The Flow Monitor and Pump Verification unit allows collecting 'rate of flow' information on existing Duplex Pump control systems and the verification of the run time characteristics of the external pumps. By monitoring the flow rate of each pump and the auxiliary contact, pump current and phase error inputs the unit ensures that the pump system is operating within specified bounds and allows the early detection of deteriorating pump performance. provides flow rate monitoring and pump run time verification. + (OPTIONAL) The early detection of a failing pump allows a significant reduction in expensive repairs and reduces the possibility of catastrophic system failures, reducing maintenance and overall operating costs. System parameters and run time statistics may be entered and viewed through the integrated HMI display or through a Modbus communications channel. The unit is supported by the LC_Config Windows based utility program for configuration, monitoring and data collection. An analog level sensor (0-10 Vdc, or 4-20 ma) may be connected to provide increased accuracy of the flow rate information and provides 5 discrete output levels (Lockout, Off, Low, Mid, High, Sensor Fault) for level discrimination, allowing the unit to act as an analog level discriminator and flow monitoring front end to discrete level Duplex controllers. I/O Expander adds Bubbler Controller and Level Discrimination outputs An integrated Bubbler controller, designed to minimize air flow requirements is provided to support low cost analog level sensing. As a member of the Ingram Products LC family of level management products the is implemented utilizing a standard set of firmware and hardware building blocks. Features The provides a low cost solution for applications requiring the addition of flow monitoring and level detection to existing Duplex control systems. 2 wire interface allows simple Flow Monitoring on existing DUPLEX controller systems Monitors inflow rate, min/max flow rate, individual pump flow rates and pump operating times Optional pump activation monitoring to ensure pumps are operating Small (71mm X 90 mm) package with integral HMI display Modular design, compatible to entire LC Family of Level Management products Low power (12-24 Vdc, 100 ma) operation Network (Modbus) support Optional PC/Windows configuration & monitoring Integrated Bubbler controller minimizes air flow requirements I/O Expansion Options Level discriminator providing 5 discrete outputs Extended pump status indicators Data Sheet 1 10/12
Flow Monitor The includes a Flow Rate Monitor, an Analog Level detector, a pump Run Time Verification system and a Bubbler controller. In the simplest applications only the Flow Rate Monitor is used, requiring only 2 connections (pump activation signals) to the external Duplex controller. The use of the Analog Level Detection function increases Flow Rate monitoring accuracy and provides 5 discrete level outputs through the I/O expansion unit. Level Detection Duplex Pump Controller By connecting an addition 2 signals (Low & Mid level contacts) or, when using the Analog Level detector, the controller will monitor pump activity and indicate an error if the external Duplex controller fails to activate the pumps. Additional pump Run Time Verification is provided by monitoring the motor starter Auxiliary contact, the current drawn by the pump and an external connection to a Phase Error sensor for each pump. Flow Rate Monitor Sampling Control Pump Health Monitoring The integrated Bubbler controller supports both tanked and tankless bubbler systems with a sampling mechanism designed to minimize air flow requirements. Bubbler Controller HMI Display Pump Run Verification Modbus The product family is built using standard hardware controllers that provide an integral HMI display, a Modbus communications option and I/O expansion options. The is provided in small (126 mm X 90 mm), DIN rail mounted controller. The integrated HMI provides access to run time statistics including flow and pump specific rates, averages, min/max values, pump operating times and pump failures. Power Sensor Pump Activity Level Reset Pump 1 Verification Pump 2 Verification A Modbus communications port allows networking multiple LC products and supports PC based configuration, monitoring, simulation and project management. External 24 Vdc power must be applied to the controller. The Sensor input is not required for all installations. If used, the sensor signal may be 0-10 Vdc, or for 4-20 ma sensors a 500 ohm resistance may be connected in parallel. The Pump inputs are connected to the existing Duplex controller and are used to sense when the pumps have been activated. The optional Level inputs allow the controller to verify that at least one pump has been activated by the Duplex controller. L+ M I0 I1 I2 I3 I4 I5 I6 I7 I8 I9 IA IB IC ID Error Increasing Decreasing Pump 1 Error Flow 35.25 O Level 18.35 O Pump 1 O Sts O Pump 2 O Sts O Pump 2 Error Air Pump 1 Air Pump 2 + OK ESC Q0 Q1 -- Q2 Q3 Q4 Q5 Q6 Q7 Purge The reset clears error conditions or the flow start cycle data. Data Sheet 2 10/12
