Pump Boss

Intelligent Pump Control

 Pump Boss

• Development Background
• Features
• Application Benefits
• Integrated Systems
• Commercial Considerations
 Development Background
Reoccurring Requirements

• Dual Pump Control

• Proportional Feed
• PPM Set Points
• % Concentration
• Feed Verification
• Auto Switchover
• Base / Trim Applications
• Timer Options
• Calibration
• Reporting
 What is the Pump Boss?

• The Pump Boss is a dual pump controller designed to replace more expensive
and complex PLC Designs.

• 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 multiple 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.
 What is the Pump Boss?

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

• W e have advanced remote trigger capabilities that allow you to use a contact closure
to initiate the start up of the Pump Boss . You can chose 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 pumps 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
control via a VFD or DC drive.
 Pump Boss Features
Features

• Touch Button Dual Pump Control in One Box

• Local or Remote Control with Feed Verification

• Automatic Switchover

• Proportional Dosing of chemical to a process signal

• Multiple Timer Control Options

• Feed Rate Totalizers

• Event Based Automation

 Pump Boss Features
• 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 operation 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.
 Pump Boss Features
• Display: Eight (8) digit, 0.3 inch high alphanumeric red LED. Resolution +/- one digit.

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

• Readouts: 0-100%, GPH, Mils/Minute

• 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 dev ice)

• 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.

• 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 v ersion number is displayed
during power-up sequence.
 Pump Boss Features
Features
Choose BASIC OPERATION when:

• You need to use timers to control your pump/s

• You wish to use event based triggers like another pump starting or a
change in a analog process variable.

Choose ENHANCED OPERATION when :

• You wish to meter chemical in proportion to a process flow

• You require a combination of event based trigger and
proportional flow
• You are using a flow verification device with your pump
• Your require auto switchover
• You require a combination of timers and proportional flow
 Pump Boss Features
Inputs / Outputs
External Inputs

• 2 (Two) Flow Meter Inputs—One 4-20mA (TB203) & One Pulse (TB202)

• 2 ( Two) Remote 4-20mA—One for each Pump– Pump One (TB208)—Pump Two (TV209)

• 2 ( Two) Feed Verification -One for each Pump– Pump One (TB204)—Pump Two (TB205)

• 2 (Two) Contact Closures-One for each Pump– Pump One (TB206)—Pump Two (TB207) ( Interlock)

Control Outputs

• 2 ( Two) Pump Speed Control Outputs 4-20mA—One for each Pump- Pump One (TB310) Pump Two (TB303)

• 2 ( Two) Pump Pulse Control Outputs — One for each Pump -Pump One (TB210) Pump Two (TB211)

• 2 (Two) Powered Relays -One for each Pump - Pump One (I201) Pump Two (1202)

Reporting Outputs

• 2 ( Two) Pump Speed Outputs 4-20mA- One for each Pump-Pump One (TB302) Pump Two (TB304)

• 2 (Two) Pump Activ e Powered Relays—One for each Pump (I203 Pump one (I204) Pump Two

• 1 (One) Alarm Powered Relay ( I205)

Integrated Systems
Integrated Systems
Introducing…..
• The Duplex Plus Series offers the ultimate in
convenience and control options. With three series
to choose from, users can select the design which
best fits specific requirements.

• Pumps offered as standards include the LMI 9 Series,

Walchem EW Series and the Grundfos DME models.

• All pump heads are PVDF for maximum flexibility of

use. Other materials are available upon request.
• The 100 Series is the most basic model, using the
powerful built-in pump controls.

• The 200 Series integrates a simple, convenient local

control panel.

• The 300 Series integrates the newly designed Pump

Boss, providing PLC like capabilities, without the PLC
like price.
All systems include:

• On– Board Calibration Assembly

• Single Suction/ Single Discharge
• Discharge Pressure Gauge
• Back Pressure Valves
• On-Board Power Receptacle
• Flush Ports

These systems are pre-plumbed using CPVC piping and fittings

and are pre-tested and deliv ered ready for use.
 Duplex Plus 100 Series: Use Pump Face Controls

The 100 series is the most version of the Duplex Plus Series. It integrates
manually controlled chemical metering pumps from LMI, Walchem and Grundfos.
All controls for the 100 Series are located on the pump face touch panels
 Duplex Plus 200 Series: Add Pump Control Panel

The 200 Series integrates a simple, convenient local control panel to provide dual pump HOA Switches
and run light. This control box is linked to the most advanced microprocessor controlled chemical
metering pumps from LMI, Walchem and Grundfos. The Series 200 Control panel can accept two 4-20mA
inputs and remote dry contacts to control the pumps. This is an ideal for dosing programs which require
chemical feed on remote contact or process control signal.

Add Controls
Mounting
Panel
 Duplex Plus 300 Series: Add Pump Boss Controller

The 300 Series integrates the newl y designed Pump Boss. This versatile multiuse
controller allows the user to execute numerous complex dosing regimes
without the extensive cost and complexity of a PLC.

From a simple, timer dual biocide application to proportional feed based on a

process variable, the unit is powerful enough, yet simple enough to easily
implement any dosing regime.
Suction Assembly Discharge Assembly
 100 Series 200 Series 300 Series
Pump Type Pump Capacity
Part Number Part Number Part Number

LMI 10GPD/140PSI DP100-CV-L10 DP200-CV-L10 DP300-CV-L10

LMI 24GPD/110PSI DP100-CV-L24 DP200-CV-L24 DP300-CV-L24

LMI 60GPD100PSI DP100-CV-L60 DP200-CV-L60 DP300-CV-L60

LMI 96GPD/100PSI DP100-CV-L96 DP200-CV-L96 DP300-CV-L96

Grundfos 15.9GPD/261PSI DP100-CV-G16 DP200-CV-G16 DP300-CV-G16

Grundfos 47.5GPD/145PSI DP100-CV-G47 DP200-CV-G47 DP300-CV-G47

Grundfos 76.8GPD/90PSI DP100-CV-G77 DP200-CV-G77 DP300-CV-G77

DP100-CV-
Grundfos 117.6GPD/90PSI DP200-CV-G117 DP300-CV-G117
G117

Walchem 14.4GPD/150PSI DP100-CV-W14 DP200-CV-W14 DP300-CV-W14

Walchem 24GPD/105PSI DP100-CV-W24 DP200-CV-W24 DP300-CV-W24

Walchem 55.2GPD/105PSI DP100-CV-W55 DP200-CV-W55 DP300-CV-W55

DP100-CV-
Walchem 132GPD/150PSI DP200-CV-W132 DP300-CV-W132
W132

Note1: CV = Viton O Rings - CE=EPDM O Rings

Note2: If you require Auto Sw itch Over: Add SW to the end of the 300 Series part number.
Example: DP300-CV-W14-SW
100 Series 200 Series 300 Series
PUMP BOSS