Bell & Gossett S14367B User Manual

INSTRUCTION MANUAL

S14367

REVISION B

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

Technologic® Constant Speed
Pump Controller

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 Constant Speed Pump Controller
can be found in the instruction manuals for the associated equipment provided. See Section 1.1, Maintenance, for a list of
relevant manuals.

Table of Contents

Section 1 — General

1.1 Purpose of Manual …………………………………………………………………………… 6

1.2 Safety …………………………………………………………………………………………… 6

1.2.1 Safety Alert Symbol …………………………………………………………………………… 6

1.2.2 Safety Instruction Decal ……………………………………………………………………… 6

1.2.3 Hazardous Voltage …………………………………………………………………………… 6

1.2.4 Pump/Motor Safety …………………………………………………………………………… 6

1.2.5 Closed System Safety Measures …………………………………………………………… 6

1.3 Storage ………………………………………………………………………………………… 6

1.4 Handling ………………………………………………………………………………………… 7

1.5 Foundation ……………………………………………………………………………………… 7

1.6 Leveling ………………………………………………………………………………………… 7

1.7 Location ………………………………………………………………………………………… 7

1.8 Piping …………………………………………………………………………………………… 7

1.9 Temperature and Ventilation ………………………………………………………………… 7

1.10 Incoming Power and Ground Wiring ………………………………………………………… 7

Section 2 — Operator Interface Panel

2.1 Key Functionality ……………………………………………………………………………… 8

2.2 LEDs …………………………………………………………………………………………… 8

2.3 I/O ……………………………………………………………………………………………… 9

2.3.1 Analog Inputs …………………………………………………………………………………… 9

2.3.2 Powered Analog Inputs ………………………………………………………………………… 9

2.3.3 RTD Inputs ……………………………………………………………………………………… 9

2.3.4 Digital Inputs …………………………………………………………………………………… 9

2.3.5 Relay and Power Monitor Rack ……………………………………………………………… 10

2.3.5.1 Digital Output Module ………………………………………………………………………… 10

2.3.5.2 Power Measurement Module ………………………………………………………………… 10

2.3.5.3 Current Transformer …………………………………………………………………………… 10

Section 3 — Operation

3.1 Power-Up ……………………………………………………………………………………… 10

3.2 Basics of Screen Navigation and User Setup ……………………………………………… 10

3.3 Pump Operation ………………………………………………………………………………… 11

3.3.1 Manual Pump Operation ……………………………………………………………………… 11

3.3.2 Automatic Pump Operation …………………………………………………………………… 11

3.4 Status Screens ………………………………………………………………………………… 11

3.4.1 Tech Status ……………………………………………………………………………………… 11

3.4.2 Pump Status …………………………………………………………………………………… 11

3.4.3 Sensor Status …………………………………………………………………………………… 12

3.4.4 Staging ………………………………………………………………………………………… 12

3.4.5 Timers …………………………………………………………………………………………… 12

3.4.6 Power …………………………………………………………………………………………… 12

Technologic® Constant Speed Pump Controller Installation, Operation and Maintenance Manual 3

