Bell & Gossett S12596B User Manual

CONSTANT SPEED PUMPING SYSTEMS INSTRUCTION MANUAL

INSTRUCTION MANUAL

S12596B

Technologic 350 Pump Controller

INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.

DESCRIPTION: Microprocessor based dedicated pump controller for constant speed pumping systems. The control panel includes the following components: microprocessor with EPROM chip, starters, overload protection, virtual H-O-A switches, optional short circuit protection and control transformer.

The microprocessor control consists of an operator interface with 2 line backlit display and membrane key pad, input/output board with 24V power supply, and microcontrolled kW transducer.

OPERATIONAL LIMITS: See the control panel nameplate for operating voltage, current draw, as well as information on the equipment to be connected to the control panel.

™

SAFETY INSTRUCTIONS

This safety alert symbol will be used in this manual and on the Technologic 350 Safety Instruction decal to draw attention to safety related instructions. When used, the safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED! FAILURE TO FOLLOW THE INSTRUCTIONS MAY RESULT IN A SAFETY HAZARD!

TECHNOLOGICTM350

CONTROLLER INSTRUCTIONS

UNIT IDENTIFICATION

The unit nameplate gives identification and rating information as identified in Figure 1.

Permanent records for this unit are kept by the factory number and it must therefore be

used with all correspondence and spare parts orders.

Model No.

Factory No.

Wired for Volts Hz Ph

System FL Amps

Largest Motor HP

System Flow GPM

Suction Pressure PSIG

Discharge Pressure PSIG

Pump TDH Feet

FIGURE 1

PREFACE

The following manual describes the new microprocessor based Technologic 350 Controller. This unit is in the tradition of the other members of the Technologic Control Panels as it incorporates many original, novel, and proprietary features that may only be found on B&G controllers. Some of these features require special emphasis here.

The controller is best described as a specific purpose programmable pump controller. This means that the hardware and software have been created for the control and diagnostics of pumps with consideration for their inherent characteristics. This results in an optimum pump controller without the cost of general purpose control hardware. Software is dedicated and established for the unit only after extensive testing. Changes to this software are not taken lightly and must pass rigid version control.

The controller has the unique patented analog input protection of other members of the control family. Upon inadvertent higher than normal input voltage the analog input resistor is sacrificed. An on-board spare is used to replace the plug-in resistor. Extreme hi-voltage is protected against by additional components.

Unique to this new controller are virtual selector switches. Microprocessor control coupled with discrete logic allows the pump keys to act as 3 position selector switches. The 3 positions are hand-off-auto. Virtual selector switches surpass standard selector switches in that they can be changed from auto to hand automatically upon a fault in order to maintain a process. It is novel that just as a standard selector switch can change position (by human hand) with power off, so can the virtual selector switch similarly change position.

Combined with the virtual selector switches is redundant control with discrete logic which is activated upon a microprocessor fault. This is explained in detail in Section 5.4.

In addition to this unique hardware the controller has provision for four 4-20mA analog signals and two RTD temperature inputs. Bell & Gossett is able to offer pressure (1PT, 2PT) and temperature inputs (T-1, T-2) as options. The third 4-20mA is used for an optional flow transmitter. The fourth 4-20mA is for optional temperature transmitter.

Bell & Gossett is thereby able to offer staging of pumps by any one of 6 methods, i.e.; watts, amps, PSI and GPM (flow), temp and Delta T. The main changes occur in the menu entries.

Staging by watts is standard. A power transducer of Bell & Gossett design is included. This transducer is factory calibrated, single conductor sensing, wide current and voltage range, and automatic adaptability to Wye or Delta systems either grounded or ungrounded. At the customer’s discretion it may be used for amp staging with the watt feature used to display total system power.

TABLE OF CONTENTS

SECTION 1 – GENERAL Page

Purpose of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Safety Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Additional Safety Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Temperature and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Field Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 2 – INSTALLATION

Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Wiring

Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Analog Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Pressure Transmitter Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Temperature Sensor Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Flow Sensor/Transmitter Wiring and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Temperature Transmitter Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Differential Pressure Switch Piping and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Remote Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Remote Alarm Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Pump On/Off Remote Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 3 – START UP

Putting Unit into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SECTION 4 – SETUP AND FEATURES

Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Setup and System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Normal Operating Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION 5 – OPERATION

Power Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Auto Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Manual Operation (CPU OK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Manual Operation (CPU fails) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

TABLE OF CONTENTS (cont’d)

SECTION 6 – MAINTENANCE Page

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Digital Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Diagnostics (Service Test) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Read Only – Digital Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Read Only – Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Manual Control – Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Digital Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Pre-determined Fault and Fault Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Instruments and Their Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Field Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Serial No. and Firmware Version No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Maintenance (Physical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

APPENDIX B

Electrical Wiring and Control Settings – Final Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

APPENDIX E

Service Test Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

APPENDIX F

Power Transducer Board (PTB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Note: The information contained in this manual is intended to assist operating personnel by providing

information on the characteristics of the purchased equipment.

It does not relieve the user of the responsibility to adhere to local codes and ordinances and the use of accepted practices in the installation, operation and maintenance of this equipment.

SECTION 1 – GENERAL

1.1 PURPOSE OF MANUAL

1.1.1 This manual is furnished to acquaint you with some of

1.1.2 Equipment cannot operate well without proper care.

1.1.3

1.1.4 Your Technologic 350 Pump Controller should have a

1.2

1.2.1 Motor must have a properly sized starter with properly

1.2.2 Refer to the motor manufacturer’s I.O.M. for specific

1.2.3 Even when the motor is stopped, it should be con-

1.2.4 The use of motor disconnect switches is acceptable.

1.2.5 Motor control equipment and electronic controls are

the practical ways to install, operate, and maintain this unit. Read it carefully before doing any work on your unit and keep it handy for future reference.

To keep this unit at top efficiency, follow the recommended installation and servicing procedures outlined in this manual.

SAFETY INSTRUCTION: This safely alert

symbol will be used in this manual and on the unit safety instruction to draw attention to safety related instructions. When used the safety alert symbol means ATTENTION, BECOME ALERT!

YOUR SAFETY IS INVOLVED! FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN A SAFETY HAZARD.

safety instruction decal (Part # S11550). If the decal is missing or illegible contact your local B&G representative for a replacement.

ADDITIONAL SAFETY REQUIREMENTS

sized overload block to provide overload and undervoltage protection. Ground fault protection should be sized properly.

installation information.

sidered “alive” as long as its controller is energized. Keep hands away from the output shaft until the motor has completely stopped and power is disconnected from the pump controller.

WARNING: Motor can start automatically. Keep

hands away from output shaft until motor is completely stopped and input power is removed from the motor control panel. Lockout main power switch while working near the motor shaft. Failure to follow these

instructions could result in serious personal injury, death, and/or property damage.

connected to hazardous line voltages. When servicing electronic controls, there will be exposed components at or above line potential. Extreme care should be taken to protect against shock. Stand on an insulating pad and make it a habit to use only one hand when checking components. Always use accurate test meters when checking electrical components. Always work with another person in case of an emergency. Disconnect power when performing maintenance. Be sure equipment is properly grounded. Wear safety glasses whenever working on electronic control or rotating equipment.

DANGER: Troubleshooting live control panels exposes personnel to hazardous voltages. Electrical trouble-

shooting must only be done by a qualified electrician.

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

1.3

1.4

1.5

1.6

1.7 POWER WIRING

STORAGE

For long periods of storage, the unit should be covered to prevent corrosion and contamination from dirt. It should be STORED in a clean, dry location between

-20 and +75°C. The relative humidity should not exceed 85%. The unit should be checked periodically to ensure that no condensation has formed. After storage, again check that it is dry before applying power.

HANDLING

Care should be taken to prevent damage due to dropping or jolting when moving the Technologic Pump Controller. Transportation damage should be brought to the carrier’s attention immediately upon receipt.

