Quadratrol
Level Controller Specification
Brochure (PDF
File)
 1.
The pump control device shall be able to control up to four pumps to
perform liquid level control. The device must be capable of controlling
any mix of constant speed and variable speed pumps. It shall be capable
of alternating the pumps, and shall provide lag pump delays and high
and low level alarms.
2. The pump control device shall be standard “off the shelf” equipment
with published literature and fully tested hardware and operating program.
The device must be field configurable from the front of the unit, and
require no special tools or software to set-up or operate. It shall be
a microprocessor-based device and not require a battery to maintain the
operating program. All set-up values shall be stored in non-volatile
memory.
3. The pump control device shall be UL listed as Industrial Control
Equipment, UL 508.
4. A numerical level display must be provided on the front of the unit.
It shall have a 3 digit, 7 segment LED display and show levels in feet
and tenths of feet.
5. The pump controller shall not require an external power supply or
any external I/O modules to be a fully functioning unit. An isolated
analog input (4-20mA) with zero and span adjustments must be provided
for the wet-well level input. Relay outputs must be provided as standard
for high and low level alarms and for the control of up to four pumps.
Up to four analog outputs (4-20mA) must be available, as an option, for
VFD speed control when needed. Up to four isolated analog inputs (4-20mA)
inputs must also be available, as an option, for use when needed as telemetry
inputs. All electrical connections, for power or I/O, must be by quick-disconnect,
phoenix-style connectors.
6. The pump control device must have at least 18 discrete inputs. The
inputs must be transient protected and be programmable for the following
functions:
- Pump disable with HOA in OFF, or pump fault
- External Alternator Selector Switch
- All pump disable – for connection to Phase Monitor
- Limit number of pumps, called to run, while on emergency power
- Alternation by External Time Clock
- Freeze wet well level during a bubbler tube purge
- Call pump last – for connection to VFD/Bypass logic
- Pump disable upon low level – for connection to low level float switch
- Float switch backup
- Bubbler system fault
- A variety of telemetry functions
7. Trouble shooting features must include a fault indicator on the front
of the unit and retrievable fault codes that aid in diagnosing most common
problems.
8. Status of the discrete inputs must also be viewable from the front of the
unit.
9. A level simulation feature must also be available from the front of the
unit. If left in the level simulation mode, the controller must reset to normal
operation after sixty seconds.
10. Menu selectable First-On/First-Off or First-On/Last-Off alternation
sequences must be available.
11. Six menu selectable alternation modes must include:
Standard alternation
Jockey pump with pump 1 always lead, stays on with other pumps
Jockey pump with pump 1 always lead, goes off with other pumps
Split alternation – Pumps 1 & 2 and Pumps 3 & 4
Fixed sequence – Pump 1 always lead
Stepped On/Off – Only one pump runs at a time
12. Pump disable discrete inputs must cause the alternator to skip over
disabled pumps.
13. Where VFDs are required to match pumping rate with in-flow rate,
the control device must provide an isolated analog output (4-20mA) for
each VFD for speed control. Menu selectable parameters must be available
to form a linear wet-well level versus pump speed curve.
14. An RS232 serial port with the Modbus protocol shall be provided
for SCADA. Modbus RTU or ASCII modes must be menu selectable. RTS and
CTS hardware connections along with all necessary programming must be
in place to fully interface with commonly used radio or telephone modems.
Programming must be in place to collect and transmit the station status,
and to allow for the remote control of the pumps. The pump On/Off levels,
high level alarm, and low-level alarm setup values must be viewable and
changeable from a remote location. Pump elapsed time meters must be viewable
and resettable from a remote location. Pump elapsed time meter values
must be stored in non-volatile memory during a power outage.
15. The Controller must have provisions for float back-up control built
into the unit.
16. The Controller must contain an internal power supply to power the
level input transducer.
17. The controller must be able to give an indication for the low and
high level alarms based on the transducer input or separate discrete
inputs.