3.4.7 Optional Sensors ……………………………………………………………………………… 13

3.5 Alarms/Events ………………………………………………………………………………… 13

Section 4 — Setup Menu

4.1 Sensor Setup …………………………………………………………………………………… 15

4.2 Pump Setup Menu ……………………………………………………………………………… 15

4.2.1 Number of Pumps ……………………………………………………………………………… 15

4.2.2 Pump Nameplate Data ………………………………………………………………………… 15

4.3 System Setup Menu …………………………………………………………………………… 16

4.3.1 Stage Menu …………………………………………………………………………………… 16

4.3.1.1 Primary Staging ………………………………………………………………………………… 16

4.3.1.2 Secondary Staging …………………………………………………………………………… 17

4.3.1.3 Force Destage/Minimum Pump Run Time ………………………………………………… 17

4.3.2 Alternation ……………………………………………………………………………………… 17

4.3.3 Pump Exercise ………………………………………………………………………………… 18

4.3.4 Start/Stop ……………………………………………………………………………………… 18

4.3.5 Scheduling ……………………………………………………………………………………… 19

4.3.6 Date/Time ……………………………………………………………………………………… 19

4.3.7 Password ……………………………………………………………………………………… 19

4.3.8 Relay Outputs Setup …………………………………………………………………………… 19

4.3.9 Save/Load Menu ……………………………………………………………………………… 20

4.3.9.1 Save to Flash …………………………………………………………………………………… 20

4.3.9.2 Load from Flash ………………………………………………………………………………… 20

4.3.9.3 Load Defaults …………………………………………………………………………………… 20

4.3.10 Communications ……………………………………………………………………………… 20

4.3.10.1 BACnet MS/TP ………………………………………………………………………………… 20

4.3.10.2 Metasys N2 ……………………………………………………………………………………… 21

4.3.10.3 Modbus ………………………………………………………………………………………… 21

4.3.10.4 Lonworks ………………………………………………………………………………………… 21

4.3.10.5 Analog Input Override ………………………………………………………………………… 22

4.3.11 Tech 350 ………………………………………………………………………………………… 22

4.4 Test Menu ……………………………………………………………………………………… 22

4.4.1 Digital Input Test ……………………………………………………………………………… 22

4.4.2 Digital Output Test ……………………………………………………………………………… 22

4.4.3 Analog Input Test ……………………………………………………………………………… 22

4.4.4 LED Test ………………………………………………………………………………………… 22

4.4.5 Key Test ………………………………………………………………………………………… 23

4.4.6 Display Test …………………………………………………………………………………… 23

4.4.7 Comm Test ……………………………………………………………………………………… 23

4.5 Alarms/Events Menu …………………………………………………………………………… 23

4.5.1 Pump Failure …………………………………………………………………………………… 23

4.5.2 Low System Pressure ………………………………………………………………………… 23

Table of Contents

Technologic® Constant Speed Pump Controller Installation, Operation and Maintenance Manual 4

Table of Contents

4.5.3 High System Pressure ………………………………………………………………………… 24

4.5.4 Low Suction Pressure ………………………………………………………………………… 24

4.5.5 High Suction Pressure ………………………………………………………………………… 24

4.5.6 No Flow Shutdown …………………………………………………………………………… 25

4.5.7 High Temperature Cutout ……………………………………………………………………… 25

4.5.8 Low Level ……………………………………………………………………………………… 26

4.5.9 Volts Tolerance ………………………………………………………………………………… 26

4.6 EZ-Start ………………………………………………………………………………………… 26

4.7 Log Menu ……………………………………………………………………………………… 27

4.7.1 Alarm Log ……………………………………………………………………………………… 27

4.7.2 Pump Log Menu ……………………………………………………………………………… 27

4.7.2.1 Pump State Log ………………………………………………………………………………… 27

4.7.2.2 Pump Runtime Log …………………………………………………………………………… 27

4.7.2.3 Reset Pump Runtime ………………………………………………………………………… 27

4.7.3 Data Log ………………………………………………………………………………………… 27

4.7.4 Data Log Rate ………………………………………………………………………………… 28

4.7.5 Operation Log Menu …………………………………………………………………………… 28

4.7.5.1 Operation Mode Changes Log ……………………………………………………………… 28

4.7.5.2 Power Cycles Log ……………………………………………………………………………… 28

4.7.5.3 Events Log ……………………………………………………………………………………… 28

4.7.5.4 Purge Log ……………………………………………………………………………………… 28

4.7.5.5 Exercise Log …………………………………………………………………………………… 29

4.7.5.6 Operating Hours ……………………………………………………………………………… 29

4.7.6 Totals …………………………………………………………………………………………… 29

4.7.7 Reset Totals …………………………………………………………………………………… 29

4.7.8 Log Book ………………………………………………………………………………………… 29

Section 5 — Maintenance

5.1 Battery …………………………………………………………………………………………… 30

5.2 Signal Generator (analyzer) - recommended ……………………………………………… 30

5.3 Field Repair …………………………………………………………………………………… 30

5.4 Program Updating ……………………………………………………………………………… 30

5.5 Info Screens …………………………………………………………………………………… 30

5.6 Troubleshooting ………………………………………………………………………………… 31

Section A — Parameter List ……………………………………………………………………………………………… 32

Section B — BACnet Protocol Implementation Conformance Statement for BACnet MS/TP …………………… 35

Section C — Serial Communications Points …………………………………………………………………………… 37

Section D — Procedure for Field Balancing 70E/70M PRVs ………………………………………………………… 39

Section E — Electrical Wiring and Control Settings – Final Check List ……………………………………………… 39

Section F — System Piping and Unit Installation - Final Check List ………………………………………………… 40

Section G — Quick Startup Check List ………………………………………………………………………………… 40

Section H — Drawings …………………………………………………………………………………………………… 42

Technologic® Constant Speed Pump Controller Installation, Operation and Maintenance Manual 5

Section 1 — General

1.1 Purpose of Manual

This m a n u al describes the op e r a t i o n of the

Technologic® Constant Speed Pump Controller for
control of constant speed pump systems.

The control panel consists of an operator interface

panel (OIP), a disconnect switch, control transformer,
motor starters, motor branch circuit protection
including fuses or circuit breakers and thermal over­loads, a 24VDC power supply, and terminal blocks
for customer connections.