TEMPERATURE AND VENTILATION

All electrical equipment is susceptible to failure if operated in ambient temperatures outside of its rating. The OPERATING temperature range for this unit is 0 to 40°C. The relative humidity should not exceed 95% non-condensing. The unit should not be operated outside these extremes.

WARNING: Prevent electrical shocks. Disconnect the power supply before beginning installation. Failure to

follow these instructions could result in serious personal injury, death, and/or property damage.

GROUND CONNECTIONS

A grounding terminal is provided for a dedicated ground wire connection. All provisions of the National Electrical Code and local codes must be followed.

WARNING: Conduit grounds are not adequate. A

separate ground wire must be attached to the ground lug provided in the enclosure to avoid potential safety hazards. Failure to follow these instructions could re-

sult in serious personal injury, death, and/or property damage.

Power wire types and sizes must be selected based upon conformance with the National Electrical Code and all local codes and restrictions. In addition, only copper (Cu) wire rated for 75°C (minimum) may be used for the power connections. Refer to the input current as listed on the nameplate on the enclosure door when sizing wire.

1.8 FIELD CONNECTION DIAGRAMS

1.8.1 Refer to the pump Installation, Opreation, and mainte-

1.8.2 Refer to the flow sensor/transmitter Installation,

nance Manual for specific details unique to the pump.

Operation, and Maintenance Manual for specific details unique to the flow sensor/transmitter.

SECTION 2 – INSTALLATION

2.0 LOCATION

2.1 Locate the Technologic Controller so that it will be

2.2

2.3

2.4 WIRING

2.4.1 POWER WIRING

2.4.2

easily accessible for inspection, maintenance and service.

DANGER: Heavy load, may drop if not lifted properly. Do not lift the entire unit by the motor eyebolts. Lift

the unit with slings placed under the unit base rails.

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

INSTALLATION

This unit is built to give you years of service; install it properly and provide a suitable foundation. (Check the shipping ticket for unit weight.) Mount the unit to provide a rigid connection that will not move or shift under any circumstance.

LEVELING

Mount the unit on a level surface and check that it is plumb on all sides.

DANGER: Electrical shock hazard. Inspect all electri-

cal connections prior to powering the unit. Wiring connections must be made by a qualified electrician in accordance with all applicable codes, ordinances, and good practices. Failure to follow these instructions

could result in serious personal injury, death, and/or property damage.

The Technologic 350 control panel can be set up to operate across a broad range of voltages. It was factory set to operate on the voltage shown on the nameplate. Verify proper transformer primary wiring per the job-specific wiring diagram. Check power leads in accordance with wiring diagram enclosed in control cabinet. The voltage tolerance is +10%/-10%.

ANALOG SIGNAL WIRING

If installing the panel on an existing system, shielded cable (#22 AWG, Belden type 8762, Alpha #2411 or equal) should be installed for the DC control wiring. The shield must be terminated in the Technologic 350 control panel. Do not connect the shield at the other end of the cable! Insulate the shield so that no electrical connection is made at the other end of the cable. A twisted pair of #22 AWG conductors (Belden 8442 or equal) can be used in place of shielded cable. The cable length must be limited to 3000 feet for #22 AWG wire.

1.8.3 The following field connection diagrams should be

2.4.2.1

reviewed prior to unit installation and operation.

Drawing # Description

Job Specific Print(s) Wiring Diagram(s)

Job Specific Print Dimensional Drawings

PRESSURE TRANSMITTER WIRING (Optional) (4-20mA Analog Signals)

Terminals (J3) + - Shield 1PT Pressure Transmitter 3 2 4 2PT Pressure Transmitter 3 6 4

2.4.2.2 TEMPERATURE SENSOR WIRING

(Optional) (Analog Resistance Input)

The Tech 350 uses resistance temperature detectors (RTDs) to sense the T-1 and T-2 water temperatures. These devices change their resistance as the water temperature changes.

Temperature Sensor (RTD) Wiring Terminals (J3) T-1 Low Temperature Sensor 13, 14 T-2 High Temperature Sensor 16, 17

2.4.2.3 FLOW SENSOR/TRANSMITTER WIRING

AND INSTALLATION (Optional) (4-20mA Analog Signal)

The flow sensor should be installed at an angle no greater than 45 degrees from top dead center in a horizontal installation (see Manufacturer’s IOM). See the Bell & Gossett drawing for installation instructions. The signal wiring should be terminated in the Tech 350 panel at the terminals below.

Optional Flow Sensor/Transmitter (1FT) + - Shield Terminals (J3) 9 8 10

2.4.2.4 TEMPERATURE TRANSMITTER WIRING

(Optional) (4-20mA Analog Signal)

Terminal J3 + - Shield AI-4 Temperature Transmitter 9 12 10

2.4.3 DIGITAL SIGNAL WIRING

2.4.3.1 DIFFERENTIAL PRESSURE SWITCH

PIPING AND WIRING (Optional) (Digital Signal)

Differential pressure switches installed to sense the increase in pressure between the pump suction and discharge gauge taps are used to determine whether a pump is running. Each switch should be wired from the normally closed contact to the terminals below.

Pump # 1 2 3 Terminal (J4) 9, 8 10, 11 11, 12

2.4.3.2 REMOTE START/STOP (Digital Signal)

Install a non-powered dry contact digital input to terminals J4-1 and J4-2. With the LOCAL-REMOTE-OFF switch in the REMOTE position this contact closure will provide the start signal.

2.4.3.3

REMOTE ALARM INDICATION (Digital Signal)

A digital output dry contact rated 2 Amps at 115V is supplied on terminals J5-7 and J5-8. This output closes to indicate that an alarm condition exists.

SECTION 3 – START UP

2.4.3.4

PUMP ON/OFF REMOTE SIGNAL (Digital Signal)

A digital output dry contact (one per pump) rated 2 Amps at 115V is provided for remote monitoring of pump On/Off status. This contact closes when a pump is running.

Pump On/Off Signal Pump #1 Pump #2 Pump #3 Terminal (J5) 9, 10 11, 12 13, 14

3.0 PUTTING THE UNIT INTO SERVICE

3.1 PUMP ROTATION, 3 PHASE MOTORS ONLY

CAUTION: Seal Damage may occur. Do not run

pumps dry. Fill and vent the pump volute prior to operation. Failure to follow these instructions could

result in property damage and/or moderate personal injury.

WARNING: Rotating shafts can catch loose clothing.

Do not operate the pump without all guards in place.

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

With the disconnect switch engaged to the “ON” position, momentarily the pump motor key on the key pad. See Paragraph

5.3. Observe the pump shaft rotation.

start and stop each motor with

SECTION 4 – SETUP AND FEATURES

4.1 GENERAL NOTES

4.1.1 The HELP key can be pressed at any time without

4.1.2 The key names are shown as CAPITAL LETTERS and

4.2

disrupting system operation. The HELP key will give details on alarm conditions or if used in conjunction with any function key will give a detailed explanation of the function key application.

the operator interface responses are shown as bold

CAPITAL LETTERS.

POWER -UP

WARNING: Electrical shock hazard. Inspect all elec-

trical connections prior to powering the unit. Wiring connections must be made by a qualified electrician in accordance with all applicable codes, ordinances, and good practices. Failure to follow these instructions

could result in serious personal injury, death, and/or property damage.

3.2 If incorrect, turn the main disconnect off and interchange any two wire leads leaving the starter overload block and going to the motor.

DANGER: High Voltage 3 phase power can kill. Disconnect and lockout power prior to servicing unit.

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

3.3 Unit is now ready for operation (factory assembled tested units only).

4.2.1 Put LOCAL-REMOTE-OFF (LRO) switch in the LOCAL position.

WARNING: Electrical shock hazard. Multiple power

sources. The off position of the LOCAL-REMOTEOFF switch does not disconnect all of the power sources in the technologic panel, All power sources must be disconnected prior to entering the control panel. Failure to

follow these instructions could result in serious personal injury, death, and/or property damage.

