BRINKMANN PUMPS Bplogic User manual

Operating manual
Intelligent pump controller
Bplogic
Please read this manual prior to starting any work!

1 Overview
2 bplogic intelligent pump controller 18/02/2021
Brinkmann Pumpen
K.H. Brinkmann GmbH & Co. KG
Friedrichstr. 2
58791 Werdohl
GERMANY
[phone]
[email protected]
www.brinkmannpumps.de
BRIN-46069-EN, Version 03.01, en_UK
©Brinkmann Pumpen 2021

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Table of contents
1Overview....................................................................................................7
1.1 Preliminary remarks...........................................................................7
1.2 General description of the intelligent pump controller........................9
1.3 Pump tasks and system integration.................................................10
2Safety.......................................................................................................12
2.1 Symbols in this operating manual....................................................12
2.2 Proper use.......................................................................................14
2.3 Safety equipment.............................................................................15
2.4 Residual risks..................................................................................16
2.5 Owner responsibility ........................................................................19
2.6 Staff requirements...........................................................................21
2.7 Personal protective equipment........................................................23
2.8 Environmental protection.................................................................24
3Pump controller fields of application and layout.................................25
3.1 Typical areas of application.............................................................25
3.2 Pump controller layout.....................................................................26
3.2.1 Housing...............................................................................27
3.2.2 Touchscreen .......................................................................28
3.2.3 I/O level slots.......................................................................29
3.2.4 I/O modules and slot allocation...........................................30
3.2.5 USB and micro SD..............................................................33
3.2.6 Ethernet...............................................................................34
3.2.7 Modbus RTU.......................................................................35
3.2.8 Supported bus protocols .....................................................35
3.2.9 Connections and interfaces.................................................36
3.2.10 Automatic and manual mode...............................................38
4Installing the pump controller ...............................................................39
4.1 Fitting the pump controller...............................................................39

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4.2 Network topologies ..........................................................................41
4.3 Connecting the pump controller electrically .....................................42
4.3.1 Basic layout of the I/O level.................................................42
4.3.2 Connecting I/O modules......................................................43
5Operating the pump controller ..............................................................52
5.1 Switching on and logging in.............................................................52
5.1.1 Optional pump controller operation via remote access........54
5.2 Operating principles.........................................................................56
5.2.1 General screen layout .........................................................56
5.2.2 Status bar............................................................................58
5.2.3 Title bar ...............................................................................59
5.2.4 Navigation bar .....................................................................59
5.2.5 Main screen.........................................................................62
5.2.6 Dialogue: “Quick access”.....................................................68
5.2.7 Navigation ...........................................................................70
5.2.8 Input helps...........................................................................73
5.2.9 Global data..........................................................................79
5.2.10 File manager .......................................................................81
5.2.11 Main menu overview............................................................83
5.3 Application modules.........................................................................91
5.3.1 Checking the assignments to application modules..............92
5.3.2 Displaying parameters as favourites....................................97
5.3.3 Switching the application module into manual mode...........99
5.4 Primary functions...........................................................................100
5.4.1 Executing adjustment mode with one pump......................100
5.4.2 Executing control mode with one pump.............................103
5.4.3 Parallel mode ....................................................................105
5.4.4 Saw tooth cycle mode .......................................................109
5.4.5 Pressure increase..............................................................115
5.4.6 Logic module.....................................................................117
5.5 Secondary functions ......................................................................157
5.5.1 Offset control.....................................................................157

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5.5.2 Wear detection..................................................................158
5.6 Setting pump controller parameters...............................................165
5.6.1 Setting I/O parameters......................................................167
5.6.2 System settings.................................................................189
5.6.3 Setting LAN parameters....................................................201
5.6.4 Setting WLAN module parameters....................................204
5.6.5 Checking field bus parameters..........................................207
5.6.6 Using the PROFINET IO field bus or the EtherNet/IP field
bus....................................................................................210
5.6.7 Exchanging data ...............................................................218
5.7 Operation.......................................................................................223
5.7.1 Locking and unlocking the screen.....................................223
5.7.2 Ejecting the removable storage device safely...................224
5.7.3 Using the application overview during operation...............226
5.7.4 Using the pump overview during operation.......................228
5.7.5 Using the application oscilloscope during operation..........231
5.8 Shutting down the pump controller................................................237
5.9 Re-commissioning after an extended shutdown............................237
6Additional functions.............................................................................238
6.1 Using logging.................................................................................239
6.2 WLAN 243
6.3 Automatic time setting ...................................................................245
7Performing maintenance......................................................................247
7.1 Cleaning the housing.....................................................................247
7.2 Backup and restore .......................................................................248
7.2.1 Backup and restore preparation........................................249
7.2.2 Backing up and updating application modules..................250
7.2.3 Backing up and updating the system software..................253
7.2.4 Backing up and updating settings .....................................256
7.3 Event messages............................................................................259
7.3.1 Layout of an event message.............................................259

