Commander LI90 Series Controller User Manual Flowline Inc. 10500 Humbolt Street Los Alamitos, CA 90720 Tel: (562) 598-3015 Fax: (562) 431-8507 www.flowline.
of 57 PRELIMINARY MANUAL Commander LI90 Series 27 AUG 08 Rev 1_3
Preface This manual explains how to use the Commander LI90 series controller. Warranty, Service & Repair To register your product with the manufacturer, go to the Flowline website for on-line registration. The website address is as follows: www.flowline.com On-line Warranty Registration can be found under Contact Us in the Navigation Bar along the side of the home page.
Warranty Flowline warrants to the original purchaser of its products that such products will be free from defects in material and workmanship under normal use and service for a period which is equal to the shorter of one year from the date of purchase of such products or two years from the date of manufacture of such products. This warranty covers only those components of the products which hare non-moving and not subject to normal wear.
Table of Contents Safety Warnings and Guidelines ..........................................................................................6 Introduction ..........................................................................................................................7 Installation............................................................................................................................9 Panel Mounting .................................................................................
Safety Warnings and Guidelines When found on the product, the following symbols specify: Warning: Consult user documentation. Warning: Electrical Shock Hazard. WARNING: To avoid the risk of electric shock or burns, always connect the safety (or earth) ground before making any other connections. WARNING: To reduce the risk of fire, electrical shock, or physical injury it is strongly recommended to fuse the voltage measurement inputs. Be sure to locate fuses as close to the source as possible.
Introduction The Commander Series has three unique application configurations. The choice of application is field selectable. The three configurations are: • Multi-Tank Display (Application #1) – Commander will accept up to Four 4-20 mA input transmitters and will provide a 3A SPST relay output for each input. • Differential Level Controller (Application #2) – Commander will monitor the levels above and below a rake and control a relay based upon the defined differential between the two levels.
• 8 of 57 Pump Controller (Application #3) – Commander will accept a single 4-20 mA input transmitter and will provide up to Six 3A SPST relay outputs.
Installation • Overview o The mechanical installation greatly affects the operation, safety and appearance of the system. Information is provided to mechanically install the unit such as cut out sizes, mounting procedures and other recommendations for the proper mechanical installation of the unit.
• DIN Rail Mounting o The LI90 series is designed to clip onto standard 35 millimeter DIN rail. If your installation requires liquid or dust protection, make sure the controller is placed in an appropriate sealed panel when mounting on DIN rail. Use the following steps to mount on DIN rail. Move the DIN rail clip to the lower position. Clip the “Top Clips” on the top of the DIN rail. Press the unit into place and press the DIN rail clip up.
• Dimensions Front View • • • • Side View Temperature / Ventilation o Ensure that the panel layout design allows for adequate ventilation and maintains the specified ambient temperature range. Consider the impact on the design of the panel layout if operating at the extreme ends of the ambient temperature range. For example, if it is determined that a cooling device is required, allow adequate space and clearances for the device in the panel box or on the panel door.
Electrical • Grounding Definition o Ground: The term Ground is defined as a conductive connection between a circuit or piece of equipment and the earth. Grounds are fundamentally used to protect an application from harmful interference causing either physical damage such as by lightning or voltage transients or from circuit disruption often caused by radio frequency interference (RFI). • Ground Specifications o Ideally, a ground resistance measurement from equipment to earth ground is 0 ohms.
• Wiring o Power • Connect to Earth Ground. Apply 10 - 30 VDC. o Inputs • Commander can connect up to four 4-20 mA inputs.
o Outputs • Commander can connect up to 6 relays, depending on the application selection. • Relays can switch voltages up to 275 VAC, 30 VDC with a maximum output current of 3 A at 250 VAC, resistive.
Specifications Display Graphics/Text: Pixels: Display Technology: Keypad Touch screen Total Keys: Function Keys: Controller Memory: Logic Scan Rate: Memory Card Slot: General Specs Height: Width: Depth: Weight: Environmental: Wash down: Max. panel thickness: Cut-out: Required Power Steady State: Inrush: Primary Power Range: Relative Humidity: Clock Accuracy: Operating Temp.: Terminal Type: Certifications: Analog Inputs Number of Channels: Input Ranges: Max.
Startup • When the Commander is powered for the first time, the LI90 series will allow the end user to select the application to be used. Follow the instructions on the screen to choose the application. o Application #1 / Multi-Tank Display (Press F2) – Commander will accept up to Four 4-20 mA input transmitters and will provide a 3A SPST relay output for each input.
o Application #2 / Differential Level Controller (Press F3) – Commander will monitor the levels above and below a rake and control a relay based upon the defined differential between the two levels. In addition, a differential alarm can be programmed as well as individual alarms for each input. o Application #3 / Pump Controller (Press F4) – Commander will accept a single 4-20 mA input transmitter and will provide up to Six 3A SPST relay outputs.