4.2.2 Turn main disconnect on.

4.2.3 The operator interface will display the ITT Bell & Gossett Corporation signature.

4.3.4 The operator interface will perform a lamp test and display test.

4.2.5 Press CLEAR to stop the test.

4.2.7 The START-STOP led will be red.

4.2.8 If the START-STOP led is not illuminated as described above, press the START-STOP button once to obtain the red LED.

4.2.9 The Auto-Hand led should be green for auto operation. If not green, press the AUTO-HAND key to obtain green led.

4.2.10 Press the PUMP 1 ON/OFF key to obtain a flashing green light. On two pump systems, press the PUMP 2 ON/OFF key to obtain a flashing green LED and press PUMP 3 ON/OFF key, for 3 pump systems, to obtain a flashing green LED. Refer to Section 5 for operation.

4.3

SETUP & SYSTEM CONFIGURATION

4.3.1 Press the SETUP key. Enter the serial number of the assembly by pressing the appropriate numeric keys. Press the ENTER key. The serial number may always be found by reading the 4th message after power up and the word “booting” disappears.

4.3.2 Confirm the user setup values per the following table. Use the UP or DOWN arrow keys to move through the menu. To change values press ENTER, modify the value using the numeric key pad or UP and DOWN arrow keys, press ENTER to accept the modification.

Line # DISPLAY ➀ Value Range Value

Default Allowable Field

1 Number of Pumps

Number of Pumps on the System (1-2-3) 1 1 - 3

2 Alternation Sequence

Use up/down keys to select: None, Duplex, Triplex - all, Triplex - 132A None As Listed

3 Auto Alt. Period

O = Manual only, for Auto Enter Alternation period in hours 0 0 - 6553

4 Reset Pump 1 Time

Yes = arrow key to reset No Y/N

5 Reset Pump 2 Time

Yes = arrow key to reset No Y/N

6 Reset Pump 3 Time

Yes = arrow key to reset No Y/N

7 Staging Type

Use up/down keys to select the primary method of pump staging: Watts, AMPs, PSI, GPM, TEMP, DELTA T Watts As Listed

8 Pump #1 HP

Enter Motor #1 nameplate horsepower 0 999.9

9 Pump #2 HP

Enter Motor #2 nameplate horsepower 0 999.9

10 Pump #3 HP

Enter Motor #3 nameplate horsepower 0 999.9

11 Pump 1 AMPs

Enter Motor #1 nameplate FLA 0 999

12 Pump 2 AMPs

Enter Motor #2 nameplate FLA 0 999

13 Pump 3 AMPs

Enter Motor #3 nameplate FLA 0 999

14 Pump #1 GPM

Enter Staging GPM of Pump #1 0 0 - 30,000

15 Pump #2 GPM

Enter Staging GPM of Pump #2 0 0 - 30,000

16 Pump #3 GPM

Enter Staging GPM of Pump #3 0 0 - 30,000

17 1 - 2 Stage %

Enter percent of NPHP, NPFLA, or GPM to stage 2nd pump in sequence 80 0 - 100

18 2 - 3 Stage %

Enter percent of NPHP, NPFLA , or GPM to stage 3rd pump in sequence 80 0 - 100

19 Destage %

Enter percent of stage percent for destaging with HP, AMPs, or GPM only 90 0 - 99

20 Staging PSI

Enter pressure to stage in PSI mode after entering system 0 0 - System pressure span Span

➀ The top line of each display is stationary while the changeable value, if any, is flashing. The bottom line scrolls from right to left continuously. To scroll from display continuously press either arrow. At any display the data may be changed by pressing enter, pressing the key or keys to change data, and pressing ENTER again. If a value to be entered is out of range the following is displayed: Top Line – value out of range Bottom Line – X1 < = Value < = X2 With X1 being the maximum value and X2 the maximum value of the range

Line # DISPLAY ➀ Value Range Value

Default Allowable Field

21 Destaging PSI

Enter pressure to destage in PSI mode after entering system 0 0 -System pressure span Span

22 Forced Destg Tmr.

Enter in minutes (0 - 99) value of a timer after which the pump will be forced to de-stage; ‘0’ disables this function 60 0 - 99

23 GPM Xmiter Span

Enter value equal to GPM transmitter calibration 0 0 - 30,000

24 2nd Stage Proof

2nd pump stage proof time in seconds 2 1 - 999

25 3rd Stage Proof

3rd pump stage proof time in seconds 2 1 - 999

26 Display Watts

Use up/down keys to enter yes or no Yes Y/N

27 Three phase Watts

Use up/down keys to enter yes or no, YES = three phase, NO = single phase Yes Y/N

28 Display AMPs

Use up/down keys to enter yes or no Yes Y/N

29 Display GPM

Use up/down keys to enter yes or no No Y/N

30 1PT Display Variable

Use the up/down keys to select the variable name for the signal originating from pressure transmitter 1PT: pressure - 1PT, inlet pressure, return pressure, not used. Not Used As Listed

31 1PT Span

Enter value equal to pressure span 100 0 - 999

32 High 1PT Press.

Enter value of the high pressure above which an alarm will be set 0 0 - 100

33 High 1PT Pr. TMR.

Enter in seconds (0 - 999) value of high pressure proof timer, ‘0’ disables this function 0 0 - 999

34 High 1PT Reset

Enter value of the high reset pressure 0 0 - 100

35 Low 1PT Press.

Enter value of the low pressure below which an alarm will be set 5 0 - 100

36 Low 1PT Pr. TMR.

Enter in seconds (0 - 999) value of low pressure proof timer; ‘0’ disables this function 20 0 - 999

37 Low 1PT Reset

Enter value of the low reset pressure 10 0 - 100

38 Low 1PT Auto RST

To change the low reset, use UP/DOWN key to enter yes or no Yes Y/N

39 2PT Display Variable

Use the up/down keys to select the variable name for the signal originating from pressure transmitter 2PT: pressure 2PT, outlet pressure, supply pressure, not used. Not Used As Listed

40 2PT Span

Enter value equal to system pressure span 100 0 - 999

41 High 2PT Press.

Enter value of the 2PT pressure above which an alarm will be set 125 0 - SPAN

42 High 2PT PR. TMR.

Enter in seconds (0 - 60) value of proof timer, ‘0’ disables this function 20 0 - 60

Line # DISPLAY ➀ Value Range Value

Default Allowable Field

43 Audible Alarm

Enter Y to select audible alarm for all alarm conditions, N to disable audible alarm N Y/N

44 Low 2PT Press.

Enter value of low 2PT pressure below which an alarm will be set 0 0 - Span

45 Low 2PT Pr. Tmr.

Enter in seconds (0 - 60) value of proof timer, ‘0’ disables this function 0 0 - 60

46 T-1 Display Variable

Use the up/down keys to select the variable name for the signal originating from RTD T-1: TEMP-1, suction temp, return temp, not used Not Used As Listed

47 T-2 Display Variable

Use the up/down keys to select the variable name for the signal originating from RTD T-2: TEMP-2, discharge temp, supply temp, not used Not Used As Listed

48 High T-2 Cut Out

Enter value of the high temp cut-out in deg. F above which an alarm will be set 125 0 - 200

49 High T-2 PR. TMR.

Enter in seconds (0 - 60) value of proof timer, ‘0’ disables

this function 20 0 - 60

50 High T-2 Reset

Enter value of the high temp. Reset in deg. F 100 0 - 199

51 DP 1 Proof Time

Pump #1 failure proof time in seconds 3 0-30

52 DP 2 Proof Time

Pump #2 failure proof time in seconds 3 0-30

53 DP 3 Proof Time

Pump #3 failure proof time in seconds 3 0-30

54 Minimum Run Timer

Minimum time a pump will run after auto start in minutes 5 0-25

55 Backup Staging WATTS,

Select method of backup staging in the event the primary WATTS AMPS, method fails GPM, PSI,

