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LC USER MANUAL - Ingram Products

1. Each detector consists of a comparator that includes a hysteresis calculation If the input level is at or above the user defined threshold ON level the comparator output will be active If the input level is below the user defined threshold OFF level the comparator output will be inactive The hysteresis levels are typically set 0 25 below the threshold level Comparator Output Hysteresis To avoid sporadic or false triggering a dual timer is used for each threshold that verifies the comparator output remains constant for a user defined time referred to as the THRESHOLD ON and THRESHOLD OFF time When the comparator is turned on it must remain on for the specified ON time When it turns off it must remain off for the specified OFF time 37 74 Rev 1 02 Chapter 4 DUPLEX CONTROLLER The Over Current Error and the Under Current Error are latched and can only be cleared by setting the Reset Error state to non zero Phase Error Contact The Phase Error contact input is connected to an external Phase Error relay contact to ensure that no phase errors occur The sense of the contact may be configured as Normally Open NO or Normally Closed NC Failure to close will be treated as an Phase Error Error Phase monitoring occurs after the specified Pump Start Delay time The Phase Error Time ON determines the maximum time for external Phase Error relay contact to close after the Pump Start Delay time and is typica
2. Update Rate value The following table provides a estimate of the time required to update each panel which depends on the amount of data displayed by the panel Control Panel Time System Panel 80 msec Level Panel 80 msec Flow Panel 150 msec Pump Panels each 80 msec Air Pump Panels each 80 msec 64 74 Rev 1 02 Chapter 9 LC Config Utility If all panels are activated for update it requires 650 msec for the entire update process Individual panels may be selected for updating by checking the Auto Update box immediately below the panel If a panel is selected for Auto Update the master Auto Update control will be enabled Pause Update The Pause Update button temporarily suspends the Auto Update function Update Rate The update rate is specified in seconds and should be selected to allow sufficient time for all control panels sub panels and the simulator to update the required data Setting an update rate too low fast will cause sluggish reactions to the mouse and keyboard since the system is loaded updating the controls Main Menu Options Menu Item Sub Menu Sub Menu Description File Open Opens and loads a system configuration file Save Saves the current configuration file Save As Saves the current configuration file under a new name Printer Setup Establishes parameters to be used when printing reports Print Preview
3. v Auto Step if enabled Simulator Step Rate 2 000 Reset Level 15 000 Rev 1 02 Chapter 9 LC Config Utility Configuration Each of the configuration screens allow setting the machine configuration as discussed in the associated chapters Project The project screen allows defining project specific parameters al Project Configuration 0 03 8 23 2012 8 23 2012 Pump 1 Serial Number 0 Pump 1 Install Date N 8 23 2012 Joe Plumber Pump 1 Auxiliary Info 0 j Anytown USA Pump 2 Serial Number 0 j 0 Pump 2 Install Date n 8 23 2012 Location Install Date N 8 23 2012 Pump 2 Auxiliary Info 0 Location Auxiliary Info 0 Air Pumps Edit Entri Air Pump 1 Serial Number SystemSerialNum Air Pump 1 Install Date N 8 23 2012 Name Comments Air Pump 2 Serial Number 0 Air Pump 2 install Date N 8 23 2012 rr AR il Air Pump 2 Auxiliary Info 0 All of the fields entered are used as information only fields and do not affect the operation of the LC controller The information is stored as part of the configuration file as well as on the device The project information is grouped into 4 major sections The System Pump and Air Pump section each include 3 fields a user assigned serial number up to 9 digits a user assigned date of installation and an optional Auxiliary Info field that will accept a value from 0 65535 70 74 Rev 1 02 Chapter 9 LC Config Utility The
4. Chapter 6 BUBBLER SYSTEM Air Pump Run Times The Air Pump 1 and Air Pump 2 Run Time parameters determine how long each air pump operates before switching to the alternate air pump In Mode O tank less the current air pump is turned on at the beginning of each Sample time and remains on until the start of the Sample Delay time At the beginning of the Sample Delay time the total accumulated running time for the current pump is compared to the Pump Run time value and if the time has been exceeded the alternate pump will be selected for subsequent samples The Air Pumps will not be switched during a Sample period On a tank less system the Pump Run times may be set to 0 010 seconds to cause the pumps to alternate on each cycle In Mode 1 tanked the air pumps are started based on the air pressure of the tank using an external pressure switch An external SPDT relay may be controlled by the Apump1 Select output to alternate which pump will be activated when the tank pressure drops below the pressure switch level At the beginning of the Sample Delay time the total accumulated air flow time for the current pump is compared to the Pump Run time value and if the time has been exceeded the alternate pump will be selected by switching the state of the Apump1 Select output for subsequent samples The activation of air tanks is dependent on the air tank pressure switch although which pump will be activated is determined by the Apump1 Select output In
5. Lead OFF delay is lt than the Lag Off delay the turn off sequence is First ON First OFF Lead OFF Delay Lag OFF Delay 7 Both pumps turn off at the same time Sequencer Configuration The sequencer is configured by setting the Even and Odd sequence information the Time Of Day information the LAG ON delay and the Lead and Lag OFF delays Block Parameter Description 060 SCHD lt times gt 32 defined ON OFF times to select sequence group 1 or sequence group 2 061 WARP Offset Even Sequence Group 1 Time Of Day OFF 062 WARP Offset Odd Sequence Group 1 Time Of Day OFF 063 WARP Offset Even Sequence Group 2 Time Of Day ON 064 WARP Offset Odd Sequence Group 2 Time Of Day ON 065 WARP Offset Lead Off Delay time delay from when Low level goes inactive to turning off Lead Pump 066 WARP Offset Lead Off Delay time delay from when Low level goes inactive to turning off Lag Pump O67 CMPR Offset LAG On delay time required between turning on Lead pump before turning on Lag pump The following LC_Config screen shows the Duplex Sequencing parameters that may be configured 31 74 Rev 1 02 Chapter 4 DUPLEX CONTROLLER a Duplex Congroller Sequence Configuration Sequencer Configuration Sequence 1 Even Cycles None DUPLEX CONTROLLER CONFIGURATION The DUPLEX controller supports Alternating 1 2 and 2 1 sequences 3 Selectwhich
6. Mode 1 the second output Apump2 Valve is used to activate a pneumatic value allowing the air to flow during the sampling period Purging If at any time the measured level exceeds the Block Level Threshold it is assumed that a blockage has occurred and the system will enter a purge cycle The controller will activate the Purge valve bypassing the regulator and applying the full pressure to the bubbler tube for the time specified by the Purge ON Time parameter In mode O Tank less both Air Pump 1 and Air Pump 2 outputs will be activated If at the end of the Purge ON Time the level still exceeds the Tank Level Threshold the ALARM output will be activated LC_Config Bubbler Configuration The Bubbler subsystem is configured by setting the Bubbler Mode the Air Pump 1 and Air Pump 2 Run times the Blocked Level preset and the Maximum Purge time parameters 52 74 Rev 1 02 Chapter 6 BUBBLER SYSTEM Block Parameter Description 068 CMPR Offset Mode O Tanked 1 Tankless 069 CMPR Offset Air Pump 1 Run Time 070 CMPR Offset Air Pump 2 Run Time 071 WARP Von Blocked Level Preset activates Purge cycle if level reaches the value Voff Blocked Level Hysteresis 072 TOND Ton Maximum Purge time before and Error is reported The following LC_Config screen shows the Bubbler parameters that may be configured al Bubbler Configuration Bubbler Mode Air Pump Configuration Ta
7. N button beside each date field will insert the current date The File Information section defines the overall installation information Configuration File Name The configuration file name up to 16 characters is saved on the device When a device is first attached the system will attempt to read the specified file to reload the configuration information for editing If the file is not available the information from the device is used Configuration Version The configuration version information includes a version number date of creation and date last modified An Auto Update option is included that will cause the version number to increment whenever the Configuration file is save to disk Installation Information The installation information includes the name of the person installing the configuration and the where the device was installed Each field will accept up to 16 characters In addition a user defined numeric location code and date of installation is provided Edit Entries The Edit Entry area allows reviewing all configuration information contained on the device Each field is displayed and may be modified A comment field is provided allowing each parameter to have a comment added Note that comments are retained in the configuration file but not on the device Configuration File Format Configuration files are saved in standard TAB Delimited files Each entry consists of the Parameter Name the Parameter
8. Offline In the Online mode the pump is controlled by the Duplex Sequencer In the Force OFF mode the pump is not available to the Duplex Sequencer and is off In the Force ON mode the pump is not available to the Duplex Sequencer and is forced ON subject to the zero level detection level In the Offline mode the pump is prevented from operating Mode Description O Online Operates under the control of the Duplex Controller 1 Force OFF Pump is unavailable to the Duplex controller and is held in the OFF state 2 Force ON Pump is unavailable to the Duplex controller and is held in the ON state Note that the Zero Level Detect will over ride the ON state to ensure that the pump is turned OFF if the level drops below the Zero Level 3 Offline Pump is not available to the Duplex Controller or Force Modes and is held in the OFF state Online In the Pump Online mode the pump is switched on or off under the control of the Duplex Sequencer If the pump is currently operating as the Lead Pump and is switched to another mode the alternate pump will be immediately switched On Force OFF If the pump mode is set to Force OFF mode it will force the pump to the OFF state The turn off will be immediate the Lead Lag off delay times will be ignored 33 74 Rev 1 02 Chapter 4 DUPLEX CONTROLLER Force ON If the pump mode is set to Force ON mode it will force the pump to the ON state The turn on of the pump will be delayed
9. Offset Sample Delay Time 022 CMPR Offset Sample Delay Adjustment O for no auto adjust 023 CMPR Offset Sample Segments The following LC_Config screen shows the Sampling parameters that may be configured The LC_Config interface uses the values of the Sample Delay and Sample Adjust times to determine which of the 3 modes are currently in effect y all Sampling Configuration Nominal Sampling Time 4 490 Level Sampling gt Continuous Timed Auto Tuned Delay Time 0 990 Sec msec Auto Adjustment 0 000 Sec msec Segments 5 Sample Settling 2 000 Sec msec The follow parameters are determine the system sampling times Timed mode will sample the levels at a fixed time interval determined by the sum of the ON OFF Threshold times the settling time 0 5 seconds the Delay Time Auto Tuned will use the inflow rate change in level between samples to adjust the Delay time between each sample The system will adjust time to approximately one sample for each segment The maximum time between samples is set by the time parameter Threshold ON 0 500 Threshold OFF 0 500 During the last segment or if any pump is operating the sampling is internally switched to continuous For example ifthe total span between the current level and the next level is 5 feet and the segments value is setto 10 the system will adjust the sample time based on the inflow rate to sample every 6
10. Preview print pages on screen Print Prints the current configuration for documentation purposes Exit Exits the LC_Config application Tools Configuration Files Defines an application configuration same as Project Definition Files Defines the underlying device attributes Advanced Users Modbus Interface Allows Reading Writing all parameters using specific Modbus commands Manual Mode Allows placing pump into FORCE Mode to manually control the pumps Calibrate Configuration assistant Simulator Opens Simulator display Data Logging Data Logging Future Application Support Options User define preferences options Future Application Support Configure System Configure the SYSTEM parameters Sensor Configure the SENSOR parameters Level Configure the Level Thresholds Dimensions Units Configure dimensions of tank and units of measure Duplex Controller Configure DUPLEX CONTROLLER sequencer Pump 1 Health Configured Pump Health parameters 65 74 Rev 1 02 Chapter 9 LC Config Utility Pump 1 Run Verification Configure Pump 1 Run Time Verification Parameters Pump 2 Health Configured Pump 2 Health parameters Pump 2 Run Verification Configure Pump 2 Run Time Verification Parameters Bubbler Configure the BUBBLER system Project Project Management options Simulator Opens Simulator display Help Provides help File The file menu provides access to configuration files that define the parameters of the LC contr
