Ultimate Pump
Controller
Instruction Manual
2
PULSAR MEASUREMENT
3
ULTIMATE CONTROLLER (THIRD EDITION REV 2)
February 2022
Part Number M-1U0-8-003-2P
COPYRIGHT
© Pulsar Measurement, 2001 -22. All rights reserved. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval
system, or translated into any language in any form without the written permission of Pulsar Measurement.
WARRANTY AND LIABILITY
Pulsar Measurement guarantee for a period of 2 years from the date of delivery that it will either exchange or repair any part of this product
returned to Pulsar Measurement if it is found to be defective in material or workmanship, subject to the defect not being due to unfair wear and
tear, misuse, modification or alteration, accident, misapplication, or negligence.
DISCLAIMER
Pulsar Measurement neither gives nor implies any process guarantee for this product and shall have no liability in respect of any loss, injury or
damage whatsoever arising out of the application or use of any product or circuit described herein.
Every effort has been made to ensure accuracy of this documentation, but Pulsar Measurement cannot be held liable for any errors.
Pulsar Measurement operates a policy of constant development and improvement and reserves the right to amend technical details, as necessary.
CONTACT
For technical support, please contact:
Europe: supporteurope@pulsarmeasurement.com
Outside Europe: supportnorthamerica@pulsarmeasurement.com
If you have any comments or suggestions about this product, please contact:
Europe: europe@pulsarmeasurement.com
Outside Europe: northamerica@pulsarmeasurement.com
Pulsar Measurement website:
www.pulsarmeasurement.com
United States Canada UK
11451 Belcher Road South 16456 Sixsmith Drive Cardinal Building,
Largo, FL 3373 Long Sault, Ont, K0C 1P0 Enigma Business Centre
888-473-9546 855-300-9151 Sandy’s Road, Malvern WR14 1JJ
00 44 (0)1684 891371
ULTIMATE CONTROLLER INSTRUCTION MANUAL
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CONTENTS
Contents ....................................................................................................................................... 4
Chapter 1: Start Here… ........................................................................................................... 7
1.1 About this Manual ........................................................................................................ 7
1.2 About the Ultimate Controller ................................................................................. 7
1.3 Product Specification .................................................................................................. 8
1.4 Declaration of Conformity ...................................................................................... 10
Chapter 2 Installation ........................................................................................................... 11
2.1 Power Supply Requirements ................................................................................. 11
2.2 Location ......................................................................................................................... 11
2.3 Safety Symbols ............................................................................................................ 11
2.4 Dimensions ................................................................................................................... 13
2.5 Terminal Connection Details ................................................................................. 16
2.6 Fuse Location ............................................................................................................... 19
2.7 Preparation for Operation ...................................................................................... 20
2.8 Maintenance ................................................................................................................ 20
2.9 RS485 Connectivity ................................................................................................... 21
Chapter 3 How to Use Your Ultimate Pump Controller ......................................... 23
3.1 Run Mode ..................................................................................................................... 23
3.2 Program Mode ............................................................................................................ 37
3.3 Parameter Defaults .................................................................................................... 41
Chapter 4 Set Up Menu ....................................................................................................... 42
4.1 Main Menu ................................................................................................................... 42
4.2 Application Setup ...................................................................................................... 42
mA Inputs ............................................................................................................................. 45
Operation ............................................................................................................................. 46
Example Setup: ................................................................................................................... 47
4.3 Relays .............................................................................................................................. 49
4.4 Pump Advanced ......................................................................................................... 72
Run Time ............................................................................................................................... 75
Auto Reset ............................................................................................................................ 76
Pumped Volume ................................................................................................................ 77
Efficiency ............................................................................................................................... 80
Storm Detect ....................................................................................................................... 81
Override ................................................................................................................................ 82
Odour Reduction ............................................................................................................... 82
Wall Cling ............................................................................................................................. 83
Septicity Prevention ......................................................................................................... 83
Block & Burst ...................................................................................................................... 84
Peak Tariff............................................................................................................................. 85
Pump Reversing ................................................................................................................. 87
Over Spill .............................................................................................................................. 90
Backup ................................................................................................................................... 92
VSD Controls ....................................................................................................................... 93
4.5 Digital Inputs ............................................................................................................... 95
Common Settings ............................................................................................................. 95
General .................................................................................................................................. 97
Function ................................................................................................................................ 97
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Pump ...................................................................................................................................... 98
Backup ................................................................................................................................... 99
Maintenance ..................................................................................................................... 100
4.6 Sensors ......................................................................................................................... 101
Flow Pulse .......................................................................................................................... 101
Speedy ................................................................................................................................. 105
MicroFlow ........................................................................................................................... 108
4.7 Volume ......................................................................................................................... 111
Setup .................................................................................................................................... 111
Vessel Shape ..................................................................................................................... 112
Breakpoints ........................................................................................................................ 116
4.8 OCM App. (Open Channel Measurement Application) ............................ 118
OCM Setup ........................................................................................................................ 118
Setup .................................................................................................................................... 119
Exponent ............................................................................................................................. 119
BS3680 Flume ................................................................................................................... 122
BS3680 Weir ...................................................................................................................... 124
Area Velocity ..................................................................................................................... 126
Special.................................................................................................................................. 128
Universal ............................................................................................................................. 130
Area Velocity Universal ................................................................................................. 132
Totaliser ............................................................................................................................... 135
OCM Totaliser Logs ........................................................................................................ 137
Breakpoints ........................................................................................................................ 137
Totalisers ............................................................................................................................. 138
4.9 Display .......................................................................................................................... 141
Main Display ...................................................................................................................... 141
AUX Display ....................................................................................................................... 142
Failsafe ................................................................................................................................. 143
Secondary Auxiliary ........................................................................................................ 144
4.10 mA Outputs ............................................................................................................. 145
4.11 Compensate ............................................................................................................ 148
4.12 Stability ...................................................................................................................... 150
Rate ....................................................................................................................................... 150
Damping ............................................................................................................................. 151
4.13 Echo Process ............................................................................................................ 152
4.14 Remote Alarms ....................................................................................................... 153
Remote Alarms ................................................................................................................. 153
4.15 Logical Output ........................................................................................................ 154
4.16 Simulation ................................................................................................................ 157
Chapter 5 Advanced Configuration .............................................................................. 159
5.1 Modules ....................................................................................................................... 159
5.2 Live List......................................................................................................................... 161
5.3 Log Setup .................................................................................................................... 162
5.4 Communications ...................................................................................................... 165
5.5 Networking ................................................................................................................. 173
5.6 CCTV camera ............................................................................................................. 174
ULTIMATE CONTROLLER INSTRUCTION MANUAL
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5.7 User accounts ............................................................................................................ 176
5.8 General settings ........................................................................................................ 178
5.9 Maintenance .............................................................................................................. 181
Chapter 6 System ................................................................................................................. 182
6.1 Hardware Test ........................................................................................................... 182
6.2 Soft Default ................................................................................................................ 183
6.3 Setup Profiles............................................................................................................. 184
6.4 Hardware ..................................................................................................................... 187
6.5 Firmware Upgrade ................................................................................................... 189
6.6 Hard Default ............................................................................................................... 189
6.7 Backup Profile............................................................................................................ 190
6.8 Software ....................................................................................................................... 190
Chapter 7 Asset Management ........................................................................................ 191
7.1 Overall Station Data ................................................................................................ 191
7.2 Logged Performance Data ................................................................................... 192
7.3 Pump Predictive Maintenance ............................................................................ 196
7.4 Pumps Info ................................................................................................................. 197
7.5 Alarms Info ................................................................................................................. 198
7.6 Controls Info .............................................................................................................. 198
7.7 Misc. Info ..................................................................................................................... 198
Chapter 8 Ultimate Webserver ....................................................................................... 199
8.1 Webserver key ........................................................................................................... 200
8.2 Traces Webpage ....................................................................................................... 201
8.3 Parameters Webpage ............................................................................................. 202
8.4 Camera Webpage .................................................................................................... 213
8.5 Events Webpage....................................................................................................... 213
8.6 Trending Webpage ................................................................................................. 214
8.7 System Info Webpage ............................................................................................ 215
8.7 Assets Webpage ....................................................................................................... 216
Chapter 9 Troubleshooting .............................................................................................. 222
To read a parameter ...................................................................................................... 222
Transducer voltage check ............................................................................................ 222
Appendix A – Dynamic Parameter Memory Map ................................................... 223
Appendix B – Ultimate Static Parameter .................................................................... 237
Appendix C – Ultimate Profibus Module Definitions ............................................ 251
Appendix D - Disposal ....................................................................................................... 262
Instructions on returning products to Pulsar ....................................................... 262
Instructions for disposal ............................................................................................... 262
Notes ........................................................................................................................................ 263
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CHAPTER 1: START HERE…
Congratulations on your purchase of a Pulsar Ultimate Pump Controller. This quality system has been developed
over many years and represents the latest in high technology ultrasonic level measurement and control.
It has been designed to give you years of trouble-free performance, and a few minutes spent reading this operating
manual will ensure that your installation is as simple as possible.
Disclaimer: Pulsar accepts no responsibility for any loss or damage caused by miss-application of the information
contained in this document.
1.1 About this Manual
It is important that this manual is referred to for correct installation and operation.
There are various parts of the manual that offer additional help or information as shown:
Tips
TIP : Look for this i c o n t h r o ughout your Puls a r M e a s u r e m e n t manua l to f ind helpful inf o r m a t i o n a n d
answers to freq u e n t l y a s ke d questions .
Additional Information
References
See Also
References to other parts of the manual.
1.2 About the Ultimate Controller
Ultimate Controller integrates intelligent pump control, Remote Telemetry (RTU), and level and flow measurement
within one economically sized unit.
Ultimate is the next generation of controller, providing you features never seen before, such as predictive
maintenance, pump economy, duty selection and pump station overall efficiency index, as well as sophisticated,
advanced routines to cater to your every need. Building on Pulsar’s renowned user-friendly operation, Ultimate
Controller now provides an even easier menu-driven set-up operated through a colour touch-screen HMI.
Ultimate Controller has been designed to be modular and expandable offering you a customised solution. A range
of options are available such as an infra-red camera allowing remote monitoring of process and assets, pump power
monitoring including pump reversing and other peripherals that provide I/O.
Complete control, monitoring and management – Ultimate Controller.
Additional Information
At various parts of the manual, you will find sections
like this that explain specific things in more detail.
ULTIMATE CONTROLLER INSTRUCTION MANUAL
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1.3 Product Specification
PHYSICAL
Wall Mount
Outside Dimensions
225 x 262 x 105 mm (8.85 x 10.3 x 4.13”)
Weight
Nominal 2kg (4.4 lb)
Enclosure Material/Description
Polycarbonate flame resistant to UL94-V0
Cable entry detail
11 off: 9 x M20 and 2 x M16 underside
Fascia Mount
Outside dimensions
124 x 224 x 114mm (4.88 x 8.8 x 4.48”)
Weight
1.5kg (3.3 lb)
Enclosure material/description
Stainless steel with Polycarbonate UL94 –V0 front and bezel
Transducer Cable Extensions
2-core screened
Maximum Separation
1000m (3,280 ft), 500m (1,640 ft) for mmWave
ENVIRONMENTAL
IP Rating
Fascia: IP64 (front panel) Wall: IP65 Pollution
degree 2 IK06 @ -20oC
Altitude
2000m maximum
Max. & min. temperature
(electronics)
-30 ºC to +50 ºC (-22oF to 122oF) ambient
Flammable atmosphere approval
Safe area: compatible with approved dB transducers (see transducer spec'
sheet)
UL Approval
Report Number: E257330-D1000-1/A0/C0
CE Approval
See EU Declaration of Conformity
PERFORMANCE
Accuracy
0.25% of the measured range or 6 mm (whichever is greater). mmWAVE
± 2mm.
Resolution
0.1% of the measured range or 2 mm (whichever is greater)
Max. Range
Dependant on transducer (maximum 40m dB40)
Min. Range
Dependent upon application and transducer (minimum zero dB Mach3)
Rate Response
Fully adjustable
OUTPUTS
DATEM
DATEM (Digital Adaptive Tracking of Echo Movement)
Analogue Output
2 off Isolated (floating) outputs (to 150V) of 4-20 mA or 0-20 mA into 1K
(user programmable and adjustable) 0.1% resolution
Digital Output
Volt free contacts, number, and
rating
8 form “C” (SPDT) rated at 5A max., total of eight 24A maximum.
Display
5.7-inch colour TFT display with capacitive Touch Screen.
INPUTS
Analogue Input
2 off 4-20mA or 0-20 mA sink or source (user programmable and
adjustable) 0.1% resolution, open circuit voltage (source mode) 24V,
output voltage (source mode) @ 4mA, 22V, @ 20mA, 18V.
Digital Inputs
8 Digital Inputs Min. Input Voltage 5VDC
Max. Input Voltage 30VDC (Max. Current 3mA)
24VDC Input Supply maximum total current 24mA.
PROGRAMMING
On-board programming
By Capacitive Touch Screen
Programming security
Via passcode (user selectable and adjustable)
Programmed data integrity
Via non-volatile memory
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MEMORY
On-board (internal)
4GB non-volatile memory
External
SD card 4GB supplied
CONNECTIVITY
Mini USB (External)
Connecting of laptop/PC, located under flap on side of unit.
USB ‘A’ Socket (Internal)
Connecting of peripherals such as modems.
‘D’ Type 9 pin (Internal)
Connection of optional comms. (Modbus and Profibus), RS232
Camera Port (Internal)
Power and comms. for Pulsar Camera.
Modbus Master 5-way connector
(internal)
Connection of Pulsar peripheral devices
Ethernet
External Modem/Network Connection
SUPPLY
Power supply – Mains AC
85 – 264V AC 47 - 400Hz, 50W maximum input power
Fuses (mains)
2A ‘T’ 20mm fuse
‘Power supply (DC)
22 – 28VDC (internally fused 2A ‘T’)
COMMUNICATIONS
PBUS (Modbus Master)
RS485 Pulsar expansion bus
Modbus (optional)
Modbus RTU, ASCII, TCP/IP
Profibus (optional)
Profibus V1
DNP3 (optional)
DNP3 communications via Ethernet or modem.
RS232 (optional)
Communication via RS232
Pulsar Measurement operates a policy of constant development and improvement and reserve the right to amend
technical details, as necessary.
ULTIMATE CONTROLLER INSTRUCTION MANUAL
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1.4 Declaration of Conformity
PULSAR MEASUREMENT
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CHAPTER 2 INSTALLATION
2.1 Power Supply Requirements
The Ultimate can operate from AC / DC supply or from a DC battery. The AC range is 100–240V AC 50/60Hz. The
DC range is 22-28V.
2.2 Location
The Ultimate Pump Controller must be mounted in a non-hazardous (safe) area, and the transducer can be fitted in
a hazardous area.
TIP : Refer to sen s o r / t r ans du ce r instructions f o r f u l l d e t a i l s
2.3 Safety Symbols
Detailed below are descriptions and meanings of safety/warning symbols that are used on the Ultimate and in this
manual.
SYMBOL
DESCRIPTION
DIRECT CURRENT (DC)
ALETRNATING CURRENT (AC)
PROTECTIVE CONDUCTOR TERMINAL
FUNCTIONAL EARTH
CAUTION/MISE EN GARDE
(Refer to accompanying Documents)
!
Additional Information
All electronic products are susceptible to electronic shock, so follow proper
grounding procedures during installation.
