PUMP BOSS

Intelligent Pump Control

Operation Manual

HOW SMART PEOPLE CONTROL CHEMICALS

 TABLE OF CONTENTS
September2008

PUMP BOSS

Introduction / Overview 3
Specifications 5
Inputs /Outputs 6
Installation 7
Connections\ Board layout 8
Compatible Flow Devices 9
Flow Verification Devices 10
Navigation 11
Programming 12
Automatic Pump Switchover 13
Proportional Dosing / PPM 15
Basic Timer Functions 17
Proportional Dosing with Timer & Auto Switchover 19
Menu Flow Charts 20
Wiring Diagram 23
Timer Settings Sheet 24
Default and User Settings Log 25
Warranty 26

Copyright ©2008 Chem Flow, Inc. All rights reserved

No part of this publication may be duplicated and/or published through printing, photo-copying, mi-
crofilm, electronically or via audio tapes or be stored in any other manner without prior written con-
sent from Chem Flow, Inc

2
 INTRODUCTION

The Pump Boss is a dual pump controller capable of complex pump control with a variety of
controller algorithms. In its most basic operation the Pump Boss can be used as a single or
dual channel timer with up to eight daily events, weekly timer with multiple days and multi-
ple events or a duration timer with a single event that repeats (useable for example as a 14,
28 90 day timer). Each channel is programmable so a dual timer based program can be run
from a Pump Boss.

When used with a flow verification device Pump Boss can control the pump in gallons per
hour and totalize flow. Again the Pump Boss can control two pumps independently or when
used together powerful dual pump capabilities are possible such as an automatic switch over
feature or the ability to use two pumps in a base and trim combination.

If a process flow meter is added the Pump Boss can become a powerful process controller
allowing you to proportionally dose two separate process flows at separate dose rates, or a
single process flow with two separate dose rates, or when coupled with our auto-switch over
a single flow with a single dose rate but with automatic pump redundancy. The proportional
flow concentration can be displayed in ppm or as a percentage of the flow.

The Pump Boss is also an excellent local control station for pumps in your plant. It allows for
remote start stop, 4-20 mA follower, alarm if pump/s fail and indication of pumps running.

We have advanced remote trigger capabilities that allow you to use a contact closure to initi-
ate the start up of the pump boss. You can chose for simple remote on off, activation after a
number of contact closures, activation after a duration of a contact being closed and then
when activated the response being just turning on, dosing a specific volume, or proportional
dosing in ppm.

Keep in mind that the Pump Boss has the ability to run two pump separately. This means you
can use the Pump Boss to run two completely different regimes such as channel one dosing
proportionally to a flow and the second channel doing simple on off timer control. Also with
the inclusion of 2 powered relays for each channel the relay can be used to power valves or
other devices to accomplish things like boiler blow down.

The Pump Boss is also designed to provide 4-20 mA control signals as well as pulse control.
This allows you to use the Pump Boss with larger capacity pumps that may have speed con-
trol via a VFD or DC drive.

As you become a more accomplished Pump Boss user, you will see how the programming
modes can be mixed and matched for you to accomplish pump control schemes that in the
past would require you to program a PLC.

3
 INTRODUCTION
Operational Modes
The Pump Boss has three ( 3) operational modes.

Manual: The chemical pump/s are set to a fixed pumping rate via front panel push buttons for LOCAL op-
eration or external 4-20mA signals for REMOTE operation. Each pump is independently adjustable and not
affected by system water flow. Use the manual mode when no flow meter is required.

Auto: The chemical pump/s will “follow” the input flow meter to maintain a selected set-point of ppm or %
concentration( depending on controller configuration) Set-point can be adjusted via front panel buttons for
LOCAL operation or external 4-20mA signals for REMOTE operation. NOTE;A flow meter input is required for
auto mode operation.

Trigger: The trigger mode has various configurations to operate the controller. To “activate” the controller ,
an input trigger must be selected.

There are two (2) input types:

♦ Contact Closure
♦ 4-20mA

Contact Closure Trigger : A dry contact connection to pump#2 REMOTE CONTROL (TB207,1 TB207-2)

The are three (3) trigger options: On/Off, # Events and Duration.