11. Tia US A dde 23 2 74 Rev 1 02 EevelEhresholdS isaac toreo terca battre tito 23 Nartable Low Threshold mid ibs ewer ook REEE Ea Git aa eee 23 Level Confieuration ds 24 bevel Run Tine Dat e el Ln e e ces da h 25 Loyel Run Time Status a A ova seins 25 Level Information with Discrete Inputs isi iscesccatsussene orita 26 LC Config Level DAS DIA pecs ates SS RA a i i 26 Chapter 4 DUPLEX CONTROLLER aia ola cani 28 Pump SUE A A E td 29 SEUERCE SO A S 29 a A A TAO 29 SEquenes Type Lead VA AA RA IATA EE AAA ARA A 29 mequence Type LE E E EE E E E E EE ais 30 Sequenos Type Bothi rections A io 30 Mm OI D AY E A E E T A E E S 30 A EE E AE A AE E E E E EE A A 31 Tur Off S gn e it 31 Sequencer Configuration sion ieai A A As 31 Sequencer Run Time Data c calle Neca tila ghee 32 Sequence R n Time Sd le i oi 33 PUNO Coto AS LES Sas La oes de 33 RUT Modei e at aee reee aid 33 ROT NS a ate O O O 33 ENEE rea RSA am COE ore a cp dl o co eee a oia 33 A A A A anon la cient Catal 34 Oia A A A Eaa Flea toh ew eben a gaa 34 Hardware FORCE ON E dtr eet ROMO on 34 P mp Mode OACI AA TA a 34 P mp cd loas 34 Seal Leak Input ceiro ieni E E RA EA I aT EE E AR A 34 Over TEMPS et 35 Pump Health CONE A oa 36 A A A aa eiae aTe TAC TEET TOE ses 36 Pump Start Delays ener a narn AAA A a lamas deers 36 Auxiliary Contacta aa ease A E E A A A oss e 36 Pumpi Curenta NO US ES 37 Phase Error COn dea 38 Pump Run Verification Cont Out OM isa 38 Pu
12. Value and the optional comment field with a TAB character between each field These files may be read and modified using standard spread sheet programs Excel Open Office etc A B c Parameter Value Comments SystemSerialNum 12345 Any Number 0 999999999 SysteminstallDate 8 17 2012 SystemAuxinfo 554 Any Number 0 65535 in e La hs A The Parameter Name has a leading and trailing symbol which is used by LC_Config when reading the configuration file to differentiate Parameter Names Files may be modified with additional records added provided the first character of the line does not begin with a character 71 74 Rev 1 02 Chapter 9 LC Config Utility When generating the file the LC_Config program outputs a header line consisting of Parameter tab Value tab Comments followed by a blank line Simulator The LC controller includes a simulation option allowing the controller inputs to be internally mapped to simulated signals The simulator is invaluable in testing LC applications without the need of running physical pumps NOTE The simulator does NOT emulate the actions of the LC controller but simply remaps the analog and digital inputs to internal registers within the LC controller allowing the LC_Config application to drive the level input and emulate the actions of the external pumps All control logic is performed by the LC controller al LC Controller System Simulator Sensor Simu
13. defined setpoints A discrete float detector accepts one of 5 digital inputs typically connected to float switches to determine the current level System Architecture Duplex Pump Controller Pump Controller Linear or 5 Discrete Levels gt Discrete Pump Controller Flow Monitoring Bubbler Controller Air Pump Controller System Controller Air Pump Controller The level detection system supports 5 distinct levels The linear level comparators include hysteresis to avoid false readings due to signal jitter Following the threshold comparison the signal is further conditioned with a dual timer to ensure that the signal is stable prior to being latched at the end of each sampling period Discrete level detectors apply the float signals directly to the dual timers Level Detector ON OFF Lan mp Level o Analog g Tae ON OFF Level JOJe1e duo Other Level Detectors Discrete Input The Input Scaling and Latch function converts the input signal into standard engineering units Feet Inches or Meters Centimeters allowing user defined levels to be specified in the corresponding units and then is applied to each level detector In addition the input signal is latched as the current level during at the end of each sample period allowing it to be used in the flow rate calculations E
14. device to operate in the simulation mode While in the simulation mode the analog inputs Level Seal Current are remapped to internal registers that may be written to by configuration tools such as the LC_Config tool The digital inputs are not remapped Simulation tools may write to internal registers that are internally OR d with the physical inputs If operating in simulation mode the external digital inputs must be held in the OFF state The simulator mode is entered if the Simulator Enable word is set to a value gt 0 Refer to the Simulator Chapter for additional information Operating Mode The operating mode controls the overall operation of the device Mode Description 0 Disabled All control outputs Pumps Air Pumps are held in the OFF state No level sampling or flow calculations are performed 1 Enabled Normal operating mode 2 Lockout disabled Normal operating mode The Zero Level Lockout that prevents pumps from operating below the Zero Level is disabled allowing manual control of the pumps to levels below the zero level 3 Calibrate Duplex controller disabled zero level lockout disabled Allows calibration of sensor input The Lock Out function attempts to protect the pumps from manual operation below a configurable Zero Level When disabled damage may occur to the pumps if activated below the Zero Level The Calibrate mode disables the Lock Out feature and the duplex contro
15. inches The minimum sample time is 0 010 seconds The minimum number of segments is 1 Continuous mode will continuously sample the level A brief0 010 sec delay is inserted between each sample to allow for flow calculations Air Pumps are not halted Sampling Run Time Data The following SAMPLING run time information is available through the indicated DW Registers All SAMPLING run time data except the Actual Sample ON and OFF times are non volatile retained if power is lost Data Register Name Description DW16 Sensor Level Input provided by Sensor See Sensor Run Time Data DWw120 Threshold ON time Value provided by Level Configuration DWw121 Threshold OFF time Value provided by Level Configuration Dw122 Sample Delay Time Value provided by Sampling Configuration DWw123 Sample Segments Value provided by Sampling Configuration DWw124 Sample Adjust Time Value provided by Sampling Configuration DW125 Sample Settle Time Value provided by Sampling Configuration DW126 Off Low Segment Size Calculated as Low Level Off Level Sample Segments 22 74 Rev 1 02 Chapter 3 LEVEL DETECTION DWw127 Low Mid Segment Size Calculated as Mid Level Low Level Sample Segments DW128 Actual Sample OFF time Calculated Sample OFF time based on mode DW129 Actual Sample ON time Calculated Sample ON time based on mode Sampling Run Time Status The foll
16. is used to allow the system to vary the LOW threshold from the user defined Low Threshold value The Variable Low Range parameter defines the maximum level above the user defined Low Threshold The controller will adjust the Low level by adding 1 5 of the Variable Low Range value after each cycle After 6 cycles the Low level is reset to the User Defined Low Threshold 23 74 Rev 1 02 Chapter 3 LEVEL DETECTION Setting the Variable Low Range value to O will disable the adjustable Low Threshold feature The Variable Low Range value must be selected such that the Low Threshold Variable Low Range is less than the Mid Threshold to avoid having the LAG pump triggered Level Configuration The Level Detector is configured by setting each of the level setpoints the hysteresis value and the ON and OFF threshold times Block Parameter Description 002 WARP Offset Zero Level inhibits pumps from operating below this level 003 WARP Voff Zero Level Hysteresis 004 WARP Offset Off Level Pumps will shut off when level drops below the OFF level 005 WARP Voff Off Level Hysteresis 006 WARP Offset Low Level Lead pump will turn on when level rises above the LOW level 007 WARP Voff Low Level Hysteresis 008 WARP Offset Mid Level Lag pump will turn on when level rises above the MID level 009 WARP Voff Mid Level Hysteresis 010 WARP Offset High Level Hi
17. level is less than the previous level the Decreasing Flag is set Flow Information Run Time Data The following Flow Information run time information is available through the indicated DW Registers All Flow Information run time data is volatile not retained if power is lost Data Register Name Description DW1i6 Sensor Value Sensor Value see Sensor DW17 Sample Flow Rate Value provided by Dimension Configuration DW18 Last Level Last Sample Level DW19 Sample Level Change Change in level DW20 Sample Flow Volume Calculated Change in Volume DW21 Unscaled Sensor Value Unscaled Sensor see Sensor DW22 Flow Time Counter Inflow Outflow timer DW23 Inflow Time Latched Inflow time DW24 Outflow Time Latched Outflow time DW25 Flow Start Level Level when Inflow or Outflow stage begins DW26 Flow Volume Inflow or Outflow Volume DW27 Inflow Volume Latched Inflow volume DW28 Inflow Rate Latched Outflow volume DW29 Inflow While Pumping Calculated inflow volume while pump is active DW30 Pump Flow Volume Calculated pumped value DW31 Pump Flow Rate Calculated pump flow rate DW96 Current Level Used by Flow Calculations contained as part of the Levels Run Time Data Flow Information Run Time Status There is no Flow Information Run Time status information 48 74 Rev 1 02 Chapter 5 Flow Monitoring LC_Config Flow Display The LC_Config tool displays
18. parameters Pump Simulator There are two Pump Simulators provided The Pump simulator panels allow the user to set the characteristics of the virtual pumps seal resistance on delays pump rates etc These values are written to the LC controller Simulation inputs which are applied in place of the physical I O The Pump Simulator reads the state of the LC Pump Controller to determine if the LC controller has activated the pump When the pump is activated the simulator ramps the virtual flow rate using the Start Up Ramp time When the pump output is deactivated the simulator ramps the virtual flow rate down using the Shut Down Ramp time The Turn On and Turn Off of the pump simulator will cause the Auxiliary Contact Current and Phase Contact to activate as the pump state is switched The Seal Resistance and Pump Temperature inputs remain constant but may be varied by the user 74 74 Rev 1 02
19. specific sensor Sensor Configuration The sensor is configured by setting the Gain and Offset for the two buffer stages Block Parameter Description 024 AMP Gain Multiplier to convert signal to 0 10 00 span Offset Offset to provide O level when physical level is O 025 AMP Offset Multiplier to provide true level ie 10 feet as output Gain Offset to provide O level when physical level is O The following LC_Config screen Configuration Sensor shows the Sensor Parameters that may be set The configuration screen also shows the Stage 1 and Stage 2 outputs from the dual stage buffer ul Sensor Configuration Sensor Configuration The Sensor Stage 1 parameters accountfor sensor specific offset and gain factors The parameters should be setto provide a 0 volt offset when no level is preset and a value of 10 at full scale The Sensor Stage 2 parameters account for conversion between the raw sensor input level volts to the corresponding engineering units The values should be adjusted to provide a 0 level at bottom of the tank and a valid level when the tank is half full 18 74 Rev 1 02 Chapter 3 LEVEL DETECTION Sensor Calibration To calibrate the LC controller to use a specific sensor the following steps should be performed 1 Set machine into Calibration Mode 2 With a zero level presented to the sensor set the Stage 1 Offset to provide a 0 00 stage 1 output 3 W
20. the Time Of Day clock is ON the Even Seg 2 and Odd Seg 2 pair are used If a pump is Disabled or Demoted the alternate pump will be used as the Lead pump Sequence Selection The Sequence selection is made by specifying a value 0 3 for each of the Even Odd cycles for Group 1 Time Of Day OFF and Group 2 Time Of Day ON Sequence Type Description O NONE The Lead Pump and Lag Pump are activated at the MID level 1 LEAD 1 Pump 1 acts as Lead Pump activated at the LOW level 2 LEAD 2 Pump 2 acts as Lead Pump activated at the LOW level 3 BOTH Both pumps will be activated as Lead Pumps at the LOW level Either pump may be taken off line by deactivating the corresponding Pump Enable control If a pump is off line the alternate pump will assume the Lead role If both pumps are off line an error alarm is generated Sequence Type None If type NONE is selected neither pump will turn on at the LOW level When the level reaches the MID level the least recently used pump will activate as the Lead pump If the level has not dropped below the MID level prior to the LAG On Delay the second pump will turn On The pumps will alternate Sequence Type Lead 1 Pump 1 will be used as the Lead pump and turn on at the LOW level If the level continues to rise to the MID level Pump 2 will be used as the Lag pump 29 74 Rev 1 02 Chapter 4 DUPLEX CONTROLLER Sequence Type Lead 2 Pump 2 will be
21. time status information is available through the indicated DW Registers All SAMPLING run time data is non volatile retained if power is lost Data Register Name Description DWw91 Zero Level Value provided by Level Configuration DW92 Off Level Value provided by Level Configuration DW93 Low Level Value calculated based on Low Level Base Variable Low Level data DW94 Mid Level Value provided by Level Configuration DW95 High Level Value provided by Level Configuration DW96 Current Level Level determined by the current Sampling cycle DW97 Variable Count Cycle Value ranging from O 5 indicating what adjustment to be made to Variable Low Level DW98 Low Level Base Value provided by Level Configuration DW99 Variable Range Value provided by Level Configuration Level Run Time Status The following LEVEL run time status information is available through the indicated Bit Registers All status information is volatile not retained if power is lost 25 74 Rev 1 02 Chapter 3 LEVEL DETECTION Bit Register Name Description M88 Zero Level Level is gt Zero Level Threshold M89 Off Level Level is gt Off Level Threshold M90 Low Level Level is gt Low Level Threshold M91 Mid Level Level is gt Mid Level Threshold M92 High Level Level is gt High Level Threshold M93 Near Low Level Level is gt Low Level Threshold Segment Size M94 Near Mid Lev
22. used as the Lead pump and turn on at the LOW level If the level continues to rise to the MID level Pump 1 will be used as the Lag pump Sequence Type Both Both pumps will be activated when the level reaches the LOW level The least recently used pump will be activated as the Lead pump turn on immediately and the second pump will turn on after the Lag On Delay Time Of Day The Time Of Day scheduler selects between Group 1 sequences and Group 2 sequences Each entry consists of a year month day and time of day as well as which group should be active OFF Group 1 ON GROUP 2 Sixteen different date entries are supported As shown below if for example the scheduler is operating on a Monthly basis the Year and Month information is not required The ON OFF activity will occur on the specified day of each month Multiple days within a month could be supported by utilizing the 32 different time entries available The time entries are consecutive and must be in ascending order Type Year Month Day of Month Day of Week Time State 1 Yearly Year Month 1 12 Day 1 31 0 6 Mon Fri 00 00 00 23 59 59 ON or OFF 2 Monthly 2 Day 1 31 00 00 00 23 59 59 ON or OFF 3 Day of Month Day 1 31 00 00 00 23 59 59 ON or OFF 4 Fixed Date Year Month 1 12 Day 1 31 0 6 Mon Fri 00 00 00 23 59 59 ON or OFF 5 Mon 4 E ES z 00 00 00 23 59 59 ON or OFF 6 Tue
