ALDERON FLXP1D Flex Power Pak Duplex User Manual

ALDERON FLXP1D Flex Power Pak Duplex User Manual

Introduction

The Flex Power Pak Duplex is a control panel capable of controlling and monitoring two pumps and five sensor inputs. It can be configured as a five floa  panel, or as a four float + one transducer panel. Additionally, it features  pump seal fail sensor inputs, auxiliary cutout inputs, and optional current sensor inputs for each pump. Pump mode control (hand mode, off mode, and auto mode) are controlled via buttons on the inner front door of the control panel. For controlling the pumps, the panel can be equipped with either contactors or with a cost saving replaceable power relay board. The Flex Power Pak can be configured for demand dose or time dose control. An auxiliary dry contact output is also included for interfacing to remote alarms or to building automation systems. This panel also features a menu system to enable maximum field configuration as well as thorough statistics tracking. Finally, the panel can be connected to Vizzysite for remote tracking, control, and configuration

Before Installation

Before proceeding with the installation or operation of the control panel read all instructions thoroughly, as well as comply with all Federal, State and Local Codes, Regulations and Practices. The control panel must be installed by qualified personnel familiar with all applicable local electrical and mechanical codes. Refer to the National Electrical Code (NFPA 70). Failure to properly install and test this product can result in personal injury or equipment malfunction. All conduit connected to the panel must be sealed with conduit sealant to prevent moisture or gases from entering the panel. NEMA 1 enclosures are for indoor use only while NEMA 4X panel enclosures may be used indoor or outdoor. Refer to panel model name plate on inside of door for enclosure rating.

Note : If options are ordered that affect the number of floats, refer to the panel schematic for complete information.

Safety Guidelines

WARNING

1. DO NOT USE WITH FLAMMABLE OR EXPLOSIVE FLUIDS SUCH AS GASOLINE, FUEL OIL, KEROSENE, ETC. DO NOT USE IN EXPLOSIVE ATMOSPHERES. CONTROL PANEL SHOULD ONLY BE USED IN WATER AND WASTEWATER APPLICATIONS THAT ARE NOT RATED AS A HAZARDOUS LOCATION.
2. DO NOT WORK ON THE CONTROL PANEL WITH LIVE VOLTAGE APPLIED TO THE CONTROL PANEL WITH WET HANDS OR WHEN STANDING ON A WET SURFACE.
3. DISCONNECT ALL ELECTRICAL SERVICE BEFORE WORKING ON OR HANDLING THE CONTROL PANEL
4. INCOMING VOLTAGE MUST MATCH THE CONTROL PANEL VOLTAGE. REFER TO THE PANEL SCHEMATIC FOR COMPLETE INFORMATION.

Menu System

Interface
The user interface of the Flex Power Pak comprises a 16×2 OLED display, three RGB indicator LEDs, and a rotary knob (scroll wheel) used to navigate the menu system. While the system is idle, the menu screen will be turned off to conserve the life of the display. To wake it up, simply make any input on the menu navigation knob.

Navigating the Menu
The scroll wheel is used for all user inputs to the menu system. This includes navigation, configuration inputs, alarm clears, and so on. Below is a table summarizing the interface to the menu system.

this may
Test/Silence Switch| start the system test routine; to cancel, make any input with the scroll wheela

Menu Conventions

There are a set of arrow indicators that will appear on the bottom line of the display to aid with menu navigation. Below is a table summarizing these indicators:

config from here. Press the scroll wheel to take this action.
Left Arrow on Bottom Right| | The user can navigate backwards from here. Press the scroll wheel to take this action.
Blinking Right Arrow on Bottom Left| | A config is being modified when this is shown. Scroll the wheel to change the config. Press the scroll wheel to commit the change. To cancel the input, either wait for the timeout OR press the test/silence switch to exit the menu
Enter Arrow on Bottom Right| | This arrow indicates a config can be committed. Press the knob to commit OR cancel the input as described in the entry above.

To Change a Setting
Configurations on the Flex Power Pak are organized into a config path type structure similar to a file path on a computer. All configuration “paths” are of the type shown below.

All configurations are located behind the password in the menu. After the password, configurations are organized into groups, sub-groups, and individual configurations. The config “path” for every configuration is displayed in the table in Available Settings.

Please see the Settings section of this document for an exhaustive list of all available configurations.

To Clear an Alarm
To clear an alarm, simply scroll to it in the main screen (press the test/silence switch to jump there) and then press the rotary knob. A confirmation screen will appear and ask if the alarm should be cleared. Press the knob again to clear the alarm.

