Bell & Gossett S13641B User Manual
VARIABLE SPEED PUMPING SYSTEMS
INSTRUCTION MANUAL
Technologic®5500 Series
INSTRUCTION MANUAL
S13641B
Pump Controller
WARNING LABEL PART #S11550
INSTALLED IN THIS LOCATION.
IF MISSING IT MUST BE REPLACED.
INSTALLER: PLEASE LEAVE THIS MANUAL FOR THE OWNER’S USE.
DESCRIPTION
Microprocessor based dedicated pump controller for variable
volume pumping systems. The control panel consists of the
following components: microprocessor, operator interface
with 4 line display and membrane key pad, 24 VDC power
supply. Multi-pinned connecting cables for connection to
bypass panels are available as options.
OPERATIONAL LIMITS
See the control panel nameplate for operating voltage, current
draw, as well as information on the equpiment to be connected to the control panel.
This safety alert symbol will be used in this manual and on the
Technologic 5500 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 INSTRUCTION
MAY RESULT IN A SAFETY HAZARD!
SAFETY
INSTRUCTIONS
2
Preface
The following manual describes the new microprocessor based Technologic 5500 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 analog input protection
of other members of the control family. In the event of
a short circuit condition the current limit circuitry prevents failure of the analog input components.
This new controller has standard manual bypass
switches when a Bell & Gossett automatic bypass is
supplied. The manual bypass switches allow the user
to de-energize the programmable logic controller and
take manual control of the pumping system. This is
helpful during system startup to confirm pump rotation
and to purge air from the system prior to switching to
automatic control.
3
SECTION 1 - GENERAL Page
Purpose of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Safety Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Additional Safety Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Temperature and Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Input Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Ground Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Output/Motor Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Analog Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Field Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sensor & Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
SECTION 2 - INSTALLATION & STARTUP
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Putting Unit into Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 3 - SETUP AND FEATURES
General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Sensor Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pump Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Stage/Destage Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PID Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Alarm Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Alternation Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Bypass Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
AFD Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Date/Time Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Password Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
I/O Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Communication Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Special Functions Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Testing Inputs & Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Index
4
INDEX (continued)
SECTION 4 - TYPES OF PROGRAMS Page
AO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
B3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
C0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
D0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
D4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Special Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Pump Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Manual Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hand Manual Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hand Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Setpoint Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Process Variable Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
SECTION 5 - MAINTENANCE
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Technical Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Instruments and Their Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Field Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Program Updating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Program Type and Version Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Data Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Maintenance (Physical) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
APPENDIX A System Check List - Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
APPENDIX B System Check List - Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
APPENDIX C Valid I/O Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Drawing, Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Drawing, Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Drawing, Operator Interface and CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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.
Further information pertaining to the installation, operation, and maintenance of your Technologic 5500
series pump controller can be found in the I.O.M.s for the associated equipment provided see Section 5,
Maintenance, for a list of relevant manuals.
1.1 PURPOSE OF MANUAL
1.1.1 This manual is furnished to acquaint you with some
of 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.
1.1.2 Equipment cannot operate well without proper care.
To keep this unit at top efficiency, follow the recommended installation and servicing procedures outlined in this manual.
1.1.3
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.
1.1.4 Your Technologic 5500 Series Pump Controller
should have a safety instruction decal (part #S11550).
If the decal is missing or illegible contact your local
B&G representative for a replacement.
1.2
ADDITIONAL SAFETY REQUIREMENTS
1.2.1 Each motor must have a properly sized starter with
properly sized overload block to provide overload
and undervoltage protection. Ground fault protection
should be sized properly. Refer to local electrical
codes for sizing and selection.
1.2.2 Refer to the motor manufacturer’s I.O.M. (Installation
Operation Manual) for specific installation information.
1.2.3 Even when the motor is stopped, it should be considered “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.
5
Section 1 - General
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.
Glossary of Terms
AFD – Adjustable Frequency Drive; converts a constant
power input into a variable power output for the motor; a
device for controlling motor speed.
Alternation – Process of determining which pump will serve
as lead pump and which pump will serve as lag pump.
Bypass – Controller bypasses the AFD, pumps stop running
in variable speed mode and run at constant speed (50 Hz /
60 Hz).
Destage – To turn off a lag pump.
