Commander
LI90 Series
Controller
User Manual
Flowline Inc.
10500 Humbolt Street
Los Alamitos, CA 90720
Tel: (562) 598-3015
Fax: (562) 431-8507
www.flowline.com
27 AUG 08 PRELIMINARY MANUAL 1 of 57
Rev 1_3 Commander LI90 Series
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Commander LI90 Series Rev 1_3
Preface
This manual explains how to use the Commander LI90 series controller.
Warranty, Service & Repair
To register your product with the manufacturer, go to the Flowline website for on-line
registration. The website address is as follows:
www.flowline.com
On-line Warranty Registration can be found under Contact Us in the Navigation Bar along the
side of the home page.
If for some reason your product must be returned for factory service, go to the Flowline website
to receive a Material Return Authorization number (MRA), providing the following information:
1. Part Number, Serial Number
2. Name and telephone number of someone who can answer technical questions related
to the product and its application.
3. Return Shipping Address
4. Brief Description of the Symptom
5. Brief Description of the Application
On-line Material Return Authorization can be found under Contact Us in the Navigation Bar
along the side of the home page. Click on Return Authorization to begin the MRA request. Once
you have received a M RA number, ship the product prepaid in its original packing to:
Flowline Factory Service
MRA_____
10500 Humbolt Street
Los Alamitos, CA 90720
To avoid delays in processing your repair, write the MRA on the shipping label. Please include
the information about the malfunction with your product. This information enables our service
technicians to process your repair order as quickly as possible.
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Rev 1_3 Commander LI90 Series
Warranty
Flowline warrants to the original purchaser of its products that such products will be free from
defects in material and workmanship under normal use and service for a period which is equal to
the shorter of one year from the date of purchase of such products or two years from the date of
manufacture of such products.
This warranty covers only those components of the products which hare non-moving and not
subject to normal wear. Moreover, products which are modified or altered, and electrical cables
which are cut to length during installation are not covered by this warranty.
Flowline’s obligation under this warranty is solely and exclusively limited to the repair or
replacement, at Flowline’s option, of the products (or components thereof) which Flowline’s
examination proves to its satisfaction to be defective. FLOWLINE SHALL HAVE NO
OBLIGATION FOR CONSEQUENTIAL DAMAGES TO PERSONAL OR REAL
PROPERTY, OR FOR INJURY TO ANY PERSON.
This warranty does not apply to products which have been subject to electrical or chemical
damage due to improper use, accident, negligence, abuse or misuse. Abuse shall be assumed
when indicated by electrical damage to relays, reed switches or other components. The warranty
does not apply to products which are damaged during shipment back to Flowline’s factory or
designated service center or are returned without the original casing on the products. Moreover,
this warranty becomes immediately null and void if anyone other than service personnel
authorized by Flowline attempts to repair the defective products.
Products which are thought to be defective must be shipped prepaid and insured to Flowline’s
factory or a designated service center (the identity and address of which will be provided upon
request) within 30 days of the discovery of the defect. Such defective products must be
accompanied by proof of the date of purchase.
Flowline further reserves the right to unilaterally waive this warranty and to dispose of any
product returned to Flowline where:
a. There is evidence of a potentially hazardous material present with product.
b. The product has remained unclaimed at Flowline for longer than 30 days after dutifully
requesting disposition of the product.
THERE ARE NO WARRANTIES WHICH EXTEND BEYONDTHE DESCRIPTION ON THE
FACE OF THIS WARRANTY. This warranty and the obligations and liabilities of Flowline
under it are exclusive and instead of, and the original purchaser hereby waives, all other
remedies, warranties, guarantees or liabilities, express or implied. EXCLUDED FROM THIS
WARRANTY IS THE IMPLIED WARRANTY OF FITNESS OF THE PRODUCTS FOR A
PARTICULAR PURPOSE OR USE AND THE IMPLIED WARRANTY OF
MERCHANTABILITY OF THE PRODUCTS.
This warranty may not be extended, altered or varied except by a written instrument signed by a
duly-authorized officer of Flowline, Inc.
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Table of Contents
Safety Warnings and Guidelines ..........................................................................................6
Introduction ..........................................................................................................................7
Installation............................................................................................................................9
Panel Mounting ........................................................................................................9
DIN Rail Mounting ................................................................................................10
Dimensions ........................................................................................................................11
Electrical ............................................................................................................................12
Wiring ................................................................................................................................13
Configuration .....................................................................................................................14
Specifications .....................................................................................................................15
Startup ................................................................................................................................16
Common Information.........................................................................................................19
Analog (Scaled Input) ............................................................................................19
Analog (Fixed Input)..............................................................................................20
Application #1 ....................................................................................................................21
Overview ................................................................................................................21
General (Open Functions) ......................................................................................22
General (Secured Functions) ..................................................................................24
Configuration of Inputs ..............................................................................25
Configuration of Outputs ...........................................................................27
Application #2 ....................................................................................................................29
Overview ................................................................................................................29
General (Open Functions) ......................................................................................30
General (Secured Functions) ..................................................................................32
Configuration of Inputs ..............................................................................33
Configuration of Outputs ...........................................................................35
Application #3 ....................................................................................................................38
Overview ................................................................................................................38
General (Open Functions) ......................................................................................39
General (Secured Functions) ..................................................................................40
Configuration of Inputs ..............................................................................41
Volume ...........................................................................................43
Configuration of Outputs ...........................................................................46
Appendix ............................................................................................................................51
Simulation mode ....................................................................................................51
Factory Reset .........................................................................................................53
Changing Applications...........................................................................................54
Removable Media for Data Transfer .....................................................................55
Micro SD Cards .........................................................................................55
Micro SD File System ................................................................................55
Using Removable Media to Log Data .......................................................56
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Rev 1_3 Commander LI90 Series
Safety Warnings and Guidelines
When found on the product, the following symbols specify:
Warning: Consult user documentation. Warning: Electrical Shock Hazard.
