4501 Pump Station Monitor User Manual
Contents
1. Always use pump capaci by Use volume to find flows Uolume E et E of fi S425 Gal Set Capaci tu Pump ii 1223 Gem CHANGE O communis with direct link This display is selected by pressing UP or DOWN Noisy means the instrument will beep to get your attention when an alarm condition occurs This display lets you set the flow units Press UP or DOWN to select between G m MG D and Li s Gallons per Minute Million Gallons per Day and Liters per Second This display lets you set the volume units Press UP or DOWN to select between Gal MG Li and M3 Gallons Millions of Gallons Liters and Cubic Meters Additional flow and volume units can be programmed using Pumplink software This display means the inflow is calculated based on preset pump capacity In other words what goes out must have come in If you select this option you must enter the pump capacity for every combination of pumps including single pumps When you switch between this selection and Use Volume to Find Flows all the cumulative volumes are reset Press UP or DOWN to get to the other choice shown next This display means that you calculate inflow and outflow based on volumetric drawdown calculation If you select this option you must enter the volume between the start lead and stop level when the next display asks for it The algorithm is good for single pump operation only When using Use Volume t2. CHANGE Digital output 1i off CHANGE Analog ALG he output In f CHANGE Analog output Gti Ses CHANGE date formati mmddyy CHANGE month date Ari RI CHANGE binaria Lime 12515545 is displayed This display is used to test the inputs By default the instrument expects normally open connections which means not energized when not in operation If for any reason the connection that you have works the opposite way Pumplink software may be used to change them to normally closed Refer to Pumplink s help file for more infor mation To enter the instrument settings mode press SELECT until a new display appears To scroll in the settings displays press ENTER If a value must be entered press DOWN or UP to select it Press ENTER to accept the value set and get to the next display If you incorrectly change a setting you can return to the screen by pressing ENTER until you return to the screen Note that depending which setting must be changed it may be quicker to exit and re enter the settings mode and press ENTER until you return to the display This display lets you reset all the events in memory but not the settings It is useful after you have checked the instrument to make sure that all is operating properly with the pumps then you do the Events Reset Press UP and DOWN simultaneously until it says All Records Are Now Erased This display lets yo
3. charges both ways within the 48 contiguous United States if the instrument proves to be defective within 30 days of shipment Throughout the remainder of the warranty period the customer will pay to return the instrument to Teledyne Isco and Teledyne isco will pay surface transportation to return the repaired instrument to the customer Teledyne Isco will not pay air freight or customer s packing and crating charges This warranty does not cover loss damage or defects resulting from transportation between the customers facility and the repair facility Teledyne Isco limited warranty The warranty for any instrument is the one in effect on date of shipment The warranty period begins on the shipping date unless Teledyne Isco agrees in writing to a different date Excluded from this warranty are normal wear expendable items such as charts ribbon lamps tubing and glassware fittings and wetted parts of valves and damage due to corrosion misuse accident or lack of proper maintenance This warranty does not cover products not sold under the Teledyne Isco trademark or for which any other warranty is specifically stated No item may be returned for warranty service without a return authorization number issued by Teledyne Isco This warranty is expressly in lieu of all other warranties and obligations and Teledyne Isco specifically disclaims any warranty of merchantability or fitness for a particular purpose The warrantor is Tele
4. is HOT ACTIVE Max pump war for alarmi GEO Pump alarm is LATCHED Analog alarm is ACTIVE AHALOG ALARM IS LATCHEE 4501 Pump Station Monitor Section 3 Operation This display lets you set the actual minutes Press UP or DOWN to adjust the minutes This display lets you set the actual seconds Press UP or DOWN to adjust the seconds This display lets you specify if you want to start the timers ofthe pumps at zero or if you prefer to enter the values read off the control panel elapsed timers Press UP or DOWN to select between Timer Instrument zero and Timer Ctrl Panel elapsed timers This display appears if Timer Ctrl Panel is selected Press UP to increase the pump timer value or DOWN to decrease it by 4 10 Pressing and holding the arrow key will adjust the value at a faster rate This display gives you the choice of closing the digital alarm output based on abnormal pump capacity The capacity of the pump must have changed by more than a predetermined per centage next display for at least five times in a row not neces sarily five cycles in a row Press UP or DOWN to select between Not Active alarm not activated based on abnormal pump capacity and Active If Active the following screens will be dis played This display appears if Pump Alarm Is Active Press UP or DOWN to change the percentage in 1 steps The percentage rep resents the difference between the a
5. level in the appropriate section of the settings for the instrument The volumetric method must be used for the instrument to gen erate pump capacity alarms If you don t want to use the volu metric method but want to use preset pump capacity then don t forget to enter capacities for each pump More information on this is in section 3 3 This display shows the capacity of pumps 1 2 and 3 If you have selected Use Volume to Find Flows in the settings mode then the pump capacity is based on the last drawdown calculation If you have selected Always Use Pump Capacity in the Settings section then the pump capacity is the one entered in the Set Pump Capacity screen Press DOWN to scroll through each pump Only the single pumps are shown because only their capacity can be calculated if the volumetric method is used This display shows the operation time of the pumps Press DOWN to scroll through each pump and combination of pumps The 4501 will record pump operation even if the pump is oper ating only for 40t of a second something that control panel elapse timers can t do This is why it is possible to have a dif ference between them This is especially true for pumps having chattering relays This intermittent abnormal condition is seen in most pump stations and is usually how major problems begin This condition will deteriorate if nothing is done about the relay Power Fa GELS Hee AGERE 14117 AL