EOC – End Of Curve; point at which a pump is staged or
destaged.
I.O.M. – Installation Operation Manual.
Lag pump – Standby pump which activates only when lead
pump alone cannot efficiently provide sufficient pressure or
flow rate.
Lead pump – Duty pump which runs continuously until a
standby pump is required.
LED – Light emitting diode, located on OIP and controller.
OIP – Operator Interface Panel.
O.L. – Overload, device to protect a motor from overheating.
PID – Proportional Integral Derivative; 3 variables required
for error control.
Process variable – Signal generated by a sensor which is
set up to control the system.
Proof timer – Minimum time period before controller
acknowledges an input; time period for which a signal must
be stable before it is accepted by the controller as a
sustained and valid signal.
RTC – Real time clock.
Stage – To start a lag pump
6
1.2.4 The use of motor disconnect switches is acceptable.
Consult the factory for proper interlocking with
adjustable frequency drives, AFD’s. See Section 1.9.
1.2.5 Motor control equipment and electronic controls are
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.
1.3
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 +60ºC. 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.
NOTE: EXTENDED STORAGE OF AFDs MAY
REQUIRE SPECIAL ATTENTION PRIOR TO STARTUP. SEE MANUFACTURER’S I.O.M. FOR DETAILS.
1.4
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.
1.5
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.
1.6
INPUT VOLTAGE
The AFD and Technologic Pump Controller 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. Check the AFD nameplate for the
proper input and output voltages before wiring the
AFD.
The voltage tolerance is +10/-5% and phase to
phase voltage must not have an imbalance greater
than 5 VAC.
1.7
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.
1.8
POWER WIRING
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.
1.9
OUTPUT/MOTOR DISCONNECT
It is necessary that any device which can disconnect
the motor from the output of the AFD be interlocked
to the emergency shutdown circuits of the AFD. This
will provide an orderly shutdown if the disconnecting
device is open circuited while the AFD is in operation.
Failure to provide this interlock may result in damaged components due to improper installation.
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 RESULT IN SERIOUS PERSONAL INJURY,
DEATH, AND/OR PROPERTY DAMAGE.
CAUTION: Metal filings can create electrical short
circuits. Do not drill, saw, file or perform any operation on the AFD conduit entry plate while attached to the
AFD.
FAILURE TO FOLLOW THESE INSTRUCTIONS
COULD RESULT IN PROPERTY DAMAGE AND/OR
MODERATE PERSONAL INJURY.
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.
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.
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.
7
1.10
ANALOG SIGNALS
Shielded cable (#22 AWG, Belden type 8762, Alpha
#2411, or equal) should be installed for all D.C. control wiring. The shield must be terminated in the
Technologic Pump Controller 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 5,000 feet for #22 AWG wire.
1.11
FIELD CONNECTION DIAGRAMS
1.11.1 Refer to the pump Installation, Operation, and
Maintenance Manual for specific details unique to the
pump.
1.11.2 Refer to the flow sensor/transmitter Installation,
Operation, and Maintenance manual for specific
details unique to the flow sensor/transmitter.
1.11.3 The following field connection diagrams should be
reviewed prior to unit installation and operation.
Drawing # Description
Job Specific Wiring Diagram(s)
Print(s) Dimensional Drawings
Job Specific Field Connection
Print Diagram
Job Specific
Print
1.12
SENSOR AND CONTROL WIRING
1.12.1 The following sections are based on the installation
of standard Technologic 5500 product. Because
customized software and hardware is available the
installing contractor should base all wiring connections on the wiring diagrams that accompany each
controller. These sections are meant to complement,
not replace, those wiring diagrams.
1.12.2 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.
1.12.3 To monitor if an adjustable frequency drive is running
it is necessary to wire from each AFD’s normally
open “run” or “on” contact.
1.12.4 For the Technologic 5500 Controller to start and stop
each AFD it is necessary to wire to the remote start
terminals in each AFD.
1.12.5 Additional wiring to each of the adjustable frequency
drives may be required with certain types of controller programs. Refer to the wiring diagram for all
connection points.
