FlowLine Commander LI90 Series User manual

27 AUG 08 PRELIMINARY MANUAL 1 of 57
Rev 1_3 Commander LI90 Series
Commander
LI90 Series
Controller
User Manual
Flowline Inc.
10500 Humbolt Street
Los Alamitos, CA 90720
Tel: [phone]
Fax: [phone]
www.flowline.com

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Commander LI90 Series Rev 1_3

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Rev 1_3 Commander LI90 Series
Preface
This manual explains how to use the Commander LI90 series controller.
Warranty, Service & Repair
To register your product with the manufacturer, go to the Flowline website for on-line
registration. The website address is as follows:
www.flowline.com
On-line Warranty Registration can be found under Contact Us in the Navigation Bar along the
side of the home page.
If for some reason your product must be returned for factory service, go to the Flowline website
to receive a Material Return Authorization number (MRA), providing the following information:
1. Part Number, Serial Number
2. Name and telephone number of someone who can answer technical questions related
to the product and its application.
3. Return Shipping Address
4. Brief Description of the Symptom
5. Brief Description of the Application
On-line Material Return Authorization can be found under Contact Us in the Navigation Bar
along the side of the home page. Click on Return Authorization to begin the MRA request. Once
you have received a M RA number, ship the product prepaid in its original packing to:
Flowline Factory Service
MRA_____
10500 Humbolt Street
Los Alamitos, CA 90720
To avoid delays in processing your repair, write the MRA on the shipping label. Please include
the information about the malfunction with your product. This information enables our service
technicians to process your repair order as quickly as possible.

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Warranty
Flowline warrants to the original purchaser of its products that such products will be free from
defects in material and workmanship under normal use and service for a period which is equal to
the shorter of one year from the date of purchase of such products or two years from the date of
manufacture of such products.
This warranty covers only those components of the products which hare non-moving and not
subject to normal wear. Moreover, products which are modified or altered, and electrical cables
which are cut to length during installation are not covered by this warranty.
Flowline’s obligation under this warranty is solely and exclusively limited to the repair or
replacement, at Flowline’s option, of the products (or components thereof) which Flowline’s
examination proves to its satisfaction to be defective. FLOWLINE SHALL HAVE NO
OBLIGATION FOR CONSEQUENTIAL DAMAGES TO PERSONAL OR REAL
PROPERTY, OR FOR INJURY TO ANY PERSON.
This warranty does not apply to products which have been subject to electrical or chemical
damage due to improper use, accident, negligence, abuse or misuse. Abuse shall be assumed
when indicated by electrical damage to relays, reed switches or other components. The warranty
does not apply to products which are damaged during shipment back to Flowline’s factory or
designated service center or are returned without the original casing on the products. Moreover,
this warranty becomes immediately null and void if anyone other than service personnel
authorized by Flowline attempts to repair the defective products.
Products which are thought to be defective must be shipped prepaid and insured to Flowline’s
factory or a designated service center (the identity and address of which will be provided upon
request) within 30 days of the discovery of the defect. Such defective products must be
accompanied by proof of the date of purchase.
Flowline further reserves the right to unilaterally waive this warranty and to dispose of any
product returned to Flowline where:
a. There is evidence of a potentially hazardous material present with product.
b. The product has remained unclaimed at Flowline for longer than 30 days after dutifully
requesting disposition of the product.
THERE ARE NO WARRANTIES WHICH EXTEND BEYONDTHE DESCRIPTION ON THE
FACE OF THIS WARRANTY. This warranty and the obligations and liabilities of Flowline
under it are exclusive and instead of, and the original purchaser hereby waives, all other
remedies, warranties, guarantees or liabilities, express or implied. EXCLUDED FROM THIS
WARRANTY IS THE IMPLIED WARRANTY OF FITNESS OF THE PRODUCTS FOR A
PARTICULAR PURPOSE OR USE AND THE IMPLIED WARRANTY OF
MERCHANTABILITY OF THE PRODUCTS.
This warranty may not be extended, altered or varied except by a written instrument signed by a
duly-authorized officer of Flowline, Inc.