Further information pertaining to the system can be

found in the following IOMs:

1. Bell & Gossett 1510 # P81673

2. Bell & Gossett 1531 # P81567

3. CLA-VAL Pressure Reducing Valve # TM90-01

4. McDonnell & Miller Series 750B and 750BM
Condu c tan c e Ac t u ate d L e v el Con t r ols #
MM-248(C)

5. McDonnell & Miller FS250 General Purpose
Liquid Flow Switch # MM-625

6. Squa re D Differe ntial Pres sure Switche s #
65013-009-32C

7. United Electric Cont rols 54 Series Pressu re
Switches # IMP54-03

1.2 Safety

1.2.1 Safety Alert Symbol

SAFETY INSTRUCTION

This safely alert symbol will be used in this manu­al 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.

1.2.2 Safety Instruction Decal

Your Technologic

should have a safety instruction dec al (part #
S11550) located on the front of the enclosure near
the disconnect switch. If the decal is missing or illegi­ble contact your local B&G representative for a
replacement.

1.2.3 Hazardous Voltage

Only qualified electricians should perform electrical

service of any kind on the control panel or pumping
system. Visually inspect the control panel for loose or
stranded wires and for damaged components or wires
prior to performing electrical service. Never trouble­shoot or perform service on a live control panel. Do
not turn the disconnect switch on while the enclosure
door is open. Live voltage is still connected to the
incoming side of the disconnect switch even when the

®

Constant Speed Pump Controller

disconnect switch is off. Turn off and lock out the
incoming power prior to troubleshooting or perform­ing service on this control panel.

WARNING: High Voltage! Do not work

on live control panels. Disconnect the
incoming power prior to performing service on
this unit. FAILURE TO FOLLOW THIS

INSTRUCTION MAY RESULT IN DEATH OR
PROPERTY DAMAGE.

1.2.4 Pump/Motor Safety

All electrical installation or service on the motors

should be performed by a qualified electrician.
Ground fault protection should be sized properly.
Refer to local electrical codes for sizing and selection.
Refer to the I.O.M. for the motors for specific instal­lation information. Even when the Pum ps are
stopped, they should be considered alive as long as its
controller is energized. Keep hands away from the
pumps until the power is disconnected from the
pump controller.

1.2.5 Motor Control Equipment Safety

Do not install and operate a pumping package 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.

DANGER: The heating of water and

other fluids causes volumetric expansion.
The associated forces may cause failure of system
components and release 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 CAN RESULT IN SERIOUS
PROPERTY DAMAGE AND SERIOUS
PERSONAL INJURY OR DEATH.

1.3 Storage

For long periods of storage, the pumping package

should be covered to prevent corrosion and contami­nation from dirt. It should be stored in a clean, dry
location between -20 and +60º C. The relative
humidity should not exceed 95%. The unit should be
checked periodically to ensure that no condensation
has formed. After storage, check that it is dry before
applying power.

1.4 Handling

Care should be taken to prevent damage due to drop-

ping or jolting when moving any panel or pumping
package. Transportation damage should be brought
to the carrier’s attention immediately upon receipt.

Technologic® Constant Speed Pump Controller Installation, Operation and Maintenance Manual 6

General

The unit should be unloaded and handled by quali­fied personnel. A pumping package that includes this
panel may be top heavy due to the position of the
motors. Lift the unit with slings placed under the unit
base rails. Be sure not to load the lifting mechanism
beyond its rated limits. Use the motor eyebolts to sta­bilize the unit while lifting to prevent overturning.

DANGER: Heavy load, may drop if

not lifted properly. Do not load cables,

chains or hoists beyond their rated limits.

FAILURE TO FOLLOW THESE INSTRUC­TIONS COULD RESULT IN SERIOUS
PERSONAL INJURY, DEATH AND/OR
PROPERTY DAMAGE.

1.5 Foundation

A concrete base weighing at least 2.5 times the weight

of the pumping package is recommended. Check the
shipping ticket for the 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.

1.6 Leveling

Place the pumping package on its concrete founda-

tion, 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.

1.7 Location

Install the pumping package appropriately for ease of

inspection, maintenance and service. Observe local
electrical codes concerning control panel spacing.

1.8 Piping

Be sure to eliminate any pipe strain on the pumping

package. Support all pipes independently by use of
pipe hangers near the unit. Ordinary wire or band
hangers are not adequate to maintain alignment. It is
very important to provide a strong, rigid support for
the suction and discharge lines. A saddle hanger is
recommended. Do not attempt to force the suction
or discharge lines into position. Refer to the assembly
drawing for customer piping connections.

