Pump Boss - Intelligent Pump Control Powerpoint
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Pump Boss
Intelligent Pump Control
Pump Boss • Development Background • Features • Application Benefits • Integrated Systems • Commercial Considerations
Development Background Reoccurring Requirements
• • • • • • • • • •
Dual Pump Control Proportional Feed PPM Set Points % Concentration Feed Verification Auto Switchover Base / Trim Applications Timer Options Calibration Reporting
What is the Pump Boss? •
The Pump Boss is a dual pump controller designed to replace more expensive and complex PLC Designs.
•
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.
What is the Pump Boss? •
The Pump Boss is also an excellent local control station for pumps in a plant. It allows for remote start stop, 4-20 mA follower, alarm if pump/s fail and indication of pumps running.
•
W e 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 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 pumps 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.
Pump Boss Features Features
• Touch Button Dual Pump Control in One Box •
Local or Remote Control with Feed Verification
• Automatic Switchover • Proportional Dosing of chemical to a process signal • Multiple Timer Control Options • Feed Rate Totalizers • Event Based Automation
Pump Boss Features • 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.
Pump Boss Features •
Display: Eight (8) digit, 0.3 inch high alphanumeric red LED. Resolution +/- one digit.
•
Programming: Eight (8) panel pushbuttons allow programming and controller operation.
•
Readouts: 0-100%, GPH, Mils/Minute
•
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 dev ice)
•
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.
•
Enclosure: Polycarbonate, Grey NEMA-4X, IP-66
•
Size:
•
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 v ersion number is displayed during power-up sequence.
14.21” L-R
10" T-B
4.37" Depth
Pump Boss Features Features Choose BASIC OPERATION when: • You need to use timers to control your pump/s • You wish to use event based triggers like another pump starting or a change in a analog process variable. Choose ENHANCED OPERATION when : • You wish to meter chemical in proportion to a process flow • You require a combination of event based trigger and proportional flow • You are using a flow verification device with your pump • Your require auto switchover • You require a combination of timers and proportional flow
Pump Boss Features Inputs / Outputs External Inputs •
2 (Two) Flow Meter Inputs—One 4-20mA (TB203) & One Pulse (TB202)
•
2 ( Two) Remote 4-20mA—One for each Pump– Pump One (TB208)—Pump Two (TV209)
•
2 ( Two) Feed Verification -One for each Pump– Pump One (TB204)—Pump Two (TB205)
•
2 (Two) Contact Closures-One for each Pump– Pump One (TB206)—Pump Two (TB207) ( Interlock)
Control Outputs •
2 ( Two) Pump Speed Control Outputs 4-20mA—One for each Pump- Pump One (TB310) Pump Two (TB303)
•
2 ( Two) Pump Pulse Control Outputs — One for each Pump -Pump One (TB210) Pump Two (TB211)
•
2 (Two) Powered Relays -One for each Pump - Pump One (I201) Pump Two (1202)
Reporting Outputs •
2 ( Two) Pump Speed Outputs 4-20mA- One for each Pump-Pump One (TB302) Pump Two (TB304)
•
2 (Two) Pump Activ e Powered Relays—One for each Pump (I203 Pump one (I204) Pump Two
•
1 (One) Alarm Powered Relay ( I205)
Integrated Systems
Integrated Systems Introducing…..
• The Duplex Plus Series offers the ultimate in convenience and control options. With three series to choose from, users can select the design which best fits specific requirements. • Pumps offered as standards include the LMI 9 Series, Walchem EW Series and the Grundfos DME models. • All pump heads are PVDF for maximum flexibility of use. Other materials are available upon request.
• The 100 Series is the most basic model, using the powerful built-in pump controls. • The 200 Series integrates a simple, convenient local control panel. • The 300 Series integrates the newly designed Pump Boss, providing PLC like capabilities, without the PLC like price.
All systems include: • • • • • •
On– Board Calibration Assembly Single Suction/ Single Discharge Discharge Pressure Gauge Back Pressure Valves On-Board Power Receptacle Flush Ports These systems are pre-plumbed using CPVC piping and fittings and are pre-tested and deliv ered ready for use.
Duplex Plus 100 Series: Use Pump Face Controls The 100 series is the most version of the Duplex Plus Series. It integrates manually controlled chemical metering pumps from LMI, Walchem and Grundfos. All controls for the 100 Series are located on the pump face touch panels
Duplex Plus 200 Series: Add Pump Control Panel The 200 Series integrates a simple, convenient local control panel to provide dual pump HOA Switches and run light. This control box is linked to the most advanced microprocessor controlled chemical metering pumps from LMI, Walchem and Grundfos. The Series 200 Control panel can accept two 4-20mA inputs and remote dry contacts to control the pumps. This is an ideal for dosing programs which require chemical feed on remote contact or process control signal.