23. 000 of 1 000 Seal Gain Offset Allows conversion to ohms Typical values Gain 10 Offset 0 Temp Contact Temp Filter NO NC La Time MM Msec On 3 000 OF 0 100 Temp NO NC Complementthe sense ofthe temperature input Temp Settling Time Filter time for temperature detection contento The Pump Health Run Time information is made available as part of the Pump Run Time Data and Pump Run Time Status see Below Run Verification The Run Verification function monitors each pump while it is running to ensure that the pump is operating within specifications The controller monitors the Auxiliary contact from the motor contactor block the operating current and a contact from an external Phase monitoring or other fault detection relay Auxiliary contact and Phase errors are internally latched Pump Start Delay The Pump Start delay provides an on delay from the activation of the pump to when monitoring of the pump current is started to allow the pump to stabilize The time delay is a function of the start up characteristics of the pump and is typically 1 3 seconds Auxiliary Contact The Auxiliary contact input is connected to the pump starter auxiliary contact and ensures that the contact closes within the specified time from the activation of the pump The sense of the contact may be configured as Normally Open NO or Normally Closed NC Failure to close within the specified Aux Contact ON Time will be treated a
24. 3 Run Time The number of days hours mins that the pump has been operating since the last reset see Pump Reset DW66 DW74 Cycle Time The current time that the pump has been operating since the last pump switch over DW7O DW78 Reset Errors Writing a non zero value will cause the Latched errors to be cleared Dw71 DW79 Reset Stats Writing a non zero value will reset the Count and Run Time values DW107 Bubbler Mode As set in Bubbler Configuration DW108 DW109 Pump ON Time Pump ON time as set in Bubbler Configuration Cleared by pump Reset Statistics retained on loss of power Bubbler Run Time Status The following status information is collected for each pump and is available through the indicated Bit Registers Bit Register Name Description Pump 1 Pump 2 M80 M84 Pump State O Pump is OFF 1 Pump is ON M81 M85 Pump Status No Errors or Warnings 1 Pump Error M104 M105 Pump Trigger Pump is being trigger to Run M106 Bubbler Mode Tanked System Tankless System M107 M108 Pump Time Out Pump has reached it s ON time as defined in the Bubbler Configuration M108 M110 Pump Zero Time Bubbler Configuration has set the ON time for the pump to O M113 Block Purge Blocked Level has been reached Purge cycle in progress M114 Block Error A Blocked Error condition has occurred M115 Block Block State prior to Ton Toff filtering Latched Error condit
25. Current Min Max Gallons Imp Gallons or Liters Reported per second minute or hour Rev 1 02 Chapter 7 LC 1 HARDWARE INTERFACE Hardware Connections The LC 1 controller Hardware Interface is shown below INPUT Description AIO 10 Sensor Input Analog Pump 1 Pump 2 All 11 AT 17 Pump Seal Input Analog AR 12 AI8 18 Pump current level Analog 13 19 Pump Temperature contact 14 IA Pump Auxiliary contact I5 IB Pump Phase Error relay contact 16 IC Manual ON Pump will be turned on when the input is active ID Reset Pump Errors Note The 14 inputs are labeled IO 11 19 IA IB IC ID OUTPUT Description Q0 Active if any WARNING conditions exist Ql Active if any ERROR conditions exist Q2 Active if HIGH Level is reached Pump 1 Pump 2 Q3 Q4 Pump ON turn on pump when output is activated Q5 Air Pump 1 Bubbler System Q6 Air Pump 2 Bubbler System Q7 Purge Bubbler System Power Sensor Pump 1 Inputs Pump 2 Inputs Reset OO e0 L M 0 i B TA 5 6 iy B 9 IA B IC D LC 1 ESC Q0 Qi Q2 Q3 Q4 Q5 Q6 Q7 31 06 8 6 8 Warning Error High Pump Pump2 Air Air Purge Alarm Pump 1 Pump 2 57 74 Rev 1 02 Chapter 8 Chapter 8 LC 6 HARDWARE INTERFACE LC 6 HARDWARE INTERFACE The LC 6 configuration allows for a lin
26. Error State prior to time ON OFF filtering M136 M146 Reset Stats Pulse generated when Statistic information is reset M137 M147 Pump Started Pump is not started active low 43 74 Latched Error condition cleared by pump Reset Error function Rev 1 02 Chapter 5 Flow Monitoring Chapter 5 Flow Monitoring The flow monitoring subsystem is responsible for monitoring the inflow and outflow of the fluid System Architecture Duplex Pump Controller Level Detector 1 E troll Linear or ump Controller Discrete Pump Controller Bubbler Controller Air Pump Controller System Controller Air Pump Controller Flow rates are calculated by measuring the change in level over a unit of time and using the geometry of the holding tank to calculate the flow volume and flow rate The system tracks the instantaneous level changes the INFLOW rate and the estimated OUTFLOW rate Holding Tank Geometry To perform flow calculations the length width and radius of the tank must be known E Top View Length For a square tank the radius is set to O For a circular tank the length and width are set to O For oblong tanks the length width and radius can be used If the tank surface area is non geometric the measured area may be entered as the Length and set the Width to 1 and the Radius to O The surface area is calculated as Ar
27. LC USER MANUAL Table of Contents Chapter il PEOICLOVE VIE a AS A a eae 6 A AN 6 E di 6 Level DM E olor T Bubbler Controlled sua 7 Eloy Rate Monitoringa ia ia AE a dd IAS 7 A a E EE 7 Pump Es NOOO EA A A AN tastes 7 AA EE gata eed os ea ick Mads case ees eave A ace vu wats E a a arias Lee T PRIMI TOS PLAY esien a IO A A ele REA E 8 Comm nicati hs NS NA id 8 A A A E A IA 8 TIPICAS iia 8 Configuration SUPPORd EE a R E E N A T A A EA 8 ModilarCapablites a dd T 9 A ght aon het a Sgt O oe oe ta Nr i aha Sele a sa a Reals 9 Chapter 2 SS TEM isc dada ae id a ada 10 System Confused ia 10 NE A AN A EAS 10 Configuration WO a o dl 11 Simulator Enable nnes a E A AAA eeseeuadtousel twee 11 Operating Modena nea o ds actas 11 Real Time io AE A E A E A A at E E NE 11 LC C nfig System CON OTAN AS AL 12 Stat s Indicators a A is 12 R n Mme Dt E A EA A AAA RA 13 R n Tine SU A NN A ere 13 EC Config Systenr A A NA 14 Chapter LEVELDETECTION 00d aa 16 Sensor MP a 17 Sensor Conf e raoN onea E Autor lds ade eogerkdietncaduttoles a 18 Sensor CADA a cue Seer id tale hel alta kN ait Me thet cule Nine a a UT laa haat 19 Sensor Rua Time Dala sa ase aterm elders ios teria orettacet 19 Sensor R n Time SU a sia 20 Distrele pulsa A AA A A Ade 20 USS VSS AIP t at ea A E tied ducersuietlate cess 20 Sample settling TIAS A A a 20 Sample EME A A eames 20 A A A E A TERE NITE 21 Sampling COn A A A 21 Sampling Run Time Dita A ic 22 Samplins Run
28. LC controller Simulator Controls The simulator is controlled by three control functions upper left corner Enable Disable Simulator The Enable Simulator button activates the simulator function within the LC controller The standard input connections are remapped to internal registers which may be modified by the simulator allowing the simulator to apply a virtual level input based on the virtual sensor and modify the pump inputs based on the state of the virtual pumps NOTE The simulator mode within the LC controller handles the analog and digital signals differently The Analog signals Level Seal Resistance Current are remapped and the corresponding hardware inputs have no affect The digital signals Pump Temperature Auxiliary Contact Phase Error Contact are OR d with the hardware inputs The hardware inputs should remain disconnected for the simulator to operate correctly Once the Simulator mode has been entered it will remain enabled until specifically disabled using the DISABLE Simulator When the Simulator is entered it reads the state of the LC controller and will display the activation button as either Enable Simulator or Disable Simulator Power cycling the unit does not affect the simulation mode setting Inflow Rate The Inflow rate determines the flow rate units timer period of the liquid flowing INTO the tank The flow rate value is provided to the Tank Simulator Auto Step The Auto Step
29. Level threshold DW46 DW62 Reset Errors Writing a non zero value will cause the Latched errors to be cleared DW47 DW63 Reset Stats Writing a non zero value will reset the Count Run Time Flow Average and Flow Volume values DW8 DW11 Average Flow Rate The Average Flow Rate DW9 Dw12 Total Volume The total volume pumped since the last reset Cleared by pump Reset Statistics retained on loss of power Pump Controller Status Information The following status information is collected for each pump and is available through the indicated Bit Registers Bit Register Name Description Pump 1 Pump 2 M16 M48 Pump State O Pump is OFF 1 Pump is ON M17 M49 Pump Status Online and No Errors or Warnings M18 M50 Temperature Input pump temperature error condition M19 M51 Aux Contact Input 1 Aux contact is active M20 M52 Phase Error Input 1 Phase Error contact is active M21 M53 Seal Warning Seal input is lt specified warning threshold M22 M54 Seal Error Seal input is lt specified error threshold self clearing M23 M55 Aux Contact Error Aux contact input not active within the specified Aux Contact ON delay time M24 M56 Thermal Overload Aux contact input became inactive before pump turn off M25 M57 Phase Error Phase error contact inactive after Pump Start UP delay time M26 M58 Over Current Curr
30. ON OFF ON OFF OFF Integer Y Enabled Display AS Integer Y Enabled Display AS 8 BINARY V Enabled Number Display AS IA e ltem Number Item Index Value 500 a Ee ae Rate Manual Mode The Manual Mode allows the direct control of the pump The Pump Mode control DUPLEX CONTROLLER may be set to any of the ONLINE FORCE ON FORCE OFF or OFFLINE modes and the SYSTEM Zero Lockout control may be over ridden allowing the pump to operate below the Zero Level threshold 67 74 Rev 1 02 Chapter 9 LC Config Utility al Manual Pump 1 ONLINE Running Error OFFLINE Pump 2 ONLINE omme Rumina O Error O Z Ato Update 1645 Sensor 136 Calibrate To calibrate the LC controller to use a specific sensor the following steps should be performed 1 Set machine into Calibration Mode 2 With a zero level presented to the sensor set the Stage 1 Offset to provide a 0 00 stage 1 output 3 With a full scale level presented to the sensor set the Stage 1 Gain to provide a 10 00 stage 1 output 4 With a zero level presented to the sensor set the Stage 2 Offset to provide a 0 00 stage 2 output 5 With a known level presented to the sensor set the Stage 2 Gain to provide the known level as the stage 2 output 6 Return the machine to the Run Mode To assist in the calibration process the LC_Config tool includes a Calibrat
31. Pump Inflow 0 00 Pump Volume Help Air Pump 1 ON O ERROR O Cycle Time 11 Cycle Count Run Time Cycle Time Cycle Count Run Time pdate Control Update Rate Sec Additional Pump Details are available by selecting the Details button on the appropriate Pump Control panel 39 74 Rev 1 02 Chapter 4 DUPLEX CONTROLLER al Pump 2 Status o B xs Pump Status Operating Status Pump ON O Pump Status FORCE MODE seal Waming O Pump Temp O os 2 HH MM Seal Error O Phase Enor O Cycle Count 8 Aux Contact Eror Over Current Sl POPPEA 30 00 Kohms Thermal Oveload UnderCument O Flow Rate OK Pump Current 2 00 Amps Run Statistics Run Control Avg Flow Rate 30 65 On Line O Available Lead O Total Flow Volume 5827 Forced OFF Demoted O Lead Called ay Cycle Flow Rate 29 47 ForcedON Disabled LagCalled O Cycle Flow Volume 648 35 Ofline Q Stated O Update Update Rate 500 gt Y Auto Update Pump Configuration Blocks The following table itemizes the configuration blocks used when configuring the Pump Controllers Pump 1 Pump 2 Parameter Description User Values Block Block 026 CMPR 042 CMPR Offset Mode O Automatic 1 Force OFF 2 Force ON 3 Disabled 027 CMPR 043 CMPR Von Seal Warning Level Gain Parameters to convert input reading to K Ohms Offset Parameters t
32. Sensor Input Linearized Level The LC controller accepts a 0 10 Vdc input with an input impedance gt 50 Kohms If a 4 20 mA sensor is used the signal may be converted to 2 10 Vdc using the following circuit Stage 1 is typically used to remove the 2 volt offset by setting the Offset to 2 00 and the gain to 1 25 resulting in a Sensor Value signal of O 10 Vdc For sensors that supply a voltage 0 10 Vdc output the Stage 1 gain may be set to 1 and the Offset to O If the sensor supplies a 0 5 Vdc signal the gain is set to 2 and the offset set to O Other sensor input types may be used provided the maximum input voltage is limited to 10 Vdc Positive displacement sensors will have an increasing output signal as the level increases Negative displacement sensors will have a decreasing output signal as the level increases Setting the gain of the stage 1 buffer to a negative number ie 1 00 and providing an offset of 10 00 will convert a negative displacement 10 O Vdc signal to one that increases O 10 Vdc as the level increases 17 74 Rev 1 02 Chapter 3 LEVEL DETECTION 4 20 mA Converter Ve 24Vde R 50 kohm input Internal to controller R 500 ohms 1 2 W do not install The second stage buffer is used to convert the 0 10 Vdc signal to a signal representing the level within the tank represented in engineering units inches feet meters and the Gain and Offset values are particular to the
