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Elite Pump Controller

Specifications

The pump controller shall be microprocessor based and have the capability to control 2 pumps in an alternating or simple lead/lag configuration. The controller shall support operation using a set of five (5) float switches, an analog sensor proportional to level or a combination of analog sensor and floats.

The controller shall monitor pump conditions for failure and shall be capable of initiating alarm notification via phone, pager or fax when a failure occurs. The controller shall have a battery backup that is automatically engaged when power is lost and initiate an alarm notification sequence to inform designated personnel.

The controller shall have the ability to have pumps turn on/off remotely via a phone and PC connection over a modem. The controller shall log all pump starts and stops and keep track of the total elapsed pump run times and total number of pump starts. Pump run times and complete pump status must be available from the web.

The controller shall support expansion of up to a total of 16 additional analog or digital points in the controller enclosure.

Construction
EnclosureNEMA 4X or panel mount
Environmental Limits
TemperatureHumidity
Electronics: -40 to 185F
(-40 to 85C)
0-80% non-cond.
@ 140F
Battery: -4 to 176F
(-20 to 80C)
0-90% non-cond.
@ 104F
Power Requirements115 VAC 10% or 230 VAC 10%; 50 to 60 Hz; 25 watts
Maximum current draw on DC power850 mA at 15 VDC
Current Loop Supply24VDC provided on each analog input card. Each dialer shall provide sufficient loop current to power up to 24 current loops. 240 ohm loop resistance. 500ma total current per dialer.
Relay Output Rating8A at 125VAC, 6A at 277VAC, 5A at 30VDC
Dimensions10.5"W x 12.5"H x 7.00"D (258mm W x 307mm H x 172mm D)
Weight9.5 lbs. (4.3kg)
Serial Port115.2Kbaud - DB9 (male)
Electrical ProtectionTransient voltage/surge protection on power line, telephone and all input channels. Solid state surge protection on digital input, analog input, serial port, parallel port, telephone and AC power circuitry.
Digital InputsDry Contact/Digital Input cards capable of interfacing directly to dry contacts or digital input signals with voltages up to 24VDC.
Analog InputsAnalog Input cards capable of interfacing directly to 4-20ma, 0-20ma, 0-1V, 1-5V and 0-10V signals. Each channel shall be programmable for range independently from any other channel on the same board. All channel range programming via the keypad, phone or PC with no switches or resisters required. All channels internally converted and presented to the user in engineering units.
Lift or Pump Station Control
Level-based ControlThe controller shall monitor the level in the lift station via an analog input signal from a level or pressure transducer. There shall be 5 sets of limits specified in engineering units for the following control/alarm settings:
  • Low Level: Alarm
  • Off: Turn all active pumps off
  • Lead On: Turn lead pump on
  • Lag On: Turn lag pump on
  • High Level: Alarm
Float-based ControlThe controller shall monitor 3 float switches to control the running of the pumps and up to 2 additional floats for Low and High Alarm.
Control OperationWhen a pump is selected for Automatic operation (HOA in Auto mode), the pump shall be started and stopped by the controller.
When the Lead On condition exists, the controller shall attempt to start the Lead pump. If the Lag On condition exists indicating additional pumping capacity is needed, the controller shall start the Lag pump.
If the Lead or Lag pumps do not respond, the Controller should sense this through a Motor Starter failure input specific to each pump and provide an alarm signal and call out.
The Controller shall display the number of pump starts and the total elapsed run time for each pump on a text display.
The Controller shall support separate total elapsed run times and daily run times for each pump..
The Controller shall support 2 modes of pump operation: automatic alternation of pumps and specifying a specific pump to always be the lead pump.
A pump shall be able to be started from the keypad manually if configured for Automatic operation.
Once a pump is turned off, the controller shall keep it off for a predetermined period of time before it is permitted to restart. This period of time shall be operator adjustable from the local keypad.