Note that if the alarm immediately re-activates and the buzzer activates again, this means that the alarm condition is still present and the system cannot clear the alarm. If this happens, check for the source of the alarm

Quick Setup Guide

This section will cover all of the information needed to get a panel up and running for its specific application. It will cover running the Setup Wizard, which will configure the most important configurations, as well as several examples of optional configurations that can be used to customize the application. An exhaustive list of configurations can be found in the Settings section of the Wiki (https://wiki.aind.co/ L ).

System Setup with the Setup Wizard

The Setup Wizard will set the critical system configurations and get a system up and running quickly. It will configure all inputs as well as basic pump configurations. Refer to the panel schematic to see what each input will be configured as by default.

Step 1
Run the Setup Wizard by following the menu path shown below.

This will configure all of the primary configurations for the panel, including:

• Dosing Type
• Transducer Configurations
• Float Configurations
• Pump Current Monitoring Configurations (only on models with current sensing)

Step 2 (In Setup Wizard)
Set Dosing Configuration. This configures the system for Demand Dosing or Time Dosing. Note: this is the only way to change this setting.

In Demand Dose Mode, if the start float triggers the pump will run continuously until the stop float goes down.

In Time Dose Mode, when the timer enable float triggers the system will time dose until the timer enable float goes down. If this option is selected, the system will ask the user to configure all of the dose time information.

Step 3 (In Setup Wizard)

Enable or Disable the Transducer Input This will configure Input 5 to be either a 4-20 mA pressure transducer or a regular float input.

If the transducer is enabled, the system will then ask the user to enter the basic transducer configurations.

If the transducer is disabled, the system will skip the transducer configuration options.

Step 4 (In Setup Wizard)

Configure the Float Inputs. This will configure the float inputs of the system.

If the transducer was enabled, the system will ask whether or not a 2-float backup should be activated. This will set a Low Alarm/Redundant Off Float and a High Alarm/Redundant Start Float as backups in case the transducer fails.

Otherwise, if the transducer was disabled, it will ask the user to enable or disable the Low Alarm Float and whether or not the Lag float should also activate a high water alarm.

Please refer to the panel schematic to see what each input will be configured as based on the above configuration s.

Step 5 (In Setup Wizard)

Enter Full Load Amps (FLA) for each pump (Only if the Panel Has Current Sensors). This will configure the high and low amps alarm points for each pump. The system will set the trip points at 25% above and below the FLA entered here. Note that both high and low amps can be field modified individually in the Pump Set Up section of the menu.

Optional Configurations

These configurations are not absolutely critical for each application, but can be useful for customizing the behavior of the panel.

Step 6 (Optional)

Set Pump Exercise Timer for each pump. If set, the exercise timer will run the pump for a set amount of time after it has been idle for the configured number of days. By default, the exercise timer is disabled.

the pump has been inactive for the indicated number of days, the system will briefly run the pump to maintain long term pump health.
Pump One Exercise Time| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 1->P1 EXERCISOR TIME| 0:00 – 5:00| This is how long in minutes and seconds pump one will run during an exercise event.
Pump Two Exercise Interval| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 2->P2 EXERCISOR INT| Disabled – 45 Days| This is the exercise timer for pump two. If the pump has been inactive for the indicated number of days, the system will briefly run the pump to maintain long term pump health.
Pump Two Exercise Time| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 2->P2 EXERCISOR TIME| 0:00 – 5:00| This is how long in minutes and seconds pump two will run during an exercise event.

Step 7 (Optional)
Change The System Password. This will change the password from the system default of 1919.

Step 8 (Optional)
Review the Settings section of this manual for any other configurations that may be relevant to the application. The system at this point is configured for a basic application. However, there are several other configurations available in the system that may be useful depending on the specific system requirements.

Stats

The Flex Power Pak panel tracks several statistics for the system. These are accessed through the menu system by following the menu path template shown below. Specific paths for each event’s stats are described in the Viewable Events section of this document.