ULTIMATE CONTROLLER INSTRUCTION MANUAL
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When choosing a location to mount the enclosure, bear in mind the following:
• Ensure that the Ultimate is installed in a “Safe”, non-hazardous, area.
• Do not mount with the TFT display exposed to direct sunlight.
• For a clear view of the TFT display it is recommended that you mount it at eye level.
• The mounting surface is vibration-free.
• The ambient temperature is between -30ºC and +50ºC (-22ºF and +122ºF).
• There should be no high voltage cables or inverters close by.
• Avoid mounting adjacent to or above heat sources. Refer to the diagram below for recommended
clearances.
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2.4 Dimensions
Wall Mount
The dimensions of the wall mount fixing holes are as detailed as below:
The Ultimate wall mount should be mounted by drilling three holes suitable for size 8 screws (length to suit
application) and fixing the top screw in place. Hang the Ultimate on this screw and fix the two remaining screws by
removing the terminal cover, on the front of the unit, to gain access to the pre-drilled holes.
ULTIMATE CONTROLLER INSTRUCTION MANUAL
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The full dimensions of the wall mount enclosure are as shown below:
Cable Entry
There are 11 cable gland knockouts on the underside (base) of the Ultimate wall mount, 9 x M20 and 2 x M16. Select which ones
you wish to take out and remove them by using a circular cutter, such as a tank cutter. Care should be taken not to damage the
circuit board inside whilst undertaking this. Do not use a hammer, as this may cause damage to the enclosure.
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Fascia Mount
The Ultimate should be installed by cutting a hole in the panel as detailed below:
The full dimensions of the enclosure are as shown below:
Earth Stud (Size = M5)
Earth Stud
(Size = M5)
ULTIMATE CONTROLLER INSTRUCTION MANUAL
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2.5 Terminal Connection Details
Wall Mount
PULSAR MEASUREMENT
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Fascia Mount
ULTIMATE CONTROLLER INSTRUCTION MANUAL
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Power
The Ultimate can operate from mains AC and automatically from DC or battery backup in the event of power failure
or can be operated permanently from DC or batteries.
Transducers
The transducer should be installed, and connected, in accordance with the installation instructions contained in the
Transducer User Guide.
Wire the transducer to the Ultimate transducer terminals, as follows:
Transducer 1
FASCIA UNIT
TERMINAL CONNECTION DETAILS
Black
0 Volts
White
Signal
Red
Power
Green
Screen
51
52
53
54
Transducer 2
FASCIA UNIT
TERMINAL CONNECTION DETAILS
Black
0 Volts
White
Signal
Red
Power
Green
Screen
55
56
57
58
When using 2-core screened extension cable, the Black and Green wires of the transducer should be connected to
the screen of the extension cable, which in turn should be connected to the appropriate 0-volt terminal of the
Ultimate.
Atex & IECEx
For Ex m (Zone 1) applications the correct transducer must be used (please consult your local Pulsar distributor for
assistance), and must be supplied via a 4000A breaking fuse, which is fitted as standard to the Ultimate.
For Ex ia (Zone 0) applications the correct transducer must be used (please consult your local Pulsar distributor for
assistance), which must be connected to the Ultimate via an external Zener barrier.
FM
For AEx m (Class 1, Zone 1) applications a transducer certified to FM Class I Div. 1 Group A, B, C & D, ClassII Div.
1 Group E, F & G, Class III is used, and must be supplied via a 1500A breaking fuse, which is fitted as standard to
the Ultimate.
Restrictions of use: Do not use in the presence of these groups of Chemicals - Aliphatic Hydro Carbons, Ketones or
Esters
For AEx ia (I.S.) a transducer certified to FM Class I Div. 1 Group A, B, C & D, ClassII Div. 1 Group E, F & G is
used, which must be connected to the Ultimate via an external Zener barrier. See transducer label for certification
details.
Wire/Cable ratings & sizes
Warning for cable temperature rating: Where ambient temperatures are expected to exceed 40°C, ensure that the
wiring is rated for the elevated operating temperature when carrying normal and possible abnormal currents.
WALL UNIT
TERMINAL CONNECTION DETAILS
Black
0 Volts
White
Signal
Red
Power
Green
Screen
67
68
69
70
WALL UNIT
TERMINAL CONNECTION DETAILS
Black
0 Volts
White
Signal
Red
Power
Green
Screen
67
68
69
70
CONNECTOR
RATING
WIRE SIZE, MIN
WIRE SIZE, MAX
Power, AC
240V 4A min.
0.5mm2 / 20AWG
2.5mm2 / 12AWG
Power, DC
30V 5A min.
1mm2 / 18AWG
2.5mm2 / 12AWG
Relays
For max. rated 240V 5A use 1mm2 / 18AWG min.
Depends on load.
2.5mm2 / 12AWG
Transducers
30V 0.2A min. Standard cable is 0.5mm2 /
20AWG.
0.2mm2 / 30AWG
2.5mm2 / 12AWG
PBUS, DC
30V 4A min.
0.5mm2 / 20AWG
2.5mm2 / 12AWG
Camera, DC
30V 1A min.
0.2mm2 / 30AWG
2.5mm2 / 12AWG
Other terminals
Signal & control; low voltage & current.
0.2mm2 / 30AWG
2.5mm2 / 12AWG
PULSAR MEASUREMENT
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Relay Outputs
The eight relays can be programmed for a variety of alarms, pump control, or other process functions. The relay
contacts are all rated at 5A at 240V AC. All connections should be such that the short circuit capacity of the circuits
to which they are connected, is limited by fuses rated so that they do not exceed the relay rating.
Current Outputs
These are isolated (floating) mA outputs (to 150 V), of 4 - 20mA or 0 - 20mA and the load should not exceed 1K.
Current Inputs
The current input is 4 - 20mA or 0 -20mA sink or source, user programmable and adjustable.
Digital Inputs
Where the Ultimate is required to provide power for a Device Input the appropriate Digital Input dip switch should
be in the ON position. (TOTAL maximum current available, for all eight digital inputs, from the 24VDC supply is
24mA). When Device Inputs are self-powered, the appropriate Digital Input dip switch should be in the OFF position.
(Min Input voltage 5VDC, and Maximum Input voltage 30VDC with a maximum current of 3mA).
The Digital Input power switches all contained within a red block of dip identified as ‘(3) Digital Inputs 1 – 8’ and
located as follows:
Wall Mount – to the right-hand side of the connector board above Transducer 1 terminals.
Fascia Mount – to the left-hand side of the connector board above Transducer 2 terminals.
2.6 Fuse Location
Wall Mount
The mains fuse is located within the wiring compartment towards the bottom left hand side of the unit, as illustrated
below.
ULTIMATE CONTROLLER INSTRUCTION MANUAL
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Fascia Mount
The mains fuse is located on the right-hand side just below the earth stud.
2.7 Preparation for Operation
Before switching on, check the following:
• The Ultimate is mounted correctly and is in a ‘safe’ area.
• The power supply is correctly installed.
• The I/O, relays and any peripherals are connected correctly.
• Ensure any controlled equipment, e.g., valves, servos & motors, can operate without danger to people or
property.
2.8 Maintenance
There are no user serviceable parts inside your Ultimate, except the mains fuse. If you experience any problems with
the unit, then please contact Pulsar Process Measurement for advice.
To clean the equipment, wipe with a damp cloth. Do not use any solvents on the enclosure or front panel.
Important Information
The rear metal case of the fascia unit must be connected to earth via the earthing stud located on the rear of
the unit, see drawing on page 11, using wiring to meet local requirements.
For both Wall & Fascia units an external isolation switch or circuit breaker should be installed, in an accessible
location and labelled to identify the equipment, near to the Ultimate to allow the supply to be removed
during installation and maintenance. The isolation switch must be rated according to local regulations and
supply voltage, 100V or 240V AC and > 4A. In addition, the relay contacts should also have a means of
isolating them from the unit.
Interconnecting cables must be adequately insulated in accordance with local regulations. Strip back 30 mm
of the outer insulation of the cable. Strip 5 mm of insulation from the end of each conductor. Twist all
exposed strands of the conductor together. Insert the stripped conductor into the terminal block as far as it
will go and tighten the terminal block screw. Ensure that all strands are firmly clamped in the terminal block
and that there is no excess bare conductor showing, and no stray strands.
Important Information
If the equipment is installed or used in a manner not specified in this manual, then the protection provided by
the equipment may be impaired.
Important Information
The unique DATEM software comes into operation as soon as power is applied and is designed to monitor a
moving level or target with the transducer in a fixed position.
If, after any period of use, it should become necessary to move the transducer, for any reason, from its
original operating position, switch off the Ultimate, before proceeding, to prevent any undesirable updates
to the DATEM trace. If after moving the transducer the reading is not as expected, please refer to Chapter 8
Troubleshooting.
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2.9 RS485 Connectivity
There are several peripheral devices that can be connected to the Ultimate. Connection of these devices to the
Controller and the location of the terminals are shown later in this section.
The following Pulsar products can be connected to the Ultimate Controller:
PBUS Modbus master (RS485 Terminals)
• MicroFlow velocity sensor.
• Power Monitor.
• Pulsar’s I/O Interface module.
• FlowPulse.
• Camera (3 and 2 pin mini terminals)
• Pulsar’s Input expansion unit.
D-Type Connector
• Speedy velocity sensor.
• Connection of optional Modbus or Profibus comms.
The configuration of this connector must be specified at the time of ordering. (The connector shell is floating
ground for Profibus but is local 0V for Speedy).
A diagram of the pin layout for the D-Type connector can be seen below:
ULTIMATE CONTROLLER INSTRUCTION MANUAL
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Wall Mount
The RS485 terminal, Digital Input switches (The ON position uses a pull-up resistor to keep the input high. The
change in state will occur when the input is connected to ground. The OFF position is used when an external DC
voltage is used to change the input state), camera terminal and D-type connection is located on the top right-hand
side of the unit as illustrated below:
Fascia Mount
The RS485 terminal, Digital Input switches, camera terminal and D-type connection is located on the left-hand side
of the unit as illustrated below:
DIGITAL INPUT
SWITCHES
RS485 TERMINALS
CAMERA
TERMINALS
D-TYPE CONNECTOR
D-TYPE CONNECTOR
CAMERA TERMINALS
RS485 TERMINALS
DIGITAL INPUT
SWITCHES
Important Information
For further information on the devices that can connect to the Ultimate Controller. Please refer to the
separate Ultimate Peripherals Manual.
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CHAPTER 3 HOW TO USE YOUR ULTIMATE PUMP CONTROLLER
3.1 Run Mode
This mode is used once the Ultimate has been set up in program mode. It is also the default mode that the unit will
assume on initial power up or when resuming operation after a power failure. During Run Mode the display will
show the value of the principal process variable being monitored along with a bar graph showing the percentage
value of the principal process variable.
When the Ultimate is switched on for the first time, it will display, in metres, the distance from the face of transducer
1 to the target. All relays by default are switched off.
Main Display
The 5.7-inch colour TFT display with capacitive touch screen is used to provide information on the current mode of
operation, and status of alarms, pumps and other programmed features. The display also provides the method for
programming the Ultimate to the desired application, through a structured menu system.
Initial Display
On initial powering up the Ultimate controller you will see a screen like the following display.
Once the Ultimate has been set up for an application, the display can be configured to show additional information
about the application and which features are in use. An example is shown below.
Level / Volume Display
ULTIMATE CONTROLLER INSTRUCTION MANUAL
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When the Ultimate has been setup for a differential application, the display will be configured to show the two levels
like the example shown below:
Differential Level Display
When the Ultimate has been set up for an OCM application, the display can be configured to show the type of PMD
selected, and additional information such as any MicroFlow / Speedy velocity sensors and current velocity
measurements obtained.
OCM Display
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Display Icons and Legends
A description of all icons and legends that can be accessed and viewed whilst in Run Mode are detailed below.
1. Principle Measurement Variable: This variable is also used for determining the display of the bar graph.
2. Application Name: Can be assigned during application set up.
3. Time: Displays the current time.
4. Audible alarm symbol: This is displayed when an alarm relay has been programmed and the enable audio
option is selected to energise when an alarm condition is present. Touching the symbol on the screen will
mute the audible sound emitted by the controller.
5. Auxiliary Display: Besides the principal measurement variable, up to two other measured variables can be
displayed.
6. Enabled Pump Advanced Features: This shows which Pump Advanced features are enabled. When the
features are in operation, the associated indicators will turn green.
7. Main Menu button: Provides access to the program mode to configure the Ultimate controller to the required
application.
8. Event log: Date and time stamped log of the previous 300 I/O events, it will also show any modules that have
been added.
9. Pump status and set point indicators: Shows the status of the pump and duty level set point in relation to
the bar graph for each pump.
10. Pumped Flow indicator: This indicator provides a pumped flow rate figure for the application.
11. Level alarm set point indicator: Displays alarm level set points in relation to the bar graph level.
12. Level Bar Graph: Shows the percentage value of the principal measurement variable.
13. Inflow Indicator: Provides indication of rate of flow into the well.
14. dB transducer diagnostics: Provides access to transducer echo profiles and allows adjustments to be made, if
required. This icon will turn red when there is a failed safe condition.
15. Relay indicators: indicates the state of all programmed relays which are not pumps. For alarms, the indicator
will turn RED in the alarm condition, green if active for control and miscellaneous relay types.
11
10
12
13
14
2 3 4
5
6 7 8
9
1
15
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Differential Display Icons and Legends
A description of all icons and legends that can be accessed and viewed when a differential application is displayed,
whilst in Run Mode are detailed below.
1. Upstream Transducer: Provides access to the Upstream transducer echo profiles, and allows adjustments to
be made, if required. This icon will turn red when there is a failed safe condition.
2. Downstream Transducer: Provides access to the Downstream transducer echo profiles, and allows
adjustments to be made, if required. This icon will turn red when there is a failed safe condition.
3. Application Name: Can be assigned during application set up.
4. Relay indicators: indicates the state of all programmed relays which are not pumps. For alarms, the indicator
will turn RED in the alarm condition, green if active for control and miscellaneous relay types.
5. Principle Measurement Variable: This variable is used for determining the display in difference of the levels
of the application.
6. Time: Displays the current time.
7. Auxiliary Display: Besides the principal measurement variable, up to two other measured variables can be
displayed.
8. Enabled Pump Advanced Features: This shows which Pump Advanced features are enabled. When the
features are in operation, the associated indicators will turn green.
9. Main Menu button: Provides access to the program mode to configure the Ultimate controller to the required
application.
10. Event log: Date and time stamped log of the previous 300 I/O events, it will also show any modules that have
been added.
11. Pump status: Shows the status of the pump and provides access to the duty and level set point in relation to
each pump.
12. Pumped Flow indicator: This indicator provides a pumped flow rate figure for the application.
13. Downstream Level: This displays the current level of the downstream vessel in measurement units.
14. Upstream Level: This displays the current level of the upstream vessel in measurement units.
16. Inflow Indicator: Provides indication of rate of flow into the vessel.
1
2 3 4 5 6
7
8
9
10
11
12
13
14
15
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OCM Display Icons and Legends
A description of all icons and legends that can be accessed and viewed when an OCM application is displayed,
whilst in Run Mode are detailed below:
1. Application Name: Can be assigned during application setup.
2. Principle Measurement Variable: This displays the current flow reading in measurement units.
3. Time: Displays the current time.
4. Auxiliary Display: Besides the principal measurement variable, up to two other measured variables can
be displayed.
5. Main Menu button: Provides access to the program mode to configure the Ultimate controller to the
required application.
6. Event log: Date and time stamped log of the previous 300 I/O events, it will also show any modules that
have been added.