WARNING: To avoid the risk of electric shock or burns, always connect the safety (or
earth) ground before making any other connections.
WARNING: To reduce the risk of fire, electrical shock, or physical injury it is strongly
recommended to fuse the voltage measurement inputs. Be sure to locate fuses as close to
the source as possible.
WARNING: Replace fuse with the same type and rating to provide protection against risk
of fire and shock hazards.
WARNING: In the event of repeated failure, do not replace the fuse again as a repeated
failure indicates a defective condition that will not clear by replacing the fuse.
WARNING: Only qualified electrical personnel familiar with the construction and
operation of this equipment and the hazards involved should install, adjust, operate, or
service this equipment. Read and understand this manual and other applicable manuals in
their entirety before proceeding. Failure to observe this precaution could result in severe
bodily injury or loss of life.
• All applicable codes and standards need to be followed in the installation of this product.
• For I/O wiring (discrete), use the following wire type or equivalent: Belden 9918, 18
AWG or larger.
Adhere to the following safety precautions whenever any type of connection is made to the
module.
• Connect the green safety (earth) ground first before making any other connections.
• When connecting to electric circuits or pulse-initiating equipment, open their related
breakers. Do not
• Make connections to the module first; then connect to the circuit to be monitored.
• Route power wires in a safe manner in accordance with good practice and local codes.
• Wear proper personal protective equipment including safety glasses and insulated gloves
when making connections to power circuits.
• Ensure hands, shoes, and floors are dry before making any connection to a power line.
• Make sure the unit is turned OFF before making connection to terminals. Make sure all
circuits are de-energized before making connections.
• Before each use, inspect all cables for breaks or cracks in the insulation. Replace
immediately if defective.
make connections to live power lines.
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Introduction
The Commander Series has three unique application configurations. The choice of application is
field selectable. The three configurations are:
• Multi-Tank Display (Application #1) – Commander will accept up to Four 4-20 mA input
transmitters and will provide a 3A SPST relay output for each input.
• Differential Level Controller (Application #2) – Commander will monitor the levels
above and below a rake and control a relay based upon the defined differential between
the two levels. In addition, a differential alarm can be programmed as well as individual
alarms for each input.
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Rev 1_3 Commander LI90 Series
• Pump Controller (Application #3) – Commander will accept a single 4-20 mA input
transmitter and will provide up to Six 3A SPST relay outputs.
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Installation
• Overview
o The mechanical installation greatly affects the operation, safety and appearance of the
system. Information is provided to mechanically install the unit such as cut out sizes,
mounting procedures and other recommendations for the proper mechanical
installation of the unit.
• Components
o Commander Series display
o Terminal Strips
Power (3-pin black)
Inputs (15-pin Orange)
Outputs (15-Pin Black)
Optional Interface (5-pin Orange)
o Mounting Clips (set of four)
Quick Start Guide
• Mounting requirements
o Commander series can be mounted through a panel or on a DIN rail.
• Panel Mounting
o Once the panel design has been completed using the criteria and suggestions in the
following sections, use the following steps to panel mount the LI90 series.
Remove all connectors from the unit.
Press the DIN rail clip up to make passing the unit through the cutout easier.
Make sure the gasket is installed on the LI90 series and is free from dust and
debris. Check that the corners of the gasket are secure.
Pass the unit through the panel.
Insert the each of the four (4) mounting clips into the slots in the
Commander’s case. One clip should be installed on each corner. Lightly
tighten each screw so the clip is held in place.
Tighten the screws on the clips such that the gasket is compressed against the
panel.
o For panel mount, use the standard cutout for a ¼ DIN [3.622” (92 mm) x 3.622” (92
mm)]. Use the four mounting clips to secure the display to the panel. A mounting
clip will attach to all four sides of the display.
Not to Scale
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Rev 1_3 Commander LI90 Series
• DIN Rail Mounting
o The LI90 series is designed to clip onto standard 35 millimeter DIN rail. If your
installation requires liquid or dust protection, make sure the controller is placed in an
appropriate sealed panel when mounting on DIN rail. Use the following steps to
mount on DIN rail.
Move the DIN rail clip to the lower position.
Clip the “Top Clips” on the top of the DIN rail.
Press the unit into place and press the DIN rail clip up. A small flat-head
screwdriver can be used in the slot of the DIN rail clip if clearance is an issue.
o Note: The DIN rail connection does not
o For DIN rail, use a 35 mm DIN Rail.
Move the DIN rail clip to the lower position.
Clip the “Top Clips” on the top of the DIN rail.
Press the unit into place and press the DIN rail clip up. A small flat-head
screwdriver can be used in the slot of the DIN rail clip if clearance is an issue.
provide an earth ground.
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• Dimensions
Front View Side View
• Temperature / Ventilation
o Ensure that the panel layout design allows for adequate ventilation and maintains the
specified ambient temperature range. Consider the impact on the design of the panel
layout if operating at the extreme ends of the ambient temperature range. For
example, if it is determined that a cooling device is required, allow adequate space
and clearances for the device in the panel box or on the panel door.
• Orientation
o When panel-mounted, there are no orientation restrictions on the LI90 series.
• Noise
o Consider the impact on the panel layout design and clearance requirements if noise
suppression devices are needed. Be sure to maintain an adequate distance between
the controller and noisy devices such as relays, motor starters, etc.
• Shock and Vibration
o The LI90 series has been designed to operate in typical industrial environments that
may inflict some shock and vibration on the unit. For applications that may inflict
excessive shock and vibration please use proper dampening techniques or relocate the
Commander to a location that minimizes shock and/or vibration.
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Rev 1_3 Commander LI90 Series
Electrical
• Grounding Definition
o Ground: The term Ground is defined as a conductive connection between a
circuit or piece of equipment and the earth. Grounds are fundamentally used to
protect an application from harmful interference causing either physical damage
such as by lightning or voltage transients or from circuit disruption often caused
by radio frequency interference (RFI).