1.12.6 With certain bypass and control methods it is necessary to disable an adjustable frequency drive from
running. This is accomplished by wiring from the
Technologic 5500 terminals to each AFD’s interlock
terminals. Should this wiring be required, any jumpers
which may be found on the AFD’s interlock terminals
should be removed.
1.12.7 The Technologic 5500 control family may be provided with the capability to accept many analog
inputs. Typically all analog inputs must be 4-20mA
and powered by the 24VDC power supply in the
Technologic 5500. All shields must be grounded in
the Technologic 5500 only to prevent ground loops
and improper signals.
It is not necessary for all analog inputs to be used to
monitor system zones. It is necessary, however, that
all zone transmitters be connected consecutively
starting with zone 1. Optional transmitters (i.e., other
than zones) may be supplied.
1.12.8 Analog Input Sensors Powered By Others
The following steps describe the general procedure
for rewiring an analog input sensor when the sensor’s
power source is not the Technologic 5500 controller.
1) Turn off all power to the Technologic 5500 controller
2) Refer to the appropriate controller wiring diagram
that was shipped with unit. Locate the analog
input sensors on the wiring diagram that will be
rewired. They are labeled AI X.
3) Remove the 24 VDC positive (+) wire from TB 40
for the respective analog input sensor connection.
This wire needs to be removed completely or
terminated if used as a jumper, to avoid any
accidental contact with a negative (-) voltage
source (i.e. control panel); as this could become a
short circuit. Care should be taken to ensure that
24 VDC positive (+) voltage is still provided to any
remaining sensors that will still be powered by the
Technologic 5500 controller.
4) Remove the 24 VDC negative (-) wire from TB 41
for the respective analog input sensor connection.
This wire needs to be removed completely or
terminated if used as a jumper, to avoid any
accidental contact with a positive (+) voltage
source; as this could become a short circuit. Care
should be taken to ensure that 24 VDC (-) negative
voltage is still provided to any remaining sensors
that will still be powered by the Technologic 5500
controller
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.
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.
8
5) Terminate the negative (-) wire of the sensor to TB
41 of the respective analog input sensor connection. Terminate the positive (+) wire of the
sensor to the terminal block which is connected to
the positive (+) terminal shown on the Analog input
card.
NOTE: Be certain that the power supplied to other
terminal blocks has not been interrupted since the
wires that have been removed in the proceeding
steps may have been used as jumpers.
1.12.9 Drive speed (follower) signals must be wired from the
Technologic 5500 Controller to each of the adjustable
frequency drives. The AFDs must be configured to
accept a 0-10 VDC speed signal with the minimum
speed set for 30% (0 VDC) and maximum speed set
for 100% (10 VDC). All shields must be grounded in
the Technologic 5500 only to prevent ground loops
and improper signals.
1.12.10 Hardwire communications refers to the capability of
the Technologic 5500 Controller to communicate with
an energy management system. Standard communication features are listed below:
1.12.11 Remote Start/Stop
Install a switch as indicated on the wiring diagram.
With the LOCAL-REMOTE-OFF switch in the
REMOTE position this contact closure will provide
the start signal.
1.12.12 Remote Alarm Indication
A digital output rated 8 AMPs at 115V is supplied.
This output closes to indicate an alarm condition
exists.
1.12.13 User Configurable I/O
The Technologic 5500 Controller comes equipped
with the capability to define the operation of any
unused input or output signal. Refer to Section 3.15
for detailed information on the I/O setup menus
2.0
LOCATION
2.1 Install the pumping unit appropriately for ease of
inspection, maintenance and service. Observe local
electrical codes concerning control panel spacing.
2.2
INSTALLATION OF SKID MOUNTED SYSTEMS
WITH FACTORY SUPPLIED PUMPS
This unit is built to give you years of service; install it
properly and provide a suitable foundation. A base of
concrete weighing 2-1/2 times the weight of the unit
is recommended. (Check the shipping ticket for unit
weight.) Tie the concrete pad in with the finished
floor. Use foundation bolts and larger pipe sleeves to
give room for final bolt location.