If the High Level float switch becomes active, the controller shall turn the next pump in the sequence on/off regardless of the level indicated by a level transmitter or other float switch. The pump shall run until either an Off or Low/High Level condition exists. If the High Level float became active and neither pump was already running, then the controller shall turn both pumps on/off, waiting a predetermined period of time between the pump starts. This period of time shall be operator adjustable from the local keypad.
Both pumps shall have independent maximum on timers so that the pumps will shut off in the event that no Off or Low/High Level condition exists. Timer values shall be operator adjustable from the keypad.
If a Lag On float switch becomes active and the Lead On float switch was not active, the controller shall turn both pumps on, waiting a predetermined period of time between the pump starts.
If an over temperature input on the controller is activated, then that pump will be shut off and not run again until the over temperature condition clears. During the over temperature a unique alarm condition for that pump will exist, an LED will illuminate and an alarm callout will be enabled.
If a motor starter failure input on the controller is activated, then that pump will be shut off and not run again until the motor starter failure condition clears. During the motor starter failure a unique alarm condition for that pump will exist, an LED will illuminate and an alarm callout will be enabled.
If the phase monitor input on the controller is activated, then both pumps will be shut off and not run again until the phase monitor condition clears. During the phase monitor failure a unique alarm condition exists for the station, an LED will illuminate and an alarm callout will be enabled.
If a seal failure input on the controller is activated, then the pump will continue to run, an LED will illuminate and an alarm callout will be enabled.
Local DisplayThe Lead Pump shall be displayed.
The current status (running or off), of each pump shall be displayed.
The Automatic or Lead/Lag mode shall be displayed.
If float switches are used for control, then the current condition (on or off) of each float switch shall be displayed.
If a level sensor is used for control, then the current level of the tank and the setpoints for Lead On, Lag On and Off shall be displayed.
The current settings of the HOA switches for each pump shall be displayed.
The current settings of the High and Low alarm floats (if present) shall be displayed.
The total run time and total number of pump starts shall be displayed for each pump.
There shall be independent LED indications for: Pump 1 running Pump 2 running
  • HOA 1 in auto
  • HOA 2 in auto
  • Pump 1 overtemp
  • Pump 2 overtemp
  • Pump 1 seal failure
  • Pump 2 seal failure
  • Pump 1 motor starter fail
  • Pump 2 motor starter fail
  • Low alarm
  • High alarm
  • Phase monitor fault (if used)
  • Controller in Run or Programming mode
  • Controller running on primary power
  • Controller running on battery backup
Local Keypad OperationsThe operator shall be able to modify the level setpoints, pump start, pump restart, and maximum pump run time settings from the local keypad.
The operator shall be able to start or stop a pump from the local keypad.
The operator shall be able to call the manufacturers customer service from the keypad if a working phone or cell phone line is connected to the controller.
The operator shall be able to acknowledge any alarm conditions to prevent further callouts with the pressing of a single key.
The operator shall be able to disarm the controller from making any callouts or turning pumps on or off by pressing a single key.
Monitoring and AlarmingThe controller shall continually monitor all failures and when one occurs log that event to the internal event log. The event log can be locally printed out the printer port, remotely accessed via modem or remotely accessed via the Internet.
When any failure occurs, the controller shall have the ability to callout to a series of phone numbers to notify personnel of the specific failure. The controller must support calling to phones, cell phones, pagers, alphanumeric pagers, fax machines and modems.
The controller shall have the capability of issuing a fax report indicating the current status of all input and relay conditions when any failure occurs or on a predetermined periodic basis. The report shall include the following:
  • Total pump run time
  • Total pump starts
  • Primary power voltage
  • ackup battery voltage
  • Current loop supply voltage
  • Temperature in the controller
  • Current tank level (if using level sensor)
  • State of all float switches
  • State of all pump monitoring signals