7. Speedy sensor: Displays current velocity of a speedy sensor if allocated to the OCM application.
8. Velocity Sensor (mA input): Displays current velocity of a velocity sensor via mA Input, if allocated to the
OCM application.
9. PMD: Selected OCM display source’s PMD is displayed.
10. Level Display: Displays the current level of the PMD in measurement units, as measured by the
transducer.
11. Movement of Flow: Arrow shows the direction of flow/velocity that is being measured by a sensor.
12. Velocity Measurement: This displays the current velocity of all velocity sensors that are allocated with the
OCM application displayed. If multiple sensors are used and ‘Differential’, ‘Average’ or ‘Sum’ is selected,
the value will be shown here.
13. Level Indicator: Shows the percentage value and current level of the PMD, as measured by the transducer.
14. dB transducer diagnostics: Provides access to transducer echo profiles and allows adjustments to be
made, if required. This icon will turn red when there is a failed safe condition.
15. MicroFlow sensor diagnostics: Provides access to MicroFlow trace screen and allows adjustments to be
made, if required.
16. MicroFlow Velocity: Displays current velocity reading of all MicroFlow sensors allocated to the OCM
application displayed.
17. Relay indicators: indicates the state of all programmed relays which are not pumps. For alarms, the
indicator will turn RED in the alarm condition, green if active for control and miscellaneous relay types.
7
8
11
12
14
16
17
1 2 3
4
6 9 10
13
15
5
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Extended information screens
From the main run mode screen, there are several “active” areas on the touch screen that will give more information
about that specific item. Using these screens will not halt any measurements or change any of the application
settings within the controller.
Hot key banner
A - Provides a set of buttons to view totaliser, I/O, and diagnostics information.
HOT KEY
FUNCTION
Show camera image (if camera module connected)
Shows the status of Digital inputs and Relay outputs. Useful for verifying digital
input signals.
For applications including open channel flow measurement, this will show the
System, Resettable, and daily totaliser values.
If the pumped volume feature is enabled, this will show the system, resettable,
and daily totaliser values.
A
B
C
D
F
E
G
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Transducer diagnostic traces
B – This screen will display the echo traces from any active dB transducers. Select between the transducers by using
the dropdown list at the top of the screen. The checkboxes select which traces are shown. Touching an area on the
echo trace graph will show that point as a coordinate of signal strength and distance.
HOT KEY
FUNCTION
Displays distance, level, rate, echo confidence, echo strength, H.A.L.L., average
noise, peak noise and temperature for each dB transducer connected.
Displays individual pump information such as number of starts, total run time,
total volume pumped, and kWh used.
Displays the current mA input and output values.
Displays system information such as serial number, firmware and hardware
revisions.
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Relay information
C - The Relay information screen gives more detail about programmed Alarm, Control, and Miscellaneous relays.
Information includes relay name, setpoints and number of closures and failsafe settings.
A Bar graph of the main measurement variable is given on the right-hand side of the screen.
BUTTON
FUNCTION
Momentarily bypasses damping and updates the measurement to the current
echo trace.
Allows access to echo algorithm adjustment parameters via a service passcode.
Back - Returns to the main run mode screen.
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Trend View
D – The Ultimate will automatically trend all measurements used in an application setup. The sample frequency is
user definable in the Advanced Config. → Log Setup menu.
Use the drop-down list at the top of the screen to select the trend to be viewed. Use the arrow keys to view the
trend history.
A new trend will be started each time the Ultimate is power cycled, and once a trend has reached 10000 samples,
that data is stored as a file to memory, and a new trend is started. Trend files can be transferred to the external SD
card and are of .CSV format.
Flow Pulse diagnostic trace
E – Where Pulsar Flow Pulse flow monitors are being used, an icon of a Flow Pulse will be in this position.
Selecting this will show the diagnostic trace, strength, and confidence figures for the connected Flow Pulse devices.
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Pump Information and manual control
F - This screen gives specific information about the individual pump relay setup. The basic information given is
Pump Name, start and stop levels, and pump duty. A bar graph of the main measurement variable is also given on
the right of the screen.
If Pulsar Power Monitors are connected, the voltage, current, and power factor per phase, and KWh total for the
previous/current pump run are also given.
If a Pulsar Flow Pulse flow monitor has been assigned to a particular pump relay, then the flow rate will also be
displayed.
Manual Pump controls
This screen also provides manual controls for the individual pump relays. The default position is Auto – where the
operation of the relay is managed by the Ultimate controller from the programmed relay setpoints and Advanced
pump features.
Off – overrides the pump relay to the off state. The Pump relay will remain in the off state until it is set to the Auto,
or Run positions. When set to Off, the relative pump icon on the main run screen will turn black and a text
warning will be shown indicating the pump is set to manual Off.
Run – overrides the pump relay to the on state. The Pump relay will remain in the on state until it is set to the Auto,
or off positions. When set to Run, the relative pump icon on the main run screen will turn blue and a text
warning will be shown indicating the pump is set to manual Run.
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Manual trip counter and Pump demotion reset
In addition to the manual controls, if digital inputs are being used to monitor pump failures/trips, or if feature has
been enabled which can demote a pump. Selecting the pump icon for an individual pump will provide pump trip
counter information, and controls to reset the counter/demotion.
Event log
G – Provides a scrollable list to view the 300 most recent system events. Each event is date and time stamped, and
the list is stored in memory which can be transferred to SD card.
Common screens and controls
Throughout the Ultimate controller’s menu system, you will find there are some common buttons and screens for
navigation and parameter entry.
Common control buttons
BUTTON
FUNCTION
Go Back – Return to previous screen
Information – provides more information about the topic currently shown on
the screen
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The menu system in Ultimate Controller has control and selection mechanisms commonly found in modern
computer windowing systems. These include buttons, scroll bars, checkboxes, radio buttons, tree lists, tables, and
dropdown list boxes.
Text entry
Throughout the Ultimate controller, you can assign names of your own choosing to items including input sensors,
measurement points, volume profiles, digital inputs and relay outputs. Doing so can tailor the Ultimate controller
configuration specifically for a process or application, especially if specific measurements or alarms have a named
purpose.
Anywhere you see a line of text within a black box (entry box), that text can be edited.
For example, in the setup menu, the App. Name (the text shown in the banner during run mode) can be changed.
Just touch the text box next to the App. Name label and the common text entry screen will appear.
This is a common screen for editing text labels. The box at the top of the screen shows information about the label
you are editing. The red text is the current name which can be edited using the alphanumeric keyboard and the
clear and default buttons. Press Enter to accept the new text.
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Numeric entry
Where changes in numeric parameter values are permitted, the parameter value will be within an entry box (same as
text entry). Touching the entry box will open the common numeric entry screen. The box at the top of the screen
shows the parameter name, acceptable range of values and default value.
Use the numeric buttons to make the change and press enter to accept the value. Values outside the permitted
range will not be accepted.
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Operational philosophy
The Ultimate controller can take input variables from a variety of sensor types ranging from the Pulsar dB Ultrasonic
transducers to mA input devices. Using the Ultimate controller’s PBUS expansion port, even more sensors and
interfaces can be added. The Ultimate Controller also has several outputs ranging from digital communications
through to relay and mA outputs. These outputs need to take their operation from a single or combination of
measurements provided by the input sensors.
To handle the allocation of input sensors and outputs, the Ultimate utilises a system of measurement points. This
system declares a value from a sensor as a measurement of a particular type (level, flow, power, temperature…).
Each individual measurement point can be specifically named to suit the process it is measuring. Average, sum and
differential measurement points can be declared using a number of sensor variables.
The output devices (relays & mA outputs) can then take their operation from a specific measurement point.
Volume and OCM conversions are declared in their own menus, and take a measurement point as their input
variable.
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3.2 Program Mode
This mode is used to set up the Ultimate or change information already set.
How to Access Program Mode
Touch the button and an authentication window will appear.
Touch the entry box and enter the following
numeric passcode:
1997
This passcode is the default Administrator
passcode.
Main Menu
Once you have entered the passcode you will see the following screen which contains four sub menus, a brief
description of each sub menu can be found below.
Program mode has an adjustable automatic time out of 15 minutes, where the Ultimate will return to run mode if
there is no activity.
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Setup
The setup menu provides sub
menus for controlling the I/O
of the Ultimate Controller.
Advanced Config
Advanced Config. Has
options for adding Devices
on the PBUS port, digital
communications
configuration, Adding user
accounts and general
Date/Time, and power
settings.
System
System provides functions
for testing the hardware and
backing up and restoring
parameter settings.
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Asset Management
Asset management
provides statistical data
of the application
collected during
general operation.
User accounts
The Ultimate Controller uses a user account system where custom usernames and passcodes can be created. Using
accounts provides a method of restricting access to certain users, and the username will be logged in the event log
each time program mode is accessed. User accounts can only be created or deleted when in program mode as the
administrator.
To create a user account from main menu (accessed with passcode 1997)
Press
and complete the new account
registration boxes.
then press
STEP
ICON
FUNCTION
1
Advanced Config.
2
User accounts
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It is prudent at this stage for the administrator to
change the admin passcode to keep the administrator
rights secure.
To change the passcode, simply touch the admin entry
in the Account ID table, and then amend the Passcode
boxes to the required passcode and then press
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3.3 Parameter Defaults
Factory Defaults
To carry out a Factory Default from main menu (accessed with passcode 1997).
A soft default will delete and return, all
user application settings, to their factory
default settings, it is recommended that
a ‘Backup Profile’ be taken before
proceeding in case it is needed to
‘restore’ the controller to its original
settings.
When you first switch the Ultimate on, it will be reading the distance from the face of the transducer to the surface.
It will be indicating in metres, as shown on the display. All relays are set OFF.
The date and time in the Ultimate were set at the factory, but may need checking, and amending if, for example the
application is in a time zone other than GMT, to change see details below.
TIP : Look for this i c o n t h r o ughout your Puls a r M e a s u r e m e n t m a n u al to find helpful in f o r m a t i o n and
answers to freq u e n t l y a s ke d questions.
Once you are satisfied with the installation, and the Ultimate is reading what you would expect in terms of distance
from the face of the transducer to the material level, then you can proceed with programming, for the intended
application. It is sensible to program all the required parameters at the same time. The system will be then set-up.
Note that the span is automatically calculated from the empty level, so the empty level should be entered
first.
STEP
ICON
FUNCTION
1
Advanced Config.
2
Soft Default
Important Information
When first installing the Ultimate, or subsequently moving or using the unit on a new application,
before proceeding to program the unit for its intended application it is recommended that you ensure
that all parameters are at their default values by completing a Factory Defaults, as described below.
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CHAPTER 4 SET UP MENU
This chapter outlines all parameters available in the Ultimate, as they appear in the Set Up menu.
4.1 Main Menu
Enter Program mode and enter the setup menu and the Main Menu will be displayed, this screen contains the
various sub menus which are used to set up the Ultimate controller for the desired application and configuring the
various I/O to the required control functions. Any sub menus that are ‘greyed’ can either only be accessed by an
administrator or the function is not available.
4.2 Application Setup
On the Main Menu screen select
The application menu handles selection, spanning and scaling of dB transducers and mA input devices, and the
creation of measurement points. The application name and global system measurement unit for length are also
entered here.
From this screen you can change the App. Name by selecting the text box and entering the required description.
Measurement units can also be changed to any of those listed in the drop-down menu, as shown above.
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Distance
From the Application Setup Menu select
Ultrasonic Sensor
The distance menu selects the dB transducer type and sets the empty distance, span and blanking distances for the
application. The tree list on the left side of the screen can be used to select between transducer 1 and transducer 2
input on the hardware. If any additional Interface Board (IFB) have been registered on the PBUS, the list will include
any extra dB transducer inputs available.
Location
Displays which Interface Board the selected transducer is located upon and its address on the PBUS.
Name
This defaults as transducer 1 (for TDR1) or transducer 2 (for TDR2) but can be renamed to something more
application specific if required.
Transducer
The drop down box is used to select the transducer being used the options are follows.
OPTION
DESCRIPTION
None
No Transducer.
dB3
Transducer is a dB3. Range 0.125 to 3.00 metres
dB6 (Default)
Transducer is a dB6. Range 0.3 to 6.00 metres
dB10
Transducer is a dB10. Range 0.3 to 10.00 metres
dB15
Transducer is a dB15. Range 0.5 to 15.00 metres
dB25
Transducer is a dB25. Range 0.6 to 25.00 metres
dB40
Transducer is a dB40. Range 1.2 to 40.00 metres
dBS6
Transducer is a dBS6. Range 0.2 to 6.00 metres
dBMach3
Transducer is a dBMach3 Range 0.0 to 2.425 metres.
dBR16
Transducer is a mmWave Radar Range 0.077 to 16.00 metres
dBR8
Transducer is a mmWave. Range 0.077 to 8.00 metres
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Material
The
drop box allows you to select the type of material being measured by the transducer, after
selecting Ultimate will automatically select the best echo algorithm to suit the selection.
Empty
Sets the maximum distance from the face of the transducer to the empty point, (zero level) in Measurement
Units. Note this value affects span as well, (see important information below), so should be set before span.
Near Blank
Near Blanking distance sets, the distance from the face of the transducer that is not measurable. The value
defaults to the minimum allowable according to transducer selection. This parameter can be used to make the
Ultimate “Ignore” echoes from objects near the transducer above the measurement range.
*The signal emanates from the curved face of the Radar, but for the purposes of measurement it is taken from the
drip shield.
Span
This Represents the maximum measurable level in the application. This defaults to the Empty - Near blank. This is
also the default span used if a mA output is allocated to a measurement point using the level of the transducer.
FarBlank
Far Blanking distance sets the range beyond the empty distance (as a percentage of the empty distance) that the
Ultimate will be able to measure. Default 20%
OPTION
DESCRIPTION
Liquid (Default)
No Transducer.
Solids
Solid material that is heaped or at an angle.
Closed Tank
Used where material is contained in a closed tank.
OPTION
DESCRIPTION
dB3
Default Blanking Distance = 0.125m
dB6 (Default)
Default Blanking Distance = 0.3m
dB10
Default Blanking Distance = 0.3m
dB15
Default Blanking Distance = 0.5m
dB25
Default Blanking Distance = 0.6m
dB40
Default Blanking Distance = 1.2m
dBS6
Default Blanking Distance = 0.2m
dBMach3
Default Blanking Distance = 0.0m
dBR16
*Default Blanking Distance = 0.077m
dBR8
*Default Blanking Distance = 0.077m
Important Information
When using the dB Mach 3 the empty distance is measured from the end of the horn to the empty
point in Measurement Units.
Important Information
When changing the Empty Distance, you can also recalculate the values for the Span so that it equals
the empty distance minus Near Blanking. You will be asked the question “Recalculate Span?” if you
choose OK, then the span will be recalculated.
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mA Inputs
From the Application Setup Menu select
mA Sensor
This menu defines the type and range of sensor being used at the mA inputs. There is also a facility for a 5-point
linearization between the mA input value and the process variable it represents.
The tree list selects which input is currently being configured. An identical screen is used to configure input 2. The
graph shows the relationship between the mA input value and the process variable seen by Ultimate.
Location
Displays which Interface Board the selected mA input device is located upon and its address on the PBUS.
Name
This defaults as mA1 In or mA2 In but can be renamed to something more application specific if required.
Sensor
The drop down box is used to select the type of variable the mA input sensor represents, the
options are follows.
OPTION
DESCRIPTION
Level (Default)
4 to 20mA input representative of Level.
Flow
4 to 20mA input representative of Flow.