Inspect all unit piping connections. Joints may also

become loose during transit due to vibration and
shock. All joints should be checked for tightness.
Flanged joints should be checked for proper torque
of all flange bolts prior to filling the system with
fluid.

Eccentric increasers may be used in the suction lines

when increasing the pipe size, with the straight sides
of the increaser on top to eliminate air pockets.

For critical installations, equipment for absorbing

expansion and vibration should be installed in the
inlet and outlet connections of the unit.

Drain plugs are placed in a cloth bag and secured to

the unit prior to shipping from the factory. Reinstall
the drain plugs prior to filling the system with fluid.

On an open system with a suction lift, use a foot

valve of equal or greater area than the pump suction
piping. Prevent clogging by using a strainer at the
suction inlet next to the foot valve. The strainer
should have an area three times that of the suction
pipe. Provisions must be made to prime the pump
suction piping on start up. Do not start the pump
unless all suction piping is full of water.

A thermal relief valve is installed on the discharge

header to prevent potentially dangerous thermal
buildup in the package. This valve acts as a safety
device and it should never be removed or tampered
with. It is factory set to open and discharge when the
water temperature in the discharge header exceeds
125°F. The 3/8” NPT opening of this valve must be
piped to a floor drain.

Before starting, all pumps and motors should be

checked for proper lubrication.

1.9 Temperature and Ventilation

The operating temperature range for this unit is 0 to

50°C. The relative should be kept between 10% and
90% non-condensing. The unit should not be operat­ed outside these extremes.

1.10 Incoming Power and Ground Wiring

A qualified electrician should bring incoming power

and ground wiring to the disconnect switch. If holes
are drilled in the control panel, be sure to not con­taminate electrical components with metal filings. A
grounding terminal is provided next to the discon­nect switch for an incoming ground wire connection.
Wire types and sizes must be selected according to
the National Electrical Code and all local codes and
restrictions. Refer to the input current and voltage as
listed on the nameplate on the enclosure door when
sizing the power wires. Only copper (Cu) wire rated
for 75°C (minimum) may be used for the power con­nections. The voltage tolerance is +10/-5% and
phase to phase voltage must not have an imbalance
greater than 5 VAC.

WARNING: Prevent electrical shocks.

Disconnect the incoming power supply to
the control panel before beginning installation.

FAILURE TO FOLLOW THESE INSTRUC­TIONS MAY RESULT IN DEATH OR
PROPERTY DAMAGE.

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.

Technologic® Constant Speed Pump Controller Installation, Operation and Maintenance Manual 7

1

Yes

2 3

Setup

4No5

Log

6

7 8

Info9Alt

Clear

0

Enter

Tec hnolog ic® Const ant Sp eed Pu mp Con troll er

NextPrev

GREEN = RUN

OFF = STOP

GRE EN = A UT O

OFF = M AN UA L

ON SOLID-PUMP RUNNING
OFF-PUMP DISABLED

FLASH SLOW-PUMP READY
FLASH FAST-PUMP FAILED

Start /

Stop

Pump 1

Enabled

Pump 2
Enabled

Pump 3
Enabled

Reset /
Silence

Auto /

Manual

Pump 4

Enabled

Pump 5
Enabled

Pump 6
Enabled

Help

Section 2 — Operator Interface Panel

The OIP consists of a 4 x 20 character LCD screen

and a 26 button keypad with LEDs which display sys­tem status. It also is equipped with onboard I/O
including (16) 24VDC digital inputs, (4) 4-20mA
analog inputs, (2) PT100 RTD inputs, and an RS232/
RS485 serial port for communications all mounted
on the back of the OIP. The OIP communicates
through a CAN bus to the relay and power monitor
rack.

2.1 Key Functionality

The names of the keys on the Operator Interface

Panel (OIP) are shown as CAPITAL LETTERS in this
manual. Table 1 shows the functionality of the keys
on the OIP.

Note: The contrast can be adjusted from any screen

by pressing the UP and DOWN arrows while holding
the ENTER key.

Key Name Functionality

START/STOP Starts or stops the system. When

the Start/Stop method is not
“Keypad”, pressing the START/
STOP key will toggle between
“Ready” and “Stop”. “Ready”
indicates the system is waiting
for a remote signal to start.

AUTO/ Toggles the operation mode. The

MANUAL system must be stopped to
change the operation mode.

PUMP 1-6 Enables or disables the

ENABLE corresponding pump. Pumps
cannot be disabled while they
are failed.

RESET/ This key is used to reset pumps

Technologic® Constant Speed Pump Controller Installation, Operation and Maintenance Manual 8

SILENCE and alarms. When the A/V Alarm
relay output (section 4.3.8) is
set, initial pressing of this key
opens the relay to silence the
horn or turn off the pilot light.
Pressing a second time resets the
pumps and alarms.

