Universal Pump Control

Transcription

1 Universal Pump Cntrl Operatinal Instructins versin 1.00 UPC Operatinal Features The TXAM Pumps Universal Pump Cntrl is available in AC, DC r Brushless Mtr cnfiguratins. Can be cnfigured t perate ALL TXAM Pumps. Cmmn Setup and Operatins, Independent f the Pump Type. Watertight Enclsure with a Seven Switch Keypad and 2 x 20 Line Display. Built in Mdbus Interface t Allw Cnnectin t a Mdbus Master. A 4 20mA Input fr External Clsed Lp Cntrl f the pump. Optinal Temperature Prbe allws fr Multipint Temperature Cntrlled Operatin. Pump Prime Feature and Manifld Valve Cntrl. Flashing LED t Indicate Operatin, LED Heartbeat at One Secnd. Incrprates Energy Saving Pump Cutback peratin t extend peratin f a Battery (Patented). Lw Battery Shutdwn. Inhibit Cntact Input.

2 Cntrller A seven switch keypad is used fr pump peratinal cntrl with a tw line display that displays infrmatin & prmpts fr: Setup Mde Rate Setting Pump Operatin Additinally, the timer may be cntrlled slely by a 4 t 20mA Lp, Mdbus r a Cntact Inhibit.

3 Settings The UPC may be cnfigured fr any f the fllwing peratins 1. Cycles per Minute (with Patented life extending battery peratin) 2. On Time / Off Time Cntrl in Secnds 3. On Time / Off Time Cntrl in Minutes 4. Quarts per Day 5. Liters per Day 6. Gallns per Day 7. Batch Operatin (Quarts) 8. Mdbus Cntrlled 9. Manifld Cntrl (Quarts) 10. Manifld Cntrl (Time Based) 11. Remte 4 20mA Lp Cntrlled 12. Cntact Clsure Inhibit Operatin 13. Single r Multiple Temperature Set Pint Operatin Set Pint Range by Mde f Operatin CpM (Cycles per Minute) 1 t 10 cycles per minute, duratin 1 t five secnds (On Time) On/Off Time Secnds 0.5 t 90 secnds in half secnd increments On Time 1 t 240 secnds in ne secnd increments Off Time On/Off Time Minutes 10 t 240 Minutes (4 hurs) in ten minute increments On Time 10 t 1440 Minutes (24 hurs) in ten minute increments Off Time Quarts per Day, Liters per Day and Gallns per Day 1 t 99 (may be limited by pump selectin) Max Head Capacity Set Range is 12 t 99 Gallns

4 Operatin When the UPC pwers n a quick self test is perfrmed and pump mtr type detectin is perfrmed and then it displays infrmatin abut the peratinal settings. Pressing the ON/OFF key pwers the UPC (Universal Pump Cntrl) n and ff. Pressing the SETUP key the UPC will prmpt yu with questins. Yu then use the up/dwn keys t select the answer and then press the enter key fr selectin. Yu can just press ENTER t select the currently displayed answer. One f the imprtant questins which is critical is the Max Head Capacity. This is the amunt f chemical that the pump is capable f pumping per day. This capacity is used fr all rate calculatins. Setting this parameter crrectly will imprve pump accuracy and adjustments t this allw yu t hne in t an accurate rate. Watching the tank sight glass during a prime cycle allws yu t determine the Max Head Capacity. Pressing and hlding dwn the SETUP key fr abut 5 secnds will initiate a pump prime cycle, this is a 30 secnd cntinuus run f the pump. Pressing it again allws yu t abrt the prime cycle. If yu are cntrlling a manifld, the prime cycle is run fr each valve. The display will cunt dwn the time left until it resumes nrmal peratin. Pressing the MODE key will allw yu t cycle thrugh different mdes f peratin. The display will display the peratinal mde and by then using the up/dwn keys allw selectins f the ther mdes which are Cycles per Minute, On time/off time in secnds, On time/off time in Minutes, Quarts per day, Liters per Day, Gallns per day, Batch Cntrl mde, Mdbus peratin, Manifld Cntrl Quarts, Manifld cntrl Time based, r 4 20mA lp cntrlled. If yu press the RATE key it allws yu t change the rate f the pump. Fr example, the number f Quarts r Gallns being pumped, r the On/Off Time. Always press the Enter key after yur selectin fr the rate t take effect. Sme rate changes will nt take effect until the next cycle. The display indicates the system is perating. Anytime yu select SETUP r MODE keys and entering infrmatin with the Enter key yu will be prmpted t enter a new rate. Als if yu select the SETUP r MODE keys the pump will stp, and wait fr yu t enter infrmatin. Pressing the UP key while in nrmal peratin causes the display t display the battery vltage (r if it is an AC pump it displays the internal pwer supply vltage). Pressing the DOWN key while in nrmal peratin will display several types f infrmatin. The display always blanks ut after a few minutes when n keys have been pressed. The first key press while there is a blanked display will bring the display back n. Nte the green LED in the upper left crners flashes each secnd t let yu knw the UPC has pwer n. If yu see the LED flash at a slwer rate (2 SEC s) that indicates the pumping has stpped due t Temperature settings.

