Bell & Gossett 10-001-275 XLS User Manual

INSTRUCTION MANUAL

10-001-275

THIS MANUAL IS FOR TECHNICIAN USE ONLY

™

XLS

Integrated Pump

Controller

HUMAN MACHINE INTERFACE (HMI) FOR THE TECHNOFORCE™ BOOSTER SYSTEM

TECHNICIAN GUIDE

Acknowledgements

All materials ©2014 by Xylem Inc.
All rights reserved. No parts of this work may be reproduced in any form or by any means -

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reserved.

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PUBLISHER AND THE AUTHOR ASSUME NO RESPONSIBILITY FOR ERRORS OR OMISSIONS,
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OR

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COMMERCIAL DAMAGE CAUSED OR ALLEGED TO HAVE BEEN CAUSED DIRECTLY
INDIRECTLY

BY THIS

DOCUMENT.

graphic,

retrieval

include

DOCUMENT

OR

of the

THE

OR

EVENT
OTHER

2

Table of Contents

ACKNOWLEDGEMENTS .................................................. 2

INTRODUCTION

HMI OVERVIEW

TYPICAL PUMPING OPERATION

TOUCH-SCREEN PANEL OPERATION

SYSTEM BOOT UP

BOOSTER SCREEN LAYOUT

USER TYPES

TOUCH PANEL LOGIN

HOME SCREEN NAVIGATION

PUMP STATUS
STATION DISCHARGE STATUS
MODES OF OPERATION

Auto

Manual
ALTERNATION SETUP
LOW PRESSURE OVERRIDE
SYSTEM VIEW

Trends

Technical Overview
ALARM TAB
SETPOINT TAB
SERVICE TAB

Lockout Setup

Events

Email Setup

Set Sync HMI-PLC Date/Time

Security Setup

Tuning..................................................................... 19

System Setup

Analog Scaling

Alarm Conguration

ENERGY TAB
COMMUNICATIONS TAB

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PID Settings
Supplemental Control
Combos

Pump Curve Conguration

Station Information
Basic Pump Information

Zone Conguration
Pump Conguration

Control Options

Combo Denitions

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WEB REPORTS

Log on to Web Reports................................................ 31

Web Reports Menu...................................................... 31

Trend View
Alarms Report
Historical Report
Usage Report
Smart Phone and PDA access:

APPENDIX A - GLOSSARY OF TERMS

APPENDIX B - NETWORKING OPTIONS

APPENDIX C - TYPICAL ALARMS CONFIGURATION

APPENDIX D - EMAIL TROUBLESHOOTING

DETERMINING THE IP ADDRESS OF THE SMTP
SERVER
TROUBLESHOOTING GENERAL EMAIL FAILURES

Troubleshooting Email SET Failures
Troubleshooting Email Send Failures

APPENDIX E: COMPUTER SETUP AND DETERMINING

THE IP ADDRESS OF YOUR PUMP STATION ............... 44

DETERMINING THE IP ADDRESS:

APPENDIX F – GENERAL NETWORKING AND ROUTER

CONFIGURATION DISCUSSION: ................................... 48

APPENDIX G – QUICK START GUIDE:

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.. 38

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41

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SETUP/CONFIGURATION FILE

NETWORKING AND REMOTE ACCESS

Remote Software Log In

...................................... 30

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Table of Figures/Tables

Figure 1 Connection for USB Keyboard (c) ........................ 6

Figure 2: Start Up Screen
Figure 3: Basic Booster Home Screen
Figure 4: Guest Service Screen
Figure 5: Supervisor Service Screen
Figure 6: Log In Screen
Figure 7: Log In Keypad
Figure 8: Technician Service Screen
Figure 9: Home Screen Navigation
Figure 10: Pump Symbols
Figure 11: Pump Switch Screen
Figure 12: Pump Detail
Figure 13: Pump Information
Figure 14: Station Discharge Status
Figure 15: Basic Booster Idle Screen
Figure 16: Basic Booster Manual Screen
Figure 17: Manual On/Off
Figure 18: Manual Pump Control Screen

Figure 19: Default Alternation Screen................................11

Figure 20: Example Alternation Screen

Figure 21: Low Pressure Override.....................................11

Figure 22: Trends Screen

Figure 23: Congure Period
Figure 24: Congure Data

Figure 25: Technical Overview
Figure 26: Combo Information

Figure 27: Combo Information Detail................................ 13

Figure 28: Alarms Home Screen

Figure 29: Period Screen.................................................. 14

Figure 30: Alarm Warning
Figure 31: Setpoint Home Screen
Figure 32: Setpoint Detail A

Figure 33: Setpoint Detail B.............................................. 14

Figure 34: Setpoint Detail C
Figure 35: Setpoint Detail D

Figure 36: Setpoint Detail E.............................................. 15

Figure 37: Service Home Screen
Figure 38: Lockout Screen
Figure 39: Individual Lockout Setup
Figure 40: Parameter Tab in Lockout Setup
Figure 41: Event Setup
Figure 42: Email Settings

Figure 43: Set/Sync Screen.............................................. 18

Figure 44: Sync Pop-up Detail.......................................... 18

Figure 45: Clear/Update Totalizers
Figure 46: Security Setup Home Screen
Figure 47: User Setup

Figure 48: Tuning Home Screen....................................... 19

Figure 49: Tuning PID Drop Down.................................... 19

Figure 50: Supplemental Control Home Screen
Figure 51: Combos Home Screen

Figure 52: Pump Conguration Home Screen.................. 23

Figure 53: Station Information

Figure 54: Conguration File

Figure 55: File Browser
Figure 56: Basic Pump Information
Figure 57: Zone Totalizer Setup

Figure 58: Service Pump Conguration............................ 25

Figure 59: Service Pump Type Conguration

Figure 60: Control Options

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Figure 61: Combo Denitions

Figure 62: Analog Scaling................................................. 26

Figure 63: Analog Scaling Channel Detail

Figure 64: Alarm Conguration

Figure 65: Energy Home Screen
Figure 66: Flow Totals Overview
Figure 67: Daily Flow Totals Overview.

Figure 68: Communications Home Screen....................... 28

Figure 69: Communications Protocol Selection................ 28

Figure 70: Communications Protocol Selection 2............. 28

Figure 71: Communications Protocol Selection 3............. 28

Figure 72: Active X & IP Updates
Figure 73: WinCE Remote Access
Figure 74: Web Reports Menu
Figure 75: Trends View
Figure 76: Alarms & Events
Figure 77: Historical Reports
Figure 78: Usage Reports

Table 1: MODBUS Settings
Table 2: BacNet Settings

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For additional questions, contact your local
Bell & Gossett Representative.

Introduction

This manual is written for Bell & Gossett Technicians
and is an introduction to the XLS HMI (Human
Machine Interface). The HMI is a browser- based
system which allows the user to interact with the
settings and reports of the pumping system.
manual only covers the HMI aspect of the
Please see the TechnoForce Booster Instruction
Manual for any questions not related

to

This manual assumes that the reader has used
understands basic Internet browser operation
has used a Microsoft© Windows Operating
GUI (Graphical User Interface), such as
2000©, Windows NT©, Windows ME©, or
XP©. This device uses Windows CE-as
operating
component-based version of the

system (OS). Windows CE© is

Windows
operating system designed for embedded
such as PDAs or touch-panel

displays.

This manual also assumes the user has some
knowledge of pumps and pumping

systems.

Note: Button names are shown enclosed in
brackets, such as [Button], whenever the actual
or button graphic is not

displayed.

The interface is displayed at the pumping station
the HMI. Users make selections of the options
enter data using a stylus or hands, and
directly on the HMI’s color, touch-screen

system.

the

HMI.

System

Windows

Windows

an

a

devices,

square

tapping

panel.

This

and

and

basic

key

and

CAUTION: Equipment Damage

Only use a stylus or clean hands on the
touch-panel device to access screens
data. Use of any other tool, sharp
contact with dirt or chemicals can
damage to the

screen.

Failure to follow these instructions indicates
potentially hazardous situation, which, if
avoided, may result in equipment damage
void any

warranty.

Hazard

object,

cause

and

HMI

enter

or

a

not

and

on

CAUTION: Equipment Damage

To clean the

equipment:

Disconnect the equipment from any AC
use a clean damp cloth. Do not use liquid
spray detergents for

cleaning.

Failure to follow these instructions indicates
potentially hazardous situation, which, if
avoided, may result in equipment damage
void any

warranty.

Hazard

outlet,

HMI Overview

The XLS is a modular and
that is used by the HMI
Interface) to control a station’s pumps.
a variety of changing conditions to operate the
booster station using

A web-based version of the application
operational

on the HMI and permits the user
supervise the pumping station’s operation
at any time from any internet-accessible
The web-based screens are identical to the
viewed on the HMI. Web Reports can also
viewed
interface via the

and printed by users who access the

internet.

Data and information is exchanged with
pumping

station’s master controller, also called
Programmable Logic Controller (PLC),
physically in the NEMA rated enclosure.
communication exchanges are made over
The PLC is responsible for the
the system. The
interface (GUI)
be monitored,
be changed
control

information
station remotely
based version.
the remote user,
is illustrated

HMI

which

and

allows the controls or variables to

when

necessary. All monitoring and

can be sent to the pumping

over

This basic

the

below.

scalable

(Human

a

touch panel display.

architecture

Machine

It

handles

is

to

remotely

computer.

screens

be

the

located

The

Ethernet.

real-time control

provides a graphical user

permits the pumping station to

the Internet using the web-

communication between

HMI, and the pumping station

or

a

not

and

HMI

a

of

5

Typical Pumping Operation

Several common control variables including
pressure, and level can be used for operating
booster system. Pump starts and
the changes in these

control
(Variable Frequency Drive)
speed of the
control valve.
smoothly, resulting in

pumps,

Pressure

replacing the function of a

recovery can be made

power

stops

variables. A VFD

is

used to regulate the

and cost

When pressure is used as the key process
the VFD pumping system constantly

monitors
pressure to maintain the required demand.
starts and stops are based on the changes in
system pressure.

Other configurations are also possible. Consult

flow,

a

are based on

savings.

variable,

Pump

the

your
Bell & Gossett Representative for proper operation of
your system.

Touch-Screen Panel Operation

This XLS HMI device
operation of the touch-panel
enclosure door of the control unit
station.

•

Use a stylus to tap the buttons or

when using the touch-screen

•

Use the Enhanced Key Pad to

text or numbers in blank fields.
and hold the stylus in a blank field
open the Enhanced Key Pad pop
screen.

•

A USB Keyboard may also be

instead of the Enhanced Key
Plug in the USB Keyboard into
back of the

Danger: Electric Shock

Disconnect power before opening
enclosure. Any procedure
electrical enclosure must
qualified personnel

Failure to follow this guideline could result
injury or

death.

manual

display.

only.

describes the

display,

of

the booster

Hazard

any

requiring

be

performed by

located on the

fields

panel.

enter

Tap

to

up

used

Pad.

the

electrical

opening an

in

Figure 1: Connection for USB Keyboard

System Boot Up

Once the station is installed and field wiring is
complete, the system is ready to start. Upon
engaging power the control will start up and the
HMI will boot. Once the boot up sequence is
complete the user will see the station
information screen.