2.2.1 Place the unit on its concrete foundation, supporting
it with steel wedges or shims totaling 1” in thickness.
These wedges or shims should be put on both sides
of each anchor-bolt to provide a means of leveling
the base.
2.2.2 After the frame has been leveled and securely bolted
to the pad, a good grade of grout should be installed
beneath the base. A suggested mixture for grout is:
one part Portland Cement and two or three parts
plain, sharp sand mixed with water until it will pour
easily. Commercial grout mixtures with suspended
iron particles are available. Wet the concrete base
before pouring grout. To hold wedges or shims in
place, allow the grout to flow around them and
beneath the entire length of the base flange.
2.2.3 Important. Do not install and operate the Bell &
Gossett Technologic 5500 pump controller in a
closed system unless the system is constructed with
properly sized safety and control devices. Such
devices include the use of properly sized and located
pressure relief valves, compression tanks, pressure
controls, temperature controls and flow controls as
appropriate. If the system does not include these
devices, consult the responsible engineer or architect
before making pumps operational.
2.2.4 Eccentric increasers can be used in the suction lines
when increasing the pipe size, with straight sides of
increaser on top to eliminate air pockets. Be sure to
eliminate any pipe strain on the unit. Support the suction and discharge pipes independently by use of
pipe hangers near the unit. Line up the vertical and
horizontal piping so that the bolt holes of the flanges
match. DO NOT ATTEMPT TO SPRING THE SUCTION OR DISCHARGE LINES INTO POSITION.
2.2.5 As a rule, ordinary wire or band hangers are not adequate to maintain alignment. It is very important to
provide a strong, rigid support for the suction line. A
saddle hanger is recommended.
2.2.6 For critical installations, equipment for absorbing
expansion and vibration should be installed in the
inlet and outlet connections of the unit.
2.2.7 Before starting, all pumps and motors should be
checked for proper lubrication.
Section 2 - Installation
DANGER: The heating of water and other fluids
causes volumetric expansion. The associated forces
may cause failure of system components and releases of
high temperature fluids. This will be prevented by installing
properly sized and located pressure relief valves and compression tanks.
FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN SERIOUS PROPERTY DAMAGE AND SERIOUS PERSONAL INJURY OR DEATH.
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.
9
2.3
PUTTING THE UNIT INTO SERVICE
2.3.1 PUMP ROTATION, 3 PHASE MOTORS ONLY
With the disconnect switch engaged to the “ON”
position, momentarily start and stop each motor .
Observe the pump shaft rotation.
2.3.2 If a Bell and Gossett bypass panel is supplied, place
the AUTO-OFF-HAND switch in HAND. In the HAND
position the controller is off and the user has local
control of the pumps through the DRIVE-BYPASS
switches. Momentarily start the pump in the DRIVE
and BYPASS mode.
2.3.3 If incorrect, turn the main disconnect off and refer to
Section 4.9.
2.3.4 While the unit may be hydro tested at the factory to
internal quality standards, there may be some joints
that are not pressure tested. Some joints may have
also been loosened to allow for draining of the system, and not retightened. Thus, some joints may be
loose for due to system grainage or shocks during
the shipping process.
All flanged joints are to be checked for tightness and
proper torque of the flange bolts prior to filling the
system with fluid. See the next section for proper
setup.
3.1
GENERAL NOTES
3.1.1 The HELP key can be pressed at any time without
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.
3.1.2 The key names are shown as CAPITAL LETTERS and
the operator interface responses are shown as bold
CAPITAL LETTERS.
3.1.3 On data input screens the ENTER key can be used to
advance to the next item, the CLEAR key can be
used to return to the previous item.
3.1.4 When the green LED’s on the PREV. SCREEN or
NEXT SCREEN keys are flashing the keys can be
pressed to navigate to neighboring screens.
3.2
POWER-UP
3.2.1 Put LOCAL-REMOTE-OFF (LRO) switch in the
LOCAL position. Put the optional AUTO-OFF-HAND
switch in the AUTO position.
3.2.2 Turn main disconnect on.
3.2.3 The operator interface will display the Technologic
Pump Controller default screen.