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7.3.2 Acknowledging and closing event messages ....................260
7.3.3 “Event list” menu ...............................................................262
7.4 Fault table......................................................................................266
7.5 Restarting in the event of errors.....................................................267
8Technical data.......................................................................................268
8.1 Device properties...........................................................................268
8.1.1 Functions...........................................................................269
8.1.2 Frequency converter..........................................................269
8.1.3 Interfaces...........................................................................269
8.1.4 WLAN communication.......................................................270
8.2 Ambient and operating conditions..................................................271
8.3 Electrical properties .......................................................................272
8.3.1 Pump controller.................................................................272
8.3.2 I/O module 1......................................................................273
8.3.3 I/O module 2......................................................................275
8.4 Connection line requirements........................................................277
8.5 Permits277
8.6 Type plate......................................................................................278
8.7 Supplied as standard.....................................................................278
9Storage, transport, dismantling and disposal....................................279
9.1 Storage and transport....................................................................279
9.2 Dismantling and disposal...............................................................279
10 Licensing information ..........................................................................281
11 EC Declaration of Conformity..............................................................282
12 Accessories and required materials ...................................................284
13 Index ......................................................................................................285

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1 Overview
1.1 Preliminary remarks
Information regarding this operating manual
This operating manual (subsequently referred to as “Manual”) contains impor-
tant information that must be observed when installing, operating and maintain-
ing the bplogic intelligent pump controller (subsequently referred to as “pump
controller”). This operating manual must therefore be read by the electricians
and the responsible technical personnel/owner prior to assembly and commis-
sioning and must always be available at the pump controller’s operating loca-
tion.
Illustrations in this operating manual are for basic understanding and may differ
from the actual design.
Complete installation
The pump controller is part of a system to supply machine tools with cooling lu-
bricant. “Complete installation” or “system” designates all of the installations,
machines, sensors, and actuators controlled by the pump controller, as well as
their safety equipment.
The pump controller and the complete installation are considered
a functional unit here even if the complete installation is not sup-
plied as standard.
Further applicable documents
In addition to this operating manual, also observe the documentation for all ma-
chines and other installations contained in the complete installation, as well as
the documents relevant for assembly and safety:
Documentation for:
Machines (e.g. pumps)
Frequency converters
Actuators (e.g. valves)
Sensors (e.g. throughput, pressure sensors)
Safety equipment
Other installations

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Higher-level controllers (e.g. machine tool)
Configurator (requirements on the pump controller’s manufacturer-side configu-
ration before installation)
The parameter list for the pump controller.
Operating instructions of the operator.
The order and delivery notes, as well as the system-specific con-
figurator, provide an overview of the complete installation.
Customer service
When contacting customer service:
Provide customer service with the current configuration file
Section 7.2.1 “Backup and restore preparation”on
page 249.
And/or:
Have the pump controller’s order number and serial number
at hand.
Address
Brinkmann Pumpen
K.H. Brinkmann GmbH & Co. KG
Friedrichstr. 2
58791 Werdohl
GERMANY
Phone
[phone]
E-mail
[email protected]
Internet
www.brinkmannpumps.de

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1.2 General description of the intelligent pump
controller
Fig1_Overview-01.png
Fig. 1: Overview (sample illustration)
1
Touchscreen
2
Service access
3
I/O level
The pump controller (Fig. 1) consists of a cast aluminium housing, inside of
which the main circuit board is located.
The touchscreen (Fig. 1/1) and the I/O level with the connections (Fig. 1/3) are
accessible for the operator from the outside. Various I/O modules can be in-
serted into the I/O level and therefore connected to the main circuit board. The
service access (Fig. 1/2) is located on one of the two short device sides.