• Ground Specifications
o Ideally, a ground resistance measurement from equipment to earth ground is 0 ohms.
In reality it typically is higher. The U.S. National Electrical Code (NEC) states the
resistance to ground shall not exceed 25 ohms. Flowline recommends less than 15
ohms resistance from our equipment to ground. Resistance greater than 25 ohms can
cause undesirable or harmful interference to the device.
• How to Test for Good Ground
o In order to test ground resistance, a Ground Resistance Tester must be used. A
typical Ground Resistance Meter Kit contains a meter, two or three wire leads,
and two ground rods. Instructions are supplied for either a two-point or threepoint ground test. Below shows a two-point ground connection test.
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• Wiring
o Power
o Inputs
• Connect to Earth Ground. Apply 10 - 30 VDC.
• Commander can connect up to four 4-20 mA inputs.
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Rev 1_3 Commander LI90 Series
o Outputs
• Commander can connect up to 6 relays, depending on the application
selection.
• Relays can switch voltages up to 275 VAC, 30 VDC with a maximum
output current of 3 A at 250 VAC, resistive.
Configuration
• Commander Series is configured via the Human Machine Interface (HMI) located on the
front cover of the controller
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Specifications
Display
Keypad Touch screen
Controller
General Specs
Analog Inputs
Relay Outputs
Graphics/Text: Yes / Yes
Pixels: 128 x 64
Display Technology: Backlit LCD
Total Keys: 20
Function Keys: 10
Memory: 256 KB
Logic Scan Rate: 1.2 mS/K
Memory Card Slot: Up to 1 GB
Height: 3.7” (95.1 mm)
Width: 3.7” (95.1 mm)
Depth: 2.5” (63.9 mm)
Weight: 12.5 oz (0.354 kg)
Environmental: 0 to 50 °C
Wash down: NEMA 4X
Max. panel thickness: 5 mm
Cut-out: 3.622” (92 mm) x 3.622” (92 mm)
Required Power
Steady State: 130 mA @ 24 VDC
Inrush: 30 A for 1 ms @ 24 VDC
Primary Power Range: 10 – 30 VDC
Relative Humidity: 5 to 95% Non-condensing
Clock Accuracy: +/- One Minute/Month at 20C
Operating Temp.: 0°C to +50°C
Terminal Type: Screw Type, 5 mm Removable
Certifications: CE UL
Number of Channels: 4
Input Ranges: 4 – 20 mA
Max. Over-Current: 35 mA
Outputs per Module: 6 relay
Commons per Module: 6
Max. Output Current: 3 A at 250 VAC, resistive
Max. Output Voltage: 275 VAC, 30 VDC
Max. Switched Power: 1250 VA, 150 W
Expected Life
No load: 5,000,000
Rated load: 100,000
Max. Switching Rate: 300 CPM at no load / 20 CPM at rated load
Type: Mechanical Contact
Response Time: One update per ladder scan plus 10 ms
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Rev 1_3 Commander LI90 Series
Startup
• When the Commander is powered for the first time, the LI90 series will allow the end
user to select the application to be used. Follow the instructions on the screen to choose
the application.
o Application #1 / Multi-Tank Display (Press F2) – Commander will accept up to
Four 4-20 mA input transmitters and will provide a 3A SPST relay output for each
input.
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o Application #2 / Differential Level Controller (Press F3) – Commander will
monitor the levels above and below a rake and control a relay based upon the defined
differential between the two levels. In addition, a differential alarm can be
programmed as well as individual alarms for each input.
o Application #3 / Pump Controller (Press F4) – Commander will accept a single
4-20 mA input transmitter and will provide up to Six 3A SPST relay outputs.
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Rev 1_3 Commander LI90 Series
• If you need to change the application selection, press and hold the ESC button for 5
seconds. This will return you to the Selection Screen and allow for a new application to
be selected.
o The selection can be accessed at any time.
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Common Information – There are several configuration aspects that are similar for all three
applications in the LI90 series.
• Analog Input
o The Commander accepts any 4-20 mA signal.
o The Commander has the ability to accept a 4-20 mA that has been scaled to the
size of the tank / vessel or with a 4-20 mA that is from a non-configured
transmitter (in its original factory setup).
o There are six parameters required to configure an analog input in the LI90 series.
o For a scaled output. Use this description when using a transmitter that has been
configured with 4 mA set to an empty tank/vessel and 20 mA set to a full
tank/vessel.
• Sensor Max. Range – This is the distance from the bottom of the tank to
the bottom of the installed sensor.
• Sensor Dead Band – This is the distance from the full level of liquid to
the bottom of the sensor.
• Sensor Height – This is the distance from the bottom of the tank to the
bottom of the installed sensor. This will be the same setting as the Sensor
Max. Range.
• Sensor Fill_H – This is the distance from the bottom of the tank to the
highest level of liquid. Adding the Fill_H value to the Dead Band value
will equal the Max. Range or Height values.
• Empty Setting – This is the display value when the tank is empty.
• Full Setting – This is the display value when the tank is full.
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Rev 1_3 Commander LI90 Series
o For a non-scaled output. Use this description when using a transmitter that is
either set with its original Factory Settings or with a transmitter that has a fixed
(non-configurable) 4-20 mA output:
• Sensor Max. Range – This is the maximum range of the sensor. This is
typically the 4 mA set point for the sensor. Use the sensor’s manual to
obtain the sensors maximum range (4 mA output).
• Sensor Dead Band – This is the dead band for the level sensor. Use the
sensor’s manual to obtain the sensors dead band (20 mA output).
• Sensor Height – This is the distance from the bottom of the tank to the
bottom of the installed sensor
• Sensor Fill_H – This is the distance from the bottom of the tank to the
highest level of liquid
• Empty Setting – This is the display value when the tank is empty.