6. voltage should be carried out only when the power has been disconnected Figure 2 1 4501 in Portable Protective Enclosure 2 1 4501 Pump Station Monitor Section 2 Installation 2 2 Electrical Installation Ay WARNING Always remove power from the control panel before attempting any modification Ay WARNING Electrical connections should be made by qualified electrician Most control panels use the following color code for the wires e Green Ground e White Neutral e Black 120V AC also called Hot is always ON except when the Master Switch is OFF e Red Controlled live These lines can become live at any stage of the operation Always treat them as if they were live The terminal blocks on the back of the 4501 are removable These can be removed from the instrument while attaching the various wires and replaced after the wires have been inserted into the block and tightened The removable terminal blocks allow you to quickly remove and replace the 4501 If the instrument sees temporary use in several locations spare terminal blocks can be ordered from the factory to facilitate quick change outs at all locations See Appendix A for a listing of accessories When making the connections to the 4501 you may find that it s easiest to start with the lowest terminal blocks and work towards the top Connections to each of the terminal blocks are discussed in sections 2 3 through 2 5 2 3 Digital Inputs and
7. 240 VAC 50 to 60 Hz Includes external fuse holder with fuse May be connected to most international AC power systems with a user supplied power cord that is termi nated with a standard IEC 320 power connector 60 4504 063 4501 Interrogator Cable with Stereo Connector 6 ft con nects computer 9 pin serial connector to stereo connector on front of flow monitor LL 60 4504 058 4501 Interrogator Cable with 9 pin Connectors 6 ft con nects computer 9 pin serial port connector to 9 pin connector on back of flow monitor LL 60 4504 060 9 pin to 25 pin serial port adapter kit 60 4509 001 Terminal Connector 6 position Allows field wiring to remain in place when 4501 is removed from pump station 6 position for power supply input and two 4 to 20 mA outputs inflow and outtlow s Sees nee 60 4504 009 Terminal Connector 10 position Allows field wiring to remain in place when 4501 is removed from pump station 10 position for 8 analog imputs 60 4504 010 A 1 4501 Pump Station Monitor Appendix A Accessories A 2 Terminal Connectors 12 position Allows field wiring to remain in place when 4501 is removed from pump station 12 position for 3 pump inputs 4 additional digital inputs rain gauge etc and 2 relay outputs 60 4504 011 Current Clamp for one pump Used to connect a 4501 to a pump motor Current clamp attaches around a motor lead to sense current
8. 4501 Pump Station Monitor Installation and Operation Guide su TELEDYNE ISCO A Teledyne Technologies Company 60 4503 016 Copyright 2001 2005 All rights reserved Teledyne Isco Inc Revision H April 6 2011 Foreword This instruction manual is designed to help you gain a thorough understanding of the operation of the equipment Teledyne Isco recommends that you read this manual completely before placing the equipment in service Although Teledyne Isco designs reliability into all equipment there is always the possi bility of a malfunction This manual may help in diagnosing and repairing the malfunc tion If the problem persists call or e mail the Teledyne Isco Technical Service Department for assistance Simple difficulties can often be diagnosed over the phone If it is necessary to return the equipment to the factory for service please follow the shipping instructions provided by the Customer Service Department including the use of the Return Authorization Number specified Be sure to include a note describing the malfunction This will aid in the prompt repair and return of the equipment Teledyne Isco welcomes suggestions that would improve the information presented in this manual or enhance the operation of the equipment itself Teledyne Isco is continually improving its products and reserves the right to change product specifications replacement parts schematics and instruc tions without notice Co
9. GROUND PUMPI PUMP2 PUMP3 USER4 USERS USERS USER7 ALARM SAMPLER LowVotage ooaoooooeooae o 4 1 Connection may be Ground and or Neutral and or Negative depend ing on the application and electrical codes 2 Pump connections are to any source that changes state at the same time as the pumps The source can be 12 to 120 Volts AC or DC tapped from points such as starters timers relays or pilot lights 3 Atipping bucket rain gauge is depicted as a user input User inputs can be a variety of true false conditions such as High and Low Level alarms Intrusion interlocks or maintenance alarms 4 The alarm system requires a power source to drive your indicator of choice For example the power source may be 120 VAC from the con trol panel 5 A sampler or similar device can be paced by the 4501 Here the sam pler output is connected to the Teledyne Isco sampler s flow meter con nector pins A 12 VDC and C Flow Pulses In Figure 2 2 Typical Digital Connections 2 3 4501 Pump Station Monitor Section 2 Installation The electronics will detect change of state at lower voltage than 12 volts so it is important to check that you do not see a pump ON status X on the display when that pump is OFF Sometimes there is some residual elect
10. L PRESSURE 35 25 PSI Recorder PESOS from Dial Glee Inputs 12345075 EMERGE 4501 Pump Station Monitor Section 3 Operation causing the problem This condition should not affect the flow calculation unless major problems occur Pumplink software shows them as filtered events A chattering relay can deteriorate to the point where it won t start the pump any longer which means the same pump is always operating A chattering relay can also deteriorate to the point where its contacts melt which means the pump is oper ating until it burns itself out This display shows the number of starts of the pumps and the number of times each combination of pumps was used Press DOWN to scroll through each pump and combination of pumps This display shows the cumulative number of power failures and their cumulative time This display shows the optional analog inputs 1 All to 8 AI8 If the 4501 has not been configured with Teledyne Isco s Pumplink software the label and units of measure are blank its description By default the inputs will be displayed as a per centage between 0 and 5 volts or between 4 and 20 mA depending on the DIP switch setting for that analog channel If the 4501 has been configured with Pumplink the label and units of measure can be displayed with the value as shown in the next display This analog input display includes the label and units of measure that were set up using Pumpl