Figure 2: Start-Up Screen

6

(c).

Home Screen

3 21

Once the startup screen clears the HMI will
display the home screen for the configured
station.

Figure 3: Basic Booster Home Screen

The application uses a three-part structure for
screens:

1. The Header/Home Tab, located at the top of the
screen, will display the active system and will allow
navigation back to the home screen at any point.

2. The Navigation Bars, located just below the
home tab, displays buttons to tap which will navigate
to
the
of user is logged

3. The Main Window, located in the center of
screen, displays one or more panes of
about the booster station. Depending on which
screen is active will depend on the information that is
available to view or edit.

other key areas of the application. The content of

navigation bar changes depending on what

in.

information

all

type

the

User Types

There are different types of users recognized by
system:

Guest: Only operation screens are accessible
view-only mode. Users are logged in as a Guest

default.
Supervisor: End-User configurable setup

operation screens are accessible. Supervisors
log-in using a
word is “1234”. This passwor d should be changed
upon the first log in.

password as there is no way to r eco ver i f l o st.

password. The default Su pervisor pass

Ensure you do not lose this

the

in

and

must

by

Technician: All setup and operation screens

accessible. Technicians must log-in using a password.
The default technician password will be provided to the
certified installer at the time of installation.

Note: Some values require you to set the
Writes” checkbox before you can change the
values.
prevent unwanted and accidental register
writes. These values are available to
only. Values normally accessed at the
level or lower are not

This is a precautionary measure intended

technicians

Supervisor

affected.

are

“Enable

to

value

Touch Panel Log In

Tap [SERVICE] from the Home

Note that when logged in as a Guest certain boxes are
disabled, shown in Figure 4.

When logged in as a Supervisor more options will be
made available as shown in Figure 5.

7

Figure 4: Guest Service Screen

Screen.

to exit without logging

in.

Once back to the Log In screen tap [ OK] t o log in or
[Cancel] to abort. If Log in was s uc cessful the Service
Screen should appear as in

Figure 8.

Figure 5: Supervisor Service Screen

In order to enable all of these parameters you will need
to log in as Technician.

Tap [Log on/off] from the Service
User type.

Figure 6: Log in

To log in as a Technician, tap [Technician],
then tap on the empty Password field to enter
Technician password. This will bring up an enhanced
screen shown in Figure 7.

Figure 7: Log In Keypad

Enter your password and Tap to log in, or

Screen to change

Screen

and

the

Figure 8: Technician Service Screen

Now that you are logged in as a Technician you can
view or alter any of the station parameters. Note that
the station has been pre-configured from the factory
so that changes required for station operation should
be minimal. Please see the Quick Set-up portion of
this guide for standard start-up procedure.

Tap [BOOSTER] to return to the Home Screen

8

Home Screen Navigation

3 5 6

11

10 7 8 2 4

1

Stand-By

Running

Off

Alarm

- Status

- Total runtime

9

The Booster home screen has been designed to mimic
the look of the configured booster and to allow for quick
visual cues for ease of navigation.

a. By tapping , in either Idle or Auto Modes, an

enhanced screen shown in Figure 11 will appear to
set individual pump status.

Figure 9: Home Screen Navigation

The Home screen has various buttons and information
blocks detailed below.

1. Pump Status

2. Station Discharge Status

3. Modes of Operation

4. Alternation Set-up

5. Low Pressure Override

6. System View

7. Alarm Tab

8. Setpoint Tab

9. Service Tab

10. Energy Tab

11. Communications Tab

PUMP STATUS

The Individual pumps fo r eac h will ha ve multi pl e mea ns
of status display both vis ual l y and wi t h dat a.

1. Visual Pump Symbols:

Figure 10: Pump Symbols

Figure 11: Pump Switch Screen

2. Pump Status Detail:

- Percent Speed

- Hertz

- kW

- Flow Rate

Figure 12: Pump Detail

a. By tapping , an enhanced screen shown in

Figure 13 will appear with more detailed
information.

Figure 13: Pump Information

STATION DISCHARGE STATUS

The station discharge status bar will display the current
discharge condi tions for the station.

Figure 14: Station Discharge Status

9

MODES OF OPERATION

a

b

The HMI will display various modes of operation with
dedicated screens. These modes of operation can be
accessed through the interface on the home screen.

1.

IDLE MODE will be active when the unit is not in

[MANUAL] or [AUTO] and the pumps will not be
allowed run.

Figure 17: Manual on/off

b. The PERCENT SPEED displays the current set

speed.
By tapping , an Enhance d Scr e en shown in

Figure 18 will appear and allow for manual control
of the pump speed and status.

Figure 15: Basic Booster Idle Screen

2.

Auto Mode is act i v a t ed /deactivated by tapping

[AUTO]. To enter or exit this mode of operation
simply tap [AUTO] from the IDLE screen.

*Details on setting up the station for proper AUTO
operation are detailed in the startup procedure.

3.

Manual Mode is activated/deactivated by tapping

[MANUAL] from the home screen. When activated,
a dedicated screen will appear as shown in Figure

16 to allow manual operation of individual pumps.

Figure 16: Basic Booster Manual Screen

a. [ON], allows for the manual ability to turn on/off

the pump.

Figure 18: Manual Pump Control Screen

10

ALTERNATION SET UP

a b d

c

The default alternation sequence is set from the factory to
alternate the pumps every time a pump is turned off by the
system. The co nt rol wi ll autom a tic al l y sel ec t the pum p wi th
the lowest number of run-hours every time a pump is
staged on/off.

By tapping [ALTERNATION] an enhanced screen shown
in Figure 19 will appear that allows th e modi fi ca ti o n of
the alternation sequence for the station.

Figure 19: Default Alternati on Screen

The Alternation screen will allow th e use r to force
alternation of a given pump during a particular time of
day.

a. Enables forced alternation for given pump group

based on scheduled parameters in remaining
fields. Leaving this unchecked will disable the
forced alternation based on time of day. The
pumps will still alternate as they turn on and off

due to demand.
b. Sets the time for forcing alternation.
c. This section will default to the “unchecked”

position as shown. By ”checking” one of these

boxes, you will be forcing that pump to be the lead

pump when alternation occurs. Only one box

needs to be checked. If multiple boxes are

checked then the first checked pump from the right

will always be the lead pump.
d. Sets the day in which the system will force

alternation

Figure 20: Example Alternation Screen

In the above example alte rn atio n wi ll oc cu r no rmal l y
anytime the pumps are turned off. However, alternation
will be forced daily at 2:00 a.m. with pump 1
established as the lead.

LOW PRESSURE OVERRIDE

The Low Pressure Override button allows the station’s
low pressure s afeties to be disabled for system service.
This function wil l allow for the technician to perform
system checks without low pressure alarms shutting the
station down. This feature should never be left on

while the station is unattended.

Figure 21: Low Pressure Override

11

SYSTEM VIEW &

c

b e d

a

TRENDS

By tapping from home screen,
View accesses color-coded

operational

trends or historical data for several

System

system
variables such as flow, pressure, speed,
setpoint.

and

b. User SP field

By tapping in the “User SP” from the System
View you can adjust the system Normal Set
Point.

c. Time Period

By tapping [Time Period] from the System
View an enhanced screen

allows you to set
date and duration for viewing system
information.

a

Figure 22: Trends

Screen

You can turn on and off logged channels on
viewer by tapping any of the values at the
bottom of

Power readings may not be available on
Also on some systems a power reading

the screen.

all systems.

of
cause the Power display to disappear, and
reappear when power readings

return.

a. The trends will be shown for the Duration

value,

ending at the current time. When ‘Now’

checked,

is
date and

the system defaults to the current

time.

If ‘Now’ has been checked, ‘Duration’ is the
only

editable

viewing historical data, uncheck

field under [Time Period] .

‘Now’.

Enter the start date and time, along with

to

duration
[Apply] to

changes.

any

view data for desired time. Tap

apply

changes or [Close] to cancel

NOTE: If ‘Now’ is left unchecked, the system
does

not default back to the current date and

time.

the

0 will

will

For

Figure 23: Configure

Period

d. Configure Data

By tapping [Configure Data] for the System View
menu will bring up an enhanced screen that will
allow you to change way the data is displayed
on the trends screen.

Figure 24: Configure

Data

Check the box next to the data you want to
show.

Not all data is available for all systems.

Use

the

slider bar on the right to adjust the

12

graph scaling
comfortable to
100% means the graph scale is the same as
the

analog scaling max value. 110% means
graph

the

to

a value that makes it most

read.

scaling is 110% of the analog max

scaling for

a b c

d

the KW

reading,
because KW is
scaled.

Click “Channels” to access the calibration
screen
screen.

directly from the “Configure Data”

This screen is accessible also from
>”Options Setup” and is discussed in detail

that section.

in

e. Technical Overview

By tapping [Technical Overview] a new detail
screen shown in Figure 25 appears showing
system operation.

the

channel. The exception here is

which is an absolute number

read

directly, rather than

“Setup”-

This field shows, from left to right, the
combo

(highlighted), start time, psi below
setpoint,
stop, for
detailing the
The example above
of the PM Pump, Combo
(or any other single pump in
combo 3 is two main pumps,
main

stop time and psi above setpoint to

each

combo. To the right is a table

pumps

to run in each combo.

shows

combo 1 consists

2

consists of pump 1

the

and

pumps.

Figure 27: Combo

Information

current

same group),

combo 4 is 3

This shows the Overpressure accumulator
“Not Combo” indicates that OPA will operate at
combo level above 2.

settings.

any

ALARMS

The [ALARMS] tab wil l tak e you to the Ala r ms detail
screen.

Figure 25: Technical

Overview

This screen shows an overview of the
configuration
necessary
settings page for
accessed by touching the
technicians, the fields available on this
screen
However,
clarification:

Figure 26: Combo

of the station. Most data that is

for tuning

is shown, and the

the

information can be

value.

For

should be fairly self-explanatory.

some

fields can use some

Information

Figure 28: Alarms Home Screen

a. The Alarm history field will display particular alarms

based on the drop down selection detail in (b). The
time of the alarm and the type of alarm will be
displayed.

b. Drop down selection that will allow you to sort

alarms

i. Critical – Current (current day)

ii. Critical – History

iii. Non-Critical

13

b a c

a

b

c d e

c. The [Ack All] button will clear any alarms that are

currently active.

d. Tapping [Period], available in ‘Critical – History” and

“Non-Critical” modes, will open an enhanced screen
shown in Figure 29 to allow for the display of only
alarms during a given range.

SETPOINTS

The [SETPOINTS] tab will take yo u to th e Set poi nt de tail
screen. From this screen you will be able to view the
station setpoints along with the current values of certain
parameters.