Across-the-Line Pump Control using the Quadratrol Level Controller
The Quadratrol Controller is designed to perform level control with
up to four constant speed pumps in a wide variety of applications. Selection
of the number of pumps to control is easily accomplished by setting parameter
P.13 to the desired number of pumps, 1 through 4.
The Controller comes standard with four pump call to run relay outputs
for turning the pumps on and off. The Quadratrol comes standard with
one 4-20mA analog input for level input control. Additional settings
determine the number of pumps that can run at the same time, the number
of pumps to run under generator power, pump up or pump down, and first
on-first off, or first on-last off. The values for the on and off setpoints
are easily entered into the unit via the front keypad.
Variable Speed Pump Control for up to Four Pumps
VFD Operation with One Pump
Pump is off, and the level begins to rise. As the level rises to the
FIRST PUMP ON LEVEL, the VFD will run at the speed determined by where
on the speed-ramp curve that the pump is turned on at. Setting up the
Quadratrol for VFD operation is straightforward and simple, requiring
setting only three parameters, parameters 20, 21, and 22. VFD MINIMUM
SPEED is set by Parameter 20, and the LEVEL AT MINIMUM SPEED is set by
Parameter 21. LEVEL AT 100% SPEED is set by Parameter 22.
The VFD will continue to run at 100% speed until the level drops below
the setting of parameter 22, at which time the speed will decrease with
the level. When the setting for parameter 21 is reached, the VFD speed
will remain at the minimum speed until the level falls to the 1ST PUMP
OFF LEVEL setpoint, at which time the VFD/Pump will be turned off.
VFD Operation with Two Pumps
Both Pumps are off, and the level begins to rise. As the level rises
to the 1st PUMP ON LEVEL, the FIRST VFD will run at the speed determined
by where on the speed-ramp curve that the pump is turned on at. Setting
up the Quadratrol for VFD operation is straightforward and simple, requiring
setting only three parameters, parameters 20, 21, and 22. VFD MINIMUM
SPEED is set by Parameter 20, and the LEVEL AT MINIMUM SPEED is set by
Parameter 21. LEVEL AT 100% SPEED is set by Parameter 22.
As the level continues to rise, the SECOND VFD will bring on the second
pump when the level reaches the setpoint for the 2nd PUMP ON LEVEL. The
speed at which the second pump would be called to run at is determined
by where on the speed-ramp curve the SECOND VFD is called to run.
If 100% speed has been achieved, the SECOND VFD will continue at this
speed until the level drops below the setting of parameter 22, at which
time the speed will decrease with level.
The SECOND VFD will shut off at the 2ND PUMP OFF LEVEL, which is typically
above the setpoint of the 1st PUMP OFF LEVEL, when using the selection
of First-On, Last-Off pump stop mode, Parameter 17.
The FIRST VFD’s speed will continue to decrease with the decrease
in level. When the setting for parameter 21 is reached, the FIRST VFD
speed will remain at the minimum speed until the level falls to the 1ST
PUMP OFF LEVEL setpoint, at which time the FIRST VFD will be turned off.
VFD Operation with Three Pumps
All three Pumps are off, and the level begins to rise. As the level
rises to the 1st PUMP ON LEVEL, the FIRST VFD will run at the speed determined
by where on the speed-ramp curve that the pump is turned on at. Setting
up the Quadratrol for VFD operation is straightforward and simple, requiring
setting only three parameters, parameters 20, 21, and 22. VFD MINIMUM
SPEED is set by Parameter 20, and the LEVEL AT MINIMUM SPEED is set by
Parameter 21. LEVEL AT 100% SPEED is set by Parameter 22.
As the level continues to rise, the SECOND VFD will bring on the second
pump when the level reaches the setpoint for the 2nd PUMP ON LEVEL. The
speed at which the second pump would be called to run at is determined
by where on the speed-ramp curve the SECOND VFD is called to run.
As the level continues to rise, the THIRD VFD will bring on the third
pump when the level reaches the setpoint for the 3rd PUMP ON LEVEL. The
speed at which the third pump would be called to run at is determined
by where on the speed-ramp curve the THIRD VFD is called to run.