• If you need to change the application selection, press and hold the ESC button for 5 seconds. This will return you to the Selection Screen and allow for a new application to be selected. o The selection can be accessed at any time.
Common Information – There are several configuration aspects that are similar for all three applications in the LI90 series. • Analog Input o The Commander accepts any 4-20 mA signal. o The Commander has the ability to accept a 4-20 mA that has been scaled to the size of the tank / vessel or with a 4-20 mA that is from a non-configured transmitter (in its original factory setup). o There are six parameters required to configure an analog input in the LI90 series. o For a scaled output.
o For a non-scaled output. Use this description when using a transmitter that is either set with its original Factory Settings or with a transmitter that has a fixed (non-configurable) 4-20 mA output: • • • • • • 20 of 57 Sensor Max. Range – This is the maximum range of the sensor. This is typically the 4 mA set point for the sensor. Use the sensor’s manual to obtain the sensors maximum range (4 mA output). Sensor Dead Band – This is the dead band for the level sensor.
Application #1 • Overview o Multi-Tank Display – The LI90 series in this application is typically used to eliminate the need of one display for each transmitter. This application can accept up to Four 4-20 mA input transmitters and will provide a 3A SPST relay output for each input.
• General (Open Functions) o Opening Screen indicates the Level of Liquid in the tank/vessel along with the true analog (4-20 mA) input for channel #1 and the status of Relay #1 • Regardless on how the input level is configured, the bar graph will show the true 4-20 mA input provided by the sensor o Pressing the Lower Right Soft key will jump the display to a screen showing the same information for Channel #2.
• • The H.O.A. screen for each relay will indicate each relay, the current status of each relay and soft keys to jump back or to the next relay. The first time the LI90 series is powered up, all of the relays will be in the OFF mode. To activate the relay, you will need to change the relay mode to AUTO. • • • 27 AUG 08 Rev 1_3 AUTO – This mode places the relay in automatic. Relay will energize based upon the ON setting and will De-energize based upon the OFF setting.
• General (Secured Functions) o The configuration of the display/input and relays/output are all under the secured section of the display. o To access these functions, press and hold the ENTER key for 5 seconds. The display will jump to the configuration section.
• Configuration of Inputs o Once in the Secured Function Section, press the Config Inputs soft key o Press the Next or Back soft keys to scroll to the input you would like to configure. o Upon selecting an input channel, the controller will ask for the following 6 settings to configure the input. The first four settings must be in the same units (i.e. inches, cm, feet, m, etc.) typically in units of length. The last two settings can be in any engineering units as long as they are the same (i.e.
Scaled 4-20 mA Output Fixed 4-20 mA Output o To change a value, first press the Enter key • The value will be highlighted • Use the 10-digit keypad to enter the desired value • I.e. for 123.4, press the following keys: , , , <▼>, , • Press Enter when completed to store this value to memory • • 26 of 57 Follow the sequence above: • 1. Press Enter to begin • 2. Press F1 for number 1 • 3. Press F2 for number 2 • 4. Press F3 for number 3 • 5. Press ▼ for “.” • 6. Press F4 for number 4 • 7.
• Configuration of Outputs o Once in the Secured Function Section, press the Config Outputs soft key o Each relay will ask for a Relay ON and Relay OFF level.
• Follow the sequence above: • 1. Press Enter to begin • 2. Press F1 for number 1 • 3. Press F2 for number 2 • 4. Press F3 for number 3 • 5. Press ▼ for “.” • 6. Press F4 for number 4 • 7. Press Enter to save setting • The screen cannot change until a value is stored in memory.
Application #2 • Overview o Differential Level Controller – Commander will monitor the levels above and below a rake and control a relay based upon the defined differential between the two levels. In addition, a differential alarm can be programmed as well as individual alarms for each input.
• General (Open Functions) o Opening Screen indicates the Level of Liquid in the tank/vessel along with the true analog (4-20 mA) input for both input channel#1 and #2 • Regardless on how the input level is configured, the bar graph will show the true 4-20 mA input provided by the sensor o Pressing the Lower Right Soft Key will jump the display to show the following: • Channel 1 and 2, Channel 1 only, Channel 2 only, Relay Info… Channel 1 & 2 Channel 2 only 30 of 57 Channel 1 only Relay info PRELIMI
o In the Relay Info screen, pressing the upper right soft key will jump the screen to the HAND / OFF / AUTO (H.O.A.) functions for each relay. • The H.O.A. screen for each relay will indicate each relay, the current status of each relay and soft keys to jump back or to the next relay • AUTO – This mode places the relay in automatic. Relay will energize based upon the ON setting and will De-energize based upon the OFF setting. • OFF – This mode turns the relay OFF (de-energized).