• Full Setting – This is the display value when the tank is full.
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Commander LI90 Series Rev 1_3
Application #1
• Overview
o Multi-Tank Display – The LI90 series in this application is typically used to
eliminate the need of one display for each transmitter. This application can accept
up to Four 4-20 mA input transmitters and will provide a 3A SPST relay output
for each input.
• Power: Operate from 12 to 24 VDC power
• Inputs: Accept up to four 4-20 mA inputs, the inputs will be powered by
12 to 24 VDC power source
• Outputs: Each input channel has a relay assigned (4 relays total)
• Mounting: Commander can be ¼ DIN mounted and DIN rail mountable
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Rev 1_3 Commander LI90 Series
• General (Open Functions)
o Opening Screen indicates the Level of Liquid in the tank/vessel along with the
true analog (4-20 mA) input for channel #1 and the status of Relay #1
• Regardless on how the input level is configured, the bar graph will show
the true 4-20 mA input provided by the sensor
o Pressing the Lower Right Soft key will jump the display to a screen showing the
same information for Channel #2.
o Pressing the lower Right soft key will continue to Channels #3 and #4 and then
the Relay Status Page
• Sequence is as follows:
• Channel 1, Channel 2, Channel 3, Channel 4, Relay Info, Channel
1, …
Channel 1 Channel 2 Channel 3
Channel 4 Hand/Off/Auto (HOA)
o In the Relay Info screen, pressing the upper left soft key will jump the screen to
the HAND / OFF / AUTO (H.O.A.) functions for each relay.
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• The H.O.A. screen for each relay will indicate each relay, the current
status of each relay and soft keys to jump back or to the next relay.
• The first time the LI90 series is powered up, all of the relays will be in the
OFF mode. To activate the relay, you will need to change the relay mode
to AUTO.
• AUTO – This mode places the relay in automatic. Relay will
energize based upon the ON setting and will De-energize based
upon the OFF setting.
• OFF – This mode turns the relay OFF (de-energized). The ON
and OFF settings are ignored in this mode. This mode is helpful in
taking a relay off-line for maintenance.
• HAND – This mode turns the relay ON (energized). This mode is
helpful in overriding a relay function. Relay will be energized
until
o The OFF is selected or
o When the AUTO mode is selected and the level drops
below the OFF setting
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Rev 1_3 Commander LI90 Series
• General (Secured Functions)
o The configuration of the display/input and relays/output are all under the secured
section of the display.
o To access these functions, press and hold the ENTER key for 5 seconds. The
display will jump to the configuration section.
o To leave the Secured Function section, press Exit
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• Configuration of Inputs
o Once in the Secured Function Section, press the Config Inputs soft key
o Press the Next or Back soft keys to scroll to the input you would like to configure.
o Upon selecting an input channel, the controller will ask for the following 6
settings to configure the input. The first four settings must be in the same units
(i.e. inches, cm, feet, m, etc.) typically in units of length. The last two settings
can be in any engineering units as long as they are the same (i.e. inches, cm,
gallons, liters, etc.)
1. Sensor Max. Range 2. Sensor Dead Band 3. Sensor Height
4. Sensor Fill_H 5. Empty Setting 6. Full Setting
1. Sensor Max. Range –This is the distance from the bottom of the tank to
the bottom of the installed sensor with a scaled 4-20 mA output. For a
fixed output, this is the maximum range of the sensor. Use the sensor’s
manual to obtain the sensors maximum range (4 mA output)
2. Sensor Dead Band – This is the distance from the full level of liquid to
the bottom of the sensor with a scaled 4-20 mA output. For a fixed output,
this is the dead band for the level sensor. Use the sensor’s manual to
obtain the sensors dead band (20 mA output).
3. Sensor Height – This is the distance from the bottom of the tank to the
bottom of the installed sensor.
4. Sensor Fill_H – This is the distance from the bottom of the tank to the
highest level of liquid.
5. Empty Setting – This is the display value when the tank is empty.
6. Full Setting – This is the display value when the tank is full.
• Use the Next soft key to advance to the next setting.
• Use the Back soft key to return to the previous setting.
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Rev 1_3 Commander LI90 Series
Scaled 4-20 mA Output Fixed 4-20 mA Output
o To change a value, first press the Enter key
• The value will be highlighted
• Use the 10-digit keypad to enter the desired value
• I.e. for 123.4, press the following keys: <F1>, <F2>, <F3>, <▼>,
<F4>,
• Press Enter when completed to store this value to memory
• Follow the sequence above:
• 1. Press Enter to begin
• 2. Press F1 for number 1
• 3. Press F2 for number 2
• 4. Press F3 for number 3
• 5. Press ▼ for “.”
• 6. Press F4 for number 4
• 7. Press Enter to save setting
• The screen cannot change until a value is stored in memory.
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• Configuration of Outputs
o Once in the Secured Function Section, press the Config Outputs soft key
o Each relay will ask for a Relay ON and Relay OFF level. These settings must be
in the same units used for the Empty and Full settings
Relay ON Relay OFF
• If you are reading between 0 to 500 gallons, then the relay set points must
be in gallons
• For Pumps and Valves, use both settings as the ON/OPEN and
OFF/CLOSE points for the device
• For Alarms, use the ON point where the relay will start and the OFF as a
hysteresis to prevent chattering of the relay
High Alarm Low Alarm Automatic Fill Automatic Empty
o To change a value, first press the Enter key
• The value will be highlighted
• Use the 10-digit keypad to enter the desired value
• I.e. for 123.4, press the following keys: <F1>,
<F2>,<F3>,<.>,<F4>,
• Press Enter when completed to store this value to memory
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Rev 1_3 Commander LI90 Series
• Follow the sequence above:
• 1. Press Enter to begin
• 2. Press F1 for number 1
• 3. Press F2 for number 2
• 4. Press F3 for number 3
• 5. Press ▼ for “.”