1. On/Off: Controller operates immediately when the contact closure is made.

2. # Events: Controller operates AFTER the preset number of contact closures are made. While waiting for
the trigger, the number of events can be adjusted via front panel push buttons. Once activated, the
NEXT contact closure will disable the controller and wait for the next sequence of contact closures.
3. Duration: Controller operates AFTER contact closure has been maintained for a pre-set number of min-
utes. While waiting for the trigger, the duration delay can be adjusted via front panel push buttons.

4-20 Trigger : A 4-20madc connection to Pump #2 REMOTE CONTROL 4-20 INPUT ( TB209-1, TB209-2)
Controller operates immediately when a preset mA is present at the EXTERNAL INPUT.
While waiting for the trigger, the level can be adjusted via front panel push buttons.

After a trigger function has been defined, the controller ACTION must be configured.

There are three(3) types of controller actions for the trigger mode:
♦ Full On
♦ Volume
♦ Proportional.

Full On: Controller delivers chemical at 1005 pumping rate for a preset number of minutes. The set point du-
ration can be adjusted via front panel push buttons.

Volume: Controller delivers a preset volume of chemical at 100% pumping rate. The set point volume can be
adjusted via front panel push buttons.

Proportional (PROPRTNL) : Controller maintains a selected set point of ppm or % concentration (depending
on controller configuration). The set point can be adjusted via front panel push buttons.
Note: A flow meter input is required for proportional mode of operation.

4
 SPECIFICATIONS

Inputs//Outputs:

(See attached Pump Boss I/O Connection figure)

Display: Eight (8) digit, 0.3 inch high alphanumeric red LED. Resolution +/- one digit.
Temporary or long-term power loss does not affect program setups. Four LED indicators for
each pump (total eight) monitor pump operation status.

Pump Power Output: Relay, contact closure, SPST,

10 ampere N.O. may be connected for controlling AC loads.

Pump Status Outputs: Relay, contact closure, SPST,

10 ampere N.O. may be connected for controlling AC loads.

Alarm Power Output: Relay, contact closure, SPST, 10 ampere N.O. may be connected to
signal for alarm purposes. Operates during pump error.( With Feed Verification device)

Note 1 : All relays are non-powered , dry contacts.

Note2: Concentration error does not activate alarm.

Electronic Pump Control: Two solid state switch contact closure, SPST,
25 mAdc, 15 VDC, isolated

Input Operating Voltage: 100 to 240 VAC, 47 to 63 Hertz. Fuse, 3AG, 5 ampere.

Programming: Eight (8) panel pushbuttons allow programming and controller operation.

Enclosure: Polycarbonate, Grey NEMA-4X, IP-66

Size: 14.21” L-R
10" T-B
4.37" Depth

Program Memory: All operating software is contained in three microprocessors with flash
memory to facilitate easy field changes in the operation or adding features. Software version
number is displayed during power-up sequence.