11. LER CURRENT 12vDC N FLOW euro Figure 2 3 Connecting a Single Current Clamp 2 5 4501 Pump Station Monitor Section 2 Installation 2 3 2 Digital Outputs The two digital outputs use dry form C SPDT contacts and are rated 300 mA 120 VAC The pump capacity alarms relay con tacts close when a pump capacity varies by more than 30 for a minimum of five cycles The variation of 30 is a default value suitable for most applications but can be changed to any per centage in 1 increments see Section 3 The sampler contacts are programmed Pumplink for Windows software to generate a one second pulse each time the preset volume is pumped out of the station 2 4 Power Supply and The power supply negative and positive must not be reversed If Analog Output you use the analog outputs the power supply positive must be on Terminals the first leftmost terminal AN CAUTION Always connect the power supply adapter leads to the 4501 terminal before plugging the adapter into the 120 VAC outlet This reduces the build up of surge by the power supply coil The terminals are from left to right 12 VDC 12 VDC Inflow 4 20 mA and 4 20 mA Outflow 4 20 mA and 4 20 mA refer to Figure 2 4 To connect an analog instrument on the analog outputs of the 4501 con
12. The digital inputs will work with AC and DC current It is pos Outputs Terminal sible to use AC and DC at the same time if the ground is used as the common The terminals are from left to right the ground or neutral or negative pump 1 pump 2 pump 3 user 4 to user 7 which can be used for level alarms maintenance time recording rain gauge intrusion etc pump capacity and analog input alarms contacts and sampler contacts The user inputs can be labeled using Pumplink software otherwise generic labels are used such as INPUT 4 Using the ground as the common instead of the neutral is prac tical because AC and DC of different voltages can be connected at the same time This can be useful when a rain gauge is connected at the same time as the pumps refer to Figure 2 2 The ground is also one of the easiest connections to find 2 2 4501 Pump Station Monitor Section 2 Installation M Note Using the ground as common for mixed voltages and polarities may not meet code requirements in some jurisdictions Consult code authority before making such an installation The instrument is made to record change of state of the digital inputs The voltage should be between 12 and 120 volts Any thing that changes condition at the same time as the pump such as starters lights or timers can be connected to the corre sponding pump input Digital Inputs Digital Outputs DIGITAL INPUTS 12T0120VOLTSDCORAC 0 3ARELAY CONTACTS
13. activity data is also stored in the 4501 memory By using drawdown calculations rather than manufacturers pump curves the Teledyne Isco Pump Station Monitor measures influent flow and pump capacity at most pump stations within 1 Pump activity is monitored to derive a cumulative volume daily volumes average inflow of the last cycle calculated outflow cumulative time and number of occurrences for power failures high and low level pump operating time and pump starts The flow rates and volumes can be calculated based on preset pump capacity or on a simple volumetric method The 4501 is extremely flexible Its multiple inputs and outputs can be configured to perform sewer flow monitoring and pump performance studies The 4501 can also become the central com ponent of a proactive pump maintenance program Other pos sible uses may include e monitor events from external sensors e activate alarms such as high levels or intrusion e pace a sampler to collect a flow proportioned sample e record data on a strip chart or circular chart recorder e activate a dialer to notify personnel when an alarm condition occurs The 4501 Pump Station Monitor is a sophisticated data logger It stores up to 29 000 events in battery backed memory Examples of events are pump start pump stop rain gauge pulse intrusion power failure etc If analog events are recorded fewer events will be recorded When the memory is full the data is over writte
14. bers e 60 5314 025 a single current clamp to monitor one pump e 60 5314 097 a pair of pre wired current clamps for monitoring two pumps e 60 5314 174 three pre wired current clamps for monitoring three pumps Current Clamp Installation A CAUTION Before attaching the current clamp disconnect and lock out power from the circuits that will be monitored 1 Attach the sensor around a single conductor to be moni tored Low lt 1 5 amps and high gt 200 amps current applications may require special installation If the current is less than 1 5 amps wrap conductor through the center hole and around the sensor body to pro duce multiple turns and increase current flow 2 4 4501 Pump Station Monitor Section 2 Installation Measured Current Actual Current x Number of turns If the current exceeds 200 amps select another conductor that powers a device at the same time the pump is pow ered M Note The current clamp should be placed around a single conductor 2 Connect one side of the sensor s terminal to the 4501 s 12 VDC power and the other terminal to the corresponding pump input on digital input terminal See Figure 2 3 The connections on the current clamp are not polarity sensi tive 3 Start the pump If the monitored conductor exceeds 1 5 amps the 4501 should indicate a Pump On status DIGITAL INPUTS 12T0120 VOLTSDCORAC 0 3ARELAY CONTACTS GROUND PUMPI PUMP2 PUNP3 USER4 USERS USER6 USER7 ALARM SAMP
15. dyne Isco Inc 4700 Superior Lincoln NE 68504 U S A This warranty applies to the USA and countries where Teledyne Isco Inc does not have an authorized dealer Customers in countries outside the USA where Teledyne Isco has an authorized dealer should contact their Teledyne Isco dealer for warranty service Before returning any instrument for repair please call fax or e mail the Teledyne Isco Service Department for instructions Many problems can often be diagnosed and corrected over the phone or by e mail without returning the instrument to the factory Instruments needing factory repair should be packed carefully and shipped to the attention of the service department Small non fragile items can be sent by insured parcel post PLEASE BE SURE TO ENCLOSE A NOTE EXPLAINING THE PROBLEM Teledyne Isco Inc Attention Repair Service 800 775 2965 lab instruments 866 298 6174 samplers amp flow meters Sales amp General Information 800 228 4373 USA amp Canada Shipping Address 4700 Superior Street Lincoln NE 68504 USA Mailing Address Teledyne Isco Inc PO Box 82531 Lincoln NE 68501 USA Phone Repair service Fax 402 465 3001 Email IscoService teledyne com March 8 2011 P N 60 1002 040 Rev E A Teledyne Technologies Company NN TELEDYNE ISCO