• 6. Press F4 for number 4
• 7. Press Enter to save setting
• The screen cannot change until a value is stored in memory.
o Use the Next soft key to advance to the next setting
o Use the Back soft key to return to the previous setting
o When done, press Exit to leave the Secured Function Section
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Application #2
• Overview
o Differential Level Controller – Commander will monitor the levels above and
below a rake and control a relay based upon the defined differential between the
two levels. In addition, a differential alarm can be programmed as well as
individual alarms for each input.
• Power: Operate from 12 to 24 VDC power
• Inputs: Accept up to two 4-20 mA inputs, the inputs will be powered by
12 to 24 VDC power source
• Outputs: Two alarm relays (one for each channel) and two relays that
activate based upon the differential value between the two inputs.
• Mounting: Commander can be ¼ DIN mounted and DIN rail mountable
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Rev 1_3 Commander LI90 Series
• General (Open Functions)
o Opening Screen indicates the Level of Liquid in the tank/vessel along with the
true analog (4-20 mA) input for both input channel#1 and #2
• Regardless on how the input level is configured, the bar graph will show
the true 4-20 mA input provided by the sensor
o Pressing the Lower Right Soft Key will jump the display to show the following:
• Channel 1 and 2, Channel 1 only, Channel 2 only, Relay Info…
Channel 1 & 2 Channel 1 only
Channel 2 only Relay info
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o In the Relay Info screen, pressing the upper right soft key will jump the screen to
the HAND / OFF / AUTO (H.O.A.) functions for each relay.
• The H.O.A. screen for each relay will indicate each relay, the current
status of each relay and soft keys to jump back or to the next relay
• AUTO – This mode places the relay in automatic. Relay will
energize based upon the ON setting and will De-energize based
upon the OFF setting.
• OFF – This mode turns the relay OFF (de-energized). The ON
and OFF settings are ignored in this mode. This mode is helpful in
taking a relay off-line for maintenance.
• HAND – This mode turns the relay ON (energized). This mode is
helpful in overriding a relay function. Relay will be energized
until
o The OFF is selected or
o When the AUTO mode is selected and the level drops
below the OFF setting
o Pressing the lower right soft key (Next) will return the controller to the opening
screen
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Rev 1_3 Commander LI90 Series
• General (Secured Functions)
o The configuration of the display/inputs and relays/outputs are all under the
secured section of the display
o To access these functions, press and hold the ENTER key for 5 seconds. The
display will jump to the configuration section.
o To leave the Secured Function section, press Exit
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• Configuration of Inputs
o Once in the Secured Function Section, press the Config Inputs soft key
o Press the Next or back soft keys to scroll to the input you would like to configure.
o Upon selecting an input channel, the controller will ask for the following 6
settings to configure the input. The first four settings must be in the same units
(i.e. inches, cm, feet, m, etc.) typically in units of length. The last two settings
can be in any engineering units as long as they are the same (i.e. inches, cm,
gallons, liters, etc.)
1. Sensor Max. Range 2. Sensor Dead Band 3. Sensor Height
4. Sensor Fill_H 5. Empty Setting 6. Full Setting
1. Sensor Max. Range –This is the distance from the bottom of the tank to
the bottom of the installed sensor with a scaled 4-20 mA output. For a
fixed output, this is the maximum range of the sensor. Use the sensor’s
manual to obtain the sensors maximum range (4 mA output)
2. Sensor Dead Band – This is the distance from the full level of liquid to
the bottom of the sensor with a scaled 4-20 mA output. For a fixed output,
this is the dead band for the level sensor. Use the sensor’s manual to
obtain the sensors dead band (20 mA output).
3. Sensor Height – This is the distance from the bottom of the tank to the
bottom of the installed sensor.
4. Sensor Fill_H – This is the distance from the bottom of the tank to the
highest level of liquid.
5. Empty Setting – This is the display value when the tank is empty.
6. Full Setting – This is the display value when the tank is full.
• Use the Next soft key to advance to the next setting.
• Use the Back soft key to return to the previous setting.
27 AUG 08 PRELIMINARY MANUAL 33 of 57
Rev 1_3 Commander LI90 Series
Scaled 4-20 mA Output Fixed 4-20 mA Output
o To change a value, first press the Enter key
• The value will be highlighted
• Use the 10-digit keypad to enter the desired value
• I.e. for 123.4, press the following keys: <F1>, <F2>, <F3>, <. >,
<F4>,
• Press Enter when completed to store this value to memory
• Follow the sequence above:
• 1. Press Enter to begin
• 2. Press F1 for number 1
• 3. Press F2 for number 2
• 4. Press F3 for number 3
• 5. Press ▼ for “.”
• 6. Press F4 for number 4
• 7. Press Enter to save setting
• The screen cannot change until a value is stored in memory.
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• Configuration of Outputs
o Once in the Secured Function Section, press the Config Outputs soft key
• Relays #1 and #2 will ask for a Relay ON and Relay OFF level. These
settings must be in the same units used for the Empty and Full settings
Relay ON Relay OFF
• If you are reading between 0 to 500 gallons, then the relay set points
must be in gallons
• For Pumps and Valves, use both settings as the ON/OPEN and
OFF/CLOSE points for the device
• For Alarms, use the ON point where the relay will start and the OFF as
a hysteresis to prevent chattering of the relay
High Alarm Low Alarm Automatic Fill Automatic Empty
27 AUG 08 PRELIMINARY MANUAL 35 of 57
Rev 1_3 Commander LI90 Series
• To change a value, first press the Enter key
• The value will be highlighted
• Use the 10-digit keypad to enter the desired value
o I.e. for 123.4, press the following keys: <F1>, <F2>, <F3>,
<.>, <F4>,
• Press Enter when completed to store this value to memory
• Follow the sequence above:
• 1. Press Enter to begin
• 2. Press F1 for number 1
• 3. Press F2 for number 2
• 4. Press F3 for number 3
• 5. Press ▼ for “.”