TEMP,

DELTA T

56 AI-4 Display Variable

Use the up/down keys to select the variable name for the signal originating from transmitter AI-4: staging temp, staging Delta T, temp (display only), DT (display only), not used Not Used As Listed

57 AI-4 Xmitr Span

Enter value equal to transmitter span. Note this input requires a 4-20mA transmitter. 0 999

58 Stage TEMP Rise

Select yes to stage pumps on temperature or differential temperature rise based on setpoint. Yes Y/N

59 Temp/Staging H

Enter the DT high temperature for staging/destaging. 75 999

60 Temp/Staging L

Enter the DT low temperature for staging/destaging. 50 999

61 Default All ?

Sets all parameters to factory defaults N Y/N

4.3.3 Press the CLEAR key. You will return to the standard operating display.

4.4

KEY FUNCTIONS

HELP MESSAGES. PRESS HELP AFTER

CLEARING ANY ALARMS

LINE KEY MESSAGE

➀ 1 Start/Stop Used to start and stop pumps. ➁ 2 Auto/Hand Used to select auto or manual operation.

➀ 3 Pump 1

Enable Used to start/stop pump 1; green = run, flashing green = enable, flashing red = failure.

➀ 4 Pump 2

Enable Used to start/stop Pump 2; green = run, flashing green = enable, flashing red = failure.

➀ 5 Pump 3

Enable Used to start/stop Pump 3; green = run, flashing green = enable, flashing red = failure.

➂ 6 Alternation Used to alternate pump sequence.

➀ 7 Service Test Used to perform service test. ➀ 8 Reset /Silence Used to reset alarm after its correction and to silence audible alarm. ➀ 9 Used for selection in a menu.

➔

10 Set Up Used to define system parameters - security. 11 Clear Clears latest entry (operation and data). 12 Help User assistance; press: Help + Key/Item. 13 Enter Used to accept data and operation input.

In every case above the message scrolls right to left twice and blanks out. Press CLEAR twice to exit. NOTE: Keys from Line 2 through Line 12 (except clear) also have numbers for numerical entry within a menu.

➀ One pump must be enabled to obtain start function. Has green - run and red - stop LED.

Notes:

➁ To change selection the START-STOP key must be in stop. Green LED-AUTO, red LED-HAND. ➂ The alternation sequence will be according to the user menu selection and will be displayed according to the message of 4.5 below to match that selection.

4.5 NORMAL OPERATING MESSAGES

4.5.1

NORMAL SCROLL AUTO OR HAND LOCAL OR REMOTE ➀ ➁

MESSAGE CONDITION

Alternation ➂ “None” or “1-2, 2-1” or According to menu entry for simplex, duplex or triplex.

“1-2-3, 2-3-1”

3-1-2 or “1-2-3,

1-3-2” Elapsed Time P1 Hrs. XXX Elapsed Time P2 Hrs. XXX If 2 pumps selected Elapsed Time P3 Hrs. XXX If 3 pumps selected High 1PT Cutout ➂ Bottom Line Only 1PT Pressure PSI XX If span is entered 2PT Pressure PSI XX If span is entered T-1 Temperature F° If high temperature cut-out is entered T-2 Temperature F° If high temperature cut-out is entered Staging Temp ºF If span is entered Total AMPS XXX If selected in menu Total KW XXXX If selected in menu Flow = XXXXX ➃ GPM If span entered. * Alarm (flashing) When an alarm occurs Startup — Standby Bottom Line only Alternation Engaged Standby Bottom Line only Pump Not Available Bottom Line only Please Enable a Pump Bottom Line only Not Allowed Bottom Line only User Setup Lost Top Line Call Factory For Assistance Bottom Line only

* See 4.5.2 for alarm messages.

➀ Press ENTER and ARROW keys for scroll lock.

Notes:

➁ Display is blank if CPU fails. ➂ Not scrolled in hand operation. ➃ XXXX reverts to ??? if span is entered and signal is less than 4mA.

4.5.2 ALARMS

ALARMS

CONDITION HELP MESSAGE

Overload X Failure Check AMP draw, use manual reset if OK High 1PT PSI High suction pressure - check suction pressure and trip point Low 1PT PSI Low suction detected - check suction pressure and trip point High 2PT PSI High pressure detected in the system - check trip point Low 2PT PSI Low pressure detected in the system - check PRV and set point Water Temp High Check water temperature Pump X Off Need pump in system - if OK enable pump 1PT Fail Check wiring, piping, polarity, and continuity 2PT Fail Check wiring, piping, polarity, and continuity AI-4 Fail Check wiring, piping and continuity 1FT Fail Check wiring, piping, polarity, and continuity T-1 Fail Check wiring, continuity T-2 Fail Check wiring, continuity Power Board Fail Check cable connections and plug insertions Pump X Failure Check DP switch, impeller, coupler, motor Remote Contact Open ➀ 7 Day Timer Off ➀

Notes: ➀ Bottom line only. No help message.

SECTION 5 – OPERATION

5.1 POWER UP

5.11 Initial – turn selector switch to local or remote with

5.1.2 Message Scroll

5.1.3 Set Up and System Configuration. User Menu.

5.2 AUTO OPERATION

5.2.1 Local

5.2.2 Auto/Hand

5.2.3 Enable/Pump/s by pressing 1, 2 or 3 PUMP ENABLE

5.2.4 Start/Stop

power on.

A. “Booting” B. “Bell & Gossett”

“Pressure Booster”

C. “Technologic 350”

“Pump Controller”

“Fluid Handling Division”

E. “FW Release VX.XX”

“Serial # XXXXX”

F. Normal Scroll per 4.5 commences

A. Press the SETUP key. Enter the serial number

followed by the ENTER key.

B. Press the UP or DOWN arrow key to step through

user menu of paragraph 4.3.2. To change any value press ENTER, modify the default value using the numeric key pad, and then press ENTER to load. Press CLEAR to exit menu.

(turn selector switch to local or remote).

– select Auto.

keys according to number of pumps in menu. Green LED’s flash.

– Press START/STOP key momentarily. Green LED is on. Note: Only if selector switch is turned to local or remote and at least 1 pump is

enabled. Message: Top Line – see below. Bottom Line – “start up standby”.

5.2.5 Pump Start sequence starts and LED turns to solid green. Only 1 pump is on.

5.2.6 Alternation pump in sequence starts and both pumps then run for 5 seconds at which time the first pump stops. During alternation: Top line – normal scroll. Bottom line – “Alt. Engaged standby”.

If Alternation Timer picks up the action is the same as above provided an entry other than 0 is made in the user menu.

5.2.7 Staging in the user menu, i.e., HP, AMPs, PSI, GPM, Temp and Delta T the 2nd pump in the alternation sequence will turn on when:

or 2. AMP value matches % stage value or 3. GPM value matches % stage value or 4. Pressure matches PSI stage value or 5. Temp matches temp stage value

The third pump in the alternation sequence turns on similarly.

Staging will not occur if:

The 3rd pump stages in the same manner as the second pump according to the menu entry for that pump.

– According to the method of staging selected

1. HP matches % stage value

1. High 1PT alarm is on.

2. Low 1PT alarm is on.

3. High T-2 alarm is on.

4. High 2PT alarm is on.

5. Timed de-stage is on.

6. Starter feedback is not on.

– The first pump in the alternation

– If the alternation key is pressed the next

5.2.8 Destaging

1. HP or AMPs (selected method of staging) of the last pump staged, plus the cumulative value of all other running pumps, reaches the destage percent value entered in the user menu, and a proof timer and the minimum run timer time out.

occurs when:

5.2.9.8 (B) Alarms discussed with the balance self-explanatory.