Key Name Functionality

HELP Press the HELP button, from the

status screens, to view alarms or
events while the HELP LED is
flashing. While in the Alarm
screen, press the HELP button
again to view help messages for
active alarms. Press HELP any
other time to view screen
specific help messages.

YES/1 Press YES at OK prompts to

accept values and proceed

SETUP/3 Press SETUP, from the status

screens, to bring up the Setup
Menu shown in section 4

NO/4 Press NO at OK prompts to edit

the parameters

LOG/5 Press LOG, from the status

screens, to bring up the Log
Menu, shown in section 4.7

INFO/8 Press INFO, from the status

screens, to bring up the Info
screens, shown in section 5.5

ALT/9 Press ALT, from the status

screens, to manually alternate
the pump staging sequence, see

section 4.3.2
ENTER Confirms entries
CLEAR Clears entries or used to exit

some screens
PREV (←) Navigates to neighboring screens
NEXT (→) Navigates to neighboring screens
UP (↑) Used to modify values and

navigate to neighboring screens
DOWN (↓) Used to modify values and

navigate to neighboring screens

Table 1: Key Functionality

2.2 LEDs

Table 2 gives the meaning of the LED states.

LED Description

START/STOP On = Start
Off = Stop
Blink Slow = Ready (waiting for

remote method)

AUTO/ On = Auto
MANUAL Off = Manual

PUMP 1-6 On = Pump On
Off = Pump Disabled
Blink Slow = Pump Ready
Blink Fast = Pump Failed

RESET/ Off = OK
SILENCE Blink Slow = Reset Required
Blink Fast = A/V Alarm output

is active

LED Description

HELP Off = OK
Blink Slow = Event (press HELP

from the status
screens to view)

Blink Fast = Alarm (press HELP

from the status
screens to view)

Table 2: LED Functionality

2.3 I/O

2.3.1 Analog Inputs

The Technologic

is equipped with 4 analog input channels. The analog
inputs must provide a 4-20mA signal. Typically, ana­log inputs will be powered by the 24V power supply
within the panel. For analog inputs which source
their own power, see the following section. See sec­tion 4.1 for more information on sensor setup.

Shielded 22 AWG cable should be installed for all

analog input wiring. The shield must be terminated
in the Technologic
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 can be used in place of
shielded cable. The cable length must be limited to
5,000 feet for #22 AWG wire.

®

Constant Speed Pump Controller

®

Constant Speed Pump Controller.

Operator Interface Panel

1) Turn off all power to the Technologic
Speed Pump 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 AI1 – AI4.

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. This will prevent any
accidental contact with a negative (-) voltage
source (i.e. control panel) and avoid becoming a
short circuit. Care should be taken to ensure that
24 VDC positive (+) voltage is still provided to
any remaining sensors that will be powered by the
Technologic

®

Constant Speed Pump 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. This will prevent any
accidental contact with a positive (+) voltage
source and avoid becoming 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®
Constant Speed Pump Controller.

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! The wires
that were removed in the preceding steps may have
been used as jumpers.

2.3.3 RTD Inputs

®

The Technologic

Constant Speed Pump Controller
is equipped with (2) PT100 RTD input channels. (2)
RTDs will be shipped with standard units. The sys­tem RTD will be factory mounted, on the suction
header, unless the control panel is sold separate from
the pump package. The suction RTD will be shipped
loose inside the control panel and will need to be
field mounted upstream of the suction header.

®

Constant

2.3.2 Powered Analog Inputs

The following steps describe the general procedure

for wiring an analog input when the sensor’s power
source is not the Technologic

®

Constant Speed Pump

Controller.

2.3.4 Digital Inputs

The Technologic

is equipped with (16) 24VDC digital input channels.
This signal voltage must be obtained from the 24VDC
power supply mounted to the subpanel. It is not rec-

®

Constant Speed Pump Controller

ommended that other power sources be used without

WARNING: Prevent electrical shocks.

Disconnect the power supply before begin-

ning installation. FAILURE TO FOLLOW

factory approval. All digital inputs are automatically
assigned based on Table 3. See the typical wiring dia­gram in Appendix H.

THESE INSTRUCTIONS COULD RESULT IN
SERIOUS PERSONAL INJURY, DEATH AND/
OR PROPERTY DAMAGE.

Technologic® Constant Speed Pump Controller Installation, Operation and Maintenance Manual 9

Operator Interface Panel

Functionality DI # Description

1M-6M 1-6 Motor starter feedbacks

Feedback (generate overload alarm)

Start/Stop Sw 7 Remote contact can be

used to start/stop the
system. The start/stop
method must be set to
Remote. See section 4.3.4.
“Rem” will be displayed in
the Tech Status screen
shown in section 3.4.1
when this method is active.