• 6. Press F4 for number 4
• 7. Press Enter to save setting
• The screen cannot change until a value is stored in memory.
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• Relays #3 and #4 will ask for a Differential ON and Differential OFF level.
These settings must be in the same units used for the Empty and Full settings.
Differential ON Differential OFF
• This allows the end use to select a differential level between the two
analog inputs
• Channel #1 must be the upstream level and Channel #2 the
downstream level
• Typically, Relay #3 is used for the main differential control and Relay
#4 is for an alarm differential
• Use the Next soft key to advance to the next setting
• Use the Back soft key to return to the previous setting
• When done, press Exit to leave the Secured Function Section
27 AUG 08 PRELIMINARY MANUAL 37 of 57
Rev 1_3 Commander LI90 Series
Application #3
• Overview
o Pump Controller – The LI90 series in this application is typically used to provide
multiple relay contacts for a single 4-20 mA input. Relays 5 and 6 can be combined
to be programmed as duplexing / alternating relays.
• Power: Operates from 12 to 24 VDC power
• Inputs: Accepts a single 4-20 mA input, the input will be powered by 12
to 24 VDC power source
• Outputs: 6 relays are available to program as alarms, pumps or valves
• Enclosure: Front panel must be NEMA 4X rated
• Mounting: Panel must be ¼ DIN mounted and DIN rail mountable
• Volumetric: Display can indicate level in either Gallons or Liters for
vertical and horizontal tanks
• Simulation mode: Use this mode to simulate the level of liquid and test
relay operation without changing the true liquid level
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• General (Open Functions)
o Opening Screen indicates the Level of Liquid in the tank/vessel along with the
true analog (4-20 mA) input
• Regardless on how the input level is configured, the bar graph will show
the true 4-20 mA input provided by the sensor
o Pressing the Lower Left Soft key will jump the display to indicate the relay status.
Above the relay status will be the liquid level.
• Pressing the lower left soft key will return the display back to the opening
screen
• Pressing the upper left soft key will jump the screen to the HAND / OFF /
AUTO (H.O.A.) functions for each relay.
o The H.O.A. screen for each relay will indicate each relay, the current status of
each relay and soft keys to jump back or to the next relay
• AUTO – This mode places the relay in automatic. Relay will energize
based upon the ON setting and will De-energize based upon the OFF
setting.
• OFF – This mode turns the relay OFF (de-energized). The ON and OFF
settings are ignored in this mode. This mode is helpful in taking a relay
off-line for maintenance.
• HAND – This mode turns the relay ON (energized). This mode is helpful
in overriding a relay function. Relay will be energized until
• The OFF is selected or
• When the AUTO mode is selected and the level drops below the
OFF setting
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Rev 1_3 Commander LI90 Series
• General (Secured Functions)
o The configuration of the display, relays and simulations are all under the secured
section of the display
o To access these functions, press and hold the ENTER key for 5 seconds. The
display will jump to the configuration section.
o To leave the Secured Function section, press Exit
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• Configuration of Inputs
o Once in the Secured Function Section, press the Config Inputs soft key
o Next, select if the application will show a Scaled Input or a Volumetric Input
• Scaled Input – Allows for the current inputs to display in any engineering
units the linear scale from the current
• Volumetric Input – Calculates the total volume (gallons or liters) for both
vertical or horizontal tanks
• Scaled Inputs
o The controller will ask for the following 6 settings to configure the input. The
first four settings must be in the same units (i.e. inches, cm, feet, m, etc.) typically
in units of length. The last two settings can be in any engineering units as long as
they are the same (i.e. inches, cm, gallons, liters, etc.)
1. Sensor Max. Range 2. Sensor Dead Band 3. Sensor Height
4. Sensor Fill_H 5. Empty Setting 6. Full Setting
• Sensor Max. Range – This is the maximum range of the sensor located on
top of the tank.
• Sensor Dead Band – This is the dead band for the level sensor
• Sensor Height – This is the distance from the bottom of the tank to the
bottom of the sensor
• Sensor Fill_H – This is the distance from the bottom of the tank to the
highest level of liquid
27 AUG 08 PRELIMINARY MANUAL 41 of 57
Rev 1_3 Commander LI90 Series
• Empty Setting – This is the display value when the tank is empty
• Full Setting – This is the display value when the tank is full
• Use the Next soft key to advance to the next setting
• Use the Back soft key to return to the previous setting
Scaled 4-20 mA Output Fixed 4-20 mA Output
o To change a value, first press the Enter key
• The value will be highlighted
• Use the 10-digit keypad to enter the desired value
• I.e. for 123.4, press the following keys: <F1>, <F2>, <F3>, <. >,
<F4>,
• Press Enter when completed to store this value to memory.
• Follow the sequence above:
• 1. Press Enter to begin
• 2. Press F1 for number 1
• 3. Press F2 for number 2
• 4. Press F3 for number 3
• 5. Press ▼ for “.”
• 6. Press F4 for number 4
• 7. Press Enter to save setting
• The screen cannot change until a value is stored in memory.
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• Volumetric Inputs
o The controller will ask basic shape and dimensional information in order to
display either the gallons or liters within the tank or vessel.
o Select between either Vertical Tanks or Horizontal Tanks.
• Dimensional information must be entered as either inches or cm.
• Dimensional inches must show gallons and cm must show liters.
• Transmitter must be configured such that tank empty is 4 mA and tank full
is 20 mA.
Vertical Tanks Horizontal Tanks
o Choose between Gallons or Liters for the display output.
• When choosing Gallons, make sure all dimensional information entered is
in inches.
• When choosing Liters, make sure all dimensional information entered is in
cm.
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Rev 1_3 Commander LI90 Series
o Vertical Tanks – Select among Rectangular, Round Bottom or Cone Bottom.