5.2.9.9 Normal Stop Enabled pumps have flashing green LEDs. All faults are in memory and do not reset. Status of the 3 pump keys is written to memory.

– are listed in Table 4.5.2. Most alarms are

– with power on press start/stop key.

2. GPM

3. PSI

4. Temperature setting of the destage temperature in

All of these methods of destaging are exclusive and may not be mixed.

5.2.9 Pump Shut Down

5.2.9.1 High 1PT Pressure 1PT Pressure” of the menu is reached and the “High 1PT proof timer” of the menu expires. All pumps stop. Alarm message is set. Pumps start when “High 1PT Reset” is reached.

5.2.9.2 Low 1PT Pressure” in the menu and “Low 1PT proof timer” in menu times out. All pumps stop. Alarm message is set. Audio visual alarm is set. Pumps restart when “Low 1PT Reset” setting in the menu is reached. Auto reset.

5.2.9.3 High 2PT Pressure 2PT Pressure: of the menu is reached and “High 2PT proof timer” of menu setting expires. All pumps stop. Alarm message is set. A-V alarm turns on. Manual reset to start pumps.

5.2.9.4 Low 2PT Pressure 2PT Pressure” and after “Low 2PT proof timer” menu setting times out the alarm message is set. Does not stop pumps. Auto reset.

5.2.9.5 High T-2 the menu. The “High T-2 proof timer” times out. Alarm message set. Pump/s stop. Auto reset occurs when “High T-2 Reset” of the menu is reached. NOTE: A value must be entered for temperature display.

5.2.9.6 O.L.X Failure and 3M from pumps 1, 2 and 3, respectively trip and shut down the associated pump. The next pump in the sequence will start. “Alarm” message flashes. Manual reset. Upon manually resetting the tripped starter and pushing the reset key the previously tripped starter starts its pump and the pumps run together for 5 seconds and then return to normal operation.

5.2.9.7 Pump X Failure through 3, respectively trip and shut down the associated pump 1, 2, or 3 respectively. The next pump in sequence then starts. Pump fail message set. Manual reset. Shut off pump now restarts with 2 seconds delay.

decreased to the value of the destage GPM in the menu. The pump stops after a proof timer and then a minimum run timer.

setting of the destage PSI value in the menu is reached. The destage PSI is higher than stage PSI and a proof timer and the minimum run timer time out.

the menu is reached.

analog signal reaches the level of “Low 1PT

analog reaches “High T-2 Cut Out” value of

from digital inputs from starters 1M, 2M

occurs when:

analog signal triggers when “High

analog reaches menu setting “Low

from digital inputs from DP switches 1

5.2.9.10 Stop

5.3 MANUAL OPERATION (Watchdog LED Off)

5.3.1 Choose local or remote operation.

5.3.2 AUTO/HAND Key

5.3.3 Enable Pumps by pressing 1, 2 or 3 PUMP keys.

5.3.4 Start/Stop as 5.2.4 above.

5.3.5 Pump Start

5.3.6 Alternation – none.

5.3.7 Staging

5.3.8 De-staging – none.

5.3.9 Pump Shut Down – none. However, all alarms of

5.4 MANUAL OPERATION

– with power failure, alarms are reset but status

of start/stop key and 3 pump keys is held in memory.

– select HAND.

as 5.2.5 above.

– none.

Table 4 are active but do not shut the pumps down. Some items are not in normal scroll. See foot note 3 of Table 3. Note that motors are still protected with O.L. relays as part of the respective starter.

(CPU Fails, Watchdog LED on)

The Technologic 350 has a redundant feature allowing critical operation even though the microprocessor and its support I.C.’s may have failed. Although this is a rare occurrence, B&G has planned for this possibility.

When the Watchdog LED is “on” a separate section of LOGIC is used to bypass the problem area. This LOGIC has its own memory which is held with power off by a small clock battery (B1). This memory must be pre-set for operation as desired upon CPU failure. To set this memory perform the following (assuming unit is running in auto):

1. Press STOP Key – Red stop LED is on.

2. Press AUTO/HAND Key – Red HAND LED is on.

3. Press PUMP ENABLE keys in any order for pumps to run upon a CPU failure. Associated green LED’s will flash.

4. Press AUTO/HAND key – green AUTO LED is on.

5. ENABLE PUMPS as required and press START/STOP key – green LED on.

The unit is now running in auto. If the CPU fails the system reverts to the manual operation that was preset in steps above. Pumps do not stop except for overload trip. Press the PUMP ENABLE key to stop a specific pump or press START/STOP key to stop all pumps.

Press PUMP ENABLE key to re-start a pump. Only the hand and pump LED’s are active. All other LED’s and the display are off.

SECTION 6 – MANTENANCE

6.0 Preface: The following is a description of the hard- ware, diagnostics, and corrective action to maintain a process being controlled by the Technologic 350.

NOTE: The following should not be interpreted as the maximum configuration of this controller, rather this describes its application as a Technologic 350 only.

6.1 TECHNICAL OVERVIEW

The Technologic 350 is a micro-processor based dedicated pump controller unique to and exclusively manufactured by Bell & Gossett. All aspects of this unit are strictly proprietary to Bell & Gossett.

It consists of 3 electronic assemblies. The first assembly consists of 3 circuit boards, i.e., display, keyboard, and central processor unit (CPU) and is referred to as the operator interface panel (OIP).

This operator interface is connected (with ribbon cable) to a large board assembly known as the input/output (I/O) board. This board contains a 24 volt DC power supply to power the unit, all I/O, and a limited number of sensors. It also has the terminals to connect to external devices. All hard wire interface to the outside world resides on this board and is protected from the external environment.

The third electronic assembly is the power board which connects to the OIP with a special cable. This board senses amps, voltage, and calculates the total power for staging and display on the OIP.

6.2 DIGITAL INPUTS

The controller has provision for digital inputs with a voltage operating range of 22 to 26.4 VDC. This signal voltage must be obtained from the on-board 24 VDC power supply. Eighteen terminals are provided with 6 of these terminals used to connect to the 24 VDC power supply.

It is not recommended that other power sources be used without factory approval.

The terminal will accommodate (2) No. 18 AWG wires.

6.3 DIGITAL OUTPUTS

The controller has provision for relay outputs to control 120 V 50/60 HZ devices.

Sixteen terminals are provided. All terminals will accept up to (2) No. 14 AWG wires.

The relays are not removable. If defective the I/O board must be returned to the factory for repair.

All relays operate as single pole single throw. Components are provided to reduce contact arc and extend electrical life.

6.4 ANALOG INPUTS

Analog inputs are provided on the I/O board for process variables and for flow readout. All analog inputs operate at 4-20mA. They may be powered from 24 VDC on board or self powered, in any mix, without isolators.

Each analog input has 4 terminals associated with it, i.e., 2 for signal input, 1 for 24 VDC, and 1 for shield chassis ground.

Each analog input terminal will accommodate (2) No. 18 AWG conductors.

6.5 MEMORY

6.5.1 The EPROM is the only removable chip. However, it is not recommended that it be changed by other than the factory.

The EPROM is programmed by Bell & Gossett and its code is copyrighted. On power up the software version is displayed as FW RELEASE VX.XX on the top line and unit assembly serial No. on the bottom line.

6.5.2 The EEPROM holds all data entered by the operator. It is not removable. Old data is erased with new. All data may be erased by the factory at which time all data reverts back to default values published elsewhere in this manual.

6.5.3 The RAM chip is not replaceable and requires no maintenance.

6.6 CPU

The CPU does not require any maintenance, and cannot be replaced as a field repair.

6.7 POWER SUPPLY

The power supply provides 24 VDC for all digital and analog signals. It is specifically rated only for the controller and other loads should not be applied without factory approval.

