Features ♦ ♦ ♦ ♦

Manual Start Stop Local control of pump set point Remote Stop Start 4-20 mA control of pump output

INPUTS ♦ ♦

Remote stop/start contact closure 4-20 mA pump speed

OUTPUTS ♦ ♦ ♦

Pump Running Alarm Pump Speed 4-20 mA

Note: For auto switch over, it is recommended that both pumps be the same and/or calibrated the same.

TWO PUMPS IN A DUTY STANDBY CONFIGURATION WITH AUTOMATIC SWITCH OVER TO THE STANDBY PUMP IF THE DUTY PUMP HAS LOSS OF FLOW.

Steps For a Quick and Successful Start-Up 1) Press the on/off button for five seconds and enter the password 0000 2) Cycle to the setup menu and reenter the password 3) Set the type of remote stop start contact you want to use 4) Select auto-switch over and the delay between the pumps switching 5) Select two flow verification devices and a delay. This delay should be a few seconds longer than you think it will take for the device to register flow at start up. 6) Set up the maximum number of strokes per minute the pump is rated for and the ml/stroke. 7) Select if you want the pump boss to show pump flow in GPH or percentage of speed. 8) Set your new set up password. Write it down here__________ 9) Exit set up

Steps For Calibration 10) Go to the cal menu and select pulse. 11) Go through the calibration process for each pump by selecting the pump in the menu A) Set the volume of the calibration column. B) The % stroke (for record only) C) Hit the on button to start D) Hit the on button when the volume is empty. E) Select yes if the calibration is correct F) Set concentration span

13

AUTO SWITCH OVER

1 NOTE: The Pump Boss default Mode is manual operation

11 10

1

2

3

4

5 6 7

9

8

14

2

PROPORTIONAL DOSING WITH AUTO SWITCH OVER

When To Use This Configuration: When you want to dose a chemical in proportion to a process flow in either ppm or percentage and make sure that if your main pump fails to meter chemical that a second pump will recover metering without user intervention. This is ideal for applications where chemical needs to fluctuate with increases and decrease of flow and equipment is remote or has limited supervision.

Features Manual Start Stop Local control of ppm or % of process flow Remote Stop Start 4-20 mA control of ppm or % of process flow Set Point Range: 1.0-10.0% 0.1-1000ppm

♦ ♦ ♦ ♦ ♦

INPUTS ♦ ♦ ♦

Remote stop/start contact closure Pulse or 4-20 mA process flow 4-20 mA ppm or % of process flow

OUTPUTS ♦ ♦ ♦

Pump Running Alarm Pump Speed 4-20 mA

TWO PUMPS IN A DUTY STANDBY CONFIGURATION WITH AUTOMATIC SWITCH OVER TO THE STANDBY PUMP IF THE DUTY PUMP HAS LOSS OF FLOW.

Steps For a Quick and Successful Start-Up 1) Press the on/off button for five seconds and enter the password 0000 2) Select Auto mode 3) Set the default ppm or % you only need to do this for pump one 4) Cycle to the setup menu and re-enter the password 5) Set the type of remote stop start contact you want to use 6) Select auto-switch over and the delay between the pumps switching 7) Select two flow verification devices and a delay. This delay should be a few seconds longer than you think it will take for the device to register flow at start up. 8) Set up the maximum number of strokes per minute the pump is rated for and the ml/stroke. 9) Select if you want the pump boss to show pump flow in GPH or percentage of speed. 10) Select the type of flow meter, scale the flow meter, and choose both 11) Set your new set up password. Write it down here__________ 12) Exit set up

Steps For Calibration 13) Go to the cal menu and select pulse. 14) Go through the calibration process for each pump by selecting the pump in the menu A. Set the volume of the calibration column. B. The % stroke (for record only) C. Hit the on button to start D. Hit the on button when the volume is empty. E. Select yes if the calibration is correct