Flow Switch 8 Used for no flow shut-

down, see section 4.5.6.

Pressure Sw 9 Used to detect low suction

pressure alarm or event,
see section 4.5.4.

Low Level 10 Low level relay to sense a

low level condition in a
tank. All pumps will stop
when active.

DP 1-6 11-16 Differential pressure

switches

Table 3: Digital Inputs Functionalities

# 22 AWG cable should be installed for all field wir-

ing to digital inputs.

2.3.5 Relay and Power Monitor Rack

The relay and power monitor rack consists of an

EX270 CAN bus controller, a DO722 digital output
module and an AI984 power measurement module.

2.3.5.1 Digital Output Module

The digital output module consists of 8 normally

open single pole single throw relays rated at 2.5A at
either 240VAC or 24VDC. One relay will be used to
energize the coil of each motor starter. These will be
factory wired. Customer connections are made direct­ly to the terminals mounted on the digital output
module. If a relay is defective, the digital output
module must be replaced. Refer to section 4.3.8 for
relay output setup.

2.3.5.2 Power Measurement Module

The power measurement module calculates total

power by measuring the incoming voltage and the
total current from the current transformer.

2.3.5.3 Current Transformer

The current transformer (ct) comes in three different

sizes measuring up to 40A, 150A, or 400A. It plugs
directly into the AI984 module on the relay and
power monitor rack. The ct measures the total amp
draw of all motors in the system. The four digit hex
numbers displayed on the label on the current trans­former are calibration values, unique to each ct, that
have been input into the controller prior to shipment.
See section 5.5 to view the values used.

Section 3 — Operation

3.1 Power-Up

Turn the disconnect switch “ON” to power up the controller.

WARNING: Electrical shock hazard.

Inspect all electrical 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 INSTRUC-

TIONS COULD RESULT IN SERIOUS
PERSONAL INJURY, DEATH AND/OR
PROPERTY DAMAGE.

In order to recover from a power loss, the controller

will start up in the operating mode that it was in
prior to the last shutdown. On power up, the con­troller will display the Tech Status screen shown in
section 3.4.1.

Technologic® Constant Speed Pump Controller Installation, Operation and Maintenance Manual 10

3.2 Basics of Screen Navigation and User
Setup

Numeric inputs (represented by the # symbol) must

be input from the numeric keypad. Text fields (repre­sented by the $ symbol) must be modified by using
the UP and DOWN arrow keys. For numeric or text
fields, ENTER must be pressed to confirm values.

The arrow keys are also be used to navigate to neigh-

boring screens. Flashing arrows shown on the display
indicate when the corresponding arrow keys are
active.

An OK prompt is used in most user setup screens.

Press NO (the number 4 key) followed by ENTER at
the OK prompt to edit the parameters shown, or
press YES (the number 1 key) followed by ENTER to
accept the values and exit the screen.

The YES/1 and NO/4 keys are also used for text

inputs for some parameters. They will appear as “Y”
or “N” when a text input is required.

Operation

The CLEAR key is also used to exit some screens

including: Log screens, Test screens, Info screens, and
the Alarm screen.

3.3 Pump Operation

The pumps can be controlled manually or automati-

cally. See the following sections for instructions on
both types of operation.

3.3.1 Manual Pump Operation

To manually control the pumps with the controller,

the operation mode must be set to Manual by press­ing the AUTO/MANUAL key. Note that this key is
not allowed unless the system is stopped. The Auto/
Manual LED will be off to indicate manual opera­tion. The system must also be started by pressing the
START/STOP key. The Start/Stop LED will be on to
indicate the system is started.

Pumps are automatically disabled when operation

mode is changed to manual. Press the corresponding
PUMP ENABLE keys to start or stop pumps. The
corresponding LED will turn solid green to indicate a
pump is on.

3.3.2 Automatic Pump Operation

To automatically control the pumps with the control-

ler, the operation mode must be set to Auto by press­ing the AUTO/MANUAL key. Note that this key is
not allowed unless the system is stopped. The Auto/
Manual LED will be on to indicate automatic opera­tion. The system must also be started by pressing the
START/STOP key. The Start/Stop LED will be on to
indicate the system is started.

During automatic pump operation, the pumps will

turn on or off based on the primary staging method.
If more pumps are required to meet the system
demand, they will stage on as required. When the
system demand is met, and the minimum pump run
timer is met, the pumps will destage until only one
pump is running. When there is no demand in the
system, the no flow shutdown alarm or event will
occur, shutting down the last running pump. During
this sequence, alarms may occur that shut down a
specific pump or all of the pumps. Various automatic
pump alternation methods may be used to alternate
the pump sequence at any time.