Settings

Available Settings

General System Configurations

These settings modify general system behaviors, such as how long the buzzer stays silenced, how bright the pump run LEDs are, etc.

themselves once the error conditions are resolved. Note that this does not apply to pump errors; pump errors will always require user interaction.
Auxiliary Failsafe Mode| MENU->SETTINGS- >PASSWORD->SYSTEM SET UP->AUX FAILSAFE| DiWabled, Enabled| This setting flips the NO/NC contacts of the auxiliary contacts so that they will trip on system power loss.
Silence Time| MENU->SETTINGS- >PASSWORD->SYSTEM SET UP->SILENCE TIME| 0 – 99:59:59| This controls how long the buzzer will stay silenced after the silence button is pressed.
Pump Run LED Brightness| MENU->SETTINGS- >PASSWORD->SYSTEM SET UP->PUMP RUN LED| High, Med, Lo[, Off| This controls how bright the pump run indicator LEDs are.
System Normal LED Brightness| MENU->SETTINGS- >PASSWORD->SYSTEM SET UP->NORMAL LED| High, Med, Lo[, Off| This controls how bright the system normal indicator LEDs are.
Password Change| MENU->SETTINGS- >PASSWORD->SYSTEM SET UP->PASSWORD| 0000 – 9999| This is the system password. It can be changed from here.

General Pump Configurations
These configurations modify the behavior of the pumps in the system

shut off their pump.
High Amps Alarm Configuration| MENU->SETTINGS- >PASSWORD- >PUMP SET UP- >HIGH AMP ALARM| Alarm Only, Alarm + Stop| This controls whether or not high amp alarms shut off their pump. Note that this is only visible if at least one of the pumps has its current sensor enabled.
Finish Dose Enable| MENU->SETTINGS- >PASSWORD- >PUMP SET UP- >FINISH DOSE| Disabled, Enabled| If enabled, pumps will finish their dose on cycle even if the stop float goes down. If disabled, the pump will stop running immediately if the stop float goes down.
Extra Peak Doses| MENU->SETTINGS- >PASSWORD- >PUMP SET UP- >XTRA PK DOSES| 0-10| This is the number of peak doses that are done after the peak timer float has deactivated. This is used to make sure enough water is pumped out during a peak dosing event to prevent a repeat
Pump Lead Configuration| MENU->SETTINGS- >PASSWORD- >PUMP SET UP- >PUMP LEAD MODE| Alternate Lead, Pump 1 Lead, Pump 2 Lead| This sets which pump is the designated lead pump during a pumping event

Pump One Configurations

inputs will be unresponsive and the pump will never turn on.
Pump One Auxiliary Cutout Configuration| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 1->P1 AUX CUT OUT| Normally Open normally Open| This sets the contact type of the pump one auxiliary cut off input.
Pump One Current Sensor Enable| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 1->P1 CURRENT SENSE| Disabled, Enabled| This enables or disables the current sensor for pump one. Note that this is option is only available on systems shipped with a current sensor.
Pump One Over Current Level| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 1->P1 OVER CURRENT| 0 – 50 Amps| This is the over current threshold for pump one. This is only visible if the current sensor is enabled.
Pump One Under Current Level| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 1->P1 LOW AMP LVL| 0 – 50 Amps| This is the under current threshold for pump one. This is only visible if the current sensor is enabled.
Pump One Flow Rate| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 1->P1 FLOW RATE| 0 – 999 GPM| This is the under current threshold for pump one. This is only visible if the current sensor is enabled.
Pump One Exercise Interval| MENU->SETTINGS- >PASSWORD->PUMP| Disabled – 45 Da]W| This is the flowrate for pump one. It is used to calculate total gallons pumped.
| SET UP->PUMP 1->P1 EXERCISER INT| | the indicated number of days, the system will briefly run the pump to maintain long term pump health.
Pump One Exercise Time| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 1->P1 EXERCISER TIME| 0:00 – 5:00| This is how long in minutes and seconds pump one will run during an exercise event.
Pump One Extended Run Alarm| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 1->P1 EXT RUN ALARM| 00:00:00 – 99:59:59| This is how long the system will run the pump before triggering an extended run time alarm. To disable this, set the time to zero.
Pump One Dose On Time| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 1->P1 DOSE ON TIME| 0 – 30:59| This is the duration of the dose on portion of the dosing cycle.
Pump One Dose Off Time| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 1->P1 DOSE OFF TIME| 0 – 24:00:00| This is the duration of the dose off portion of the dosing cycle.
Pump One Peak On Time| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 1->P1 PEAK ON TIME| 0 – 30:59| This is the duration of the dose on portion of the peak dosing cycle. This cycle is used during high water alarms.
Pump One Peak Off Time| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 1->P1 PEAK OFF TIME| 0 – 24:00:00| This is the duration of the dose off portion of the peak dosing cycle. This cycle is used during high water alarms.