Add Controls Mounting Panel
Duplex Plus 300 Series: Add Pump Boss Controller The 300 Series integrates the newl y designed Pump Boss. This versatile multiuse controller allows the user to execute numerous complex dosing regimes without the extensive cost and complexity of a PLC. From a simple, timer dual biocide application to proportional feed based on a process variable, the unit is powerful enough, yet simple enough to easily implement any dosing regime.
Suction Assembly
Discharge Assembly
100 Series
200 Series
300 Series
Part Number
Part Number
Part Number
10GPD/140PSI
DP100-CV-L10
DP200-CV-L10
DP300-CV-L10
LMI
24GPD/110PSI
DP100-CV-L24
DP200-CV-L24
DP300-CV-L24
LMI
60GPD100PSI
DP100-CV-L60
DP200-CV-L60
DP300-CV-L60
LMI
96GPD/100PSI
DP100-CV-L96
DP200-CV-L96
DP300-CV-L96
Grundfos
15.9GPD/261PSI
DP100-CV-G16
DP200-CV-G16
DP300-CV-G16
Grundfos
47.5GPD/145PSI
DP100-CV-G47
DP200-CV-G47
DP300-CV-G47
Grundfos
76.8GPD/90PSI
DP100-CV-G77
DP200-CV-G77
DP300-CV-G77
Grundfos
117.6GPD/90PSI
DP100-CVG117
DP200-CV-G117
DP300-CV-G117
Walchem
14.4GPD/150PSI
DP100-CV-W14
DP200-CV-W14
DP300-CV-W14
Walchem
24GPD/105PSI
DP100-CV-W24
DP200-CV-W24
DP300-CV-W24
Walchem
55.2GPD/105PSI
DP100-CV-W55
DP200-CV-W55
DP300-CV-W55
Walchem
132GPD/150PSI
DP100-CVW132
DP200-CV-W132
DP300-CV-W132
Pump Type
Pump Capacity
LMI
Note1: CV = Viton O Rings - CE=EPDM O Rings Note2: If you require Auto Sw itch Over: Add SW to the end of the 300 Series part number. Example: DP300-CV-W14-SW
100 Series
200 Series
300 Series
PUMP BOSS
Intelligent Pump Control
Pump Boss • Development Background • Features • Application Benefits • Integrated Systems • Commercial Considerations
Development Background Reoccurring Requirements
• • • • • • • • • •
Dual Pump Control Proportional Feed PPM Set Points % Concentration Feed Verification Auto Switchover Base / Trim Applications Timer Options Calibration Reporting
What is the Pump Boss? •
The Pump Boss is a dual pump controller designed to replace more expensive and complex PLC Designs.
•
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.
What is the Pump Boss? •
The Pump Boss is also an excellent local control station for pumps in a plant. It allows for remote start stop, 4-20 mA follower, alarm if pump/s fail and indication of pumps running.
•
W e 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 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 pumps 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.
Pump Boss Features Features
• Touch Button Dual Pump Control in One Box •
Local or Remote Control with Feed Verification
• Automatic Switchover • Proportional Dosing of chemical to a process signal • Multiple Timer Control Options • Feed Rate Totalizers • Event Based Automation
Pump Boss Features • 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.
Pump Boss Features •
Display: Eight (8) digit, 0.3 inch high alphanumeric red LED. Resolution +/- one digit.
•
Programming: Eight (8) panel pushbuttons allow programming and controller operation.
•
Readouts: 0-100%, GPH, Mils/Minute
•
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 dev ice)
•
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.
•
Enclosure: Polycarbonate, Grey NEMA-4X, IP-66
•
Size:
•
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 v ersion number is displayed during power-up sequence.