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Rev 1_3 Commander LI90 Series
Table of Contents
Safety Warnings and Guidelines..........................................................................................6
Introduction..........................................................................................................................7
Installation............................................................................................................................9
Panel Mounting........................................................................................................9
DIN Rail Mounting................................................................................................10
Dimensions ........................................................................................................................11
Electrical............................................................................................................................12
Wiring................................................................................................................................13
Configuration.....................................................................................................................14
Specifications.....................................................................................................................15
Startup................................................................................................................................16
Common Information.........................................................................................................19
Analog (Scaled Input)............................................................................................19
Analog (Fixed Input)..............................................................................................20
Application #1....................................................................................................................21
Overview................................................................................................................21
General (Open Functions)......................................................................................22
General (Secured Functions)..................................................................................24
Configuration of Inputs..............................................................................25
Configuration of Outputs...........................................................................27
Application #2....................................................................................................................29
Overview................................................................................................................29
General (Open Functions)......................................................................................30
General (Secured Functions)..................................................................................32
Configuration of Inputs..............................................................................33
Configuration of Outputs...........................................................................35
Application #3....................................................................................................................38
Overview................................................................................................................38
General (Open Functions)......................................................................................39
General (Secured Functions)..................................................................................40
Configuration of Inputs..............................................................................41
Volume...........................................................................................43
Configuration of Outputs...........................................................................46
Appendix............................................................................................................................51
Simulation mode....................................................................................................51
Factory Reset .........................................................................................................53
Changing Applications...........................................................................................54
Removable Media for Data Transfer .....................................................................55
Micro SD Cards .........................................................................................55
Micro SD File System................................................................................55
Using Removable Media to Log Data .......................................................56

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Commander LI90 Series Rev 1_3
Safety Warnings and Guidelines
When found on the product, the following symbols specify:
Warning: Consult user documentation. Warning: Electrical Shock Hazard.
WARNING: To avoid the risk of electric shock or burns, always connect the safety (or
earth) ground before making any other connections.
WARNING: To reduce the risk of fire, electrical shock, or physical injury it is strongly
recommended to fuse the voltage measurement inputs. Be sure to locate fuses as close to
the source as possible.
WARNING: Replace fuse with the same type and rating to provide protection against risk
of fire and shock hazards.
WARNING: In the event of repeated failure, do not replace the fuse again as a repeated
failure indicates a defective condition that will not clear by replacing the fuse.
WARNING: Only qualified electrical personnel familiar with the construction and
operation of this equipment and the hazards involved should install, adjust, operate, or
service this equipment. Read and understand this manual and other applicable manuals in
their entirety before proceeding. Failure to observe this precaution could result in severe
bodily injury or loss of life.
•All applicable codes and standards need to be followed in the installation of this product.
•For I/O wiring (discrete), use the following wire type or equivalent: Belden 9918, 18
AWG or larger.
Adhere to the following safety precautions whenever any type of connection is made to the
module.
•Connect the green safety (earth) ground first before making any other connections.
•When connecting to electric circuits or pulse-initiating equipment, open their related
breakers. Do not make connections to live power lines.
•Make connections to the module first; then connect to the circuit to be monitored.
•Route power wires in a safe manner in accordance with good practice and local codes.
•Wear proper personal protective equipment including safety glasses and insulated gloves
when making connections to power circuits.
•Ensure hands, shoes, and floors are dry before making any connection to a power line.
•Make sure the unit is turned OFF before making connection to terminals. Make sure all
circuits are de-energized before making connections.
•Before each use, inspect all cables for breaks or cracks in the insulation. Replace
immediately if defective.

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Rev 1_3 Commander LI90 Series
Introduction
The Commander Series has three unique application configurations. The choice of application is
field selectable. The three configurations are:
•Multi-Tank Display (Application #1) – Commander will accept up to Four 4-20 mA input
transmitters and will provide a 3A SPST relay output for each input.
•Differential Level Controller (Application #2) – Commander will monitor the levels
above and below a rake and control a relay based upon the defined differential between
the two levels. In addition, a differential alarm can be programmed as well as individual
alarms for each input.

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•Pump Controller (Application #3) – Commander will accept a single 4-20 mA input
transmitter and will provide up to Six 3A SPST relay outputs.