Rectangular Round Bottom Cone Bottom
1. Sensor Height 2. Tank Height
3. Tank Width/Diameter 4. Tank Length/Cone
• Sensor Height – This is the distance from the bottom of the tank to the
bottom of the sensor
• Tank Height – This is a dimension for either the Height of the Tank or
the Height of the Straight Side of the cone bottom tank.
• Tank Width / Diameter – This is either the width of the tank or the
diameter of the tank
• Tank Length / Cone – This is either the length of the tank or the Height
of the Cone. You do not need to configure this setting for the Round
Bottom tank.
• Use the Next soft key to advance to the next setting
• Use the Back soft key to return to the previous setting
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Commander LI90 Series Rev 1_3
o Horizontal Tanks – Select among Flat Ends or Round Ends.
Length
Diameter
Flat Ends Round Ends
1. Sensor Height 2. Tank Length
3. Tank Diameter 4. End Cap Length
• Sensor Height – This is the distance from the bottom of the tank to the
bottom of the sensor
• Tank Length – This is a length of the tank.
• Tank Diameter – This is diameter of the tank.
• End Cap Length – This is the distance for one of the end caps. You do
not need to configure this setting for the Flat End Tank.
• Use the Next soft key to advance to the next setting
• Use the Back soft key to return to the previous setting
27 AUG 08 PRELIMINARY MANUAL 45 of 57
Rev 1_3 Commander LI90 Series
• Configuration of Outputs
o Once in the Secured Function Section, press the Config Outputs soft key
o Each relay will ask for a Relay ON and Relay OFF level. These settings must be
in the same units used for the Empty and Full settings
Relay ON Relay OFF
• If you are reading between 0 to 500 gallons, then the relay set points must
be in gallons
• For Pumps and Valves, use both settings as the ON/OPEN and
OFF/CLOSE points for the device
• For Alarms, use the ON point where the relay will start and the OFF as a
hysteresis to prevent chattering of the relay
High Alarm Low Alarm Automatic Fill Automatic Empty
46 of 57 PRELIMINARY MANUAL 27 AUG 08
Commander LI90 Series Rev 1_3
o To change a value, first press the Enter key
• The value will be highlighted
• Use the 10-digit keypad to enter the desired value
• I.e. for 123.4, press the following keys: <F1>, <F2>, <F3>, <. >,
<F4>,
• Press Enter when completed to store this value to memory
• Follow the sequence above:
• 1. Press Enter to begin
• 2. Press F1 for number 1
• 3. Press F2 for number 2
• 4. Press F3 for number 3
• 5. Press ▼ for “.”
• 6. Press F4 for number 4
• 7. Press Enter to save setting
• The screen cannot change until a value is stored in memory.
o Use the Next soft key to advance to the next setting
o Use the Back soft key to return to the previous setting
o Option – Relays 5 and 6 can be used as a Duplex / Alternation function
o Select Config. Relay #5 and #6 to configure relays #5 and #6. This setting will
always configure both relays #5 and #6.
27 AUG 08 PRELIMINARY MANUAL 47 of 57
Rev 1_3 Commander LI90 Series
o Select either an Independent Relay #5 and #6 or Duplexing Relays #5 and #6.
Independent
Relay #5 & #6
o Independent Relays – Relays #5 and #6 perform the same as relays #1 through
#4. The two relays are not linked together.
o Duplex Relays – Relays #5 and #6 are linked together with two unique start
levels and a common off position. The relays will also alternate between each
LEAD start. If the level ever reaches the LAG start, the remaining relay will
activate.
o Alternating Relays – Relays #5 and #6 will switch back and forth each time the
ON level is reached. This is used to maintain a common use/life cycle for
equipment.
o Relay settings must be in the same units used for the Empty and Full settings
1. Relay #5 ON or LEAD ON 2. Relay #5 OFF or ALL OFF
Duplex
Relay #5 & #6
Alternate
Relay #5 and #6
3. Relay #6 ON or LAG ON 4. Relay #6 OFF
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Commander LI90 Series Rev 1_3
•
•
• To use as Independent Relay mode, press the IND soft key and then press
Next.
Independent Relays #5 and #6
Enter the Relay #5 ON set point (where Relay
#5will energize) and press Next
• Enter the Relay #5 OFF set point (where
Relay #5 will de-energize) and press Next
• Enter the Relay #6 ON set point (where Relay
#6 will energize) and press Next.
• Enter the Relay #6 OFF set point (where
Relay #6 will de-energize) and press Next.
• To change to a Duplex mode, press the DUP soft key and then press Next.
Duplex Relays #5 and #6
Enter the LEAD ON relay set point (where
the lead relay will energize) and press Next
• Enter the ALL OFF relay set point (where
both relays will de-energize) and press Next
• Enter the LAG ON relay set point (where the
lag relay will energize) and press Next.
o You do not need to provide a value for
Relay #6 OFF.
o Duplex can be used as a Filling or
Emptying configuration.
o Always make sure that the LAG ON is
above the LEAD ON for an Empty
configuration or below the LEAD ON for
a Fill configuration.
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Rev 1_3 Commander LI90 Series
• To change to an Alternation mode, press the DUP soft key and then press
•
Next.
Alternate Relays #5 and #6
Enter the LEAD ON relay set point (where
relay #5 will energize) and press Next
• Enter the ALL OFF relay set point (where
both relays will de-energize) and press Next
• Enter the LAG ON relay set point (where
relay #6 will energize) and press Next.
o You do not need to provide a value for
Relay #6 OFF.
• To return Relays 5 and 6 back to an independent mode, press the IND soft
key
o When done, press Exit to leave the Secured Function Section
o Alternate can be used as a Filling or
Emptying configuration.
o Always make sure that the LAG ON is
the same as the LEAD ON. This will
enable Relays 5 and #6 to alternate
each time a relay is to become
energized.