5

POWER - LARGE TERMINALS:
TB201-1 - POWER IN (HOT)
TB201-2 - POWER IN (COM)
TB201-3 - POWER IN (EARTH)
TB201-4 - PUMP #1 POWER CONTROL
TB201-5 - PUMP #1 POWER COMMON
TB201-6 - PUMP #2 POWER CONTROL
TB201-7 - PUMP #2 POWER COMMON
TB201-8 - PUMP #1 ACTIVE SIGNAL
TB201-9 - PUMP #1 ACTIVE COMMON
TB201-10 - PUMP #2 ACTIVE SIGNAL
TB201-11 - PUMP #2 COMMON
TB201-12 - ALARM OUTPUT
TB201-13 - ALARM COMMON
ANALOG BOARD:
TB301-1 - PUMP #1 CONTROL(4-20mADC) + OUTPUT
TB301-2 - SPARE TERMINAL FOR LOAD SERIES CONNECTION
TB301-3 - PUMP #1 CONTROL(4-20mADC) COMMON
TB302-1 - PUMP #1 REMOTE PUMP SPEED(4-20mADC) + OUTPUT
TB302-2 - SPARE TERMINAL FOR LOAD SERIES CONNECTION
TB302-3 - PUMP #1 REMOTE PUMP SPEED(4-20mADC) COMMON
TB303-1 - PUMP #2 CONTROL(4-20mADC) + OUTPUT
TB303-2 - SPARE TERMINAL FOR LOAD SERIES CONNECTION
TB303-3 - PUMP #2 CONTROL(4-20mADC) COMMON
TB304-1 - PUMP #2 REMOTE PUMP SPEED(4-20mADC) + OUTPUT
TB304-2 - SPARE TERMINAL FOR LOAD SERIES CONNECTION
TB304-3 - PUMP #2 REMOTE PUMP SPEED(4-20mADC) COMMON
Note: Input 4-20mAmadc signals are not isolated.
Inputs & Outputs
SIGNALS - SMALL TERMINALS:
TB202-1 - PULSE FLOW METER +12VDC
TB202-2 - PULSE FLOW METER +INPUT
TB202-3 - PULSE FLOW METER -INPUT
TB202-4 - PULSE FLOW METER COMMON
TB203-1 - FLOW METER (4-20mADC ) + INPUT
TB203-2 - FLOW METER (4-20mADC) COMMON
TB204-1 - PUMP #1 POSI-FLOW +12VDC
TB204-2 - PUMP #1 STANDARD POSI-FLOW SIGNAL
TB204-3 - PUMP #1 TURBINE CHEM FLOW SIGNAL
TB204-4 - PUMP #1 POSI-FLOW COMMON
TB205-1 - PUMP #2 POSI-FLOW +12VDC
TB205-2 - PUMP #2 STANDARD POSI-FLOW SIGNAL
TB205-3 - PUMP #2 TURBINE CHEM FLOW SIGNAL
TB205-4 - PUMP #2 POSI-FLOW COMMON
TB206-1 - PUMP #1 REMOTE CONTROL + INPUT
TB206-2 - COMMON
TB207-1 - PUMP #2 REMOTE CONTROL + INPUT
TB207-2 - COMMON
(NOTE: TB207 IS ALSO TRIGGER MODE C.C. INPUT)
TB208-1 - PUMP #1 REMOTE CONTROL (4-20mADC) + INPUT
TB208-2 - PUMP #1 REMOTE CONTROL (4-20mADC) COMMON
TB209-1 - PUMP #2 REMOTE CONTROL (4-20mADC) + INPUT
TB209-2 - PUMP #2 REMOTE CONTROL (4-20mADC) COMMON
(NOTE: TB209 IS ALSO TRIGGER MODE 4-20mADC INPUT)
TB210-1 - PUMP #1 PULSE OUTPUT
TB210-2 - PUMP #1 PULSE COMMON
TB211-1 - PUMP #2 PULSE OUTPUT
TB211-2 - PUMP #2 PULSE COMMON
6
 INSTALLATION

Select a location for mounting the controller on a vertical wall, pole, or panel with good visual
accessibility and away from direct sunlight. Operating power must be supplied together with
the input/outputs. A customer supplied external power disconnect switch with ground fault
interruption (GFI) protection must be provided as a power switch or GFI protection is not pro-
vided within the controller.

7
 CONNECTIONS

♦ YELLOW ARE PUMP ONE CONNECTIONS

♦ RED ARE PUMP TWO CONNECTIONS

♦ GREEN ARE COMMON ITEMS (FLOW METERS AND ALARMS)

All of the descriptions and terminal numbers are silk screened onto the PCB

P Q R S

F G H I J k L M N O

A B C D E

F: FLOW METER PULSE

G: FLOW METER 4-20 mA

LARGE TERMINAL STRIP A-E

Non Powered Relays 90-265 VAC
based on incoming voltage.

Pump One Power: A

Pump One Running Relay: C

Pump One Power: B

Pump One Running Relay: D
8
 COMPATIBLE FLOW DEVICES

PROCESS FLOW METERS:

The Pump Boss can accept two process flow signals that the pumps can deliver chemical in pro-
portion to the flow. If there is only one pump, you are using auto switch over, or base and trim
then the Pump Boss can only control proportionally to one flow signal. This flow signal can either
be a pulse type or a 4-20 mA signal.

If you run two pumps from the Pump Boss each pump can be proportional to a separate process
flow. However you will need to use one flow meter that has a pulse and one that provides a 4-20
mA signal. You can not run a pump boss with two analog or two pulse flow meters.

