Xylem 19-001-351R2 User Manual

INSTRUCTION MANUAL

19-001-351R2

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

TM

PACE

Integrated Pump Controller

Human Machine Interface (HMI)
for the Silent Storm VFD Pumping System

USER GUIDE

2

Acknowledgements

All materials ©2013 by Flowtronex, A Xylem company.

Flowtronex® is a registered trademark of Flowtronex a Xylem Company.

All rights reserved. No parts of this work may be reproduced in any form or by any means - graphic,
electronic, or mechanical, including photocopying, recording, taping, or information storage and retrieval
systems - without the written permission of the publisher.

Products that are referred to in this document may be either trademarks and/or registered trademarks
of the respective owners. The publisher and the author make no claim to these trademarks. These include
Microsoft, Windows, Windows NT, ActiveX that are either registered trademarks or trademarks of Microsoft
Corporation in the United States and/or other countries. ©2013 Microsoft Corporation. All rights reserved.

WHILE EVERY PRECAUTION HAS BEEN TAKEN IN THE PREPARATION OF THIS DOCUMENT, THE
PUBLISHER AND THE AUTHOR ASSUME NO RESPONSIBILITY FOR ERRORS OR OMISSIONS, OR
FOR DAMAGES RESULTING FROM THE USE OF INFORMATION CONTAINED IN THIS DOCUMENT
OR FROM THE USE OF PROGRAMS AND SOURCE CODE THAT MAY ACCOMPANY IT. IN NO EVENT
SHALL THE PUBLISHER AND THE AUTHOR BE LIABLE FOR ANY LOSS OF PROFIT OR ANY OTHER
COMMERCIAL DAMAGE CAUSED OR ALLEGED TO HAVE BEEN CAUSED DIRECTLY OR
INDIRECTLY BY THIS DOCUMENT.

3

TABLE OF CONTENTS

ACKNOWLEDGEMENTS ......................................... 2

ACKNOWLEDGEMENTS ......................................... 2

INTRODUCTION ....................................................... 6

HMI OVERVIEW ........................................................ 6

TYPICAL PUMPING OPERATION ................... 7

TOUCH-SCREEN PANEL OPERATION .................. 7

ENHANCED KEY PAD ...................................... 7

BASIC SCREEN LAYOUT ........................................ 7

USER TYPES ............................................................ 8

OPERATION MENU .................................................. 8

SYSTEM VIEW & TRENDS .............................. 9

Configure Period Screen ....................................... 9

FLOW TOTALS ................................................. 9

PUMP STATUS ............................................... 10

AUXILIARY EQUIPMENT STATUS ................ 11

Booster Pumps: ................................................... 11

Automated Lake (ALS) Monitoring Screen .......... 11

Lake Level Controls Monitoring Screen .............. 11

Lake Level/Transfer/Timed Pump Monitoring Screen:

............................................................................ 12

Simple Filters Monitoring Screen ........................ 12

Scanner Filters Monitoring Screen ...................... 12

ALARMS .......................................................... 12

EVENTS .......................................................... 13

LOCKOUT VIEW ............................................. 13

KWH RECORDS ............................................. 13

SETUP MENU .......................................................... 14

USER SETUP .................................................. 15

Set/Sync HMI-PLC Date/Time ............................ 15

Lamp Test ........................................................... 15

LOCKOUT SETUP ........................................... 15

SECURITY SETUP .......................................... 16

AUXILIARY SETUP ......................................... 17

ALS Setup ........................................................... 17

Lake Level Controls Setup .................................. 17

CONFIGURING TIMED PUMPS: .................... 18

Lake Level Controls Setup (Non-Integrated only)18

Timed Pump Setup (Non-Integrated only) .......... 19

Simple Filters Setup ............................................ 19

Simple Filters Setup ............................................ 19

Scanners Filter Setup ......................................... 19

VFD Bypass ........................................................ 19

Alternate SP ........................................................ 20

Database Settings ............................................... 20

NETWORKING AND REMOTE ACCESS ................ 22

Remote Software Log In ..................................... 22

WEB REPORTS ....................................................... 22

Log on to Web Reports ....................................... 22

Web Reports Menu ............................................. 22

Trend View .......................................................... 23

Alarms Report ..................................................... 23

Historical Report ................................................. 24

Usage Report ...................................................... 24

Smart Phone and PDA access: .......................... 24

APPENDIX A–GLOSSARY OF TERMS .................. 25

NOTE: The information contained in this book is intended to assist operating personnel by providing

information about the characteristics of the purchased equipment.

It does not relieve the user of their responsibility of using accepted engineering practices in the installation,
operation, and maintenance of this equipment.