15

PROPORTIONAL DOSING WITH AUTO SWITCH OVER 3

2 14 13

1

4

4

5 6 7 8 9 10

12

11

16

3

BASIC TIMER FUNCTIONS WHEN YOU REQUIRE YOUR CHEMICAL DOSING TO BE INITIATED BASED ON TIME OF DAY, REGULAR WEEKLY INTERVALS OR DURATIONS

When To Use This Configuration: This section covers the basic timer function. The timer function can be used to turn on any device that does not exceed amps load. In the case of pumps you can use the powered relay to turn the pump on and off. If you wish to use flow verification and advanced features you will need to power the pumps either from a different source or from the hot terminals on the Pump Boss as most pumps using remote pulse or 4-20 mA will fault if they start at the same time as a control signal is sent to them.

Steps For a Quick and Successful Start-Up 1) Follow the installation Instructions 2) Configure the Controller as noted on this page

Set the time, date, month and year per user name. Note: The real time clock (RTC) has battery back-up and compensates for leap year 2100. All times are 24 hour format.

17

18

4

PROPORTIONAL DOSING WITH TIMER FUNCTION AND AUTO SWITCH OVER

When To Use This Configuration: When you want to dose a chemical in proportion to a process flow in either ppm or percentage and make sure that if your main pump fails to meter chemical that a second pump will recover metering without user intervention. This is ideal for applications where chemical needs to fluctuate with increases and decrease of flow and equipment is remote or has limited supervision. All times are 2400 format.

Features 4-20 mA control of concentration Remote Stop Start Timer Control

♦ ♦ ♦

TWO PUMPS IN A DUTY STANDBY CONFIGURATION WITH AUTOMATIC SWITCH OVER TO THE STANDBY PUMP If THE DUTY PUMP HAS LOSS OF FLOW. CONTROL STRATEGY REQUIRES BOTH TIMER CONTROL AND PROPORTIONAL DOSING

Steps For a Quick and Successful Start-Up

Use the set up table from Proportional dosing (pg.14) and the directions from timer settings. (pg.16)

INPUTS ♦ ♦ ♦

Remote stop/start contact closure Pulse or 4-20 mA process flow 4-20 mA ppm or % of process flow

OUTPUTS ♦ ♦ ♦

Pump Running Alarm Pump Speed 4-20 mA

19

20

User Menu Flow Chart

SP=Span

0.1-1000ppm 1.0-10.%

Total A & B are both the same and can be rest. Gross is only reset with factory reset. Units are expressed in gallons

SP=Set Point

Sets the 20 madc at top of span

21

Set Up Menu Flow Chart

For both channels

22

Timer Menu Flow Chart

Wiring Diagram

23

Timer Settings Sheet

24

25

Range: 1.0-10% 0.1-1000ppm

*

Strokes per minute

* Will change with pump calibration

Default and User Settings

WARRANTY AND ASSISTANCE

The PUMP BOSS Pump Controller is warranted to be free from defects in materials and workmanship under normal use and service for twenty-four (24) months from date of shipment unless otherwise specified. Batteries have no warranty. Chem-Flow obligation under this warranty is limited to repairing or replacing defective products at Chem-Flow's option. The customer shall assume all costs of removing, reinstalling and shipping defective products to Chem-Flow. Chem-Flow will return such products by surface carrier prepaid. The warranty shall not apply to any Chem-Flow products subjected to modification, misuses, neglect, accidents of nature or shipping damage. The warranty is in lieu of all other warranties, expressed or implied, including warranties of merchantability or fitness for a particular purpose. Chem-Flow is not liable for special, indirect, incidental or consequential damages. Products may not be returned without prior authorization. To obtain a Returned Materials Authorization (RMA), contact Chem-Flow, telephone number 630-543-1911. After an applications engineer determines the nature of the problem, an RMA number will be issued together with return shipping instructions. Please write the RMA number clearly on the outside of the shipping container together with specific contact person and telephone number. Chem-Flow does not accept collect calls. Non-warranty products returned for repair should be accompanied by a purchase order to cover the repair.

1450 West Fullerton Avenue Addison, Illinois 60101 26