Pulse

The maximum flow for dilution water input is selected based upon the size of flow meter se-
lected. The Menu allows inputting the “K” value for the particular flow meter. “K” value re-
fers to the number of pulses per gallon of water for the specific flow meter utilized.

When the ON/OFF Key is pressed, a default number will be displayed. To change, press an
arrow key to increase or decrease, then press ON/OFF. Press ON/OFF to return to the
Menu after the number is complete. Press the arrow key for the next selection.

Depending upon the type of pulse flow meter selected, jumper JB201/JB202 located on the
main power supply must be correctly positioned.
For “sinking” output (Seametrics) connect as
follows:
For “source” output connect as
1. Flow meter power to TB202A
follows:
2. No connection to TB202B
3. Signal to TB202C
Flow meter power to TB202A
4. Common to TB202D
Signal to TB202B
5. Shunt jumper on JP201
No connection to TB202C
6. Open connection on JP202
Common to TB202D
Open connection on JP201
Shunt connection on JP202
4-20mA Set Up Procedure

Allows calibrating both the 4-20 mAdc input and output. Use arrow keys to select Input or
Output. Refer to Setup Menu #2. Use must supply known, stable 4-20mA signal for
Calibration.

9
 FLOW VERIFICATION DEVICES
The pump boss works with a wide variety of flow verification devices that are either three or
four wire devices. Please see wiring diagram to wire up the device of your choice.

Approved devices are :

Iwaki Posiflow flow verification device ( Primary Preferred Device)
Kobold Oval Gear Meter ( Secondary Preferred Device)
Blue White Micro flow verification device

Select the device based on the fluid and volume you are pumping. Connect as determined by
the flow signal developed. Flow verification devices must be installed, enabled and pump cali-
bration must be performed for chemical pump totalizer operation and accuracy.

Slo-Blo
Fuse

10
 NAVIGATION

The Pump Boss interface has a single line scrolling LED interface providing data and
messages. The system also includes a LED to denote when a particular pump is in re-
mote control, in an alarm state or under timer control.

The Pump On light blinks with each pulse the Pump Boss sends to the associated pump.

DOWN ARROW UP ARROW

FOR CYCLING FOR CYCLING
MENUS AND THROUGH
ADJUSTING MENUS AND
SPEED DOWN INCREASING
SPEED
TURNS PUMP ON AND OFF.
PRESS FOR 5 SECONDS TO SWITCHES FROM
GET INTO PROGRAMMING. LOCAL CONTROL TO
REMOTE CONTROL

Navigating controls is done through the keypad on the

front of the controller. All programming is done with the
use of the on/off button and the up and down arrows. To
enter the programming menus, press and hold the
on/off button for five seconds when the pump is not
operating.
(Pumps will turn off automatically)

Panel Control Description

Eight Digit Alpha-numeric Display

a. When operating, the display provides

real- time parameters as values and/or unit
status.

b. During programming mode, the display

shows the programmed information for each input
and preset value.
11
 PROGRAMMING YOUR PUMP BOSS

The Programming Menu has two levels. The first is the user level and the second is the
set up level. Both are password protected and can have separate passwords.

No passwords are needed to adjust flow rate, to stop and start the pumps, or to switch
between remote and local operation.

The default password is 0000

If you chose to run each channel separately then you have the ability to run two entirely
different control strategies. If however you wish to use the auto switchover feature or
the base and trim feature then only one strategy can be programmed.

In either case, modes of control are designed to be used together, so you can use
the real time clock (2400 hr format) to start the pump AND dose in ppm or percentage
concentration to a process stream.

You can use trigger modes and also dose in ppm. This allows for complex addition
strategies that also accommodate process fluctuations, and in the case of auto switch
over increase reliability with automated redundancy.

Control Options

1. Auto-Switchover with remote control

2. Auto-switchover with proportional dosing and remote control

3. Basic Timer control

4. Timer Control with Auto-Switchover

12
 1 AUTO SWITCH OVER
TWO PUMPS IN A DUTY
STANDBY CONFIGURATION
WITH AUTOMATIC SWITCH
OVER TO THE STANDBY
PUMP IF THE DUTY PUMP
When To Use This Configuration: HAS LOSS OF FLOW.