For additional questions, contact:

XYLEM FLOWTRONEX

8:00 AM to 5:00 PM Central time [phone] x3

5:00 PM to 8:00 AM Central time

After Hours technician for emergency assistance: [phone]

[e-mail]

4

TABLE OF FIGURES

Figure 1: Basic Operation 7
Figure 2: Enhanced Key Pad 7
Figure 3: Basic Screen Layout 8
Figure 4: Log in Screen 8
Figure 5: Operation Menu 9
Figure 6: Trends Screen 9
Figure 7: Configure Period 9
Figure 8: Flow Totals, Overview 9
Figure 9: Flow Totals, Daily Flows 10
Figure 10: Flow Totals, Weekly Flows 10
Figure 11: Flow Totals Monthly Flows 10
Figure 12: Flow Totals, Yearly Flows 10
Figure 13: Animated Pump Status 10
Figure 14: Individual Pump Stats 11
Figure 15: Booster Monitoring Screen 11
Figure 16: ALS Monitoring Screen 11
Figure 17: Lake Level Controls Monitoring Screen 12
Figure 18: Simple Filters Monitoring Screen 12
Figure 19: Scanner Filter Monitoring Screen 12
Figure 20: Alarms Screen 13
Figure 21: Events Screen 13
Figure 22: Lockout View Screen 13
Figure 23: KWH Records, Overview 13
Figure 24: KWH Records, Daily Usage 14
Figure 25: KWH Records, Weekly Usage 14
Figure 26: KWH Records, Monthly Usage 14
Figure 27: KWH Records, Yearly Usage 14
Figure 28: Setup Menu, Guest 14
Figure 30: Setup Menu, Supervisor 15
Figure 29: User Setup Menu, Guest 15
Figure 31: Set/Sync HMI-PLC Date/Time 15
Figure 32: Individual Lockout Setup 16
Figure 33: Parameter Tab in Lockout Setup 16
Figure 34: Security Setup 16
Figure 35: ALS Setup 17
Figure 36: Lake Level Controls Setup 17
Figure 37: Level/Timed pump configuration 17
Figure 38: Integrated Timed Pump configuration 18
Figure 39: Lake Level Controls Setup 19
Figure 40: Timed Pump Setup 19
Figure 41: Simple Filters Setup 19
Figure 42: Scanners Filter Setup 19
Figure 44: VFD Bypass 20
Figure 48: Alternate SP 20
Figure 49: Pressure SP 20
Figure 50: Fertigation SP 20
Figure 51: Database Settings 21
Figure 52: Email Settings 22
Figure 55: Web Reports Menu 23
Figure 56: Trends View 23
Figure 57: Alarms & Events 24
Figure 58: Historical Report 24
Figure 59: Usage Report 24

5

WARRANTY INFORMATION

Company warrants title to the product(s) and, except as noted below with respect to items not of Company’s
Manufacturer, also warrants the product(s) on date on shipment to Purchaser, to be of the kind and quality
described herein, and free of defects in workmanship and material.

THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, INCLUDING BUT NOT
LIMITED TO IMPLIED WARRANTIES OF MECHANTABILITY AND FITNESS, AND CONSTITUTES THE
ONLY WARRANTY OF COMPANY WITH RESPECT TO THE PRODUCT(S).

If within one year from date of initial operation, but nor more than eighteen months from date of shipment by
Company of any item of product(s), Purchaser discovers that such item was not as warranted above and
promptly notifies Company in writing thereof, Company shall remedy such non-conformance by, at Company
affected part of the product(s). Purchaser shall assume all responsibility and expense for removal,
reinstallation, and freight in connection with the foregoing remedies. The same obligations and conditions
shall extend to replacement parts furnished by Company hereunder. Company shall have the right of disposal
of parts replaced by it.

ANY SEPARATELY LISTED ITEM OF THE PRODUCT(S) WHICH IS NOT MANUFACTURED BY THE
COMPANY IS NOT WARRANTED BY COMPANY and shall be covered only the express warrant, if any, of
the manufacturer thereof.

THIS STATES PURCHASER’S EXCLUSIVE REMEDY AGAINST COMPANY AND ITS SUPPLIERS
RELATING TO THE PRODUCT(S), WHETHER IN CONTRACT OR IN TORT OR UNDER ANY OTHER
LEGAL THEORY, AND WHETHER ARISING OUT OF WARRANTIES, REPRESENTATIONS,
INSTRUCTIONS, INSTALLATIONS OR DEFECTS FROM ANY CAUSE. Company and its suppliers shall
have no obligation as to any product which has been improperly stored and handled, or which has not been
operated or maintained according to instructions in Company or supplier furnished manuals.