16. e and reassemble the 4501 4501 Pump Station Monitor Section 4 Maintenance 4 3 Troubleshooting The following table list symptoms and possible causes A A WARNING Troubleshooting should be performed by a trained technician The following procedures are performed while power is applied to the 4501 Although lethal voltages do not exist on the input power and analog output terminals dangerous voltages may be present on the analog or digital channels and nearby terminals on the pump station control panel Symptom Possible Cause Nothing appears on the display Power supply not connected Power supply wires not well connected to terminal Fuse blown or missing No power at AC voltage receptacle Turn display brightness adjustment pot clockwise The 4501 will not download data Communication settings on incorrect mode direct modem or external modem Instrument was not powered off after change in communication settings The so called Null modem cable is not really a null modem cable When one pump goes ON Use a voltmeter to check voltage between the ground and the OFF pump see an X on another pump when another pump in ON it should be near 0 volts If it is not check to see that the ground is indeed solidly grounded Try the neutral common and retry Call the electrician and ask them how to correct the problem It is a com mon but abnormal condition do not have the same voltage on Use the ground as the commo
17. ection ili di 3 8 3 5 1 Interrogator Cable oo ooooooooororrrrr een n nes 3 9 3 5 2 Optional Internal Modem 3 10 Section 4 Maintenance 4 1 Hardware Settings a ie an aa See TRI 4 1 4 1 1 Display Brightness LL 4 1 4 1 2 Analog Output Adjustments 0 0 ccc eee eens 4 1 4 1 3 DIP Switches ooo ti We rc sch 4 2 4 2 Fuse Replacement 4 2 4 3 Troubleshooting 28 2 ersehen 4 3 4 4 Advanced Troubleshooting ooooooooorrrrrrr een 4 3 Appendix A Accessories Al Accessories Lists 2 ii A A ea A 1 List of Figures 1 1 Model 4501 Pump Station Monitor L eens 1 2 vi 1 2 2 1 2 2 2 3 2 5 3 1 3 2 4 1 1 1 Rear View Connectors 1 3 4501 in Portable Protective Enclosure 0 0c cece eee e tenes 2 1 Typical Digital Connections 2 3 Connecting a Single Current Clamp 0 0 c cece eee nee eee 2 5 Power Supply and Analog Output Connections naseer eee eee 2 6 Analog Input Examples 2 7 Communication Port Connectors LL 3 8 Cable Configurations LL 3 9 Location of Pots and Dip Switches 0 cece cece eee nee 4 1 List of Tables 4501 Pump Station Monitor Specifications LL 1 4 General Warnings Hazard Severity Levels 4501 Pump Station Monitor Safety Before installing operating or maintaining this equipment it is imperative that all hazards and preventive measures are fully understood Whi
18. ee seconds Press ENTER until the 4501 displays the CHANGE Analog output screen Press the UP button until the displayed percentage reads 100 5 Adjust the left potentiometer of the pair to read 5 volts when the analog output display reads 100 6 Press the DOWN button until the displayed percentage reads 0 7 Adjust the right potentiometer of the pair to read 1 volt when the analog output display reads 0 These steps can be repeated for the other analog output channel The DIP switches on the left side of the unit are only used when changing the internal software of the instrument Otherwise the two DIP switches should always be OFF If you receive new software for the instrument the steps to follow to program the instrument will be included with the software documentation The 4501 has internal fuses to protect its circuits from errant digital input signals If blown the 120mA board mounted fuses can be replaced A A WARNING Fuse replacement should only be performed by a trained service technician A AN WARNING Live electrical circuits may cause personal injury or death from electrical shock or may cause fire or equipment damage Disconnect the instrument from mains power and all input outputs before servicing the internal fuses Disconnect power supply Disconnect the terminal blocks Remove back cover by carefully prying it off Remove the second board from top Ot e dea Replace the blown fus
19. flows up to 200 amps Monitors the current of a single pump Requires 12 VDC power which may be available from a 4501 power supply not included 60 5314 025 Current Clamps for two pumps Includes two current clamps and a 4501 power supply Factory wired so that installation only requires plugging into AC power and connecting current clamps to the conductors LL 60 5314 097 Current Clamps for three pumps Includes three current clamps and a 4501 power supply Factory wired so that instal lation only requires plugging into AC power and connecting current clamps to the conductors 60 5314 174 4501 Instruction Manual 60 4503 016 Portable Protective Enclosure A lockable enclosure with internal wiring and overload protection for the 4501 Available in portable and fixed installation configurations CALL Teledyne Isco One Year Limited Warranty Factory Service for Teledyne Isco Flow Meters Waste Water Samplers and Syringe Pumps This warranty exclusively covers instruments providing a one year covering parts and labor Any instrument that fails during the warranty period due to faulty parts or workmanship will be repaired at the factory at no charge to the customer Teledyne Isco s exclusive liability is limited to repair or replacement of defective instruments Teledyne Isco is not liable for consequential damages Teledyne Isco will pay surface transportation
20. gnal Ready NOT USED RTS Request To Send NOT USED CTS Clear To Send NOT USED RI Ring Indicator NOT USED O O0 J O OI A O0O N Figure 3 2 Cable Configurations 3 9 4501 Pump Station Monitor Section 3 Operation 3 10 3 5 2 Optional Internal Modem The internal modem lets the 4501 transmit and receive data over phone lines It is auto answer and operates at 2400 baud Pumplink has all the modem communication functions built in and instructions on how to use it The only thing required is the standard telephone cable usually found between the telephone and the wall The communication cable and the modem are the only means of setting the analog inputs the sampler output and some alarm parameters If the 4501 has a firmware version less than 1 22 it must be updated to at least 1 22 for successful communication with an internal modem 4501 Pump Station Monitor Section 4 Maintenance 4 1 Hardware Settings The analog outputs and the display brightness are factory set However if there is a later need to readjust these settings they can be calibrated with the potentiometers on the left side of the 4501 Refer to Figure 4 1 Calibration procedures are described in the following sections 4 N WARNING Adjustments should be performed by a trained technician The following procedures are performed while power is applied to the 4501 Although lethal voltages do not exist onthe input power and analog outputterm