5 Definitins f Terms in the Setup Menu Remte Cntact this indicates hw the Status Input will be used 1. Inhibit mde indicates that the input will stp pump peratin if a cntact clses. 2. Status mde indicates this input is nly fr infrmatin fr Mdbus. 3. Flw Switch Input indicates a flw switch is cnnected ad passes Flw/N Flw infrmatin t Mdbus. Max Head Capacity is the amunt f chemical that the pump set is capable f pumping per day. This capacity is used fr all rate calculatins, but des nt affect CpM r On/OFF mdes. This number is based n the mtr, plunger, strke, head, etc. This can be determined by asking TXAM Pumps Persnal r by running a prime cycle. Mtr Speed, the DC mtrs speed may be adjusted t ther than 100% t allw fine tuning f the chemical injectin rate. Temperature cntrl can be enabled r disabled (if it is enabled and the prbe is unplugged the temperature cntrl will be active until a temperature prbe is detected). Multi Temperature enable allws fr fur different temperature set pints with independent rates. On Temperature is the temperature that the pump will start peratin. Off Temperature is the temperature that the pump will stp peratin. Pre batch wetting time is a delay that allws a valve t pen befre starting a batch. Pst batch flush time is a delay that allws a valve t pen r clse after a batch. Batch Delay t Start is the time delay befre a batch treatment actually starts after pwer up. Battery Saver mde is a incremental rate cut back based n lw battery vltage, t allw the pump t run fr a lnger amunt f time as ppsed t just stpping all peratin. This feature is typically sught after as an additin and is a standard feature built in. Nte: Setting mtr speed is nrmally used t lwer rates while running CpM r On/Off Time mdes. When running in Quarts, Liters r Gallns, the mtr shuld be set t 100%, unless yu are fine tuning the pump rate. Anything ther than 100% will cause the rate calculatin mde t be ff. Variable Speed settings are nly available when using a DC mtr. Fr AC applicatins yu will need t surce a VFD (Variable Frequency Drive) r use ur DC mtr with AC inverter. The Display will ask prmpting questins r prvide infrmatin when keys are pressed and will guide yu thrugh peratin. Always pwer ff timer prir t any wrk n pump