6

Introduction

This manual is written for end users and is an
introduction to the Xylem-Flowtronex® PACETM HMI
(Human Machine Interface). The HMI is a browser­based system which allows the user to interact with
the settings and reports of the pumping system.
This manual only covers the HMI aspect of the
system. Please see the Silent Storm VFD Pumping
System Instruction Manual for any questions not
related to the HMI.

This manual assumes that the reader has used and
understands basic Internet browser operation and
has used a Microsoft© Windows Operating System
GUI (Graphical User Interface), such as Windows
2000©, Windows NT©, Windows ME©, or Windows
XP©. This device uses Windows CE-as an
operating system (OS). Windows CE© is a
component-based version of the Windows
operating system designed for embedded devices,
such as PDAs or touch-panel displays.

This manual also assumes the user has some basic
knowledge of pumps and pumping systems.

Note: Button names are shown enclosed in square
brackets, such as [Button], whenever the actual key
or button graphic is not displayed.

The interface is displayed at the pumping station on
the HMI. Users make selections of the options and
enter data using a stylus or hands, and tapping
directly on the HMI’s color, touch-screen panel.

CAUTION: Equipment Damage Hazard

Only use a stylus or clean hands on the HMI
touch-panel device to access screens and
enter data. Use of any other tool, sharp object,
or contact with dirt or chemicals can cause
damage to the screen.

Failure to follow these instructions indicates a
potentially hazardous situation, which, if not
avoided, may result in equipment damage and
void any warranty.

CAUTION: Equipment Damage Hazard

To Clean the equipment:

Disconnect the equipment from any AC outlet,
use a clean damp cloth. Do not use liquid or
spray detergents for cleaning.

Failure to follow these instructions indicates a
potentially hazardous situation, which, if not
avoided, may result in equipment damage and
void any warranty.

HMI Overview

The Flowtronex PACE is a modular and scalable
architecture that is used by the HMI (Human
Machine Interface) to control a station’s pumps. It
also handles a variety of changing conditions using
a touch panel display including normal operation,
operation with a variety of auxiliary equipment
including lake fill controls, boosters, filtration, and/or
fertilization injection (fertigation) equipment, and
operation with timed water features.

A web-based version of the application is
operational on the HMI and permits the user to
supervise the pumping station’s operation remotely
at any time from any internet-accessible computer.
The web-based screens are identical to the screens
viewed on the HMI. Web Reports can also be
viewed and printed by users who access the HMI
interface via the internet.

Data and information is exchanged with the
pumping station’s master controller, also called a
Programmable Logic Controller (PLC), located
physically in the NEMA 4 enclosure. The
communication exchanges are made over Ethernet.
A primary PLC is responsible for the real-time
control of the main pumps, while additional PLC(s)
are used to control auxiliary items. The HMI
provides a graphical user interface (GUI) which
permits the pumping station to be monitored, and
allows the controls or variables to be changed when
necessary. All monitoring and control information
can be sent to the pumping station remotely over
the Internet using the web-based version. This
basic communication between the remote user, the
HMI, and the pumping station is illustrated below.

7

Figure 1: Basic Operation

TYPICAL PUMPING OPERATION

Several common control variables including flow,
pressure, and level are used for operating an
automatic pumping system. Pump starts and stops
are based on the changes in these control
variables. A VFD (Variable Frequency Drive) is
used to regulate the speed of the lead pump,
replacing the function of a control valve. Pressure
recovery can be made smoothly, resulting in power
and cost savings.

When pressure is used as the key process variable,
the VFD pumping system constantly monitors
pressure to maintain the required demand. Pump
starts and stops are based on the changes in the
system pressure. For example, a pumping system
with one Pressure Maintenance (PM) pump and two
interchangeable main pumps may be grouped into
several different combos (combination of pumps)
that start or stop a specific pump, or a sequence of
pumps, according to defined setpoints.

Each combo has an individual start pressure that
references a setpoint pressure and a start delay
time. At very low demand, the PM pump maintains
the setpoint pressure. Once the demand becomes
greater than the PM pump can handle, the first
combo is activated. The lead pump in this combo is
controlled by the VFD. As demand increases,
additional lag pumps are added, or a different
combination of pumps is activated.

Other configurations are also possible. Consult your
Flownet Technician for proper operation of your
system.

Touch-Screen Panel Operation

This Flowtronex PACE HMI device manual
describes the operation of the touch-panel display,
located on the enclosure door of the control unit of
the pumping station.

• Use a stylus to tap the buttons or fields
when using the touch-screen panel.