33. Value provided by Sequencer Configuration DW83 Group 1 Odd Seq Value provided by Sequencer Configuration DW84 Group 2 Even Seq Value provided by Sequencer Configuration DW85 Group 2 Odd Seq Value provided by Sequencer Configuration DW86 Pump 1 Off Delay Determined based on Lead Lag position during current cycle DW87 Pump 2 Off Delay Determined based on Lead Lag position during current cycle DW88 Lead Pump Off Delay Value provided by Sequencer Configuration DW89 Lead Pump Off Delay Value provided by Sequencer Configuration 32 74 Rev 1 02 Chapter 4 DUPLEX CONTROLLER Sequencer Run Time Status The following SEQUENCER run time status information is available through the indicated Bit Registers All status information is volatile not retained if power is lost Bit Register Name Description M117 Lead Pump Active The Lead Pump level Low Mid has been reached M118 Group 2 Active The Time of Day clock output is ON M119 Lag Pump Enable The LAG ON Delay timer has expired Pump Controller The Duplex Controller supports 2 pumps each controlled by an internal Pump Controller Each pump may be set to run under the control of the Duplex Controller Online Mode may be manually forced ON or OFF or may be taken Offline disabled The pump controller is responsible for monitoring the Health and Run Time Verification of the pump Pump Mode Each pump operates in one of four modes Online Force OFF and Force ON and
34. a a dd das 58 Hardware CON ll la sido 59 Chapter 9 iC Conte DIE A TANTA AA AAA 62 Start RR 62 A A OP eee AA 63 Update Control Panda a A A RN 63 Modbus Hai a da 64 A ia at E E ations va pti Macon tees esac heed A E ET 64 Auto CUP ates ES AN NN NS 64 Pause Update A A A E 65 Update Rat ius tin daa 65 Mat Menta OPI da 65 dd an lcd 66 OP o Ne tthe ak gens eel a NL Aces atte ce aaa tuted 66 NN 66 AVS AN Siay Salinas cacpandetaon bean aneysannnenmbunedunibendtns and tou shapnaniltand E E EE sand eols sealant 66 Print Setup A AA A asia a a nial 66 Print PVC A A 66 PA elas aioe ced A ideal aa MG aad Reina E Hace ie oa sma ios 66 SM stg O saw auc eee eats 66 O E aS OY ERROR ERT TE OY ia daa 67 IV US EIST RA estat A SE o esta 67 Manta Mod o aeons 67 4 74 Rev 1 02 5 74 Ma e A KIAT AE A A A A 68 A O a a a a e TTE 69 A A E saan ea Ab E E T 69 Configuration asan A a sea O a a 70 aR A 70 Configuration Pile Name sia cul ere niies R tiny E T coord 71 CONSUL Versiot ssni A AS did 71 Instaltation Informations cesna A aia 71 Edit EU A A a E a E a EE 71 Confisuration Als Coma AS 71 SIMAO A A A NE 72 Sim lat r CONOS 0 SAA A A A AS AAA AR 73 Enable Disable IAS 73 E 73 AO cines O 73 JN A A RE tr ee A NA oN 73 Sensor SITU O aia 74 Purp STA AA od 74 Rev 1 02 Chapter 1 Chapter 1 Introduction The Ingram Products Level Controller Product Family provides Level Detection with an integrated Bubbler controller a Duplex Pump Contro
35. ach linear level detector consists of a comparator that includes a hysteresis calculation If the input level is at or above the user defined threshold ON level the comparator output will be active If the input level is below the user defined threshold OFF level the comparator output will be inactive The hysteresis levels are typically set 0 25 below the threshold level Chapter 3 LEVEL DETECTION Comparator Output Hysteresis AY To avoid sporadic or false triggering a dual timer is used for each level threshold that verifies the comparator output or discrete float input remains constant for a user defined time referred to as the THRESHOLD ON and THRESHOLD OFF time When the comparator is turned on it must remain on for the specified ON time When it turns off it must remain off for the specified OFF time At the end of the Sample Time the Detection Level states are latched and will remain constant until the end of the next sample period The Sampling subsystem ensures the inputs are sampled at a periodic rate and is used to establish flow information Note that discrete inputs will not provide information of the level between each discrete float input Sensor Input The Sensor Input provided in the linear level detector provides a two stage buffer to linearize the sensor signal and convert it into a signal representing the tank level Each stage offers a Gain and Offset value Sensor Input Buffer Stage 1
36. ag pump turn on delay ensures that a specific time elapses after turning on the lead pump before the lag pump will turn on The turn off sequence of the pumps is determined by the Lead and Log turn off delays specified within the Sequencer If the level reaches the High Level an alarm will be activated indicating that the Inflow rate exceeded the pumping capacity of the two pumps and immediate interaction is required 28 74 Rev 1 02 Chapter 4 DUPLEX CONTROLLER Pump Sequencer The two pumps may be operated in Alternating Fixed 1 2 or Fixed 2 1 sequences Two additional sequences are defined referred to as Both or None described below A time of day clock is provided allowing two different sequencing controls to be implemented based on the time date A sequence cycle is defined as starting when the level rises above the OFF level and continuing until the level drops below the OFF level Pump cycles are broken into Even and Odd cycles The Even Seq 1 parameter determines which pump None 1 2 or Both should act as the Lead pump during even cycles and the Odd Seg 1 parameter determines which pump None 1 2 or Both should act as the Lead pump during odd cycles The Time Of Day clock may be set to trigger ON or OFF at 32 specific times based on a yearly monthly weekly daily or on specific days of the week When the Time Of Day clock is OFF the Even Seq 1and Odd Seq 1 pair are used to determine the Lead Pump If
37. ays the SYSTEM information as shown below The Details button will display the cause of any System Warnings or System Errors al LC Configuration Tool File Tools Configuration Pump 1 Pump 2 Air Pump 1 Air Pump 2 ON O ON O ON ON ERROR ERROR ERROR ERROR WARNING O WARNING O In Time 0 Out Time 0 00 0 0 00 33 0 Start Level Flow Rate Cycle Time Cycle Time 0 00 Cycle Volume 0 00 In Flow Volume In Flow Rate 0 00 1 1 11 0 Pump Inflow Cycle Count Cycle Count Cycle Count Cycle Count 0 00 0 0 33 0 Pump Volume Run Time Run Time nan 0 00 Reset Stats Reset Stats Reset Stats eset Stats Update Rate Pump Rate eset Errors eset Errors Reset Errors Reset Errors Gec S Auto Update J Auto Update Auto Update Auto Update Auto Update Auto Update lt Data logging Status gt 14 74 Rev 1 02 Chapter 2 The Details button will display additional System status information 15 74 oe Update Rate Pump 1 Disabled Pump 2Disabled O gt High Level Error O Blocked Level Error Waming Status Pump 1 Demoted O Pump 1 Flow Pump 2 Demoted O Pump 2 Flow gt Blocked Level lt Zero Level SYSTEM Rev 1 02 Chapter 3 LEVEL DETECTION The Level Detector subsystem accepts either linear analog or discrete digital inputs and is responsible for determining the current level within the tank A linear detector samples an Analog signal representing the current tank level which is compared against user
38. by the LAG ON delay time if the alternate pump has been started within the LAG ON delay time Offline When a pump is in the Offline mode it is not available to the Duplex controller The pump is held in the OFF state Hardware FORCE ON Each pump has a dedicate input signal which will force the pump ON When activated the Hardware FORCE ON input will force the pump ON if the pump is in the ONLINE Force On or Force OFF modes It will have no affect if the pump is in the OFFLINE mode The Zero Level LockOut will be observed Pump Mode Configuration The Pump Mode is configured by setting the Mode value within the Pump Configuration blocks See Pump Configuration below The LC_Config provides access to the Pump Mode information as part of the LC_Config Pump Status display See Below The Pump Mode information is made available as part of the Pump Run Time Data and Pump Run Time Status see Below Pump Health The Pump Health function monitors the seal leak detector and pump temperature inputs to determine the health of the pump The seal detection input for each pump may be connected directly to the seal leak signals from the pump or connected to an external seal leak relay contact The pump temperature input may be configured as normally open NO or a normally closed NC contact Timers are provided to ensure that the signals are valid for a specific time before acted upon Seal Leak Input The seal leak detector of a submersibl
39. check box and corresponding time Seconds indicates how often the Inflow rate is updated Tank Simulator The Tank simulator acts as a virtual tank with a user settable Inflow Rate The Auto Step parameter defines how often the tank information is updated After the step interval expires the Tank Simulator Calculates a new tank Level by calculating New Volume Inflow rate Pump 1 Flow Rate Pump 2 Flow Rate Elapsed Time 73 74 Rev 1 02 Chapter 9 LC Config Utility New Level New Volume Length Width Radius X Pi The Conversion Units is compared to the know constants see Level Detection and if known the units of measure are updated e Gallons Feet or Gallons Inches etc Similarly the Time Span parameter is used to determine if the controller is monitoring Units Hr Units Min or Units Sec The Dimension Units cannot be modified within the Simulator Changes to the Dimensions Units must be made through the device configuration screens The Refresh buttons will re read the current device settings At any time the current level may be reset to a user specified level The New Level is then passed to the Sensor Simulator Sensor Simulator The Sensor Simulator accepts a level from the Tank Simulator and translates it into a sensor voltage using the value provided by the Sensor Parameters read from the LC controller If the Sensor is reconfigured the Refresh button will re read the current
40. ct 16 IC Manual ON Pump will be turned on when the input is active ID Reset Pump Errors Note The 14 inputs are labeled IO 11 19 IA IB IC ID OUTPUT Description Q0 Active if any WARNING conditions exist Ql Active if any ERROR conditions exist Q2 Active if HIGH Level is reached Pump 1 Pump 2 Q3 Q4 Pump ON turn on pump when output is activated Q5 Sample Active Q6 Under range ERROR Q7 Over range ERROR Power Sensor Pump 1 Inputs Pump 2 Inputs Reset 59 74 00 o 0 00 amp 00 06 13 068 L M w BR B LC 1 Q0 Qi Q2 060 000 60600 6 R 19 IA B IC ID BOB OK ESC Q5 Q6 Q7 80 8 Warning Error High Alarm Sample Under Over Active Range Range Rev 1 02 Chapter 8 LC 6 HARDWARE INTERFACE LC 6 CONTROLLER The LC 6 Controller supports the addition of an I O expander APB 22ERD that provides additional status information outputs and optional discrete level inputs Note that power must be connected to both the controller and the expander unit INPUT Description 110 Discrete Zero Lockout Level 11 Discrete Off Level 112 Discrete Low Level 113 Discrete Mid Level 114 Discrete High Level 115 Discrete Purge Over range Level 116 11D Unused The discrete inputs may be used as backup inputs connected to float switches to protect agai
41. d relay may be swapped allowing the circuit to operate as a normally closed open if fail configuration By setting the gain to 1 and the offset to 10 00 normally closed open if fail contacts may be used If the seal leak input drops below the Warning Level the warning output is activated and the pump will be demoted removed from the lead position option but will still operate in the lag position If the seal leak input drops below the Error Level the error output is activated and the pump will be disabled A timer is provided to filter momentary level transitions The Seal Inputs to the controller are applied to analog threshold detector offering a gain offset and threshold value Setting the gain to 10 and the offset to O when connected to the circuit shown above will provide a approximate resistance reading K Ohms corresponding to the probe resistance Typical values for the Warning threshold is 80 00 Kohms and 50 00 Kohms for the Error Threshold The Seal Detection Filter Time ensures that the signal is stable The signal must be above the specified threshold for at least the Seal On Time typically 1 000 seconds before it is considered ON and must drop below the threshold for the Seal OFF time typically 0 100 seconds before it is considered OFF Over Temperature The Over Temperature contact is provided by the pump and if activated it indicates that the pump internal operatin
42. delay time A large sample delay time will reduce the cycling on air pumps but level detection will only be enabled during the Sample On time Large changes may occur if the Sample time is set to a large value a Sample Time gt lt Sample ON gt lt Sample Delay Lue Threshold Threshold 5 Threshold ette ON Time OFF Time OFF Time Time 1 1 5 i DIV Lx i User Defined A A Se Level t Level Threshold A AA AAA RO NI Po pa h ee an ES A va Sealed 7 TA ts L Level ene 4 A Level Output N In Auto Tune Mode the sample delay time is tuned by the system based on the user provided segment value Following a sample cycle the change in level is compared to the current segment size and if the level has changed more than the segment size the Sample Delay is reduced If the level has changed less than 1 2 of the segment size the Sample Delay is increased For all modes when the level is within 1 segment size of the next threshold level or if any pump is active the system automatically switches to continuous sampling Sampling Configuration The Sampling subsystem is configured by setting the sampling mode the Delay Time the Auto adjust Time the number of segments and the Sample Settling time 21 74 Rev 1 02 Chapter 3 LEVEL DETECTION Block Parameter Description 020 CMPR Offset Sample Settling Time 021 CMPR
43. e pump consists of a set of contacts that measures the resistance of the internal bearings area of the pump and if the resistance drops below 100k ohms it indicates that water has leaked past the internal seals of the pump If the controller is connected directly to the seal leak contacts of the pump it allows both a Warning Level typically 80 K ohms and an Error Level typically 50 K ohms to be set 34 74 Rev 1 02 Chapter 4 DUPLEX CONTROLLER The analog inputs of the controller has an input impedance of a nominal 50 Kohms The following circuit may be used to connect to the seal leak sensor of the pump directly to the controller input and the Table shows expected input voltages The zener diode 1N5240 or equivalent clamps the open circuit voltage at 10 0 volts Va 24 Vde Oil only gt 1mohm 10 Vdc 1 Condition Reait Voltage A R 25k 1 2 W a Interface R 25k 1 2 W Slight leak 100 kohm 7 5 Vdc Seal Leak Input Fault leak 50 kohm 5 0 Vdc R 50 kohm input Ss Short O ohm O volts lt Internal to controller _ do not install 0 Vde If an external Pump Seal relay is used it may be connected as a normally open close if fail contact between the SEALOK input and 24 Vdc supply Note that if an external seal leak relay is used the Error and Warning values should be set gt 100 K Ohms Only the Seal Error condition will be detected Alternatively the resistor an