When you want to dose a chemical in proportion to a process

flow in either ppm or percentage and make sure that if your
main pump fails to meter chemical that a second pump will
recover metering without user intervention.
This is ideal for applications where chemical needs to
fluctuate with increases and decrease of flow and equipment
is remote or has limited supervision.
Features
♦ Manual Start Stop
♦ Local control of pump set point
♦ Remote Stop Start
♦ 4-20 mA control of pump output
INPUTS
♦ Remote stop/start contact closure
♦ 4-20 mA pump speed
OUTPUTS
♦ Pump Running
♦ Alarm
♦ Pump Speed 4-20 mA
Note: For auto switch over, it is recommended
that both pumps be the same and/or calibrated
the same.
Steps For a Quick and
Successful Start-Up
1) Press the on/off button for five
seconds and enter the password
0000
2) Cycle to the setup menu and re-
enter the password
3) Set the type of remote stop start
contact you want to use
4) Select auto-switch over and the de-
lay between the pumps switching
5) Select two flow verification devices
and a delay. This delay should be a
few seconds longer than you think it
will take for the device to register
flow at start up.
6) Set up the maximum number of
strokes per minute the pump is rated
for and the ml/stroke.
7) Select if you want the pump boss to
show pump flow in GPH or percent-
age of speed.
8) Set your new set up password.
Write it down here__________
9) Exit set up
Steps For Calibration
10) Go to the cal menu and select pulse.
11) Go through the calibration process
for each pump by selecting the pump in
the menu
A) Set the volume of the calibration
column.
B) The % stroke (for record only)
C) Hit the on button to start
D) Hit the on button when the volume is
empty.
E) Select yes if the calibration is correct
F) Set concentration span

13
 AUTO SWITCH OVER
1
NOTE:
The Pump Boss default
Mode is manual operation

11
10
1

3 4

14
 2 PROPORTIONAL DOSING WITH AUTO SWITCH OVER
OVER TO THE STANDBY PUMP IF
When To Use This Configuration:
When you want to dose a chemical in proportion to a
process flow in either ppm or percentage and make
sure that if your main pump fails to meter chemical
that a second pump will recover metering without
user intervention.
This is ideal for applications where chemical needs
to fluctuate with increases and decrease of flow and
equipment is remote or has limited supervision.
Features
♦ Manual Start Stop
♦ Local control of ppm or % of process flow
♦ Remote Stop Start
♦ 4-20 mA control of ppm or % of process flow
♦ Set Point Range: 1.0-10.0%
0.1-1000ppm
INPUTS
♦ Remote stop/start contact closure
♦ Pulse or 4-20 mA process flow
♦ 4-20 mA ppm or % of process flow
OUTPUTS
♦ Pump Running
♦ Alarm
♦ Pump Speed 4-20 mA
TWO PUMPS IN A DUTY
STANDBY CONFIGURATION
WITH AUTOMATIC SWITCH
THE DUTY PUMP HAS LOSS OF
FLOW.
Steps For a Quick and
Successful Start-Up
1) Press the on/off button for five sec-
onds and enter the password 0000
2) Select Auto mode
3) Set the default ppm or % you only
need to do this for pump one
4) Cycle to the setup menu and re-enter
the password
5) Set the type of remote stop start con-
tact you want to use
6) Select auto-switch over and the delay
between the pumps switching
7) Select two flow verification devices and
a delay. This delay should be a few
seconds longer than you think it will
take for the device to register flow at
start up.
8) Set up the maximum number of
strokes per minute the pump is rated
for and the ml/stroke.
9) Select if you want the pump boss to
show pump flow in GPH or percentage
of speed.
10) Select the type of flow meter, scale the
flow meter, and choose both
11) Set your new set up password. Write
it down here__________
12) Exit set up
Steps For Calibration
13) Go to the cal menu and select pulse.
14) Go through the calibration process for
each pump by selecting the pump in the menu
A. Set the volume of the calibration column.
B. The % stroke (for record only)
C. Hit the on button to start
D. Hit the on button when the volume is
empty.
E. Select yes if the calibration is correct
15
 PROPORTIONAL DOSING WITH AUTO SWITCH OVER