3.2.4 The START-STOP LED will be flashing.
3.2.5 If the START-STOP LED is not illuminated as
described above, press the START-STOP button
once to light the LED.
3.2.6 The Auto-Manual LED should be green for auto operation. The display should also indicate
MANUAL in
the lower right hand corner. If not, press the AUTOHAND key to enter the operation mode menu, press
the SET POINT/2 key, then the ENTER key to select
manual operation.
Section 3 - Setup and Features
CAUTION: Seal damage may occur. Do not run
pump dry. Fill and vent the pump volute prior to oper-
ation.
FAILURE TO FOLLOW THESE INSTRUCTIONS
COULD RESULT IN PROPERTY DAMAGE AND/OR
MODERATE PERSONAL INJURY.
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.
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.
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.
WARNING: Failure to check all joints for tightness,
and flange bolts for proper torque, could result in
leaks and/or flooding.
FAILURE TO FOLLOW THESE
INSTRUCTIONS COULD RESULT IN SERIOUS PERSONAL INJURY, DEATH, AND/OR PROPERTY DAMAGE.
10
3.3
SETUP
3.3.1 Upon powering up the controller the display will light
and show the following:
TECHNOLOGIC PUMP
CONTROLLER
MM/DD/YY HH:MM:SS A/P
Normal Manual
The current date and time will be displayed on the
third line.
3.3.2 Press the SETUP/3 key once and the following will be
displayed:
SETUP SELECTION: 0
1 = SENSORS 4 = TEST
2 = PUMPS 5 = DEFAULT
3 = SYSTEM 0 = EXIT
3.3.3 A detailed description of each setup menu item
follows.
3.4
SENSOR SETUP
3.4.1 Press the PROCESS VARIABLE/1 key at the Setup
Selection menu. Then press the ENTER key.
3.4.2 The display will show:
SENSOR NO: #
Press the numeric key(s) for the sensor you wish to
set up. The sensor number is limited to the maximum
number of sensors allowed, typically 16. Press the
ENTER key to proceed with the set up.
3.4.3 The display will now show:
SENSOR NO #
1 - Edit 2 - Copy : #
0 – Exit
Press the PROCESS VAIABLE/1 and ENTER keys to
edit the sensor setup. Continue to section 3.4.4
Press the SET POINT/2 and ENTER keys to from an
existing sensor 3.4.6.
3.4.4 When sensor is set up the display will show:
SENSOR NO ## (FLOW, DP, SYSDP, KW SNS,
TEMP, PR SNS, DELTA T, or NONE)
SPAN= # ZERO= #
PV: (Y or N) SET POINT NO: ##
OVERRIDE: (Y or N) OK? (Y/N)
Press the YES/7 and ENTER keys to accept the
values and continue to section 3.4.6.
Press the NO/0 and ENTER keys to set up each field
and skip to section 3.4.7.
3.4.5 If the sensor is not set up, the display will show:
SENSOR NO ## NONE
SPAN= 0 ZERO= 0
OK? (Y/N)
Press the YES/7 and ENTER keys to accept the
values and continue to section 3.4.16.
3.4.6 The displays will show:
Copy to Sensor No: #
From Sensor No: #
OK (Y/N)
The copy to sensor number will refer to the sensor
number for which the setup is being performed.
The from sensor will be the sensor from which the
information will be copied from.
To change this valve, enter the approprite number
using the key pad. Then press Enter to accept the
valve.
Press the YES/7 and Enter keys to accept the values
and proceed to section 3.4.4
Press the NO/0 and ENTER keys to set up each field
and continue to section 3.4.7.
3.4.7 If YES is selected at the sections 3.4.4 or 3.4.5; or
NO is selected from 3.4.6 the following is displayed:
DO ANOTHER ? (Y/N)
Press the YES/7 and ENTER keys to set up another
sensor. Return to section 3.4.2 and repeat for all
remaining sensors.
Press the NO/0 and ENTER keys to return to the
setup selection screen.
3.4.8 If NO is selected at section 3.4.3, the following is displayed:
NO: ## SENSOR TYPE: #
1 = DP, 2 = PR, 3 = Flow
4=KW, 5 = Temp, 6 = DT
7 = SysDP, 8 = SysKW, 0 = None
The following selections are valid.