44. ea Length X Width Radius X PI 44 74 Rev 1 02 Chapter 5 Flow Monitoring Units The dimensions may be entered as inches feet liters or other user defined scaler units The volume information is displayed as Gallons Imperial Gallons or Liters or other user defined units The Units parameter value is used to convert the volume to conventional flow units such as Gal Min The following table provides common conversion factors although other units of measurement may be used Units Conversion Factor Inches Feet Meters Other US Gallons 0 00433 Gal In 7 48052 Gal ft 264 17200 Gal m Imp Gallons 0 00360 Imp Gal In 6 22883 Imp Gal ft 219 96900 Imp Gal m Liters 0 01638 Liters In 28 31680 Liters ft 1000 00000 Liters m All flow calculations are done based on a 10 msec based clock which is resolved to 1 sec time span The Time Span value is used to convert the measured volume changes to specific intervals for example Gal Min Dimensions Units Configuration The Dimensions and Unit information is configured by setting the Length Width Radius Unit and Time Span parameters Block Parameter Description 015 WARP Offset Length 016 WARP Offset Width 017 WARP Offset Radius 018 WARP Offset Unit Conversion Factor 018 WARP Offset Time Span value The following LC_Config screen Configuration Dimensions shows the Dimension and Uni
45. ear analog input and provides DUPLEX pump controller outputs There is no Bubbler sub system An optional I O expander unit provides additional status outputs DC12V 24V ARR Y APB 22MRDL Power Size Environment EMC Inputs Outputs Levels Pump Sequencer Pump Health Run Verification Flow Optional 58 74 24 Vdc 100 mA 126 mm X 90 mm X 58 5 mm IEC68 2 IEC801 3 24 Vdc digital 200 kohms seal detect 0 10 Vdc 4 20 mA external level detect NO Relay 0 240 Vac 10 Amp resistive NPN sink 24 Vdc 2 Amp PNP Source 24 Vdc 2 Amp 5 Level Zero Off Low Mid High Set in Inches Feet or Meters 1 2 2 1 Alternating or user defined sequence 4 user defined sequences 2 user defined Time of Day sequence groups Seal Resistance Pump Temperature contact Auxiliary Contact Closure Pump Current Min Max Gallons Imp Gallons or Liters Reported per second minute or hour APB 22ERD expansion unit to provide additional status information and optional discrete inputs Rev 1 02 Chapter 8 Hardware Connections LC 6 HARDWARE INTERFACE The LC 6 controller Hardware Interface is shown below INPUT Description AIO 10 Sensor Input Analog Pump 1 Pump 2 All 11 Al7 17 Pump Seal Input Analog AR 12 AI8 18 Pump current level Analog 13 19 Pump Temperature contact 14 IA Pump Auxiliary contact 15 IB Pump Phase Error relay conta
46. el Level is gt Mid Level Threshold Segment Size M95 Variable Low Level Variable Range gt 1 M120 Zero Level Level is gt Zero Level Threshold prior to Ton and Toff delay processing M121 Off Level Level is gt Off Level Threshold prior to Ton and Toff delay processing M122 Low Level Level is gt Low Level Threshold prior to Ton and Toff delay processing M123 Mid Level Level is gt Mid Level Threshold prior to Ton and Toff delay processing M124 High Level Level is gt High Level Threshold prior to Ton and Toff delay processing Level Information with Discrete Inputs The flow calculations are dependent on accurate level information If discrete float inputs are used the corresponding Level configurations must accurately reflect the float levels The hysteresis values and variable low level information are ignored In addition there is no ability to detect when the level is approaching the Low or Mid levels LC_Config Level Display The LC_Config tool displays the LEVEL information as shown below Each of the level Thresholds are displayed and as the current level approaches the Low or Mid level the text color changes The current level is shown both graphically and as the actual value 26 74 Rev 1 02 Chapter 3 LEVEL DETECTION Tee E Auto Update F Auto Update IEA EA ee 27 74 Rev 1 02 Chapter 4 DUPLEX CONTROLLER Chapter 4 DUPLEX CONTROLLER The Duplex Controller sup
47. ent exceeded specified maximum current level M27 M59 Under Current Current less than specified minimum current level M28 M60 Offline Pump has been disabled by user See Pump Controls M29 M61 Disabled Pump removed from service due to an error condition ERROR M30 M62 Demoted Pump removed from Lead position due to warning condition WARNING M31 M63 Available Pump is available to participate in Lead Lag control M32 M64 Forced OFF Pump has been forced OFF by user See Pump Controls M33 M65 Forced ON Pump has been forced ON by user See Pump Controls M34 M66 Lead Select Pump will act as LEAD pump on next pump cycle M35 M67 Lead Call Pump has been called to act as the LEAD pump by the duplex controller active low M36 M68 Lag Call Pump will act as the LAG pump on the next pump cycle active Low M37 M69 Pump Called Pump has been called as Lead or Lag pump M38 M70 Pump Started Pump has been started 42 74 Rev 1 02 Chapter 4 DUPLEX CONTROLLER M39 M71 Flow Rate OK Flow rate is within user defined limits M130 M140 Temp NONC State of Temperature NO NC control bit M131 M141 Temp Temperature State prior to time ON OFF filtering M132 M142 Aux NONC State of Auxiliary Contact NO NC control bit M133 M143 Aux Auxiliary Contact State prior to time ON OFF filtering M134 M144 Phase NONC State of Phase Error Contact NO NC control bit M135 M145 Phase Auxiliary Phase
48. evel Change Level tz Level t The Sample Flow Volume information is calculated by the controller as Sample Flow Volume Level Change X Area X Units The Sample Flow Rate information is calculated by the controller as Sample Flow Rate Sample Flow Volume Sample Time Cycle Flow A cycle begins when the level rises above the Off Level The current level is latched as the Start Level and the Flow timer is started beginning the Inflow portion of the cycle When the level rises above the Low Level a pump will start The Inflow Volume and Rate are calculated as Inflow Volume Start Level Current Level X Area X Units Inflow Rate Inflow Volume Flow Time The Start Level is reset to the current level and the Flow Timer is reset starting the Outflow portion of the cycle When the pump is turned off the Outflow Volume and Rate are calculated as Outflow Volume Start Level Current Level X Area X Units Outflow Rate Outflow Volume Flow Time The calculated Outflow Rate and Volume are assigned to the currently operating pump These values are then added to the Total Flow Volume and Average Flow Rate values for the pump 47 74 Rev 1 02 Chapter 5 Increasing Decreasing Flags Flow Monitoring Internal Increasing Decreasing flags are set based on the change in levels between each successive Sample If the current level is greater than the previous level the Increasing Flag is set If the current
49. g temperature has been exceeded The pump will be disabled and will not operate until it has cooled The Temperature Inputs may be configured as Normally Open closes on error condition or Normally Closed opens on error condition The Temperature Filter ensures that the signal is stable The signal must be active for at least the Temperature On Time typically 1 000 seconds before it is considered ON and go inactive for the Temperature OFF time typically 0 100 seconds before it is considered OFF 35 74 Rev 1 02 Chapter 4 DUPLEX CONTROLLER Pump Health Configuration The Pump Health parameters are configured by setting the Seal Warning Level Thresholds and filter times and the Temperature NO NC state and filter time within the Pump Configuration blocks See Pump Configuration below The following LC_Config screen Configuration Pump Health shows the Pump Health parameters that may be configured The LC_Config configuration screen allows copying the parameters between Pump 1 and Pump 2 all Pump Health Configuration gt e xs Pump 1 Pump Configuration Seal Waming 2909 KOhms Gain 10 00 Offset 0 00 E eae Resistance s i gt Seal Warning Resistance Will demote the pump if resistance drops i below the indicated value Soa Warina SS Msec On 1 000 of 1 000 OS Sead Eror Seal Error Resistancce Will disable the pump if resistance drops Resistance 60 00 KOhms Gain 10 00 Offset 0 00 below the indicated value a SS Msec On 1
50. gh Alarm will be activated if level rises above the HIGH level 011 WARP Voff High Level Hysteresis 012 WARP Offset Threshold ON time time level must be at or above the setpoint to be turned ON 013 WARP Offset Threshold OFF time time level must be below the setpoint to be turned ON 014 CMPR Offset Range for auto adjustment of Low level The following LC_Config screen shows the Level Threshold parameters that may be configured 24 74 Rev 1 02 Chapter 3 LEVEL DETECTION a Level Detection Levels Level Detection Level HIGH Level Alarm Level HIGH Level 28 00 f MID Level Level to turn on LAG pump LOW Level Level to turn on LEAD Pump OFF Level Level to turn off pumps LOW Level 18 00 y f PUMP LOCKOUT Level to disable pumps MID Level 26 00 OFF Level 15 00 A non zero LOW RANGE will cause the controller to vary the Low range setpoint by the specified amount in 5 equal steps Setthe LOW RANGE to ee 8 00 0 for a fixed Low Setpoint value NOTE The LOW RANGE LOW SETPOINT must be less than the MID SETPOINT to avoid trigging the Lag pump Theshold Timers The Hysteresis level determines when the level is OFF If blank it will be set equal to 0 25 The Hysteresis level must be equal or less than zero Threshold ON Time Threshold OFF Time The Threshold Timers set the time that the level must remain stable in either the ON or OFF state Level Run Time Data The following LEVEL run
51. gh the PC USB interface but are internally treated as a conventional serial channel The APB DUSB adapter appears to the PC as a serial adapter and provides an alternative interface that connects directly to the LC Controller The Offline option allows using the LC_Config tool to prepare configuration files No interaction with external devices will occur and the Control Panels and Simulator are disabled _ Device Select xs Serial Ports USB Adaptors Offline COM5 v USBXpress Device v Device Device Address 1 5 FindNext Retries 3024 _ok_ canca The Device Address must correspond to an LC device connected to the interface adapter The default address is 1 although this may be changed using the LC HMI interface if several LC devices are connected to the same network The Number of Retries allows the communications to make several attempts if a communication failure occurs Find Next The Find Next option will cause LC_Config to search for each of the 254 possible devices addresses 1 254 to determine if any device is present When clicked the button will change to Cancel allowing the searching to be terminated Update Control Panel The Update Control panel allows viewing the individual Modbus transaction packets a button that will cause all control panels to be updated a button that allows continuous updating of selected control panels at a specific update rate and a final button t
52. hat allows pausing the automatic update 63 74 Rev 1 02 Chapter 9 LC Config Utility Modbus Traffic The Modbus Traffic button will open a separate display window that shows the Modbus transaction data In normal operation this is not required If used it should be noted that the updating of the display may impact the overall LC_Config update times The Suspend and Resume buttons only affect the display not the Modbus transactions The Hide display button collapses the display Modbus Traffic 01H 01H 26H 30H 00H 01H 01H 01H 01H 00H lt lt lt SYSTEM UPDATE gt gt gt 01H 03H 48H 1AH 00H 06H 01H 03H 0CH 00H 00H 00H 34H 00H 00H 00H 70H 00H 00H 50H E2H 01H 01H 26H 00H 00H 10H 01H 01H 02H 00H 08H 01H 01H 26H 58H 00H 08H 01H 01H 01H 83H 01H 03H 48H B6H 00H 0CH 01H 03H 18H 00H 00H 03H 20H 00H 00H 05H DCH 00H 00H 08H 98H 00H 00H 0AH 28H 00H 00H 0AH FOH 00H 00H 06H SDH 01H 03H 80H 2CH 00H 02H 01H 03H 04H 00H 00H 00H 01H 01H 03H 80H 04H 00H 02H 01H 03H 04H 00H 00H 4EH 20H lt lt lt SIMULATOR UPDATE gt gt gt 01H 10H 47H 00H 00H 02H 04H 00H 00H 01H 55H 01H 10H 47H 00H 00H 02H 01H 01H 26H 10H 00H 01H 01H 01H 01H 00H 01H 01H 26H 30H 00H 01H 01H 01H 01H 00H Chon Sap So it i Single Update The Single Update button will update all the LC_Config Control panels Auto Update The Auto Update button will update the LC_Config Control panels at a periodic rate determined by the
53. ided with an integrated HMI display and a Modbus compatible communications port Other custom user configurations are available Power Size Environment EMC Inputs Outputs Levels Bubbler Pump Sequencer Pump Health Run Verification Flow Specifications 24 Vdc 100 mA 126 mm X 90 mm X 58 5 mm IEC68 2 IEC801 3 24 Vdc digital 200 kohms seal detect 0 10 Vdc 4 20 mA external level detect NO Relay 0 240 Vac 10 Amp resistive NPN sink 24 Vdc 2 Amp PNP Source 24 Vdc 2 Amp 5 Level Zero Off Low Mid High Set in Inches Feet or Meters 1 or 2 air pumps with or without air tank 1 cm 0 3 Min sample rate 0 5 sec 1 2 2 1 Alternating or user defined sequence 4 user defined sequences 2 user defined Time of Day sequence groups Seal Resistance Pump Temperature contact Auxiliary Contact Closure Pump Current Min Max Gallons Imp Gallons or Liters Reported per second minute or hour Rev 1 02 Chapter 2 SYSTEM The LC family of level controllers consist of 5 major components a System controller a Level Detector a Duplex Pump controller Flow Monitoring and an optional Bubbler controller All implementations include a System controller that controls the overall operation of the device System Architecture Level Detector Linear or Discrete 5 Discrete Levels gt Duplex Pump Controller Pump Controller Pump Contr
54. ion cleared by pump Reset Error function 54 74 Rev 1 02 Chapter 6 BUBBLER SYSTEM LC_Config Bubbler Display The LC_Config tool displays the operating state of the two air pumps as shown below O e e WARNING O WARNING O Flow Rate Flow Rate Modbus Single Update Run Time r Reset Stats Reset Erors vV Auto Update Auto Update Auto Update Auto Update Auto Update Auto Update 55 74 Rev 1 02 Chapter 7 Chapter 7 LC 1 HARDWARE INTERFACE LC 1 HARDWARE INTERFACE The LC 1 configuration allows for a linear analog input and provides DUPLEX pump controller outputs and a Bubbler sub system DC12V 24V ARRAY APB 22MRDL Power Size Environment EMC Inputs Outputs Levels Bubbler Pump Sequencer Pump Health Run Verification Flow 56 74 24 Vdc 100 mA 126 mm X 90 mm X 58 5 mm IEC68 2 IEC801 3 24 Vdc digital 200 kohms seal detect 0 10 Vdc 4 20 mA external level detect NO Relay 0 240 Vac 10 Amp resistive NPN sink 24 Vdc 2 Amp PNP Source 24 Vdc 2 Amp 5 Level Zero Off Low Mid High Set in Inches Feet or Meters 1 or 2 air pumps with or without air tank 1 cm 0 3 Min sample rate 0 5 sec 1 2 2 1 Alternating or user defined sequence 4 user defined sequences 2 user defined Time of Day sequence groups Seal Resistance Pump Temperature contact Auxiliary Contact Closure Pump