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Rev 1_3 Commander LI90 Series
Installation
•Overview
oThe mechanical installation greatly affects the operation, safety and appearance of the
system. Information is provided to mechanically install the unit such as cut out sizes,
mounting procedures and other recommendations for the proper mechanical
installation of the unit.
•Components
oCommander Series display
oTerminal Strips
Power (3-pin black)
Inputs (15-pin Orange)
Outputs (15-Pin Black)
Optional Interface (5-pin Orange)
oMounting Clips (set of four)
Quick Start Guide
•Mounting requirements
oCommander series can be mounted through a panel or on a DIN rail.
•Panel Mounting
oOnce the panel design has been completed using the criteria and suggestions in the
following sections, use the following steps to panel mount the LI90 series.
Remove all connectors from the unit.
Press the DIN rail clip up to make passing the unit through the cutout easier.
Make sure the gasket is installed on the LI90 series and is free from dust and
debris. Check that the corners of the gasket are secure.
Pass the unit through the panel.
Insert the each of the four (4) mounting clips into the slots in the
Commander’s case. One clip should be installed on each corner. Lightly
tighten each screw so the clip is held in place.
Tighten the screws on the clips such that the gasket is compressed against the
panel.
oFor panel mount, use the standard cutout for a ¼ DIN [3.622” (92 mm) x 3.622” (92
mm)]. Use the four mounting clips to secure the display to the panel. A mounting
clip will attach to all four sides of the display.
Not to Scale

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•DIN Rail Mounting
oThe LI90 series is designed to clip onto standard 35 millimeter DIN rail. If your
installation requires liquid or dust protection, make sure the controller is placed in an
appropriate sealed panel when mounting on DIN rail. Use the following steps to
mount on DIN rail.
Move the DIN rail clip to the lower position.
Clip the “Top Clips” on the top of the DIN rail.
Press the unit into place and press the DIN rail clip up. A small flat-head
screwdriver can be used in the slot of the DIN rail clip if clearance is an issue.
oNote: The DIN rail connection does not provide an earth ground.
oFor DIN rail, use a 35 mm DIN Rail.
Move the DIN rail clip to the lower position.
Clip the “Top Clips” on the top of the DIN rail.
Press the unit into place and press the DIN rail clip up. A small flat-head
screwdriver can be used in the slot of the DIN rail clip if clearance is an issue.

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Rev 1_3 Commander LI90 Series
•Dimensions
Front View Side View
•Temperature / Ventilation
oEnsure that the panel layout design allows for adequate ventilation and maintains the
specified ambient temperature range. Consider the impact on the design of the panel
layout if operating at the extreme ends of the ambient temperature range. For
example, if it is determined that a cooling device is required, allow adequate space
and clearances for the device in the panel box or on the panel door.
•Orientation
oWhen panel-mounted, there are no orientation restrictions on the LI90 series.
•Noise
oConsider the impact on the panel layout design and clearance requirements if noise
suppression devices are needed. Be sure to maintain an adequate distance between
the controller and noisy devices such as relays, motor starters, etc.
•Shock and Vibration
oThe LI90 series has been designed to operate in typical industrial environments that
may inflict some shock and vibration on the unit. For applications that may inflict
excessive shock and vibration please use proper dampening techniques or relocate the
Commander to a location that minimizes shock and/or vibration.

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Electrical
•Grounding Definition
oGround: The term Ground is defined as a conductive connection between a
circuit or piece of equipment and the earth. Grounds are fundamentally used to
protect an application from harmful interference causing either physical damage
such as by lightning or voltage transients or from circuit disruption often caused
by radio frequency interference (RFI).
•Ground Specifications
oIdeally, a ground resistance measurement from equipment to earth ground is 0 ohms.
In reality it typically is higher. The U.S. National Electrical Code (NEC) states the
resistance to ground shall not exceed 25 ohms. Flowline recommends less than 15
ohms resistance from our equipment to ground. Resistance greater than 25 ohms can
cause undesirable or harmful interference to the device.
•How to Test for Good Ground
oIn order to test ground resistance, a Ground Resistance Tester must be used. A
typical Ground Resistance Meter Kit contains a meter, two or three wire leads,
and two ground rods. Instructions are supplied for either a two-point or three-
point ground test. Below shows a two-point ground connection test.

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Rev 1_3 Commander LI90 Series
•Wiring
oPower
•Connect to Earth Ground. Apply 10 - 30 VDC.
oInputs
•Commander can connect up to four 4-20 mA inputs.