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The service access is sealed with a cover during operation. After opening the
screws, two USB connections, one RJ45 Ethernet connection for service pur-
poses and one Micro SD slot are accessible.
1.3 Pump tasks and system integration
Pump tasks
The pump controller co-ordinates pump tasks, e.g. supplying machine tools
with cooling lubricant. The pump controller controls the pumps contained in the
complete installation, bearing in mind the sensors and actuators that can be
connected to the pump controller. Up to 6 pumps can be connected. The
pumps can be operated individually or together, e.g. to also achieve even bal-
anced utilisation.
The sensors, pumps and remaining actuators can be combined in up to 6 appli-
cation modules. In this context, “application modules” means basic application
functions (adjustment, control, pressure increase and rinsing applications). The
number, type and scope of the application modules depend on the complete in-
stallation’s task and equipment.
System integration
The pump controller controls the pumps contained in the complete installation
(generally via frequency converters) depending on the selected application
module and the sensor signals present (e.g. flow rate or pressure).
Information is exchanged between the complete installation (sensors and ac-
tuators) and the higher-level controller using different field bus protocols
(ethernet or modbus connection) or in the form of analog and digital signals. A
PROFINET IO field bus can be used additionally on a pump controller with the
PROFINET option.
The pump controller is delivered preconfigured for the complete installation into
which it is integrated. After assembly, you only have to set parameters for func-
tions and settings.

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Supported frequency converters
ABB
Brinkmann
Danfoss
Emotron
Fuji Electric
Kostal
Mitsubishi

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2 Safety
2.1 Symbols in this operating manual
Safety instructions
Safety instructions in this manual are marked by symbols. The safety instruc-
tions are introduced by signal words that express the degree of danger.
DANGER!
This combination of symbol and signal word advises of an im-
mediately dangerous situation that causes death or serious
injuries if not avoided.
WARNING!
This combination of symbol and signal word advises of a possi-
bly dangerous situation that may cause death or serious injuries
if not avoided.
CAUTION!
This combination of symbol and signal word advises of a possi-
bly dangerous situation that may cause moderate or minor inju-
ries if not avoided.
NOTICE!
This combination of symbol and signal word advises of a possibly
dangerous situation that may cause damage to property if not
avoided.

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ENVIRONMENTAL PROTECTION!
This combination of symbol and signal word advises of possible
dangers for the environment.
Tips and recommendations
This symbol highlights useful tips and recommendations, and
information for efficient and fault-free operation.
Other labels
The following labels are used in this manual to highlight handling instructions,
results, lists, references and other elements:
Label
Explanation
1., 2., 3. ...
Step-by-step handling instructions

Results of handling instructions
References to other sections in this manual and to
further applicable documents
●
Lists without a fixed order
[Button]
Controls (e.g. buttons, switches), indicators (e.g.
indicator lights)
“Display”
Screen elements (e.g. on-screen buttons, alloca-
tion of function keys)
Safety instructions in handling instructions
Safety instructions can refer to specific, individual handling instructions. These
safety instructions are embedded into the handling instruction so that they do

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not interrupt the flow of text when performing the handling instruction. The
aforementioned signal words are used.
Example:
1. Undo the screw.
CAUTION!
Risk of pinching on the cover!
2. Close the cover carefully.
3. Screw the screw tight.
2.2 Proper use
The pump controller co-ordinates pump tasks, e.g. supplying machine
tools with cooling lubricant.
The pump controller is intended solely to operate a complete installation
as described in the configurator and in this operating manual.
Proper use also includes adhering to all specifications in this operating manual.
Any use that differs from or goes beyond proper use is considered misuse.

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WARNING!
Danger if misused!
Misusing the intelligent pump controller can cause dangerous
situations.
Never grant unauthorised people access to the pump con-
troller.
Never set target values that are outside the controlled ma-
chine's specifications.
Never set target values that are outside the application-
specific operating conditions.
Never operate the pump controller without additional sys-
tem-specific safety equipment.
Observe Section 2.3 “Safety equipment”on page 15.
Never use the pump controller to switch the controlled ma-
chine off for maintenance or troubleshooting purposes.
Never operate the pump controller in an explosive atmos-
phere.
Never open the pump controller’s housing.
Never convey media that is not specified for the pumps,
actuators, sensors and installations into the complete instal-
lation.
2.3 Safety equipment
The pump controller is not a piece of safety equipment. The sys-
tem owner is responsible for developing a system-wide safety
concept and equipping the system with corresponding safety
equipment.
Each system component can pose hazards. The system owner is
responsible for checking whether using the pump controller would
make further safety equipment necessary, such as using a safety
control system.