55. ion Tool Tools Calibrate that sequences through the preceding steps 68 74 Rev 1 02 Chapter 9 al Calibrate Simulator LC Config Utility Calibrate the Sensor NOTE WHILE IN CALIBRATE MODE NO LEVEL CONTROL WILL BE PERFORMED The Sensor Scaling parameters accountfor sensor specific offset and gain factors The parameters should be setto provide a 0 volt offset when no level is preset The Level Scaling parameters account for conversion between the raw sensor input level volts to the corresponding engineering units The values should be adjusted to provide a 0 level at bottom of the tank and a valid level when the tank is half full The Start Machine option will disable the CALIBRATION MODE and enable the level control system ce a The Simulator option within the Tools menu links to the Main Menu Simulate option Options The Options screen allows setting the options to be configured when the LC_Config program first starts up These values are NOT updated during the operation of the LC_Config program but must be manually set by the user Options are automatically stored when LC_Config exits allowing the same operating environment to be used the next time the LC_Config program starts al Options 69 74 Configuation Files V Enforce Config Dates C Users Tom Documents LCProjex Project Folder Simulator Start Up
56. ith a full scale level presented to the sensor set the Stage 1 Gain to provide a 10 00 stage 1 output 4 With a zero level presented to the sensor set the Stage 2 Offset to provide a 0 00 stage 2 output 5 With a known level presented to the sensor set the Stage 2 Gain to provide the known level as the stage 2 output 6 Return the machine to the Run Mode To assist in the calibration process the LC_Config tool includes a Calibration Tool Tools Calibrate that sequences through the preceding steps a Calibrate Calibrate the Sensor NOTE WHILE IN CALIBRATE MODE NO LEVEL CONTROL WILL BE PERFORMED The Sensor Scaling parameters account for sensor specific offset and gain factors The parameters should be setto provide a 0 volt offset when no level is preset The Level Scaling parameters account for conversion between the raw sensor input level volts to the corresponding engineering units The values should be adjusted to provide a 0 level at bottom of the tank and a valid level when the tank is half full The Start Machine option will disable the CALIBRATION MODE and enable the level control system Sensor Run Time Data The following run time data is available for the Sensor Data Register Name Description DW16 Sensor Level The output from the Stage 2 buffer Dw21 Sensor Value The output from the Stage 1 buffer 19 74 Rev 1 02 Chapter 3 LEVEL DETECTION Sensor Ru
57. lator Pump 1 Simulator Pump 2 Simulator Offset 2 00 Max Max Flow Rate 40 00 Flow Rate 40 00 Simulator Max Level 10 00 HE Flow Rate 0 000 Flow Rate 0 000 Max Depth 50 00 InFlow Rate Stat Up 1 000 Stat Up 1 000 Enable Auto Step Y H 2 On Fault Shut Down 1 000 Shut Down 1 000 Aux Contact Aux Contact Fault Level 2 00 H Volts On Delay 0 010 On Delay 0 010 Dimensions Units O 0 00 Off Delay 0 010 Off Delay 0 010 Sensor Voltage C Enabled NO NC 7 Enabled NO NC Width 0 00 3 21 Current Current On Delay 0 010 On Delay 0 010 O Tank Simulator Max Depth 50 00 Off Delay 0 010 Off Delay 0 010 o ED y V Enabled Level 14 04 Level Change 0 23 are Pump 2 Volume 0 00 90m Or 0 Stage 1 Gain 1 01 Pump 1 Volume 1 63 Phase Error Contact Stage 1 Offset 2 00 On OF O Stage 2 Gain 15 50 Seal Resistance Stage 2 Offset 5 25 Resistance 90 0 72 74 Rev 1 02 Chapter 9 LC Config Utility There are three major components to the Simulator A Tank Simulator a Sensor Simulator and 2 Pump Simulators The simulator uses the parameters defined in the Level Detection subsystem Sensor Data and the Dimensions defined in the Flow Monitor subsystem Dimensions Time Span and Units When the Simulator window opens it immediately reads the Dimension Units and Sensor Gain Offset parameters from the current device and the state of the Simulation control logic on the
58. ller and is typically used when establishing the Sensor parameter Real Time Clock The device Real Time Clock is used to control alternate sequences within the Duplex Controller Setting the Real Time Clock may be performed through the HMI display or through the LC_Config application 11 74 Rev 1 02 Chapter 2 SYSTEM LC_Config System Configuration The following LC_Config screen Configuration System shows the System parameters that may be configured The LC_Config screen allows setting the Modbus address used to address the device the number of retries in case of communication failures the device Real Time Clock and the device operating mode To simplify setting the real time clock a PC Time button is available that reads the current PC time and date and loads it to the configuration screen device time of day display To modify the actual device time the Set Time button must be pressed The Device Address option allows changing the Modbus address used by the LC_Config application to access the device It does NOT change the address of the device If the device is not found an error message will be displayed To change the Device Address use the HMI interface screen or the LC_Config Modbus Interface tool all System Configuration Device Address Device Info LC 1 Version 1 05 BUBBLER 2 Air Pumps 2 Pumps Operating Mode Disable Run 0 Device Time Saturday Day Of Week Status Indicators Tw
59. ller with pump Health monitoring and Run Verification and integrated Flow Rate Monitoring Duplex Pump Controller Sampling Control Pump Run Verification Modbus The LC 1 provides a fully functional Level Control solution in a small DIN rail mounted controller The integrated HMI provides access to an extensive set of run time statistics covering pump health pump performance and system operating costs 6 74 Product Overview Product Overview Features Multi pump Tankless Bubbler system Alternator Variable duty factor Variable Sample rate auto tuning Auto purging Integrated Duplex Controller 2 pump control alternate 1 2 2 1 user defined automatic switch if lead fail Error Pump Health Monitoring Leak Seal monitor Pump Temperature monitor Run Verification e Aux Contact Monitor Current Monitor verifies current to pump Flow Rate monitoring Phase unbalance monitoring Integrated Flow Rate Monitor Measure rate of flow Low Outflow Error thresholds Extensive Diagnostics Indicators for Air Pump 4 Pump status Indicators for Off Low Mid 4 High Levels HMI statistics System amp individual pump run times Pump Flow rate Pump Seal Leak Resistance Communications Modbus RTU Ethernet Modbus TCP IP Highly Configurable All parameters configured thru HMI Password protected All values shown in engineering unit
60. lly lt 1 0 second The Time OFF determines the time that the contact may be momentarily open contact bounce before reporting a Phase Error Error Although designated as the Phase Error condition the Phase input may be connected to any fault detecting device The Phase Error are latched and can only be cleared by setting the Reset Error state to non zero Pump Run Verification Configuration The Pump Run Verification parameters are configured by setting the Auxiliary Contact NO NC state and filter time the Maximum and Minimum current thresholds and linearization parameters and the Phase Error NO NC state and filter time within the Pump Configuration blocks See Pump Configuration below The following LC_Config screen Configuration Pump Run Verification shows the Pump Run Verification parameters that may be configured The LC_Config configuration screen allows copying the parameters between Pump 1 and Pump 2 a Run Verification Configuration Pump 2 Pump Run Verification ded et 4 000 SS Msec Pump ON Settle Time Time requred for pump to turn ON Aux Contact Aux Contact NO NC complement sense of Aux Contact Input NO NC Ae Fier Ta 3 Aux Filter Time Filter time for Aux Input contact Mn Omo On 100 Hysteresis 000 Gain i Current MIN Min operating current with Gain Offset scaling Typical Values Gain 1 Offset 0 Min Current Filter Time On 1 i Current MIN Filter Time Min ON and OFF times f
61. mp RCS CU hss Soe esata a ease E E Ren eis Steet ih lie Neue hod aL aa eh ius Re 39 LC Config Pump Controller Dispara 39 Pump Configuration Blocks A ao 40 Pump Controller Run Time Data iS sa ata 41 Pump Controller Status Mirna tion E dense ede seesecedbaceasoeensvceovess sesveeen tre ted Eat ecans 42 Chapter 5 WEIN NC Heit teas A A a Meats 44 Holding Tank Coombs 44 3 74 Rev 1 02 Dimensions Units CONT Our at OM aise suis cpeiciesevicessciicae 45 Dimension Run Tim Data A Codie TE A da 46 Dimension Run Time SS sit tum oh ees saan bet teh ouch E oe euneialaday ce 46 BIG WTO A ead colada muon tienes 47 Sample FloW AS 47 Cycle lO A Oca ya i 47 Increasing Decreasing FLAGS A A cadwbyenduseas upedaueer eons Sen eeuaihes 48 Flow Information Rin Time Dia dE 48 Flow Information Run Time MU a ai eee nage 48 ESSE AR ee E ea ectle ela fas od A Panetta Mod aS 49 Chapter 6 BUBBLERS YS TEM unica AN eave tuted Advent e ia 50 Bubbler Controller id A da A eee sense vaneless 51 Bubbler Mode bea E E e E cea Ge vemos ead Gaye ms eau 51 Air Pump Rin PMeS a tes scoigetdee rata oan aio 52 E Se AES NRO ATU IV SNE ERAT ROMO SOE TEST NC E UTES NE 52 LC Config Bubbler CONSI OM ssoore ceicesdeselecsnazs pupitre ln ei detras 52 Bubbler R n Time DA A A A E A aa Gite 54 BUD DIE R n Tie Stats a 54 CC Config Bubbler Disp ay ss a e le eos tie a 55 Chapter Y TC II HARDWARE N R A CE 00 aa ei e di Ea ahai 56 Hardware Conner di 57 Chapter 8 LC 6 HARDWARE INTERFACE cc
62. n Time Status There is no Run Time Status available for the sensor Discrete Inputs Systems that use discrete inputs require no specific sensor configuration The five digital inputs are configured as Active High implying that the signal should be activated when the corresponding level switch is closed Level Sampling The level detection system sampling sequence is broken into 5 distinct time periods as shown below Time Period Units Description Sample Settling Time Secs msec Time required for level detection device to stabilize Threshold ON Time Secs msec Minimum time for a level to be at or above the threshold before being set ON Threshold OFF Time Secs msec Minimum time for a level to be under the threshold before being set OFF Threshold Timer Delay 0 5 secs Fixed 0 5 second threshold timer delay Sample Delay Secs msec Time delay before the next sample period Sample Settling Time The Sample Settling Time allows the input signal to stabilize For purely analog inputs Pressure transducer ultrasonics etc continuous Bubbler systems etc this time may be set to a minimum of 0 01 seconds For pulsed Bubbler systems this time represents the time required for the air flow to stabilize The Threshold ON and Threshold OFF times set as part of the Level Thresholds ensure that the level remains above or below the user defined level for a specified time typically 1 2 seconds At
63. ng the integrated HMT display A Windows based application program LC_Config is available that provides a GUI screen view of all operating parameters allows setting the configuration options and includes an integrated tank pump simulator Application profiles may be loaded from a computer file allowing fast configuration within the field and current operating statistics may be collected and saved Rev 1 02 Chapter 1 B LC Configuration Tool Modular Capabilities Product Configurations Nig e 2 alela lala A o me O o fom yu o a ye As 3 fe er Se a 3 ala E ES E O AIA S S e E o 2 3 Silo 0 13 28 7 2 33 8 oS ESA ESA Sarl e Flo 2 23 y 2 86 x 9 S 43 8 SIS aSa lg lE s a O E ES 5 e ES LC 1 XIXIXIXIXIXIXIX LC 2 xX xX XiX LC 3 xX X xX X LC 4 F IX XX X X Lc 5 X X LC 6 Xx X X X X X X The Standard LC 1 controller provides an advanced fully functional level control solution The LC 2 and LC 3 provides 5 discrete digital outputs which may be used with alternate Duplex Controllers The LC 4 and LC 5 accepts discrete inputs to provide a Duplex Controller with optional flow rate information providing a convenient add on for any existing level control product The LC 6 supports all the LC 1 functions with the exception of the Bubbler subsystem 9 74 Product Overview All products are prov
64. nked Air Pump 1 Runtime Air Pump 2 Runtime Air Blockage Blocked Level Blocked Hysteresis Max Purge Time The Air Pump Configuration determines how long each pump operates before switching to the alternate air pump The Bubbler Mode determines how the outputs operate refer to the User Manual Air Pump 1 will run forthe Air Pump 1 Runtime accumulated time and then switch to Air Pump 2 Setting Air Pump 1 Runtime to 0 0 will disable Air Pump 1 Air Pump 2 will run for the Air Pump 2 Runtime accumulated time and then switch to Air Pump 1 Setting Air Pump 2 Runtime to 0 0 will disable Air Pump 2 lf both Air Pump 1 and Air Pump 2 Runtimes are setto 0 0 the pumps will alternate on each sample NOTE The run time indicates the accumulated operating time If the sampling configuration is in timed or auto tune mode the run time indicates the times thatthe pumps are turned on The Blocked Level indicates the level which will cause a purge cycle The Max Purge Time sets the maximum Purge time before an error is reported 53 74 Rev 1 02 Chapter 6 BUBBLER SYSTEM Bubbler Run Time Data The following run time data is collected for each pump and is accessible through the indicated DW Registers DW Register Name Description Pump 1 Pump 2 DW64 DW72 Cycle Count The number of ON OFF cycles that the pump has experienced since the last reset see Pump Reset DW65 DW7
65. nst failures within the linear analog level detectors The discrete inputs are OR d with the comparator outputs see Level Detection and will force pump operation if the analog input fails If the discrete inputs are not used the corresponding input signals should be connected to O Vdc All discrete inputs are configured as normally open contacts When the level reaches a specific level the float switch should close applying a 24 Vdc input to the discrete input OUTPUT Description Q10 Pump 1 ERROR Disabled state Q11 Pump 1 WARNING Demoted state Q12 Pump 2 ERROR Disabled state Q13 Pump 2 WARNING Demoted state Q14 Level INCREASING Q15 Level DECREASING Q16 Q17 Unused The status outputs may be used to drive indicators to provide additional panel based information The I O Expander is optional If the unit is connected the LC 6 will be automatically configured to provide the additional outputs and process the discrete level inputs NOTE The LC 1 controller does NOT support the I O expander 60 74 Rev 1 02 Chapter 8 LC 6 HARDWARE INTERFACE Power Sensor Pump 1 Inputs Pump 2 Inputs Reset Power Discrete Inputs Unused Inputs Warning Error High Pump Pump2 Sample Under Over Pump Pump 1 Pump2 Pump2 Increase Decrease Unused Outputs Alarm Active Range Range Error Warning Error Warning 61 74 Rev 1 02 Chapter 9 LC Config Utility Chapter 9 LC_Config Utility The LC_Config applicati
