electronic, or mechanical, including photocopying, recording, taping, or information storage and
systems - without the written permission of the
publisher.
Products that are referred to in this document may be either trademarks and/or registered trademarks
respective owners. The publisher and the author make no claim to these trademarks. These
Microsoft, Windows, Windows NT, and ActiveX that are either registered trademarks or trademarks of
Microsoft
reserved.
WHILE EVERY PRECAUTION HAS BEEN TAKEN IN THE PREPARATION OF THIS DOCUMENT,
PUBLISHER AND THE AUTHOR ASSUME NO RESPONSIBILITY FOR ERRORS OR OMISSIONS,
FOR DAMAGES RESULTING FROM THE USE OF INFORMATION CONTAINED IN THIS
OR
FROM THE USE OF PROGRAMS AND SOURCE CODE THAT MAY ACCOMPANY IT. IN NO
SHALL THE PUBLISHER AND THE AUTHOR BE LIABLE FOR ANY LOSS OF PROFIT OR ANY
COMMERCIAL DAMAGE CAUSED OR ALLEGED TO HAVE BEEN CAUSED DIRECTLY
INDIRECTLY
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
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
phonenumber@MyMetroPcs.com
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:
mypumpstation@runbox.com
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
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