21. in wet well measurements 1 4 4501 Pump Station Monitor Section 2 Installation 2 1 Physical Installation A 1 4 DIN square hole size 35 8 x 3 s 92mm x 92 mm should be cut in the control panel front door Six inches 153 mm of free space behind the panel must be available If the only space available to you is six inches or 153 mm it would be prudent to put some electrical insulation behind the connectors The screw type brackets slide into place from front to rear after the unit is inserted in place M Note Never install the unit closer than one foot from the pump s starters Microprocessor based instruments can be affected by strong magnetic fields 2 1 1 Optional Portable If mounting the 4501 in a control panel is not practical for your Protective Enclosure application the 4501 can be ordered in a portable protective enclosure This lockable enclosure includes internal wiring that provides overload protection for the 4501 It is available in por table and fixed installation configurations Contact the factory for ordering information WARNING HAZARD of ELECTROCUTION AC line voltage is present on terminals inside this enclosure Disconnect power before opening case or front panel or before servicing To avoid electrical shock installation and service should be done by qualified personnel Incorrect handling of the 115 230 VAC power supply can kill you For this reason service of components subject to high
22. inals dangerous voltages may be present on the analog or digital channels and nearby terminals on the pump station control panel Display Brightness Front 00 0 ll VW 7 Outflow Inflow DIP Analog Analog Switches Output Output oN Figure 4 1 Location of Pots and Dip Switches 4 1 1 Display Brightness 4 1 2 Analog Output Adjustments The display brightness can be set with a miniature screwdriver The adjustment potentiometer is located in the hole on the left side of the instrument closest to the front Adjust the potenti ometer for the desired brightness The analog outputs are factory adjusted but can be recalibrated The four holes on the left side of the 4501 housing are for adjusting the analog outputs To calibrate 1 Remove existing wiring from the terminals of the output channel to be adjusted 2 Install a 250 ohm resistor between the and terminals of the analog output to be adjusted 4 1 4501 Pump Station Monitor Section 4 Maintenance CHANGE Analog output Quii 166 CHANGE Analog output Quill Bees 4 1 3 DIP Switches 4 2 Fuse Replacement To replace the fuse 4 2 M Note Each output Outflow and Inflow channel has a pair of potenti ometers Refer to Figure 4 1 for the correct location of the pairs 3 Connect a voltmeter across the and terminals 4 Access the settings mode by pressing SELECT for thr
23. ink In addition to labeling the inputs the linear input scale and the displayed range of values can be set For example if a pressure sensor reads 50 PSI at a full scale voltage of 2 0 volts the input range 0 to 100 can be modified to 0 to 2 volts and the displayed range can be set to read from 0 to 50 PSI M Note The precision used to record the input is 8 bits Eight bits means a precision of 1 256 or 99 6 Most applications will not require higher accuracy because the sensors connected to the input or their installation do not permit accuracy higher than 99 6 Refer to Pumplink s help file for more information on Instrument Settings and the Item gt Program Instrument function This display shows daily volume of the last eight days or since last reset with the date and volume units Press DOWN to scroll through the past days and to get to the next display This display shows the number of records in memory and the date and time of the first record The first in first out condition makes the date and time change when the memory is full This display shows the status of the seven digital inputs which are Pump 1 Pump 2 Pump 3 User 4 to 7 When the input is not energized a 0 is displayed When the input is energized an X 3 3 4501 Pump Station Monitor Section 3 Operation 3 3 Instrument Settings 3 4 Preps both arrow for events RESET Press both arrow for TOTAL RESET
24. ive cycles in a row Pressing a key resets the alarm condition and clears the screen 3 1 4501 Pump Station Monitor Section 3 Operation date Lime Hoc 154007 11251227 Aris 11252 Gal F Uolume ido Trifle Ok flo cm LA a fi f4 36 Capacity Pump i 125 12 Gem Pump Hee i Goasi zziiz 3 2 This display shows the actual date and time Ifthe time is wrong the events will be recorded with the wrong time To correct this enter the instrument settings mode It is recommended that you do an Event Reset or Total Reset after changing the date This display shows volume units and cumulative volume since the reset of the instrument The instrument uses a very simple algorithm to calculate volumes and flows Pumplink software uses the full power of a computer to calculate volumes and flows Therefore you will not see the same results on both the software and the instrument M Note If the instrument is used for billing purposes we strongly sug gest using Pumplink software This display shows the average inflow of the last cycle and the pump capacity of the pumps in operation The inflow is calcu lated using the preset or calculated pump capacities You must enter a pump capacity for every combination of pumps used in the station If you want the instrument to calculate the flow in and out using a volumetric method then you need to enter the volume between lead and stop
25. le specific hazards may vary according to location and application take heed in the following general warnings A WARNING Avoid hazardous practices If you use this instrument in any way not specified in this manual the protection provided by the instrument may be impaired A AVERTISSEMENT Eviter les usages p rilleux Si vous utilisez cet instrument d une mani re autre que celles qui sont specifi es dans ce manuel la protection fournie de l instrument peut tre affaiblie cela augmentera votre risque de blessure This manual applies Hazard Severity Levels to the safety alerts These three levels are described in the sample alerts below N CAUTION Cautions identify a potential hazard which if not avoided may result in minor or moderate injury This category can also warn you of unsafe practices or conditions that may cause property damage AN WARNING Warnings identify a potentially hazardous condition which if not avoided could result in death or serious injury DANGER DANGER limited to the most extreme situations to identify an imminent hazard which if not avoided will result in death or serious injury vi 4501 Pump Station Monitor Safety Hazard Symbols Warnings and Cautions gt gt The equipment and this manual use symbols used to warn of hazards The symbols are explained below Hazard Symbols The exclamation point within the triangle is a warning sign alerting you of important i