• Use the Enhanced Key Pad to enter
text or numbers in blank fields. Tap
and hold the stylus in a blank field to
open the Enhanced Key Pad pop up
screen.

ENHANCED KEY PAD

Tap and hold the stylus in an editable field
(indicated by a white background) to open the
Enhanced Key Pad.

To use an Enhanced Keypad:

• To clear an entry, tap to
backspace over entry.

• To close key pad without saving

entries, tap the red on the key
pad.

• To switch between various alphabetic

and numeric key pads, tap or

• To submit an entry tap

Figure 2: Enhanced Key Pad

Basic Screen Layout

The application uses a three-part structure for all
screens:

1. The Navigation Bar, located on the far left of
the screen, displays buttons to tap which will

8

navigate to other key areas of the application. The
content of the navigation bar changes depending on
what type of user is logged in.

2. The Header, located at the top center of the
screen, displays the screen name in the banner,
and (depending on the buttons selected on the
right) the date and time, or the pumping station’s
current flow and pressure readings.

NOTE: A flashing header is indicative of a system
fault.

3. The Main Window, located in the center of the
screen, displays one or more panes of information
about the pumping station. A grayed-out field in this
window is read-only. Other fields (with a few
exceptions) may be edited.

Figure 3: Basic Screen Layout

User Types

There are different types of users recognized by the
system:

Guest: Only operation screens are accessible in
view-only mode. Users are logged in as a Guest by
default.

Supervisor: End-User configurable setup and
operation screens are accessible. Supervisors must
log-in using a password.

Technician: All setup and operation screens are
accessible. Technicians must log-in using a
password. See the Technician Guide for additional
functions.

Note: Some values require you to set the “Enable
Edit” checkbox before you can change the values.
This is a precautionary measure intended to
prevent unwanted and accidental register value
writes. These values are available to technicians
only. Values normally accessed at the Supervisor
level or lower are not affected.

Touch Panel Log In

Tap [Log In] from the Home Screen.

The screen displays the current user type at the top
of the screen.

Figure 4: Log in Screen

Default user is a Guest user. No log in is required.

To log in as a Technician, tap [Technician], and
then tap on the empty Password field to enter the
Technician password. Tap [OK] to log in or [Cancel]
to exit without logging in.

To obtain a Technician password, call Flowtronex
customer service and give them the APP code
displayed on the screen. Customer Service will then
give you a password corresponding to that APP
code which will remain active until the last day of
the current month.

After a password has expired, a new APP code
must be generated allowing you to get a new
password. See Security Setup for information on
how to generate an APP code.

NOTE: The web-based screens require an
immediate log-in as either a guest (no username or
password required), a Supervisor (username and
password are required) or a Technician (username
and password are required). The log-in screen will
be displayed first on the web-based application
only.

Operation Menu

Tap [Operation] from the Home screen.

The Operation Menu allows you to view the
pumping station’s operational trends (System
View), flow totals, pump and auxiliary equipment
status, alarms, events, lockouts, and power
consumption (KW Data).

9

Figure 5: Operation Menu

SYSTEM VIEW & TRENDS

Tap [System View] from the Operation menu.

System View accesses color-coded operational
trends or historical data for several system
variables such as flow, pressure, speed, and
setpoint.

Figure 6: Trends Screen

In the System View screen, a supervisor can
change the setpoint using the User SP field.

You can turn on and off logged channels on the
viewer by tapping the value at the bottom of the
screen.

Power readings may not be available on all
systems. Also on some systems a power reading of
0 will cause the Power display to disappear, and will
reappear when power readings return.

Demand is a function specific to interaction with
Lynx irrigation control systems and will only display
when this data is available from Lynx.

Configure Period Screen

Tap from the System View menu.

The Configure Period screen allows you to set a
date and duration for viewing system information.

The trends will be shown for the Duration value,
ending at the current time. When ‘Now’ is checked,
the system defaults to the current date and time. If
‘Now’ has been checked, ‘Duration’ is the only
editable field.

For viewing historical data, uncheck ‘Now’.

Enter the start date and time, along with duration to
view data for desired time. Tap [Apply] to apply
changes or [Close] to cancel any changes.

NOTE: If ‘Now’ is left unchecked, the system does
not default back to the current date and time.

Figure 7: Configure Period

The trends graph may be enlarged for a better view
by tapping on it.

FLOW TOTALS

Tap [Flow Totals] from the Operation menu.

The totalized values (in GAL) for the daily, weekly,
monthly, and yearly flow are displayed in a tabular
format.

Tap [Next] to successively view the totals for each
day, week, month and year. Use the scroll bar to
move up and down or left and right.

Figure 8: Flow Totals, Overview