Bell & Gossett 10-001-278 XLS User Manual
INSTRUCTION MANUAL
10-001-278
™
XLS
Integrated Pump
Controller
HUMAN MACHINE INTERFACE (HMI) FOR THE TECHNOFORCE™ BOOSTER SYSTEM
USER GUIDE
Acknowledgements
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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
SYSTEM VIEW
Trends
ALARM TAB
SETPOINT TAB
SERVICE TAB
Lockout Setup
Events
Email Setup
Set Sync HMI-PLC Date/Time
Security Setup
Alarm Conguration
ENERGY TAB
COMMUNICATIONS TAB
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WEB REPORTS
Log on to Web Reports................................................ 22
Web Reports Menu...................................................... 22
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 ............... 35
DETERMINING THE IP ADDRESS:
APPENDIX F – GENERAL NETWORKING AND ROUTER
CONFIGURATION DISCUSSION: ................................... 39
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.. 29
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32
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SETUP/CONFIGURATION FILE
NETWORKING AND REMOTE ACCESS
Remote Software Log In
...................................... 21
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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: Home Screen Navigation
Figure 9: Pump Symbols
Figure 10: Pump Switch Screen
Figure 11: Pump Detail
Figure 12: Pump Information
Figure 13: Station Discharge Status
Figure 14: Basic Booster Idle Screen
Figure 15: Basic Booster Manual Screen
Figure 16: Manual On/Off
Figure 17: Manual Pump Control Screen
Figure 18: Default Alternation Screen............................... 10
Figure 19: Example Alternation Screen
Figure 20: Trends Screen
Figure 21: Congure Period
Figure 22: Congure Data
Figure 23: Alarms Home Screen
Figure 24: Period Screen.................................................. 12
Figure 25: Alarm Warning
Figure 26: Setpoint Home Screen
Figure 27: Setpoint Detail A
Figure 28: Setpoint Detail B.............................................. 13
Figure 29: Setpoint Detail C
Figure 30: Setpoint Detail D
Figure 31: Setpoint Detail E.............................................. 14
Figure 32: Service Home Screen
Figure 33: Lockout Screen
Figure 34: Individual Lockout Setup
Figure 35: Parameter Tab in Lockout Setup
Figure 36: Event Setup
Figure 37: Email Settings
Figure 38: Set/Sync Screen.............................................. 17
Figure 39: Sync Pop-up Detail.......................................... 17
Figure 40: Clear/Update Totalizers
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Figure 41: Security Setup Home Screen
Figure 42: User Setup
Figure 43: Alarm Conguration
Figure 44: Energy Home Screen
Figure 45: Flow Totals Overview
Figure 46: Daily Flow Totals Overview.
Figure 47: Communications Home Screen....................... 19
Figure 48: Communications Protocol Selection................ 19
Figure 49: Communications Protocol Selection 2............. 19
Figure 50: Communications Protocol Selection 3............. 19
Figure 51: Active X & IP Updates
Figure 52: WinCE Remote Access
Figure 53: Web Reports Menu
Figure 54: Trends View
Figure 55: Alarms & Events
Figure 56: Historical Reports
Figure 57: 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 booster station owners and
is a basic overview to the XLS HMI (Human Machine
Interface). For more detailed start-up/service please
contact your local Bell and Gossett Representative.
The HMI is a browser- based system which allows
the user to interact with the settings and reports of
the pumping system.
HMI aspect of the
TechnoForce Booster
questions not related
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
system (OS). Windows CE© is
component-based version of the
operating system designed for embedded
such as PDAs or touch-panel
This manual also assumes the user has some
knowledge of pumps and pumping
Note: Button names are shown enclosed in
brackets, such as [Button], whenever the actual
or button graphic is not
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
This
manual only covers the
system.
Please see the
Instruction Manual for any
to
the
HMI.
Windows
displays.
systems.
displayed.
tapping
and
System
Windows
Windows
an
a
devices,
basic
square
and
panel.
and
key
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
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
affected.
“Enable
to
value
technicians
Supervisor
Touch Panel Log In
Tap [SERVICE] from the Home
Figure 4: Guest Service Screen
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.
Figure 5: Supervisor Service Screen
7
Screen.
Only qualified Bell and Gossett Service Reps will have
3 5 6
11
10 7 8 2 4
1
Stand-By
Running
Off
Alarm
9
access to the complete system parameters.