Temperature
4 to 20mA input representative of Temperature.
Velocity
4 to 20mA input representative of Velocity.
Pressure
4 to 20mA input representative of Pressure.
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Input Range
This table can be edited to
set the relationship between
the mA input value and the
process variable seen by
Ultimate. If a linear
relationship is required, just
the two points are used.
Touch the box to be edited
and enter the required value.
Resets all linearization points
for the mA input device.
Operation
From the Application Setup Menu select
Point Setup
The operation menu takes measurement values from the dB transducers and mA input sensors and assigns them to
a point of measurement. By default, there is one point of measurement pre-allocated as the level measurement
from transducer 1. This measurement point is also used as the main measurement variable for the display and bar
graph in run mode.
Measurement points will be listed by their given names in the tree list on the left-hand side of the screen. Swap
between measurement points by touching a name on the tree list. New points can be added, or existing ones
deleted. Compound measurement points (Average, Differential, and Summation of two sensor inputs) and validated
measurements of multiple sensor inputs can also be created.
Name
Name of measurement point. This can be edited to suit the application. (e.g., Sump level, Pit level, Chemical
Storage, Main Flow etc.)
Mode
Selects the type of measurement that the point will represent. The options will be dynamically modified depending
on input device chosen in the Allocation section.
Operation
Defines whether the measurement point is single or compound (Validated, Average, Sum, Differential). This
information can be displayed in run mode.
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Allocation
Lists the available input sensors by their given names that can provide the chosen Mode. If extra sensors have been
registered on the PBUS port, these will also appear in the allocation list. When a compound measurement point is
being created, the Allocation selection method will turn to checkbox (to select multiple sensors).
Example Setup:
Level Measurement
In this example, the transducer connected to TDR1 input has been named Well Xducer. In the operation menu, the
measurement has been named Well Level and has been allocated to use the Level of Well Xducer.
Distance menu
Operation Menu
Adds a new measurement point to be configured
Deletes currently selected measurement point.
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Validation
For critical measurements, multiple sensors can be used to measure the same process to ensure a reliable
measurement. Ideally, sensors utilising different technologies and measurement principles should be used to
overcome unfavourable process conditions that might affect a single measurement technology.
When a validation measurement point has been selected, there are several methods which define the rules of the
measurement validation. For a sensor measurement to be valid, its measured value must be below the High Limit
and above the Low limit.
Method
Tolerance
This sets the tolerance band applied to each sensor input to define the modular values. If the sensor value with the
tolerance applied of two or more inputs overlaps, the average of the overlapping inputs is used for the
measurement value.
OPTION
DESCRIPTION
Mean: Validate and average all values
(Default)
Uses the average value of all valid sensor inputs
Mode: Validate and average modal
values
Uses the average of valid sensor inputs that have the most sensor
values within tolerance.
Median: Validate and select Median
value
Uses the “middle” value of all valid sensor inputs. If an even
number of inputs are valid, the average of the middle two is used.
Custom: Validate and Average Nearest
two
Uses the average of the two sensor inputs that are closest together
in value.
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4.3 Relays
On the Main Menu screen select
This Relays Menu is used to configure any new relays and to view, edit or delete existing configured relays. To set up
or make any changes to existing relays you must first highlight the relay required. Once the required relay is
highlighted the ‘Clear’ and ‘Configure’ buttons will become available and can be selected for use. To configure a
new relay or edit or view the configuration of an existing relay press the ‘Configure’ button, to delete the settings
of an existing relay press the ‘Clear’ button and follow the on-screen instructions.
Default Relay Screen
Relay Screen with configured relays
Once you have selected the relay you wish to use
and have pressed ‘Configure’ you will see the
screen as detailed on the right. The screen will
confirm the Relay number and the Interface Board
(IFB) on which it is located, in this case R1 on IFB1*.
*IFB1 is the Ultimate’s internal set of digital
input/outputs, analogue input/outputs and dB
transducer inputs.
Type
To proceed with the setup of the relay you must
first choose the relay ‘Type’ from the drop-down
box.
All relays can be configured to any of the ‘Type’
detailed in the following table:
RELAY TYPE
DESCRIPTION
None
Relay is not in use
Pump
Relay is configured to control a Pump, relay will energise to switch the pump On and deenergise to switch the pump OFF.
Alarm
Relay configured to activate an Alarm, relay will de-energise to switch the alarm ON and
energise to switch the alarm OFF. This will ensure an alarm condition is initiated if power to
the Ultimate fails.
Control
Relay configured as a Control relay which will energise On and de-energise OFF.
Misc.
Relay configured as a Miscellaneous relay which will energise On and de-energise OFF.
Logical
Relay configured to activate when there is a change of state with a Logical Output. The relay
will energise ON and de-energise OFF.
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Pump
Having selected ‘Pump’ as the relay ‘Type’ you
will be presented with the screen detailed to the
right.
Name
If required you can enter a name for the pump in
the ‘Name’ field.
Function
Pump Group
Next you need to determine the ‘Pump Group’ you
wish to allocate your pump to, you can have up to a
total of 5 pump groups and all similar duties within
a ‘Pump Group’ will work together.
To select the ‘Pump Group’ you require, select it
from the dropdown box under ‘Function’ and then
press the blue ‘Select Pump Groups’ button which
then open a further screen which allow you to set
up the ‘Pump Duty’ for the selected ‘Pump
Group’.
Pump Duty
Once you have selected the chosen ‘Pump Group’
you will be presented with another screen, as
detailed to the right, which will allow you to select
the ‘Pump Duty’. By default, the selected ‘Pump
Duty’ for all groups is set to ‘Fixed Duty Assist’
(FDA) but this can be changed via the ‘Pump Duty’
drop down box for the group required for any one
of the ‘Pump Duty’ detailed in the table that
follows.
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PUMP DUTY
DESCRIPTION
FDA - Fixed Duty Assist (Default)
All pumps are used to assist each other (run at the same time) and each
pump has its own setpoints which are configured in the setpoints menu
option.
FDB - Fixed Duty Backup
If a pump fails to meet the demand (due to malfunction, intake blockage
etc.), then it is stopped, and another pump shall take over. Each pump has
its own setpoints which is configured in the setpoints menu option.
ADA - Alternate Duty Assist
All pumps are used to assist each other (run at the same time) and each
pump has its own setpoints which is configured in the setpoints menu
option. But each time all pumps have stopped, then the setpoints are
sequentially rotated between the pumps to ensure equal pump use
ADB - Alternate Duty Backup
If a pump fails to meet the demand (due to malfunction, intake blockage
etc.), then it is stopped, and another pump shall take over. Each pump has
its own setpoints, which is configured in the setpoints menu option. But
each time all pumps have stopped, then the setpoints are sequentially
rotated between the pumps to ensure equal pump use
SRDA - Service Ratio Duty Assist
All pumps are used to assist each other (run at the same time) and each
pump has its own setpoints and service ratio setting. The third setpoint
(also configured in the setpoints menu option) is used to set the service
ratio. Each time a pump is required to start then the pump with the least
running hours (with respect to the service ratio) is started (i.e., the setpoints
are re-assigned accordingly). For example, if two pumps A and B have the
service ratio set to 2 and 1 respectively, then pump A will operate for twice
as many hours as pump B
SRDB - Service Ratio Duty Backup
If a pump fails to meet the demand (due to malfunction, intake blockage
etc.), then it is stopped, and another pump shall take over. Each time a
pump is required to start, the pump with the least running hours (with
respect to the service ratio) is started (i.e. the setpoints are re-assigned
accordingly). Each pump has its own setpoints. The third setpoint (also
configured in the setpoints menu option) is used to set the service ratio. For
example, if two pumps A and B have the service ratio set to 2 and 1
respectively, then pump A will operate for twice as many hours as pump B.
FOFO - First On First Off (alternate duty assist
The first pump switched on is the first pump to be switched off, etc.
regardless of the set points, so the setpoints are dynamically changed to
enable this.
TPS - Two Pump Sets
There are four pumps. Two rotate their start-up sequence with each other. If
the two pumps cannot keep up, the level rises to the setpoints of the other
two pumps, which take over and rotate their sequence with each other.
DBA - Duty Backup Assist
First pump comes on, if it cannot cope, it goes off and next pump comes on
(duty backup). This continues until the last pump comes on and if it cannot
cope the first pump comes back on to assist the last pump (duty assist) if
the level continues to rise all other pumps will come on (assist) in turn until
the level decreases to the pump off points. Each pump has its own
setpoints which is configured in the setpoints menu option
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Once you have selected the desired ‘Pump Duty’ you have the choice of further modifying the pump cycle so that
the pump can either be set to run ‘By Time’ or for the most energy efficient pump to be selected to run first ‘Eco
Pump’. Please note that pump relays can only be allocated to one of these additional control routines and not both.
Pump By Time
When the relay is assigned to, ‘By Time’ the pump will come on (energise) at its normal “ON” level setpoint, and deenergise at its ‘OFF’ level setpoint or after a predetermined time period, whichever occurs first.
Economy Pumping
When the relay is assigned to, ‘Eco. Pump’ priority is given to selecting and starting the most energy efficient pump
based on the calculated kWh/m
3
(Power and flow monitoring is required).
Setpoints
Once the required ‘Pump Duty’ has been selected press the ‘OK’ button and you will be returned to the ‘RelayConfigure’ screen.
The next step is to enter the setpoints for the pump, the number of setpoints will depend on the ‘Pump Duty’
chosen and any other additional features selected.
To gain access to the ‘Setpoints’ press the button at which time the ‘Setpoints’ button will change from being
greyed out to being highlighted blue, selecting the highlighted button will take you to the following screen.
Name
This displays the name given to the relay in the
Relay Configure screen.
Details
This confirms to which Pump Group and to what
Pump Duty the relay has been configured too.
Setpoints
There are four possible Setpoints to enter,
depending on the Pump Duty and any other
features selected, as detailed in the table below.
PUMP DUTY
DESCRIPTION
Setpoint 1
Determines the ‘ON’ point for the pump.
When pumping down ‘ON’ setpoint is set ‘higher’ than ‘OFF’ setpoint.
When pumping up ‘ON’ setpoint is set ‘lower’ than ‘OFF’ setpoint. Setpoint
entered in Display Units (Measurement Units) as referenced to Empty Level.
Setpoint 2
Determines the ‘ON’ point for the pump.
When pumping down ‘ON’ setpoint is set ‘higher’ than ‘OFF’ setpoint.
When pumping up ‘ON’ setpoint is set ‘lower’ than ‘OFF’ setpoint. Setpoint
entered in Display Units (Measurement Units) as referenced to Empty Level.
Setpoint 3
Only available if SRDA and SRDB pump types have been selected in Pump
Duty and will determine the service ratio in values of %.
Setpoint entered as a % with reference to Ratio of Usage.
Setpoint 4
Only available when Pump by time selected.
Setpoint is entered in seconds.
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NAME
DESCRIPTION
Standby
Only available when pump duty SRDA or SRDB is and a pump is used on a
standby basis and will only run when it replaces a failed pump. The
setpoints of the standby pump will be automatically forced to a high level
beyond span to ensure that it only starts when replacing the duty cycle of a
failed pump.
Allocation
This allows you to assign the relay to a specific point of measurement as
setup in ‘Application-Operation’
Flow
This associates a flow measurement point with the pump relay and is
required for pump economy calculation.
Flow
This associates a flow measurement point with the pump relay and is
required for pump economy calculation.
Power
This associates a power measurement point with a pump relay and is
required for pump economy and performance calculations.
Minimum Current
This is only available when a power measurement point has is associated
with a pump relay and defines the current threshold (in Amps) for the
“Pump under current” register in the dynamic memory.
Maximum Current
This is only available when a power measurement point has is associated
with a pump relay and defines the current threshold (in Amps) for the
“Pump over current” register in the dynamic memory.
Closures
The Ultimate will record how many times each relay has operated and
display the number of times the relay has activated since the relay has been
in use in this box. It can be reset with any value
Failsafe
The unit has a general fail-safe selection option in ‘Display-Failsafe’.
However, this can be overwritten so that each individual relay has its own
independent fail-safe mode as follows:
• Default - relay assumes the default mode as set in Display-Failsafe.
• Hold – relay will remain in its current state.
• De-energise – relay will de-energise.
• Energise – relay will energise
Max Rate
This will allow the relay to be switched at a pre-determined Rate of change
of Level, irrespective of the “ON” level (setpoint 1). Once a relay has been
switched “ON” by the pre-determined Rate of Change, it will remain
energised until the level reaches the “OFF” level (setpoint 2).
Calibrated throughput
Enter the value of the volumetric throughput for the pump which will be
used as the starting or comparison value for the calibration factor applied
to pump efficiency.
Event SMS
This option when selected will allow a pre-determined message to be sent
to a remote telephone number as set in Remote Alarms, detailing the date,
time, site ID, level, and relay status at the time the message is sent.
VSD Control
This associates the Pump with a PID control loop setup in the Pump
Advanced → VSD Control menu.
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Alarm
Function
Having selected ‘Alarm’ as the relay ‘Type’ you will
be presented with the screen detailed to the left.
Name
If required you can enter a name for the alarm in the
‘Name’ field.
Next you need to determine the ‘Function’ that the
alarm relay will respond to.
To select the ‘Function’ you require, select it from
the dropdown box under ‘Function’.
Full details of the ‘Functions’, and their descriptions,
that are available, when the relay is selected as an
‘Alarm’ relay, are shown in the table below:
FUNCTION
DESCRIPTION
Measurement Point
Alarm is based on the measurement point, and the ID of the measurement
point alarm, two setpoints are required, one for ON and another for OFF.
These setpoints are entered in measurement units as referenced to the
Empty Level.
Rate of Change
Alarm is based on the rate of change of level in the vessel, and the ID of the
rate of change alarm, two setpoints are required, one for ON and another
for OFF. These setpoints are entered in measurement units per minute. A
negative value should be entered for a Rate Alarm on a de-creasing level,
and a positive value for an increasing level.
Temperature
Alarm is based on the temperature, and the ID of the temperature alarm,
two setpoints are required, one for ON and another for OFF. Temperature
used depends on the temperature source. Setpoints entered in ◦C
Flow
Alarm is based on flow, when available, and the ID of the alarm. Both
setpoints must be set and are entered in the display units
Velocity
Alarm is based on velocity, when available, and the ID of the alarm,
setpoints must be set in metres/second
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Alarm ID
Level, Rate, Temperature, Flow or Velocity
When the alarm function Level, Rate of Change,
Temperature, Flow or Velocity is selected an ‘ID’ can
be chosen for the alarm.
To select the ‘ID’ you require, select it from the
dropdown box under ‘ID’.
The table below shows the ID options, and their
descriptions, which are available and to which the
relay will respond to if selected:
FUNCTION
DESCRIPTION
Loss of Echo
Alarm is raised if the Failsafe timer (refer to section ‘8.3 - Failsafe’ on how to
change this value) expires and no setpoints are required
Pump Efficiency
When Pump Efficiency is enabled, Alarm is based on the Efficiency of the
pump which is allocated to the Relay I.D. and setpoints1 & 2 must be set
and are entered in %
Device Fail
Alarm is raised if a device, connected to the relay assigned in Alarm ID fails,
e.g. pump is put out of service. No setpoints are required
Device Alarm
Alarm is raised if a fail signal is detected on the digital input as assigned in
Alarm ID. No setpoints are required
Overflow Alarm
This alarm is used in conjunction with the Pump Advanced > Overspill
feature. And will energise when there is an overflow condition
RMA Alarm
Used in conjunction Pump Advanced > Block & Burst feature. Alarm is
based on the rate of change of level during a pumping cycle, and on the ID
of the alarm. 3 points are set, Alarm setpoint in rate measurement units,
Min Head in level display units where the alarm will not activate below this
level. And Persistence time in seconds.