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Retrofitting safety functions
DANGER!
Danger of serious to fatal injuries due to operating the
complete installation unsafely!
Ensure that safety equipment is installed for the complete installation’s specific
dangers (e.g. to prevent overpressure, uncontrolled start-ups and to create a
safe state).
2.4 Residual risks
Safe state of the complete installation
DANGER!
Danger of serious to fatal injuries due to an unsafe com-
plete installation!
The pump controller does not have any safety functions.
Operating errors or faults can cause faults in the complete instal-
lation (e.g. overpressure, uncontrolled start-ups), which can
result in serious injuries or material damage.
Do not operate the pump controller in a complete installation
if none of the safety equipment specified for the complete
installation’s concrete hazards is installed and ready for op-
eration.
For more information, see the further applicable documents
(“Further applicable documents”on page 7), especially:
Documentation for the machines, actuators, sensors
and safety equipment in the complete installation.
Owner operating instructions.

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Power supply requirements
DANGER!
Danger of electric shock due to improper power supply!
The pump controller requires SELV (safety extra-low voltage) /
PELV (protective extra-low voltage) power with high insulation
requirements to be used. If these requirements are not met,
there is the risk of serious to fatal injuries due to electric shock.
Ensure that the 24 V power supply meets the requirements
of protective extra-low voltage (PELV) or safety extra-low
voltage (SELV protection class III).
The electrical connection may only be established by an
electrician.

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Consideration of the maximum permissible currents
DANGER!
Danger of serious to fatal injuries due to missing or incor-
rectly designed overcurrent protective devices!
The maximum supply currents for the “Logic and sensors” and
the “Actuators” voltage domains must be limited. In the event of
short circuits or impermissibly high currents, impermissibly high
maximum currents may overload the pump controller and/or
lines. For this reason, the owner must ensure that the specified
maximum currents are not exceeded and also that external
overcurrent protection units and connection lines with the correct
measurements are used in order to prevent an overload condi-
tion. Otherwise, there is a risk of serious to fatal injury due to
fire.
When connecting sensors and especially actuators, observe
the maximum permissible currents per connection and in to-
tal:
Section 8.3 “Electrical properties”on page 272
Section 8.3.2 “I/O module 1”on page 273
Section 8.3.3 “I/O module 2”on page 275
The electrical connection may only be established by an
electrician.

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Housing protection category
NOTICE!
Risk of damage due to penetrating moisture!
The pump controller is protected against moisture by the design of
the housing and connections in accordance with IP65. If the hous-
ing is opened without authorisation or the connections are not
established properly, protection category IP20 applies to the
housing. In this case, penetrating moisture can cause malfunc-
tions or damage to the pump controller.
Screw the M12 connections for slots A - C together properly.
Cover unwanted M12 connections with sealing caps (supplied
as standard).
Always close the service access cover properly.
Do not open any of the other screw connections on the hous-
ing.
Loss of warranty
NOTICE!
Do not open the housing!
There are no components relevant for operation, maintenance or
troubleshooting in the housing. The housing may only be opened
by the manufacturer’s staff.
2.5 Owner responsibility
Owner
The owner is the person who operates the pump controller and the complete
installation for commercial or economic purposes themselves or contracts a
third party to use/operate it, and who bears the legal product responsibility for
protecting the user, the staff or third parties during operation.

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Owner obligations
The pump controller and the complete installation are used in industrial applica-
tions. The owner is therefore obliged to comply with and implement the legal
obligations for occupational safety.
In addition to the safety instructions in this operating manual, the safety, occu-
pational safety and environmental protection regulations that are applicable for
the pump controller’s application area must be adhered to at all times.
The following applies in particular:
The owner must inform himself of the applicable occupational safety regulations
and use a risk assessment to determine additional hazards that are posed by
the special working conditions at the operating location for the pump controller
and the complete installation. Occupational safety must be ensured by addi-
tional operating instructions for operating the pump controller and the complete
installation.
The owner must retrofit safety equipment to protect against dangers that arise
due to operating the complete installation.
For the entire usage duration of the pump controller and the complete installa-
tion, the owner must check whether the operating instructions that they drew up
correspond to the current rules and standards, and adjust the operating instruc-
tions if required.
The owner must clearly define responsibilities for installation, operation, trou-
bleshooting, maintenance and cleaning.
The owner must ensure that everybody who handles the pump controller and
the complete installation has read and understood this operating manual. Fur-
thermore, they must train the staff in regular intervals and inform them of the
dangers.
The owner must provide the staff with the required protective equipment and
instruct that wearing it is mandatory.
Furthermore, the owner is responsible for ensuring that the pump controller and the
complete installation are always in a technically perfect condition. Therefore, the
following applies:
The owner must ensure that the maintenance intervals described in this operat-
ing manual and the further applicable documents are adhered to.
The owner must have all safety equipment checked on a regular basis to en-
sure that it is functioning and complete.