• General (Secured Functions) o The configuration of the display/inputs and relays/outputs are all under the secured section of the display o To access these functions, press and hold the ENTER key for 5 seconds. The display will jump to the configuration section.
• Configuration of Inputs o Once in the Secured Function Section, press the Config Inputs soft key o Press the Next or back soft keys to scroll to the input you would like to configure. o Upon selecting an input channel, the controller will ask for the following 6 settings to configure the input. The first four settings must be in the same units (i.e. inches, cm, feet, m, etc.) typically in units of length. The last two settings can be in any engineering units as long as they are the same (i.e.
Scaled 4-20 mA Output Fixed 4-20 mA Output o To change a value, first press the Enter key • The value will be highlighted • Use the 10-digit keypad to enter the desired value • I.e. for 123.4, press the following keys: , , , <. >, , • Press Enter when completed to store this value to memory • • 34 of 57 Follow the sequence above: • 1. Press Enter to begin • 2. Press F1 for number 1 • 3. Press F2 for number 2 • 4. Press F3 for number 3 • 5. Press ▼ for “.” • 6.
• Configuration of Outputs o Once in the Secured Function Section, press the Config Outputs soft key • Relays #1 and #2 will ask for a Relay ON and Relay OFF level.
• To change a value, first press the Enter key • The value will be highlighted • Use the 10-digit keypad to enter the desired value o I.e. for 123.4, press the following keys: , , , <.>, , • Press Enter when completed to store this value to memory • • 36 of 57 Follow the sequence above: • 1. Press Enter to begin • 2. Press F1 for number 1 • 3. Press F2 for number 2 • 4. Press F3 for number 3 • 5. Press ▼ for “.” • 6. Press F4 for number 4 • 7.
• Relays #3 and #4 will ask for a Differential ON and Differential OFF level. These settings must be in the same units used for the Empty and Full settings.
Application #3 • Overview o Pump Controller – The LI90 series in this application is typically used to provide multiple relay contacts for a single 4-20 mA input. Relays 5 and 6 can be combined to be programmed as duplexing / alternating relays.
• General (Open Functions) o Opening Screen indicates the Level of Liquid in the tank/vessel along with the true analog (4-20 mA) input • Regardless on how the input level is configured, the bar graph will show the true 4-20 mA input provided by the sensor o Pressing the Lower Left Soft key will jump the display to indicate the relay status. Above the relay status will be the liquid level.
• General (Secured Functions) o The configuration of the display, relays and simulations are all under the secured section of the display o To access these functions, press and hold the ENTER key for 5 seconds. The display will jump to the configuration section.
• Configuration of Inputs o Once in the Secured Function Section, press the Config Inputs soft key o Next, select if the application will show a Scaled Input or a Volumetric Input • • • Scaled Input – Allows for the current inputs to display in any engineering units the linear scale from the current Volumetric Input – Calculates the total volume (gallons or liters) for both vertical or horizontal tanks Scaled Inputs o The controller will ask for the following 6 settings to configure the input.
• • • • Empty Setting – This is the display value when the tank is empty Full Setting – This is the display value when the tank is full Use the Next soft key to advance to the next setting Use the Back soft key to return to the previous setting Scaled 4-20 mA Output Fixed 4-20 mA Output o To change a value, first press the Enter key • The value will be highlighted • Use the 10-digit keypad to enter the desired value • I.e. for 123.4, press the following keys: , , , <.
• Volumetric Inputs o The controller will ask basic shape and dimensional information in order to display either the gallons or liters within the tank or vessel. • Dimensional information must be entered as either inches or cm. • Dimensional inches must show gallons and cm must show liters. • Transmitter must be configured such that tank empty is 4 mA and tank full is 20 mA. o Select between either Vertical Tanks or Horizontal Tanks.
o Vertical Tanks – Select among Rectangular, Round Bottom or Cone Bottom. Rectangular Cone Bottom 1. Sensor Height 2. Tank Height 3. Tank Width/Diameter 4. Tank Length/Cone • • • • • • 44 of 57 Round Bottom Sensor Height – This is the distance from the bottom of the tank to the bottom of the sensor Tank Height – This is a dimension for either the Height of the Tank or the Height of the Straight Side of the cone bottom tank.
o Horizontal Tanks – Select among Flat Ends or Round Ends. Length Diameter Flat Ends • • • • • • 27 AUG 08 Rev 1_3 Round Ends 1. Sensor Height 2. Tank Length 3. Tank Diameter 4. End Cap Length Sensor Height – This is the distance from the bottom of the tank to the bottom of the sensor Tank Length – This is a length of the tank. Tank Diameter – This is diameter of the tank. End Cap Length – This is the distance for one of the end caps.