Mains Fail
Alarm is raised if AC power is lost from the Ultimate controller.
DC Fail
Alarm is raised if DC power is lost from the Ultimate controller.
Service Alarm
This alarm is raised when the Ultimate controller is due for a service, the
default value is 5000 hours. (90 hours in version 2.0)
Pump PMI
Alarm is raised based on the pump PMI and indicates that the pump’s
performance has fallen below the required criteria (see Chapter 7.3 Pump
predictive maintenance)
Station API
Alarm is raised based on the station API and indicates that the station
performance has fallen below the required criteria (see page 181 - Station
API (Assets Performance Index).
Maintenance
Alarm is raised when the maintenance mode Timeout has expired i.e., if the
Ultimate has been left in Maintenance mode.
ALARM ID
DESCRIPTION
General = Default
Relay goes “ON” when the value rises to the ON setpoint and goes “OFF”
when the value lowers to the OFF setpoint
High
Relay goes “ON” when the value rises to the ON setpoint and goes “OFF”
when the value lowers to the OFF setpoint. Setpoints can be set in any
order as the unit ‘knows’ that you are setting a high-level alarm
HiHi
This is the same as High but a different identifier.
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56
LOE, Overflow, Service and Station API
Alarm ID option is not required for alarms set as Loss Of Echo, Overflow Alarm, Service Alarm and Station API
Alarm.
Efficiency or Pump PMI
When the alarm function Pump Efficiency or Pump
PMI is selected then the ‘ID’ selection is used to
assign the alarm to the appropriate pump.
You can choose to set an individual pump or by
choosing Any Pump the alarm is assigned to all
pumps.
To select the ‘ID’ you require, select it from the
dropdown box under ‘ID’.
Device Fail
Device Fail alarm relays are used in conjunction with
Digital Inputs. An alarm is raised when a device
(pump) allocated to the relay assigned in ID fails.
When the alarm function Device Fail is selected then
the ‘ID’ selection is used to assign the alarm to the
appropriate relay.
Or you may select either ‘Any 1 Fail’ which will
energise the relay ‘ON’ if a device failure is detected
on any 1 relay, or ‘Any 2 Fail’ where the relay
energises ‘ON’ when 2 device failures are detected
on any 2 relays.
ALARM ID
DESCRIPTION
Low
Relay goes “ON” when the value lowers to the ON setpoint and goes “OFF”
when the value rises to the OFF setpoint. Setpoints can be set in any order
as the unit ‘knows’ that you are setting a low-level alarm
LoLo
This is the same as Low but a different identifier
Inbounds
Relay goes “ON” if value is inside the zone between the two setpoints.
Setpoints can be set in any order as the unit ‘knows’ that you are setting an
inbounds alarm.
Outbounds
Relay goes “ON” if value is outside the zone between the two setpoints.
Setpoints can be set in any order as the unit ‘knows’ that you are setting an
out of bounds alarm.
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Device Alarm
When the alarm function Device Alarm is selected
then the ‘ID’ defines which digital input the alarm
should respond to.
The DIN number selected will cause the relay to go
on if a fail signal is detected on that digital input.
To select the ‘ID’ you require, select it from the
dropdown box under ‘ID’.
To select the ‘ID’ you require, select it from the
dropdown box under ‘ID’.
RMA
RMA alarms are used in conjunction with the Block
and Burst feature (see page 78 ‘Block & Burst’).
When the alarm function RMA is selected there are
four alarm ‘ID’s that the relay could respond, details
of each, and the number of setpoints required are
listed in the following table:
To select the ‘ID’ you require, select it from the
dropdown box under ‘ID’.
To select the ‘ID’ you require, select it from the
dropdown box under ‘ID’.
ALARM ID
DESCRIPTION
Blockage
Relay goes ‘ON’ when the pumping rate is lower than the Min Rate
setpoint for longer than the Persistence Time provided the level is above
the Min Head and goes ‘OFF’ when the pumping rate rises above Min Rate
setpoint for longer than the Persistence Time.
Burst
Relay goes ‘ON’ when the pumping rate is above the Max Rate setpoint for
longer than the Persistence Time provided the level is above the Min head
and goes ‘OFF’ when the pumping rate lowers below the Max Rate
setpoint for longer than the Persistence Time.
NRV (Non-Return Valve)
This alarm triggers on the detection of flow on idle pumps, and the relay
goes ‘ON’ when a pumping rate above the Max Rate is seen in a FlowPulse
that is allocated to either an individual pump relay or all pumps, for longer
than the Persistence Time, provided the level is above the Min Head and
goes ‘OFF’ when the pumping rate lowers below the Max Rate setpoint for
longer than the Persistence Time.
Storm
Relay goes ‘ON’ when the pumping rate is above the Max Rate setpoint
and the level is above the Storm Level, regardless of the rate, for longer
than the Persistence Time provided the level is above the Min head and
goes ‘OFF’ when the pumping rate lowers below the Max Rate setpoint for
longer than the Persistence Time.
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Setpoints
Once the required ‘Alarm Function’ and the appropriate ‘ID’ have been selected, the next step is to enter the
setpoints for the ‘Alarm’ chosen.
To gain access to the ‘Setpoints’ press the button at which time the ‘Setpoints’ button will change from being
greyed out to being highlighted blue, selecting the highlighted button will take you to the following screen.
Level, Rate, Temperature, Flow, Velocity or Pump Efficiency
When the ‘Alarm Function’ is ‘Level’, ‘Rate of
Change’, ‘Temperature’, ‘Flow’, ‘Velocity’ or
‘Pump Efficiency’ two setpoints are required.
Name
This displays the name given to the relay in the Relay
Configure screen.
Setpoints
The Setpoints are used to determine the ‘ON’ and
‘OFF’ points for the ‘Alarm’ as shown in the table
below.
Setpoints are entered in values according to the function selected.
• Level - entered in Display Units (Measurement Units) as referenced to Empty Level.
• Rate of Change - entered in Display Units (Measurement Units) per minute. For an alarm on an
increasing level enter setpoints as a positive value, for an alarm on a decreasing level enter setpoints as
a negative value.
• Temperature - entered in ºC.
• Flow – entered in flow Units per time period e.g., ltrs/sec, or m
3
/hour.
• Velocity – entered in m/sec.
• Pump Efficiency – entered in % value of efficiency.
ALARM ID
DESCRIPTION
Setpoint 1
Determines the ‘ON’ point for the ‘Alarm’, according to the ‘Alarm ID’
selected.
Setpoint 2
Determines the ‘OFF’ point for the ‘Alarm’, according to the ‘Alarm ID’
selected.
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RMA
When the ‘Alarm Function’ is ‘RMA’ setpoints are
dependent on the ‘Alarm ID’ selected and details of
all setpoints are shown in the table below.
Name
This displays the name given to the relay in the Relay
Configure screen.
Setpoints
The Setpoints are used to determine the ‘ON’ and
‘OFF’ points for the ‘Alarm’ as shown in the table
below.
Mains or DC Fail
When the ‘Alarm Function’ ‘Mains Fail’ or ‘DC Fail’
is selected you will be asked to enter a value for
Persist this is the amount of time, in seconds, that
the failure must ‘persist’ before the alarm is
activated, no further setpoints are required.
Name
This displays the name given to the relay in the
Relay Configure screen.
Setpoint
The Setpoint is used to determine the amount of
time, in seconds, that the failure must ‘persist’
before the alarm is activated.
ALARM ID
DESCRIPTION
Max Rate / Min Rate
These determine the RMA alarm ON/OFF points, this is the rate of change
during pumping at which a potential condition may occur (depending on
Relay Alarm ID). Units are in rate measurement units.
Persist
This is the amount of time the rate must persist above/below the alarm
setpoint before the alarm will change state. It is used to prevent relay
‘chatter’ if the rate is near the alarm setpoint. Units are in seconds.
Minimum Head
An alarm will not be raised below this level but will allow an alarm to turn
off. The units are in the measurement units displayed.
Storm Level
Determines the level at which a Storm condition is in effect. Entered in
measurement units displayed.
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Station API
When the ‘Alarm Function’ ‘Station API’ is
selected, you will be asked to enter a value for
Threshold entered as a % of the ‘Station API’ at
which the alarm is to be activated.
Name
This displays the name given to the relay in the
Relay Configure screen.
Setpoint
The Setpoint is used to determine the the
Threshold at which the alarm is to be activated.
LOE or Overflow
When the ‘Alarm Function’ is ‘Loss of Echo’ or
‘Overflow’ no setpoints are required but you must
allocate the alarm to a specific point of
measurement.
Name
This displays the name given to the relay in the Relay
Configure screen.
Device Fail, Device Alarm, Service or Pump PMI
When the ‘Alarm Function’ is ‘Device Fail’, ‘Device
Alarm’ ‘Service’ or ‘Pump PMI’ no setpoints or
allocation are required.
Name
This displays the name given to the relay in the Relay
Configure screen.
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Other Parameters
Control
Function
Having selected ‘Control’ as the relay ‘Type’ you
will be presented with the screen detailed to the
right.
Name
If required you can enter a name for the control
function in the ‘Name’ field.
ALARM ID
DESCRIPTION
Closures
The Ultimate will record how many times each relay has operated and
display the number of times the relay has activated since the relay has been
in use in this box. It can be reset with any value
Allocation
This allows you to assign the relay to a specific point of measurement as
setup in ‘Application-Operation’
Failsafe
The unit has a general fail-safe selection option in ‘Display-Failsafe’.
However, this can be overwritten so that each individual relay has its own
independent fail-safe mode as follows:
• Default - relay assumes the default mode as set in Display-
Failsafe
• Hold – relay will remain in its current state.
• De-energise – relay will de-energise.
Energise – relay will energise
Event SMS
This option when selected will allow a pre-determined message to be sent
to a remote telephone number as set in Remote Alarms, detailing the date,
time, site ID, level and relay status at the time the message is sent.
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Next you need to determine the ‘Function’ that the
control relay will respond to.
To select the ‘Function’ you require, select it from
the dropdown box under ‘Function’.
Full details of the ‘Functions’, and their descriptions,
that are available, when the relay is selected as a
‘Function’ relay, are shown in the table below:
FUNCTION
DESCRIPTION
Measurement Point
Relay will function with respect to the measurement point and will come
ON at the On Level and go OFF at the Off Level.
Setpoints are entered in measurement units displayed.
Time
Relay will function in respect to time, the relay will come ON after the
entered Cycle Time and go OFF after the chosen On Time.
Setpoints are entered in minutes.
Storm
Relay will come ON when a storm condition is in effect and the level
reaches the Storm Level and go OFF when the level falls to the Reset
Level.
Used in conjunction with Storm Detect see Pump Advanced features.
Setpoints entered in measurement units as referenced to the Empty Level.
Aeration
Relay will function in respect to the time since All Pumps have gone OFF.
Relay will come ON after the entered Cycle Time, which starts from the
time that All Pumps have switched Off and go OFF after the chosen Cycle
Time. This can be used to activate a device based on elapsed time since all
pumps have switched off, such as a mixer/stirrer or the introduction of fresh
air to reduce gas concentration. Setpoints are entered in minutes.
Flush Valve
Relay will come ON when Flush condition is in effect and goes off when
Flush condition is cleared. A relay being used for Flush Valve/Pump must be
assigned to one of the main pumps in use. Flush relay ID is used to enter
the relay number, to which the assigned pump is connected. The relay
will operate after the number of Start Cycles have elapsed, which is the
number of main pump cycles that should occur before the Flush
Valve/Pump operates. The relay will continue to operate for a set number of
Flush cycles meaning that the relay will be operated for a number of main
pump starts after which the Flush Valve activity will cease until the Flush
Interval comes around again. The duration of each Flush Cycle is set by
the Flush Duration which is entered in seconds.
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ID
Flush Valve or Pump Reset
When the control function Flush Valve or Pump
Reset is selected an ‘ID’ must be assigned to the relay
To select the ‘ID’ you require, select it from the
dropdown box under ‘ID’.
When the alarm function Flush Valve or Reset is
selected then the ‘ID’ defines which pump the
‘Function’ should be applied to.
FUNCTION
DESCRIPTION
Step Time
Step Time Control allows relays to be used to control a device, such as a
motorised valve or gate, to maintain the level within two predetermined
points. Relays will
come ON when Step Time condition is in effect and go OFF when the level
is maintained at the required level.
One relay will be required to control an increase in level, (‘open’ the device)
and a second relay is required to control a decrease in level, (‘close’ the
device). Step Time ID is used to assign the relay to control either the open
or close condition.
The relay will operate when the Control Level is reached, and the Start
Delay time has elapsed and will remain ON for the desired Duration. N.B.
Control Level for open relay, increase the level, must be lower than the
Control Level for the close relay, decrease the level.
Differential
This allows the relay to be used to activate a device as a result of a
differential level, between two points e.g., operate a rake on a screen. Relay
will come ON when a differential condition is in effect and go OFF when the
differential conditions cease.
Setpoints entered in measurement units to the differential required.
Pump Reset
This allows the relay to be used to reset a failed pump and is used in
association with Auto Reset function, see Pump Advanced features.
The relay will come ON for the period of the Reset Pulse after expiry of the
Reset Interval, provided the level is above the Prime Level, as set in Pump
Advanced, Auto Reset. Pump Reset ID is used to enter the pump to which
the reset is to be applied.
Pump Reversal
This is used with the Pump Reversing feature and allows the relay to be
used when the Action in the Pump Reversing menu includes Reverse.
The Relay needs to be wired to contactors that allow the pump motor to
run in reverse direction when energised. One reverse relay is required per
pump.
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Step Time
When the control function Step Time is selected an
‘ID’ must be assigned to the relay
To select the ‘ID’ you require, select it from the
dropdown box under ‘ID’.
When the alarm function Step Time is selected then
the ‘ID’ is used to determine if the relay is to be used
to control an Open PSC condition or a Close PSC
condition.
Setpoints
Once the required ‘Control Function’ and the appropriate ‘ID’ have been selected, the next step is to enter the
setpoints for the ‘Control’ chosen.
To gain access to the ‘Setpoints’ press the button at which time the ‘Setpoints’ button will change from being
greyed out to being highlighted blue, selecting the highlighted button will take you to the following screen.
Level or Storm
When the ‘Control Function’ is ‘Measurement
point’ or ‘Storm’ two setpoints are required.
Name
This displays the name given to the relay in the Relay
Configure screen.
Setpoints
The Setpoints are used to determine the ‘ON’ and
‘OFF’ points for the ‘Control Function’ as shown in
the table below.
SETPOINTS
DESCRIPTION
On or Storm Level
Determines the ‘ON’ point for the relay, according to the ‘Control
Function’ selected.
Setpoint is entered in Display Units (Measurement Units) as referenced to
Empty Level.
Off or Reset Level
Determines the ‘OFF’ point for the relay, according to the ‘Control
Function’ selected.
Setpoint is entered in Display Units (Measurement Units) as referenced to
Empty Level.
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Time or Aeration
When the ‘Control Function’ is ‘Time’ or ‘Aeration’
two setpoints are required.
Name
This displays the name given to the relay in the Relay
Configure screen.
Setpoints
The Setpoints are used to determine ‘When’ and for
what ‘Duration’ the ‘Control’ relay will operate for,
as shown in the table below.
Flush Valve
When the ‘Control Function’ is ‘Flush Valve’ three
setpoints are required.
Name
This displays the name given to the relay in the Relay
Configure screen.
Setpoints
The Setpoints which are used to determine ‘When’,
how ‘Often’ and for what ‘Duration’ the relay will
operate for are detailed in the table below.
SETPOINTS
DESCRIPTION
Cycle Time
Determines the Cycle Time that must elapse before the relay will switch ‘ON’.
Setpoint is entered in minutes.
On Time
Determines the period of time, On Time that the relay will remain active for
before being switched ‘OFF’. Setpoint is entered in minutes.
SETPOINTS
DESCRIPTION
Start Cycles
Determines the number of pump cycles that must be completed before the
Flush Valve will be switched ‘ON’.
Setpoint is entered as a number of cycles.
Flush Cycles
Determines the number of pump cycles over which the Flush Valve
continues to operate. Setpoint is as a number of cycles.
Flush Time
Determines the duration of the Flush Cycle. After which it will switch ‘OFF.
Setpoint is entered in seconds.
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Step Time
When the ‘Control Function’ is ‘Step Time’, it allows
relays to be used to control a device. Such as a
motorized valve or gate, in order to maintain the
level, three setpoints are required.
Name
This displays the name given to the relay in the Relay
Configure screen.
Setpoints
The Setpoints which are used to determine the
‘Level’ at which the relay will become active, the
‘Delay’ time before the relay will activate and the
‘Duration’ that the relay will remain active for are
detailed in the table below.
Differential
When the ‘Control Function’ is ‘Differential’ two
setpoints are required.
Name
This displays the name given to the relay in the Relay
Configure screen.
Setpoints
The Setpoints are used to determine the ‘ON’ and
‘OFF’ points for the relay as detailed in the table
below.
SETPOINTS
DESCRIPTION
Control Level
Determines the level, at which the relay is to be activated,
N.B. level setpoint for open relay, (increase the level), must be lower than
the setpoint for the close relay, (decrease the level).
Setpoint is entered in Display Units (Measurement Units) as referenced to
Empty Level.
Duration
Determines the period of time that the relay will remain active after which it
will switch ‘OFF’.
Setpoint is entered in seconds.
Start Delay
Determines the time after which the level has been reached before the relay will
switch ‘ON’. Setpoint is entered in minutes
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Pump Reset
When the ‘Control Function’ is selected for ‘Pump
Reset’, there are no setpoints required.
Name
This displays the name given to the relay in the Relay
Configure screen.
Pump Reversal
When the ‘Control Function’ is selected for ‘Pump
Reversal’, there are no setpoints required.
Name
This displays the name given to the relay in the Relay
Configure screen.
Other Parameters
NAME
DESCRIPTION
Closures
The Ultimate will record how many times each relay has operated and
display the number of times the relay has activated since the relay has been
in use in this box. It can be reset with any value
Allocation
This allows you to assign the relay to a specific point of measurement as
setup in ‘Application-Operation’
Failsafe
The unit has a general fail-safe selection option in ‘Display-Failsafe’.
However, this can be overwritten so that each individual relay has its own
independent fail-safe mode as follows:
• Default - relay assumes the default mode as set in Display-
Failsafe.
• Hold – relay will remain in its current state.
• De-energise – relay will de-energise.
Energise – relay will energise
Event SMS
This option when selected will allow a pre-determined message to be sent
to a remote telephone number as set in Remote Alarms, detailing the date,
time, site ID, level, and relay status at the time the message is sent.
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Miscellaneous
Function
Having selected ‘Miscellaneous’ as the relay ‘Type’
you will be presented with the screen detailed to the
right.
Name
If required you can enter a name for the
miscellaneous function in the ‘Name’ field.
Next you need to determine the ‘Function’ that the
control relay will respond to.
To select the ‘Function’ you require, select it from
the dropdown box under ‘Function’.
There are two ‘Functions’, available and both are
described in the table below:
Setpoints
Once the required ‘Miscellaneous Function’ has been selected, the next step is to enter the setpoints for the
function chosen.
Press the button to allow access the setpoints screen. Pressing the button will take you to the following
screen.
FUNCTION
DESCRIPTION
Clock
Relay will turn ‘ON’ at a specified time each day and it will turn ‘OFF’ after
the specified ‘Duration’ period.
Totaliser
Relay will energise ‘ON’ momentarily each time the specified units of flow
or volume have passed.
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Clock
When the ‘Miscellaneous Function’ is ‘Clock’ two
setpoints are required.
Name
This displays the name given to the relay in the Relay
Configure screen.
Setpoints
The Setpoints are used to determine the ‘ON’ and
‘OFF’ points for the relay as shown in the table
below.
Totaliser
When the ‘Miscellaneous Function’ is ‘Totaliser’
two setpoints are required.
Name
This displays the name given to the relay in the Relay
Configure screen.
Setpoints
The Setpoints are used to determine ‘When’ and for
what ‘Duration’ the relay will operate for, as shown
in the table below.
SETPOINTS
DESCRIPTION
On Time
Determines the time of day at which the relay will operate.
Setpoint is entered in Hours and Minutes (HHMM).
Duration
Determines the time duration that the relay will remain ‘ON’
Setpoint is entered in seconds.
SETPOINTS
DESCRIPTION
Pulse Vol
This determines the factor by which the on board totaliser should be
multiplied by to provide a relay closure. For example, if the Totaliser is
totalising in litres and you require a pulse every cubic litre then a factor of
1000 would be entered. Setpoint is entered as a multiplication factor of the
on board totaliser.
On Time
Determines the time period of the relay pulse. Setpoint is entered in
seconds.
Allocation
This allows you to assign the relay to a Pumped volume or a totaliser from
an OCM app. Select the point of measurement from the drop-down list.
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Other Parameters
Logical
Function
The Logical relay function is used to assign a relay
output to a programmed logic point (see Chapter
4.15 Logical Output for more information)
Having selected ‘Logical’ as the relay ‘Type’ you will
be presented with the screen detailed to the right.
Name
If required you can enter a name for the Logic relay
function in the ‘Name’ field.
Next you need to determine the ‘Function’ that the
control relay will respond to.
To select the ‘Function’ you require, select it from
the dropdown box under ‘Function’.
The Function allocates the relay to a programmed
logic point. The names of all logic points will be
listed here that have been set up in ‘Logical Output’
(up to 20).
NAME
DESCRIPTION
Closures
The Ultimate will record how many times each relay has operated and
display the number of times the relay has activated since the relay has been
in use in this box. It can be reset with any value
Failsafe
The unit has a general fail-safe selection option in ‘Display-Failsafe’.
However, this can be overwritten so that each individual relay has its own
independent fail-safe mode as follows:
• Default - relay assumes the default mode as set in Display-
Failsafe.
• Hold – relay will remain in its current state.
• De-energise – relay will de-energise.
Energise – relay will energise
Event SMS
This option when selected will allow an SMS message to be sent to a
remote telephone number as set in Remote Alarms, detailing the date, time,
site ID, level and relay status at the time the message is sent.
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ID
When the Logical Function is selected an ‘ID’ must be
assigned to the relay
To select the ‘ID’ you require, select it from the
dropdown box under ‘ID’.
When the function Logic is selected then the ‘ID’ is
used to determine if the relay is to be used to control
a Normally Open condition or a Normally Close
condition.
Setpoints
Once the required ‘Logical Function’ has been selected, the next step is to enter the setpoints for the function
chosen.
To gain access to the ‘Setpoints’ press the button at which time the ‘Setpoints’ button will change from being
greyed out to being highlighted blue, selecting the highlighted button will take you to the following screen.
Logical
When the ‘Logical Function’ is selected, two
setpoints are required.
Name
This displays the name given to the relay in the Relay
Configure screen.
Setpoints
The Setpoints are used to determine the ‘ON’ and
‘OFF’ points for the relay as shown in the table
below.
SETPOINTS
DESCRIPTION
Start Delay
Determines the time duration in seconds before the relay will energise.
Min. On Time
Determines the minimum time duration that the relay will remain ‘ON’
Setpoint is entered in seconds.
Max. On Time
When the logic point is active, this determines the maximum time duration
that the relay will remain ON before de-energising and re-entering the start
delay. A setting of zero gives infinite ON time.
Closures
The Ultimate will record how many times each relay has operated and
display the number of times the relay has activated since the relay has been
in use in this box. It can be reset with any value
Event SMS
This option when selected will allow a pre-determined message to be sent
to a remote telephone number as set in Remote Alarms, detailing the date,
time, site ID, level and relay status at the time the message is sent.
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4.4 Pump Advanced
On the Main Menu screen select
Once selected the ‘Advanced Control Menu’ will appear, as shown below, this screen allows access and set up of
the various ‘Advanced’ pump features available, each of which are described below.
Run On
From the Advanced Control Menu select
This feature is used to periodically allow the pumps to continue operating below their normal “OFF” point, in order
to discharge any sediment that may have settled at the bottom of the vessel.
Enable
Determines whether Run On is active or not.
Prime Level
Sets the required level to ensure pumps are fully primed after a pump run on has occurred. Following a pump run
on, any pump, whose “ON” point is below the Prime Level will be held “OFF” until the Prime Level has been
exceeded.
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Run Interval
Set required time period, in hours, at which pump run on should occur.
Run Duration
Sets the length of time, in seconds, that pumps will run on for, it should be noted that only one run on is allowed
per Run Interval.
Min Head
Sets the minimum level (head) of material that must be present before permitting pump Run On to take place.
Exercise
From the Advanced Control Menu select
This feature is used to reduce idle pump corrosion and sediment build up. Pumps are allowed to run after a
specified Idle Time for a determined period of Exercise time, providing a Minimum head /level is present and all
other pumps are switched off.
Enable
Determines whether Exercise is active or not.
Idle Time
Sets the Idle Time to elapse before Pump Exercising is to be activated. Set the required time period in minutes.
Default = 720 minutes
Exercise Time
Set the required Exercise Time in seconds. Default = 30 seconds
Minimum Head
To prevent the dry running and the possibility of cavitation, of the pump, enter the minimum level (head) of
material, in metres, that is to be present before permitting pump exercising to take place.
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Delays
From the Advanced Control Menu select
This feature is used to reduce the effects of power surges, caused by switching of pumps, in the following instances,
(Start Delay) Power surge (mains or hydraulic) that is generated when multiple pumps are started simultaneously,
(Power Delay) Power resumption following a power failure.
Enable
Determines whether Pump Start & Stop Delay is active or not.
Power Delay
Set the required time period, in seconds, that should elapse before pumps are allowed to start following recovery
from a power failure. Default = 10 seconds.
Start-Start Delay
Set the required time period, in seconds, that should elapse between pumps starting. Default = 10 seconds.
Stop-Stop Delay
Set the required time period, in seconds, that should elapse between pumps stopping. Default = 0 seconds.
Start-Stop Delay
If required, this feature will prevent pumps, with a common set point being switched off all at the same time
pumps will be switched in turn as determined by the delay set in Start-Stop Delay. Set the required time period, in
seconds, that should elapse between pumps stopping. Default = 0 seconds.
Stop-Start Delay
If required, this feature will prevent pumps, with a common “OFF” point being switched off all at the same time
pumps will be switched “OFF” in turn as determined by the delay set in Stop Delay. Set the required time period, in
seconds, that should elapse between pumps stopping. Default = 0. seconds.
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Run Time
From the Advanced Control Menu select
This feature can be used to demote a pump to last in the duty cycle based on number of minutes run in a particular
pump cycle, or the number of pump starts in a defined time interval.
For this feature to work there must be at least two pumps programmed into the unit. Run Time will only work if
there is at least one pump that is not currently running its pump cycle (OFF) and is available to run (healthy).
Enable
Determines whether Run Time is active or not.
Max. Run Time
Sets the maximum time, in any one cycle, that any individual pump will be allowed to run, before being switched off
and the duty passed to the next available pump, according to individual setpoints.
Max. Starts
Sets the maximum number of starts (cycles), in any given time interval, that any individual pump will make, before
being switched off and the duty passed to the next available pump, according to individual setpoints.
In Interval
Set in conjunction with Max Starts function and will determine the period of time that Max starts is allowed.
Max. Run Pumps
Determines the maximum number of pumps that can run at any one time.
Max. Start Override
Determines the level which will be present for the unit to override Run Time operation.
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Auto Reset
From the Advanced Control Menu select
When using digital inputs to monitor pump failure and have assigned relays to “Pump Reset”, this function allows for
a pre-programmed number of pump “fails” (Consecutive, or trips in a 24-hour period) to be automatically reset before
putting a pump out of service.
A pump “fail” is defined as the change of state of the trip signal from normal condition to tripped. At the point of
failure both the consecutive trip counter and the 24-hour rolling counter will be advanced by an increment of 1. After
any such pump “fail” is observed the unit will initiate a “cooling” down period (Reset Int.) before initiating an automatic
reset (Reset Pulse).
At this point, the pump has been reset and will operate as normal the next time its ‘ON’ setpoint is reached. If the
pump then successfully pumps to its ‘OFF’ setpoint, thereby completing a successful pump cycle, then the consecutive
trip counter will be reset and the 24-hour rolling counter preserved. When any Pump Trip counter equals the number
of trips allowed (24hr Trips) in any rolling 24-hour period, starting with the first increment of the Trip counter or the
pump fails consecutively, exceeding the number of consecutive trips without completing a successful pump cycle, that
pump will be put out of service and will not be rest until such time that the fail condition is removed.
Enable
Determines whether Auto Reset is to be used or not.
Reset Interval
Sets the “cooling” off period prior to the Reset Pulse being initiated.
Reset Pulse
Determines the duration of the Reset Pulse.
Consec. Trips
Sets the number of consecutive pump “fails” that can be automatically reset before putting a pump out of service.
24hr Trips
This parameter sets the maximum number of pump “fails” allowed in any 24-hour rolling period.
Trip Counter
This displays the number of times that a pump has ‘tripped’ since the last successful Reset was performed. You can
reset the Trip Counter by selecting
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Pumped Volume
From the Advanced Control Menu select
.
This feature totalises the volume pumped in the application.
The source for the volume can a flow measurement point, the flow measurement associated with pump relays, or
derived via the rate of change in level and the volume profile of the pumping vessel.
Source
Determines the source that is used to provide the
volume data in order to calculate the pumped
volume, there are a total of three sources available
each of which are described below.
Derived Flow
Derived Flow is used in conjunction a volume profile in order to provide a calculation of pumped volume and
you will need to set up the volume profile before using Derived Flow to provide a calculation of pumped volume.
Derived Flow is the method of calculating the flow rate based on the rate of change in level. While the pumps are
not running, the inflow is calculated by taking an average of the rate of change. At the point when a pump cycle
begins the inflow value at that point is used as a constant for the inflow throughout the pump cycle. The rate of
change whilst the pump is running is then calculated and added to the inflow rate to give the pumping rate this.
The pumping rate is then multiplied by the calculated volume between the pump ON and OFF point to give the
pumped volume.
Pumps
To use the Pumps option to provide Pumped Volume each pump must have a flow measurement point.
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FlowPulse
To add a FlowPulse to the system go to Advanced Config > Modules > Add FlowPulse
To setup the FlowPulse go to Setup > Sensors > FlowPulse to set up the FlowPulse.
To allocate the FlowPulse to a pump go to Setup > Main Menu > Relays > Configure > Setpoints and allocate the
appropriate FlowPulse to the relevant pump.
mA Input device
To add a mA Input device, go to Setup > Application > mA Inputs and name and set up device.