Pump verifications from each pump include: 1. Auxiliary contact closure indicates that the motor contactor has been activated 2. Pump Current analog signal indicating number of amps drawn by the pump 3. Phase Error contact closure indicating a phase error has occurred. Five relay outputs are provided to drive indicators and to signal error conditions. Three outputs are provided to operate an optional Bubbler controller. Field Wiring Controller I/O Expander INPUT Description INPUT Description AI0 (I0) Sensor Input (Analog) I10 <unused> I1 Pump 1 Activation I11 <unused> I2 Pump 2 Activation I12 <unused> I3 Low Level (discrete input) I13 <unused> I4 Mid Level (discrete input) I14 <unused> I5 Flow Monitor Reset I15 <unused> I6 Error Reset I16 <unused> AI7 (I7) Pump 1 Current I17 <unused> I8 Pump 1 Auxiliary Contact I18 <unused> I9 Pump 1 Phase Error Contact I19 <unused> AIA (IA) Pump 1 Current I1A <unused> IB Pump 1 Auxiliary Contact I1B <unused> IC Pump 1 Phase Error Contact I1C <unused> ID <unused> I1D <unused> Analog signals: 0 10 Vdc or 4-20 ma (500 ohm resistor in parallel) Digital signals: 0-24 Vdc (5 volt threshold), configurable as Normally Open or Normally Closed LC-1 Controller I/O Expander INPUT Description INPUT Description Q0 Error Q10 Lockout Level (Level Discriminator output) Q1 Increasing (level is increasing) Q11 Off Level (Level Discriminator output) Q2 Decreasing (level is decreasing) Q12 Low Level (Level Discriminator output) Q3 Air Pump 1 / Flow (Sample Active) Q13 Mid Level (Level Discriminator output) Q4 Air Pump 2 / Select Q14 High Level (Level Discriminator output) Q5 Purge Q15 Purge Level (Level Discriminator output) Q6 Q16 Pump 1 Warning Q7 Q17 Pump 2 Warning Relay Outputs: 0-24 Vdc @ 10 Amps, 120/240 Vac @ 10 Amps (resistive), 2 Amps (inductive) Special Order: NPN or PNP outputs, 24 Vdc @ 2 Amps Power: 12-24 Vdc @ 100 ma. The LC product family is UL508a compliant when used with Class II power. Slave UL508a compliant relays should be used when switching voltages greater than 48 Vdc. Data Sheet 3 10/12
Flow Rate Monitoring The LC Family Flow Rate monitoring subsystem uses the change in levels over time and the known tank dimensions to calculate pump flow rates and flow volumes. The controller uses the pump activation by an external Duplex controller to determine flow activity. For the controller it is assumed that the pumps are controlled by an external pump (Duplex) controller and the following actions are taken: 1. The Lead pump will turn on when the level reaches the LOW level 2. The Lag pump will turn on when the level reaches the MID level 3. Both pumps will turn off when the level drops to the OFF level In the simplest applications the pump activation signals from the Duplex controller are connected to the controller. If the Duplex controller uses 24 Vdc control signals these may be directly connected to the. If necessary, interposing relays may be used to connect 120/240 Vac activation signals to the. The may be configured to accept Normally Open or Normally Closed contacts. Outputs may be connected to indicators or other control equipment as required. Connecting the discrete level inputs (Low and Mid) allows the to monitor the current level information and verify that at least one of the pumps has been activated when the level is above the LOW level. If the existing duplex controller uses 24 Vdc discrete inputs the connections may be made in parallel, otherwise interposing relays are required. The inputs may be configured as Normally Open (active at specified level) or Normally closed (inactive at the specified level). The inputs include time filtering to eliminate false signals due to contact noise. The pump activation time is configurable to allow for Duplex controller delays. }Low/Mid Level signals Data Sheet 4 10/12
Pump Run Verification Pump Run Verification ensures that when activated a pump operates within specifications. The monitors the state of the Low and Mid level inputs (or uses the actual measured level see Analog Level Detection) and ensures that at least one pump is activated within a user specified delay time if either the Low or Mid level inputs have been activated. The monitors the Auxiliary contact from the motor starter to ensure that the contactor closes within a specified time. Once closed, the controller continues to monitor the auxiliary contact closure and assumes that a premature open state has been caused by a thermal overload relay connected to the motor starter. The pump current is monitored using a low cost current transducer. In most applications a single phase of the pump may be monitored. If required, a more elaborate 3 phase power monitor may be used (0-10 Vdc or 4-20 ma output) to allow tracking the 3 phase power usage. A low cost phase monitoring relay may be connected to the pump and the output contact connected to the pump phase error input. Pump 1 Aux Contact, Pump 2 Aux Contact, }Low/Mid Level signals Analog Level Detector In the preceding configurations the flow calculations are based on user defined levels corresponding to the external Duplex controller OFF/LOW/MID levels and the corresponding pump On/Off activity. Flow rate accuracy can be greatly increased by adding an Analog level detector input to the controller such that the flow calculations and pump activation monitoring are based on the actual measured level when the pump inputs are activated. Analog Signal Level Pump 1 Aux Contact, Pump 2 Aux Contact, Optional Run Verifications inputs Data Sheet 5 10/12