14
13
1

7
8

10

12

11

16
 BASIC TIMER FUNCTIONS
3 WHEN YOU REQUIRE YOUR
CHEMICAL DOSING TO BE
INITIATED BASED ON TIME
OF DAY, REGULAR WEEKLY
INTERVALS OR DURATIONS

When To Use This Configuration:

Steps For a Quick and
This section covers the basic timer function. The timer func- Successful Start-Up
tion can be used to turn on any device that does not exceed
amps load. In the case of pumps you can use the powered
1) Follow the installation
relay to turn the pump on and off.
Instructions
2) Configure the Controller
If you wish to use flow verification and advanced features
as noted on this page
you will need to power the pumps either from a different
source or from the hot terminals on the Pump Boss as most
pumps using remote pulse or 4-20 mA will fault if they start
at the same time as a control signal is sent to them.

Set the time, date, month and year per user name.

Note: The real time clock (RTC) has battery back-up and
compensates for leap year 2100.

All times are 24 hour format.

17
18
 PROPORTIONAL DOSING WITH TIMER
4 FUNCTION AND AUTO SWITCH OVER
TWO PUMPS IN A DUTY
STANDBY CONFIGURATION
WITH AUTOMATIC SWITCH
When To Use This Configuration: OVER TO THE STANDBY PUMP If
THE DUTY PUMP HAS LOSS OF
When you want to dose a chemical in proportion to a FLOW. CONTROL STRATEGY RE-
process flow in either ppm or percentage and make sure QUIRES BOTH TIMER CONTROL
that if your main pump fails to meter chemical that a AND PROPORTIONAL DOSING
second pump will recover metering without user inter-
vention.

This is ideal for applications where chemical needs to Steps For a Quick and
fluctuate with increases and decrease of flow and equip- Successful Start-Up
ment is remote or has limited supervision.

All times are 2400 format. Use the set up table from
Proportional dosing (pg.14)
Features and the directions from
♦ 4-20 mA control of concentration timer settings. (pg.16)
♦ Remote Stop Start
♦ Timer Control

INPUTS
♦ Remote stop/start contact closure
♦ Pulse or 4-20 mA process flow
♦ 4-20 mA ppm or % of process flow

OUTPUTS
♦ Pump Running
♦ Alarm
♦ Pump Speed 4-20 mA

19
 User Menu Flow Chart

SP=Set Point 0.1-1000ppm

1.0-10.%

SP=Span

Sets the 20 madc at top of span

Total A & B are both the same

and can be rest. Gross is only
reset with factory reset. Units
are expressed in gallons

20
 Set Up Menu Flow Chart

For both channels

21
 Timer Menu Flow Chart

22
Wiring Diagram

23
Timer Settings Sheet

24
 Default and User Settings

Strokes per minute

Range: 1.0-10% * Will change with pump calibration

0.1-1000ppm

25
 WARRANTY AND ASSISTANCE

The PUMP BOSS Pump Controller is warranted to be free from defects in materials and work-
manship under normal use and service for twenty-four (24) months from date of shipment unless
otherwise specified. Batteries have no warranty. Chem-Flow obligation under this warranty is lim-
ited to repairing or replacing defective products at Chem-Flow's option.

The customer shall assume all costs of removing, reinstalling and shipping defective products to
Chem-Flow. Chem-Flow will return such products by surface carrier prepaid. The warranty shall
not apply to any Chem-Flow products subjected to modification, misuses, neglect, accidents of na-
ture or shipping damage. The warranty is in lieu of all other warranties, expressed or implied, in-
cluding warranties of merchantability or fitness for a particular purpose. Chem-Flow is not liable
for special, indirect, incidental or consequential damages.

Products may not be returned without prior authorization. To obtain a Returned Materials Authori-
zation (RMA), contact Chem-Flow, telephone number 630-543-1911. After an applications engi-
neer determines the nature of the problem, an RMA number will be issued together with return ship-
ping instructions. Please write the RMA number clearly on the outside of the shipping container to-
gether with specific contact person and telephone number.

Chem-Flow does not accept collect calls. Non-warranty products returned for repair should be ac-
companied by a purchase order to cover the repair.

1450 West Fullerton Avenue

Addison, Illinois 60101

26