View the status screens, shown in section 3.4, to get

system information including on/off or auto/manual
status, pump status, sensor values, or staging status.

3.4 Status Screens

The status screens are the main level in screen naviga-

tion and show most of the relevant system informa­tion. The status screens can be scrolled by pressing
PREV or NEXT.

The Setup Menu(3), Log Menu(5), Info screens(8),

Ma n ua l Al t er na ti on scr ee n( 9) , and Ala r m
screen(HELP) are only accessible from the status
screens.

All of the status screens will display “Alm”, “Evt”, or

“NFSD” in the lower right corner if an alarm or
event or NFSD condition exists. If this message is
flashing, press the HELP key for more details.

3.4.1 Tech Status

The Tech Status screen, shown below, is the first of

the status screens. This screen is displayed on power
up. See Table 4 below for a description of the Tech
Status variables.

 ← TECH STATUS →
HH:MMam MM/DD/YY
Stop :(Method)
Manual Alm

Variable Description

Start/Stop/ Stop: System is stopped. Pumps

Ready will not start.

Start: System is started. The

pumps can be controlled manually
or automatically.

Ready: System is waiting for

remote start/stop method,
see section 4.3.4.

Press the START/STOP button

to toggle.

Method System Start/Stop Method, see

section 4.3.4.

Key: Keypad
Rem: Remote contact
Sch: Scheduled start/stop
Ser: Serial Communications

Auto/Manual Manual: System is in manual

operation mode. The user can
manually start and stop the pumps
by pressing the corresponding
Pump On/Off key.

Auto: The system is in automatic

operation mode. The pumps will
be controlled automatically based
on the user setup info.

Press the AUTO/MANUAL key

to toggle.

Table 4: Tech Status Variables

3.4.2 Pump Status

Pressing NEXT, the controller will display the Pump

Status screen shown below. See Table 5 for a descrip­tion of the Pump Status variables.

 ← PUMP STATUS →
1:On 2:On 3:Off
4:Rdy 5:Fail 6:Rdy
Alm

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Operation

Variable Description

P1-P6 On: pump is running
Off: pump is disabled from the

keypad

Rdy: pump is enabled but not

running

Fail: pump is failed

Table 5: Pump Status Variables

3.4.3 Sensor Status

Pressing NEXT, the controller will display the Sensor

Status screen shown below. See Table 6 for a descrip­tion of the Sensor Status variables.

  ←Suc Press= ###→
Sys Press= ###
Suc Temp=###.#
Sys Temp=###.# Alm

Variable Units Description

Suc Press PSI Suction Pressure
Sys Press PSI System (discharge) Pressure
Suc Temp °F Suction Temperature

(mounted upstream of the
suction header)

Sys Temp °F System Temperature

(mounted on the suction
header)

Table 6: Sensor Status Variables

3.4.4 Staging

Pressing NEXT, the controller will display the Staging

screen shown below. See Table 7 for a description of
the Staging variables.

  ←STAGING: (Type)→
Stg Seq:1-2-3-4-5-6
Dstg: #### Stg: ####
Actual: ###.# Alm

Variable Description

Type Type will display the active staging

method.

Stg Seq Pump staging sequence from left

to right. A 0 indicates that a pump
is failed or disabled. See section

4.3.2 for information on alternat­ ing the staging sequence.

Stg Next staging value (N/A indicates

end of staging sequence or no
staging values set up)

Variable Description

Dstg Next destaging value (N/A indi-

cates end of destaging sequence
or no destaging values set up)

Actual Current value of the staging

variable

Table 7: Staging Variables

Note: “Stg” and “Dstg” will be displayed in units of

the active staging method shown in the “Type” field.
To change the staging type or values, see section

4.3.1.

3.4.5 Timers

Pressing NEXT, the controller will display the Timers

screen shown below. The numeric values on the left
are elapsed times, and the numeric values on the right
are the limits that they must reach prior to perform­ing their respective action. See Table 8 for a descrip­tion of the Staging variables.

  ←Pump MnRn:##/##m→
NFSD MnRn:###/###m
Stg PT:##/##
Dstg PT:##/## Alm

Variable Units Description

Pump Min Minutes Pump minimum run time,

Run see section 4.3.1.3. When the
timer reaches its limit pumps
will be allowed to destage.

NFSD Minutes No flow shutdown minimum

MnRn run time, see section 4.5.6.
When the timer reaches its
limit, a no flow shutdown
will be allowed to occur. Note
that the timer immediately
resets to zero after expiring.

Stg PT Seconds Staging proof timer, see

section 4.3.1.1. When the
timer reaches its limit,
another pump will stage on.