26. liquid crystal 2 lines x 16 characters Keypad Membrane 4 position Pump inputs 3 rated 12 to 120V AC or DC Inputs may be anything that changes state when the pumps are activated Digital Inputs 4 rated 12 to 120V AC or DC Data Storage Memory Capacity 29 000 events maximum Storage Mode Rollover Data Retrieval Direct RS 232 connection optional internal modem Data Analysis Teledyne Isco Pumplink for Windows Software Battery Back up Life 10 year internal battery life expectancy protecting program and data storage memory Typical Accuracy 4501 Monitor 1 totalized flow 8 cycle to cycle Pumplink Software 1 totalized flow 5 cycle to cycle Relay Outputs 2 normally open rated 1 A at 30 V DC or 0 3 A at 125 VAC one proportional to outflow one activated based on minimum and maximum analog inputs and abnormal pump capacity Analog Outputs 2 proportional to inflow and outflow rates 4 to 20 mA into a maximum of 400 ohms Operating Temperature 0 to 140 F 18 to 60 C Storage Temperature 40 to 140 F 40 to 60 C Available Options e Universal AC input 120 to 240 VAC 50 to 60 Hz Power Supply e Analog Inputs 8 single ended mixed with 4 differential individually select able 4 to 20 mA or 0 to 5 V e Internal 2400 baud auto answer telephone modem e Fixed site portable protective enclosure with power supply and 9 pin stereo interrogator cable Does not include errors
27. mory records events such as pump start or stop high level rain gauge pulse power failure analog inputs etc When the memory is full the newest infor mation is written over the oldest It is called first in first out or roll over mode The 4501 starts to record when it is powered This means you could connect the 4501 and leave it there without touching the keyboard and it would record the events anyway 3 7 4501 Pump Station Monitor Section 3 Operation What do 29 000 events signify If you had a pump station with an average pumping cycle of 20 minutes 10 minutes during the day and 30 minutes at night you would then be able to record about six months data You might never need this data but if you suspect that some thing unusual is going on at the pump station the 4501 will have the last few months in its memory Of course if you use Pumplink software this data is required The instructions on how to retrieve the information from the 4501 is in the Pumplink help file 3 5 Data Collection When using the Data Logger feature of the Pump Station Monitor the stored data must be retrieved from the unit This data can then be processed and viewed with Pumplink Data can be collected with an RS 232 connection via an Interrogator Cable or the optional modem and PC Card Pumplink for Windows To read the station file from a PC Card or to communicate directly with the 4501 Pumplink must first be configured properly The setti
28. n This way you can connect 12 VDC with all my inputs 120 VAC without any problem See section 2 3 4 4 Advanced We recommend that the unit be returned to an approved service Troubleshooting facility for servicing beyond what is covered in this instruction manual At times advanced diagnostic and calibration tools are necessary to properly service the instrument However If you need technical assistance with a Teledyne Isco Product consult with Teledyne Isco s Technical Service Department Often a problem can be solved in the field with just a little extra help Contact information can be found at the front of this manual 4 3 4501 Pump Station Monitor Section 4 Maintenance 4 4 4501 Pump Station Monitor Appendix A Accessories A 1 Accessories List Accessories can be purchased by contacting Teledyne Isco s Cus tomer Service Department Contact information can be found at the front of this manual Pumplink Software for Windows Single License Used to program the 4501 Pump Station Monitor Software also retrieves data and for storage and analysis Presents data in graphs or tables ss Nias 60 4504 003 Power Supply for 4501 Pump Station Monitor Universal AC input 100 to 240 VAC 50 to 60 Hz Includes external fuse holder with fuse Supplied with a 120V grounded AC power cord suitable for most North American users 68 4500 018 Power Supply for 4501 Pump Station Monitor Universal AC input 100 to
29. n as first in first out commonly called roll over mode Optional Teledyne Isco Pumplink software can be used to retrieve and analyze the stored data Retrieved data may be used for e detailed billing e inflow and infiltration I amp I studies e analyzing events logged by external sensors e detailed analysis of pump station performance 1 1 4501 Pump Station Monitor Section 1 Introduction Data Retrieval Pumplink software also allows you to assign labels to the data recorded on the user inputs program the 4501 to pace a sampler and can be used to update the 4501 firmware Basic configurations of the 4501 allow data retrieval through a direct serial RS 232 connection For convenience a serial port is available on the front panel permanent installations may opt to use the rear panel DB 9 connection instead Other configurations add a telephone modem to the standard RS 232 data transfer methods Pump Station Monitor Ave J Figure 1 1 Model 4501 Pump Station Monitor 1 1 1 Instrument Features Standard size DIN enclosure for easy installation Alphanumeric display for easy to read and easy to understand data Clear plastic splash proof cover to protect the display keyboard RS 232 connector and PC Card slot Seven digital inputs three pumps and four user inputs rain gauge high level intrusion etc Two digital outputs open collector fo
30. nect the and from the instrument to the and of the 4501 If the analog instrument uses 0 5 VDC connect a 250 ohm resistor between the and 2 a 2 gt 3 e 2 S o o a z 2VDC NFLOW loyrrLow li SUPPLY W CHART RECORDER Figure 2 4 Power Supply and Analog Output Connections 2 6 2 5 Analog Inputs optional Flow Meter Figure 2 5 Analog Input Examples Differential Analog Inputs 2 5 1 Labeling Analog Input Data 4501 Pump Station Monitor Section 2 Installation The analog inputs option provides eight analog inputs They can be a mix of 4 20 mA and 0 5 Volts DIP switches are used to select between Volts and mA The ON position will be clearly labeled on the DIP switch e DIP switch ON 4 20 mA e DIP switch OFF 0 5 Volts Only one terminal is provided for a common which means all inputs must have the same common Figure 2 5 shows an example of some possible analog input connections ANALOG INPUTS DIP SWITCH OFF 1 6V ON 4 20mA 1 2 3 4 5 6 7 UNUSED COMMON ON Magnetic Flow Meter Pressure Transducer When using the four differential inputs the DIP switches must be OFF If con
31. necting differential inputs the input terminal pairs are 1 2 3 4 5 6 7 8 and note that the COMMON input is not used If the pair of differential inputs is a 4 20 mA signal install a 250 ohm resistor between the two terminals where the 4 20 mA current loop wires are connected By default analog input data is undefined That is the 4501 stores and displays the analog input as a percentage of the selected range without a descriptive label and measurement units For example ifthe input voltage was 3 volts the displayed and stored value would be 60 of the 0 to 5 volt scale Optional Pumplink software can be used to define the input scale the displayed readings scale descriptive labels and mea surement units Refer to Pumplink s help file for more infor mation 2 7 4501 Pump Station Monitor Section 2 Installation 2 8 4501 Pump Station Monitor Section 3 Operation 3 1 Using the Instrument THITIALIZATION Version 1 22 For SETUP Press SELECT E seconda 3 2 Instrument Displays ALARM ALARM Scrolling messag The basic parameters needed by the 4501 in order to calculate volume and inflow are the pump capacities for each combination of pumps and the volume between the lead and stop level if single pump capacities are calculated on site If you want the 4501 to log the data properly the correct date and time must be programmed It is highly recommended that you do an E