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Appendix
Simulation Mode
This mode enables the end user to simulate changes in level without having the level of liquid
move. The display will simulate level of liquid and will turn the relays ON and OFF according
to how they were configured. For example, if Relay 1 is set as a Pump Empty with an ON
setting for 100.0 inches and an OFF setting of 30.0 inches, then when the display goes above
100.0, Relay 1 will energize and when the level falls below 30.0, Relay 1 will de-energize. This
function can be used to test the wiring and to verify if the configuration is set accordingly.
Please note: Simulation mode will energize and de-energize all configured relays. Any devices
wired to the relays will become active during simulation mode. To turn off individual relays,
Select OFF in the H.O.A. section before entering the Simulation mode.
• Simulation Mode I sunder the secured section of the display
o To access this function, press and hold the ENTER key for 5 seconds. The
display will jump to the configuration section.
o Once in the Secured Function Section, press the Simulation Mode soft key
27 AUG 08 PRELIMINARY MANUAL 51 of 57
Rev 1_3 Commander LI90 Series
o Next, press the Begin Simulation soft key to proceed or the Back soft key to
return
o Next press the YES soft key to begin the Simulation
o Simulation mode will begin after a short count down
o Once in Simulation mode, use the two soft keys on the left to increase and
decrease the level per your requirements
o Check all active relays to verify operation
o To exit from Simulation mode, press the Exit soft key in the lower right corner of
the screen
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Commander LI90 Series Rev 1_3
Factory Reset
• At anytime, the Commander Series can be reset to its original factory settings. To do so
perform the following:
o Press and hold the F10 button for 10 seconds
o Release the F10 button when the Factory Reset? Screen appears.
o To reset, press the soft key for Yes and press F10 to enter
o The LI90 series will be reset to its original setting
o Pressing Enter with NO active will return the display back to it current setting and
nothing will be reset.
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Rev 1_3 Commander LI90 Series
Changing Applications
• If you need to change the application selection, press and hold the ESC button for 5
seconds. This will return you to the Selection Screen and allow for a new application to
be selected.
o The selection can be accessed at any time.
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Commander LI90 Series Rev 1_3
Removable Media for Data Transfer
Overview
• All Commander models provide a Removable Media slot, labeled Memory, which
supports standard Micro SD Flash memory cards. Micro SD cards can be used to save
and load applications, to capture graphics screens and to log data for later retrieval.
Micro SD Cards
• When the Micro SD card format was introduced, it was originally called TransFlash.
Cards labeled either Micro SD or TransFlash, with up to 2.0 GB of Flash memory, are
compatible with the Commander’s Memory slot.
• The Memory slot is equipped with a “push-in, push-out” connector and a Micro SD
card can be safely inserted into the Memory slot whether the power is On or Off.
o To install a Micro SD card: Align its 8-pin gold edge connector down,
facing the front of the unit as shown below; then carefully push it all the
way into the Memory slot. Ensure that it clicks into place.
o To remove the Micro SD card: Push down on the top of the card gently to
release the spring. The card pops up for removal.
Installing Removable Memory Card
Micro SD File System
• The Micro SD Memory slot uses the PC-compatible FAT16 File System. This means
that a PC, with a Micro SD-compatible card reader, can read files that have been written
by the Commander and can write files that can be read by the Commander.
• However, the Commander does not
8.3 filename format. This means that all file and directory names must consist of up to 8
characters, followed by an optional dot, and an optional extension with up to 3
characters.
• Directories and sub-directories can be nested up to 16 levels deep as long as each
pathname string does not exceed 147 characters.
support long filenames, but instead implements the
27 AUG 08 PRELIMINARY MANUAL 55 of 57
Rev 1_3 Commander LI90 Series
Using Removable Media to Log Data
• The Commander has the feature of logging data to a Micro SD card in the form of
comma-delimited files, with a .CSV extension. These files are compatible with
standard database and spreadsheet PC programs.
• To activate the data log in the commander, press and hold the Left Arrow (shown above)
for 10 seconds. When Data Log Activated appears, release the button. The unit will log
the four analog inputs at rate of once per 15 seconds.
• When completed, follow the previous instructions for removing the Micro SD card.
• The data in the card will appear in five folders. Folder A_Inputs contains the raw and
scaled data for the four analog inputs (see chart below).
Data Folder
Raw analog input
(referenced between
0 to 32,000 units)
Scaled input
(referenced between
Empty and Full settings)
Channel 1 Channel 2 Channel 3 Channel 4
A_Inputs A_Inputs A_Inputs A_Inputs
%AI0001 %AI0002 %AI0003 %AI0004
%R0107 %R0207 %R0307 %R0407
• Folders AI1_Set, AI2_Set, AI3_Set and AI4_Set contain the configuration information
for the analog inputs (see below).
Data Folder
Sensor Max. Range
Sensor Dead Band
Sensor Height
Sensor Fill_H
Empty Setting
Full Setting
Channel 1 Channel 2 Channel 3 Channel 4
AI1_Set AI2_Set AI3_Set AI4_Set
%R0123 %R0223 %R0323 %R0423
%R0125 %R0225 %R0325 %R0425
%R0133 %R0233 %R0333 %R0433
%R0135 %R0235 %R0335 %R0435
%R0103 %R0203 %R0303 %R0403
%R0105 %R0205 %R0305 %R0405
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Commander LI90 Series Rev 1_3
Troubleshooting
PROBLEM SOLUTION
No power to the
transmitters
No power from the relay
contacts
Relays stays OFF all the
time
The Analog Inputs are not internally powered. Power for
transmitters must be provided from an alternative source.
Typically, it is the same power supply that is providing
power to the LI90-1001.
All of the relays are dry contact relays. Power for the
device the relays are switching must come from an
alternative source.
Make sure that the Hand, OFF Auto for the relay is set
for Auto. The OFF setting will keep the relay OFF until
this setting has been changed.
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Rev 1_3 Commander LI90 Series
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