66. o System Status indicators are available the WARNING indicator that indicates some non fatal abnormal condition exists and the ERROR indicator that indicates a machine fault exists A separate output is provided to indicate when the level exceeds the High Level point The following table summarizes the conditions that will activate the Warning and Error states 12 74 Rev 1 02 Chapter 2 SYSTEM Warning Condition Related To M6 Zero Lock Out disabled System M13 Machine Disabled System M30 Pump Demoted Duplex Controller M42 Pump Flow Not OK Duplex Controller M62 Pump 2 Demoted Duplex Controller M74 Pump 2 Flow Not OK Duplex Controller M88 Level below Zero Level Level Detection M113 Level Above Blocked Level Bubbler System indicates complemented logic active when off Error Condition Related To M29 Pump Disabled Duplex Controller M61 Pump 2 Disabled Duplex Controller M92 Level above High Level Level Detection M114 Blocked Error Bubbler System Run Time Data The following SYSTEM run time data is collected and is available through the indicated Data Registers All system run time data is retained if power is lost These values may not be reset Data Register Name Description DW13 Cycle Count The number of cycles that the system has experienced A cycle is initiated when the level rises above the OFF level and ends when the level dro
67. o convert input reading to K Ohms 028 TONF 044 TONF Ton Seal Warning Filter ON Time Toff Seal Warning Filter OFF Time 029 CMPR 045 CMPR Von Seal Error Level Gain Parameters to convert input reading to K Ohms Offset Parameters to convert input reading to K Ohms 030 TONF 046 TONF Ton Seal Error Filter ON Time Toff Seal Error Filter OFF Time 031 UDCT 047 UDCT Threshold Temperature Input O NO 1 NC 032 TONF 048 TONF Ton Temperature Error Filter ON Time Toff Temperature Error Filter OFF Time 033 UDCT 048 UDCT Threshold Auxiliary Contact Input O NO 1 NC 40 74 Rev 1 02 Chapter 4 DUPLEX CONTROLLER 034 TONF 050 TONF Ton Auxiliary Contact Filter ON Time Toff Auxiliary Contact Filter OFF Time 035 TOND 051 TOND Ton Pump Settling Time 036 WARP 052 WARP Von Maximum Current ON level Voff Maximum Current Hysteresis Gain Parameters to convert input reading to Amps Offset Parameters to convert input reading to Amps 037 TONF 053 TONF Ton Maximum Current Filter ON Time Toff Maximum Current Filter OFF Time 038 WARP 054 WARP Von Minimum Current ON level Voff Minimum Current Hysteresis Gain Parameters to convert input reading to Amps Offset Parameters to convert input reading to Amps 039 TONF 054 TONF Ton Minimum Current Filter ON Time Toff Minimum Current Filter OFF Time 040 UDCT 055 UDCT Thre
68. o extend the life of the pumps If a pump fails the alternate pump will be switched on If the measured air pressure rises above the expected maximum indicating a blocked bubbler line the system will attempt to purge the line If the air pressure drops below the expected minimum indicating a faulty pump the alternate pump will be switched on Bubbler Mode The bubbler system may be run as either a tank less system where the air pumps are directly connected to the air regulator or a tanked system where the air is pumped into a tank and released to the regulator through a pneumatic valve Three outputs are provided by the controller to control the air pump system The functioning of the outputs are determined by the Bubbler Mode configuration Setting the Bubble Mode to 2 disables the Bubbler controller functionality Output Bubbler Mode O Tankless Bubbler Mode 1 Tanked Apump1 Select Activates to turn on Pump 1 OFF if Pump 1 should operate ON if Pump 2 should operate Apump2 Valve Activates to turn on Pump 2 Activate pneumatic value to allow air flow Purge Active to bypass regulator to purge air line Active to bypass regulator to purge air line Tankless System Tanked System i 4 20 mA gt Pump 2 F Pump2 _ Check Valve Apump2 Valve Ri Pump 1 P Tank Pressure Purge Apumpl Select urge Switch Check Valve Apump 1 Select 51 74 Rev 1 02
69. oller Flow Monitoring System Configuration Bubbler Controller Air Pump Controller Air Pump Controller The system configuration information includes the firmware version and a configuration word that defines the hardware configuration and a control word the defines the operating mode of the device Block Parameter Description 000 THRD Gain Version ie 1 05 Offset Configuration Word Voff Simulator Mode 001 THRD Offset Operating Mode Gain Password Version The Firmware version number is represented as a Major Minor version number for example Version 1 05 The version information is not monitored by the LC device and should not be changed by the user Chapter 2 SYSTEM Configuration Word The configuration word consists of 4 fields Number of Bubbler Pumps 0 9 Detector Type 0 9 Number of Pumps 0 9 Model Type 0 99 0 2 indicating number of bubbler pumps used by 0 Discrete 0 2 indicating number of pumps LC Model Number Bubbler Controller 1 Linear used by Duplex Controller 2 Bubbler The configuration word is made available for configuration and monitoring tools such as the LC_Config application program to determine the hardware configuration The configuration word is not monitored by the LC device and should not be changed by the user Simulator Enable The Simulator Enable word configures the
70. oller Open Opens a configuration file and loads it to the device Save Saves the current device configuration file Save As Saves the current device configuration file Print Setup Allows setting the printer information to be used when printing the configuration report Print Preview Displays the configuration report on the screen prior to printing Print Prints a configuration report summarizing the current device configuration Exit Exit the program If the current configuration has not been saved the program will prompt asking whether the file should be saved 66 74 Rev 1 02 Chapter 9 Tools LC Config Utility The Tools menu options provide access to several accessories Modbus Interface The Modbus interface allows direct access to all of the internal LC controller DW data registers M Bit Registers control blocks parameters and the system Time of Day clock and Device Address Extreme care should be exercised in writing to any of the control blocks as the LC controller may be permanently damaged all ModBus Access Modbus Device Address Read Items Block Parameters v Access Type Block Parameters X Access Type Block Parameters X Access Type M Registers X Access Type Write Item Access Type Modbus 1 1 Parameter Parameter Parameter ltem 1 109 gt ltem 2 21201 Integer Z Enabled pon 3 1 Display AS ltem 4 OFF ON ON
71. on program operates on a Windows compatible PC providing a graphic configuration simulation and monitoring tool for the LC product family at LC Configuration Tool File Tools Configuration Project Simulator Help Y Auto Update V Auto Update T Auto Update 7 Auto Update F Auto Update Saved Demo lt Data logging Status gt Enabled Simulator ON USB Each of the 5 major components of the LC controller System Level Detector Duplex Controller Flow Monitoring and Bubbler system are represented by a number of control panels The Duplex Controller and Bubbler system each provide two panels one for each of the pumps used within the subsystem The operation of the LC_Config application is controlled by the Update Control panel Start Up When started the LC_Config tool displays a initial start up screen that allows selecting the interface type the device to be addressed and the number of retries in cases of communication failures The USBExpress device provides a USB to RS485 adapter that offloads the Modbus specific protocol from the PC and provides a higher performance and more reliable interface It requires a APB EXPMC Modbus adapter connected to the LC controller 62 74 Rev 1 02 Chapter 9 LC Config Utility The alternative interface is through a PC serial port The serial port adapter RS485 or RS232 must connect through an APB EXPMC interface Note that on many PC s the serial channels may connect throu
72. or signal change Current MAX Max operating current with Gain Offset scaling 2 50 Hysteresis 0 00 Gain i Typical Values Gain 1 Offset 0 Max Gaxrent Aller Time On Current MAX FilterTime Min ON and OFF times for signal change Phase Contact NO NC complement sense of Phase Contact input Phase Fitter Time On Phase Filter Time Filter time for Phase Input contact Max 650 00 The Flow Rate Min Max values set the acceptable range for the Rate 38 74 Rev 1 02 Chapter 4 Pump Reset DUPLEX CONTROLLER Two reset functions are available for each pump The Reset Error allows resetting the latched error status of the pump The Reset Statistics will reset the accumulated statistics for each pump The Reset operation is performed by writing a non zero value to the appropriate Data DW register Following the reset operation the register will be returned to zero When activated the Hardware Reset Signal will reset the latched error conditions on BOTH PUMPS LC_Config Pump Controller Display The LC_Config tool displays the PUMP CONTROLLER information as shown below al LC Configuration Tool File Tools Configuration System Disabled ON LockOut Calibrate Error Waming Pump ON O Increasing O Decreasing Q Details 1 Cycle Count Run Time 0 Total Pumped J Auto Update Project Simulator In Time Out Time 0 00 Start Level 0 00 Cycle Volume 0 00 In Flow Volume 0 00 In Flow Rate 0 00
73. owing SAMPLING run time status information is available through the indicated Bit Registers All status information is volatile not retained if power is lost Bit Register Name Description M96 Force Continuous System is forcing continuous mode M97 Continuous Mode Continuous mode Sample Delay lt 0 010 sec M98 Auto Tune Mode Auto Tuning mode Sample Adjust Time gt O M99 Segments Number of segments gt 1 M100 Sample ON Sample ON state is active M101 Sample ACTIVE Sample Settle Time has expired M102 Sample OFF Strobe Pulse generated at the end of the Sample ON time M103 Reserved Level Thresholds Five user defined Level Thresholds are supported Threshold Definition Zero Threshold Determines absolute lowest level Pumps will be disabled below the Zero Threshold Off Threshold When the level drops below the OFF threshold the duplex pump controller will turn off the pumps Low Threshold When the level goes above the LOW threshold the LEAD pump will be turned on Mid Threshold When the level goes above the MID threshold the LAG pump will be turned on High Threshold When the level goes above the HIGH threshold the HIGH ALARM will be activated Variable Low Threshold In normal operation the Lead pump will be activated whenever the Low Threshold is reached To introduce a degree of variation in the low level to avoid build up on the tank wall a Variable Low Range value
74. ports a Lead and Lag pump system with flexible sequencing options and extensive pump health and run time verification System Architecture Duplex Pump Controller Level Detector Pump Controller Linear or 5 Discrete Levels Discrete Flow Monitoring Bubbler Controller Air Pump Controller System Controller Air Pump Controller The Duplex Controller is implemented as 3 major components a Pump Sequencer that selects which pump should operate and two Pump Controllers Each Pump controller includes a Pump Health monitor that ensures the pump is capable of operating and a Run Verification monitor that ensures that the pump operates within specifications In addition several manual control functions are provided to allow enabling and controlling each pump as well as clearing error conditions and run time statistics The Duplex Controller supports 2 pumps When the level rises above the specified Low Level one of the pumps designated as the ead pump will be turned on When the level drops below the OFF Level the pump will turn off The selection of which pump should act as the Lead pump is determined by the Sequencer If the level continues to rise after the lead pump is activated and reaches the Mid Level the second pump referred to as the ag pump will turn on and both pumps will remain on until the level drops below the Off Level A l
75. ps below the OFF level DW14 Run Time The number of days hours mins that the system has been operating The maximum value is 999 999 999 minutes representing 1902 years DW15 Total Pumped Total volume pumped The maximum value is 999 999 999 and is provided in the units selected when configuring the system Flow information The value provided is the sum of the Pump 1 and Pump 2 Flow Volume information Cleared by pump Reset Statistics retained on loss of power Run Time Status The following SYSTEM run time status information is available through the indicated Bit Registers All status information is volatile not retained if power is lost Bit Register Name Description MO 5 Reserved Reserved M6 LockOut Disabled Zero detect lockout has been disabled 13 74 Rev 1 02 Chapter 2 SYSTEM M7 Calibrate Mode System is in the calibrate mode M8 System Warning A warning condition exists M9 System Error An error condition exists Cleared by clearing the corresponding error condition M10 Any Pump ON One of the pumps is active M11 Increasing Level increased during the last sample period M12 Decreasing Level decreased during the last sample period M13 Machine Disabled System is in the Disabled mode M14 Second Tick Internal second clock tick M15 Minute Tick Internal minute clock tick LC_Config System Display The LC_Config tool displ