The analog level signal may be connected to an external sensor (ultra-sonic, radar, pressure etc.) or, if the existing Duplex controller uses an analog level input, connected in parallel to the existing sensor. Internal scaling parameters allow converting virtually any 0-10 Vdc or 4-20 ma signal into standard engineering units (inches, feet, meters etc.). Flow calculations and pump activation monitoring will be done using the actual levels detected when the pump signals are turned On or Off. The external connections to the Low/Mid sensors are not required. Bubbler Controller/Level Detection The provides 3 outputs that support the Bubbler control sub-system. The Bubbler sub-system supports systems with one or two pumps, with or without an air reservoir tank. To minimize air usage the bubbler outputs activate the air flow only when a level sample is required. In 2 pump systems the pumps are alternated using a user defined duty cycle. A purge output signal may be used to activate a purge function if the bubbler pressure rises above a user defined setpoint. Analog Signal Level Bubbler Control Purge APump 1/Select Pump 1 Aux Contact, Pump 2 Aux Contact, Optional Run Verifications inputs APump 2/Flow Bubbler systems use the measured air pressure required to cause bubbles to flow through a depth of liquid to determine the depth of the liquid. They offer a low cost, intrinsically safe measurement technique, requiring only a low pressure air supply (typically ~ 12 psi), a pressure regulator and a low cost pressure transducer that provides a 0-10 Vdc or 4-20 ma signal proportional to the measured air pressure. Systems without an air reservoir (tankless) activate the air pumps when a level sample is required. Systems using an air reservoir tank (tanked) activate a pneumatic valve to allow air to flow from the tank when a level sample is required. The Apump 1/Flow signal enables the flow of bubbler air (tanked systems) or activates Air Pump 1 (tankless). The Apump 2/Select signal selects between Air Pump 1 and Air Pump 2 (tanked systems) or activates Air Pump 2 (tankless). The Purge output is activated when the air pressure exceeds a user defined threshold, indicating a blocked bubbler line. Level Discriminator If an external analog Level Detector and I/O Expander is used the will provide 5 discrete level contact closures, allowing the unit to act as a Level Detector/Flow Monitoring and Run Time Verification front end to external Duplex controllers that only accept discrete level switch inputs. The levels are fully programmable in standard engineering units and provide both time filtering and hysteresis to ensure consistent level detection. The controller supports a 'variable' LOW level option that causes the LOW level threshold to be automatically varied over a user defined range. The outputs may be configured as Normally Open (close at specified level) or Normally Closed (open at specified level). Data Sheet 6 10/12
Analog Signal Level Bubbler Control Purge APump 1/Select Pump 1 Aux Contact, Pump 2 Aux Contact, Optional Run Verifications inputs APump 2/Flow Inputs to external Duplex Controller Zero Off Low Mid High I/O Expander Pump 1 Warning Pump 2 Warning External Communications The may be configured and operating statistics are accessible using the integrated HMI display. In addition, the unit may be configured and monitored using across a standard Modbus/RTU network. To connect the unit to a Modbus network the APB-EXPMC Modbus adapter may be used. The APB-DUSB adapter provides a low cost, single point adapter allowing the unit to be connected to a PC/Windows computer for configuration and monitoring purposes. LC_Config The LC_Config application program operates on a Windows based PC and provides a graphic interface for configuring and monitoring the LC Family of controllers. The configuration utility includes a set of program management tools to streamline the configuration and commissioning of devices as well as providing run time monitoring of flow data and pump performance. The LC_Config program may communicate to an device using a Modbus RTU interface through the APB-EXPMC adapter or the APB-DUSB USB adapter. Data Sheet 7 10/12
Specifications Specification Controller I/O Expander Notes Power 24 Vdc, @ 100 ma 24 Vdc, @ 100 ma Size 126 mm X 90 mm X 58.5 mm 126 mm X 90 mm X 58.5 mm Environment IEC68-2 IEC68-2 EMC IEC801-3 IEC801-3 Inputs (digital) 24 Vdc (Off = 0-5, On = 10-24) Inputs (analog) 0-10 Vdc, 50 kohm impedance Analog Level Detector Pump 1 & 2 Current monitoring Outputs Outputs (special order) Relay 24 Vdc, 10 Amp, 240 Vac, 10 Amp resistive 240 Vac, 2 Amp inductive NPN (sink) 24 Vdc, 2 Amp PNP (source) 24 Vdc, 2 Amp Relay 24 Vdc, 10 Amp, 240 Vac, 10 Amp resistive 240 Vac, 2 Amp inductive NPN (sink) 24 Vdc, 2 Amp PNP (source) 24 Vdc, 2 Amp Level Input Level Discrimination Flow Run Verification Bubbler 0-10 Vdc or 4-20 ma +ve/-ve displacement Gallons, Imperial Gallons, Meters Reported in seconds, minutes, hours Auxiliary Contact closure Pump Current Pump Phase Error Relay contact Min sample rate 0.5 sec One or two air pumps with pump alternator, variable duty cycle Time filtering & Hysteresis Dual stage scaling 5 levels (Lockout, Off, On, Mid, High) User defined in inches, feet or meters Data Sheet 8 10/12