The controller shall speak user-recorded messages to the called party describing its location and the alarm conditions that are present. The controller shall then verbally request that an acknowledgment be given. The called party shall acknowledge the call by momentarily depressing the '8', '9' or '*' key on their telephone keypad. If the controller is not acknowledged during the call, it shall hang up, wait from 1 to 3600 seconds and then dial the next number in its phone list. If a successful acknowledgment occurs, the controller shall give a sign-off message, hang up and then wait a user-programmed period of time for the alarm conditions to be corrected. If this period of time elapses and the alarm condition(s) still exist, the controller shall begin the alarm notification cycle again.
The controller shall initiate a callout sequence upon loss of primary power.
If the controller is calling out when a High or Low Level alarm condition exists and a level sensor is used for control, the current level of the tank shall be reported in engineering units.
The controller shall record all events to an internal date/time stamped event log including:
  • Failures
  • Alarm calls
  • Alarm acknowledgements
  • Pump starts and stops
  • Programming changes
  • Arming and disarming
Wireless OperationsThe controller shall support monitoring the level in a tank and controlling pumps that are remote from each other using either radio or cellular telemetry.
The controller shall support communications from the tank to the pumps that do not have direct line of sight.
Alarm Notification Capability
Telephone Number Capacity16 lists of 16 numbers, each number containing up to 50 digits
Recorded Speech Capacity8 seconds per input channel message
8 seconds for System Identification message
Monitoring CapacityUp to 68 inputs in any combination of digital (4 or 8 per board) or analog (8 per board)
Speech TechnologyDigitally recorded voice messages plus permanent library.
Message Requirements8 second messages for, power loss, low battery message, user selectable 1 or 2 alarm/normal messages for each input channel, 1 channel identification message per input or relay
Telephone Number RequirementsUp to 512 available numbers up to 50 digits each. Numbers can include '*', '#', delays, and detection of dial tone.
Individual phone lists shall have independent access codes for acknowledgement.
Types of Alarms
  • System
    • loss of primary power,
    • low battery,
    • phone fault
  • Digital
    • on or off,
    • number of times in a condition,
    • accumulated time in a condition
  • Analog
    • a user-specified high or low limit for a specified period of time,
    • a user-specified positive or negative rate of change.
All alarms are recorded in the event log with the date/time of the alarm.
Alarm PrioritizationThe automatic dialer prioritizes alarms by the telephone list designated to each alarm channel. Additionally, alarms are prioritized by time of day to different phone lists.
Alarm AcknowledgementThe automatic dialer provides acknowledgement of all alarms from:
  • the front panel,
  • a phone that is called with an alarm condition,
  • a dial-in from a remote location with appropriate access codes.
All acknowledgements are recorded in the event log with the date/time of the acknowledgement, the method of acknowledgement and the Caller ID if from a remote location.
System Capabilities
SetupThe Controller shall be support setup via an integral keypad, via call-in and via local or remote PC connection.
Status ReportingThe automatic dialer shall have the capability of documenting all alarms, dial-out, dial-in, and alarm acknowledgement, activities with time and date to a standard parallel printer, over a modem connection to a PC or to the Internet.
The status report contains the last 1000 events. Each event has the date/time of the event and the action performed.
Caller IDThe automatic dialer shall record the Caller ID in the event log of anyone calling into the dialer to acknowledge alarms or perform any programming functions.
Channel StatusEach alarm channel shall be individually programmed to be either enabled for alarms, disabled or status only.
Battery BackupThe automatic dialer shall have internal battery back-up capacity sufficient to allow the dialer to perform its alarm call-out function for a minimum of 64 consecutive hours upon loss of primary AC power in a 4-channel configuration and a minimum of 24 consecutive hours in a 48-channel configuration.
Modbus CommunicationA dialer option shall support Modbus RTU communication for a direct, modem or radio modem connection to SCADA and HMI software packages. The Modbus option shall be installable via a phone connection to any dialer already installed in the field. The Modbus option shall support reading of all digital and analog inputs, alarm states, acknowledgement states, and reading and writing relays.
PLC InterfaceA dialer option shall support direct communication to any PLC that supports Modbus RTU communications. The PLC Interface option shall be installable via a phone connection to any dialer already installed in the field. The PLC Interface option shall support reading coils status, input status, input register, and holding registers. The Interface shall support writing coils. The PLC Interface option shall provide for reading/writing up to 72 total channels of PLC I/O in any combination of registers. The Interface shall allow for up to 48 channels of physical I/O to exist in the dialer. All alarm notification, control and reporting functions that the dialer supports shall be operational for all PLC I/O being monitored, including remote voice access to all data and parameters.
Communcation between DialersAny dialer with the Modbus RTU option shall be able to communicate with any other dialer directly over a phone or cell phone connection to have complete activation and de-activation control of the relays on the called dialer.
Alarm NotificationThe dialer shall be capable of notifying alarm conditions by the following methods:
  • telephone and cell phone
  • digital and alphanumeric pager
  • Internet call-out
  • Internet call-in,LEDs
  • parallel printer
  • relay activation.
Each alarm channel is programmable to continue alarm notification if condition returns to normal.
Arming and DisarmingThe automatic dialer is capable of being armed or disarmed either manually or automatically based on time-of-day and day-of-week.
Arming or disarming is recorded to the event log.
Customer ServiceThe automatic dialer manufacturer has a toll-free number for customer service calls. The automatic dialer has a 2-key sequence that when pressed on the local keypad an automatic speaker phone call to the manufacturer's customer service facility is placed.
CertificationsFCC Part 15, Class B and Part 68 requirements with a FCC registration number of 6ODUSA-34830-AL-E.
Industry Canada registration of 4825A-SCOUT
CE Mark, tested by TUV Rheinland of North America View Declaration of Conformity
Safety IEC 60950 3rd Edition (UL 60950, CSA C22.2 no. 60950, EN 60950), NRTL listed for US and Canada.
International PSTN Certification according to Council Decision 98/682/EC for pan-European connections to public switched telephone network (PSTN). Compatible according to EG 201-121.
Warranty
 Five year warranty is standard with the purchase of a new unit.