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oOutputs
•Commander can connect up to 6 relays, depending on the application
selection.
•Relays can switch voltages up to 275 VAC, 30 VDC with a maximum
output current of 3 A at 250 VAC, resistive.
Configuration
•Commander Series is configured via the Human Machine Interface (HMI) located on the
front cover of the controller

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Rev 1_3 Commander LI90 Series
Specifications
Display
Graphics/Text: Yes / Yes
Pixels: 128 x 64
Display Technology: Backlit LCD
Keypad Touch screen
Total Keys: 20
Function Keys: 10
Controller
Memory: 256 KB
Logic Scan Rate: 1.2 mS/K
Memory Card Slot: Up to 1 GB
General Specs
Height: 3.7” (95.1 mm)
Width: 3.7” (95.1 mm)
Depth: 2.5” (63.9 mm)
Weight: 12.5 oz (0.354 kg)
Environmental: 0 to 50 °C
Wash down: NEMA 4X
Max. panel thickness: 5 mm
Cut-out: 3.622” (92 mm) x 3.622” (92 mm)
Required Power
Steady State: 130 mA @ 24 VDC
Inrush: 30 A for 1 ms @ 24 VDC
Primary Power Range: 10 – 30 VDC
Relative Humidity: 5 to 95% Non-condensing
Clock Accuracy: +/- One Minute/Month at 20C
Operating Temp.: 0°C to +50°C
Terminal Type: Screw Type, 5 mm Removable
Certifications: CE UL
Analog Inputs
Number of Channels: 4
Input Ranges: 4 – 20 mA
Max. Over-Current: 35 mA
Relay Outputs
Outputs per Module: 6 relay
Commons per Module: 6
Max. Output Current: 3 A at 250 VAC, resistive
Max. Output Voltage: 275 VAC, 30 VDC
Max. Switched Power: 1250 VA, 150 W
Expected Life
No load: 5,000,000
Rated load: 100,000
Max. Switching Rate: 300 CPM at no load / 20 CPM at rated load
Type: Mechanical Contact
Response Time: One update per ladder scan plus 10 ms

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Startup
•When the Commander is powered for the first time, the LI90 series will allow the end
user to select the application to be used. Follow the instructions on the screen to choose
the application.
oApplication #1 / Multi-Tank Display (Press F2) – Commander will accept up to
Four 4-20 mA input transmitters and will provide a 3A SPST relay output for each
input.

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Rev 1_3 Commander LI90 Series
oApplication #2 / Differential Level Controller (Press F3) – Commander will
monitor the levels above and below a rake and control a relay based upon the defined
differential between the two levels. In addition, a differential alarm can be
programmed as well as individual alarms for each input.
oApplication #3 / Pump Controller (Press F4) – Commander will accept a single
4-20 mA input transmitter and will provide up to Six 3A SPST relay outputs.

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•If you need to change the application selection, press and hold the ESC button for 5
seconds. This will return you to the Selection Screen and allow for a new application to
be selected.
oThe selection can be accessed at any time.

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Rev 1_3 Commander LI90 Series
Common Information – There are several configuration aspects that are similar for all three
applications in the LI90 series.
•Analog Input
oThe Commander accepts any 4-20 mA signal.
oThe Commander has the ability to accept a 4-20 mA that has been scaled to the
size of the tank / vessel or with a 4-20 mA that is from a non-configured
transmitter (in its original factory setup).
oThere are six parameters required to configure an analog input in the LI90 series.
oFor a scaled output. Use this description when using a transmitter that has been
configured with 4 mA set to an empty tank/vessel and 20 mA set to a full
tank/vessel.
•Sensor Max. Range – This is the distance from the bottom of the tank to
the bottom of the installed sensor.
•Sensor Dead Band – This is the distance from the full level of liquid to
the bottom of the sensor.
•Sensor Height – This is the distance from the bottom of the tank to the
bottom of the installed sensor. This will be the same setting as the Sensor
Max. Range.
•Sensor Fill_H – This is the distance from the bottom of the tank to the
highest level of liquid. Adding the Fill_H value to the Dead Band value
will equal the Max. Range or Height values.
•Empty Setting – This is the display value when the tank is empty.
•Full Setting – This is the display value when the tank is full.

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oFor a non-scaled output. Use this description when using a transmitter that is
either set with its original Factory Settings or with a transmitter that has a fixed
(non-configurable) 4-20 mA output:
•Sensor Max. Range – This is the maximum range of the sensor. This is
typically the 4 mA set point for the sensor. Use the sensor’s manual to
obtain the sensors maximum range (4 mA output).
•Sensor Dead Band – This is the dead band for the level sensor. Use the
sensor’s manual to obtain the sensors dead band (20 mA output).
•Sensor Height – This is the distance from the bottom of the tank to the
bottom of the installed sensor
•Sensor Fill_H – This is the distance from the bottom of the tank to the
highest level of liquid
•Empty Setting – This is the display value when the tank is empty.
•Full Setting – This is the display value when the tank is full.