The power supply also supplies 5 VDC for all TTL devices.

The power supply is protected with Fuse F1 located near the 120 VAC line terminals.

6.8 DIAGNOSTICS (SERVICE TEST)

The Technologic 350 has built in I/O diagnostic capabilities activated with a SERVICE TEST key while in normal message scroll. It consists of 2 menus, i.e., read only and read/write. Read/write overrides the program and requires a security code.

NOTE: Service test cannot be used if any of the following occur.

1. Power is off.

2. Display and or the start/stop LED is off (red or green).

3. Watch dog LED (CR6) on the I/O board is on.

6.9 READ ONLY – Digital Inputs

6.9.1 To Enter – press CLEAR key twice and then press SERVICE TEST key once only while in normal scroll.

6.9.2 Display – numbers 1 through 12 (implied) on the top line and status on the second line. Status is displayed as a “1” for signal on and “0” for signal off.

6.9.3 Interpretation – compare the status shown to the following terminals and the wiring diagram. For example, starter 1M “on” signal at J4 4 and 8 is display No. 3 and should be a “1” if the 1M starter is energized. Input

Input J4 Input No.

Signal Terminals On Display

Local ** 1 to 2 1 Remote 3 to 2 2

1M 4 to 5 3 2M 6 to 5 4

3M 7 to 8 5 * DP1 9 to 8 6 * DP2 10 to 11 7 * DP3 12 to 11 8 * 7 Day Timer 19 to 20 13

**Optional

**This input is also used for remote start when the selector switch is in the REMOTE position.

NOTE: Terminal No’s. on the right , e.g. 2, 5, 8, etc. are all in common.

6.10.3 Interruption – read channel values from connected devices with channel 1 as 1PT pressure, channel 2 as 2PT pressure, channel 3 as flow input (optional) and channel 4 is temperature input (optional).

If there is a problem replace the analog source with a known source such as a 20mA signal generator. Connections to terminal block J3 are as follows:

Source 2 Wire

*Step Signal Input Terms Terms

1 1PT 1 1-, 2+ 2-, 3+

2 2PT 2 5-, 6+ 6-, 3+

3 Flow (1FT) 3 7-, 8+ 8-, 9+

Polarity shown is that of the signal analyzer and not the markings on the I/O board.

4 Temp (AI-4) 4 11, 12 9, 12

5 T-1 RTD in 1 - 13, 14

6 T-2 RTD in 2 - 16, 17

A substitute 100 OHM resistor @ terms. 13 & 14, or 16 & 17 will result in a temperature reading of 32°F.

7 DC Supply = 24.00 VDC ±10% is satisfactory.

8 Display top line changes to: Power Board

Readings.

8 Voltage = XXX VAC equal to system line voltage.

6.9.4 Corrective Action – compare the inputs to the device/s connected to the digital inputs and trigger same. If a “1” is not received check the associated wiring or the particular device and correct or replace the cause of the fault.

6.9.5 Controller Operation – the keyboard (except the CLEAR key) and all LED’s cannot change state. The display is dedicated to the digital input display. The program is otherwise active.

6.9.6 Exit – press CLEAR twice and then press ENTER twice.

6.10 READ ONLY ANALOG INPUTS

6.10.1 To enter (from normal scroll) – press CLEAR key twice and press SERVICE TEST key once. Then press CLEAR key once.

6.10.2 Display – ANALOG INPUT TEST on top line and input type and measurement on bottom line. Press key 1, 2, 3 or 4 to read channels 1, 2, 3 or 4 in % with 4mA @ 20% and 20mA at 100%. Six other items may be accessed with the up arrow key. These items are: RTD 1(°F), RTD 2(°F), DC supply (DCV), and power board readings. “Power Board Readings” is now displayed on top line. These readings are: voltage in volts, current in amps, and power in watts.

9 Current = XXX amps equal to actual load.

10 Power = XXX watts actual power.

*Step = each momentary step of up arrow key.

WARNING: Prevent electrical shock. Disconnect the power supply before beginning installation. Failure to

follow these instructions could result in serious personal injury, death, and/or property damage.

6.10.4 Corrective Action – correct the wiring or a faulty device. If a signal is good with a signal generator then the inter-connection wires are good and the sensor is bad. In the case of RTD’s a substitute 100 OHM resistor will isolate a problem to the sensor.

Power board readings may be confirmed by a separate clamp-on line current readings, line voltage reading, and calculations for watts.

DANGER: Troubleshooting live control panels ex-

poses personnel to hazardous voltages. Electrical troubleshooting must only be done by a qualified electrician. Failure to follow these instructions could result

in serious personal injury, death, and/or property damage.

6.10.5 Controller Operation – keyboard (except arrows, clear, 1,2,3 4) and all LED’s cannot change state. The display is dedicated to the analog input display. The program is otherwise active.

6.10.6 Exit – press CLEAR once and then press ENTER twice.

6.12.4 Corrective Action – if a fault is suspected trigger the associated output to confirm that either connections or the connected device is the problem.

6.12.5 Controller Operation – all outputs are static and controlled by the numerical keys. The program is static. Confine operation to numerical keys. LEDs are static.

6.11 MANUAL CONTROL – OUTPUTS

To enter this section a user code (serial no.) is required. Since the program is being overridden caution must be exercised.

IF NOT SURE CALL THE FACTORY. IF “USER CODE” IS DISPLAYED PRESS THE ENTER KEY TWICE TO RETURN TO NORMAL SCROLL.

DO NOT LEAVE UNIT IN SERVICE TEST.

6.12 DIGITAL OUTPUTS

6.12.1 To enter: A. Normal scroll on display B. Press CLEAR twice C. Press SERVICE TEST D. Press CLEAR twice E. Enter user code (serial no.) F. Press ENTER key

6.12.2 Display = output #1 through 8 on top line and state, either 0 or 1, on bottom line. A “1” = output “on” (relay coil energized) and a “0” = off. Toggle output with a numerical key to match the output #.

6.12.3 Interpretation – this is an output forcing operation to allow checking of wiring and the connected device. Since some outputs are normally closed the following must be observed.

Relay

Contact

Output Relay with a Output

# Function # State of 1" Terminals

1 1M control K5 Closed J5 1-2 2 2M control K6 Closed J5 3-4 3 3M control K7 Closed J5 5-6 4 Alarm K8 Open J5 7-8 5 Pump 1 on K1 Closed J5 9-10 6 Pump 2 on K2 Closed J5 11-12 7 Pump 3 on K3 Closed J5 13-14 8 not used K4 Closed J5 15-16

6.12.6 Exit – press CLEAR and ENTER. All forced outputs are cleared.

6.13 PRE-DETERMINED FAULT AND FAULT CONTROL

6.13.1 Predetermined Fault – a software timer known as a watch dog times out upon a software or CPU failure and shuts down in a predicable manner. LED CR6 on the I/O board turns on and all outputs are turned off.

OIP board components are now used to determine the state of all relays according to LOGIC installed by the factory.

6.13.2 Fault Control – operates as follows:

A. Press START-STOP key for stop.

B. Press AUTO-HAND key for HAND.

C. Enable pump/s as desired. (Press PUMP keys) to

run upon control failure.

D. Press AUTO-HAND key for auto. Press START-

STOP key to start.

E. Upon a CPU or software fault the unit will revert

to pumps selected in C above.

If power is momentarily interrupted the unit will return to the same “hand” operation as before provided pump keys were not pressed while the power was off.

6.14 PROTECTION

6.14.1 Analog inputs – the analog inputs provided on the Technologic 350 must be wired according to the wiring diagram that shipped with the unit.