Figure 29: Period Screen

If an alarm is active the Home screen will also display
various visual warnings to alert the system status

Figure 30: Alarm Warning

a. The [ALARM] will turn red to alert that there is an

active alarm.

b. [Reset Alarm] will flash from yellow to red to indicate

there is an active alarm. By tapping [Reset Alarm],
the alarm will be acknowledged.

c. The pump status will show an alarm state

Figure 31: Setpoint Home Screen

a. This portion of the screen displays the current

running set point of the station and the “enable
writes” check box. By checking this box any
changes made while in this screen will be saved.
By leaving it unchecked no changes can be
made.

Figure 32: Setpoint Detail A

b. This portion of the screen will display the current

set points being used by the system. When
tapping in the numbered area an enhanced
keypad will appear that will allow you to change
the current value.

Figure 33: Setpoint Detail B

If factory configured, checking the “Use AI”
check box will allow control by a factory
configured Analog Input. This input is separate
from the settings for remote transducers or BMS
override. If you do not have an external AI
configured, these boxes should remain
unchecked.

The “Input” indicator will be active if that current

14

input is on.

c. “Lockout Setpoint” will display what the Lockout

system has identified as the required set point.
“Remote (Comm)” enable is the setpoint being

communicated by the remote communication
system. The enable box must be checked in
order for the remote communication system to
adjust the system set point.

Figure 34: Setpoint Detail C

d. This portion of the screen will display the Remote

Transducer Settings. The remote transducers are
enabled in the System Setup - Control Options
section. If you have configured/enabled the
remote transducers the “Current” box will display
a value. If not it will show 0.0. By checking the
enable box the system will use the configured
remote transducers.

Figure 35: Setpoint Detail D

e. This portion of the screen displays the Dynamic

Flow Compensation set up.
“Psi Drop” is the setpoint for the calculated

building losses in the system.
“Flow Calc Pacing Time” is the setpoint for the

rate at which the “Current Running Setpoint” will
change due to changes in system flow.

The graph is a representation of system curve
and the cross hairs will display where the station
is currently operating.

Figure 36: Setpoint Detail E

SERVICE

The [SERVICE] tab will take you to the Service detail
screen. From this screen you will be able to access all of
the setup parameters for the station detailed in this
section.

Figure 37: Service Home Screen

1. [ Lockout Setup]

Tap [Lockout Setup] from the SERVICE
The Lockout Setup will allow the station setpoints
to be scheduled during cert ai n periods. An example
of using this parameter would be for scheduling
operation during “unoccup i ed” periods when
demand will be less.

Menu.

15

Figure 38: Lockout Screen

Individual lockouts may be setup by tapping
each lockout inset. Tapping any inset opens
configuration window. The day, start time,
duration may be entered in the interval tab at
top. In the parameter tab, the combo
setpoint, and speed can be entered. Tap [Apply]
to

save settings or [Close] to discard any

number,

over

a

and

the

changes.

2. [Events]

Figure 40: Parameter Tab in Lockout

Setup

The Parameter

RPM

maximum

number,
in

tab enables

pressure, and maximum speed

a user to define Combo

By tapping [Events] you will be taken to the Events
home screen shown in Figure 41. This page will
detail any event that has happened within the given
period.

Figure 39: Individual Lockout

Setup

The screen shown in Figure 39 sets up a lockout
for Sunday
set

to
6:00 PM on Sunday. The animated display
an indication about time.

beginning at 6:00 AM. The duration is

be 12 hours. Thus this lockout will

end

at

gives

16

Figure 41: Event Setup

By tapping [Period] you will be able to adjust the
range to show only information required.

Tapping [< Back] will take you back to the Service
Home Screen.

3. [ Email Setup]

This page allows you to set up email
where Alarm and shutdown messages will be
sent.

These emails will notify the user if the

has

station
that the
way the
of a

pump

email will

shut down or experienced a problem

site

personnel should be aware of. This

user

will be notified immediately in case

station problem. If a fault occurs, an

be

sent to

him.

The email settings can be configured to
emails

to multiple individuals or email
The vast majority of cell phone providers also
allow

email messages to be sent to cell phones

as

text

messages. A list of known formats is

provided below.
Enable: Check this box to enable email

alarms

from the Pace

controls.

Use Authentication: Check this box if your
email

service requires POP3

authentication.

Note: The POP3 and SMTP servers will usually
have the same address. Enter this value in both
boxes. Sometimes the values are different so
separate boxes have been provided.

To: Enter the email address where the
messages will be sent to. Multiple email
addresses can
email addresses with

be

entered by separating the

a semicolon.

Examples:

[e-mail];
[e-mail]; [e-mail];
[e-mail].

The following list shows email address formats
for

various cell carriers. Sending an email to

these

addresses will generate an SMS text

message

to

the cellular

phone where
“phonenumber” is the 10 dig it phone number of
the user.

T-Mobile:
[e-mail]
Virgin Mobile:
[e-mail]
Cingular:
[e-mail]
Sprint:
[e-mail]

addresses

send

addresses.

alarm

Verizon:
Nextel:

[e-mail]

[e-mail]

US Cellular:
SunCom:
Powertel:
AT&T:

[e-mail]

[e-mail]

[e-mail]

[e-mail]

Alltel: [e-mail]
Metro PCS:

[e-mail]
SMTP: Enter the IP address of the SMTP

server
require
name.

you will be using. Windows CE devices

the

IP address rather than the server

See “Determining the IP address of the
SMTP

server” in Appendix F for these

instructions.
From: Enter the complete email address

for

used
ignore
address does not

this service. Most email servers will

your

email request if the “From”

match

the

account.

Example:

[e-mail]

User: For most email service providers, enter
the

first part of the email address without the
domain
require the
name.

name. Note that some providers

full

email address as your user

Example:

mypumpstation

Password: The password to your email
account.

Example:

Xlem1234

After configuring your email settings, test the
setup.

Tap [Set] to load the information into the
email

generator. Then tap [Send]. A test email

be

will

immediately sent to the address(es)

provided.
If the colored box remains green after hitting

the

Send,
correctly. If the box
an error. The number after
the type of error, table for which can

configurations are working

turns red

there has been

“Status”

indicates

be

found

in Appendix F.
Additional

troubleshooting
configuration can also be found
F.

options for email

in

Appendix

17

Tap

[Set Date] to synchronize HMI & PLC date
and time. You will get a pop up m es sage shown
below, hit [OK].

Figure 42: Email

Occasionally, the settings changes here
may

require restarting the HMI. Try this if
you experience
email to
through cycling power
down and restarting the
see appendix “F” for other
troubleshooting aids.

problems getting the test

work.

This can be accomplished

Settings

or

by shutting

application.

Then

4. [ Set / Sync HMI-PLC Date/Time]

Tap [Set/Sync HMI-PLC Date/Time] from the
SERVICE menu.

Figure 43: Set/Sync Screen

This screen allows the date and time to be set,
and

synchronized for the PLC and HMI. To
manually set the date check “Change
Date/Time”. Note the Date and Time boxes
will changed to editable fields. To allow for
Daylight Savings Time please check the
appropriate box.

Figure 44: Sync Pop-up Detail

To adjust the totalizers tap [Totalizers]. In the new
pop up you will be able to adjust the time/date
when the system will total ize.

Figure 45: Clear/Update Totalizers

Use the available cells to enter the date and
Tap [Set Date/Time] to save changes.
Totalizers] to clear all

Note that when the HMI time is set, the HMI
automatically sync the PLC time

Synchronization should not be done
the Internet-based remote client as
potential to negatively affect the
the system. Syncing should only
locally.

totalizers.

Tap

once/day.

while

this

time

settings of

be

performed

using

has the

time.

[Clear

will

18

5. [ Securit y Setup]

Tap [Security Setup] from the SERVICE

Menu.

6. [Tuning]

Tap [Tuning] from the SERVICE
Tuning screen will allow you t o s et the PID and
speed control settings for s tati on operation.

Menu. The

Figure 46: Security Setup Home Screen

The Supervisor can change the password
assigned
after
field).
Password]
Enter the
‘Confirm
changes.

to him/her, and set the number of days

which

the password expires (in the editable

To

change the password, tap [Change

to

change the supervisor password.

new

password in the ‘Password’ and

Password’

field. Tap [Apply] to save

From this screen you will also be able to assign
Users to the station by tapping [Setting User].

Figure 48: Tuning Home Screen

Pumps using this PID

Set:

The decision on which PID set to use is based
on

the “best” fit of pumps running on VFD and

the

pumps selected

here.

group.

the

Figure 47: User Setup

Enter the desired User Name and password and
tap [Apply]. The User will now be available in the
User dropdown.

Figure 49: Tuning PID Drop Down

Read:

Click “Read” to read the PID values from the
PID

group set selected (this is automatically

for

clicked

Write:

you when you enter the

screen).

Click “Write” to save the values to the PID

19

Copying PID

The Read/Write buttons are provided to allow

data:

technician to copy values from one PID group to
the

other. To copy, select the PID group to copy

from

and click “Read”, then select the PID group

to

copy

to and press

“Write”.

Speed

Test

:
Speed test is a method to shut down the lead
VFD w

hen only 1 VFD is running. The PID value

is

artificially reduced and the system is

monitored

for

PID response (pressure

drop).

Speed Test shutdown is initiated when flow
falls

below “Flow” for “Delay”

seconds.

“Speed” is the speed to which the PID must drop
to

pass speed test and shut down the

pump.

“Period” is the time between steps for the
test routine to lower the PID output, and “Step
Size”

is the amount of PID drop per

step.

If the speed test routine detects the PID ramping
up

during the test, speed test will abort and
operation
below

will return to normal until flow is again

the

“Flow” setpoint for “Delay”

seconds.

Discussion of Proportional and Derivative
settings, high and low flow:

Configuring the proportional and derivative
values is essentially a trade-off. Both these
values have an impact on the system
response. A high proportional value causes the
system to respond faster, thus reaching the
setpoint faster. At the same time, this faster
response means that the system will easily
overshoot the desired setpoint. This can be
checked by lowering the proportional value,

increasing the derivative (d-Term) value.

and
The derivative term controls the systems
response to rapid changes in pressure,
regardless of the value of the pressure. Th
system uses this to begin reducing VFD output
speed when pressure is rising quickly, helping
to avoid overshoot. The system can also
detect fast pressure drops to begin increasing
VFD output speed before large errors are
detected, increasing the systems
responsiveness.

Good starting values are 7 for proportional and 4
for derivative. Increase proportional when the
system lags too long changing the speed when
pressure is away from setpoint but relatively
steady. Decrease proportional and increase
derivative to reduce overshoot. Decrease
derivative when the system becomes unsteady
near setpoint under steady demand. Generally
speaking, only use enough derivative to reduce
overshoot.

speed

is

Low and high flow settings:

The low flow and high flow settings are used
together to calculate the proportional and
derivative terms at any given time. The low flow
settings are what the proportional and derivative
terms would be if flow were 0. The High Flow
settings are what the proportional and derivative
terms would be if flow were greater than or equal

20

to “Max Flow for Low/High Flow”. The value to use
for each parameter is calculated based on the flow
at the time.