6 DC PUMP SELECTION HWP100 DC HBT1 HBT2 HBT3 HBTEXP DC HBTEXP BLDC 3/16" MAX GPD 3/16" MAX GPD 3/16" MAX GPD 3/16" MAX GPD 3/16" MAX GPD PSI PSI PSI PSI PSI Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 MAX 8 MAX 13 MAX 11 MAX 12 MAX 13 HWP100 DC HBT1 HBT2 HBT3 HBTEXP DC HBTEXP BLDC 1/4" MAX GPD 1/4" MAX GPD 1/4" MAX GPD 1/4" MAX GPD 1/4" MAX GPD 1/4" MAX GPD PSI PSI PSI PSI PSI PSI Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 MAX 7.7 MAX 15 MAX 23 MAX 17 MAX 21 MAX 25 HWP100 HBT1 HBT2 HBT3 HBTEXP DC HBTEXP BLDC 3/8" MAX GPD 3/8" MAX GPD 3/8" MAX GPD 3/8" MAX GPD 3/8" MAX GPD 3/8" MAX GPD PSI PSI PSI PSI PSI PSI Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 MAX 17.2 MAX 32 MAX 50 MAX 36 MAX 48 MAX 52 HBT1 HBT2 HBT3 HBTEXP DC HBTEXP BLDC 1/2" MAX GPD 1/2" MAX GPD 1/2" MAX GPD 1/2" MAX GPD 1/2" MAX GPD PSI PSI PSI PSI PSI Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 MAX 53 MAX 90 MAX 63 MAX 86 MAX 93 HBT2 HBT3 HBTEXP DC HBTEXP BLDC 1" MAX GPD 1" MAX GPD 1" MAX GPD 1" MAX GPD PSI PSI PSI PSI Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 MAX 320 MAX 248 MAX 305 MAX 325 AC PUMP SELECTION HWP100 AC HBT2 AC HBT2 AC Inverted HBT3 AC Inverted HBTEXP AC HBTEXP AC IGB 3/16" MAX GPD 3/16" MAX GPD 3/16" MAX GPD 3/16" MAX GPD 3/16" MAX GPD PSI PSI PSI PSI PSI Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 MAX 12 MAX 13 MAX 12 MAX 13 MAX 13 HWP100 AC HBT2 AC HBT2 AC Inverted HBT3 AC Inverted HBTEXP AC HBTEXP AC IGB 1/4" MAX GPD 1/4" MAX GPD 1/4" MAX GPD 1/4" MAX GPD 1/4" MAX GPD 1/4" MAX GPD PSI PSI PSI PSI PSI PSI Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 MAX 11.5 MAX 21 MAX 25 MAX 19 MAX 22 MAX 22 HWP100 HBT2 AC HBT2 AC Inverted HBT3 AC Inverted HBTEXP AC HBTEXP AC IGB 3/8" MAX GPD 3/8" MAX GPD 3/8" MAX GPD 3/8" MAX GPD 3/8" MAX GPD 3/8" MAX GPD PSI PSI PSI PSI PSI PSI Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 MAX 25.9 MAX 47 MAX 53 MAX 41 MAX 48 MAX 47 HBT2 AC HBT2 AC Inverted HBT3 AC Inverted HBTEXP AC HBTEXP AC IGB 1/2" MAX GPD 1/2" MAX GPD 1/2" MAX GPD 1/2" MAX GPD 1/2" MAX GPD PSI PSI PSI PSI PSI Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 MAX 85 MAX 92 MAX 74 MAX 87 MAX 86 HBT2 AC Inverted HBT3 AC Inverted HBTEXP AC HBTEXP AC IGB 1" MAX GPD 1" MAX GPD 1" MAX GPD 1" MAX GPD PSI PSI PSI PSI Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 Cntrl Setting 0 MAX 325 MAX 251 MAX 305 MAX 300