6.14.2 Protection – all analog inputs are protected from high voltage, crossed wiring, etc. A 1 AMP fuse (F1) fast acting 3AG located just above relays K6, K7 and K8 protects all analog inputs up to 600V (in error only). A sustained fault may blow this fuse and burn out the input resistors. They are located just below terminals J3 and are numbered R3, R4, R1 and R2 for channels 1, 2, 3 and 4 respectively.

6.14.3 Field Repair – resistors R1, R2, R3 and R4 plug in and are easily replaced.

Correlate output terminals to the wiring diagram for actual practice. NOTE: It is important to view status on the display before any state is changed.

This shows the actual output state of the program as it was presently running.

CAUTION: Do not trigger outputs unless the resultant action is known. Do not trigger all outputs on at one

time or trigger at random. Failure to follow these instruc-

tions could result in property damage and/or personal injury.

WARNING: Electrical shock hazard. Multiple

power sources. The off position of the HAND-OFFAUTO switch does not disconnect all of the power sources in the Technologic panel. All power sources must be disconnected prior to entering the control panel.

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

Unplug a bad resistor by pulling it from the socket and replace with a 124 OHM,

/4 watt, 1%, metal film (no substitute). Cut leads and bend to fit sockets. Resistors are also available from the factory.

NOTE: It is not always clear that a resistor is bad by observation. It may be brown or black. The best way to check is unplug the resistor and check with an ohm-meter. DO NOT check resistors on board. It may cause other problems and will not give a true reading.

6.14.4 Digital Inputs – as long as input power is derived from the integral 24VDC power supply they are protected.

6.14.5 Digital Outputs – each output shall not exceed 1 AMP @ 115 VAC (6 AMP inrush).

6.15.6 CONDITION: E2 Defaults Set on the display. Watch dog LED CR6 is not on.

Corrective Action: Remove EPROM. Watch dog LED CR6 will turn on. Pumps will run in manual operation to paragraph 5.4 above. Replace the operator interface.

6.15.7 Display Blank

A. Watch dog LED CR6 is off.

Corrective Action: Confirm power to OIP with at least 1 LED on or measure 120 volt A.C. at J6 L1 and N. If power present reboot and if display stays off, replace OIP.

6.14.6 Power Supply – the power supply has inherent short circuit protection, thermal overload shutdown, transient protection, and line noise filtering. To reset the power supply cycle input power off and on.

6.14.7 Protection – fuse F1 located near terminal J4 (power in) protects the power supply. It is rated 1 AMP fast acting #3 AG.

6.14.8 Operator Interface – it is protected by the I/O board.

6.15 FAULT ISOLATION

Certain messages, common sense, observation, and diagnostics allow fault isolation of an on-board fault.

6.15.1 CONDITION: RAM Error on the display and auto/ hand red LED on. Watch dog LED CR6 is on.

Corrective Action: Pumps will run in manual operation according to paragraph 5.4 above. Replace the operator interface.

6.15.2 CONDITION: Comm Error on the display and pump 1 red LED is on. Watch dog LED CR6 is on.

Corrective Action: Pumps will run in manual operation according to paragraph 5.4 above. Replace the operator interface.

6.15.3 CONDITION: I/O Error on the display and pump 2 red LED is on. Watch dog LED CR6 is on.

Corrective Action: Pumps will run in manual operation according to paragraph 5.4 above. Replace the operator interface and the I/O board.

6.15.4 CONDITION: E2 Bad. System Halted. Call factory for assistance. Watch dog LED CR6 is on.

Corrective Action: Pumps will run in manual operation according to paragraph 5.4 above. Replace the operator interface.

DANGER: Troubleshooting live control panels ex-

poses personnel to hazardous voltages. Electrical troubleshooting must only be done by a qualified electrician. Failure to follow these instructions could result

in serious personal injury, death, and/or property damage.

B. Watch dog LED CR6 is on.

Corrective Action: None. No display. This condition except back light is on. Unit will run in manual per paragraph 5.4.

6.15.8 Key Board Inoperative

A. Watch dog LED CR6 is off.

Corrective Action: Be sure power is on by checking or observing display or at least one LED. Press RESET and HELP keys. If condition prevails replace OIP.

B. Watch dog LED CR6 is on.

Corrective Action: Only 4 keys are active: START/STOP, PUMP 1, PUMP 2, and PUMP 3. If these keys are inoperative replace the OIP. Unit will run in manual per paragraph 5.4.

6.15.9 LEDs Malfunction

A. Observe that all LEDs turn on during the booting

process. Watch dog LED CR6 is off.

Corrective Action: If any fail to operate replace the OIP.

B. Watch dog LED CR6 is on. Only the red HAND

LED and the 3 green LEDs with one for each pump key will turn on, or off. Unit will run in manual per paragraph 5.4.

6.15.5 CONDITION: No Program Found on the display and pump 3 red LED is on. Watch dog LED CR6 is on.

Corrective Action: Pumps will run in manual operation according to paragraph 5.4 above. Replace the operator interface.

Corrective Action: Replace OIP.

C. Watch dog LED CR6 is off but all LEDs or some

LEDs are off.

Corrective Action:

1. Check that the ribbon cable is plugged in.

2. Check for ribbon cable damage.

3. If all LEDs off check incoming power and fuse F1.

4. Reboot.

5. Replace OIP unit.

WARNING: Electrical shock hazard. Multiple

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

6.15.10 Selector Switch Malfunctions –

Press SERVICE TEST –

A. In local, input 1 should be “1” (J4).

B. In remote, input 1 = 0 with remote contact open and input 2 = “1” (J4).

Corrective Action: A and B are not present; correct wiring or replace the switch. See wiring diagram for correct wiring. A new switch may be obtained from the factory.

6.15.11 Pressure Transducer Fault (1PT)

A. Alarm per 4.5.2 indicates this fault.

B. Confirm with analog input test of CHNL 1 per

6.10.3.

Corrective Action:

1. Disable transducer by entering user menu per

4.3 and changing 1PT display to "not used" (item 30) and IPT pressure span (item 31) to “0”. Alarm message turns off. Low and high suction is disabled.

2. Replace this transducer.

6.15.12 Pressure Transducer Fault (2PT)

A. Alarm per 4.5.2 indicates this fault.

B. Confirm with analog input test of CHNL 2 per

6.10.3.

Corrective Action:

1. Disable transducer by entering user menu per

4.3 and 2PT display to "not used" (item 39) and changing 2PT pressure span (item 40) to “0”. Alarm message will turn off. Low and high system PSI and PSI staging is inoperative.

2. Replace this transducer.

6.15.13 Flow Transducer Fault (1 FT)

A. Alarm per 4.5.2 indicates this fault.

B. Scroll of GPM shows flow as: ???

C. Confirm with analog input test of CHNL 2 per

6.10.3.

Corrective Action:

1. Disable transducer by entering user menu per

4.3 and changing GPM xmitter span (item 23) to “0”. Alarm message will turn off. GPM staging is inactive.

2. Replace flow transducer.

6.15.14 Temperature Transmitter Fault (A1-4)

A. Alarm per 4.5.2 indicates fault

B. Scroll of temp shows temp as ???

C. Confirm with analog input test of CHNL 2 per

6.10.13.

Corrective Action:

1. Disable transmitter by entering user menu per

4.3 and changing A1-4-display to "not used" (Item 56) and transmitter span (Item 57) to "0". Alarm message will turn off. Temperature staging is inactive.

2. Change temperature transmitter.

6.15.15 RTD1 or RTD2 Fault (T-1, T-2)

A. Alarm per 4.5.2 indicates this fault.

B. Confirm with analog input test of RTD channels

(steps 5 or 6) per 6.10.3.

Corrective Action:

1. Disable RTD1 and RTD2 by removing respective connections at J3 13 & 14, and 16 & 17 and replacing each with a 100 OHM resistor. Both RTD’s must have this substitute resistor even though only one is defective.