1 = DP: Differential Pressure, the display will show
units in PSID.
2 = PR Sns: Pressure, the display will show units in
PSI.
3 = Flow: Capacity, the display will show units in
GPM.
4 = KW Sns: Power, the display will show units in
KW.
5 = Temp: Temperature, the display will show units in
°F.
6 = Delta T: Differential Temperature, the display will
show units in °F
7 = SysDP: System Differential Pressure, the display
will show units in PSID.
0 = Non-standard transmitter, units will not be
displayed.
3.4.9 Enter the numeric key for the type of sensor you are
setting up. Press the ENTER key. The display will
now show:
SENSOR NO ## (FLOW, DP, SYSDP, KW SNS,
TEMP, PR SNS, or DELTA T, SYS KW)
SPAN = #####
11
3.4.10 Obtain the span of the sensor from the nameplate on
the sensor. Enter the span by pressing the appropriate numeric keys followed by the ENTER key.
3.4.11 The display will now show:
SENSOR NO ## (FLOW, DP, SYSDP, KW SNS,
TEMP, PR SNS, or DELTA T, SYS KW)
SPAN = ##### ZERO = ####
Typically the variable value is zero at 4mA for many
sensors. An exception would be for a temperature
sensor. Enter the desired zero value by pressing the
appropriate numeric keys followed by the ENTER
key.
3.4.12 The display will now show:
SENSOR NO ## (FLOW, DP, SYSDP, KW SNS,
TEMP, PR SNS, or DELTA T, SYS KW)
SPAN = ##### ZERO = #####
PV: (Y or N) (Y/N)
Press the YES/7 key for all sensors that will control
the system by supplying a process variable feedback
signal. Typical process variable signals are supplied
by one
of the following: Pressure, Differential
Pressure, Temperature, or Differential Temperature
Sensors.
Press the NO/0 key for all sensors that supply optional signals. Typical optional signals are supplied by
any
of the following: System Differential Pressure,
Temperature Differential Temperature, Flow, and KW
Sensors.
Press the ENTER key to continue.
3.4.13 If NO is selected at the above section, skip to section
3.4.13. If YES is selected at the above section, the
display will now show:
SENSOR NO ## (FLOW, DP, SYSDP, KW SNS,
TEMP, PR SNS, or DELTA T, SYS KW)
SPAN = ##### ZERO = #####
PV: Y SET POINT NO ##
Enter a set point number by using the numeric key
pad. Enter the number zero for all sensors that do not
supply the process variable. Press the ENTER key.
Make sure the setpoint number agrees with the sensor number, example sensor 5 should be configured
for setpoint 5. Defining the value associated with the
setpoint number is defined in Section 4.14.
3.4.14 The display will now show:
SENSOR NO ## (FLOW, DP, SYSDP, KW SNS,
TEMP, PR SNS, or DELTA T, SYS KW)
SPAN = ##### ZERO = #####
PV: Y SET POINT NO ##
OVERRIDE: (Y or N) (Y/N)
The controller is capable of accepting sensor input
either through a 4-20mA analog input or through the
RS-485 communication port. The communication
port must be set up properly and connected to an
external building automation system. The LOCALREMOTE-OFF switch must be in the REMOTE position to allow the controller to receive sensor information via the RS-485 port.
Press the YES/7 key to receive sensor signals via the
RS-485 port. Press the ENTER key.
Press the NO/0 key to receive the sensor signals via
the analog input card. Press the ENTER key.
3.4.15 The display will now show:
SENSOR NO ## (FLOW, DP, SYSDP, KW SNS,
TEMP, PR SNS, or DELTA T, SYS KW)
SPAN = ##### ZERO = #####
PV: Y SET POINT NO ##
OVERRIDE: (Y or N) OK? (Y/N)
Press the NO/0 and ENTER keys to correct any
errors. By pressing the PREV SCREEN or NEXT
SCREEN keys, correct the item in error.
Press the YES/7 and ENTER keys after confirming all
variables are correct.