7 TXAM Pumps Universal Pump Cntrl Mdbus Registers ver1.00 Register Example Data Infrmatin C mments 0xnn indicates hex number, nn indicate decimal number(unsigned) Cntrl Cils Functin cde Pump On/Off 0xff00 Turn Pump ON = 0xff00 and OFF=0000 (hex)standard mdbus Cil 1 cntrls the pump ON and OFF (nte: befre 1st cntrl wrks must write pump type and value) Discrete Inputs Functin cde Temerature Status COLD 1 Temp sensr status fr belw 32 degrees 0 = Abve 32 degrees, 1 = Belw 32 Degrees System is turned n Running 0 System run status requested t be n/ff 0 = System halted, 1 = System Running Initializatin cmplete 1 System up and running has cmpleted initializatin 0 = Nt Initialized, 1 = OK Battery Vltage OK 1 Battery abve is 10.8 vlts 0 = Lw Battery, 1 = Battery OK Temperature inhibit 0 Temperature nt stpping peratin system within limits 0 = Temperture in Operating Range, 1 = Outside Temperature SetPints Vltage Cutback 1 Vltage getting lw 0 = Vltage OK, 1 = Battery Lw Runnning in Cutback Operatin Temerature Prbe Fault 1 Temperature Prbe status 0 = Prbe wrking, 1 = Prbe fault nt cnnected Invalid mdbus mde 1 Mdbus has sent an invalid peratinal mde 0 = Mdbus Data Valid, 1 = mdbus set invalid peratinal mde Hlding Registers functin cde 06 (03 fr read) Readback is in upper byte after set Timer Mde Type f peratin 0x0000 Strkes per 2 minute peratin = 00 Operatinal mde 00 = CpM 1 = n/ff secs, 2 = n/0ff minutes, see belw Run setpint value 0x cycles per minute and each cycle is 5 secnds 1 10 cycles, 1 t 5 secnds n time, see belw fr ther ranges Nt Used Temperature Set Pint 60 Set Temperature set pint Hi=60 F (OFF temperature) Range 30 t 90 F (if yu read this register bytes are swapped) Temperature Set Pint 30 Set Temperature set pint Lw=30 F (ON Temperature) Range 30 t 90 F (recmmend read setpints using Reg and 30011) Temperature Enable / Disable 1 Temperature Cntrl Enable r Disable 0 = Disable, 1 = Enable Temperature Cntrl (any nn zer = enable) Alternate t lwer byte 05 Cycle On Time 5 secnds Alternate t upper byte 02 2 Cycles per Minute NOTE: fr prper peratin the high (OFF) temperature Shuld be 4 degrees higher than the Lw temperature Input Registers functin cde External Input Status 0x0001 External Cntact Status Input current Status input state 0 = pen, 1 = clsed External Input Flw Switch 0x0001 External Cntact Flw input (flw fault status) 0 = flw OK, 1 = n flw fr 10 minutes Heat Sink Over Temperature 0x0001 BLDC heat sink t ht 0 = temperature OK, 1 = t ht Spare 0x0003 Unused Always set t Sftware Versin_Base 0x0010 ver 1.0 (versin number in lw byte) Used fr Internal Huskeeping functins Analg Input 164 Analg Input n Terminal Blck 164 = 4ma, 819 = 20ma Raw A/D reading Mtr Amps 121 Mtr Current DC Mtr ONLY 12.1 amps Value x 0.1 this reading is nly availiable n DC mtr Sftware Versin_Cntrl 100 ver 1.00 (versin number in lw byte) Used fr Internal Huskeeping functins Battery Vltage 126 Battery Vltage = 12.6 i.e. incming value x 0.1 Range 8 t 20 vlt Temperature Sensr 0077 Temperature Value is 77 degrees F Range 32 t +158 F Temperature High set pint 0060 Temperature OFF Set Pint Hi=60 F Range 20 t 70 F Temperature Lw set pint 0020 Temperature ON Set Pint L=20 F Range 20 t 70 F Head Capacity 0050 Setting fr Maximum Pump Rate Range 15 t 100 gallns per day UPM Pump Type 0001 Bard ID 0= DC, 1 = AC, 2 = Brushless Speed Setting 0050 Mtr Speed speed = 50% Range 2 t Spare 0015 Unused Always set t 15 (0x000F) Mdes f Operatin Settable Range 0 = Cycles per Minute 1 t 10 Cycles, 1 t 5 Secnd On Timer Each Cycle 1 = On time Off time in Secnds On Time 1 t 180, Off Time 1 t 240 (each cunt is 1/2 secnd) 2 = On time Off time in Minutes On Time 1 t 240 minutes, ff time 1 t 1440 minutes 3 = Quarts per Day 1 t 99 Quarts 4 = Liters per Day 1 t 99 Liters 5 = Gallns per Day 1 t 90 Gallns 6 = Batch Mde 1 t 100 Quarts, 1 t 30 days delay until next batch peratin