2. Ignore 32°F temperature display.

3. High temperature cut out is inoperative.

4. Replace defective RTD. Observe and perform any calibration procedure that may accompany the RTD.

WARNING: Prevent electrical shocks. Disconnect the power supply before beginning installation. Failure to

follow these instructions could result in serious personal injury, death, and/or property damage.

6.16 INSTRUMENTS AND THEIR USE

6.17 FIELD REPAIR

With the diagnostics described herein extensive instruments are not required. However, the instruments used should be quality units to meet the following at a minimum.

Under no circumstances shall any instrument be used to test any on board components. Especially risky is an ohmmeter with battery voltage higher than TTL logic or applied with incorrect polarity.

6.16.1 AC/DC Voltmeter –

- Input impedance shall not be less than 10 MEGOHM.

- Accuracy - AC ± 2% of F.S.

- DC ± 3% of F.S.

- Rated circuit to ground voltage = 1000V. Note F.S. = Full Scale.

6.16.2 OHMMETER

- Accuracy ± 2_%

- Max open circuit voltage = _ volt

6.16.3 Millimeter

- Accuracy ± 2% of F.S.

6.16.4 Signal Generator (analyzer) - recommended

A. Beta calibrator Model 434 20mA signal analyzer.

B. Altec calibrator Model 334 4-20mA loop

analyzer.

Either instrument may be purchased from your Local Process Control Distributor.

NOTE: If some other instrument is used it must float above ground, preferably battery powered.

6.17.1 General – field repair, except replacing fuses, replacing analog input resistors, and assuring connections, such as ribbon cable, are correct and secure, is not recommended.

6.17.2 EPROM Changing – normally EPROMs are not changed in the field. In an emergency this is the procedure to be performed when authorized by the factory.

A. Record all data from the OIP.

B. Turn off all power to the panel.

C. Ground your body. Touch earth ground to dis-

charge static electricity.

WARNING: Electrical shock hazard. Multiple

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

D. With one hand only gently pry EPROM (chip U1)

up from its socket alternating from each end in small increments. Use a small screwdriver. Do not place free hand on OIP components. Ground free hand if possible.

E. Insert new EPROM with all pins in the socket and

the notch oriented as chip U2 notch (adjacent chip).

F. If done carefully the EEPROM will not be corrupted.

G. Turn on power. Enter user menu per 5.1.3 and

check special data for the job at hand.

6.18 SERIAL NO. AND FIRMWARE VERSION NO.

6.18.1 Both of these numbers may be found as the 4th message after booting. If the factory is called for information or service on this unit the serial No. and firmware version No. may be requested. They are important to B&G in order to track the unit.

6.19 MAINTENANCE (PHYSICAL)

6.19.1 Electrical – no maintenance is required for the electrical panel except to keep the boards free of dirt and dust that might hold moisture. Cabinet door should be kept closed, and the components kept dry.

APPENDIX B

ELECTRICAL WIRING AND CONTROL SETTINGS –

FINAL CHECK LIST

___ 1. Does the feeder line voltage correspond to the unit

voltage? Check the unit nameplate or motor terminal

WARNING: Electrical shock hazard. Inspect all elec-

trical connections prior to powering the unit. Wiring connections must be made by a qualified electrician in accordance with all apllicable codes, ordinances, and good practices. Failure to follow these instructions

could result in serious personal injury, death, and/or property damage.

connection.

___ 2. Are the feeder wires correctly sized for the load?

___ 3. Are the fuses correctly sized? They must not exceed

1.75 times the full load current of the motor. Usual sizing is 1.15 to 1.5 times the full load current.

WARNING: Conduit grounds are not adequate. A

separate grounf wire must be attached to the ground lug provided in the enclosure to avoid potential safety hazards. Failure to follow these instructions could

result in serious personal injury, death, and/or property damage.

___ 4. Is the unit properly grounded?

___ 5. Have all the power terminals in the control panel been

checked for tightness? This is imperative since stranded wires tend to “flow” and become loose after initial installation.

DANGER: High voltage 3 phase power can kill. Disconnect and lock power prior to servicing unit.

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

APPENDIX E

SERVICE TEST OVERVIEW

Service Test is explained under paragraph 6.8; Diagnostics. The following may be used in conjunction with paragraph 6.8 as an additional aid to its utilization.

SERVICE TEST



DISPLAY STATUS

Digital Input Test

1234567890123456 0’s and 1’s xxxxxxxxxxxxxxxx



Analog Input Test

Input X = XX% % (CHANNELS 1 - 4)

Digital Output Test

Output # 12345678 0’s and 1’s State xxxxxxxx



Press SERVICE TEST key at any time. To exit press CLEAR key.



Press CLEAR key for this. X = 1, 2, 3, 4, 5, 6, 7 and 8 for analog channels from suction transmitter, system transmitter, flow transmitter, low temperature transmitter, high temperature transmitter, D.C. supply, line voltage, line current, and power in watts, respectively.

APPENDIX F

POWER TRANSDUCER BOARD (PTB)

1.0 GENERAL DESCRIPTION

The PTB is a B&G proprietary board designed to measure total RMS load current and line voltage for either single or 3 phase systems. This data is entered into a microcontroller to calculate true power. True power, amps, and volts are transmitted continuously to the Tech 350 OIP microprocessor. These values are then used for staging and/or display.

1.1 SAFETY

The PTB is an electronic board with high voltage. It carries 3 phase voltage up to 600 volts. Do not touch it. There are no manual adjustments on board. If it should become defective, as described elsewhere in this manual, replace it. Field repair is absolutely not authorized under any circumstances.

DANGER: Troubleshooting live control panels ex-

poses personnel to hazardous voltages. Electrical troubleshooting must only be done by a qualified electrician. Turn power off prior to opening control panel door.

Turn power offand confirm it is off with a voltmeter. Lock out disconnect/s.

DO NOT:

– Touch PTB with power on.

– Move jumpers with power on.

– Wire with power on.

– Even think about modifications.

– Even think about repair.

Failure to follow these instructions could result in serious personal injury, death, and/or property damage.

1.5 APPLICATION

The following is performed by the factory. However, if a PTB is being replaced in the field the following must be observed:

A. One common (to load) conductor must be run

through the doughnut.

NOTE: This conductor must not rest on the PTB components except for the current transformer. Arc the wire, in order to bias it away from the PTB, before inserting it in the current transformer. Secure in place with wire ties.

B. Insert this conductor into the hole on the flat side

of the doughnut with the load side of the conductor coming out of the opposite side of the hole.

C. 3 Phase – connect all 3 phases to terminals of J1

marked AØ, BØ, and CØ. Do not use com. AØ must also be the same phase as that inserted into the doughnut. Which is AØ, BØ or CØ is arbitrary but must be established to follow these rules.

Single Phase – connect the “hot” line to AØ only and neutral to com. Again AØ phase must be the same phase as inserted into the doughnut.

D. Move voltage jumpers J3 and J6 to a voltage as

close to actual as possible. Jumpers on J3 and J6 must match each other.

E. Move jumper J2 to next highest amp terminal

above total motor load in amps. That may run at one time.

1.2 CURRENT SENSING

This is accomplished by inserting one common power conductor through a linear output Hall effect doughnut.

1.3 VOLTAGE SENSING

This is accomplished with a resistor network and a potential transformer. Maximum voltage level is 600V RMS.

1.4 CALIBRATION

Calibration is performed at the factory for all ranges of current and voltage. This resides in the EEPROM on board the PTB.

1.6 PHASE CONSIDERATIONS

The PTB will perform well with delta or wye systems, grounded or ungrounded. However, on 3 phase grounded systems do not ground the com. terminal of J1.

1.7 MENU CONSIDERATIONS

A menu entry must be made as to whether this unit will be used in a 3 phase or 1 phase system.

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Bell & Gossett S12596B User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual