Rockwell Automation 1766-L32 User Manual

Pump Station Controller

Quick Start

Important User Information

WARNING

IMPORTANT

ATTENTION

SHOCK HAZARD

BURN HAZARD

Solid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines
for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1
Automation sales office or online at http://www.rockwellautomation.com/literature/
between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the
wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that
each intended application of this equipment is acceptable.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use
or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for
actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software
described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is
prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

available from your local Rockwell

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which may lead to personal injury or death, property damage, or economic loss.

Identifies information that is critical for successful application and understanding of the product.

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Table of Contents
Preface

Configuration and Operation

Drawing Set

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Chapter 1

Pump Station Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Chapter 2

Pump Station Controller Hardware Drawings . . . . . . . . . . . . . . . . . . . 41

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Preface

Introduction

This Quick Start Guide contains step-by-step instructions for configurating
and operating the Pump Station Controller. The Controller consists of a
standard pre-engineered package using off-the-shelf products including the
MicroLogix 1400 PLC, PanelView Component C600 HMI and PowerFlex
drives. Application files are also supplied so no PLC programming is required
and HMI screens are pre-programmed.

This package includes the PLC and HMI application code plus a full set of
system, panel, and electrical drawings that includes a bill of material. You can
download the application code and drawings by going to the Rockwell
Automation Integrated Architecture Tools Website,

http://www.ab.com/go/iatools

tab. The Pump Station Controller application download can be found on this
page.

and selecting the “Beyond Getting Started”

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Preface

Notes:

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Configuration and Operation

Chapter

1

Pump Station Controller

Introduction

This application uses the MicroLogix 1400 and PanelView Component C600
to provide a "stand alone" multifunction pump controller that allows the user
the ability to choose between a pump down (lift station), pump up (water
tank), or a pressure follower (water distribution) control process, with just a
few simple screen selections.

Functionality includes:

● Control of up to 4 pumps.

● User assignable inputs.

● Use of floats, analog or a combination of both to control the process.

● Control of VFDs through Modbus communication, which reduces the

control wiring to the drives (PowerFlex 4/40/400 VFDs only)

● Pump control can be done with starters, PowerFlex 4 series VFDs or
with another manufactures VFD.

● Pump sequencing control.

● User selectable alarms with the ability to choose which ones can be used

to initiate an alarm dialer (user supplied)

● Pump statistics.

● The ability to save and load VFD parameters from the HMI. (PF4

VFDs only).

● Selectable pump interlocks.

● Screen access security.

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Chapter 1

Flashes when a Warning exists

Flashes when an Alarm exists Common header

Not visible until an application has been selected

Only visible if analog device is being used

Legend depends on if Pressure Follower,
Level Pump Down or Level Pump Up mode is selected

Legend depends on if Pressure Follower”
mode is selected or Level mode is selectd

Main Screen

The main screen displays configuration, monitoring and maintenance controls.
Some control label content displays based on the current configuration.

Several of the buttons on the Main screen do not display until the application
has been set up. So the first step is to go through the Application Config
button.

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Chapter 1

Configuring the Application

The functions available when you select the Application Config button
include:

● Select the pumps and pump modes

● Select primary and secondary measuring devices

● Select control devices for all active pumps

● Assign digital inputs and their states

● Assign backup pumps

Each of the configuration screens contains standard navigational tools:

● Press Prev or Next to navigate between screens.

● Press Up, Down, or Enter to navigate available choices on a single

screen.

● Press Exit to return to the Main menu.

To use the configuration controls:

1. From the Main screen, press Application Config to display the
configuration screen.

From the configuration screen you can:

– Use the Up/Down/Enter buttons to select from the three available

operation modes

– Press Enter The Number Of Pumps to select the number of

pumps (1-4) in use in the system

– View a description of the selected mode

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Chapter 1

TIP

TIP

2. Press Next to proceed to the Measuring Setup screen.

From the Measuring Setup screen you can:

– Use the Up/Down buttons to select the primary measuring device.

If Pressure Follower mode is selected then Analog "In 0" is the only option for
the primary measuring device.

– Select a secondary measuring device

If the primary measuring device is an analog device, you can assign a float to be
used as backup (not available if primary measuring is floats).

– Use the second analog input (IN 1) to measure flow rate from an

analog transmitter or as the process variable if the default analog
input (IN 0) fails.

When analog input "IN 1" (I:1.1) is set for Flow the flow is totalized
using a calculation in the PLC. A more accurate way to totalize would
be to use digital input I:0/0 as a totalized pulse.

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Chapter 1

3. Press Next to proceed to the Motor Control Setup screen. In the
example shown, four pumps have been configured; the screen will only
display as many pumps as you set up in the initial configuration screen.

From the Motor Control Setup screen you can use the Up/Down
buttons to select the pump control device.

The Starter and Other VFD selections use physical outputs from the
PLC to control the start/stop operation of the motors, while the

PowerFlex 4 option uses Modbus communication to control the VFD.

4. Press Next to proceed to the first Digital Inputs Assign screen. There

are four Digital Inputs Assign screens in total.

From the first Digital Inputs Assign screen you can:

– Use Digital input I:0/0 as a pulsed input to totalize flow only or to

totalize flow and calculate a flow rate.

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Chapter 1

As a flow totalizer this can be very accurate. However, using it to
calculate flow rate is not as accurate as using analog input I:1.1 as a
flow rate input.

– Press Enter Gallons Per Pulse to set the appropriate gallons per

input pulse

5. Press Next to proceed to the next Digital Inputs Assign screen.

From the remaining Digital Inputs Assign screens you can:

– Press Normally Open or Normally Closed to set the state to

match the way the digital input is wired on the field device.

– Use the Up/Down and End/Home buttons to scroll through the

list of selections

– Digital inputs I:0/0 – I:0/17 are assignable to any of the 31

selections listed; however, depending on the application, they may
not all be applicable. For example, if you only have two pumps in
your system, selection #20 Pump 3 seal fail would not apply

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Chapter 1

NOT USED --­(Selection 0 of 31)

Low Level
(Selection 1 of 31)

Pumps Stop
(Selection 2 of 31)

Lead Start
(Selection 3 of 31)

Lag Start
(Selection 4 of 31)

High Level
Selection 5 of 31)

Pump 1 Running
(Selection 6 of 31)

Pump 2 Running
(Selection 7 of 31)

Pump 3 Running
(Selection 8 of 31)

Pump 4 Running
(Selection 9 of 31)

Pump 2 OL/Fault
(Selection 11 of 31)

Pump 3 OL/Fault
(Selection 12 of 31)

Pump 4 OL/Fault
(Selection 13 of 31)

Pump 1 Motor Over Temp
(Selection 14 of 31)

Pump 2 Motor Over Temp
(Selection 15 of 31)

Pump 3 Motor Over Temp
(Selection 16 of 31)

Pump 4 Motor Over Temp
(Selection 17 of 31)

Pump 1 Seal Fail
(Selection 18 of 31)

Pump 2 Seal Fail
(Selection 19 of 31)

Pump 3 Seal Fail
(Selection 20 of 31)

Low Pressure
(Selection 22 of 31)

High Pressure
(Selection 23 of 31)

Power failure
(Selection 24 of 31)

Generator Running
(Selection 25 of 31)

Generator Fault
(Selection 26 of 31)

General Fault
(Selection 27 of 31)

Pump #1 Auto
(Selection 28 of 31)

Pump #2 Auto
(Selection 29 of 31)

Pump #3 Auto
(Selection 30 of 31)

Pump #4 Auto
(Selection 31 of 31)

Pump 1 OL/Fault
(Selection 10 of 31)

Pump 4 Seal Fail
(Selection 21 of 31)

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TIP

TIP

TIP

If during the measuring

buttons will enable or

device setup, floats are
selected as secondary
(backup) then these

disable the pumps from
running in backup mode.