To create a measurement point for the device, go to Setup > Application > Operation > Mode to Flow > Allocation
to the appropriate mA Input or device name if given.
Flow Device
Will use a single flow device such as a FlowPulse or a device suitable for connecting via the mA input, allocate to a
common outlet, with the setup of such devices being as above.
Settle Time
Determines the time allowed for the level to settle after all pumps have switched Off, to avoid any effects of flow back
or turbulence, before commencing the calculating of the Inflow Rate.
Outflow Limit
Determines the maximum limit for the outflow in ltrs/sec.
Allocation
When the source is Derived Flow, allocation determines which volume profile is used to calculate volume.
When source is Pumps and the flow measurement is provided by Flow Pulse sensors, Allocation selects a volume
profile to calibrate the Flow Pulse sensors against. Calibration is set up in the Asset management - Pump Predictive
Maintenance menu.
When the source is Flow Device, allocation determines which measurement point will provide the flow rate.
Totaliser Unit
Determines the volume units that pumped volume is
measured and totalised in.
The choices of units are detailed in the table below.
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Multiplier
This determines the factor by which the actual flowrate will be multiplied before incrementing the totaliser. This is
just a multiplier of volume. If you wanted to totalise in tens of cubic metres, you would select cubic metres and then
select *10.
Decimals
Determines the number of decimal places used in the reading during run mode.
Daily Log Time
Sets the time of day when the daily totaliser will start a new day from zero and the previous daily totaliser is
incremented into the Pump Totaliser Log. The start time should be entered in 24-hour clock format.
Daily Totaliser
Displays the current value of the daily totaliser. This cannot be reset in run mode, only by accessing Pumped Volume
and entering zero into the Daily Totaliser box can you reset this totaliser.
System Totaliser
Displays the current value of the, non-resettable totaliser. During run mode, this totaliser can be viewed via the
Totaliser hot key ‘Σ’. Unlike the resettable totaliser this cannot be reset whilst in run mode, it can however be reset
whilst in program mode by accessing Pumped volume and entering zero in the System Totaliser value box.
Resettable Totaliser
Displays the current value of the resettable totaliser. During run mode, this totaliser can be viewed via the Totaliser
hot key ‘Σ’. The resettable totaliser can also be cleared by pressing the clear button in the hot key menu displayed.
Pump Totaliser Logs
When Pump Volume is enabled, the Pump Totaliser Log table shows the date and pumped volume total for the
last ten days, the first on the list are the most recent and last ones are the oldest. When all ten total audits are full
the oldest is pushed out and all totals increment through to allow the new days total to be registered in the first
day’s total audit parameter allocation.
To clear the logs recorded, pressing the
button enables all of the Total Audits in the log table to be cleared
to factory default values.
During Run Mode, you can view the totaliser values by pressing the ‘Σ’ hot key, from here the resettable totaliser
can be reset by pressing the button which will revert the value back to 0.
SETPOINTS
DESCRIPTION
Ton
Volume will be calculated and displayed in Tons
Tonne
Volume will be calculated and displayed in Tonnes
Cubic metres (M3)
Volume will be calculated and displayed in Cubic metres (M3)
Litres
Volume will be calculated and displayed in Litres
UK Gallons
Volume will be calculated and displayed in UK Gallons (UK gal)
US Gallons
Volume will be calculated and displayed in US Gallons (US gal)
Cubic Feet (ft3)
Volume will be calculated and displayed in Cubic Feet (ft3)
Barrels
Volume will be calculated and displayed in Barrels
Pounds (lbs.)
Volume will be calculated and displayed in Pounds (lbs.)
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Efficiency
From the Advanced Control Menu select
This feature uses the rate of change in level to use the most efficient pump(s) that are available to use as determined
by comparision to the value for the pumps Calibated Throughput as detailed in Relays > Type > Pump Setpoints >
Calibrated Throughput. Any pumps that are not deemed to be running efficiently can be demoted and placed at
the end of the pumping cycle so that the most efficient pumps are allowed to run first. When first enabled, the pumps
will need to be calibrated to set the initial efficiency as 100%. The calibration is initiated in the Asset Management
> Pump Predictive Maintenance menu.
Enable
Determines whether Pump Efficiency is used or not.
Demote Pump
When an efficiency alarm is being used this option will determine if a pump is to be demoted to the last pump in the
duty cycle on activation of the alarm. When Demote Pump is enabled, and the efficiency alarm is activated after the
predetermined Persist Count the inefficient pump will be set to the last pump in the cycle which will be called to start
if the level reaches the on point for that pump. A pump which has been demoted will be indicated by the relevant
“pump” icon “flashing” RED.
Sample Rate
Determines how often the unit will check to see if a change of level has occurred in order to calculate a rate of change.
Persist Count.
If an alarm is to be used to indicate when the Pump efficiency falls below a predetermined level, this parameter
determines the number of consecutive times the pump will be allowed to run at the reduced efficiency, before the
alarm will be activated and the pump demoted if required.
Eff. Delay
Used to set a delay, after all pumps have stopped, to allow for any turbulence of the material surface to settle prior to
monitoring the level in the vessel and determining the inflow before the next pump cycle commences. The delay time
is entered in seconds and the default is 45 seconds.
Important Information
When setting the time period for the Eff. Delay it is important that it does not exceed the time from
when all pumps switch Off to the first pump Start during normal operation as it will prevent
determining the Inflow and any subsequent calculation of Efficiency.
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Eff Delay 1
Sets the time duration over which the pumps performance will be monitored, and the resulting efficiency is calculated.
Storm Detect
From the Advanced Control Menu select
For this feature to operate a relay must have been assigned to ‘Control’, ‘Storm’ and have Storm and Reset Level
setpoints programmed.
This feature enables all pumps to be disabled during a storm condition to prevent the futile running or potential
damage due to the continued use of pumps during flood conditions. Provision is also made to allow a maximum
disable time for which pumps will remain disabled during such conditions.
Enable
Determines whether Storm Disable is to be used or not.
Disable Time
Sets the maximum time pumps will remain disabled. Enter desired time in minutes, please note that if the Disable
Time is set to zero Storm Disable will be inoperative.
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Override
From the Advanced Control Menu select
Used in conjunction with the Digital Input features ‘Override On’ and ‘Override Off’ and allows the pumps
setpoints to be overridden to the chosen state provided that the level is above a minimum level and following a set
delay.
To setup a Digital Input for Override go to Set up > Digital Inputs > Select Input > Configure > Assignment =
Pump > Function = Override ON or Override OFF.
Enable
Determines whether Override is to be used or not.
Override Delay
Determines the delay, in seconds, from first seeing the Min. Override Level, after which the pumps setpoints will be
overridden to the chosen condition, On or Off, as determined by the Digital Input.
Min. Override
Sets the minimum level, in measurement units that is required before the Override Delay starts its count down and an
override condition can be put into effect.
Odour Reduction
From the Advanced Control Menu select
This screen allows you to enable the functions Wall Cling or Septicity Prevention, which reduces the amount of
material build up and/or reduce the amount of corrosion or gas build up in a sump or vessel.
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Wall Cling
To reduce material build up, (such as fat), on the wall of the sump or vessel, at the ‘normal’ material level the pump
setpoints can be varied within a specified band.
For Pump Down applications the relay setpoints for the pumps will be randomly varied within the band specified,
somewhere below ON, but to a maximum of the setting, and somewhere higher than OFF, but to a maximum of the
setting.
For Pump Up applications the relay setpoints for the pumps will be randomly varied within the band specified
somewhere higher than ON, but to a maximum of the setting, and somewhere lower than OFF, but to a maximum of
the setting.
Enable
Determines whether Wall Cling is to be used or not.
Max. Band
Enter the maximum band of variation required, in measurement units.
Septicity Prevention
If all pumps have been idle for a period of time and the level is above a minimum level, then the duty pump will be
allowed to start and pump until it reaches the minimum level in order reduce the amount of corrosion or gas build up
in a sump or vessel.
Enable
Determines whether Septicity Prevention is to be used or not.
Idle Interval
Sets the time period, after which all pumps have switched off, that has to elapse before Septicity Prevention will
become active.
Min. Head
Determines the minimum level, above which the material must be, before Septicity Prevention will operate, once the
material level falls to the Min. Head Septicity Prevention will become inoperative.
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Block & Burst
From the Advanced Control Menu select
This feature is used to detect a Burst or Block condition and provide an alarm and works in conjunction with an RMA
(Rising Main Alarm) see Relays > Function > Alarm > ID > RMA.
Enable
Determines whether Block & Burst detection is to be used or not. Please note that if Block & Burst is not enabled then
any RMA alarms set will be inoperative.
RMA Delay
Time duration from the first pump start to allow the RMA alarms to be active. This gives time for the rate of change
or FlowPulse input to settle at the pumping rate before allowing the alarms to be operational that a Block has to be
present before initiating an alarm condition.
Flow Method
Select the method by which the flow rate is to be calculated.
Derived Flow
Uses the method of calculating the flow rate based on rate of change in level, and the volume profile of the well
(Volume required). While the pumps are not running the inflow is calculated by taking an average of the rate of
change. At the point in which a pump cycle begins the inflow value at that point is used as a constant throughout
that cycle. The rate of change throughout the pumping cycle is then subtracted from the inflow to give the pumping
rate/flow.
FlowPulse
FlowPulse sensors are used to provide real time flow rate data.
Settle Period
This determines the time period allowed for the level to settle after the first pump has switched on before calculating
the value of derived flow.
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Peak Tariff
From the Advanced Control Menu select
This feature is used to reduce or avoid the use of pumps during high tariff periods by continually monitoring the level
and inflow conditions of the well and optimise the level and intelligently control the pumps according to any
impending tariff changes.
Enable
Determines whether Peak Tariff is in use or not.
Lead Time
Determines the time, prior to a Peak Tariff period, at which the vessel will be pumped down to the lowest pump OFF
level.
Min. Run
Determines the minimum amount of time that a pump will be allowed to run during a Peak Tariff period, if required,
and is used to prevent excessive wear or damage to the pump.
Ovf Level
Determines the maximum level to which the vessel will be allowed to fill. Should this level be reached all pumps will
be switched ON, according to their setpoints and pump duty, to draw the level down, as required, irrespective of the
control sequence in operation.
Lag Time
Determines the time, after a Peak Tariff period, that the vessel will be pumped down, (if required), by the first duty
pump to the lowest pump Off level. If after the Lag Time has expired the pump has not reached its Off point it will
continue to pump until the Off point is reached. On expiry of the Lag Time all pumps will assume their normal
operation and will be switched On and Off according to their respective setpoints.
Minimum Head
Determines the minimum head (level) of material required to be present before a pump will be allowed to run, if
required, during a Peak Tariff period and is used to ensure that a prime level for the pumps is maintained.
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Peak Tariff periods
Up to ten separate Peak Tariff periods can be programmed in to the unit, these periods can be set for a specific date
and time or at a specific time during a period of dates or on a daily or weekly basis.
Day
Determines the day on which the “Peak Tariff”
period will be in effect.
Week
Determines the week in which the “Peak Tariff”
period will be in effect.
Start Date
From the pop up calendar select the date on which
the “Peak Time” will start.
End Date
From the pop up calendar select the date on which
the “Peak Time” will end.
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Start Time
Sets the time at which the “Peak Time” will start.
Enter the desired time in HH:MM format
End Time
Sets the time at which the “Peak Time” will end.
Enter the desired time in HH:MM format
Pump Reversing
From the Advanced Control Menu select
The Pump Reversing feature provides a pump pre-blockage detection algorithm and provides a choice of remedial
actions triggered from the detection. A pump can be momentarily stopped to allow the reflux flow to clear the
impellor, or if the pump allows, could be reversed to free any potential blockages. If pre-blockage detections are
happening repeatedly, the pump can be demoted to last in duty. The feature continually compares the pump’s
electrical current profile to a stored “calibration” profile, which means that an initial calibration cycle is required (per
pump) when the pump is deemed to be in good running condition.
For further information and installation details see separate manual supplied with unit.
Setup Pre-requisites
• Level measurement point, to control pumps and provide data to the reversing algorithm.
• Pulsar Power monitor with a reversing feature registered on the PBUS Hardware Expansion port and declared as a
power measurement point. (one per pump)
• Relay configured for pump control to Start/Stop the pump, with its Power parameter set as the power measurement
point for monitoring that specific pump (one per pump)
• If Pump reversing is required, a Control Relay with a function of pump reverse needs to be configured (one per pump)
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Each Pump has its own set of identical pump reversing parameters, which can be accessed using the tree list on the
left-hand side of the screen.
CONTROL/PARAMETER
DESCRIPTION
Pump
Indicates which pump is currently selected.
Enable
Yes = RetroFlo feature Enabled
No = RetroFlo Feature Disabled (Default)
Action
Stop on Blockage = If a blockage is detected then the pump will be
stopped.
Reverse on Blockage = If a blockage is detected then pump will reverse.
Reverse on Start = Before a pump starts the pump will reverse for a set
amount of time.
Reverse on Fault = The pump will be reversed when failed input is
removed
Demote Pump
If the Block count reaches the Max Seq. Value. The pump can be demoted
to last to start in the duty order.
No = Pump will not be demoted (Default)
Yes = Pump will be demoted
Max. Seq.
Sets the Maximum Pump Stop or Pump Reverse Sequences that will be
allowed to occur before demoting the pump.
Range: 0 -> 9999 Default: 3
Stop Duration
This defines the duration the pump is stopped for, following a pre-blockage
event, or a pump reversal.
Rev. Duration
This defines the duration of the pump reversal.
Range: 0 -> 99999 Default:10 (seconds)
Reverse Rel.
This list box selects which Pump Reversing Relay is used to reverse the
currently selected pump. The list will only show the available relays.
Deadband
Sets the electrical current threshold above and below the stored calibration
that triggers the pre-blockage detection event.
Range: 0 -> 100 Default 20 (%)
Block Count
Total number of pre-blockage events detected.
Flush Valve
If the pump has a flush valve fitted, an extra time delay can be added from
the pump start to the start of pre-blockage monitoring.
No = No Delay added (No flush valve)
Yes = Delay added (Flush valve fitted)
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Calibration
Each pump needs to be calibrated when commissioning the RetroFlo feature. Each pump should be in its normal
healthy running condition to set the “benchmark” for subsequent pump runs to be compared. The calibration
process allows the well to fill to a pre-determined level and then run the pump to its programmed stop level.
Pump calibration is initiated from within the Assets Management > Pump Predictive Maintenance menu.
CONTROL/PARAMETER
DESCRIPTION
Min Head
Minimum level required in the well before can be started without becoming
air locked.
Range: 0 -> 99 Default: 0 (metres)
Monitor Delay
Delay time from the pump start to when the motor current starts being
monitored. This is to prevent acting on spurious current readings as the
pump starts.
Range: 0 -> 99999 Default: 5 (Seconds)
Persist Time
Sets the persistence time of the pre-blockage conditions before triggering
the pre-blockage event.
Range: 0 -> 99999 Default: 2 (seconds)
Operation Time
Flush Valve Operation time sets the duration of the Flush Valve delay.
Range: 0 -> 99999 Default: 3 (seconds)
Clean Action
When a pre-blockage is detected, the Clean action parameter sets what
action to take.
None = Take no action (Default)
Stop = The pump will be stopped for a definable period (Stop interval)
before starting again.
Reverse = The pump will be stopped for the duration of the Stop interval,
then reversed for a definable period (Reverse Int.). The pump is then
stopped for the stop interval, then started to continue pumping.
Num. Clearance
Number of Clearances totalises the number of Successfully cleared preblockages.