Pump Two Configurations

inputs will be unresponsive and the pump will never turn on.
Pump Two Auxiliary Cutout Configuration| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 2->P2 AUX CUT OUT| Normal] Oaten, Normal] Clowned| This sets the contact type of the pump two auxiliary cut off input.
Pump Two Current Sensor Enable| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 2->P2 CURRENT SENSE| disabled, Enabled| This enables or disables the current sensor for pump two. Note that this is option is only available on systems shipped with a current sensor
Pump Two Over Current Level| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 2->P2 OVER CURRENT| 0 – 50 Amps| This is the over current threshold for pump two. This is only visible if the current sensor is enabled.
Pump Two Under Current Level| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 2->P2 LOW AMP LVL| 0 – 50 Amps| This is the under current threshold for pump two. This is only visible if the current sensor is enabled.
Pump Two Flow Rate| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 2->P2 FLOW RATE| 0 – 999 GPM| This is the flowrate for pump two. It is used to calculate total gallons pumped.
Pump Two Exercise Interval| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 2->P2 EXERCISER INT| disabled – 45 Da]W| This is the exerciser for pump two. If the pump has been inactive for the indicated number of days, the system will briefly run the pump to maintain long term pump health.
Pump Two Exercise Time| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 2->P2 EXERCISER TIME| 0:00 – 5:00| This is how long in minutes and seconds pump two will run during an exercise event.
Pump Two Extended Run Alarm| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 2->P2 EXT RUN ALARM| 00:00:00 – 99:59:59| This is how long the system will run the pump before triggering an extended run time alarm. To disable this, set the time to zero.
Pump Two Dose On Time| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 2->P2 DOSE ON TIME| 0 – 30:59| This is the duration of the dose on portion of the dosing cycle. .
Pump Two Dose Off Time| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 2->P2 DOSE OFF TIME| 0 – 24:00:00| This is the duration of the dose off portion of the dosing cycle
Pump Two Peak On Time| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 2->P2 PEAK ON TIME| 0 – 30:59| This is the duration of the dose on portion of the peak dosing cycle. This cycle is used during high water alarms.
Pump Two Peak Off Time| MENU->SETTINGS- >PASSWORD->PUMP SET UP->PUMP 2->P2 PEAK OFF TIME| 0 – 24:00:00| This is the duration of the dose off portion of the peak dosing cycle. This cycle is used during high water alarms.

Input Configurations
These configurations change the behavior of the inputs of the system.
General Input Configurations

activate out of order. For example, if the start float activates before the stop float an error will be activated for the stop float.
Seal Sensor Type| MENU->SETTINGS- >PASSWORD->INPUT SET UP->SEAL INPUT TYPE| Normally Open, Normally Closed| This configures the seal fail sensor input type. A normally open sensor will alarm when the input is closed (sensor in water). A normally closed sensor will trigger an alarm when the sensor wires are opened (the seal fail relay on the pump opened).
Sensitivity| SET UP->WATER SENSOR ONE| | approximate resistance at which the input will activate. 100K is the most sensitive, and 10K is the least sensitive
Water Sensor Two Sensitivity| MENU->SETTINGS- >PASSWORD->INPUT SET UP->WATER SENSOR TWO| 10K – 100K| This is the sensitivity of water sensor (seal fail sensor) two. It represents the approximate resistance at which the input will activate. 100K is the most sensitive, and 10K is the least sensitive

Input Functions

All of the sensor inputs of the Flex Power Pak are configurable to a subset of the functions shown below. The inputs come factory configured to the functions shown in the panel schematic, but can be changed by the installer in the field. These configurations determine what each input does when it activates.

Below is a brief summary of all available input functions.

start the lead pump. On deactivation, will turn off any active pumps.
3| Stop Float| This is a stop float.
4| Lead/Start| This is a pump start float. Starts the lead pump in the system on activation.
5| Lag Float| This is the lag float. Starts the lag pump in the system on activation.
6| Lag/Alarm| This is a lag float that also activates a high water alarm. Will start the lag pump and start a high water alarm.
7| Timer 7 Enable| This is the timer enable float. It will start a time dosing cycle for the lead pump.
8| Peak Timer| This is the peak timer start float. It will start a peak time dosing cycle for the currently active pump.
9| High Alarm| This is a high water alarm float. Will start a high water alarm on activation.
10| Aux Alarm| This is a general use alarm input. Will start the Aux Alarm event on activation.
11| Transducer| This sets the input to function as a transducer. Note that this is only available on input 5.