32. ngs are located on the Station Communication tab of Pumplink s Instrument Setup window e RS 232 communication should use the Link using COM X option where X is the COM port of the serial port in use e To read a file transferred from a PC Card use the Read Raw Data from file option e To communicate via telephone modem select the Link using Modem option The modem option will also require a telephone number to be entered Front Back ON 9 El Serial Port DB 9 Serial Port Internal Modem Port Figure 3 1 Communication Port Connectors 3 8 4501 Pump Station Monitor Section 3 Operation 3 5 1 Interrogator Cable The interrogator cable can be used to download the data from the 4501 into Pumplink You cannot use the front and the rear connector simultane ously They are connected to the same internal serial port Doing so could damage the equipment M Note The interrogator cable and the modem are the only means of setting the analog inputs the sampler output and some alarm parameters MA e 5 1 m MA al JE SE Os 97 Og O a CD Carrier Detect NOT USED RX Receive data TX Transmit data DTR Data Terminal Ready NOT USED Ground DSR Data Si
33. nstructions in the instrument s technical reference manual The lightning flash and arrowhead within the triangle is a warning sign alert ing you of dangerous voltage inside the product Symboles de s curit Ce symbole signale l existence d instructions importantes relatives au produit dans ce manuel A A Ce symbole signale la pr sence d un danger d lectocution Warnungen und Vorsichtshinweise Das Ausrufezeichen in Dreieck ist ein Warnzeichen das Sie darauf aufmerksam macht daB wichtige Anleitungen zu diesem Handbuch geh ren gt gt Advertencias y Precauciones Der gepfeilte Blitz im Dreieck ist ein Warnzeichen das Sei vor gef hrlichen Spannungen im Inneren des Produkts warnt Esta se al le advierte sobre la importancia de las instrucciones del manual que acompa an a este producto gt gt viii Esta se al alerta sobre la presencia de alto voltaje en el interior del producto 4501 Pump Station Monitor Section 1 Introduction 1 1 Overview Displayed Readings Applications Extended Features The 4501 Pump Station Monitor monitors the operation of single speed pumps at the pump station as the wet well cycles between full and empty Combining this information with the known volume between the levels in the wet well the 4501 uses patented algorithms to calculate the flow into and out of the pump station and the pumping rate of each pump Pump
34. ntact Information Customer Service Phone 800 228 4373 USA Canada Mexico 402 464 0231 Outside North America Fax 402 465 3022 Email IscoCSR teledyne com Technical Support Phone 800 775 2965 Analytical 866 298 6174 Samplers and Flow Meters Email IscoService teledyne com Return equipment to 4700 Superior Street Lincoln NE 68504 1398 Other Correspondence Mail to P O Box 82531 Lincoln NE 68501 2531 Email IscoInfo teledyne com Web site www isco com Revised March 17 2009 4501 Pump Station Monitor Table of Contents Section 1 Introduction A A EEA a Ss 1 1 1 1 1 Instrument Features sisis e reen re E nee ER 1 2 Section 2 Installation 2 1 Physical Installation 2 1 2 1 1 Optional Portable Protective Enclosure oooooooooomo o 2 1 2 2 Electrical Installation 2 2 2 3 Digital Inputs and Outputs Terminal 0 0 oo 2 2 2 3 1 Current Clamps soin a bee 2 4 232 Digital Outputs oo kin etn a ees 2 6 2 4 Power Supply and Analog Output Terminals LL 2 6 2 5 Analog Inputs optional 0 0 tenet eens 2 7 2 5 1 Labeling Analog Input Data 0 0 ccc ee eens 2 7 Section 3 Operation 3 1 Using the Instrument 3 1 3 2 Instrument Displays 3 1 3 3 Instrument Settings 3 4 3 4 Pump Station Monitor Operation 3 7 3 4 1 Where the Values Come from in the Instrument 3 7 34 2 The Data logger uaar iaia RN ana pi 3 7 3 5 Data Coll
35. o Find Flows you must enter the capacity for each pump combination The algorithm assumes that the pumps can alternate In their single operation they start at the same level and stop at the same level If your station operates differently select Always Use Pump Capacity When you switch between this selection and Always Use Pump Capacity all the cumulative volumes are reset Press UP or DOWN to get to the other choice shown previously If Use Volume to Find Flows is selected you must enter a volume between the start level lead and stop level Press UP to increase the volume or DOWN to decrease it This display lets you set the outflow for each pump and combi nation of pumps This display lets you set the type of communication between the instrument and your computer Press UP or DOWN to select between With Direct Link RS 232 With Ext Modem external modem and Through Modem internal modem The external modem option only applies to European applications 3 4 Pump Station Monitor Operation 3 4 1 Where the Values Come from in the Instrument 3 4 2 The Data logger 4501 Pump Station Monitor Section 3 Operation M Note You must shut the power off for at least five seconds after changing the communication configuration for the hardware to be reset to the new configuration M Note This section discusses the Pump Station Monitor operation and its calculation of values lt does not discuss the higher accuracy calc
36. r alarms and sampler Two analog outputs proportional to outflow and inflow for telemetry system sampler or chart recorder Front RS 232 serial port for fast and easy access Rear RS 232 serial port for permanent installation Optional eight analog inputs 4 20 mA 0 5 VDC DIP switch selectable pressure temperature level etc Optional built in 2400 baud auto answer modem 4501 Pump Station Monitor Section 1 Introduction S f N INFLOW OUTFLOW I 12VDC NFLOW ro 00000 H MH Ol HEHHE DIGITAL INPUTS 12TO120VOLTSDCORAC 0 3 A RELAY CONTACTS GROUND PUMPI PUMP2 PUMPS USER4 USERS USERG USER7 ALARM SAMPLER ae en A ba ON 4 20mA UNUSED COMMON EERBERBERA Era 000000000 y 1 RS 232 Serial Port 2 Optional Internal Modem Connection USOC RJ11C 3 12 VDC Power and 4 20 mA Analog Outputs 4 Pump and User Digital Inputs 5 Analog Inputs optional 6 DIP Switches to configure Analog Inputs optional Figure 1 2 Rear View Connectors 1 3 4501 Pump Station Monitor Section 1 Introduction Table 1 1 4501 Pump Station Monitor Specifications Size H x W x D 3 75 x 3 75 x 7 1 in 9 5 x 9 5 x 18 1 cm Weight 1 4 Ib 0 63 kg Material Polyphenylene Oxide Power 12 VDC 250 mA Program Memory Battery backed RAM can be updated via interrogator port without opening the enclosure Display Backlit