Tap [Log on/off] from the Service
User type.
Screen to change
Home Screen Navigation
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.
To log in as a Supervisor, tap [Supervisor],
then tap on the empty Password field to enter
Supervisor password. This will bring up an enhanced
screen shown in Figure 7.
pass word is “1234”. This password should be
changed upon the first log in.
this password as there is n o way to r ecover if lost
Enter your password and Tap to log in, or
to exit without logging
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
Tap [BOOSTER] to return to the Home Screen
Figure 6: Log in
Figure 7: Log In Keypad
Screen
The default Supervisor
Ensure you do not lose
in.
Figure 5.
and
the
Figure 8: 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:
8
Figure 9: Pump Symbols
a
b
- Status
- Total runtime
a. By tapping , in either Idle or Auto Modes, an
enhanced screen shown in Figure 10 will appear to
set individual pump status.
MODES OF OPERATION
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 10: Pump Switch Screen
2. Pump Status Detail:
- Percent Speed
- Hertz
- kW
- Flow Rate
Figure 11: Pump Detail
a. By tapping , an enhanced screen shown in
Figure 12 will appear with more detailed
information.
Figure 14: 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
15 to allow manual operation of individual pumps.
Figure 12: Pump Information
STATION DISCHARGE STATUS
The station discharge status bar will display the current
discharge condi tions for the station.
Figure 13: Station Discharge Status
Figure 15: Basic Booster Manual Screen
a. [ON], allows for the manual ability to turn on/off
9
the pump.
Figure 16: Manual on/off
a b d
c
b. The PERCENT SPEED displays the current set
speed.
By tapping , an Enhance d Scr e en shown in
Figure 17 will appear and allow for manual control
of the pump speed and status.
ALTERNATION SET UP
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 18 will appear that allows th e modi fi ca ti o n of
the alternation sequence for the station.
Figure 18: Default Alternati on Screen
The Alternation screen will allow th e us e r to forc e
alternation of a given pump during a particular time of
Figure 17: Manual Pump Control Screen
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
10
Figure 19: Example Alternation Screen
c
b e d
a
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.
SYSTEM VIEW &
By tapping from home screen,
View accesses color-coded
trends or historical data for several
variables such as flow, pressure, speed,
setpoint.
TRENDS
operational
System
system
and
reappear when power readings
a. The trends will be shown for the Duration
value,
ending at the current time. When ‘Now’
checked,
is
date and
If ‘Now’ has been checked, ‘Duration’ is the
only
editable
viewing historical data, uncheck
Enter the start date and time, along with
duration
[Apply] to
changes.
any
NOTE: If ‘Now’ is left unchecked, the system
does
time.
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
date and duration for viewing system
information.
the system defaults to the current
time.
field under [Time Period] .
to
view data for desired time. Tap
apply
changes or [Close] to cancel
not default back to the current date and
return.
‘Now’.
allows you to set
For
a
d. Configure Data
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
cause the Power display to disappear, and
Figure 20: Trends
the screen.
Screen
the
all systems.
of
0 will
will
11
Figure 21: Configure
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.
Period
a
b
c
d
Figure 22: 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
graph scaling
comfortable to
100% means the graph scale is the same as
the
analog scaling max value. 110% means
graph
the
scaling for
the KW
because KW is
scaled.
Click “Channels” to access the calibration
screen
screen.
This screen is accessible also from
>”Options Setup” and is discussed in detail
in
that section.
to
a value that makes it most
read.
scaling is 110% of the analog max
the
channel. The exception here is
reading,
directly from the “Configure Data”
which is an absolute number
read
directly, rather than
“Setup”-
ALARMS
The [ALARMS] tab wil l tak e you to the Ala r ms detail
screen.
Figure 23: 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
12
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 24 to allow for the display of only
alarms during a given range.
Figure 24: Period Screen
If an alarm is active the Home screen will also display
b
a
c
a
b
c
d
e
various visual warnings to alert the system status
By leaving it unchecked no changes can be
made.
Figure 27: 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 25: 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
SETPOINTS
The [SETPOINTS] tab will take yo u to the S et 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 28: 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
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 29: 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
Figure 26: 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.
13
remote transducers.
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 30: 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 32: 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.
Figure 31: Setpoint Detail E
14
Figure 33: 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
and
number,
changes.
over
a
the
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