Skip to section 3.4.14
3.4.16 If NO was selected at section 3.4.9, the display will
now show:
SENSOR NO ## (FLOW, DP, SYSDP, KW SNS,
TEMP, PR SNS, or DELTA T, SYS KW)
SPAN = ##### ZERO = #####
PV: N
OK? (Y/N)
Press the NO/0 key then ENTER to correct any
errors. After pressing the ENTER key, press the PREV
SCREEN or NEXT SCREEN keys to correct the item
in error.
Press the YES/7 key after confirming all variables are
correct.
3.4.17 The screen will now display:
DO ANOTHER ? (Y/N)
Press the YES/7 key if additional sensors must be set
up. Return to section 3.4.2 and repeat for all remaining sensors.
Press the NO/0 key to return to the setup selection
screen.
Press ENTER to continue.
3.5
PUMP SETUP
3.5.1 Press the SET POINT/2 key at the Setup Selection
menu. Then press the ENTER key.
12
3.5.2 The display will show:
# PUMPS = #
P1: * P2: * P3: *
P4: * P5: * P6: *
OK ? (Y/N)
* The pump status will be displayed for each defined
pump. The valid options are as follows:
N/A = pump not available as defined by setup
Rdy = pump available, not running
On = pump is running
Off = pump disabled, will not be allowed to start
Press the YES/7 and ENTER keys to accept pump
configuration and return to setup selection screen.
Press the NO/0 and ENTER key to set up any pumps.
3.5.3 The screen will now display:
TOTAL # PUMPS = #
Press the numeric key for the total number of pumps
(1 to 6 pumps). Press ENTER to continue.
3.5.4 The screen will now display:
EDIT PUMP ? (Y/N)
Press the YES/7 and ENTER keys if any of the pumps
must be set up.
Press the NO/0 and ENTER keys to return to the
pump status screen and return to section 3.5.2.
3.5.5 The display will show:
EDIT PUMP # #
Press the numeric key(s) for the pump you wish to set
up. The pump number is limited to the maximum
number of pumps. Press the ENTER key to proceed
with the set up.
3.5.6 The screen will now display:
PUMP # #
ENABLE/DISABLE: #
1=ENABLE 0=DISABLE
Press the PROCESS VARIABLE/1 and ENTER keys if
the pump will be enabled.
Press the NO/0 and ENTER keys if the pump will be
disabled.
3.5.7 The screen will now display:
DO ANOTHER ? (Y/N)
Press the YES/7 and ENTER keys to set up another
pump. Return to section 3.5.5 and repeat for all
remaining pumps.
Press the NO/0 and ENTER keys to return to the
pump status screen and return to section 3.5.2.
3.6
SYSTEM SETUP
3.6.1 Press the SETUP/3 key at the setup selection menu.
Press the ENTER key.
3.6.2 The display will now show:
SELECTION: # 0 = EXIT
1 = STAGE/DESTAGE
2 = PID
3 - ALARMS
Press the NEXT SCREEN key.
The display now shows:
SELECTION: # 0 = EXIT
4 = ALTERNATION
5 = BYPASS
6 = AFD
Press the NEXT SCREEN key.
The display now shows:
SELECTION: # 0 = EXIT
7 = DATE/TIME
8 = PASSWORD
9 = I/O SETUP
Press the NEXT SCREEN key. The display now
shows:
SELECTION: # 0 = EXIT
10 = COMMUNICATION
11 = SPECIAL FUNCTIONS
12 = CHANGE LANGUAGE
Press the NEXT SCREEN key. The display now
shows:
SELECTION: # 0 = EXIT
13 = SAVE TO FLASH
14 = LOAD FROM FLASH
15 = SET BRITE/CNTRST
Use the appropriate numeric key to select the setup
menu desired, press the ENTER key. A detailed
description of each menu follows.
DANGER: High voltage 3 phase power can kill.
Pumps can start automatically. Disconnect and lock-
out power prior to servicing pumps.
FAILURE TO FOLLOW
THESE INSTRUCTIONS COULD RESULT IN SERIOUS
PERSONAL INJURY, DEATH, AND/OR PROPERTY
DAMAGE.
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