Example: Low Flow Proportional is 7, and
High Flow Proportional is 9, “Max Flow for
Low/High Flow” is 2000. At 1000 gpm, the
proportional value will be calculated to be

8. At 1500 gpm, the proportional value will be
calculated to be 8.5.

Minimum Speed:

This is the minimum speed
operate the VFD under PID
should equal the minimum speed
will flow water at setpoint
value too high can

cause
low demands. Setting
cause the PID to hunt since
“true” min speed are
unnecessary delay in the PID
these speed ranges. Note
made for varying inlet
setpoints. Generally speaking, a
better than a too-high min speed,
“true” min speed this is set, the
will

operate.

that

the system will

control.

This speed

that
pressure. Setting
over pressurization at

this

value too low can

the

speeds below the

ineffective

pressure

and can result in

when

operating in

that

allowances must be

and adjustable

low

but

better

the pump

Min speed is

the closer to

the system

Control

Deadband:

This value controls how far from setpoint
pressure must be before the PID responds.
units here are in 0.01 psi, so 25=0.25 psi
quarter-pound). This smooths the PID response
near setpoint. However, too large a value here
cause the system to delay response and
cause the system to “get behind” in response to
large change in

Transition

demand.

Control

Starting Speed:

VFD

This is the initial speed of the Main
the Main Pump first starts. Should be

when

high
enough to “kick start” the pump since it is
starting
must be
overshoot under
the system with
PM Pumps (or Jockey
capacity and adjust for

under unsupplied demand, but care

taken

not to force the system to

low

demand situations. Start

demand

just greater than the

Pump,

as supplied)

minimal overshoot.

this

the

The

(one

could

will

a

Combo Up (After XL Start):

This setting
the main pump will
speed lag pump starts.
overpressuring by reducing
VFD Pump, which is then
fixed speed pump after it
1/3 the value between min
This speed will be held for “Hold
generally set to 1 (may need to
systems using soft-starters for fixed speed
pumps).

Combo Down (After XL Stop):

This

setting
the main
speed lag
capacity provided
eliminate pressure
shut off. Generally set
min speed and 32767.
for “Hold Sec”, which is

Speed at 0 psi Startup:

This setting controls
Jockey OR main will start
when the pump starts
This setting should be
pump just begins to flow water
The actual starting speed will
between this speed and “Combo
Stop)” speed setting, depending on
pressure at the time of start. A function
calculate the speed between these

Threshold Deadband (psi):

This setting determines
setpoint for determining starting speed. If set
to

“20”, the threshold function is used to
calculate
equal to or

The VFD 1start factor corresponds to the starting
speed of the first main or Jockey pump starting on
VFD. A high value causes the VFD to start running at
a higher speed, creating more pressure. This helps
the system to reach the setpoint faster, but at the
same time the system may overshoot the setpoint
very quickly since the PID does not have enough
time to react to the fast occurring changes. A very
low value will make the system take a lot of time to
reach the setpoint.

Tap [Next] to move to the next Field Setup screen

controls

controls the speed the VFD running

pump

pump stops.

starting speed when pressure is

less

the speed the VFD running

be

forced to when a fixed

This

helps prevent

the

capacity of the

being

provided by the

starts.

Generally set to

speed

and 32767.

Sec”,

which is

increase

will be forced to when a fixed

This helps replace the

by

the fixed speed pump and

dips

when these pumps are

to

2/3 the value between

This

speed will be held

generally

the

speed the VFD of the

if

pressure is very low

(see

deadband below).

adjusted

the

than 20 psi below

to be the point the

at

0 psi discharge.

be

calculated

Down

pressure below

for

set to 1.

(After XL

the

actual
is

points.

setpoint.

lag

used to

Supplemental Control

Figure 50: Supplemental Control Home Screen

OPA Enable

This is a method used to shut down lag pumps
operating across-the-line in a system that uses both
VFD and XL (across-the-line) pumps. Check this box
to enable.

The overpressure accumulator measures the
overpressure, and calculates a value to add to the
Overpressure Accumulator depending on this error
on each program scan. The system will shut off a lag
pump when “Trip Preset” is reached.

Min combo:
Combo # on which, OPA is not desired because it is

preferred that the last pump stop in speed test.

Line Fill Mode

This configures how the XLS controller will respond
to powering up, or being put in “Auto”, under very low
pressure conditions. Under these conditions, air may
be in the system and it can be dangerous to the
piping to immediately start pumps and run full out to
attempt to bring pressure back too setpoint too
quickly.

The line fill system works by starting one main pump
at a fixed frequency (calculated from Speed @ 0 psi
startup) under PID control). The system will hold this
speed until pressure and flow are considered
“Steady” for a period of time. Then the system will
increase the speed. The process continues, possibly
starting additional pumps, until the max line fill
pressure is reached, at which time the system
switches over to “Ramp up” mode and continues.

21

Trigger Pressure:
Line Fill Mode will trigger below this pressure

(Percentage of setpoint) when powering up or
entering “Auto” from Off mode.

Max Combo:
Controls how many pumps can run under these

conditions by limiting the max combo of the station in
line fill.

Speed step:
Controls how much the speed of the VFD is

increased during each step.

Steady time:
Controls how long pressure and flow must be

“Steady” before continuing to the next step.

Deadband (psi):
How large of a pressure swing is considered

“Steady”.

Deadband (gpm):
How large of a flow swing is considered “Steady”

Fault Time:
How long before the systems faults, if pressure and

flow cannot reach what is considered “Steady”.

Ramp Up

Step (psi):

During ramp-up, the # of psi the system will step up.
See “Step (sec)”. Normally set to 1 psi.

Step (sec):
During ramp-up, the time between ramping the

setpoint. Normally set to 4 sec.

dP/dT Control

Enable (Checkbox):

Controls whether the “dP/dT” pump start/stop control
functionality is utilized. Check to utilize the rate of
pressure drop when starting/stopping pumps.

Start/Stop Inhibit:
The rate at which the system will inhibit pump starts

or stops as the pressure rises or drops during the
decision process. Generally 0.5-1.0 is adequate to
reduce pump cycling.

PM Skip:
Controls how much pressure drop will cause the

system to automatically skip the PM Pump in the
sequence. Fast pressure drop indicates a large
demand has suddenly been applied to the irrigation
system. This is used to detect the need to skip the
small pressure maintenance pump so that the main
pump can meet this demand as quickly as possible,
avoiding unnecessary pressure dips. Start with
values at 1.0 and monitor. To disable this feature but
continue to use the Start/Stop inhibit system above,
set this value to 10 or greater.

dP/dT Inhibit (sec):

After the main pump stops, systems will often
experience short pressure dips that may cause the
PM Skip system to restart the main pump. Set this
value to 20 seconds to prevent the PM Skip process
from restarting the main pump within this period of
time.

Current dP/dT
These values are shown to assist in tuning the
dP/dT system.

DFLC

This screen is the same as found in the SETPOINT
section detailed earlier.

Combos

This screen allows you to configure various options in a
combo.

Figure 51: Combo Home Screen

Select the maximum number of combos (up to eight). For
Combo 0, which is the ‘no pump’ combo, all values
except Overlap gray out. A brief description of all
parameters follows.

22

1. Start Pressure: number of seconds the station delays

before the start of the specified combo, once ∆P has

been reached

2. Start Time:

3. Stop Pressure: number of seconds the station delays
before it stops the specified combo, once ∆P has
been exceeded.

4. Stop Flow:

5. Stop Time:

Tap [Next] to move to the next Field Setup
screen

Pump Curve Configuration

This screen allows you to load/reload the individual pump
curves for the station. Please note that the Booster

station is pre-configured at the factory based on the
selected pumps. Any changes could be detrimental
to station performance.

Figure 53: Station Information

You have the option of loading or saving current
setpoints to and from an external drive as well by
tapping [File Save/Load].

Figure 52: Pump Configuration Home Sc reen

7. [ System Setup]

Tap [System Setup] from the SERVICE
NOTE: The screens described below will only

be

displayed if they are applicable to the

current system.

Station

Information

Enter the job information such as ‘Job
Number’,

192.168.1.10),
the fields
been grayed

‘Job Name’, ‘Main PLC IP (usually

and ‘Phone Number’. Notice that

‘HMI

Version’ and ‘PLC Version’ have

out,

and are not

editable.

Menu.

Type the file name or browse for it using

Figure 54: Configuration File

[…].

Figure 55: File Browser

The Configuration File screen lets you download
an

XML file to the PLC, save an XML file from the

PLC,

or delete an existing XML file on the PLC.

The

XML

configuration files contain the setup

settings

for

your pumping

station.

Caution:

Downloading an incorrect XML file to the
may render the system inoperable.

23

PLC

Ensure

you

have the correct file before
to

PLC].

Tap [Next] to move to the next System

Basic Pum p

The number of pumps can be selected from a
down menu. Note that this is set from the factory and
changing the number of pumps could render the station
inoperable if the selection does not match the actual
number of pumps.

The number of zones can also be set from the drop down
menu.

Each pump can be assigned a name
fields at the bottom of the

Information

selecting

screen.

[Download

Setup screen.

in

the editable

drop

Figure 56: Basic Pump Information

By selecting “Show Inlet Pressure” or “Show Feed
Tank”, those valves will be displayed on
theBooster Home Screen.

Zone Configuration

Tapping [Zone Configuration] will allow you to
configure the zones for the system.

The number of flow zones is adjusted here. Up
to

7 zones can be selected. This controls how

many

flow totalizers are operable. Each flow

zone

will

keep track of water usage by day,

week,

month

and year (5

years).

Figure 57: Zone Totalizer Setup

The name of the flow zone is set here. Also,
flow channel that is totalized for each zone
configured here. These channels match the
channels from calibration. In addition to picking
single channel for a particular zone,
channels can be added together to form a
flow zone by selecting more than one “Zone”
totalize. Flow zones can also be subtracted
total by selecting a “Subtract Flows”
may be required when a meter reads
more than one zone, and one of
zones is metered

Flow filtering is setup here as well. By
“Disable Flow Reading if No Pump Running” for
channel, that flow reading will be zero’d out when
pump is running. This is in case the system
fluctuations that cause the meter to
undesirable small flows when the pumps are
running.

separately.

multiple

channel.

flows

these

selecting

generate

the

is

flow

a

single

to

from

the

This

going to

subsequent

a

picks

not

no

up

Tap [Close] to save

.

Tap [Next] to move to the next screen

.

Pump Configuration

This section will allow you to configure the pumps for the
system. Please note that the Booster station is pre-

configured at the factory. Any changes could be
detrimental to the station.

24

Figure 58: Pump Configuration

Each pump can be selected from a drop down menu in
this screen. It can be assigned a group, type (Main,
Jockey, or PM), and number of VFDs that are going to
be

used.

Figure 59: Pump Type Configuration

Selections can be made regarding
XL, VFD, HPT, HSS, or Only
for this

VFD. For most Booster Stations these

pump

the

pump being a

selections will be limited to your configured set up.
Contact the factory for special configurations.

Pump

Enter the minimum run time, Spindown Time,

pump.