– Press Next to proceed to the Backup Pump Select screen.

The Backup Pump Selection screen is visible only if Float is selected as the
backup on the Measuring Setup screen.

Press the Delay Between Pump Starts (Seconds) to enter the delay
before the next one starts when more than one backup pump is enabled.

If on the “Measuring Setup” screen (above) the “Secondary (backup) Measuring
Device” is set to “NOT USED”, then no pumps will run in backup.

If on the “Measuring Setup” screen (above) the “Secondary (backup) Measuring
Device” is set to “Floats”, then backup pumps will start when the “Lead Start”
float is activated, and continue until the “Pumps Stop” float is activated.

A “lead start” and a “pumps stop” selection must be assigned to an input on
one of the “Digital Input Assign” screens.

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Because this is a backup operation likely due to a failure, the pumps do not
alternate.

Setup Examples

Example 1: In a pump
down application. Floats
are being used as backup.
On the Pump Sequence
Setup screen, the Primary
selection for all pumps is
set to Alternate, and the
Secondary selections are
set to Lag1. And on the
Backup Pump Selection
screen, lead, lag1 and lag2

pumps are all allowed to
run as backup. As the level rises and activates the Lead Start float. The lead
pump (because all are set for alternate, it could be any of the four pumps)
starts. Let’s say that the Delay Between Pump Starts (see graphic above) is
set for 60 sec. If the Pumps Stop float does not clear in this time, all of the
pumps assigned to Lag1 as Secondary will start (in this case all of them). If a
pump was set to Lag2 as the Secondary selection, it will start 60 sec. after the
Lag1 pump(s) start. If all of the pumps are set to Lag2 as Secondary, then no
pumps will start during the first 60 sec. (Lag1 time). The sequence is: lead
pump --- delay --- lag1 pump(s) --- delay --- lag2 pump(s). Once a pump starts,
it will continue to run until the Pumps Stop float clears.

Example 2: Same setup as
above except the
Secondary selections are
now as shown. Let’s say that
pump 2 is the lead pump.
Lead Start float is activated.

Pump 2 starts --- 60 sec.
time delay --- pump 1 (lag1) starts --- 60 sec. time delay --- pump 3 (lag2) starts.
Because pump 4 is set to Not Used it does not run.

Example 3: The setup is as
shown, however now the
Lag1 pump is not allowed
to run in backup. Again,
let’s say that pump 2 is the
lead pump. Lead Start float
is activated. Pump 2 starts

--- 60 sec. time delay --- and
although pumps 1 and 3 are
both set for lag1, they do no

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IMPORTANT

run because the lag1 pumps are not allowed to run due to the selection on the
Backup Pump Selection screen --- 60 sec. time delay --- pump 4 (lag2) starts.

Configuring Analog Inputs

Now that the application has been set up, you can continue through the rest of
the configuration.

1. From the Main screen, press Analog Inputs Config to display the
configuration screen.

This button is not visible unless an analog device is being used
(Measurement Setup screen).

The screen includes displays showing the raw data coming from the
analog input card and mA value of the input from the calibrated (zero
and span set) card.

2. Select one of the two following calibration methods:

– Apply a 4mA signal to the cards input (I:1.0), then push Apply a

4mA Signal To Analog "In 0" to make the zero adjustment. After
making the zero adjustment, choose Apply a 20mA Signal To
Analog "In 0" to make the span adjustment if a signal is available.

– Select No 4-20mA Signal Available? to calibrate the analog input

using the card's default values if no current calibrator is available.

You must use one of these calibration methods to ensure proper operation.

3. Enter a scaled value in the Enter 4mA Signal Value field. For example:
0 Ft.

4. Enter a scaled value in the Enter 20mA Signal Value field. For
example: 10 Ft.

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