Below are the configurations for the system inputs. Please reference the above table when reading the range column.

Transducer Configurations
These are the configurations for the transducer. Note that these settings will only be accessible if input five is set to transducer mode.

for the transducer will be 12V. If enabled, the voltage will be 24V
Transducer Response Type| MENU->SETTINGS- >PASSWORD->INPUT SET UP->TRANSDUCER CONFIG->RESPONSE TYPE| “LO/HI: 4/20 mA”, “LO/HI: 20/4 mA”| This setting controls the response of the transducer input to higher and lower readings. Use this if the system is using an ultra-sonic transducer with a reversed response to water depth (i.e., a maximum sensor output when the water is lowest).
Display Mode| MENU->SETTINGS- >PASSWORD->INPUT| © 2023 Alderon Industries. All rights reserved.| In absolute mode, the transducer readings are shown in feet/inches or
Transducer Display Units| MENU->SETTINGS- >PASSWORD->INPUT SET UP->TRANSDUCER CONFIG->DISPLAY UNITS| Imperial, Metric| This controls the units transducer readings are displayed in
Transducer Rated Depth| MENU->SETTINGS- >PASSWORD->INPUT SET UP->TRANSDUCER CONFIG->RATED DEPTH| 0 – 99′ 11″ (30.45 meters)| This is the rated depth of a system transducer. Used to calculate depth from the 4 – 20 mA reading of the transducer.
Transducer Field Callibration| MENU->SETTINGS- >PASSWORD->INPUT SET UP->TRANSDUCER CONFIG->SET DEPTH| 0 – 99′ 11″ (30.45 meters)| This is used to calibrate the transducer. To calibrate, put the transducer into some known depth of water (or take it completely out of the water for a zero reading) and then set the correct depth with this setting.
Transducer Tank Height| MENU->SETTINGS- >PASSWORD->INPUT SET UP->TRANSDUCER CONFIG->TANK HEIGHT| 0 – 99′ 11″ (30.45 meXeVW)| This is the depth of the tank the transducer is monitoring. This is used to calculate depth percentage readings in relative display mode
Transducer Low Level Alarm Depth| MENU->SETTINGS- >PASSWORD->INPUT SET UP->TRANSDUCER CONFIG->LOW LEVEL ALARM DEPTH| 0 – 99′ 11″ (30.45 meters)| This is the low level alarm trip point of the transducer. Set to zero to disable.
Transducer Stop Level Depth| MENU->SETTINGS- >PASSWORD->INPUT SET UP->TRANSDUCER CONFIG->STOP LEVEL DEPTH| 0 – 99′ 11″ (30.45 meters)| This is the stop level trip point of the transducer. Set to zero to disable.
Transducer Lead/Start Level Depth| MENU->SETTINGS- >PASSWORD->INPUT SET UP->TRANSDUCER CONFIG->LEAD LEVEL DEPTH| 0 – 99′ 11″ (30.45 meters)| This is the lead level trip point of the transducer. Set to zero to disable.
Transducer Lag Level Depth| MENU->SETTINGS- >PASSWORD->INPUT SET UP->TRANSDUCER CONFIG->LAG LEVEL DEPTH| 0 – 99′ 11″ (30.45 meters)| This is the lag level trip point of the transducer. Set to zero to disable.
Transducer Lag/Alarm Level Depth| MENU->SETTINGS- >PASSWORD->INPUT SET UP->TRANSDUCER CONFIG->LAG/ALARM LEVEL DEPTH| 0 – 99′ 11″ (30.45 meters)| This is the lag/alarm level trip point of the transducer. Set to zero to disable.
Transducer Timer Override Level Depth| MENU->SETTINGS- >PASSWORD->INPUT SET UP->TRANSDUCER CONFIG->TIMER OVERRIDE| 0 – 99′ 11″ (30.45 meters)| This is the level at which peak time dosing will activate. Set to zero to disable
Transducer Aux Alarm Level Depth| MENU->SETTINGS- >PASSWORD->INPUT SET UP->TRANSDUCER CONFIG->AUX ALARM LEVEL| 0 – 99′ 11″ (30.45 meters)| This is the level over which the auxiliary alarm will activate. Set to zero to disable.

Config Code

Config codes on this product can be decoded by customer support to provide a snap-shot for how the system is configured. The code itself is a base 32 number that must be decoded to yield the system configurations.

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