Capacity, Feedback Delay for each
Tap [Next] to move to the next System

Setup

screen.

Control Options

This section will allow you to configure the control options
for the system.

Figure 60: Control Options

Combo Options

This section allows you to make various selections on
control options for the station detailed below.

“PSI Start Enable”
“PSI Stop Enable”
“Skip Combo 1 on ShutDown”
“Skip Jockey on ShutDown”
“Flow Shot-off Enable”
“Overpressure Accum u lator Enable”
“kW Start Control”
“kW Stop Control”

Logic Flow

This section allows the user to enable the Dynamic Flow
Loss Compensation Mode. This mode will use built in
logic to determine the flow rate of the system and
calculate system losses without the need for external
mounted flow meters or pressure transmitters.

Power Monitor

This section allow the use to set up the use of an extrnal
power monitior.

“None, Standard or Advanced”

These are the options available for power
monitoring.

“Generator Mode Max kW”
This is the current allowable “Maximum Power”
set for the station in Generator Mode. Generator
Mode is a pre-configured factory option that
allows for the use of emergency power
generators in the event that main power is lost.

25

“Normal Mode Max kW” is the current allowable
“Maximum Power” set for the station in under
normal operating conditions.

Remote Transducers

This section will allow you to enable remote transducers
that are installed. To adjust the

“Enable Remote Sensors”

These are the options available for power
monitoring.

Combo

Definitions

This screen allows you to checkmark various combo
options. ‘PSI Start Enable’ and ‘PSI stop Enable’
essential. Without these two, the station will not

are

start
stop based on pressure indications. All other check­marks are need

based.

Logic flow enables you to select which zones
used for flow shutoff. The zones are
to provide the flow to compare to the
setpoints.

added

flow

are

together

shutoff

Figure 62: Analog Scaling

For each signal such as Pressure, the analog
input

values are shown on the left while the

scaled

output

values are shown on the

right.

Figure 61: Combo

Definitions

8. [Analog

Scaling]

Tap [Analog Scaling] from the Options Setup
Menu.

This screen allows you to scale raw values
into

engineering units for analog signal

inputs.

Figure 63: Analog Scaling Detail

Tap “Names” value to change any of
of the variables displayed (Flow,
This can also be used when adding

the

names

Pressure,

on

etc.).

functionality to the system. There are a few
‘spare’

I/O names available and those can be
to

edited

match the new variable for

scaling.

Tap [Close] to return to the Options Setup

Menu.

9. [Alarm Configuration]

This screen allows you to select various
types from the drop down menu, and fill in
required settings for each

alarm.

Default settings (standard factory settings) can
be

found in Appendix D.

alarm

the

26

Figure 64: Alarm Configuration

ENERGY

The [ENERGY] tab will tak e you to the Po we r usa ge
detail screen. From here you will be able to see the
totalized values for Flow and KW h in tabular format.

Tap [Next] to successively view the totals for
day, week, month and year. Use the scroll bar
move up and down or left and

Figure 66: Flow Totals Over vi ew

right.

each

to

Figure 65: Energy Home Screen

By tapping on the desired box a tabular screen will
appear as shown in Figure 66.

Figure 67: Daily Flow Totals Overview

COMMUNICATION

The [COM] tab will take yo u to th e Comm u nica ti ons
setup screen where you can configure the available
communications p rot ocol .

Communications takes place by way of drivers installed
on the HMI. Configuration of these drivers is done
through the “COM” screen. Due to the nature of the files
accessed by this screen, COM configuration cannot be
done via web access to the controller.

Only one driver is available at a time. Initially, no drivers
are selected. Use the checkbox to select which protocol
to use, the press the button next to the checkbox to
modify the parameters of the protocol.

27

Figure 68: COM Home Screen

Protocol settings are then available for editing. Use the
Top, Prev, Next and Last buttons to navigate among the
pages of the properties for the protocol selected. Press
Save for each page as changes are made. Once all the
changes are made, press “Set New Protocol”. The HMI
will reboot to make the required changes. The station
will still operate during this process, but the HMI will not
show pressure/flow etc., remote connection will be lost
etc. However there will be no loss of pump operation.

Figure 71: COM Protocol Selection

Figure 69: COM Protocol Sel ecti on

Figure 70: COM Protocol Selection

28

Typical settings for Modbus TCP are as follows:

Page

Modbus - Link

Serial Encapsulation

TCP/IP

Connection

TCP/IP

Station ID

1

Protocol

RTU

Page

Modbus - Modem
Configuration

Modem Identifier

Auto Detect
2

Phone Number

<As
Required >

Page

Modbus - Modem Options

Enable incoming calls

No

Auto Connect Enable

Yes

Auto Connect Retry
Interval (s)

120

Disconnect if call idle more
than...

1

Auto-Disconnect time (s)

120

Page

Modbus - Com Port

Com Port

COM2

Baud

9600

Data Bits

8

Stop Bits

1

Parity

None

Page

Modbus - TCP and UDP

IP Address

192.168.1.1
5

Port #

502

Server Mode

Yes

Page

Modbus - Advanced - A

Use Transaction ID

Yes

Word Type

Unsigned

Protocol-Retries

0

TX Buffer

512

RX Buffer

512

Page

Modbus - Advanced - B

TimeOut-Start

1000

TimeOut-End

0

TimeOut-Interval Between
Char

500

TimeOut-Wait CTS

100

Page

Modbus - Advanced - C

Control RTS

No

Verify CTS

No

Disable DTR

No

Enable IR

No

Table 1: Modbus TCP Settings

29

Typical BacNet communications settings are as

Page

BacNet - Link

Serial Encapsulation

TCP/IP

Link Type

BacNet IP

Device UDP Port

47808

MSTP MAC

Page

BacNet - Modem
Configuration

Modem Identifier

Auto Detect 2

Phone Number

<As
Required>

Page

BacNet - Modem Options

Enable incoming calls

No

Auto Connect Enable

Yes

Auto Connect Retry
Interval (s)

120

Disconnect if call idle
more than...

1

Auto-Disconnect time (s)

120

Page

BacNet - Com Port

Com Port

COM2

Baud

9600

Data Bits

8

Stop Bits

1

Parity

None

Page

BacNet - TCP and UDP

IP Address

192.168.1.15

Port #

47808

Server Mode

Yes

Page

BacNet - Advanced - A

Protocol-Station

1

Protocol-Retries

0

TX Buffer

512

RX Buffer

512

Page

BacNet - Advanced - B

TimeOut-Start

1000

TimeOut-End

0

TimeOut-Interval Between

Char

500

TimeOut-Wait CTS

100

Page

BacNet - Advanced - C

Control RTS

No

Verify CTS

No

Disable DTR

No

Enable IR

No

follows:

Table 2: BacNet Settings

Setup/Conf i g urat i on Fi le

ActiveX and IP

Tap [ActiveX and IP Updates] from the

Menu.

Setup
By default both ISSymbol URL and Agent URL

automatically
View Current Configuration: View the entire

in a popover
Set Configuration: Set and save new

configurations.
Email: Get notifications via
Tap [Close] to return to the Options Setup

Updates

populated.

screen.

Options

web

email.

Menu.

are

URL

Figure 72: ActiveX and IP

Updates

WinCE Remote

Tap [WinCE Remote Access] from the

Menu

Setup
This screen allows you to communicate with a remote

server using Telnet. This feature is
advanced custom

CAUTION:

Before using this feature or changing
on this screen, please call

Tap [Close] to return to the Options Setup

30

Access

jobs.

Options

intended

any

customer service.

Menu.

for

settings

Figure 73: WinCE Remote

Access

Networking and Remote Access

The general instructions and screen-shots
this manual for operating the HMI may be
accessing the interface via the internet on
computer.

For instructions related to configuring your
computer, please see appendix G.

Please note that when using a personal
the touch-screen functionality is not available.
navigate the

screens:

•

Click on the buttons with your

•

Use your mouse to click in a

field. Enter text or numbers using
standard PC

keyboard.

Remote Software Log In

An identical version of the HMI software may
accessed remotely by an Internet IP

(Internet
Protocol) address. Type the following address
an internet

From within your network (at the

browser:

maintenance
facility), open your web browser and type
following URL into the address

line:

http://192.168.1.15. This will take you directly to

HMI’s web

server.

To access your pump station from outside of
network, you must first determine the IP address
the router as seen from the internet. Note that
can be somewhat difficult to determine without
from your IT department (if you have one).
IP address can be found through the use

rd

party IP address resolution sites (available on

3
the internet) or by navigating the
administration

pages.

router’s

In the pop up screen, enter your username
password to log

in.

provided

used

a

personal

personal

computer,

mouse.

blank

a

be

into

the

your

this

help

The

of

and

when

To

the

of

router

After the HMI interface opens, the user type
Guest to Supervisor) may be changed by
standard procedure described for touch
log

in.

Web Reports

Internet users of the HMI interface can also
print different reports. There is an
Historical Report, Usage Report,
The navigation bar allows the
report’s setup screen and print
screen can also be

customized,
a feature which is unavailable in the local
interface.

Log on to Web

Reports

Log on to the reports menu by typing the
in the address bar of your

in

http://000.000.000.00/reportmenu.html
where 000.000.000.00 is replaced by your

address. Enter you username and password in
log in screen displayed. Click [OK] to submit
[Cancel] to

cancel.

You can obtain your IP address through your IT
department or internet service

Menu

Web Reports

After logging in, web reports menu is
containing the following buttons, Login, Trend
Alarms Report, Historical Report, Usage
Factory Report, Print Setup, Print, and

NOTE: Factory Report is available only to
supervisor or technician. It includes a list of
of various PLC registers and is not covered
in this

guide.

The banner at the top shows the current date
time. Using this bar, alarm reports, usage
(in gallons), and several setup files in .xml
All reports can be printed. Use [Exit] to exit
reports

menu.

31

user

the

browser:

provider.

(from

the

panel

view and

Alarms

and

Report,

Factory Reports.
to access each
report. The trends

HMI

following

IP

the

or

displayed

View,

Report,

Exit.

a

values
further

and

reports

format.

the

Figure 74: Web Reports

Menu

Trend

View

Select [Trend View] from the Web Reports
There are four key parts to the trends

Mean Value Graph and Detail: For each of

variables (Flow, Pressure, Speed,

key
Setpoint) the mean values are displayed as
vertical bar graph on the top while the
values are displayed in fields
Log: Graphically displays the

below.

pump

the time frame selected. These

•

Green - indicates pump is

•

Blue - indicates pump is running on

VFD.

•

Red - indicates pump is in a

condition.

Variables Graph: Line graph displays

information for key variables over a
The top bar of the graph also has
legend options. The grid below
Click […] to choose line
time and duration for
between the graph

colors.

the

and grid.

displays

Choose the start date,

graph from fields positioned

Events Listing: Details the time and events for

duration time defined by the user, as for
graph.

screen.

Maximum

Pump Run

operation for

are

color

running

specified

zoom,

and

coded:

fault

color- coded

period, and

variable data.

the

Menu.

the

a

time.

a

variables

Figure 75: Trends

View

Alarms

Select [Alarms Report] from the Web
Menu.