8 Valve Cntrl Bard (VCB 8 ) The Valve Cntrl Bard cntrls eight Slenids fr valve/manifld cntrl. It may be cntrlled either by the Universal Pump Cntrl r by a Mdbus master. It cntrls up t eight valves. When all valves are clsed the LED flashes fast, if any valve is pen the LED flashes each secnd. When pwer is applied t the VCB (12V) all valves are clsed, if yu install a jumper frm IN1 t Gnd n terminal blck TB2 the VCB will pwer up and pen valve 1. Terminal blck TB1 is the cnnectins fr the cntrl cmmands that cme frm either the Universal Pump Cntrl r Mdbus. T perate with Universal Pump Cntrl, all the DIP Switches n the bard must be OFF. Mdbus Cntrl Mde Clse Switch # 4 fr use with Mdbus. Switches 1, 2, 3 will set the Mdbus Slave Address frm 40 t 47. Mdbus Cntrls Valves 1 t 8, Mdbus will Write Cils 1 t 8. Cil ON = Valve Open Cil OFF = Valve Clsed. Valve Cntrl Bard Test Switch Pressing the test buttn in the upper right hand crner f the VCB will allw each valve t pen fr tw secnds, starting with valve 1, then valve 2, and s n in sequence. Once the manifld has cycled thrugh all eight valves the test is ver. If necessary, yu may repeat this test as desired. POWER IN TB1 & TB2 TEST Switch DIP Switches FLOW SWITCH CONNECTIONS SOLENOID CONNECTIONS

9 Universal Pump Cntrl (UPC) The display will autmatically blank ut after a few minutes withut any keys being pressed. If the display blanks ut, mmentary press the Setup key t light the display. Operatinal Mde Selectin There are tw mdes f peratin that will cntrl a manifld. T select an peratin t cntrl the manifld press the mde key and then use the up/dwn keys t select either Manifld Quarts/Day r Manifld Timed Based (and then press the enter key). When using the Valve Cntrl Bard, be sure that yu select the Setup key and answer the prmpted questins. A very imprtant questin is the Max Head Capacity; this is the ttal vlume the pump head is capable f pumping each day if it were t run cntinuusly (see max head capacity chart and chse yur pump mdel & head size). Answering the questin prperly based n the Max Head Capacity chart prvided will determine the accuracy f the Quarts/Day. This calculatin is always used when yu are in the Manifld Quarts/Day Mde. The pump will nly run nly when a valve is pen, the pump mmentarily turns ff as ne valve clses and restarts when the next valve pens. This is typically abut half a secnd. Manifld Time Based Mde Manifld Time Based allws yu t enter the amunt f time each slenid (valve) will be pened. The valves are numbered 1 t 8, yu will be prmpted t select an ON Time (valve pen and pump run time) fr each valve. This time has a range frm 0 t 60 secnds. (Zer (0) means skip the valve). Yu will be prmpted fr an ff time with a range f 0 t 120 secnds. This is the delay time after valves #8 clses and befre repening valve number 1. This is the time when n valve is pen and befre the cycle starts ver. Manifld Quarts/Day Mde Manifld Quarts/Day allws yu t set the amunt f quarts yu want t pump frm each line (valve) each day. The range is 0 t 24 quarts. If zer is set it means this valve will nt be used. If the ttal quarts (cmbinatin f all eight settings) is mre than the pump is capable f pumping, a message will appear n the screen requesting yu re enter new rates. NOTE: T run a Prime Cycle, hld dwn the Setup key fr 4 r mre secnds and then release it. The way a prime cycle wrks with manifld cntrl is that each valve will pen in sequence (1 t 8) and the pump will run fr 30 secnds with each valve, it then repeats fr each valve. If yu press the Setup key while in a prime cycle, it will end the time perid fr the pen valve and cycle t the next valve. Fr Cmplete UPC Operatinal Instructins refer t the UPC Operatin Manual.