37. ricity even when pumps are off It is not normal but it is common The residual voltage is usually too low to create a short term major problem with the electrical system but it could badly influence the events recorded by the 4501 Residual voltage is usually lower than 10 volts When this con dition occurs test the voltage between the questionable input and the common usually the ground If you measure higher than one volt check between the input and the neutral If you still show voltage and you are sure that you see a significant change of voltage on a volt meter when the pumps are turned on ask an electrician to correct the problem It is an abnormal con dition that should be corrected If a residual voltage is always present insert relays into the electrical system and use their contacts to obtain the same type of input 2 3 1 Current Clamps The optional current clamps are the fastest and safest way to connect the 4501 to a pump station control panel The adjustable set point and status LED make installation very easy Being directly connected without current sensor gives faster electrical response to the 4501 in case of chattering relays A WARNING Status indicators of this device should not be relied on to determine whether or not the monitored conductor is energized Doing so may result in injury or death from electrical shock The optional current clamps are available from Teledyne Isco under the following part num
38. u do a Total Reset of all events and settings except the date and time Press UP and DOWN simultaneously until it says Complete Reset Done This display lets you manually change the state of the two digital outputs for testing Press UP or DOWN to change the status of the output This is useful to test equipment connected to the instrument This display lets you manually change the value of the two analog inputs for testing Press UP to increase by 10 the value of the output and press DOWN to decrease the value by 10 This is useful to test equipment connected to the instrument This display lets you manually change the value of the two analog outputs for testing Press UP to increase by 10 the value of the output and press DOWN to decrease the value by 10 This is useful to test equipment connected to the instrument This display lets you set the hour format Press UP or DOWN to select between mm dd yy and dd mm yy This display lets you set the month Press UP or DOWN to adjust the month This display lets you set the day of the month Press UP or DOWN to adjust the day This display lets you set the year Press UP or DOWN to adjust the year This display lets you set the hour using the 24 hour format Press UP or DOWN to adjust the hour CHANGE minutes Lime T2 16112 CHANGE seconds Lime 12 16 00 arrow fo change TIMER IMSTEUMENT Charge timer for pump di 3425 7 Pump alarm
39. ulations that Pumplink software can offer If greater accuracy is necessary for your application you must use the Pumplink software Refer to Pumplink s help file for more information When an event occurs the time of occurrence the description and the value of the event are recorded e The cumulative number of occurrences is updated e Ifa preset low or a high limit is reached the alarm output is closed e The analog output proportional to outflow is calculated and activated e At the end of a cycle when all pumps stop an average inflow is calculated for the cycle based on the liquid that went through the station calculated from the pump capacity e The analog output proportional to inflow is calculated and activated e Every second the time of operation is updated e Every second the total and sampler cumulative volumes are updated based on the pump s capacity e Every second the display is updated e Each time the sampler s volume is reached a one second pulse is generated on the digital output SAMPLER The data logging capacity of the 4501 is a feature that you might never need or use because many customers find the displayed information of the instrument enough for their needs However data logging is there and active should you need it It could be extremely valuable especially at start up time to check the oper ation of a newly updated or newly built pump station The 4501 in its battery backed me
40. vent Reset or Total Reset after changing the date If you leave an event recorded with the wrong date like a power ON you will get blank reports for the time between the wrong date and the right date If you already preprogrammed settings in the instrument use the Event Reset The unit has two modes e Regular mode is used to display the results on the LCD screen e Instrument Settings mode is used to give the necessary parameters for the unit to process the data properly After powering the instrument this display appears momen tarily This is the only way to read the instrument internal software version This display is to remind you that you can access the 4501 Instrument Settings screens from any normal mode screen by pressing SELECT for three seconds Note that pressing SELECT a second time will exit the settings mode and return the 4501 to the regular mode To scroll to the following display press DOWN To scroll back to the previous display press UP This is a scrolling message displayed only when one or more alarms occur related to the analog inputs and or to major pump capacity variations A message having both alarms would be Analog inputs in alarm 3 4 Pumps in alarms 2 Press any key to reset every alarm This message means e A lower than minimum and or higher than maximum values were read on the analog inputs number 3 and 4 and e Pump number 2 capacity changed by more than 30 for more than f
41. verage pump capacity calcu lated over many cycles and updated every cycle and the last drawdown calculation This display shows if Pump Alarm Is Active Press UP or DOWN to select between Latched and Toggle Latched means the alarms will stay on until you press a key locking Toggle means the alarm will go off automatically if the pump goes back to its normal capacity non locking This display gives you the choice of closing the digital alarm output based on minimum and maximum values reached and set through Pumplink software Press UP or DOWN to select between Not Active alarm not activated based on analog input readings and Active If Active the following screens will be dis played Note that Pumplink can configure the 4501 to activate the alarm output for multiple conditions Conditions may include the Max Pump Var and any user defined parameters that are exceeded by an analog input The alarm is activated when any one of the conditions are true This display appears if Analog Alarm Is Active Press UP or DOWN to select between Latched and Toggle Latched means the alarms will stay on until you press a key Toggle means the alarm will go off automatically ifthe analog inputs read higher than the minimum and lower than the maximum set through Pumplink software 3 5 4501 Pump Station Monitor Section 3 Operation Alarme are HOISY Heasuring units Flow MG D Measuring units Uolume Gal
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