Alarms Report allows you to view the last
system alarms and

Report

events.

Figure 76: Alarms &

Reports

Events

10

All reports can be printed using [Print], after a printer
has been set up by clicking on [Print

Historical

Report

Select [Historical Report] from the Web
menu.

Historical Report allows you to access the data
bar graph representation of your station’s
Monthly, and Weekly Flow information. The
gallons are shown in the data table on the left,
three bar graphs (annual, monthly, and weekly)
the

right.

Setup].

Reports

Annual,

and

actual

and

on

All reports can be printed using [Print], after a printer
has been set up by clicking on [Print

Setup].

32

Figure 77: Historical

Report

Usage

Select [Usage Report] from the Web Reports
Usage Report allows you to view the totalized

values for each day, week, month, and year.
table in the middle on the left shows the times
counters when totalizers reset. Table on bottom
shows the number of starts, and runtime hours
each

Smart Phone and PDA

A simpler web page is available for smart
access. The IP address of this page is the
address determined in appendix “G”, but a
page address is required to access the
page: “<myIPAddress>/sma/logon.asp”
<myIPAddress> is the external IP address.
that “192.168.1.15” will never be the
address since the smartphone or PDA is
attempting to access the page from outside
network.

Report

pump.

Figure 78: Usage

access:

Report

correct

phone

external

specific

simplified

where

Note

always

your

Menu.

flow

The

or

left

for

33

Appendix A–Glossary of Terms

The terms used in this manual are defined in the Glossary of Terms. In addition, other
specific or product-specific terms are included that may be used by technicians or
service when talking about your pumping

system.

Across-the-line (XL) Applying 100% of line voltage to a motor during startup and run. A

large relay with a contact for each power phase (for 3 phase) is used
control the motor

OFF/ON.

Analog A signal that varies in some respect (voltage, current, frequency) in order

convey the value of some real world information (i.e. pressure,
temperature etc.). A control system can take action based on the value
such a signal. Internally, the signal will be converted to some number
on the value of the

signal.

Automatic lake screen (ALS) A screen on the intake flume of the pump station, between

irrigation pond and the wet well, which is designed to be self-cleaning
using a jet of clean water spraying from the inside-out during

Booster A pump designed to increase the pressure of a pressurized irrigation

This is usually used to move pressurized water from a lower to
elevation area of the golf

course.

Calibration The act of or specific values used to scale the output of a

device to read real-world

values.

Chemical injection The process of adding chemicals to irrigation water to fertilize or

turf

grass.

Combo A capacity level representing a predefined group of pumps on a

Normally Combos are defined as

follows:

pump.

Combo 1 Normally the PM
Combo 2 Lead pump. Normally the
Combo 3 Lead pump and first lag
Combo 4 Lead pump and two lag

VSP.

pump.

pumps.

industry

customer

simple

flow,

the

use.

line.

higher

measurement

medicate

station.

to

to

of

based

by

Control valve A valve designed to automatically open/close in order to maintain a

setpoint pressure, flow, or

level.

Control variable A value that a control system monitors in order to perform some

function.

Cycling This condition occurs when conditions require a pump to start if no pump

running, but require a pump to stop if a pump is running. This is
starting and stopping of one or more pumps and can be damaging to
equipment if allowed to

continue.

Equal HP pumps Also referred to as interchangeable pumps. Defines which pumps

available to start based on lowest run time. VSPs and XL pumps are
in the PLC program. An XL pump can be an equal HP pump, but it will
start as a lead pump, because the lead pump will always be a

34

specific

useful

excessive

are

defined

VSP.

is

the

not

Filter A device used downstream of the pumps to clean the water being

into the irrigation. These devices are typically self-cleaning, but
hardware/software to

self-clean.

Fixed speed Pumps run at a fixed RPM, defined by the motor windings and the

of the line voltage (50/60

Hz).

pumped

require

frequency

Frequency (Hz) The number of oscillations per second of any system. Typically used

refer to electrical systems, such as AC power line frequency, or
speed drive output frequency. This frequency defines the speed of an

GPM Gallons per minute. Units of flow for US

motor.

use.

HSS High speed switching. Starting pumps with a VFD to reduce inrush

and provide pressure control, but able to switch over to fixed speed so
the VFD is able to start another

pump.

Input A way for a control system to detect real-world occurrences. These can

digital or

analog.

Inverter Another term for Variable Frequency Drive (VFD). Actually, more

applied to the output circuitry of the drive, which converts DC voltage to
voltage.

Lag pump A pump used later in the pump sequence to support increasing

demand requirements. The term lag simply refers to the fact that it does
start

first.

Lake fill (LLC) A circuit designed to keep a pond or lake at or above some

level of

water.

Lead pump The pump in a lead group which is chosen by the controller to start first.

is usually determined by finding the pump in the lead group with the
run-time.

Lockout A system which limits the pump systems available pumps and or limits

speed of a variable speed pump during user-defined time of day or day
week.

Low level probe A device that “shorts” out when removed from water. This removes the

from the PLC and tells it that the pump is not safe to run due to a low
level

condition.

Main pumps The pumps which are relied on for supplying the irrigation at mid-high

rates.

Must-run time The amount of time (in seconds) that the pump must

run.

variable

AC

current

that

be

correctly

AC

irrigation

not

minimum

This

lowest

the

of

signal

water

flow

Output A way for a control system to generate real world actions. An output can be a

120VAC signal to turn on a pump, or a varying 4-20 mA signal to control
speed of a VFD. Many types of output are

available.

Overload A condition in which pumps are allowed to produce more flow rate than

motor that drives them is designed for. Also refers to a device in the
panel, which detects this situation and stops the pump in order to protect

Overpressure accumulator A counter that is used to determine the lag pump shut down

sequence.

the

the

control

it.

to

35

Phase monitor A device that analyzes incoming voltage and determines whether all

parameters are acceptable and the phase sequence is

correct.

voltage

PLC Programmable Logic Controller. A very robust/rugged computer designed

equipment control in harsh

PM pump Pressure Maintenance Pump. Handles very light flow rates and leaks

prevent the main pumps from

Pressure reducing valve (PRV) A control valve designed strictly for maintaining a specific

pressure.

environments.

cycling.

to

downstream

Pressure transducer A device that converts actual pressure to a 4-20 mA signal that is input

the PLC which converts it back to an actual pressure

PSI Pounds per square inch. Units of pressure for US

use.

reading.

Relay This is a normally open or normally closed device that changes output

when it is energized or de-energized and sends or removes a 120VAC
to the

PLC.

SCADA Supervisory Control And Data

Acquisition.

Setpoint The desired situation for a control variable. If the user wanted the

system to operate at 120 PSI, that would be the setpoint for the

Speed test The method used to shut down a VSP during normal automatic
Transfer pump A pump designed to move water from one reservoir to

another.

irrigation

controller.

operation.

Units Gives context to numbers in the PLC. Units describe what the number

about, such as PSI,

VFD Variable frequency drive. This allows a pump to run at variable

GPM.

speeds.

for

into

state

signal

is

36

Appendix B ─ Networking

Options

37

Appendix C–Typical Alarms Configuration

Default Alarms /

Faults

38

Appendix D – Email Troubleshooting

DETERMINING THE IP ADDRESS OF THE SMTP

On your Windows PC, Click “Start”, “Run”, type in “CMD” in the dialog and press

SERVER

enter.

You will see a DOS prompt window similar to that

below.

Type “ping” followed by the server name of your SMTP service. Your email provider will be
to supply these server names as a standard part of the information needed to set up your
for outlook or other email

programs.

able

email

39

Look at the line following your command entry, this will contain the IP address of the
server. In this case, smtp.runbox.com is at IP address

87.238.52.70.

SMTP

Double-check the POP3 server for the same IP address. Same procedure, but use your
server name in the ping

statement.

40

pop3

TROUBLESHOOTING GENERAL EMAIL

The following are some common problems encountered when configuring email
Double check each setting to ensure the correct information was

1. Attempting to use the server name rather than the IP address in the SMTP

2. Using an incorrect IP address - determine the IP address from the procedure

3. Entering an invalid user. Make sure the user field matches the account. Also make
the “From” field matches the user information

4. Inputting an incorrect

5. The mail service does not support

6. Your internet service provider does not allow access out of your network on TCP/IP

25.

Troubleshooting Email SET

The following table gives the number codes associated with failures received after tapping
to set the

SMTP:

password.

Failures

FAILURES

SMTP

exactly.

entered.

settings.

field.

above.

0 Success
1

Invalid format for strSMTP

2

Invalid format for strFrom

3

Invalid format for strPOP3

sure

port

[SET]

4

Invalid format for strUser

5

Invalid format for strPassword

6

Invalid format for optNumTimeout

7

Wrong number of parameters

8

Error getting host IP address (invalid POP3 server)

9

Error connecting to POP3 server

10

Error sending username

11

Error sending password

12

SMTP server does not support selected authentication mode

13

Invalid SMTP username

14

Authentication failed

SMTP error Codes, Set SMTP

Function

41

Troubleshooting Email Send

Subject

Message

The following table gives the number codes associated with failures received after
[SEND] to do a test-run of the email addresses and the

Value

0

Success

1

Invalid format for parameter 1 (

2

Invalid format for parameter 2 (

3

Invalid format for parameter 3 (To)

4

Wrong number of parameters

5

Start Socket error

6

Error getting host IP Address (i.e. invalid SMTP server)

7

Error connecting to SMTP server

8

Error sending HELO command (initialization)

9

Error sending MAIL command (sending FROM address)

10

Error sending RCPT command (sending TO address)

Failures

SMTP:

Description

)
)

tapping

11

Error sending DATA (sending message)

The following test can be used to check for access to the SMTP

•

Open a command window as in checking for the IP address

•

Use Telnet to attempt to connect to smtp.runbox.com on port 25 (or your

servers

SMTP Error Codes, Test Email

name)

Function

server:

above.

email

42

•

If successful, be sure and type “quit” <enter>. It’s bad form to leave the server

though it will reset the session

itself.

hanging

•

If you are unable to connect, attempt to Telnet to the POP3 server on port

110.

Successful Telnet to the POP3 server but unsuccessful telnet to the smtp server is typical of
port 25 block by the ISP. They often block port 25 to prevent spammers from using home
unwary business accounts for spam generation. A call to your ISP will usually resolve
problem quickly. You may have to ask for advanced technical service as this scenario
the standard script for call-center type

service.

the

isn’t

a

and

on

43

Appendix E: Computer Setup and Determining the IP address of
your pump station

Connecting to the pump station after the hardware is installed is relatively easy. The first step is to
connect your PC to the network. This simply means your PC will be connected to the LAN
the router supplied by Bell & Gossett. Step 2 is to set the IP address of your PC.

Click Local Area

Connection.

side

of

Computer Setup

44

Options

Another window will come up. Select

Properties:

Highlight Internet Protocol (TCP/IP). If there are two entries, one for v6 and one for v4, select
as shown. Then select

Properties.

v4

45

Select “Use the following IP
Check with your IT department or internet service provider for proper DNS server

These should be no different than your settings before installing the

address”

settings.

router.