• Configuration of Outputs o Once in the Secured Function Section, press the Config Outputs soft key o Each relay will ask for a Relay ON and Relay OFF level.
o To change a value, first press the Enter key • The value will be highlighted • Use the 10-digit keypad to enter the desired value • I.e. for 123.4, press the following keys: , , , <. >, , • Press Enter when completed to store this value to memory • Follow the sequence above: • 1. Press Enter to begin • 2. Press F1 for number 1 • 3. Press F2 for number 2 • 4. Press F3 for number 3 • 5. Press ▼ for “.” • 6. Press F4 for number 4 • 7.
o Select either an Independent Relay #5 and #6 or Duplexing Relays #5 and #6. Independent Relay #5 & #6 Duplex Relay #5 & #6 Alternate Relay #5 and #6 o Independent Relays – Relays #5 and #6 perform the same as relays #1 through #4. The two relays are not linked together. o Duplex Relays – Relays #5 and #6 are linked together with two unique start levels and a common off position. The relays will also alternate between each LEAD start.
• To use as Independent Relay mode, press the IND soft key and then press Next. Independent Relays #5 and #6 • Enter the Relay #5 ON set point (where Relay #5will energize) and press Next • Enter the Relay #5 OFF set point (where Relay #5 will de-energize) and press Next • Enter the Relay #6 ON set point (where Relay #6 will energize) and press Next. • Enter the Relay #6 OFF set point (where Relay #6 will de-energize) and press Next.
• To change to an Alternation mode, press the DUP soft key and then press Next. Alternate Relays #5 and #6 • Enter the LEAD ON relay set point (where relay #5 will energize) and press Next • Enter the ALL OFF relay set point (where both relays will de-energize) and press Next • Enter the LAG ON relay set point (where relay #6 will energize) and press Next. o You do not need to provide a value for Relay #6 OFF. o Alternate can be used as a Filling or Emptying configuration.
Appendix Simulation Mode This mode enables the end user to simulate changes in level without having the level of liquid move. The display will simulate level of liquid and will turn the relays ON and OFF according to how they were configured. For example, if Relay 1 is set as a Pump Empty with an ON setting for 100.0 inches and an OFF setting of 30.0 inches, then when the display goes above 100.0, Relay 1 will energize and when the level falls below 30.0, Relay 1 will de-energize.
o Next, press the Begin Simulation soft key to proceed or the Back soft key to return o Next press the YES soft key to begin the Simulation o Simulation mode will begin after a short count down o Once in Simulation mode, use the two soft keys on the left to increase and decrease the level per your requirements o Check all active relays to verify operation o To exit from Simulation mode, press the Exit soft key in the lower right corner of the screen 52 of 57 PRELIMINARY MANUAL Commander LI90 Series 27
Factory Reset • At anytime, the Commander Series can be reset to its original factory settings. To do so perform the following: o Press and hold the F10 button for 10 seconds o Release the F10 button when the Factory Reset? Screen appears. o To reset, press the soft key for Yes and press F10 to enter o The LI90 series will be reset to its original setting o Pressing Enter with NO active will return the display back to it current setting and nothing will be reset.
Changing Applications • If you need to change the application selection, press and hold the ESC button for 5 seconds. This will return you to the Selection Screen and allow for a new application to be selected. o The selection can be accessed at any time.
Removable Media for Data Transfer Overview • All Commander models provide a Removable Media slot, labeled Memory, which supports standard Micro SD Flash memory cards. Micro SD cards can be used to save and load applications, to capture graphics screens and to log data for later retrieval. Micro SD Cards • When the Micro SD card format was introduced, it was originally called TransFlash. Cards labeled either Micro SD or TransFlash, with up to 2.
Using Removable Media to Log Data • The Commander has the feature of logging data to a Micro SD card in the form of comma-delimited files, with a .CSV extension. These files are compatible with standard database and spreadsheet PC programs. • • • To activate the data log in the commander, press and hold the Left Arrow (shown above) for 10 seconds. When Data Log Activated appears, release the button. The unit will log the four analog inputs at rate of once per 15 seconds.
Troubleshooting PROBLEM No power to the transmitters No power from the relay contacts Relays stays OFF all the time 27 AUG 08 Rev 1_3 SOLUTION The Analog Inputs are not internally powered. Power for transmitters must be provided from an alternative source. Typically, it is the same power supply that is providing power to the LI90-1001. All of the relays are dry contact relays. Power for the device the relays are switching must come from an alternative source.