Clear Counts
Clears the Num. Clearance and Block Count totalisers.
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Over Spill
From the Advanced Control Menu select
The Over Spill feature is used to calculate and predict a potential Over Flow condition and provide an alarm as set in
Relays > Alarm > Overflow alarm.
Time to Spill
Enable
Determines whether Time to Spill detection is to be used or not. Please note that if Over Spill is not enabled then any
Overflow alarms set will be inoperative.
Persist Time
Determines the persistence for the Time to Spill, or the reset condition to be exceeded before the alarm changes state.
Hi Alarm
Sets a level in measurement units at which the Overflow alarm will activate as a High alarm regardless of the
calculation of time to spill, this level should be set the same as the OVF Level or just below.
Min. Head
Determines the level in measurement units, below which the calculation to time to Overspill will be suspended and
the Overspill function disabled.
OVF Level
Determines the Overflow Level (OVF Level), this is the level in measurement units at which an overflow would occur
and is the level that will be used to calculate the time to overflow.
OVF Time
Determines the time, prior to a potential overflow occurrence, at which the alarm will activate if it is calculated that an
overspill is likely to occur.
OVF Reset
Determines the point the level in measurement units has to be below (or fall below) before an activated alarm can be
considered to be deactivated, provided the calculated time to overflow is not less than the OVF Time. And the level is
below the OVF Reset, the alarm will turn OFF.
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Overspill Counts
This feature will function independently to the Time to Spill which does not have to be enabled for Overspill Count to
work. If enabled, Overspill counts will record that a spill event has taken place in each time period and accumulate the
total Spill time of each event, an Overspill Count is initiated when the level goes above the Spill Level and the Spill
Time is the time that it remains above the Spill Level.
Enable
Determines whether Overspill Count is to be used or not.
Allocation
Sets the Point of Measurement to which the Spill Count will relate to.
Spill Level
Sets the level in measurement units at which an Overspill will occur, and at which point the Overspill Count will be
initiated.
First Period
Determines the length of time, in hours, of the First Period, typically 12 hours. When a spill first occurs, the First Period
will start. The Spill Count will be advanced by 1 and the Spill Time will be recorded for the duration of the spill, should
any subsequent spill events occur, in the First Period. Then the counter will not be incremented, but the time spent
in a spill condition will be added to the Spill Time. At the end of the First Period, the Next Period will begin.
Spill Count and Spill Time are read only, and their values cannot be changed other than being Reset to zero by
using the
button.
Next Period
Determines the length of time, in hours, of the Next Period. If a spill occurs within the Next Period, the spill count is
incremented by 1 and the duration of the spill added to the spill time. Any subsequent spills within the Next Period
will not increment the spill count, but the duration will be added to the spill time. If a spill has occurred within the
next period, the current Next Period will be followed by another Next Period. This will continue until there is a Next
Period without any spill events. The next spill will then start a First Period.
Display POVF
In the event of an overspill, you can turn on/off an icon to appear on the main display.
Spill %
The percentage of the spill level that must be present for an overspill condition to be present.
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Backup
From the Advanced Control Menu select
The Backup function is used in conjunction with digital inputs where a float switch or similar contacting device will be
assigned to an input.
This feature can be used alongside a transducer or as a backup method for when a transducer goes into failsafe. The
high input has a persist timer and a level set point, which will allow for the unit to run the pumps according to the
pump routine below the setpoint for the specified amount of time. The low input will simply switch off all the pumps
set on the controller.
Enable
Determines when Backup will be used as detailed below.
Up to two Backup Hi devices and two Backup Lo
devices are able to be set (see Digital Inputs >
Backup).
Hi Switch 1 will display the Digital Input to which the
Backup Hi 1 device has been allocated.
Hi Switch 2 will display the Digital Input to which the
Backup Hi 2 device has been allocated.
Lo Switch 1 will display the Digital Input to which the
Backup Lo 1 device has been allocated.
Lo Switch 2 will display the Digital Input to which the
Backup Lo 2 device has been allocated.
OPTION
DESCRIPTION
No
Backup is not used
Always
Backup will be active continuously and will respond to an input from a Backup
device at all times.
Failed Only
Backup will only be active at times when the unit has gone into a ‘Failsafe’ mode
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Hi Level 1
If Hi Switch 1 activates a Backup Condition Hi Level 1 will determine the level that the unit will assume is present and
switch on pumps in accordance with their setpoints.
In the case of a pump down application only pumps that have their ON setpoints below the level set by Hi Level 1 will
be allowed to start when a Backup condition is by Hi Switch 1so the setting of Hi Level 1 cab be used to determine
the number of pumps that will start when a Backup condition is present.
Hi Level 2
Acts in the same way as Hi Level 1 but at a different level.
Pump Time
Determines the period of time that the pumps will be allowed to run once a Backup condition has been initiated.
Persist Time
Determines the time that a Backup signal has to be present on the Digital Input before a Backup condition will be
activated.
VSD Controls
From the Advanced Control Menu select .
Variable Speed Drive Controls function uses a PID control loop to modulate an output to control a VSD (or
proportional control valve) to maintain a pre-determined value of process variable. The process variable is chosen
from any of the available measurement points. The VSD needs to be associated with a pump control relay (assigned
in relay set points page), and the mA output used for control needs to be allocated to VSD.
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Setup
There are several methods of determining the loop control constants for PID control, but for pumping applications,
just using proportional control may give satisfactory results.
1. Allocate the Pump Relay and mA output to the VSD control.
2. Select the VSD input variable, output method, and feedback type.
3. Set the Output Percentage limits Start output as required.
4. For fast responding systems, set the Lag Time to 1s
5. Increase Proportional Kp (values typically from 1 – 20) until desired control is achieved.
OPTION
DESCRIPTION
Name
If desired, enter a name for the VSD Control in the ‘Name’ field.
Start Output (% of Max Output)
When Pump relay energises, the control output will change from the Min Output to
Start Output before handing control of the output to the control loop.
Ramp Up (s)
Time taken to ramp the control output from the Min Output to the Start Output.
Min. Output (%)
Minimum percentage of output allowed during control
Max. Output (%)
Maximum percentage of output allowed during control
Lag Time (s)
The response time of the input to a change in output. Use a larger value for slower
responding systems.
VSD Output
Analogue (mA output) or Digital (RS485 Modbus)
VSD Input
Measurement points to be controlled by the PID loop
Setpoint SP
Desired control setpoint in units of measurement
Proportional KP
Proportional control constant.
Integral Ki
Integral control constant.
Derivative Kd
Derivative control constant.
Feedback
Positive - an increasing control output will increase the VSD input variable (e.g.,
Pump flow control).
Negative – an increasing control output will decrease the VSD input variable (e.g.,
Pump down level control)
SP Offset
Used to correct steady state errors.
Proportional KP
Proportional control constant.
Step Response Test
Start (%)
Start output percentage for the step response test
Delay (s)
Time delay before step change.
Stop (%)
Stop output percentage for the step response test
Initiate Step response test. The test is conducted from this screen and the input and
output control data is sent to the separate PID tuning software which will determine
suitable values for the PID control constants.
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4.5 Digital Inputs
On the Main Menu screen select
The digital inputs are used to provide the Ultimate with information on the operational status and condition of pumps,
valves, and other process control devices. Based on the information supplied, by the inputs, the Ultimate will make
intelligent decisions and modify its control regime to meet the demand of the prevailing operational requirements.
The Digital Inputs Menu is used to configure any new digital inputs and to view, edit or delete existing configured
digital inputs. In order to set up or make any changes to existing digital inputs you must first highlight the input
required. Once the required input is highlighted the ‘Clear’ and ‘Configure’ buttons will become available and can
be selected for use. To configure a new digital input or edit or view the configuration of an existing input press the
‘Configure’ button, to delete the settings of an existing input press the ‘Clear’ button and follow the on-screen
instructions.
Default Digital Input Screen
Digital Input Screen with configured inputs
Common Settings
These parameters are common to each of the eight digital inputs and set specific operational criteria for particular
functions.
To access Common Settings, select
from the main Digital Input Menu and the following screen will
appear.
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Switch mode
This function allows the digital inputs to be used to determine, via an ‘auto/manual’ switch, which one of the devices
connected to the relay outputs, will be the ‘lead’ or ‘duty’ device.
When an external duty switch is used it is connected via the digital inputs and facilitate the selection of the duty
device manually, thereby overriding the duty programmed within the unit.
There are two types of switch that can be selected from the drop-down box, as described below.
Input Filter
This parameter is used to ignore spurious changes of state on the digital inputs and determines the time that a
change of state has to be present before it is recognised as a valid input.
Once you have selected the input you wish to use
and have pressed ‘Configure’ you will see the screen
as detailed on the right. The screen will confirm the
Input number and the Interface Board (IFB) on which
it is located, in this case DIN4 on IFB1.
Assignment
To proceed with the setup of the input you must first
assign the input to the function to which it will react
as contained in the ‘Assignment’ drop down box.
All inputs can be configured to any of the
‘Assignment’ detailed in the following table.
NAME
DESCRIPTION
Standard
A standard switch, e.g., rotary switch, can be used with one switch position and a
digital input required for each pump.
Binary
To reduce the number of digital inputs used, for manual duty selection, a binary
switch can be supplied. Max. No. of digital inputs required being four.
NAME
DESCRIPTION
None
Digital Input is not in use
General
When selected the Digital Input is used in conjunction with an alarm relay
configured as a ‘Device Alarm’ to provide an indication of when an external device
has failed.
Pump
When selected the Digital Input is used in conjunction with relays assigned to Pump.
The input can be used to indicate pump failure, to select a duty pump, override
pump setpoints or to reset failed pumps.
Backup
When selected the Digital Input works in conjunction with Pump Advanced >
Backup, where a device such as a Float Switch can be connected to the input which
if activated will override the pump setpoints and switch the pumps ON or OFF in
accordance with the setup of the Backup feature. Provision is made for up to two
Backup Hi and two Backup Lo devices to be used.
Maintenance
When selected the Digital Input works in conjunction with Advanced Config >
Maintenance. It is used to place the device into Maintenance mode.
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General
Having selected ‘General’ as the input
‘Assignment’ you will be presented with the screen
detailed to the right.
You can now complete the setup of the input as
follows.
Name
Having selected an ‘Assignment’ for the input, if
required you can enter a name for the input in the
‘Name’ field.
Input Type
By selecting the ‘Input Type’ drop down menu you
will be given the choice of ‘Active Low’ input will
be active when no voltage (signal) is present or
‘Active High’ input will be active when a voltage
(signal) is present.
Function
Next you need to determine the ‘Function’ that
the digital input will respond to.
To select the ‘Function’ you require, select it from
the dropdown box under ‘Function’.
Full details of the ‘Functions’, and their
descriptions, that are available, when the input
‘Assignment’ is selected as ‘General’, are shown
in the table below:
NAME
DESCRIPTION
Mains failed
Input will provide a signal indicating that there is a mains power failure or the
presence of a healthy signal. This is used in conjunction with the Battery Backup
unit.
Auxiliary
Input indicates the state of a device for the integral RTU, creating a logic point, or
assigning a device alarm relay.
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Pump
The ‘Pump Assignment’ allows the digital inputs to
be used to indicate pump faults and influence the
pumping philosophy by overriding pumps on/off or
forcing the duty to a specific pump. You can now
complete the setup of the input as follows.
Name
Having selected an ‘Assignment’ for the input, if
required you can enter a name for the input in the
‘Name’ field.
Input Type
By selecting the ‘Input Type’ drop down menu you
will be given the choice of ‘Active Low’ input will be
active when no voltage (signal) is present or
‘Active High’ input will be active when a voltage
(signal) is present.
Function
Next you need to determine the ‘Function’ that the
digital input will respond to.
To select the ‘Function’ you require, select it from
the dropdown box under ‘Function’.
Full details of the ‘Functions’, and their descriptions,
that are available, when the input ‘Assignment’ is
selected as ‘Pump’, are shown in the table opposite:
NAME
DESCRIPTION
Failed
If the Failed Input is present, the Ultimate Controller will indicate that the Pump is
failed (Tripped/Out of Service depending on options set in the Auto Reset feature)
Duty
Input will provide a signal to manually select the lead device.
Override ON
Input will provide a signal to activate an Override ON condition of pumps as
determined by Pump Advanced > Pump Override > Override Delay and Min.
Override.
Override OFF
Input will provide a signal to activate an Override OFF condition of all selected
pumps.
Reset
Input will provide a signal to reset all Device Fail signals.
Running
Input to identify that a pump is running. Also used for Smart Alarm signals
Unavailable
Input to identify that a pump is unavailable. Also used for Smart Alarm signals
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Allocation
When ‘Function’ ‘Failed’, ‘Duty’, ‘Override ON’ or
‘Override OFF’ are selected you will be required to
‘Allocate’ the input to the device or devices that it is
to be applied.
A list of available devices, as setup in Relays, will
appear in the ‘Available’ box, to allocate a device to
the input select it from the list in the ‘Available’ box
and press it will then be transferred to the
‘Allocation’ box confirming that it has been selected.
If it is required to allocate more than one device to
the same input, select the additional devices in turn
and repeat the process above for each device.
When the ‘Function’ ‘Reset’ has been selected you will not be asked to select an ‘Allocation’ as the reset will be
applied to all devices.
To ‘clear’ an allocated device highlight it and press
and the device will be removed from the ‘Allocation’ box.
Backup
Having selected ‘Backup’ as the input
‘Assignment’ you will be presented with the screen
detailed to the right.
You can now complete the setup of the input as
follows.
Name
Having selected an ‘Assignment’ for the input, if
required you can enter a name for the input in the
‘Name’ field.
Input Type
By selecting the ‘Input Type’ drop down menu you
will be given the choice of ‘Active Low’ input will be
active when no voltage (signal) is present or ‘Active
High’ input will be active when a voltage (signal) is
present.
Function
Next you need to determine the ‘Function’ that the
digital input will respond to.
To select the ‘Function’ you require, select it from
the dropdown box under ‘Function’.
Once the function has been setup you can change
the pump and persist time of the input in ‘Pump
advanced > Backup Controls’.
Full details of the ‘Functions’, and their descriptions,
that are available, when the input ‘Assignment’ is
selected as ‘Backup, are shown in the table below.
NAME
DESCRIPTION
Backup Hi 1
Backup device being used is Backup Hi 1
Backup Hi 2
Backup device being used is Backup Hi 2
Backup Lo 1
Backup device being used is Backup Lo 1
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Maintenance
Having selected ‘Maintenance’ as the input
‘Assignment’ you will be presented with the screen
detailed to the right.
You can now complete the setup of the input as
follows.
Name
Having selected an ‘Assignment’ for the input, if
required you can enter a name for the input in the
‘Name’ field.
Input Type
By selecting the ‘Input Type’ drop down menu you
will be given the choice of ‘Active Low’ input will be
active when no voltage (signal) is present or ‘Active
High’ input will be active when a voltage (signal) is
present.
Function
Next you need to determine the ‘Function’ that the
digital input will respond to.
To select the ‘Function’ you require, select it from
the dropdown box under ‘Function’.
Full details of the ‘Functions’, and their descriptions,
that are available, when the input ‘Assignment’ is
selected as ‘Maintenance’, are shown in the table
opposite:
Backup Lo 2
Backup device being used is Backup Lo 2
NAME
DESCRIPTION
Latch
Maintenance mode is active only while the digital input is active.
Momentary
Maintenance mode can be toggled on/off by momentary activation of the digital
input. This mode enables the time out duration and alarm features (see Chapter 5.9
Maintenance for more information).
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