DETERMINING THE IP

Determining the IP address to use to communicate with your pump station remotely can be
easy as asking your IT professional, or somewhat more complicated, requiring you to access
routers status page. Chances are if you have an IT department, they will have to be involved
setting up your router and should be able to provide you with an IP address. They will need
provide a path for port 80 to the router provided by Bell & Gossett. This router is already set up
port

forward the request to the pump

If you are connected directly to the internet through a cable or DSL modem, you can find your
address by accessing the routers status page. With the Ethernet cable connected between
PC and the router, open your internet browser and type in the address, http://192.168.1.1.
login page for the router should appear. Use the user name “admin”, the password has
left blank, simply click “Log

ADDRESS:

in”.

station.

The

been

as

your

in

to

to

IP

your

46

Select the “Status” page from the menu at the top of the screen. Scroll down the page to
“WAN” status to see the IP address assigned by your Internet service

provider.

the

Please note, if your network is more complicated than a simple connection through a cable
DSL modem, please consult your IT department. The procedure outlined above can only
the IP address of the router, and therefore the IP address of your PC, with reference to
network the router is connected to. If additional routers separate your PC from the
network, your IT department will need to provide the correct IP address, and open ports to
you access to your pump station information. If this becomes problematic, it is still possible
use the PC access services used for servicing your irrigation control computer to access
pump station information. In most cases, your pump station can still send email out of
as

required.

47

outside

the

the

or

supply

allow

to

your

network

Appendix F – General Networking and Router Configuration

Router 1

Router 2

Pump Station

Router

WAN

76.199.50.60

10.92.168.10

192.168.0.12

LAN 10.92.168.1

192.168.0.1

192.168.1.1

Port
Forwarding

80->10.92.168.10:80

80->192.168.0.12:80

80->192.168.1.15:80
8080->10.92.168.10:8080

8080->192.168.0.12:8080

None (Router

Configuration)

HMI.

address

cost.

on-site

“the

pump

a

station.

in: http://76.199.123.234

range.

80.
router

in:

router

Discussion:

Regarding the requirement for a fixed IP address: This is not a requirement of the Bell &
Gossett control system. This is required so the user attempting to access the system remotely
can

find the machine on the internet. Without a fixed IP address, the computer is at one of
4,228,250,625 theoretically possible addresses, though usually addresses are assigned within
specific range of a few thousand. The internet service provider typically assigned an IP
dynamically when the computer connects. The dynamic IP address won’t affect messaging
only accessing the station from the outside in. There are for-pay services for keeping track
your IP address via domain name, though these also come at a

There are also often complications related to getting access to the router through any
networks. There tend to be one or two routers between the pump station router and
internet”, and each of those routers has to “pass through” or “forward” messages to the
station router. This is a configuration issue for the routers in the chain and while not
complicated setup, communicating with and getting approval from local IT departments can
difficult.

On most systems, we have a single pump station the user needs to connect to remotely. If
80 messages can be sent to our router, the user can access his pump
For example: Let’s say their router is set up to pass requests to it (say it’s 76.199.123.234)
to the pump station router. The user types

Their router forwards the message: http://192.168.1.1:80 along with the request data. The
station router passes through port 80 traffic to 192.168.1.15 on port
The HMI responds with a web connection. Anything that comes in to their router requesting
from port 80, gets “routed” to the pump station router on port 80, and the pump station
routes it to the

In another example, the IT router already passes traffic to another web server on port 80, so
can’t use port 80. To work around this problem, IT can set their router up to pass port 81 traffic
us on port 80. We still route port 80 traffic to the HMI on port 80 at 192.168.1.15. Again, the
page on the HMI works, though the user will need to access the page by typing
http://76.199.123.234:81 (The IP addresses used in these examples are fictitious, except for
“pump station router” which has its LAN side IP address set to 192.168.1.1, and all equipment
the LAN side of the router is in the 192.168.1.X

If there are two or more HMIs on site, the site router would have to pass multiple ports to
router, normally 80,81,82,83. We would then route port 80 traffic to 192.168.1.15, 81 to

192.168.1.16, 82 to 192.168.1.17, etc. They would just have to set their routing table up to
us all messages for port 80 to us at port 80, all messages for port 81 to us at port 81, etc.
idea can cascade to several routers. Also, in order for Bell & Gossett to remotely configure
router, port 8080 is used, but no routing is provided in the pump station router since the
itself provides the service (the router user name and password are labeled on the back of
router).

out,

of

be

port

directly

pump

data

we

web

the

our

give

This

the

the

a

to

on

48

Router 1

Router 2

Pump Station

Router

WAN

76.199.50.60

10.92.168.10

192.168.0.12

LAN 10.92.168.1

192.168.0.1

192.168.1.1

Port
Forwarding

2000->10.92.168.10:2000

2000->192.168.0.12:80

80->192.168.1.15:80
2010->10.92.168.10:2010

2010->192.168.0.12:8080

None (Router

Configuration)

Router 1

Router 2

Pump Station

Router

WAN

76.199.50.60

10.92.168.10

192.168.0.12

LAN 10.92.168.1

192.168.0.1

192.168.1.1

Port
Forwarding

2000->10.92.168.10:2000

2000->192.168.0.12:2000

2000->192.168.1.15:80
2010->10.92.168.10:2010

2010->192.168.0.12:8080

None (Router

Configuration)

Router 1

Router 2

Pump Station

Router

WAN

76.199.50.60

10.92.168.10

192.168.0.12

LAN 10.92.168.1

192.168.0.1

192.168.1.1

Port
Forwarding

2000->10.92.168.10:2000

2000->192.168.0.12:2000

2000->192.168.1.15:80
2001->10.92.168.10:2001

2001->192.168.0.12:2001

2001->192.168.1.16:80

2002->10.92.168.10:2002

2002->192.168.0.12:2002

2002->192.168.1.17:80

2010->10.92.168.10:2010

2010->192.168.0.12:8080

None (Router

Configuration)

The user would access his station by requesting a web page at http://76.199.50.60 (default port is
80 for HTTP). Note how the pump station router, the last in the line, redirects the port requests
specific device (IP address) at the same port (80). All other routers are just passing along
message, keeping the port #s essentially intact. That doesn’t have to be the case though, due
requirements of the IT department, or because some web server may be located at some level
the network, the network may have to look like

this:

the

The user would access his station by requesting a web page at http://76.199.50.60:2000
“:2000” specifies the browser to request the data at port 2000 rather than the default port
Note that the port # gets reset to 80 before the call to our router. In this case, no change of
pump station router settings would be required. But we could, as

follows.

(The

80).

to

to

in

the

When multiple pump stations are on the site, more than one port will need to be opened to
able to access all of the stations, either simultaneously or one at a time. Bell & Gossett sets up
HMI in a range. The first HMI is at IP address 192.168.1.15. The second is at
The third is at 192.168.1.17, and so on. In the previous example, now with three HMIs to

192.168.1.16.

The user would access Station 1 by requesting a web page at http://76.199.50.60:2000,
is located at http://76.199.50.60:2001, Station 3 is located at http://76.199.50.60:2002.

be

access:

Station

each

2

49

Generally, the WAN port of the pump station router is connected directly to the cable or

Pump Station

Router

WAN

76.199.50.60 (Supplied by internet service

provider)

LAN 192.168.1.1

Port
Forwarding

80->192.168.1.15:80
81->192.168.1.16:80

82->192.168.1.17:80

Router 1

Router 2

Pump Station

Router

WAN

76.199.50.60

10.92.168.10

192.168.0.12

LAN 10.92.168.1

192.168.0.1

192.168.1.1

Port
Forwarding

80->10.92.168.10:80

80->192.168.0.12:80

80->192.168.1.15:80
8080->10.92.168.10:8080

8080->192.168.0.12:8080

None (Router

Configuration)

9000->10.92.168.10:9000

9000->192.168.0.12:9000

Programming: Not routed

until

needed

9001->10.92.168.10:9000

9001->192.168.0.12:9001

Programming: Not routed

until

needed

DSL

modem, so the complex routing configuration is not required. The pump station

router is

usually

configured as

follows:

Bell & G os s et t is also capable of accessing the HMI and PLC in the pump station for
diagnostic
access to additional
ports in the pump station router to
port forwarding for service. To support
provide a pathway into our router. Bell & Gossett
pump station router as required, so all the I
through two unused ports to our router. The first example above
example.

and

programming purposes, with the aid of personnel onsite. This requires

ports

in the same way. Normally Bell & Gossett disables these

provide

extra security, but can enable and disable this

this

capability, the IT department would need to

will

map the final port forwarding in the

T

department

would need to do is map

is

recreated below as an

Bell & G os s et t will access the router configuration and port-forward as needed for the

case,

specific
security.

then after programming is complete, disable the port forwarding for

One problem encountered occasionally is having the same IP address range on BOTH
sides of
side is set up

192.168.1.x with a subnet mask of 255.255.255.0. That means all addresses

192.168.1.x
assigned the address

192.168.1.129, this will cause problems because the pump station router doesn’t know
where
router will
addresses to use only
lower 4 bits for addressing. That could be a problem if there are devices on the
addressed higher than 192.168.1.15 (i.e. auxiliary equipment, power monitors, etc.).
In
another
operation.

a

router. That confuses the router. The Bell & Gossett pump station routers LAN

at

are

assumed to be inside the network. If the router’s WAN side is

its

LAN side ends (address wise) and where it begins. In that case, the pump station

have

to be configured with a subnet mask to 15 and restrict our internal

such

cases, it may be required that we set the IP addresses in the equipment to

domain

altogether (192.168.200.x for example). This is a non-trivial

of

the

network

50

Appendix G – Quick Start Guide

This guide will provide a Technician the steps needed to start the Technoforce XLS station.
Prior to following this guide the station must be mechanically and electrically installed
and the system filled with water. All remote sensors, if applicable, should also be installed
and calibrated. Please refer to the Station Installation Document and Technician’s IOM for
detailed set up for the station.

Access

This is for operation at the Technician level. To log in follow the steps below:

1. On the controller touch screen tap the SERVICE key

2. From this menu tap the [Log on/off key], this is at the bottom right corner of the

screen.

3. Tap [Technician] and enter the password provided at the time of purchase. Tap

to log in, or to exit without logging

in.

4. Tap [OK]

5. Tap the BOOSTER key located at the very top of the screen to return to the main

display.

Booster Home Screen

51

Unit Set-up

Prior to starting the Booster you will need to ensure all of your set points are correct.
Please note that the Booster station is pre-configured at the factory based on the work
order (WO) which is included in your station documentation.

1. Prior to starting your station verify that this information is accurate.

2. On the controller touch screen tap the SERVICE key.

3. From this menu tap [System Setup]

4. Using [Next], scroll through all of the menus and verify all settings match the

station WO. Refer to the Technician’s IOM for detailed instructions for each menu
screen if changes are required.

5. When you reach the last menu press the BOOSTER key located at the very top of

the screen to return to the main display.