Dstg PT Seconds Destaging proof timer, see

section 4.3.1.1. When the
timer reaches its limit, a
pump will stage off.

Table 8: Timers Variables

3.4.6 Power

Pressing NEXT, the controller will display the Power

screen shown below.

  ← POWER→
HP= ###.# PF= #.##
Volts= ###.#
Amps = ###.# Alm

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Operation

Variable Units Description

HP Horse- Total power measured by

power the power module

Volts Volts Average voltage measured by

the power module

Amps Amps Total current measured by the

power module

PF N/A Power factor measured by the

power module

Table 9: Power Variables

3.4.7 Optional Sensors

Pressing NEXT, the controller will display the

Optional Sensors screen shown below if any optional
sensors are set up. If they are not, the Optional
Sensors screen will be skipped. See section 4.1 for
information on sensor setup.

  ←OPTIONAL SENSORS→
Temp =### Flow=#####
Diff Temp= ###
Pressure = ### Alm

Variable Units Description

Temp °F Optional temperature
Diff Temp °F Optional differential

temperature
Pressure PSI Optional pressure
Flow GPM Optional flow

Table 10: Optional Sensor Variables

3.5 Alarms/Events

Some conditions can be defined as alarms or events,

while others are predefined to be alarms. See section

4.5 for alarm setup. Alarms are logged in the Alarm
Log and events are logged in the Events Log. See sec­tion 4.7 for logging. An alarm triggers the General
Alarm serial communications point and the A/V
Alarm relay output. An event will not trigger either
of these. See Appendix C for the serial communica­tions points list and section 4.3.8 for relay outputs
setup.

Some alarms or events will cause one or all of the

pumps to shut down. For Low System Pressure, the
user can define if the pumps will shut down or not.

All alarms or events require either a manual or auto-

matic reset. The RESET/SILENCE LED will flash
when a manual reset is required. Press the RESET key
to manually reset the system.

The values in parentheses in Table 11 are the default

values.

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Operation

Description Alarm or Event Pump Shutdown Reset Conditional Upon Help Message

Pump 1-6 DP Alarm Individual Manual Started Check DP switch, im­ Fail peller, coupler, motor

Pump 1-6 Alarm Individual Manual Started Check motor amp
Overload Fail draw and use manual
reset if ok

Low System User Defined User Defined (No) Auto always active, Started and Auto Check PRV setting
Pressure (Event) Manual reset is and trip point
allowed if Stop
Pumps or Alarm is
set to “Y”

High System Alarm Yes Manual Started and Auto Check PRV setting
Pressure and trip point

Low Suction User Defined Yes Manual always Started and Auto Check suction pressure
Pressure (AI) (Event) active, auto reset is and trip point
allowed if “Auto
Reset” is set to “Y”

Low Suction User Defined Yes Manual always Started and Auto Check suction pressure
Pressure (Sw) (Event) active, auto reset is and trip point
allowed if “Auto
Reset” is set to “Y”

High Suction User Defined Yes Auto Started and Auto Check suction pressure
Pressure (Event) and trip point

No Flow Shut User Defined Yes Auto Started and Auto and NFSD is active, check
Down (AI) (Event) only 1 pump on restart pressure

No Flow Shut User Defined Yes Auto Started and Auto and NFSD is active, check
Down (Sw) (Event) only 1 pump on restart pressure

High Alarm Yes Auto Started and Auto Check water temp­ Temperature erature and trip point

Low Level Alarm Yes Auto Started and Auto Check water level in
holding tank

AI 1-4 Fail Alarm No Auto Always active Check wiring, piping,
polarity and continuity

RTD 1-2 Fail Alarm No Auto Always active Check wiring and
continuity

Battery Alarm No Auto Always active Replace OIP battery
CAN Fail Alarm No Auto Always active Set EX270 switches

C (top), 2 (bottom),
check wiring

Volt Tol. Alarm Yes Auto Always active Check voltage reading
and trip point

Voltage Alarm No Auto Always active Check AI984 connec­ tion and voltage inputs

Table 11: Alarms/Events

The LED on the HELP key will flash to indicate that an alarm or event exists. The Status screens will also flash “Alm”,

“Evt”, or “NFSD” in the lower right corner to indicate that an alarm or event exists. Pressing the HELP key, while in the
status screens, will display all of the active alarms or events as shown in the screen below. Blinking arrows will indicate
UP/DOWN can be pressed to view more alarms or events. Press CLEAR to exit this screen, or press HELP again while in
the Alarms screen to view help messages for each alarm.

Pump1 Ovld Press ↑
AI#1 Fail Clear to
Pump2 Fail Exit
Hi Sys Pr ↓

Technologic® Constant Speed Pump Controller Installation, Operation and Maintenance Manual 14