If 100% speed has been achieved, the THIRD VFD will continue at this
speed until the level drops below the setting of parameter 22, at which
time the speed will decrease with level.
The THIRD VFD will shut off at the 3rd PUMP OFF LEVEL, which is typically
above the setpoint of the 1st and 2nd PUMP OFF LEVELS when using the
selection of First-On, Last-Off pump stop mode, Parameter 17.
The SECOND VFD will shut off at the 2ND PUMP OFF LEVEL, and the FIRST
VFD will continue to run and the speed will decrease with the level.
When the setting for parameter 21 is reached, the FIRST VFD speed will
remain at the minimum speed until the level falls to the 1ST PUMP OFF
LEVEL setpoint, at which time the FIRST VFD will be turned off.
VFD Operation with Four Pumps
All four Pumps are off, and the level begins to rise. As the level rises
to the 1st PUMP ON LEVEL, the FIRST VFD will run at the speed determined
by where on the speed-ramp curve that the pump is turned on at. Setting
up the Quadratrol for VFD operation is straightforward and simple, requiring
setting only three parameters, parameters 20, 21, and 22. VFD MINIMUM
SPEED is set by Parameter 20, and the LEVEL AT MINIMUM SPEED is set by
Parameter 21. LEVEL AT 100% SPEED is set by Parameter 22.
As the level continues to rise, the SECOND VFD will bring on the second
pump when the level reaches the setpoint for the 2nd PUMP ON LEVEL. The
speed at which the second pump would be called to run at is determined
by where on the speed-ramp curve the SECOND VFD is called to run.
As the level continues to rise, the THIRD VFD will bring on the third
pump when the level reaches the setpoint for the 3rd PUMP ON LEVEL. The
speed at which the third pump would be called to run at is determined
by where on the speed-ramp curve the THIRD VFD is called to run.
As the level continues to rise, the FOURTH VFD will bring on the fourth
pump when the level reaches the setpoint for the 4th PUMP ON LEVEL. The
speed at which the fourth pump would be called to run at is determined
by where on the speed-ramp curve the FOURTH VFD is called to run.
If 100% speed has been achieved, the FOURTH VFD will continue at this
speed until the level drops below the setting of parameter 22, at which
time the speed will decrease with level.
The FOURTH VFD will shut off at the 4th PUMP OFF LEVEL, which is typically
above the setpoint of the 1st, 2nd, and 3rd PUMP OFF LEVELS when using
the selection of First-On, Last-Off pump stop mode, Parameter 17.
The THIRD VFD will shut off at the 3rd PUMP OFF LEVEL. The SECOND VFD
will shut off at the 2ND PUMP OFF LEVEL, and the FIRST VFD will continue
to run and the speed will decrease with the level. When the setting for
parameter 21 is reached, the FIRST VFD speed will remain at the minimum
speed until the level falls to the 1ST PUMP OFF LEVEL setpoint, at which
time the FIRST VFD will be turned off.
VFD Operation with Bypass
When the controls contain VFD/Bypass selector switches, a contact from
the VFD/Bypass switch may be fed into the Quadratrol Level Controller,
allowing the Quadratrol to call last any pump that is in the “Bypass” mode
rather than the “VFD” mode. With these contacts fed into
the Quadratrol Level Controller, the Quadratrol will alternate through
its alternation sequence, which depends upon the number of pumps for
the application (Parameter P.13) and the number of pumps allowed to run
at any one time (Parameter P.14). Any pump(s) on bypass will be the last
to be called in the alternation sequence selected.
Quadratrol Level Controller Part Number
The Controller shall be manufactured by Sun Coast Hydraulic Electric
Mfg of Jacksonville, Florida (904) 693-3318. For part number Quadratrol-XX,
where the first X signifies the number of analog outputs, and the second
X signifies the number of analog inputs. (The Quadratrol Level Controller’s
analog input for level control comes standard to each unit, and does
not count toward the second X in the part number.) |