6. Tap the SETPOINT key:

7. From this screen ensure that your “Nominal Setpoint” matches the station work

order. If not tap in the box and adjust accordingly.

8. If you are using “Alternate SPs” please refer to the Technician’s IOM for proper

Adjustment.

9. If Remote Transducers have been enabled from the System Set-up screen you can

set those setpoints now. Refer to Technician’s IOM for detailed set-up. Installation
and calibration of the remote transducers should be complete prior to using this
configuration.

52

10. The Dynamic Flow Loss Compensation will be set to zero unless specified on the

WO. This setting may need to be adjusted while tuning the station.

11. Press the BOOSTER key located at the very top of the screen to return to the main

display.

ATTENTION: The following steps are going to start the station

Unit Start-up

1. From the Booster home screen tap for pump 1. An enhanced screen will

appear that will allow you to place the pump in Auto Mode.

2. Tap [Auto] and the [Close]

3. You should now have Pump 1 set to Auto and the remaining pumps are still off.

4. To start the station, tap [Auto] from the Booster Home Screen.

5. Your station should now have Pump 1 running in Auto Mode.
a. Upon start up the pump should ramp up to minimum speed.
b. Once minimum speed is reached the pump should step Pump 1 speed up

slowly to attain setpoint over a given time period (minimum fill speed).

c. IF the station is acting erratically tap [Auto] immediately to turn the

station off and review the configuration for proper set up.

d. Depending on the demand, the pump could either:

i. Meet setpoint and run at a steady state.

ii. Ramp down until it turns off.

iii. Demand exceeds pump capability and will require another pump

to start. At this point Technician should ensure station
configuration requires multiple pumps to meet demand before
turn on remaining pumps.

6. If station is running with no issues, from the Booster Home Screen place the

remaining pumps in Auto Mode.

7. Ensure that the station is functioning properly with all pumps in Auto.

8. Station should meet demand and stage down as the demand on the station is

reduced.

53

9. Ensure that when setpoint is reached and demand is zero, the station will shut

down. If not, please review configuration and Technician’s IOM for more detailed
trouble shooting.

For fine tuning of the system and system setpoints, please refer to your Technician’s
IOM.

54

WARRANTY INFORMATION

COMMERCIAL WARRANTY

Warranty. For goods sold to commercial buyers, Seller warrants the goods sold to Buyer hereunder (with the exception

of membranes, seals, gaskets, elastomer materials, coatings and other "wear parts" or consumables all of which are not
warranted except as otherwise provided in the quotation or sales form) will be (i) be built in accordance with the
specifications referred to in the quotation or sales form, if such specifications are expressly made a part of this
Agreement, and (ii) free from defects in material and workmanship for a period of one (1) year from the date of
installation or eighteen (18) months from the date of shipment (which date of shipment shall not be greater than thirty
(30) days after receipt of notice that the goods are ready to ship), whichever shall occur first, unless a longer period is
specified in the product documentation (the “Warranty”).

Except as otherwise required by law, Seller shall, at its option and at no cost to Buyer, either repair or replace any product
which fails to conform with the Warranty provided Buyer gives written notice to Seller of any defects in material or

workmanship within ten (10) days of the date when any defects or non-conformance are first manifest. Under either

repair or replacement option, Seller shall not be obligated to remove or pay for the removal of the defective product or
install or pay for the installation of the replaced or repaired product and Buyer shall be responsible for all other costs,
including, but not limited to, service costs, shipping fees and expenses. Seller shall have sole discretion as to the method
or means of repair or replacement. Buyer’s failure to comply with Seller’s repair or replacement directions shall
terminate Seller’s obligations under this Warranty and render the Warranty void. Any parts repaired or replaced under
the Warranty are warranted only for the balance of the warranty period on the parts that were repaired or replaced.
Seller shall have no warranty obligations to Buyer with respect to any product or parts of a product that have been: (a)
repaired by third parties other than Seller or without Seller’s written approval; (b) subject to misuse, misapplication,
neglect, alteration, accident, or physical damage; (c) used in a manner contrary to Seller’s instructions for installation,
operation and maintenance; (d) damaged from ordinary wear and tear, corrosion, or chemical attack; (e) damaged due to
abnormal conditions, vibration, failure to properly prime, or operation without flow; (f) damaged due to a defective
power supply or improper electrical protection; or (g) damaged resulting from the use of accessory equipment not sold or
approved by Seller. In any case of products not manufactured by Seller, there is no warranty from Seller; however, Seller
will extend to Buyer any warranty received from Seller’s supplier of such products.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ANY AND ALL OTHER EXPRESS OR IMPLIED WARRANTIES,

GUARANTEES, CONDITIONS OR TERMS OF WHATEVER NATURE RELATING TO THE GOODS PROVIDED HEREUNDER,

INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR

PURPOSE, WHICH ARE HEREBY EXPRESSLY DISCLAIMED AND EXCLUDED. EXCEPT AS OTHERWISE REQUIRED BY LAW,

BUYER’S EXCLUSIVE REMEDY AND SELLER’S AGGREGATE LIABILITY FOR BREACH OF ANY OF THE FOREGOING

WARRANTIES ARE LIMITED TO REPAIRING OR REPLACING THE PRODUCT AND SHALL IN ALL CASES BE LIMITED TO THE

AMOUNT PAID BY THE BUYER FOR THE DEFECTIVE PRODUCT. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY OTHER

FORM OF DAMAGES, WHETHER DIRECT, INDIRECT, LIQUIDATED, INCIDENTAL, CONSEQUENTIAL, PUNITIVE, EXEMPLARY

OR SPECIAL DAMAGES, INCLUDING BUT NOT LIMITED TO LOSS OF PROFIT, LOSS OF ANTICIPATED SAVINGS OR

REVENUE, LOSS OF INCOME, LOSS OF BUSINESS, LOSS OF PRODUCTION, LOSS OF OPPORTUNITY OR LOSS OF

REPUTATION.

LIMITED CONSUMER WARRANTY

Warranty. For goods sold for personal, family or household purposes, Seller warrants the goods purchased hereunder

(with the exception of membranes, seals, gaskets, elastomer materials, coatings and other "wear parts" or consumables
all of which are not warranted except as otherwise provided in the quotation or sales form) will be free from defects in
material and workmanship for a period of one (1) year from the date of installation or eighteen (18) months from the
product date code, whichever shall occur first, unless a longer period is provided by law or is specified in the product
documentation (the “Warranty”).

Except as otherwise required by law, Seller shall, at its option and at no cost to Buyer, either repair or replace any product
which fails to conform with the Warranty provided Buyer gives written notice to Seller of any defects in material or

workmanship within ten (10) days of the date when any defects or non-conformance are first manifest. Under either

repair or replacement option, Seller shall not be obligated to remove or pay for the removal of the defective product or
install or pay for the installation of the replaced or repaired product and Buyer shall be responsible for all other costs,
including, but not limited to, service costs, shipping fees and expenses. Seller shall have sole discretion as to the method
or means of repair or replacement. Buyer’s failure to comply with Seller’s repair or replacement directions shall
terminate Seller’s obligations under this Warranty and render this Warranty void. Any parts repaired or replaced under
the Warranty are warranted only for the balance of the warranty period on the parts that were repaired or replaced. The

Warranty is conditioned on Buyer giving written notice to Seller of any defects in material or workmanship of warranted
goods within ten (10) days of the date when any defects are first manifest.

Seller shall have no warranty obligations to Buyer with respect to any product or parts of a product that have been: (a)
repaired by third parties other than Seller or without Seller’s written approval; (b) subject to misuse, misapplication,
neglect, alteration, accident, or physical damage; (c) used in a manner contrary to Seller’s instructions for installation,
operation and maintenance; (d) damaged from ordinary wear and tear, corrosion, or chemical attack; (e) damaged due to
abnormal conditions, vibration, failure to properly prime, or operation without flow; (f) damaged due to a defective
power supply or improper electrical protection; or (g) damaged resulting from the use of accessory equipment not sold or
approved by Seller. In any case of products not manufactured by Seller, there is no warranty from Seller; however, Seller
will extend to Buyer any warranty received from Seller’s supplier of such products.

THE FOREGOING WARRANTY IS PROVIDED IN PLACE OF ALL OTHER EXPRESS WARRANTIES. ALL IMPLIED WARRANTIES,

INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR

PURPOSE, ARE LIMITED TO ONE (1) YEAR FROM THE DATE OF INSTALLATION OR EIGHTEEN (18) MONTHS FROM THE

PRODUCT DATE CODE, WHICHEVER SHALL OCCUR FIRST. EXCEPT AS OTHERWISE REQUIRED BY LAW, BUYER’S

EXCLUSIVE REMEDY AND SELLER’S AGGREGATE LIABILITY FOR BREACH OF ANY OF THE FOREGOING WARRANTIES ARE

LIMITED TO REPAIRING OR REPLACING THE PRODUCT AND SHALL IN ALL CASES BE LIMITED TO THE AMOUNT PAID BY

THE BUYER FOR THE DEFECTIVE PRODUCT. IN NO EVENT SHALL SELLER BE LIABLE FOR ANY OTHER FORM OF DAMAGES,

WHETHER DIRECT, INDIRECT, LIQUIDATED, INCIDENTAL, CONSEQUENTIAL, PUNITIVE, EXEMPLARY OR SPECIAL

DAMAGES, INCLUDING BUT NOT LIMITED TO LOSS OF PROFIT, LOSS OF ANTICIPATED SAVINGS OR REVENUE, LOSS OF

INCOME, LOSS OF BUSINESS, LOSS OF PRODUCTION, LOSS OF OPPORTUNITY OR LOSS OF REPUTATION.

Some states do not allow limitations on how long an implie d warranty lasts, so the above limitation may not appl y to you.
Some states do not allow the exclusion or limitation of inc idental or consequential da mages, so the above e xclusions may
not apply to you. This warr anty give s you specifi c legal ri ghts, and you may also have other rights whic h may vary f rom
state to state.

To make a warranty claim, check first with the dealer from whom you purchased the product or call t he following number
for the name and location of the nearest dealer providing warranty service. For Goulds Water Technology contact 315-568-

7123. For all other products, contact 847-966-3700.

Xylem

1) The tissue in plants that brings water upward from the roots;

2) a leading global water technology company.

We’re 12,500 people unied in a common purpose: creating innovative solutions
to meet our world’s water needs. Developing new technologies that will improve
the way water is used, conserved, and re-used in the future is central to our work.
We move, treat, analyze, and return water to the environment, and we help people
use water efciently, in their homes, buildings, factories and farms. In more than
150 countries, we have strong, long-standing relationships with customers who
know us for our powerful combination of leading product brands and applications
expertise, backed by a legacy of innovation.

For more information on how Xylem can help you, go to www.xyleminc.com

Xylem Inc.
10661 Newkirk Street

Dallas, TX 75220

www.bellgossett.com

Bell & Gossett is a trademark of Xylem Inc. or one of its subsidiaries.
© 2014 Xylem Inc. 10-001-275 REV0 July 2014