14.21” L-R
10" T-B
4.37" Depth
Pump Boss Features Features Choose BASIC OPERATION when: • You need to use timers to control your pump/s • You wish to use event based triggers like another pump starting or a change in a analog process variable. Choose ENHANCED OPERATION when : • You wish to meter chemical in proportion to a process flow • You require a combination of event based trigger and proportional flow • You are using a flow verification device with your pump • Your require auto switchover • You require a combination of timers and proportional flow
Pump Boss Features Inputs / Outputs External Inputs •
2 (Two) Flow Meter Inputs—One 4-20mA (TB203) & One Pulse (TB202)
•
2 ( Two) Remote 4-20mA—One for each Pump– Pump One (TB208)—Pump Two (TV209)
•
2 ( Two) Feed Verification -One for each Pump– Pump One (TB204)—Pump Two (TB205)
•
2 (Two) Contact Closures-One for each Pump– Pump One (TB206)—Pump Two (TB207) ( Interlock)
Control Outputs •
2 ( Two) Pump Speed Control Outputs 4-20mA—One for each Pump- Pump One (TB310) Pump Two (TB303)
•
2 ( Two) Pump Pulse Control Outputs — One for each Pump -Pump One (TB210) Pump Two (TB211)
•
2 (Two) Powered Relays -One for each Pump - Pump One (I201) Pump Two (1202)
Reporting Outputs •
2 ( Two) Pump Speed Outputs 4-20mA- One for each Pump-Pump One (TB302) Pump Two (TB304)
•
2 (Two) Pump Activ e Powered Relays—One for each Pump (I203 Pump one (I204) Pump Two
•
1 (One) Alarm Powered Relay ( I205)
Integrated Systems
Integrated Systems Introducing…..
• The Duplex Plus Series offers the ultimate in convenience and control options. With three series to choose from, users can select the design which best fits specific requirements. • Pumps offered as standards include the LMI 9 Series, Walchem EW Series and the Grundfos DME models. • All pump heads are PVDF for maximum flexibility of use. Other materials are available upon request.
• The 100 Series is the most basic model, using the powerful built-in pump controls. • The 200 Series integrates a simple, convenient local control panel. • The 300 Series integrates the newly designed Pump Boss, providing PLC like capabilities, without the PLC like price.
All systems include: • • • • • •
On– Board Calibration Assembly Single Suction/ Single Discharge Discharge Pressure Gauge Back Pressure Valves On-Board Power Receptacle Flush Ports These systems are pre-plumbed using CPVC piping and fittings and are pre-tested and deliv ered ready for use.
Duplex Plus 100 Series: Use Pump Face Controls The 100 series is the most version of the Duplex Plus Series. It integrates manually controlled chemical metering pumps from LMI, Walchem and Grundfos. All controls for the 100 Series are located on the pump face touch panels
Duplex Plus 200 Series: Add Pump Control Panel The 200 Series integrates a simple, convenient local control panel to provide dual pump HOA Switches and run light. This control box is linked to the most advanced microprocessor controlled chemical metering pumps from LMI, Walchem and Grundfos. The Series 200 Control panel can accept two 4-20mA inputs and remote dry contacts to control the pumps. This is an ideal for dosing programs which require chemical feed on remote contact or process control signal.
Add Controls Mounting Panel
Duplex Plus 300 Series: Add Pump Boss Controller The 300 Series integrates the newl y designed Pump Boss. This versatile multiuse controller allows the user to execute numerous complex dosing regimes without the extensive cost and complexity of a PLC. From a simple, timer dual biocide application to proportional feed based on a process variable, the unit is powerful enough, yet simple enough to easily implement any dosing regime.
Suction Assembly
Discharge Assembly
100 Series
200 Series
300 Series
Part Number
Part Number
Part Number
10GPD/140PSI
DP100-CV-L10
DP200-CV-L10
DP300-CV-L10
LMI
24GPD/110PSI
DP100-CV-L24
DP200-CV-L24
DP300-CV-L24
LMI
60GPD100PSI
DP100-CV-L60
DP200-CV-L60
DP300-CV-L60
LMI
96GPD/100PSI
DP100-CV-L96
DP200-CV-L96
DP300-CV-L96
Grundfos
15.9GPD/261PSI
DP100-CV-G16
DP200-CV-G16
DP300-CV-G16
Grundfos
47.5GPD/145PSI
DP100-CV-G47
DP200-CV-G47
DP300-CV-G47
Grundfos
76.8GPD/90PSI
DP100-CV-G77
DP200-CV-G77
DP300-CV-G77
Grundfos
117.6GPD/90PSI
DP100-CVG117
DP200-CV-G117
DP300-CV-G117
Walchem
14.4GPD/150PSI
DP100-CV-W14
DP200-CV-W14
DP300-CV-W14
Walchem
24GPD/105PSI
DP100-CV-W24
DP200-CV-W24
DP300-CV-W24
Walchem
55.2GPD/105PSI
DP100-CV-W55
DP200-CV-W55
DP300-CV-W55
Walchem
132GPD/150PSI
DP100-CVW132
DP200-CV-W132
DP300-CV-W132
Pump Type
Pump Capacity
LMI
Note1: CV = Viton O Rings - CE=EPDM O Rings Note2: If you require Auto Sw itch Over: Add SW to the end of the 300 Series part number. Example: DP300-CV-W14-SW
100 Series
200 Series
300 Series
PUMP BOSS
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