76. pump should act as the lead pump for EVEN and ODD cycles Odd Cycles None For 1 2 sequencing Pump 1 always LEAD select pump 1 for both Sequence 2 EVEN and ODD cycles Even Cycles For 2 1 sequencing Pump 2 always LEAD select pump 2 for both Odd Cycles gt z EVEN and ODD cycles For Alternating sequencing alternate which pump is LEAD select aE ny ee Pump 1 for EVEN cycles and Pump 2 for ODD cycles Time Entry 1 Mode Yearly X 2012 Jan vy 1 amp OFF Date 126 0 BI OK Time If NONE is selected the pumps are activated atthe MID level If BOTH is selected both pumps will turn on atthe LOW level Sequence 1 is used ifthe Sequence Scheduling time is OFF Sequence 2 is used ifthe Sequence Scheduling time is ON Sequence Timing The Lag ON delay determines the minimum delay to turn on the Lag Day 0 000 SS Msec pump after the LEAD pump is turned ON Lead Pump 0 100 SSMsec Of ng 0 100 SS Msec OFF Delay The Lead and Lag OFF delays determine whether the system uses Last ON First OFF LOFO or First ON First OFF FOFO turn off sequencing Retesh SOA Sequencer Run Time Data The following Sequencer run time information is available through the indicated DW Registers All SEQUENCING run time data except the Actual Sample ON and OFF times is volatile not retained if power is lost Data Register Name Description DW82 Group 1 Even Seq
77. s support for U S Imperial and Metric units Rev 1 02 Chapter 1 Level Detection The level detection subsystem accepts an analog signal representing the current liquid level and is scaled to standard engineering units feet meters etc before being compared to user defined thresholds setting one of 5 different output states indicating the current level Bubbler Controller The Bubbler controller provides a fully integrated bubbler control subsystem to monitor liquid levels The bubbler may be operated with or without air storage tanks and supports both continuous and pulsed pump operation greatly extending the air pump life times The bubbler supports dual air sources and provides timed alternation between the two sources In a tank less system air pumps provide the air directly to the bubbler tube eliminating the air tank To maximize pump lifetimes the pumps may be activated on a timed basis and the alternate pump will be switched on in the case of a failure Flow Rate Monitoring Flow rate monitoring measures the change in level between successive samples to determine the overall In Flow Out Flow and individual pump flow rates The tank geometry is used to calculate the flow in standard engineering units The user may select between US Imperial or metric measurement units Alarm and or warning outputs will be activated if the measured flow rate exceeds specific rates 7 74 Product Overview Duple
78. s an Aux Contact Error 36 74 Rev 1 02 Chapter 4 DUPLEX CONTROLLER If the Auxiliary contact closes and then re opens while the pump is running it is treated as a Thermal Overload Error indicating that the contactor has prematurely opened The Auxiliary Contact Time ON determines the maximum time for the pump starter auxiliary contact to close after the pump activation signal and is typically lt 1 0 second The Time OFF is reserved and should be set to 0 010 seconds The Aux Contact Error and the Thermal Overload Error are latched and can only be cleared by setting the Reset Error state to non zero Pump Current After the Pump On delay time the pump current is monitored and compared to a high and low threshold detector Each detector includes hysteresis to avoid false readings due to signal jitter as well as a dual timer to ensure that the signal is stable If the current is above the high threshold an Over Current Error is reported If the current is below the low threshold an Under Current Error is reported Current Monitor ON OFF Latch mm Level n Timer gt ON OFF The Input Scaling converts the input signal into standard engineering units Amps allowing user defined levels to be specified in the corresponding threshold comparator The Current Gain and Current Offset parameters allow converting the current sensor signal to Amps Analog Level JoyeredwoD
79. s the Length setthe Width to 1 and set the Radius to 0 Dimension Run Time Data The following Dimension and Unit run time information is available through the indicated DW Registers All Dimension run time data is non volatile retained if power is lost Data Register Name Description DW100 Length Value provided by Dimension Configuration DW101 Width Value provided by Dimension Configuration DW102 Radius Value provided by Dimension Configuration DW103 Units Value provided by Dimension Configuration DW104 Time Span Value provided by Dimension Configuration DW105 UnitArea Calculated as Length X Width Radius X 3 142 X Units DW106 Circular Area Calculated as Radius X 3 142 Dimension Run Time Status There is no Dimension Run Time status information 46 74 Rev 1 02 Chapter 5 Flow Monitoring Flow Information To estimate the flow rates for each pump the following assumptions are mode when each pump is first activated during a pump down cycle 1 The Inflow rate remains relatively constant 2 The flow rates of any currently operating pumps remains relatively constant If these two conditions are met any change in the Net Outflow Rate will be due to the incremental flow rate contributed by the pump that is being activated Sample Flow At the end of the Sample ON Time the current level is latched and used to calculate the level change between each sample Sample L
80. s z E 00 00 00 23 59 59 ON or OFF 7 Wed X E z 00 00 00 23 59 59 ON or OFF 8 Thurs z 00 00 00 23 59 59 ON or OFF 9 Fri z R x A 00 00 00 23 59 59 ON or OFF 10 Sat 00 00 00 23 59 59 ON or OFF 11 Sun z gt g 00 00 00 23 59 59 ON or OFF 12 Mon Thurs z 00 00 00 23 59 59 ON or OFF 13 Mon Fri 00 00 00 23 59 59 ON or OFF 14 Mon Sat 00 00 00 23 59 59 ON or OFF 15 Fri Sun 00 00 00 23 59 59 ON or OFF 16 Sat Sun 2 E 00 00 00 23 59 59 ON or OFF 30 74 Rev 1 02 Chapter 4 DUPLEX CONTROLLER Lag ON Delay The Lag ON Delay specifies the minimum delay time between turning on the Lead and Lag pumps preventing large current inrushes if both pumps are required to operate at the same time Turn Off Sequence If both the Lead and Lag pump have been activated the turn off sequence is controlled by the Lead OFF Delay and Lag Off Delay times If the Lead OFF Delay is less than the Lag OFF Delay the lead pump will turn off first First ON First OFF If the Lead OFF Delay is greater than the Lag OFF Delay the lead pump will turn off last First ON Last OFF Condition Turn Off Type Description Lead OFF Delay gt Lag OFF Delay FOLO The Lead pump is always turned on first Since the Lead OFF delay is gt than the Lag Off delay the turn off sequence is First ON Last OFF Lead OFF Delay lt Lag OFF Delay FOFO The Lead pump is always turned on first Since the
81. shold Phase Error Contact Input O NO 1 NC 041 TONF 056 TONF Ton Phase Error Contact Filter ON Time Toff Phase Error Contact Filter OFF Time 042 WARP 059 WARP Von Minimum acceptable flow rate Voff Maximum acceptable flow rate Pump Controller Run Time Data The following run time data is collected for each pump and is accessible through the indicated DW Registers DW Register Name Description Pump 1 Pump 2 DW32 DW48 Pump Mode Mode provided in Pump Configuration Block DW33 DW49 Cycle Count The number of ON OFF cycles that the pump has experienced since the last reset see Pump Reset DW34 DW50 Run Time The number of days hours mins that the pump has been operating since the last reset see Pump Reset DW35 DW51 Flow Rate The flow rate from the time the pump was activated Low Level threshold to the time that the pump was deactivated Off Level threshold DW36 DW52 Current The current being drawn by the pump DW37 DW53 Seal Resistance The resistance of the seal input circuit Typically shown in K Ohms but specific units may be programmed by setting the corresponding Offset amp Gain of the seal input scaling function DW38 DW54 Flow Volume The volume pumped from the time the pump was activated Low Level threshold to 41 74 Rev 1 02 Chapter 4 DUPLEX CONTROLLER the time that the pump was deactivated Off
82. statistics and run time information may be called up and error and warning conditions will be immediately displayed taking the guess work out system maintenance Communications Communications adapters allow parameters to be set using Modbus RS485 RTU or Modbus TCP IP Ethernet connections allowing all run time statistics to be easily collected An SMS adapter allows errors to be reported on remote phone systems Small Size DC12V 24V ARRAY APB 22MRDL The DIN rail mounted LC 1 measuring 3 5 X 5 requires a minimum space Some models support an I O expansion unit that provides additional status outputs Typical Application The following application illustrates an LC 1 controller providing level control on a waste water lift station A dual air pump tank less bubbler system is used for level monitoring with the duplex pump control system that provides run verification power monitoring and flow rate statistics 8 74 Product Overview Redundant Air Pump Tankless Bubbler Level Control with Duplex Pump Control Run Time Verification and Flow Monitoring 1 Li 1 1 1 Air Pump 1 1 1 1 1 1 pD Air Pump A Cp Purge Pump Health Pressure 4 20 mA Current amp Power Monitor Pump 1 Pump 2 Air Pump 1 e Error Error Error 0 Configuration Support Installations may be fully configured in the field usi
83. t parameters that may be configured The LC_Config interface allows selecting common scaler dimensions inches feet meters and common volume units Gallons Imperial Gallons Liters and will insert the appropriate Unit value User defined conversion factors may be entered Common time intervals seconds minutes hours may be selected or a user defined Time Span value may be entered 45 74 Rev 1 02 Chapter 5 Flow Monitoring all Units Dimensions Setup Flow Rate Units Set the Units of Measure US Gal Liters Imp Gal Other Enter Value Flow rate information uses a volume unit constant to calculate flow rate Select US Gallons Imperial Gallons Liters or Other Selecting Other allows Flow Rate Time entering arbitrary unit conversion values 0 Per Second Select the time span used for the flow rate calculation Per Minute For example Gal Minute or Gal Hour Set the tank Dimensions Meters Selectthe units inches feet meters to be used for the dimensions cura The Units parameter will be calculated using the dimension units la feet inches meters and the flow rate selection gal imp gal liters E Iftank is square rectangular enter the Width and the Length and set the Radius to 0 Width 0 00 Inches Iftank is circular enter the Radius and setthe Width and the Length to 0 Iftank is oblong enter the Width Length and Radius Radius 2 00 CELIA 1256 Iftank is non geometric enter the Area a
84. the FLOW information as shown below 49 74 Rev 1 02 Chapter 6 BUBBLER SYSTEM Chapter 6 BUBBLER SYSTEM The Bubbler controller provides full control over two air pumps to provide pressure to the bubbler system in with or without an air tank Tank less or Tanked system A pressure transducer 4 20 mA or 0 10 Volt may be used to measure the bubbler air pressure and is used as the sensor input to the Level Detection system System Architecture Duplex Pump Controller Level Detector Pump Controller Linear or Discrete Flow Monitoring Air Pump Controller System Controller Air Pump Controller A Bubbler system measures the depth of a liquid by forcing bubbles up from the bottom The air pressure required to force the bubbles is directly proportional to the depth of the liquid A pressure transmitter connected in the air supply path may be connected to the Analog input of the Level Detector system to determine the depth of the liquid A regulator is used to provide a constant air flow Pressure Transmitter 4 20 mA The 4 20 mA signal will be directly proportional to the depth of the liquid 50 74 Rev 1 02 Chapter 6 BUBBLER SYSTEM Bubbler Controller The Bubbler controller manages 1 or 2 air pumps with an option to use an Air Tank In a dual pump system the pumps are alternated based on the accumulated running time t
85. the end of the Sample ON time the outputs of the Input Scaling amplifier and each of the 5 level detectors are latched and will remain constant until the end of the next Sample Settle Time The Sample ON time is calculated by the system as Sample ON Sample Settling Time Threshold ON Threshold OFF 0 5 seconds Sample Segments The distance between the previous setpoint level and the next setpoint level is divided by a user provided Segment value to determine the Segment size The sampling system may adjust the sampling algorithm based on the calculated segment 20 74 Rev 1 02 Chapter 3 LEVEL DETECTION Sample Mode The Sample rate is determined by the user or can be automatically calculated by the system and will determine the overall sampling rate of the system The mode of sampling depends on the Sample Delay time and the Sample Adjust Time parameters allows three different options Mode Delay Time Adjust Time Description Continuous 0 010 sec 0 Sampling is done continuously Timed 0 010 sec 0 The sample delay is set by the Sample Delay Time parameter Auto 0 010 sec gt 0 010 sec The sample delay is calculated by the system to achieve 1 sample per segment The sample Delay Time determines the maximum delay between samples In the Continuous Mode the sampling is done continuously with a minimal delay time between each sample In the Timed Mode the user defines the sample
86. x Pump Controller An integrated Duplex Pump controller is provided that provides a wide range of user defined pump alternating sequences that may be modified based on an internal Time of Day timer The Timer supports 32 set points which may be activated on a daily weekly or monthly basis Pump activity is triggered by the Level Detection subsystem and flow rate monitoring is provided for each pump If the current LEAD pump fails the LAG pump is automatically switch in Pump Health Monitoring Pumps exist in four states ONLINE LEAD or LAG pump DEMOTED LAG pump only DISABLED will not be activated or OFFLINE user disabled Pump Health Monitoring uses seal leak detection pump over temperature detection and conditions from the Flow Rate and Run Verification subsystems to determine the state of each pump Run Verification Run verification ensures that when activated a pump operates within it s specified operating range The system monitors the auxiliary contact from the motor starter and the pump current The operating current upper and lower ranges may be set as both warnings demoted or error offline levels Operating warnings and errors are made available as discrete outputs to activate external alarm systems as well as being accessible from both the HMI and communication interfaces Rev 1 02 Chapter 1 HMI Display An HMI display allows setting all parameters and may be password protected All operating

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